CX500 TT24DE-00 Technical Manual [PDF]

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CX500-C CX550-C CX700-C Crawler Crane



Manual No. : KM-24DE Vol. No. : TT24DE-00



Technical Manual (Troubleshooting)



Technical Manual (Troubleshooting)



CX500-C CX550-C CX700-C



Crawler Crane Service Manual (Manual No. KM-24DE) consists of the following three separate volumes; Technical Manual (Operational Principle) : Vol. No. TO24DE Technical Manual (Troubleshooting) : Vol. No. TT24DE Workshop Manual : Vol. No. W24DE



Serial No. CX500-C 002245 and up CX550-C 002125 and up CX700-C 000227 and up



PRINTED IN SINGAPORE (PS)



CX500/550/700-C TM/TSH



1



25/4/03, 4:56 PM



INTRODUCTION TO THE READER • This manual is written for an experienced technician



• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.):



to provide technical information needed to maintain and repair this machine. • Be sure to thoroughly read this manual for correct product information and service procedures.



Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd. TEL: 81-298-32-7173 FAX: 81-298-31-1162



ADDITIONAL REFERENCES • Please refer to the materials listed below in addition



• Operation Manual of the Engine • Parts Catalog of the Engine • Hitachi Training Material



to this manual. • • • • • •



The Operator’s Manual The Parts Catalog Technical Manual of the Crawler Crane Workshop Manual of the Crawler Crane Operator’s Manual of the Crawler Crane Parts Catalog of the Crawler Crane



PAGE NUMBER • Each page has a number, located on the center lower part of the page, and each number contains the following information: Example : C-5 Consecutive Page Number for Each Group Section



SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage.



•



This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.



• IMPORTANT:



IN-01



CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.



Indicates a situation which, if not conformed to the instructions, could result in damage to the machine. NOTE: Indicates supplementary technical information or know-how.



INTRODUCTION UNITS USED • SI Units (International System of Units) are used in



2



Example : 24.5 MPa (250 kgf/cm , 3560 psi)



this manual. MKS system units and English units are also indicated in parenthheses just behind SI units.



Quantity Length Volume



Weight Force Torque



To Convert From mm mm L L 3 m kg N N N⋅m N⋅m



Into in ft US gal US qt 3 yd lb kgf lbf kgf⋅m lbf⋅ft



A table for conversion from SI units to other system units is shown below for reference purposees.



Quantity



Multiply By 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 1.0197 0.7375



Pressure Power Temperature Velocity Flow rate



All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice COPYRIGHT (C) 2003 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved



IN-02



To Convert From MPa MPa kW kW °C km/h -1 min L/min mL/rev



Into



Multiply By 2



kgf/cm psi PS HP °F mph rpm US gpm cc/rev



10.197 145.0 1.360 1.341 °C×1.8+32 0.6214 1.0 0.2642 1.0



SAFETY RECOGNIZE SAFETY INFORMATION • This is the SAFETY ALERT SYMBOL. • When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. • Follow recommended precautions and safe operating practices.



001-E01A-0688



SA-688



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



• CAUTION also calls attention to safety messages in this manual.



• To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine.



•



NOTE indicates an additional explanation for an element of information. 002-E01C-1223



SA-1



SA-1223



SAFETY FOLLOW SAFETY INSTRUCTIONS • Carefully read and follow all safety signs on the machine and all safety messages in this manual.



• Safety signs should be installed, maintained and replaced when necessary. • If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).



SA-003



• Learn how to operate the machine and its controls correctly and safely.



• Allow only trained, qualified, authorized personnel to operate the machine.



• Keep your machine in proper working condition. • Unauthorized modifications of the machine may impair its function and/or safety and affect machine life.



• The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance work on the machine. 003-E01B-0003



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



SA-2



SA-437



SAFETY WEAR PROTECTIVE CLOTHING • Wear close fitting clothing and safety equipment appropriate to the job. You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances.



SA-438



• Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.



• Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine. 005-E01A-0438



PROTECT AGAINST NOISE • Prolonged exposure to loud noise can cause impairment or loss of hearing. • Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.



006-E01A-0434



SA-434



INSPECT MACHINE • Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury. • In the walk-around inspection be sure to cover all points described in the “PRE-START INSPECTION” chapter in the operator’s manual.



S007-E01A-0435



SA-3



SA-435



SAFETY GENERAL PRECAUTIONS FOR CAB • Before entering the cab, thoroughly remove all dirt and/or oil from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots the operator’s foot may slip off the pedal, possibly resulting in a personal accident. • Don’t leave parts and/or tools lying around the operator’s seat. Store them in their specified locations. • Avoid storing transparent bottles in the cab. Don’t attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire. • Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine. • Keep all flammable objects and/or explosives away from the machine. • After using the ashtray, always cover it to extinguish the match and/or tobacco. • Don’t leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode. 524-E01A-0000



SA-4



SAFETY USE HANDHOLDS AND STEPS • Falling is one of the major causes of personal injury. • When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. • Do not use any controls as hand-holds. • Never jump on or off the machine. Never mount or dismount a moving machine. • Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.



SA-439



008-E01A-0439



ADJUST THE OPERATOR'S SEAT • A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to misoperations. • The seat should be adjusted whenever changing the operator for the machine. • The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back. • If not, move the seat forward or backward, and check again.



SA-464



009-E01A-0464



FASTEN YOUR SEAT BELT(IF EQUIPPED) • If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death. • Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine. • Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimize the chance of injury from an accident. • We recommend that the seat belt be replaced every three years regardless of its apparent condition. 010-E02B-0237



SA-5



SA-237



SAFETY OPERATE SEAT



ONLY



FROM



OPERATOR'S



• Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. • Start the engine only when seated in the operator's seat. • NEVER start the engine while standing on the track or on ground. • Do not start engine by shorting across starter terminals. • Before starting the engine, confirm that all control levers are in neutral.



SA-444



012-E01B-0444



JUMP STARTING • Battery gas can explode, resulting in serious injury. • If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chapter in the operator’s manual. • The operator must be in the operator’s seat so that the machine will be under control when the engine starts. Jump starting is a two-person operation. • Never use a frozen battery. • Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine.



SA-032



S013-E01A-0032



KEEP RIDERS OFF MACHINE • Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine. • Only the operator should be on the machine. Keep riders off. • Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner. 014-E01B-0465



SA-6



SA-465



SAFETY PROVIDE SIGNALS FOR FOBS INVOLVING MULTIPLE NUMBERS OF MACHINES • For jobs involving multiple numbers of machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.



018-E01A-0481 SA-481



CONFIRM DIRECTION OF MACHINE TO BE DRIVEN • Incorrect travel pedal/lever operation may result in serious injury or death. • Before driving the machine, confirm the position of the undercarriage in relation to the operator’s position. If the travel motors are located in front of the cab, the machine will move in reverse when travel pedals/levers are operated to the front. 017-E01A-0482



SA-482



DRIVE MACHINE SAFELY • Clear all persons from the work area. • Before moving the machine, find out which way to move the travel levers for the direction you wish to go. • Do not approach precipices or weak road shoulders. 019-E04B-0337



SA-337



SA-7



SAFETY AVOID ACCIDENT • Failure to obey signs used on the job may result in serious injury or death. • Lean the meaning of all signs used on the job and who has the responsibility for signaling. • Always be alert for by standers moving into the work area. Use horn or other signal to warn by standers before starting the engine, driving, or swinging the machine.



• Failure to follow basic operation procedures and precautions may result in serious injury or death.



SA-471



• Avoid sudden starts and stops while operating. • After lifting a load 50 to 60 mm (2 to 2.4 inches) above the ground, stop hoisting and check the brake and clutch for correct function. Also, check that the machine remains stable. • Constantly pay attention to overhead and surrounding obstacles. • Do not move a lifted load over anyone. • Always confirm that the hoist line is vertical before starting the lift. • NEVER lift a load by raising the boom only. • NEVER drag a load using the swing function. • NEVER use the swing parking brake to stop swing motion. Always stop swing motion by slowly moving the swing control lever into the reverse swing direction. • Be sure that all safety devices, such as the overload prevention device, overload warning device, etc., are activated before operating.



SA-472



037-E01A-0513



ALWAYS OPERATE THE MACHINE SAFELY WITH DIRECT LINE OF SIGHT VISIBILITY • Visibility may be distorted by refraction at the curved section of the windowpane. • Avoid operating the machine with your visibility distorted. • If visibility is distorted, change your eyes to a position so that direct line of sight visibility can be obtained. 060-E01A-0604 SA-604



SA-8



SAFETY AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS • If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: • Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR. • Keep the travel alarm in working condition (if equipped) ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE. • USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW. Use hand signals, which conform to your local regulations, when work conditions require a signal person. • No machine motions shall be made unless signals are clearly understood by both signalman and operator. • Learn the meanings of all flags, signs, and markings used on the job and confirm who has the responsibility for signaling. • Keep windows, mirrors, and lights clean and in good condition. • Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting. • Read and understand all operating instructions in the operator’s manual. S021-E01A-0494



SA-9



SA-383



SA-384



SAFETY AVOID TIPPING • Soft ground may collapse when operating the machine on it, causing the machine to tip over, possibly resulting in serious injury or death. • Investigate and record geographical and geological features in advance to prevent the machine from tipping over and the ground from collapsing. • Always operate on a film, level surface. • If operation on soft ground is required, sufficiently reinforce the ground with large steel plates of required strength to prevent the machine from tipping over. • Ground where underground embedding exists posed a danger of ground collapse. Be sure to sufficiently reinforce such ground. • Frozen ground becomes softer as air temperature increases.Be careful of footing when operating on frozen ground, and reinforce the ground if required. • Where flowing water or infiltration water is observed, the resultant is often soft ground. Avoid operating on such ground. If unavoidable, be sure to sufficiently reinforce the ground.



SA-116



025-E04A-0116



AVOID POWER LINES • Serious injury or death can result if the machine or front attachments, or lifting load are not kept a safe distance from electrical lines. • If operation near power lines is required, be sure to contact the utility company beforehand to take appropriate measures. • Never have any part of the machine, including the hook or load, approach power lines nearer than specified. For details, refer to the BASIC CRANE OPERATION section in the manual. • If operation near power lines is unavoidable, be sure to have a signal person observe crane proximity to power lines. • Never allow any bystanders to come in the work site. • Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site. For details, refer to the BASIC CRANE OPERATION section in operator’s manual. 029-E02A-0468 SA-468



SA-10



SAFETY DO NOT LEAVE MACHINE WITH A LOAD LIFTED AND/OR ENGINE RUNNING • Do not leave the machine with a load lifted and/or the engine running. Serious injury or death may result. When leaving the machine: • • • • • •



Park the machine on a firm, level surface. Lower the load to the ground. Securely engage all brake and drum locks. Stop the engine. Remove the key from the key switch. Lock the cab door and all access doors.



SA-474



038-E01A-0474



CORRECT MACHINE POSE FOR OPERATION • Incorrect machine pose operation may cause the machine to tip over, possibly resulting in serious injury or death. Confirm that the machine is posed as follows before starting operation. • The required counterweights are mounted. • The side frame is fully extended and pin-locked. • The gantry is in the HIGH gantry position. • Also, confirm that the machine is on a firm, level surface. Use a level to confirm that the machine is positioned correctly. Moreover, be sure to periodically calibrate the level.



SA-469



039-E01A-0469



SAFETY LIMITED



DEVICES'



CAPACITIES



ARE



• This crane is equipped with safety devices, such as a moment limiter, boom and hook overhoist prevention devices. However, these safety devices cannot detect if the machine is assembled improperly or maladjusted, if the footing is loose, nor can they automatically adjust the machine position or pose to neutralize the effect of every change of the wind. • Learn the capacities and limitations of the safety devices before ever operating the machine. • For the areas that cannot be compensated with the safety device capacities, thoroughly read the instruction in this manual and take appropriate measures to prevent accidents from occurring. 040-E01B-0473



SA-11



SA-473



SAFETY PRECAUTIONS FOR LOAD HOISTING • Accidental falling loads may result in serious injury or death. • Follow local regulations for hoisting/slinging operations. • Never come or work under a lifted load. • Never move a lifted load over a person’s head. • Always use hook(s) with a detachment prevention latch. • Use wire ropes, hooks, sling chains and shackles of appropriate sizes and sufficient strength. 041-E01A-0118 SA-118



AVOID OVERLOADING • Overloading may cause the machine to tip over or damage the boom, etc., resulting in serious injury or death. • Never lift a load heavier than the rated load at its working radius. Craning capacities for this machine is listed on the rated load table in the cab. The rated loads are determined taking both structural strength and stability of the machine into consideration. Never exceed restraints (working radius and rated load) show on the rated load table.



SA-466



The machine may tip over and/or the frame may deform if a load exceeding the rate load is lifted, or it the boom is lowered to exceed the specified working radius. 042-E01B-0466



AVOID HITTING BUCKET AGAINST BOOM OR JIB



OR



LOAD



• A bend or other damage to the boom or jib reduces the strength and may cause buckling, possibly resulting in a break. • If the boom or jib is bent or otherwise damaged, contact your authorized dealer immediately. • If a bent or otherwise damaged boom is lowered, buckling may occur, possibly leading to a break at some point before the boom is lowered to the ground. For that reason, be sure to secure the boom using an other crane if the bent or otherwise damaged boom is lowered to the ground. 043-E01A-0406 SA-406



SA-12



SAFETY NEVER ALLOW ANYONE TO RIDE ON A LIFTED LOAD • Falling from a lifted load may result in serious injury or death. • NEVER allow anyone to ride on a lifted load. • NEVER attempt to lift a person.



044-E01A-0333 SA-333



NEVER OPERATE WITH A STRONG WIND BLOWING • Operating with a strong wind blowing, the machine may tip over, possibly resulting in serious injury or death. • NEVER operate with a strong wind blowing. • Before starting operation, pay attention to the weather forecast and observe the wind direction and speed in order to decide whether to start or to postpone the operation. • If the wind direction and/or speed changes while operating so that strong winds may occur, immediately stop operation. Especially, be more cautions about changes in wind conditions when operating in a “valley” between tall buildings as wind conditions tend to change more unexpectedly and suddenly. • Depending on wind speed, follow the suggested measures stated in the “ WIND ” section in operator’s manual. S045-E01A-0334



SA-13



SA-334



SAFETY LIGHTNING • Tall objects such as crane booms are vulnerable to lightning strikes. • In the event of an electrical storm, immediately stop operation and lower the boom to the ground. Do not remain on the machine. Evacuate to a safe place away from the machine. • After the electrical storm has passed, inspect the machine, especially the safety devices. Repair any faulty or malfunctioned parts before putting the machine back to service. 046-E01A-0336 SA-336



CHARGED HOOK PRECAUTIONS • The hook may become charged with extremely high voltage by radio waves from a nearby radio or TV station, possibly causing co-worker(s) to be electrically shocked and the safety devices to malfunction. • Be sure to ground the hook before starting slinging work. • For details, refer to the BASIC CRANE OPERATION section in operator’s manual.



S047-E01A-0402



SA-402



PRECAUTIONS FOR BOOM DISASSEMBLY • Prevent the boom/jib from falling; the boom or jib may fall if disassembled with joint pins removed in the wrong order, possibly resulting in serious injury or death. Be sure to follow the precautions below to prevent the boom/jib from falling. • Select a leader from the disassembly team. Take orders only from the leader. • Support the boom/jib on blocks of required strength. • Do not allow anyone underneath the boom/jib. 048-E01A-0111



SA-14



SA-111



SAFETY PARK MACHINE SAFELY To avoid accidents: • Park the machine on a firm, level ground. • Lower the boom to the ground. • In a work site where the boom cannot be lowered to the ground, secure the boom using guy ropes so as to minimize the wind effect on the boom. • For measures to be taken against strong winds, refer to the section “WIND” (BASIC CRANE OPERATION) in operator’s manual. • Run the engine at slow idle for five (5) minutes to cool the engine down. • Engage all brake and drum locks. Stop the engine. • Remove the key from the key switch. Lock the cab and all access doors.



SA-470



S033-E04A-0470



HANDLE FLUIDS SAFELY－AVOID FIRES • Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death. • Do not refuel the machine while smoking or when near open flame or sparks. • Always stop the engine before refueling the machine. • Fill the fuel tank outdoors.



• All fuels, most lubricants, and some coolants are



SA-018



flammable. • Store flammable fluids well away from fire hazards. • Do not incinerate or puncture pressurized containers. • Do not store oily rags; they can ignite and burn spontaneously.



034-E01A-0496



SA-15



SA-019



SAFETY SAFE TRANSPORTATION • The danger of tipping is present when loading/unloading machine onto/from a truck or trailer bed. • Be sure to observe local regulations when transporting the machine on public roads. • Be sure to have a signal person when loading/unloading the machine. • Provide an appropriate trailer for transporting the machine. Take the following precautions ing/unloading the machine:



when



load-



Less then 15° SA-475



1. Select firm, level ground. 2. Be sure to use a loading dock or ramp. 3. When using a loading ramp, use one which has antislip bands on the surface. 4. Drive the machine at very slow speed. 5. Avoid steering while driving up or down the ramp as it is extremely dangerous. If steering is unavoidable, first move back to the ground or flatbed, modify traveling direction, and begin to drive again. 6. Do not operate any levers besides the travel levers when driving up or down the ramp. 7. The top of the ramp where it meets the flatbed is a sudden bump. Take care when traveling over it. 8. Securely fasten chains or cables to the machine frame. Refer to the “TRANSPORTING” chapter in the operator's manual for details. 035-E03A-0475



TOWING MACHINE • When towing the machine, be sure to attach tow wire ropes around the track frames as illustrated. To prevent the wire ropes from being damaged, place protective material between the track frames and the wire ropes. 061-E01A-0605



SA-605



SA-16



SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents: • Understand service procedure before starting work. Keep the work area clean and dry. Do not spray water or steam inside a cab. • Never lubricate or service the machine while it is moving. • Keep hands, feet and clothing away from power-driven parts. • Before servicing the machine: 1. Park machine on a solid, level surface. 2. Lower the boom to the ground. If the boom cannot be fully lowered, secure the boom with guy ropes to prevent the boom from being blown by wind. 3. Run the engine at slow idle speed without load for 5 minutes. 4. Apply all brakes and locks. 5. Turn the key switch OFF to stop the engine. 6. Remove the key from the switch. 7. Move the pilot shut-off lever to the LOCK position. 8. Attach a “Do Not Operate” tag on the cab door. • If a maintenance procedure must be performed with the engine running, do not leave machine unattended. • Securely support any machine elements that must be raised for service work. If the machine must be raised, place supporting blocks under the frame. • Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter of the operator's manual. • Keep all parts in good condition and properly installed. • Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil or debris. • Disconnect battery ground cable (-) before making adjustments to electrical systems or before performing welding on the machine. • Illuminate your work area adequately but safely. • Use a portable safety light for working inside or under the machine. • Make sure that the bulb is enclosed by a wire cage.The hot filament of an accidentally broken bulb can ignite spilled fuel or oil. 500-E04A-0028



SA-17



SA-028



SA-037



SAFETY WARN OTHERS OF SERVICE WORK • Unexpected machine movement can cause serious injury. • Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever.



S501-E01A-0287



SS2045102



SUPPORT MACHINE PROPERLY • Never attempt to work on the machine without securing the machine first. • Always lower the attachment to the ground before you work on the machine. • If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.



SA-527



519-E01A-0527



STAY CLEAR OF MOVING PARTS • Entanglement in moving parts can cause serious injury. • To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.



502-E01A-0026



SA-18



SA-026



SAFETY USE TOOLS PROPERLY • Use tools appropriate for the work to be done.



• Makeshift tools, parts, and procedures can create safety hazards. • For loosening and tightening hardware, use the correct size tools to avoid injury caused by slipping wrenches. • Use only recommended replacement parts. (See the parts catalog.) SA-040 S522-E01A-0040



PROTECT AGAINST FLYING DEBRIS • If flying debris hit eyes or any other part of the body, serious injury may result. • Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. • Keep bystanders away from the working area before striking any object. 031-E01A-0432



SA-432



PREVENT PARTS FROM FLYING • Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death. • Do not attempt to remove GREASE FITTING or VALVE ASSEMBLY. • As pieces may fly off, be sure to keep body and face away from valve.



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



SA-19



SA-344



SAFETY STORE ATTACHMENTS SAFELY • Stored attachments such as buckets, can fall and cause serious injury or death. • Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage area.



504-E02A-0034



SA-034



PREVENT BURNS Hot spraying fluids:



• After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. • To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap. • The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.



SA-039



Hot fluids and surfaces:



• Engine oil, gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well. SA-225



• Wait for the oil and components to cool before starting any maintenance or inspection work. 505-E01B-0498



SA-20



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



• Failure to periodically replace rubber hoses may



SA-019



cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death. S506-E01A-0019



AVOID HIGH-PRESSURE FLUIDS • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death. • Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. • Relieve the pressure by moving the control levers several times. Tighten all connections before applying pressure. • Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection. • If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.



SA-031



SA-292



507-E01A-0499



SA-21



SA-044



SAFETY NEVER ATTEMPT TO MODIFY SAFETY DEVICES, HYDRAULIC COMPONENTS, OR ELECTRICAL WIRING • Incorrect modification or adjustment may cause accident. • Do not modify or adjust the preadjusted parts of hydraulic components or safety devices. If readjustment or modification is required, consult your authorized dealer.



• Alternation on electrical wiring may cause fire. • If modification or alternation of electrical wiring is required, consult your authorized dealer. 520-E01A-0019



SA-22



SA-019



SAFETY PREVENT FIRES Check for Oil Leaks:



• Fuel, hydraulic oil and lubricant leaks can lead to fires. • Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts. • Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts. • Do not bend or strike high-pressure lines. • Never install bent or damaged lines, pipes, or hoses. Check for Shorts:



• Short circuits can cause fires. • Clean and tighten all electrical connections. • Check before starting work for loose, kinked, hardened or frayed electrical cables and wires. • Check before starting work for missing or damaged terminal caps. • DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc. Clean up Flammables:



• Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires. • Prevent fires by inspecting and cleaning the machine daily and by removing spilled or accumulated flammables immediately. Check Key Switch:



• If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting. • Always check key switch function before operating the machine every day: 1) Start the engine and run it at slow idle. 2) Turn the key switch to the OFF position to confirm that the engine stops. • If any abnormalities are found, be sure to repair them before operating the machine. S508-E02B-0019



SA-23



SA-019



SAFETY Check Heat Shields:



• Damaged or missing heat shields may lead to fires. • Damaged or missing heat shields must be repaired or replaced before operating the machine. S508-E02B-0019



EVACUATING IN CASE OF FIRE • If a fire breaks out, evacuate the machine in the following way: • Stop the engine by turning the key switch to the OFF position if there is time. • Use a fire extinguisher if there is time. • Exit the machine.



• In an emergency, if the cab door and/or the front



SA-393



window cannot be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab. Refer to the explanation page on “EMERGENCY EXIT” in Operator’s Manual. 518-E02B-0393



SS-1510



BEWARE OF EXHAUST FUMES • Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. • If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.



509-E01A-0016



SA-24



SA-016



SAFETY AVOID HEATING NEAR PRESSURIZED FLUID LINES • Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. • Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. • Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc..



AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS • Do not weld or flame cut pipes or tubes that contain flammable fluids. • Clean them thoroughly with nonflammable solvent before welding or flame cutting them. 510-E01B-0030



SA-25



SA-030



SAFETY REMOVE PAINT BEFORE WELDING OR HEATING • Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness. • Avoid potentially toxic fumes and dust. • Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly. • Remove paint before welding or heating: 1) If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. 2) If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.



SA-029



511-E01A-0029



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



• Battery electrolyte is poisonous. If the battery should explode battery electrolyte may be splashed into eyes, possibly resulting in blindness. • Be sure to wear eye protection when checking electrolyte specific gravity. 512-E01C-0032



SA-26



SA-032



SAFETY SERVICE AIR CONDITIONING SYSTEM SAFELY • If spilled onto skin, refrigerant may cause a cold contact burn. • Refer to the freon container for proper use when servicing the air conditioning system. • Use a recovery and recycling system to avoid venting freon into the atmosphere. • Never let the freon stream make contact with the skin. SA-405 513-E01A-0405



HANDLE CHEMICAL PRODUCTS SAFELY • Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives. • A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. • Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment. S515-E01A-0309



SA-27



SA-309



SAFETY DISPOSE OF WASTE PROPERLY • Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries. • Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. • Do not pour waste onto the ground, down a drain, or into any water source. • Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants. • Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center.



SA-226



S516-E01A-0226



BEFORE RETURNING THE MACHINE TO THE CUSTOMER • After maintenance or repair work is complete, confirm that: • The machine is functioning properly, especially the safety systems. • Worn or damaged parts have been repaired or replaced



S517-E01A-0435



SA-28



SA-435



SECTION AND GROUP CONTENTS



TECHNICAL MANUAL (Troubleshooting)



SECTION 4 OPERATIONAL PERFORMANCE TEST Group Group Group Group Group



1 2 3 4 5



Introduction Standard Engine Test Crane Test Component Test



SECTION 5 TROUBLESHOOTING Group Group Group Group Group Group Group



1 Diagnosing Procedure 2 Component Layout 3 Troubleshooting A 4 Troubleshooting B 5 Troubleshooting C 6 Troubleshooting D 7 Electrical System Inspection



TECHNICAL MANUAL (Operational Principle)



All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.



COPYRIGHT(C)2003 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved



SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION Group 1 Specifications Group 1 Pump Device Group 2 Component Layout Group 2 Swing Device Group 3 Component Specifications Group 3 Hoist Device SECTION 2 SYSTEM Group 4 Boom Hoist Device Group 5 Control Valve Group 1 Control System Group 6 Pilot Valve Group 2 Hydraulic System Group 7 Travel Device Group 3 Electrical System Group 8 Others (Superstructure) Group 9 Others (Undercarriage) Group 10 Safety Device



WORKSHOP MANUAL SECTION 1 GENERAL INFORMA- SECTION 3 UNDERCARRIAGE TION Group 1 Swing Bearing Group 1 Precautions for Disassem- Group 2 Travel Device Group 3 Center Joint bling and Assembling Group 4 Track Adjuster Group 2 Tightening Torque Group 5 Front Idler Group 3 Bleeding Air Hydraulic Group 6 Upper and Lower Roller Oil Tank SECTION 2 SUPERSTRUCTURE Group 7 Track Group 8 Crawler Extend/ Retract CylGroup 1 Cab inder Group 2 Counterweight SECTION 4 ENGINE AND ACCESGroup 3 Main Frame SORY Group 4 Pump Device Group 5 Control Valve Group 6 Swing Device Group 7 Hoist Device Group 8 Boom Hoist Device Group 9 Pilot Valve Group 10 Pilot Shut-Off Valve Group 11 Solenoid Valve Group 12 Shuttle Valve Group 13 Booster Valve



SECTION 4



OPERATIONAL PERFORMANCE TEST —CONTENTS— Group 1 Introduction Operational Performance Tests................. T4-1-1



Lever Operating Force ............................T4-4-13



Preparation for Performance Tests............ T4-1-2



Lever Stroke ............................................T4-4-15



Precautions for Starting Engine................. T4-1-3



Group 5 Component Test Group 2 Standard



Pilot Primary Pressure ..............................T4-5-1 Pilot Secondary Pressure..........................T4-5-3



List of Operational Performance Standards................................................ T4-2-1 Joy-Stick Lever...................................... T4-2-1 Bi-Directional Control Lever .................. T4-2-7 Main Pump P-Q Performance Curve....... T4-2-13 Fuel Injection Pump ................................ T4-2-14



Travel Fast/Slow Speed Control Pressure (SE Pressure)..........................................T4-5-4 Swing Brake Release Pressure (SI Pressure) ...........................................T4-5-5 Hydraulic System Relief



Pressure ..........T4-5-6



Crowler Extend/Retract System



Group 3 Engine Test



Relief Set Pressure .................................T4-5-8



Engine Speed ........................................... T4-3-1



Swing Relief Set Pressure.......................T4-5-10



Engine Compression Pressure ................. T4-3-2



Overload Relief



Valve Clearance Adjustment ..................... T4-3-4



Main/Aux. Drum Motor Multi-Disc



Nozzle Check............................................ T4-3-6 Injection Timing......................................... T4-3-8



Valve Set Pressure......T4-5-12



Brake Release Pressure........................T4-5-13 Main/Aux. Drum Motor Sequence Valve Control Pilot Pressure ...........................T4-5-14



Group 4 Crane Test



Main Pump Flow Rate .............................T4-5-15



Travel Speed............................................. T4-4-1



Swing Motor Drainage.............................T4-5-20



Mistrack .................................................... T4-4-3



Travel Motor Drainage.............................T4-5-22



Travel Parking Brake Drift ......................... T4-4-5



Boom Hoist Moter Drainage ....................T4-5-24



Swing Speed............................................. T4-4-6 Swing Bearing Play................................... T4-4-7 Hoist/Lower Speeds (Main and Aux. Drums) ........................... T4-4-8 Boom Hoist Speed .................................. T4-4-10 Main/Aux. Hoist Drum Motor Brake Drift................................... T4-4-12



24DT-4-1



(Blank)



24DT-4-2



OPERATIONAL PERFORMANCE TEST / Introduction OPERATIONAL PERFORMANCE TESTS Use operational performance test procedures to quantitatively check all systems and functions on the machine. Kinds of Operational Performance Tests 1. System Performance and Function Test Each system such as engine, travel, swing, and hydraulic cylinder is individually tested. 2. Component Performance and Function Test Each component such as hydraulic pump, motor, and various valves is individually tested. Purpose of Operational Performance Tests 1. To evaluate the performance and function of a system or component by comparing the test results to the standard specifications. 2. According to the evaluation above, repair, adjust, or replace the system or component as necessary to restore the systems and functions to the required performance level. 3. To ensure safety and high efficiency operation. Standard Specifications Specifications applied to the new machine, components, and parts. Tolerances may be indicated as necessary. NOTE: With the passage of time, the machine's operational performance deteriorates, so that the machine needs to be serviced periodically. Before servicing the machine, conduct performance tests to check the extent of deterioration and to decide what kind of service needs to be done referring to the standard specifications.



T4-1-1



OPERATIONAL PERFORMANCE TEST / Introduction PREPARATION TESTS



FOR



PERFORMANCE



Observe the following rules in order to carry out performance tests accurately and safely. 1. The Machine Before starting performance tests, perform a sight-inspection of the machine. Then, if any abnormalities such as oil or coolant leaks, loose bolts, or cracks are found, repair them. 2. Test Area and Measuring Instrument (1) Select a hard and level surface. (2) Secure enough space to allow the machine to run straight for more than 10 m (33 ft). (3) Secure enough space to allow the machine to make a full swing with the front attachment extended. (4) Provide equipment and measuring instruments suitable to the test to be performed. (5) If required, rope off the test area and provide signboards to keep unauthorized personnel away. (6) Provide measuring weights or equivalent ones. (7) Coordinate work signals and procedures with co-workers.



T105-06-01-003



3. Precautions (1) While testing, always monitor the work site conditions to avoid accidents due to landslides or contact with high-voltage power lines. (2) Always give first priority to safety. Be sure to adhere to work signals and operate the machine carefully. (3) Avoid contaminating the machine and the ground with leaking oil. When removing hydraulic pipings, use oil pans to catch escaping oil. (4) After completing the tests, properly dispose of the waste oil or the used shop towels to protect the work site from pollution. 4. Precise Measurement (1) Accurately calibrate test instruments in advance to obtain correct data. (2) Carry out tests under the exact test conditions prescribed for each test item. (3) Repeat the same test and confirm that the test data obtained can be repeated. Use the average values of the measurements.



T4-1-2



SA-331



OPERATIONAL PERFORMANCE TEST / Introduction PRECAUTIONS FOR STARTING ENGINE Joy-Stick Lever 1. Check that pilot control shut-off lever (1) is placed in the LOCK position.



LOCK Position



2. Check that all control levers are placed in the NEUTRAL position. 3. Check that main hoist brake pedal (2) and auxiliary hoist brake pedal (3) are locked, and main hoist brake mode switch (4) and auxiliary hoist brake mode switch (5) are placed in the AUTO-BRAKE mode position.



1 6



3



2



5



4 T234-04-01-001



4. Check that swing brake switch (6) is ON. NOTE: Engine will not start unless main hoist brake mode switch (4) and auxiliary hoist brake mode switch (5) are placed in the AUTO-BRAKE mode position, and swing brake switch (6) is ON.



ON



6



5. Before operating the machine, be sure to thoroughly read and understand the operator’s manual.



T333-04-02-009



T4-1-3



OPERATIONAL PERFORMANCE TEST / Introduction PRECAUTIONS FOR STARTING ENGINE



1



Bi-Directional Control Lever 1. Check that pilot control shut-off lever (1) is placed in the LOCK position. 2. Check that all control levers are placed in the NEUTRAL position.



LOCK Position



3. Check that main hoist brake pedal (2) and auxiliary hoist brake pedal (3) are kept stepping fully, and main hoist brake mode switch (4) and auxiliary hoist brake mode switch (5) are placed in the AUTOMATIC BRAKE mode position.



M324-02-041



5



4



M324-04-002



Keep Stepping Fully



3



Keep Stepping Fully



2



M324-04-011



4. Check that swing brake switch (6) is ON. NOTE: Engine will not start unless main hoist brake mode switch (4) and auxiliary hoist brake mode switch (5) are placed in the AUTOMATIC BRAKE mode position, and swing brake switch (6) is ON.



ON



6



5. Before operating the machine, be sure to thoroughly read and understand the operator’s manual. M324-04-003



T4-1-4



OPERATIONAL PERFORMANCE TEST / Standard LIST OF OPERATIONAL PERFORMANCE STANDARDS • Joy-Stick Lever Operational performance standards are listed in the following table. Refer to T4-3 to T4-5 for the detailed measurement methods.



NOTE: 1 MPa = 145 psi 1 L/min = 0.2642 US gpm



Standard Item ENGINE SPEED Fast Idle Speed Slow Idle Speed ENGINE COMPRESSION PRESSURE



min



Standard (CX550-C Joy-Stick Lever)



T4-3-1



-1



2



MPa (kgf/cm )



VALVE CLEARANCE mm IN EX 2 NOZZLE INJECTION PRESSURE MPa (kgf/cm ) INJECTION TIMING (Before TDC) Degree When Cold TRAVEL SPEED sec/10 m Crane Mode (Slow) Crane Mode (Fast) Bucket Mode (Slow) Bucket Mode (Fast) MISTRACK mm/10 m TRAVEL PARKING BRAKE DRIFT Track movement occurred until the parking brake is applied. (Revolution): Travel motor slip while parking. mm/5 min SWING SPEED sec/3 rev SWING BEARING PLAY mm HOIST/LOWER SPEEDS (MAIN AND AUXILIARY DRUMS) sec/6 rev Crane Mode 1 st Speed 2nd Speed (Full Stroke) 3rd Speed Bucket Mode 1 st Speed 2nd Speed (Full Stroke) BOOM HOIST SPEED sec/6 turns Crane Mode Bucket Mode MAIN/AUXILIARY HOIST-DRUM-MOTOR BRAKE DRIFT mm/2 min



T4-2-1



Remarks



2050 to 2230 850 to 900 3.0 to 3.3 (31 to 34)



T4-3-2 T4-3-4



0.3 0.45 17.7 (180) 11



T4-3-6 T4-3-8 T4-4-1



24.3 to 27.8 19.2 to 21.9 21.3 to 24.4 16.8 to 19.2 60 or less



T4-4-3 T4-4-5



1/6 or less 0 40.8 to 46.7 1.2 to 1.5



T4-4-6 T4-4-7 T4-4-8



8.0 to 9.1 5.2 to 5.9 7.0 to 7.9 T4-4-10 9.0 to 10.2 7.9 to 9.0 0



T4-4-12



OPERATIONAL PERFORMANCE TEST / Standard Standard Item Lever Operating Force Main Hoist/Aux. Hoist Lever



Boom Hoist Lever Travel Lever Swing Lever



Standard (CX550-C Joy-Stick Lever)



T4-4-13



N (kgf)



1st Speed



-



2nd Speed



10.8±1.0 (1.1±0.1) 10.8±1.0 (1.1±0.1) 8.3±1.0(0.85±0.1) 18.6 to 23.5 (1.9 to 2.4) 8.3±1.0(0.85±0.1) 10.8±1.0 (1.1±0.1



Hoist Lower Left Right



Lever Stroke mm Main Hoist/Aux. Hoist Lever 1st Speed 2nd Speed (Full Stroke) Boom Hoist Lever Travel Lever Swing Lever Hydraulic System Operational Performance 2 PILOT PRIMARY PRESSURE MPa (kgf/cm ) 2 PILOT SECONDARY PRESSURE MPa (kgf/cm ) Aux. Hoist/Swing Lever Full Stroke Main Hoist/Boom Hoist Full Stroke Travel TRAVEL FAST/SLOW SPEED CONTROL PRESSURE



Remarks



T4-4-15 67 to 71 67 to 71 95 to 101 67 to 71 4.9±0.5 (50±5)



T4-5-1 T4-5-2



2.5 to 2.79 (25.5 to 28.5) 2.5 to 2.79 (25.5 to 28.5) 1.5 to 1.76 (15 to 18) 1.4 (14)



T4-5-4



3.2 (33)



T4-5-5



28.9 to 29.4 (295 to 300) (At 190 L/min flow rate) 22.5 to 23.0 (230 to 235) (At 130 L/min flow rate) (Following is for reference only) 27.0 to 27.4 (275 to 280) (At 130 L/min flow rate) 17.6 to 18.1 (180 to 185) (At 135 L/min flow rate)



T4-5-6



2



MPa (kgf/cm )



SWING BRAKE RELEASE PRESSURE



2



MPa (kgf/cm )



HYDRAULIC SYSTEM RELIRF PRESSURE 2 (First Main Pump, Second Main Pump) MPa (kgf/cm ) 2 SWING RELIEF PRESSURE MPa (kgf/cm ) Crawler Extend/Retract Cylinder Relief Pressure 2



MPa (kgf/cm )



Retraction Extension



T4-2-2



T4-5-10 T4-5-8



OPERATIONAL PERFORMANCE TEST / Standard Standard Item OVERLOAD RELIEF PRESSURE Main Hoist/Auxiliary Hoist



Standard (CX550-C Joy-Stick Lever)



2



MPa (kgf/cm )



31.4 ± 0.5 (320 ± 5) (At 30 L/min flow rate) Boom Hoist 30.4 to 31.4 (310 to 320) (At 110 L/min flow rate) Boom Lower 16.2 to 17.2 (165 to 175) (At 110 L/min flow rate) Travel 23.1 to 24.1 (236 to 246) (At 150 L/min flow rate MAIN/AUXILIARY DRUM MOTOR MULTI-DISC BRAKE 2.8 (29) 2 RELEASE PRESSURE MPa (kgf/cm ) MAIN AUSILIARY DRUM MOTOR SEQUENCE VALVE 1.2 to 1.4 (12 to 14) 2 MPa (kgf/cm ) CONTROL PILOT PRESSURE MAIN PUMP FLOW RATE AT 4.9 MPa (50 kgf/cm2) DELIVERY PRESSURE L/min Crane Mode 187.5 ± 5 Bucket Mode 214.3 ± 2 SWING MOTOR DRAINAGE L/min 3±2 TRAVEL MOTOR DRAINAGE L/min 4±2 HOIST MOTOR DRAINAGE L/min 2±2



T4-2-3



Remarks T4-5-12



T4-5-13 T4-5-14 Engine Speed: 2000 min-1 (rpm)



At constant speed At constant speed At constant speed



OPERATIONAL PERFORMANCE TEST / Standard LIST OF OPERATIONAL PERFORMANCE STANDARDS • Joy-Stick Lever Operational performance standards are listed in the following table. Refer to T4-3 to T4-5 for the detailed measurement methods.



NOTE: 1 MPa = 145 psi 1 L/min = 0.2642 US gpm



Standard Item ENGINE SPEED Fast Idle Speed Slow Idle Speed ENGINE COMPRESSION PRESSURE



min



Standard (CX700-C Joy-Stick Lever)



T4-3-1



-1



MPa (kgf/cm2)



VALVE CLEARANCE mm IN EX 2 NOZZLE INJECTION PRESSURE MPa (kgf/cm ) INJECTION TIMING (Before TDC) Degree When Cold TRAVEL SPEED sec/10 m Crane Mode (Slow) Crane Mode (Fast) Bucket Mode (Slow) Bucket Mode (Fast) MISTRACK mm/10 m TRAVEL PARKING BRAKE DRIFT Track movement occurred until the parking brake is applied. (Revolution): Travel motor slip while parking. mm/5 min SWING SPEED sec/3 rev SWING BEARING PLAY mm HOIST/LOWER SPEEDS sec/6 rev (MAIN AND AUXILIARY DRUMS) Crane Mode 1 st Speed 2nd Speed (Full Stroke) 3rd Speed Bucket Mode 1 st Speed 2nd Speed (Full Stroke) BOOM HOIST SPEED sec/6 turns Crane Mode Bucket Mode MAIN/AUXILIARY HOIST-DRUM-MOTOR BRAKE DRIFT mm/2 min



T4-2-4



Remarks



2050 to 2230 850 to 900 3.1 to 3.3 (31 to 34)



T4-3-2 T4-3-4



0.3 0.45 17.7 (180) 11



T4-3-6 T4-3-8 T4-4-1



35.6 to 40.7 25.0 to 28.5 31.2 to 35.7 21.9 to 25.0 60 or less



T4-4-3 T4-4-5



1/6 or less 0 51.4 to 60.0 1.2 to 1.5



T4-4-6 T4-4-7 T4-4-8



8.0 to 9.1 5.2 to 5.9 7.0 to 7.9 T4-4-10 9.0 to 10.2 7.9 to 9.0 0



T4-4-8



OPERATIONAL PERFORMANCE TEST / Standard Standard Item Lever Operating Force Main Hoist/Aux. Hoist Lever



Boom Hoist Lever Travel Lever Swing Lever



Standard (CX700-C Joy-Stick Lever)



T4-4-13



N (kgf)



1st Speed



-



2nd Speed



10.8±1.0 (1.1±0.1) 10.8±1.0 (1.1±0.1) 8.3±1.0(0.85±0.1) 18.6 to 23.5 (1.9 to 2.4) 8.3±1.0(0.85±0.1) 10.8±1.0 (1.1±0.1



Hoist Lower Left Right



Lever Stroke mm Main Hoist/Aux. Hoist Lever 1st Speed 2nd Speed (Full Stroke) Boom Hoist Lever Travel Lever Swing Lever Hydraulic System Operational Performance 2 PILOT PRIMARY PRESSURE MPa (kgf/cm ) 2 PILOT SECONDARY PRESSURE MPa (kgf/cm ) Aux. Hoist/Swing Lever Full Stroke Main Hoist/Boom Hoist Full Stroke Travel TRAVEL FAST/SLOW SPEED CONTROL PRESSURE



Remarks



T4-4-15 67 to 71 67 to 71 95 to 101 67 to 71 4.9±0.5 (50±5)



T4-5-1 T4-5-2



2.5 to 2.79 (25.5 to 28.5) 2.5 to 2.79 (25.5 to 28.5) 1.5 to 1.76 (15 to 18) 1.4 (14)



T4-5-4



3.2 (33)



T4-5-5



28.9 to 29.4 (295 to 300) (At 190 L/min flow rate) 22.5 to 23.0 (230 to 235) (At 130 L/min flow rate) (Following is for reference only) 27.0 to 27.4 (275 to 280) (At 130 L/min flow rate) 17.6 to 18.1 (180 to 185) (At 135 L/min flow rate)



T4-5-6



2



MPa (kgf/cm )



SWING BRAKE RELEASE PRESSURE



2



MPa (kgf/cm )



HYDRAULIC SYSTEM RELIRF PRESSURE 2 (First Main Pump, Second Main Pump) MPa (kgf/cm ) 2 SWING RELIEF PRESSURE MPa (kgf/cm ) Crawler Extend/Retract Cylinder Relief Pressure 2



MPa (kgf/cm )



Retraction Extension



T4-2-5



T4-5-10 T4-5-8



OPERATIONAL PERFORMANCE TEST / Standard Standard Item OVERLOAD RELIEF PRESSURE Main Hoist/Auxiliary Hoist



Standard (CX700-C Joy-Stick Lever)



2



MPa (kgf/cm )



31.4 ± 0.5 (320 ± 5) (At 30 L/min flow rate) Boom Hoist 31.4 to 31.4 (310 to 320) (At 110 L/min flow rate) Boom Lower 16.2 to 17.2 (165 to 175) (At 110 L/min flow rate) Travel 23.1 to 24.1 (236 to 246) (At 150 L/min flow rate MAIN/AUXILIARY DRUM MOTOR MULTI-DISC BRAKE 2.8 (29) 2 RELEASE PRESSURE MPa (kgf/cm ) MAIN AUSILIARY DRUM MOTOR SEQUENCE VALVE 1.2 to 1.4 (12 to 14) 2 MPa (kgf/cm ) CONTROL PILOT PRESSURE MAIN PUMP FLOW RATE AT 4.9 MPa (50 kgf/cm2) DELIVERY PRESSURE L/min Crane Mode 187.5 ± 5 Bucket Mode 214.3 ± 2 SWING MOTOR DRAINAGE L/min 3±2 TRAVEL MOTOR DRAINAGE L/min 4±2 HOIST MOTOR DRAINAGE L/min 2±2



T4-2-6



Remarks T4-5-12



T4-5-13 T4-5-14 Engine Speed: 2000 min-1 (rpm)



At constant speed At constant speed At constant speed



OPERATIONAL PERFORMANCE TEST / Standard LIST OF OPERATIONAL PERFORMANCE STANDARDS • Bi-Directional Control Lever Operational performance standards are listed in the following table. Refer to T4-3 to T4-5 for the detailed measurement methods.



NOTE: 1 MPa = 145 psi 1 L/min = 0.2642 US gpm



Standard Item ENGINE SPEED Fast Idle Speed Slow Idle Speed ENGINE COMPRESSION PRESSURE



min



Standard (CX500-C/550-C Bi-Directional Control Lever)



T4-3-1



-1



2



MPa (kgf/cm )



VALVE CLEARANCE mm IN EX 2 NOZZLE INJECTION PRESSURE MPa (kgf/cm ) INJECTION TIMING (Before TDC) Degree When Cold TRAVEL SPEED sec/10 m Crane Mode (Slow) Crane Mode (Fast) Bucket Mode (Slow) Bucket Mode (Fast) MISTRACK mm/10 m TRAVEL PARKING BRAKE DRIFT Track movement occurred until the parking brake is applied. (Revolution): Travel motor slip while parking. mm/ 5 min SWING SPEED sec/3 rev SWING BEARING PLAY mm HOIST/LOWER SPEEDS (MAIN AND AUXILIARY DRUMS) sec/6 rev Crane Mode 1st Speed 2nd Speed 3rd Speed Bucket Mode 1st Speed 2nd Speed BOOM HOIST SPEED sec/6 turns Crane Mode Bucket Mode MAIN/AUXILIARY HOIST-DRUM-MOTOR BRAKE DRIFT mm/2 min



T4-2-7



Remarks



2050 to 2230 850 to 900 3.2 to 3.3 (31 to 34)



T4-3-2 T4-3-4



0.3 0.45 17.7 (180) 11



T4-3-6 T4-3-8 T4-4-1



23.3 to 27.4 18.7 to 21.6 20.9 to 24.0 16.4 to 18.9 60 or less



T4-4-3 T4-4-5



1/6 or less 0 40.8 to 46.7 1.2 to 1.5



T4-4-6 T4-4-7 T4-4-8



15.9 to 18.7 8.0 to 9.1 5.2 to 5.9 13.9 to 16.9 7.0 to 7.9 T4-4-10 9.0 to 10.2 7.9 to 9.0 0



T4-4-12



OPERATIONAL PERFORMANCE TEST / Standard Standard Item Lever Operating Force Main Hoist/Aux. Hoist Lever



Boom Hoist Lever Travel Lever Swing Lever Lever Stroke Main Hoist/Aux. Hoist Lever



Standard (CX500-C/550-C Bi-Directional Control Lever)



T4-4-13



N (kgf)



1st Speed



14.7 to 22.6 (1.5 to 2.3)



2nd Speed



14.7 to 23.5 (1.5 to 2.4) 14.7 to 23.5 (1.5 to 2.4) 8.8 to 13.7 (0.9 to 1.4) 14.7 to 23.5 (1.5 to 2.4) T4-4-15



mm



1st Speed 2nd Speed



Boom Hoist Lever Travel Lever Swing Lever Hydraulic System Operational Performance 2 PILOT PRIMARY PRESSURE MPa (kgf/cm ) 2 PILOT SECONDARY PRESSURE MPa (kgf/cm ) Main Hoist/Aux. Hoist Lever 1st Speed 2nd Speed Boom Hoist 1st Speed 2nd Speed Travel Lever Swing Lever TRAVEL FAST/SLOW SPEED CONTROL PRESSURE



Remarks



73 to 80 123 to 130 123 to 130 73 to 80 120 to 138 4.9 ± 0.5 (50 ± 5)



T4-5-1 T4-5-2



1.47 to 1.67 (15 to 17) 2.5 to 2.79 (25.5 to 28.5) 1.47 to 1.67 (15 to 17) 2.5 to 2.79 (25.5 to 28.5) 1.6±0.1 (16.5±1.5) 2.45 to 2.74 (25 to 28) 1.4 (14)



T4-5-4



3.2 (33)



T4-5-5



28.9 to 29.4 (295 to 300) (At 190 L/min flow rate) 22.5 to 23.0 (230 to 235) (At 130 L/min flow rate) (Following is for reference only) 27.0 to 27.4 (275 to 280) (At 130 L/min flow rate) 17.6 to 18.1 (180 to 185) (At 135 L/min flow rate)



T4-5-6



2



MPa (kgf/cm )



SWING BRAKE RELEASE PRESSURE



2



MPa (kgf/cm )



HYDRAULIC SYSTEM RELIRF PRESSURE 2 (First Main Pump, Second Main Pump) MPa (kgf/cm ) 2 SWING RELIEF PRESSURE MPa (kgf/cm ) Crawler Extend/Retract Cylinder Relief Pressure 2



MPa (kgf/cm )



Retraction Extension



T4-2-8



T4-5-10 T4-5-8



OPERATIONAL PERFORMANCE TEST / Standard Standard Item OVERLOAD RELIEF PRESSURE Main Hoist/Auxiliary Hoist



Standard (CX500-C/550-C Bi-Directional Control Lever)



2



MPa (kgf/cm )



31.4 ± 0.5 (320 ± 5) (At 30 L/min flow rate) Boom Hoist 32.4 to 31.4 (310 to 320) (At 110 L/min flow rate) Boom Lower 16.2 to 17.2 (165 to 175) (At 110 L/min flow rate) Travel 23.1 to 24.1 (236 to 246) (At 150 L/min flow rate) MAIN/AUXILIARY DRUM MOTOR MULTI-DISC BRAKE 2.8 (29) 2 RELEASE PRESSURE MPa (kgf/cm ) MAIN AUSILIARY DRUM MOTOR SEQUENCE VALVE 1.2 to 1.4 (12 to 14) 2 CONTROL PILOT PRESSURE MPa (kgf/cm ) MAIN PUMP FLOW RATE AT 4.9 MPa (50 kgf/cm2) DELIVERY PRESSURE L/min Crane Mode 187.5 ± 5 Bucket Mode 214.3 ± 2 SWING MOTOR DRAINAGE L/min 3±2 TRAVEL MOTOR DRAINAGE L/min 4±2 HOIST MOTOR DRAINAGE L/min 2±2



T4-2-9



Remarks T4-5-12



T4-5-13 T4-5-14 Engine Speed: 2000 min-1 (rpm)



At constant speed At constant speed At constant speed



OPERATIONAL PERFORMANCE TEST / Standard LIST OF OPERATIONAL PERFORMANCE STANDARDS • Bi-Derectional Control Lever Operational performance standards are listed in the following table. Refer to T4-3 to T4-5 for the detailed measurement methods.



NOTE: 1 MPa = 145 psi 1 L/min = 0.2642 US gpm



Standard Item ENGINE SPEED Fast Idle Speed Slow Idle Speed ENGINE COMPRESSION PRESSURE



min



Standard (CX700-C Bi-Directional Control Lever)



T4-3-1



-1



2



MPa (kgf/cm )



VALVE CLEARANCE mm IN EX 2 NOZZLE INJECTION PRESSURE MPa (kgf/cm ) INJECTION TIMING (Before TDC) Degree When Cold TRAVEL SPEED sec/10 m Crane Mode (Slow) Crane Mode (Fast) Bucket Mode (Slow) Bucket Mode (Fast) MISTRACK mm/ 10 m TRAVEL PARKING BRAKE DRIFT Track movement occurred until the parking brake is applied. (Revolution): Travel motor slip while parking. mm/5 min SWING SPEED sec/3 rev SWING BEARING PLAY mm HOIST/LOWER SPEEDS (MAIN AND AUXILIARY DRUMS) sec/6 rev Crane Mode 1 st Speed 2 nd Speed 3 rd Speed Bucket Mode 1 st Speed 2 nd Speed BOOM HOIST SPEED sec/6 turns Crane Mode Bucket Mode MAIN/AUXILIARY HOIST-DRUM-MOTOR BRAKE DRIFT mm/2 min



T4-2-10



Remarks



2050 to 2230 850 to 900 3.3 to 3.3 (31 to 34)



T4-3-2 T4-3-4



0.3 0.45 17.7 (180) 11



T4-3-6 T4-3-8 T4-4-1



34.1 to 39.1 23.9 to 27.4 29.9 to 34.2 20.9 to 24.0 60 or less



T4-4-3 T4-4-5



1/6 or less 0 51.4 to 60.0 1.2 to 1.5



T4-4-6 T4-4-7 T4-4-8



15.9 to 18.7 8.0 to 9.1 5.2 to 5.9 13.9 to 16.9 7.0 to 7.9 T4-4-10 9.0 to 10.2 7.9 to 9.0 0



T4-4-12



OPERATIONAL PERFORMANCE TEST / Standard Standard Item Lever Operating Force Main Hoist/Aux. Hoist Lever



Boom Hoist Lever Travel Lever Swing Lever Lever Stroke Main Hoist/Aux. Hoist Lever



Standard (CX700-C Bi-Directional Control Lever)



T4-4-13



N (kgf)



1st Speed



14.7 to 22.6 (1.5 to 2.3)



2nd Speed



14.7 to 23.5 (1.5 to 2.4) 14.7 to 23.5 (1.5 to 2.4) 8.8 to 13.7 (0.9 to 1.4) 14.7 to 23.5 (1.5 to 2.4) T4-4-15



mm



1st Speed 2nd Speed



Boom Hoist Lever Travel Lever Swing Lever Hydraulic System Operational Performance 2 PILOT PRIMARY PRESSURE MPa (kgf/cm ) 2 PILOT SECONDARY PRESSURE MPa (kgf/cm ) Main Hoist/Aux. Hoist Lever 1st Speed 2nd Speed Boom Hoist 1st Speed 2nd Speed Travel Lever Swing Lever TRAVEL FAST/SLOW SPEED CONTROL PRESSURE



Remarks



73 to 80 123 to 130 123 to 130 73 to 80 120 to 138 4.9 ± 0.5 (50 ± 5)



T4-5-1 T4-5-2



1.47 to 1.67 (15 to 17) 2.5 to 2.79 (25.5 to 28.5) 1.47 to 1.67 (15 to 17) 2.5 to 2.79 (25.5 to 28.5) 1.6±0.1 (16.5±1.5) 2.45 to 2.74 (25 to 28) 1.4 (14)



T4-5-4



3.2 (33)



T4-5-5



28.9 to 29.4 (295 to 300) (At 190 L/min flow rate) 22.5 to 23.0 (230 to 235) (At 130 L/min flow rate) (Following is for reference only) 27.0 to 27.4 (275 to 280) (At 130 L/min flow rate) 17.6 to 18.1 (180 to 185) (At 135 L/min flow rate)



T4-5-6



2



MPa (kgf/cm )



SWING BRAKE RELEASE PRESSURE



2



MPa (kgf/cm )



HYDRAULIC SYSTEM RELIRF PRESSURE 2 (First Main Pump, Second Main Pump) MPa (kgf/cm ) 2 SWING RELIEF PRESSURE MPa (kgf/cm ) Crawler Extend/Retract Cylinder Relief Pressure 2



MPa (kgf/cm )



Retraction Extension



T4-2-11



T4-5-10 T4-5-8



OPERATIONAL PERFORMANCE TEST / Standard Standard Item OVERLOAD RELIEF PRESSURE Main Hoist/Auxiliary Hoist



Standard (CX700-C Bi-Directional Control Lever)



2



MPa (kgf/cm )



31.4 ± 0.5 (320 ± 5) (At 30 L/min flow rate) Boom Hoist 33.4 to 31.4 (310 to 320) (At 110 L/min flow rate) Boom Lower 16.2 to 17.2 (165 to 175) (At 110 L/min flow rate) Travel 23.2 to 24.1 (236 to 246) (At 150 L/min flow rate) MAIN/AUXILIARY DRUM MOTOR MULTI-DISC BRAKE 2.8 (29) 2 RELEASE PRESSURE MPa (kgf/cm ) MAIN AUSILIARY DRUM MOTOR SEQUENCE VALVE 1.2 to 1.4 (12 to 14) 2 MPa (kgf/cm ) CONTROL PILOT PRESSURE MAIN PUMP FLOW RATE AT 4.9 MPa (50 kgf/cm2) DELIVERY PRESSURE L/min Crane Mode 187.5 ± 5 Bucket Mode 214.3 ± 2 SWING MOTOR DRAINAGE L/min 3±2 TRAVEL MOTOR DRAINAGE L/min 4±2 HOIST MOTOR DRAINAGE L/min 2±2



T4-2-12



Remarks T4-5-12



T4-5-13 T4-5-14 Engine Speed: 2000 min-1 (rpm)



At constant speed At constant speed At constant speed



OPERATIONAL PERFORMANCE TEST / Standard (REFERENCE) MAIN PUMP P-Q PERFORMANCE CURVE • Pump Model : A8V115SR ⋅ AL6.2 • Pump Rated Speed : 2 060 min-1 (rpm) • Hydraulic Oil Temperature : 50±5 °C NOTE: The effective delivery flow rate is less than the flow rate curve shown on the diagram due to internal pump leakage. 1 MPa = 145 psi 1 L/min = 0.2642 US gpm P 2 MPa (kgf/cm ) 2



Third Main Pump (Swing) Delivery Pressure P3=0 kgf/cm 2 2 Horsepower Control Signal Pressure PU=8.7 kgf/cm , PD=0 kgf/cm



58.8 (600) Pump Internal Leakage



2



Third Main Pump (Swing) Delivery Pressure P3=180 kgf/cm 2 2 Horsepower Control Signal Pressure PU=8.7 kgf/cm , PD=0 kgf/cm



49.0 (500)



40



39.2 (400) Total Combined Pressure [P of First Main Pump [P1] and Second Main Pump 29.4 (300) (P2) Delivery Pressures (P=P1+P2)]



30



20



10 8.7 0 50



19.6 (200)



10 20



100



When bucket mode is selected: Horsepower Control Signal Pressure 2 PX≦5 kgf/cm



150 180



When crane mode is selected: Horsepower Control Signal Pressure 2 PX≧15 kgf/cm



50



100



150



200 189.5



-1



Delivery Oil Flow Rate Per Pump (L/min )



T4-2-13



30



Horsepower Control Signal Pressure 2 PD (kgf/cm )



40



Third Main Pump (Swing) Delivery Pressure 2 P3 (kgf/cm )



9.8 (100)



0



Horsepower Control Signal Pressure 2 PU (kgf/cm )



250 216.3



T326-04-05-002



OPERATIONAL PERFORMANCE TEST / Standard (REFERENCE) FUEL INJECTION PUMP (1) Fuel Injection Pump Set Value Test Conditions 1.



Nozzle (made by ZEXEL)



105780-0000



4.



Delivery Pressure



2.



Nozzle Injection Pressure



5.



High Pressure Pipe



3.



Test Oil



17.2 MPa (175 kgf/cm2) (JIS Class 2 Gas Oil)



0.157 MPa (1.6 kgf/cm2) 2t×6ID×600 mm



6.



Test Oil Temperature



40 to 45 °C



NOTE: Injection pressure on the machine is 19.6 MPa (200 kgf/cm2). Test injection pressure is 17.2 MPa (175 kgf/cm2). Both are not identical. 1 MPa=145 psi Set Point



Pump Speed (min-1)



Rack Position (mm)



Measuring Stroke



A B C



1000 450 100



11.9 Approx. 6.1 -



-



Average Injection Volume (cm3) 123 to 126 9.0 to 11.0 130.0 to 140.0



Non-unifor mity (%)



Tightening Method



Note



±3.5 ±10



(2) Governor Performance Curve



Rack Limit Over 14



Idling Spring Set Governor Spring Set



C



A 11.9



Rack Position (mm)



9.1



B



6.1



4.8±0.2



0



290



450



(1000) -1



Pump Speed min (rpm)



T4-2-14



1125



1010



T324-06-05-002



OPERATIONAL PERFORMANCE TEST / Engine Test ENGINE SPEED Measure the engine speed using the moment limiter speed indicator.



1



2



NOTE: 1.If the engine speed is out of specification, all other measured performance data will also be out of specification. Accordingly, always measure the engine speed before performing any tests.. 2.The engine speed after starting, is the -1 slow idle speed plus 100 min (100 rpm). To reduce the engine speed to the slow idle speed, increase the engine speed faster than the starting speed by operating the accelerator grip* or lever. Then, return the accelerator grip or lever to the slow idle speed position. *accelerator grip is equipped on only Bi-Directional Control Lever machine. T324-06-01-005



Preparation: 1. Sufficiently warm up the machine until the engine coolant temperature reaches 50 °C (122 °F) or more, also, maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). 2. Check that fuel injection pump governor lever (2) comes in contact with both slow and fast-idle stopper (1) when the accelerator lever in the left console is fully stroked to both sides. NOTE: Never adjust stopper (1). Measurement: Measure the slow and fast idle speeds. Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS. Remedy: Refer to the engine shop manual.



T4-3-1



OPERATIONAL PERFORMANCE TEST / Engine Test ENGINE COMPRESSION PRESSURE Purpose: 1. Measure compression pressure in the cylinders to check for decline in the engine power. 2. Check abnormal exhaust gas color caused by incomplete combustion, the amount of blow-by gas, and the engine oil consumption rate. 3. Check for abnormalities in the air intake system, including the air cleaner. Preparation: 1. Check that the valve clearances are correctly adjusted. 2. Check that the batteries are charged properly. 3. Run the engine until the coolant temperature reaches the operating range. 4. Stop the engine. Remove the preheating plugs from each cylinder. 5. Install the adaptor Hino 09408-1010 and 09552-1030 and compression gauge in place of the glow plug in one cylinder. (Be sure to sufficiently tighten the adaptor and compression gauge to prevent air leakage.) Measurement: 1. Run the starter to crank the engine to measure compression pressure in each cylinder. 2. Repeat measurement three times for each cylinder. Use mostly repeatable values as test data, and calculate the average values. Evaluation: Refer to the performance Standard Table in Group T4-2. Remedy: Refer to the engine service manual.



T4-3-2



T105-06-02-001



OPERATIONAL PERFORMANCE TEST / Engine Test (Blank)



T4-3-3



OPERATIONAL PERFORMANCE TEST / Engine Test VALVE CLEARANCE ADJUSTMENT NOTE: 1. Perform the measurement only when the engine is cold. 2. Before starting the measurement, clean the head cover mounting area so as to prevent debris from entering the engine. Flywheel Housing



Preparation:



Flywheel



1. Locate the top dead center (TDC) of the compression stroke. Align the scale mark 1-6 on the flywheel circumference with the pointer provided on the flywheel housing. In this position, either No.1 or No.6 piston is at the TDC of the compression stroke. 2. Remove the head cover. 3. Move both No.1 cylinder intake and exhaust push rods by hand. If they moves easily, No.1 piston is at the TDC of the compression stroke. (When the exhaust valve is in the pushed-down position, No.6 piston is at the TDC of the compression stroke.) Start the measurement from either No.1 or No.6 cylinder positioned at the TDC of the compression stroke.



Pointer T108-02-12-004



T108-02-12-005



Measurement: Measure the valve clearance by inserting a thickness gauge into the gap between the rocker arm and valve stem. NOTE: The cylinders are aligned from No.1 to No.6 in that order , as viewed from the fan side.



T4-3-4



T324-06-02-002



OPERATIONAL PERFORMANCE TEST / Engine Test Evaluation: Standard Valve Clearance: Intake Valve : 0.30 mm (0.0118 in) Exhaust Valve : 0.45 mm (0.0177 in) Adjustment: If the measurement results are outside the standard specifications, adjust the valve clearances in the same order of measurement. 1. Loosen the adjusting screw lock nuts for the rocker arms. Insert the thickness gauge set at 0.30 mm (intake), or 0.45 mm (exhaust). Adjust the adjusting screws. 2. After adjusting, retighten the lock nuts to specification. Recheck the valve clearance after the lock nuts are tightened. T324-06-02-003



T4-3-5



OPERATIONAL PERFORMANCE TEST / Engine Test NOZZLE CHECK Check the injection pressure and the spray pattern with a nozzle tester. NOTE: Before starting the measurement, clean the nozzle holder mounting area so as to prevent debris from entering the engine. Preparation: 1. Remove the nozzle holder. Remove all nozzle holders and fuel injection pipings from the engine. T107-06-02-006



2. Attach a removed nozzle holder to the nozzle tester. Measurement: CAUTION: Never touch spray directly. The fuel spray from the nozzle may penetrate the skin, resulting in serious injury. If fuel penetrates into the blood stream, it may cause blood poisoning. 1. Injection Pressure After attaching the nozzle holder to the nozzle tester, strongly make several strokes of the tester to inject fuel. Then, while operating the tester at approx. 60 strokes a minute, measure the fuel injection pressure. 2. Spray Pattern For this test, turn the pressure tester knob to bypass the pressure gauge. Then, attach the nozzle holder to the nozzle tester. Strongly make several strokes of the tester and check the fuel spray pattern. NOTE: Use clean diesel fuel.



T4-3-6



OPERATIONAL PERFORMANCE TEST / Engine Test Evaluation: Normal



1. Standard Injection Pressure: 2 19.6 MPa (200 kgf/cm , 2844 psi) 2. Spray Pattern:



• Large-size spray should not be visible to the naked eye.



• No stray sideways spray should be seen. • During initial injection stage, spray size should be



T102-02-11-005



fine and injected intermittently.



• After injection, there should be no drips found.



Abnormal



• Injection spray angle must be normal.



T102-02-11-006



Adjustment:



• To adjust the injection start pressure, loosen the lock nuts. Turn the adjusting screw clock wise to increase the pressure, and counterclockwise to decrease the pressure.



• Retighten the lock nuts after adjusting.



T107-06-02-007



T4-3-7



OPERATIONAL PERFORMANCE TEST / Engine Test INJECTION TIMING



9



8



Inspection: 1. Turn flywheel (8) counterclockwise to align the 11° mark before top dead center (BTDC) of No.1 cylinder compression stroke on the flywheel circumference with pointer (3) on flywheel housing (9).



11°



2. Then, check that slotted mark (7) on the injection pump is aligned with injection timing mark (6) on coupling (4). 3



7



T108-02-12-015



Adjustment 1. If injection timing mark (6) is not aligned with slotted mark (7), loosen bolts (5) (2 used)on coupling (4), and rotate coupling (4) counter clockwise (arrow mark (1)) as viewed from the driving side. Then, rotate coupling (4) clockwise (arrow mark (2)) to align injection mark (6) on coupling (4) with slotted mark (7) on the injection pump. 5



4



6



4



T108-02-12-016



T324-06-02-004



2. Tighten bolts (5) on coupling (4). : 29 to 34 N⋅m (3 to 3.5 kgf⋅m, 21.7 to 25.3 Ib⋅f)



T108-02-12-018



5



T4-3-8



OPERATIONAL PERFORMANCE TEST / Crane Test TRAVEL SPEED Measure the time to travel 10 m (33 ft) to check the operational performance of the travel power system (from the hydraulic pump to the travel motor) comprehensively.



2 m (6.5 ft)



Preparation: 1. Adjust the track sag of both tracks equally.



60°



2. Prepare a level and solid test track 10 m (33 ft) long, with extra length of 3 to 5 m (9.8 to 16 ft) on both ends for machine acceleration and deceleration.



T324-06-03-001



3. Use the basic boom with the hook. Set the boom angle to 60°, and hoist the hook until it reaches 2 m below the height at which the hook overhoist alarm buzzer starts to operate. 4. After raising the hydraulic oil temperature to the range of 50±5 °C (122±9 °F), let the hydraulic oil flow into the circuits to be measured for more than two minutes before starting the test. Measurement: Joy-Stick Lever



3 T326-06-03-001



Perform the measurements at fast and slow travel speeds in both crane and bucket modes. Select the work mode switch (1) and travel speed mode switch (3), respectively.



1



1. After increasing the engine speed to the maximum, start driving the machine from the acceleration zone with both the right and left travel levers at full stroke. 2. Measure the time required to travel the 10 m (33 ft) test track.



Joy-Stick Lever



T326-04-03-019



3. After measuring forward travel time, turn the superstructure 180°. Then, measure the reverse travel time. 4. Repeat the measurements three times in each direction. Calculate the average values.



Start Acceleration Zone 3 to 5 m (9.8 to 16 ft)



T4-4-1



Deceleration End Zone 10 m 3 to 5 m (33 ft) (9.8 to 16 ft) T324-06-03-002



OPERATIONAL PERFORMANCE TEST / Crane Test Measurement: Bi-Directional Control Lever Perform the measurements at fast and slow travel speeds in both crane and bucket modes. Select the work mode switch (1) and travel speed mode switch (3), respectively. 1. After increasing the engine speed to the maximum, start driving the machine from the acceleration zone with both the right and left travel levers at full stroke. 2. Measure the time required to travel the 10 m (33 ft) test track. 3. After measuring forward travel time, turn the superstructure 180°. Then, measure the reverse travel time.



3 T326-06-03-001



1



4. Repeat the measurements three times in each direction. Calculate the average values. Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS. Remedy: Bi-Directional Control Lever



Refer to T5-3 TROUBLE SHOOTING.



Start Acceleration Zone 3 to 5 m (9.8 to 16 ft)



T4-4-2



M326-02-011



Deceleration End Zone 10 m 3 to 5 m (33 ft) (9.8 to 16 ft) T324-06-03-002



OPERATIONAL PERFORMANCE TEST / Crane Test MISTRACK Measure the deviation of the tracks from a 10 m (33 ft) straight line to check the variation in operational performance between the right and left travel power lines (from the hydraulic pump to the travel motor).



2 m (6.5 ft)



NOTE: When measured on a concrete test track, the deviation is generally reduced.



60 °



Preparation: 1. Adjust the track sag of both tracks equally. 2. Prepare a level and solid test track 10 m (33 ft) long, with extra length of 3 to 5 m (9.8 to 16 ft) on both ends for machine acceleration and deceleration.



T324-06-03-001



3. Use the basic boom with the hook. Set the boom angle to 60°, and hoist the hook until it reaches the 2 m (6.5 ft) below the height at which the hook overhoist alarm buzzer starts to operate. 4. After raising the hydraulic oil temperature to the range of 50±5 °C (122±9 °F), let the hydraulic oil flow into the circuits to be measured for more than two minutes before starting the test.



3 T326-06-03-001



Measurement: Joy-Stick Lever



1



Perform the measurements at fast and slow travel speeds in both crane and bucket modes. Select the work mode switch (1) and travel speed mode switch (3), respectively. 1. After increasing the engine speed to the maximum, drive the machine from the acceleration range with both the right and left travel levers at full stroke.



Joy-Stick Lever T326-04-03-019



2. Measure the maximum distance between a straight 10 m (33 ft) line and the track tread of the machine. 2 m (6.5 ft)



3. After measuring the tracking in forward travel, turn the superstructure 180°. Then, measure the tracking in reverse travel. 4. Repeat the measurements three times in each direction. Calculate the average values.



Maximum Distance



10 m (33 ft) Extra Length for Acceleration 3 to 5 m (9.8 to 16 ft)



T324-06-03-003



T4-4-3



OPERATIONAL PERFORMANCE TEST / Crane Test Measurement: Bi-Directional Control Lever Perform the measurements at fast and slow travel speeds in both crane and bucket modes. Select the work mode switch (1) and travel speed mode switch (3), respectively. 1. After increasing the engine speed to the maximum, drive the machine from the acceleration range with both the right and left travel levers at full stroke. 2. Measure the maximum distance between a straight 10 m (33 ft) line and the track tread of the machine. 3. After measuring the tracking in forward travel, turn the superstructure 180°. Then, measure the tracking in reverse travel.



3 T326-06-03-001



1



4. Repeat the measurements three times in each direction. Calculate the average values. Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS. Remedy: Refer to T5-4 TROUBLE SHOOTING.



Bi-Directional Control Lever



M326-02-011



2 m (6.5 ft) Maximum Distance



10 m (33 ft) Extra Length for Acceleration 3 to 5 m (9.8 to 16 ft)



T324-06-03-003



T4-4-4



OPERATIONAL PERFORMANCE TEST / Crane Test TRAVEL PARKING BRAKE DRIFT Summary: Measure the travel parking brake drift on a specified slope angle. Preparation: 1. The test slope shall be flat with the gradient of 20 % (11.31°). 2. Put a mark on the travel reduction gear cover. 3. Use the basic boom with the hook. Set the boom angle to 60°. 4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



2 m (6.5 ft)



60°



20 % T324-06-03-004



Measurement: Measure the track movement until the parking brake is applied. 1-1. Climb the slope and place the travel levers in neutral. 1-2. Measure the travel reduction gear cover mark movement from the position when the lever is placed in neutral to the position when the machine stops (when the brake is applied).



Position where the machine stops. comes to a stop. Position when the travel levers are in neutral. Movement (Rotation Angle) Mark



Measure the travel motor slip while the machine is parked. 2-1. Climb the slope and place the travel levers in neutral. 2-2. Stop the engine. 2-3. After parking the machine, put alignment marks on the shoe and side frame. 2-4. After 5 minutes has passed, measure the difference between mark (1) on the side frame and mark (2) on the shoe.



T107-06-03-002



Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS.



T324-06-03-005



2



T4-4-5



3



1



OPERATIONAL PERFORMANCE TEST / Crane Test SWING SPEED Measure the time to swing three complete turns to check the operational performance of the swing power system (from the hydraulic pump to the swing motor) comprehensively.



2 m (6.5 ft)



Preparation: 1. Check the lubrication of the swing gear and swing bearing. 2. Place the machine on a level and solid ground with ample space for rotation. Do not carry out this test on a slope. 3. Use the basic boom with the hook. Set the boom angle to 60°. 4. After raising the hydraulic oil temperature to the range of 50±5 °C (122±9 °F), let the hydraulic oil flow into the circuits to be measured for more than two minutes before starting the test.



60°



T324-06-03-001



Measurement: Measure the swing speed under the following three conditions: (1) With the swing mode select switch in the NORMAL SWING position. (2) With the swing mode select switch in the CONSTANT SWING SPEED position and the swing speed control dial in the SLOW position. (3) With the swing mode select switch in the CONSTANT SWING SPEED position and the swing speed control dial in the FAST position. 1. Using accelerator pedal (1) or the accelerator lever, run the engine at the maximum speed. IMPORTANT: Avoid abrupt operation of the swing control lever. Otherwise, a large swing of the hook may result, potentially causing the hook to come in contact with the boom. 2. Operate the swing control lever fully. 3. After the swing speed becomes constant, measure the time required for the superstructure to rotate one turn in the CONSTANT SWING SPEED mode and three turns in the NORMAL SWING mode. 4. Repeat step 3. in the opposite direction. 5. Repeat the measurements three times in each direction. Calculate the average values. Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS. Remedy: Refer to T5-3 TROUBLE SHOOTING.



T4-4-6



1



T333-04-03-003



OPERATIONAL PERFORMANCE TEST / Crane Test SWING BEARING PLAY Measure the swing bearing play using a dial gauge to check the wear of bearing races and balls. Preparation: 1. Check swing bearing mounting bolts for loosening. 2. Check the lubrication of the swing bearing. Confirm that bearing rotation is smooth and without noise. 3. Install a dial gauge on the track frame using a magnetic base. 4. Position the superstructure so that the boom aligns with the tracks facing towards the front idlers. 5. Position the dial gauge so that its needle point comes into contact with the bottom face of the bearing outer race. 6. Perform the measurement on level and solid ground. Use the basic boom with the hook. Set the boom angle to 60°. Apply a load of 20000 kg (44100 Ib) to the hook. 7. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



60°



T324-06-03-012



A



Center of Swing Bearing



Left



Right View A



T324-06-03-013



Measurement: 1. Before lifting a load, read the dial gauge indication (h1). 2. Lift up a 20000 kg (44100 Ib) weight until the bottom of the weight leaves the ground. Then, read the dial gauge indication (h2). 3. Obtain the swing bearing play (H) by calculating the difference between (h1) and (h2). That is, H = h2-h1



Measurement of (h2)



Measurement of (h1)



T324-06-03-014 T324-06-03-016



Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS.



T4-4-7



OPERATIONAL PERFORMANCE TEST / Crane Test HOIST/LOWER SPEEDS (MAIN AND AUXILIARY DRUMS) Measure the time required for the main and auxiliary drum to rotate six complete turns to comprehensively check the operational performance of the hydraulic pump and the main and auxiliary drum motors in the main and auxiliary drum drive system. 60°



Preparation: 1. Use the basic boom with the hook. 2. Set the boom angle to 60°. Lower the hook until it comes close to the ground surface. 3. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F) by operating the drum motors. 4. Check that the brake band is correctly adjusted. 5. Check that the weight of the hook overhoist alarm buzzer functions at the specified position. NOTE: Depending on the number of the wire rope falls, the hook travel for six turns of the hoist drum varies. Start the measurement from the position having enough margin in stroke. Measurement: Joy-stick Lever 1. With the engine running at the maximum speed, operate the hoist lever corresponding to the drum to be measured. 2. After the drum rotation speed becomes constant, measure the time required to rotate six turns. 3. When measuring the lowering time, operate the hoist lever in the opposite direction to hoist operation. 4. Repeat the measurements three times in each direction. Calculate the average values. 5. The operational combination between the work modes and the hoist (lower) speeds are obtained as shown in the table below. Measure the times in all operational combinations. Work Mode Hoist (Lower) Speed First Second (Full stroke) Second Plus Push Button (Third)



Crane



Bucket



{



{



{



-



Work Mode Switch



T324-06-03-015



Joy-Stick Lever T326-04-03-019



Left Control Lever (Aux. Hoist)



Second First Neutral Position First



Second



Right Control Lever (Main Hoist)



Lowering Main (or Aux.) Hook (With the lever placed in the first and second speed selection.) Third



Third Hoisting Main (or Aux.) Hook (With the lever placed in the first and second speed selection.)



Joy-Stick Lever T333-02-02-042



T4-4-8



OPERATIONAL PERFORMANCE TEST / Crane Test Measurement: Bi-Directional Control Lever



Work Mode Switch



1. With the engine running at the maximum speed, operate the hoist lever corresponding to the drum to be measured. 2. After the drum rotation speed becomes constant, measure the time required to rotate six turns. 3. When measuring the lowering time, operate the hoist lever in the opposite direction to hoist operation. 4. Repeat the measurements three times in each direction. Calculate the average values. 5. The operational combination between the work modes and the hoist (lower) speeds are obtained as shown in the table below. Measure the times in all operational combinations. Work Mode Crane Hoist (Lower) Speed First Second Second Plus Push Button (Third)



Bucket



Bi-Directional Control Lever



Auxiliary Main Hoist Lever Hoist Lever Second



{ {



{ {



{



-



Third



First Neutral Position First



Evaluation:



Second



Refer to T4-2 STANDARD SPECIFICATIONS



Third



Lowering Main (or Auxiliary) Hook (Detent locks are provided for first and second speed selection.) Hoisting Main (or Auxiliary) Hook (Detent locks are provided for first and second speed selection.)



Bi-Directional Control Lever



T4-4-9



M326-02-011



T324-06-03-017



OPERATIONAL PERFORMANCE TEST / Crane Test BOOM HOIST SPEED Measure the time required for the boom hoist drum to rotate six complete turns to comprehensively check the operational performance of the hydraulic pump and the boom hoist drum motors in the boom hoist drum drive system.



2 m (6.5 ft)



Preparation: 1. Use the basic boom with the hook. 2. Set the boom angle to 60°. After raising the hydraulic oil temperature to the range of 50±5 °C (122±9 °F), let the hydraulic oil flow into the circuits to be measured for more than two minutes before starting the test. 3. Check that the boom hoist drum brake functions properly. 4. Check that the boom overhoist alarm device functions properly.



60°



T324-06-03-001



Work Mode Switch



Measurement: Joy-stick Lever 1. Perform the measurements in both crane and bucket modes. 2. With the engine running at maximum speed, operate the boom hoist lever to the second detent position. 3. After the drum rotation speed becomes constant, measure the time required to rotate six turns. 4. Repeat the measurements three times in both raising and lowering directions. Calculate the average values.



Joy-Stick Lever T326-04-03-019



Right Control Lever (Boom Hoist)



Hoisting



Joy-Stick Lever



T4-4-10



Lowering



T234-04-03-001



OPERATIONAL PERFORMANCE TEST / Crane Test Measurement: Bi-Directional Control Lever



Work Mode Switch



1. Perform the measurements in both crane and bucket modes. 2. With the engine running at maximum speed, operate the boom hoist lever to the second detent position. 3. After the drum rotation speed becomes constant, measure the time required to rotate six turns. 4. Repeat the measurements three times in both raising and lowering directions. Calculate the average values. Evaluation:



Bi-Directional Control Lever



M326-02-011



Refer to T4-2 STANDARD SPECIFICATIONS. Remedy:



Boom Hoist Lever



Refer to T5-3 TROUBLE SHOOTING.



Bi-Directional Control Lever T324-06-03-006



T4-4-11



OPERATIONAL PERFORMANCE TEST / Crane Test MAIN/AUX. HOIST DRUM MOTOR BRAKE DRIFT With the engine running at slow idle speed, measure the drum drift while applying 49000 N (5000 kgf, 11000 lbf) tension to the hoist rope for two minutes to check the drum drift. Preparation: 1



1. Check that the brake band is correctly adjusted. 2. Turn brake mode switches (1) and (2) to “AUTO BRAKE” mode. 3. Use the basic boom with the hook. 4. Hoist the weight. Then, after holding the weight at the specified height, start the measurements. 5. After raising the hydraulic oil temperature to the range of 50±5 °C (122±9 °F), let the hydraulic oil flow into the circuits to be measured for more than two minutes before starting the test.



2



T234-04-03-001



Joy-Stick Lever 2



1



Measurement: 1. Set the boom angle to 60°. Make aligning marks on the brake band and free-fall drum. 2. Apply a load on the hook so that the line pull on the bare drum becomes 49000 N (5000 kgf, 11000 lbf) 3. Run the engine at the slow idle speed. 4. Lift up the load 0.5 m (1.6 ft) above the ground and hold it at that height. 5. Measure the drum drift between the aligning marks after two minutes.



M324-02-008



Bi-Directional Control Lever



Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS. Remedy: 60°



Refer to T5-3 TROUBLE SHOOTING. 0.5 m (1.6 ft)



T324-06-03-007



T4-4-12



OPERATIONAL PERFORMANCE TEST / Crane Test LEVER OPERATING FORCE Joy-Stick Lever Measure the maximum operating force of each lever to check operating smoothness. Preparation: Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Measure the maximum operating force of all control levers at just below the lever grip.



Main Hoist/Boom Hoist Lever, Aux. Hoist/Swing Lever T24D-04-04-001



2. Stop the engine. 3. Operate each lever full stroke to measure the maximum operating force. 4. Repeat the measurements three times. Calculate the average values. Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS. Travel Levers



T4-4-13



T107-06-03-004



OPERATIONAL PERFORMANCE TEST / Crane Test LEVER OPERATING FORCE Bi-Directional Control Lever Measure the maximum operating force of each lever to check operating smoothness. Preparation: Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: Main Hoist Lever/Aux. Hoist Lever/ Boom Hoist Lever



1. Measure the maximum operating force of all control levers at just below the lever grip.



T324-06-03-008



2. Stop the engine. 3. Operate each lever full stroke to measure the maximum operating force. 4. Repeat the measurements three times. Calculate the average values. Evaluation: Travel Levers



Refer to T4-2 STANDARD SPECIFICATIONS.



T324-06-03-009



Swing Lever T324-06-03-010



T4-4-14



OPERATIONAL PERFORMANCE TEST / Crane Test LEVER STROKE Measure the lever stroke of each lever to check its play in stroke and operating smoothness. Preparation: Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Stop the engine. 2. Measure the lever stroke from the neutral position to stroke end at the grip top. If there is a play at the neutral position, measure the lever stroke from the play center at the neutral position. 3. Measure the linear strokes. 4. Repeat the measurements three times. Calculate the average values. Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS.



T4-4-15



T324-06-03-011



OPERATIONAL PERFORMANCE TEST / Crane Test (Blank)



T4-4-16



OPERATIONAL PERFORMANCE TEST / Component Test PILOT PRIMARY PRESSURE 2



Measure the pilot pressure to check the pilot relief valve set pressure. Preparation: 1. Stop the engine. 2. Disconnect hose (1) from the pilot pump delivery port. Install elbow S (2) and adaptor (3) to the pump delivery port. Install hose (1) and fitting (4) to adaptor (3). Install pressure gauge unit (5) to fitting (4). : 19 mm, 22 mm



1



T324-06-04-024



5



Adaptor (3) : ST 6450 Fitting (4) : ST 6069 Pressure Gauge Unit (5) : ST 6932 3. Start the engine. Check that no oil is leaking from the pressure gauge unit connector.



4



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



3 T324-06-04-025



Measurement: 1. Measure the pilot pressure with the engine running at both the maximum and minimum speeds.



6



2. Using pressure gauge (6) in the operator’s cab and pressure gauge (5) installed at the pump delivery port, measure the pilot pressure under no load conditions. Check for difference in readings between gauges (5) and (6). 3. Repeat the measurements three times. Calculate the average values.



T234-04-04-001



Joy-Stick Lever



Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS.



6



T324-06-04-001



Bi-Directional Control Lever



T4-5-1



OPERATIONAL PERFORMANCE TEST / Component Test Adjustment of Primary Pilot Relief Pressure Adjustment:



1



Adjust the set pressure of pilot relief valve (1) provided on the pilot pump as necessary. 1. Remove cap (4) and loosen lock nut (2). 2. Turn adjusting screw (3). 3. Tighten lock nut (2). 4. Check the set pressure after adjustment. : Lock Nut (2): 24 mm : Adjusting Screw (3): 6 mm : 9.8 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)



4



NOTE: Guide for pressure Adjustment Adjusting Screw Turns Change in MPa 2 Relief (kgf/cm ) Pressure (psi)



T324-06-04-002



3 2



1/4



1/2



3/4



1



0.15 (4.6) (65)



0.9 (9.2) (130)



1.35 (13.7) (195)



1.8 (18.3) (260)



T324-06-04-003



T4-5-2



OPERATIONAL PERFORMANCE TEST / Component Test PILOT SECONDARY PRESSURE (PILOT VALVE DELIVERY PRESSURE) Measure the pilot valve delivery pressure to check the pilot valve function. Preparation: 1



1. Stop the engine. 2. Remove plug (1) from the pilot valve delivery port to the circuit to be measured. Install a pressure gauge unit to the plug hole. : 6 mm : 19 mm



T324-06-04-004



Fitting : ST 6069 Pressure Gauge Unit : ST 6932 3. Start the engine. Check that no oil is leaking from the pressure gauge unit connector. 1



4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). T324-06-04-005



Measurement: 1. Lower pilot control shut-off lever (2) to the UNLOCK position. Operate the control lever corresponding to the circuit in which the secondary pilot pressure is measured at each detent position. Then, measure the pilot pressure at full stroke with the pressure gauge.



UNLOCK Position



2



2. Repeat the measurements three times. Calculate the average values. Joy-Stick Lever



T234-04-01-001



Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS. Remedy: If the measurement results are abnormal, measure the pilot relief pressure. If the secondary pilot pressure is abnormal though the pilot relief pressure is normal, the pilot valve is faulty.



2



UNLOCK Position



M324-02-042



Bi-Directional Control Lever



T4-5-3



OPERATIONAL PERFORMANCE TEST / Component Test TRAVEL FAST/SLOW SPEED CONTROL PRESSURE (SE Pressure) Measure the travel speed control pilot pressure (SE pressure) to check the solenoid valve and electrical circuit for the travel speed control system. 5



Preparation: 4



1. Stop the engine.



1



2. Disconnect travel-speed-control hose (1) from elbow (2), then install adaptor (3) to elbow (2). : 19 mm, 22 mm Adaptor (3) : ST 6450 Fitting (4) : ST 6069 Pressure Gauge Unit (5) : ST 6932



3



3. Connect travel-speed-control hose (1) to adaptor (3). Install fitting (4) to adaptor (3), then install pressure gauge unit (5) to fitting (4). 4. Start the engine. Check that no oil leaks from the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Measure the travel speed control pilot pressures with the pressure gauge while the machine is traveling at slow and fast speeds. 2. Repeat the measurements three times. Calculate the average values. Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS. Remedy: If the measurement results are abnormal, check the pilot relief pressure (primary pilot pressure). If the primary pilot pressure is normal, either the solenoid valve or the electrical circuit may have trouble.



T4-5-4



2 T324-06-04-007



OPERATIONAL PERFORMANCE TEST / Component Test SWING BRAKE RELEASE PRESSURE (SI Pressure) Measure the swing brake release pilot pressure (SI pressure) to check the solenoid valve and electrical circuit for the swing brake release system. Preparation: 1. Stop the engine.



2



2. Disconnect swing brake release hose (1) from elbow (2), then install adaptor (3) to elbow (2). : 19 mm, 22 mm



1 T326-04-04-001



5



Adaptor (3) : ST 6451 Fitting (4) : ST 6069 Pressure Gauge Unit (5) : ST 6932 3. Connect swing brake release hose (1) to adaptor (3). Install fitting (4) to adaptor (3), then install pressure gauge unit (5) to nipple (4). 4



4. Start the engine. Check that no oil leaks from the pressure gauge connections. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



3 T324-06-04-025



6



Measurement: 1. With swing brake switch (6) turned ON or OFF, measure the swing brake release pilot pressure. 2. Repeat the measurements three times. Calculate the average values. Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS.



Joy-Stick Lever



Remedy:



T234-04-04-003



6



If the measurement results are abnormal, check the pilot relief pressure (primary pilot pressure). If the primary pilot pressure is normal, either the solenoid valve or the electrical circuit may have trouble.



T333-04-03-001



Bi-Directional Control Lever



T4-5-5



OPERATIONAL PERFORMANCE TEST / Component Test HYDRAULIC SYSTEM RELIEF PRESSURE Measure the hydraulic system relief pressure to check the main relief valve set pressure.



1 4



Preparation: 1. Stop the engine. 2. When measuring the main relief valve set pressure for the first pump (for the rear control valve), remove plug (3) from pressure check port (1) at the first pump delivery port. When measuring the main relief valve set pressure for the second pump (for the front control valve), remove plug (3) from pressure check port (2) at the second pump delivery port. Then, install fitting (4) and pressure gauge unit (5) to plug (3) hole. : 6 mm : 19 mm Fitting (4) : ST 6069 Pressure Gauge Unit (5) : ST 6934 3. (1) When measuring the main relief valve set pressure for the first main pump (the rear control valve): Disconnect left-travel-motor forward-drive piping (1) at the motor inlet. Then, install plug (ST6629) and union (ST6628) to the hose and the motor inlet pipe, respectively. (2) When measuring the main relief valve set pressure for the second main pump (the front control valve): Disconnect right-travel-motor forward-drive piping (3) at the motor inlet. Then, install plug (ST6629) and union (ST6628) to the hose and the motor inlet pipe, respectively. : 41 mm 4. Start the engine. Check that no oil leaks from the connections. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Run the engine at the maximum speed. 2. When measuring the relief valve set pressure on the first pump circuit, place the left travel lever to the forward position. When measuring the relief valve set pressure on the second pump circuit, place the right travel lever to the forward position. 3. Measure the relief pressure with the pressure gauge. 4. Repeat the measurements three times. Calculate the average values.



T4-5-6



5



3



2 T324-06-04-009



7



6



8 9



T324-06-04-035



6 - Left-Travel-Motor Forward-Drive Piping 7 - Left-Travel-Motor Reverse-Drive Piping



8 - Right-Travel-Motor Forward-Drive Piping 9 - Right-Travel-Motor Reverse-Drive Piping



OPERATIONAL PERFORMANCE TEST / Component Test Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS. 1



Remedy: Refer to T5-3 TROUBLE SHOOTING Adjustment: Adjust set pressure of relief valve (1) if necessary. 1. Loosen lock nut (3). 2. Turn adjusting screw (2) to adjust the set pressure. 3. Tighten lock nut (3) 4. Recheck the set pressure. : Lock Nut (3) : 22 mm : Adjusting Screw (2): 6 mm : 16.7 to 19.6 N⋅m (1.7 to 2.0 kgf⋅m, 12.3 to 14.5 lbf⋅ft)



NOTE: Guide for Pressure Adjustment Adjusting Screw 1/4 1/2 3/4 Turns 2.6 5.3 7.9 Change in MPa 2 Relief (kgf/cm ) (27) (54) (81) Pressure (psi) (384) (768) (1152)



2



3



T324-06-04-011



1 10.6 (108) (1536)



T326-06-04-002



3 2



Pressure Increase



Pressure Decrease W107-02-05-129



T4-5-7



OPERATIONAL PERFORMANCE TEST / Component Test CROWLER EXTEND/RETRACT SYSTEM RELIEF SET PRESSURE



1



Measure the Crawler Extend/Retract System Relief Set Pressure. Preparation: 1. Stop the engine. 2. Remove plug (1) from the pressure check port. 3. Install fitting and pressure gauge assembly to the pressure check port. : 22 mm, 19 mm, 17 mm Fitting : ST 6074 Pressure Gauge Assembly : ST 6933 4. Start the engine. Check the pressure gauge connection for oil leaks. 5. Check that the side frame securing link pin is installed. 6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: Main Relief Valve Set Pressure 1. Turn the crawler extend/retract switch to retract. 2. Gradually increase the engine speed up to the fast idle range. 3. Take a pressure gauge reading at this time. Port Relief Valve Set Pressure 1. Turn the crawler extend/retract switch to extend. 2. Gradually decrease the engine speed to the slow idle range. 3. Take a pressure gauge reading at this time. Repeat the measurement three times. Calculate the average values. Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS.



T4-5-8



T326-06-04-003



OPERATIONAL PERFORMANCE TEST / Component Test Relief Valve Set Pressure Adjustment:



3



Adjust the set pressure of relief valve (2) and port relief valve (3) if necessary. 1. Remove the cap. 2. Loosen lock nut (4). 3. Turn adjusting screw (5) to adjust the set pressure. 4. Tighten lock nut (4). T326-06-04-003



2



5. Recheck the set pressure. Relief Valve : Lock Nut (4): 24 mm : Adjusting Screw (5): 6 mm : 10 to 19.5 N⋅m (1 to 2 kgf⋅m) NOTE: Guide for Pressure Adjustment Adjusting Screw 1/4 1/2 3/4 Turns 3.3 6.7 10.0 Change in MPa 2 Relief (kgf/cm ) (34) (68) (102) Pressure (psi) (483) (967) (1450)



5 4



1 13.3 (136) (1930)



Relief Valve



5



Port Relief Valve



4



: Lock Nut (4): 17 mm : Adjusting Screw (5): 5 mm : 19.5 to 29.5 N⋅m (2 to 3 kgf⋅m) NOTE: Guide for Pressure Adjustment Adjusting Screw 1/4 1/2 3/4 Turns MPa 5.5 11.0 16.6 Change 2 in Relief (kgf/cm ) (56) (112.5) (169) Pressure (psi) (796) (1600) (2400)



1 Port Relief Valve



22.1 (225) (3200)



T326-06-04-004



4



Pressure Increase



5



Pressure Decrease W107-02-05-129



T4-5-9



OPERATIONAL PERFORMANCE TEST / Component Test SWING RELIEF SET PRESSURE



3



Preparation: 1. Stop the engine. 2



2. Remove plug (1) from the pressure check port. 3. Install fitting (2) and pressure gauge assembly (3) to the pressure check port.



1



: 22 mm, 19 mm, 17 mm Fitting (2) : ST 6074 Pressure Gauge Assembly (3) : ST 6933 4. Start the engine. Check the pressure gauge connection for oil leaks.



T326-06-04-005



5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). 4



Measurement: Joy-Stick Lever 1. Place swing lock lever (4) in the lock position to lock the swing function. 2. Run the engine at the maximum speed. 3. While relieving the oil pressure by slowly pushing or pulling swing control lever (5), take a pressure gauge reading. 4. Repeat the measurement three times. Calculate the average values.



T234-04-04-001



Joy-Stick Lever Left Swing



5



Right Swing



T234-04-04-003



Joy-Stick Lever



T4-5-10



OPERATIONAL PERFORMANCE TEST / Component Test Measurement: Bi-Directional Control Lever



4



1. Place swing lock lever (4) in the lock position to lock the swing function. 2. Run the engine at the maximum speed. 3. While relieving the oil pressure by slowly pushing or pulling swing control lever (5), take a pressure gauge reading. 4. Repeat the measurement three times. Calculate the average values. Bi-Directional Control Lever



Evaluation:



T324-06-04-013



5



Refer to T4-2 STANDARD SPECIFICATIONS. Swing Relief Valve Set Pressure Adjustment: Adjust the set pressure of relief valve (1) if necessary. Remove relief valve (1) from the swing control valve. Bi-Directional Control Lever



1. Loosen lock nut (2).



T333-04-03-001



2. Turn adjusting screw (3) to adjust the set pressure. 3. Tighten lock nut (2). 4. Recheck the set pressure. : Lock Nut (2): 13 mm : Adjusting Screw (3): 4 mm : 16.7 to 19.5 N⋅m (1.7 to 2 kgf⋅m) NOTE: Guide for Pressure Adjustment Adjusting Screw 1/4 1/2 3/4 Turns 2.6 5.3 7.9 Change in MPa 2 Relief (kgf/cm ) (27) (54) (81) Pressure (psi) (384) (768) (1150)



1



1 10.6 (108) (1540)



T326-06-04-006



2



Pressure Increase



3



Pressure Decrease W107-02-05-129



T4-5-11



OPERATIONAL PERFORMANCE TEST / Component Test OVERLOAD RELIEF VALVE SET PRESSURE Checking the pressure setting of the overload relief valves on the machine is not recommended for the following reasons: 1. With the return circuit from the control valve blocked, the circuit pressure must be increased by applying an external load. This checking method is hazardous and the results obtained with this method are unreliable. 2. Pressure setting of the overload relief valve must be made at a specified oil flow rate normally far smaller than the delivery flow rate of the main pump. Accordingly, even if the engine speed is reduced and the main relief valve pressure setting can be reset higher than the setting pressure of the overload relief valve, the main pump supplies too much oil to correctly measure the setting pressure of the overload valve. The main relief valve has pre-leaking function. Accordingly, the main relief valve pressure setting may not be reset higher than the set pressure of the overload relief valve plus the pressure at pre-leaking. Therefore, when the setting pressure of the overload relief valve must be checked correctly, remove the overload relief valve from the machine and check the overload relief valve unit performance using the test stand and test block prepared for this purpose. If the poppet of overload relief valve seats to the body of control valve, the test block requires precise machining. Use other control valve unit for the measurement instead of the test block. 3. As an easier method, however, measure the relief pressure of each cylinders in the same method as of main relief pressure setting in previous section. Then, when each relief pressure meets its respective specifications, judge that the setting pressure of the overload relief valve is correct. Measurement: Repeat the measurement three times and calculate the average values. Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS.



T4-5-12



OPERATIONAL PERFORMANCE TEST / Component Test MAIN/AUX. DRUM MOTOR MULTI-DISC BRAKE RELEASE PRESSURE 5



Check that the main/aux. drum motor brakes are correctly released. Preparation: 1. Stop the engine.



2



2. Disconnect brake release pressure hose (1) from elbow (2). Install adaptor (3) to elbow (2). Connect hose (1) and install fitting (4) to adaptor (3). Install pressure gauge unit (5) to fitting (4).



4



3



: 19 mm, 22 mm Adaptor (3) : ST 6450 Fitting (4) : ST 6069 Pressure Gauge Unit (5) : ST 6932



T324-06-04-025



1 T324-06-04-018



3. Start the engine. Check that no oil leaks from the pressure gauge connections. 4. Check that the hook overhoist prevention device functions correctly. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. While operating the hoist lever corresponding to the motor to be measured, measure the brake release oil pressure in both raise and lower directions. 2. Repeat the measurements three times. Calculate the average values. Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS.



T4-5-13



OPERATIONAL PERFORMANCE TEST / Component Test MAIN/AUX. DRUM MOTOR SEQUENCE VALVE CONTROL PILOT PRESSURE 5



Check if pilot oil pressure to control the main/aux. drum motor sequence valve is correct or not. Preparation: 1. Stop the engine.



2



2. Disconnect hose (1) from elbow (2) at the pilot oil inlet port of the sequence valve. Install adaptor (3) to elbow (2). Install hose (1) and fitting (4) to adaptor (3). Then, install pressure gauge unit (5) to fitting (4). : 19 mm, 22 mm



4



Adaptor (3) : ST 6450 Fitting (4) : ST 6069 Pressure Gauge Unit (5) : ST 6932



3 T324-06-04-025



1



3. Start the engine. Check that no oil leaks from the pressure gauge connections. 4. Check that the hook overhoist prevention device functions correctly. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. While operating the hoist lever in both raise and lower directions at the first speed position or faster, measure the pilot pressure. 2. Repeat the measurements three times. Calculate the average values. Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS.



T4-5-14



T324-06-04-018



OPERATIONAL PERFORMANCE TEST / Component Test MAIN PUMP FLOW RATE 4. Connect the measuring equipment:



Measure the first and second main pump delivery oil flow rate at the specific pressure using a hydraulic tester provided on the delivery port of the first and second main pumps to check the pump performance.



(1) Remove bolts (5) (four used) tightening split flange (4) which connects delivery pipe (2) of first main pump (1) and hose (3). : 10 mm



NOTE: This test requires two units of hydraulic testers.



(2) Remove hose (7) from second main pump (6) in the same procedure as step (1). : 10 mm



Preparation: 1. Stop the engine. 2. Remove the cap for the oil supply port on the hydraulic oil tank. 3. Connect a vacuum pump to the oil supply port. NOTE: Continue to operate the vacuum pump as long as the measuring piping is connected.



2



1 6 5 4 7



3 T326-05-01-003



1 - First Main Pump 2 - Pipe



3 - Hose 4 - Split Flange



5 - Bolt 6 - Second Main Pump



T4-5-15



7 - Hose



OPERATIONAL PERFORMANCE TEST / Component Test (3) Install pipe J (8) together with the O-ring to pipe (2) and tighten split flange (4) with bolt (5). : 10 mm (4) Install fitting (12) and fitting (13) to the inlet and outlet ports of tester (10), respectively. : 41 mm (5) Connect test hoses (9) to fitting (12) and (13). : 41 mm (6) Connect test hose (9) to pipe J (8). : 41 mm



(7) Connect flange (14) to the other end of hose (9) connected to fitting (13). : 41 mm (8) After installing O-ring (11) to hose (3), connect hose (3) to flange (14) with split flange (4) and bolt (5). : 10 mm (9) Install tester (10) and measuring pipings into the second main pump circuit in the same procedure as taken at steps 4 through 8 above.



2



8 4



7 5



14 11 4 5



9



12



234578-



Pipe Hose Split Flange Bolt Hose Pipe J (ST 6144) (with O-ring Z966993)



13



10



3



910 11 12 13 14 -



Test Hose (ST 6145) (two used) Tester (ST 6299) O-Ring (Z966993) Fitting (ST 4146) Fitting (ST 6330) Flange (ST 6118)



T4-5-16



T324-06-04-027



OPERATIONAL PERFORMANCE TEST / Component Test (10) Install pressure gauges to each port of PU (power increase signal) inlet (A), PD (power decrease signal) inlet (B) and P3 (swing pump pressure) outlet (C) of the regulator.



19 19



C



• Disconnect hoses (15, 16 and 17) from ports (A, B, and C) of the regulator. 17



• Install adaptors (18) to ports (A, B, and C). • Connect hoses (15, 16, and 17) to adaptors (18).



19



B



• Install fitting (20) to adaptors (18). 18



• Install pressure gauge units (19) to fitting (20). : 17 mm, 19 mm 18



Adaptor (18) : ST 6450 Fitting (20) : ST 6069 Pressure Gauge Unit (19) : ST 6932



A



20 16



(11) Remove the vacuum pump. (12) Loosen the plug on the pump casing to bleed air from the casing.



18



15



(13) Tighten the hydraulic oil tank cap. T324-06-04-028



(14) Install an engine tachometer to the fuel injection pipe. (15) Fully open a loading valve of the hydraulic tester. (16) Start the engine. Bleed air from the pump casing again. Check that no oil leaks from the pressure gauge connections.



15 16 17 18 19 20 -



Hose Hose Hose Adapter Pressure Gauge Unit Fitting



(17) Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Run the engine at the maximum speed. 2. Select the crane mode. 3. Read each oil pressure gauge for PU, PD, and P3. Check that their readings are within the ranges shown in the following table.



MPa 2 (kgf/cm ) (psi)



PU (Power Increase) 0.85 (8.7±2) (124±28)



PD (Power Decrease) 0±0.20 (0±2) (0±28)



T4-5-17



P3 (Third Main Pump) 0.49±0.98 (5 to 10) (71 to 142)



OPERATIONAL PERFORMANCE TEST / Component Test 4. While operating the first and second main pumps under no load, measure the pump flow rates and engine speeds, and record them. 5. Measure the pump flow rates and engine speeds at the oil pressures shown in the following table. Oil pressure shall be the combined total pressure of the first and second pump delivery pressure. Adjust the total pressure by controlling the loading valve of the two hydraulic testers. Pressure 2 MPa (kgf/cm , psi) Flow Rate L/min -1 Engine Speed min



1. 9 (50, 711)



2. 4 (330, 4693)



6. Convert the measured oil flow rate into the pump flow rate at the specified pump speed using the following formula. Qc=(Q×Np)/(i×Ne) Where: Q : Measured Flow Rate (L / min) Qc : Converted Flow Rate (L / min) -1 Np : Pump Specified Speed (2 000 min ) (rpm) -1 Ne : Measured Engine Speed (min ) (rpm) i : Pump transmission gear ratio, 1.03 Qc=2000×Q/(1.03×Ne)=1942×Q/Ne Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS.



T4-5-18



3. 2 (420, 5972)



51.0 (520, 7394)



OPERATIONAL PERFORMANCE TEST / Component Test (Blank)



T4-5-19



OPERATIONAL PERFORMANCE TEST / Component Test SWING MOTOR DRAINAGE While rotating the superstructure, measure the drain oil quantities of the swing motor to check for wear and damage in the swing motor. NOTE: 1. Evaluate the swing motor operational performance comprehensively by additionally referring to the swing speed test results. 2. The drain oil quantities of the swing motor will change depending on the oil temperature. Maintain the oil temperature within 50±5 °C (122±9 °F) for correct measurement. CAUTION: During the measurement, always give the first priority to safety of the personnel. Make sure the area is clear and large enough to safely swing the superstructure. Preparation: 1. Secure enough space on a level and solid ground to allow the machine to make a full swing. Never attempt to perform the measurement on a slope. 2. Maintain the oil temperature at 50±5 °C (122±9 °F). Rotate the swing motor to warm the inside of the motor.



1



2



3. Stop the engine. 4. Disconnect drain hose (1) from the swing motor. Install 3/8 plug to the removed end of hose (1). Then, connect hose (2) to the swing motor in place of hose (1) to receive the drain oil. : 22 mm To Hydraulic Oil Tank



T4-5-20



T326-06-04-007



OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Drain Hydraulic Oil Quantities While Swinging (1) Use the basic boom with the hook. Set the boom angle to 60 °. (2) After raising the hydraulic oil temperature to 50±5 °C (122±9 °F), let the hydraulic oil flow into the swing motor drive circuit for more than two minutes before starting the test. (3) Run the engine at the maximum speed. Operate the swing control lever to full stroke. After the swing speed reaches a maximum constant speed, measure the drain oil quantities from hose (2) and the time of measurement. (4) Repeat the measurement more than three times in both clockwise and counterclockwise directions. Calculate the average values. (5) Allow more than 45 seconds per measurement.



2 m (6.6 ft)



60°



T324-06-03-001



2



2. Drain Hydraulic Oil Quantities While the Swing Function is Locked (1) Place swing lock lever (3) in the lock position. (2) Start the engine. Operate the swing control lever to full stroke. Measure the drain oil quantities from hose (2) and the time of measurement. (3) Repeat the measurement more than three times in both clockwise and counterclockwise directions. Calculate the average values. (4) Allow more than 45 seconds per measurement.



T326-06-04-008



3



Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS.



NOTE: Measure the total quantity of drain oil with a calibrated container. Calculate the quantity of drain oil per minute using the following formula: ∆Q=(60/t)×q ∆Q : Quantity of drain oil per minute (L/min) t : Measuring time (sec) q : Total quantity of drain oil (L)



T234-04-04-001



Joy-Stick Lever 3



T324-06-04-013



Bi-Directional Control Lever



T4-5-21



OPERATIONAL PERFORMANCE TEST / Component Test TRAVEL MOTOR DRAINAGE While driving the machine straight on a level and solid ground, measure the drain oil quantities of the travel motor to check for wear and damage in the travel motor.



NOTE: Evaluate the travel motor operational performance comprehensively by referring to the travel speed and mistrack test results. CAUTION: 1. During the measurement, always give the first priority to safety of the personnel. Make sure the area is clear and large enough to safely drive the machine. 2. Be sure to have a signal person watch the area around the machine while traveling. 1



Preparation:



2



1. Maintain the oil temperature at 50±5 °C (122±9 °F). Before starting the measurement, perform the break-in operation of the machine to warm the inside of the motor. 2. Disconnect drain hose (1) from the travel motor. Install 3/8 plug to the removed end of drain hose (1). 3. Connect hose (2) to the travel motor to receive the drain oil. : 22 mm



T4-5-22



T326-06-04-009



OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Start the engine. 2. Following instructions of the signal person, set the boom with the hook in the position as illustrated in the figure at right.



2 m (6.6 ft)



3. Select the fast travel mode. 60 °



4. Run the engine at the maximum speed. Following instructions of the signal person, move the travel lever to the forward position to start traveling. 5. Receive drain oil from hose (2) with a measuring container and measure the time simultaneously.



2



T324-06-03-001



6. Repeat the measurements three times. Calculate the average values. 7. Take more than 45 seconds per measurement. Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS.



NOTE: Measure the total quantity of drain oil with a calibrated container. Calculate the quantity of drain oil per minute using the following formula: ∆Q=(60/t)×q ∆Q : Quantity of drain oil per minute (L/min) t : Measuring time (sec) q : Total quantity of drain oil (L)



T4-5-23



T326-06-04-010



OPERATIONAL PERFORMANCE TEST / Component Test BOOM HOIST MOTOR DRAINAGE Summary: 1. The boom hoist motor performance is checked by measuring the drain oil amount from the boom hoist motor while slowly operating the boom hoist lever forward (to the boom lower position) with the boom hoist drum locked. 2. Secure the inspectors’ safety during the measurement. Take care not to damage any surrounding buildings or vegetation. 3. Drain oil amount from the boom hoist motor will be greatly affected by the oil temperature. Maintain the oil temperature in the proper range. Boom Hoist Motor



Preparation: CAUTION: Be sure to check that safety is secured around the drum and the base machine, and the boom and hook are securely held. 1. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Rotate the boom hoist motor to warm the inside of the motor. 2. Stop the engine. Disconnect boom hoist motor drain hose (1) at the return oil port to the hydraulic oil tank. Put plug to the return oil port to the hydraulic oil tank. : 27, 32 mm : 157 N⋅m (18 kgf⋅m, 130 lbf⋅ft)



T4-5-24



T333-04-04-100



OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Attach the basic boom with the boom angle set at 60 °. (Or dismount the front attachment and counterweight.) 2. Start the engine. With the boom hoist drum locked, slowly operate the boom hoist lever forward (to the boom lower position) to relieve the boom hoist circuit pressure. Increase the engine speed to the fast idle speed. 3. Receive the hydraulic oil coming out of the drain hose and measure the time and the volume at the same time. 4. Repeat the measurement three times and calculate the average value. 5. Take the measurement for more than 45 seconds.



2 m (6.6 ft)



60°



Evaluation: Refer to T4-2 STANDARD SPECIFICATIONS. T324-06-03-001



NOTE: Conversion of the Measured Values Receive the drain oil with a measuring vessel such as a measuring cylinder or cup. Obtain the converted drain oil amount using the formula below: ∆Q = 60 × q t Where:



∆Q: Drain Oil Amount (L/min) t: Measuring Time (sec) q: Measured Drain Oil Amount (L)



T4-5-25



OPERATIONAL PERFORMANCE TEST / Component Test (Blank)



T4-5-26



MEMO .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... ....................................................................................................................................................................



MEMO .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... .................................................................................................................................................................... ....................................................................................................................................................................



SECTION 5



TROUBLESHOOTING



—CONTENTS— Group 1 Diagnosing Procedure



Malfunction of ESS (Engine Speed Sensing)



Introduction ..............................................T5-1-1 Diagnosing Procedure ..............................T5-1-2



Control .................................................T5-3-16 Malfunction of Pump Superfine Speed Control.......................................T5-3-23



Group 2 Component Layout



Malfunction of Boom Hoist Speed Control.......................................T5-3-28



Joy-Stick Lever Major Components ...................................T5-2-1



Malfunction of Slow Stop Control ............T5-3-34



Electrical System (Inside Cab)..................T5-2-2



Malfunction of Hoist Third Speed



Electrical System (Outside Cab) ...............T5-2-4



Selection Control ....................................T5-3-40



Bi-Directional Lever



Malfunction of Drum Speed Sensing .......T5-3-44



Major Components ...................................T5-2-7



Malfunction of Swing Speed Control .......T5-3-50



Electrical System (Inside Cab)..................T5-2-8



Malfunction of Work Mode Control..........T5-3-57



Electrical System (Outside Cab) .............T5-2-10 Pump Device..........................................T5-2-12



Group 4 Troubleshooting B



Swing Device .........................................T5-2-13



Troubleshooting B Procedure ...................T5-4-1



Hoist Device ...........................................T5-2-14



Troubleshooting List .................................T5-4-2



Boom Hoist Device .................................T5-2-15



Engine Troubleshooting ............................T5-4-4



Control Valve..........................................T5-2-16



Actuator Control System



Travel Device .........................................T5-2-20



Troubleshooting ....................................T5-4-18



Solenoid Valve........................................T5-2-20



Hoist Drum Control Troubleshooting .......T5-4-20 Joy-Stick Lever



Group 3 Troubleshooting A



Brake System Set Dimensions



Troubleshooting A Procedure....................T5-3-1



and Checking Procedures.....................T5-4-32 Check and Adjust Hoist Brake ................T5-4-36



Monitor Indicator Display and Failure Type ...........................................T5-3-2 Failure in Main Controller System .............T5-3-3 Failure in Engine Controller System..........T5-3-6



Bi-Diretional Control Lever Brake System Set Dimensions and Checking Procedures.....................T5-4-40 Check and Adjust Hoist Brake ................T5-4-44



Malfunction of Pump Torque Calibration Control................................ T5-3-11



24DT-5-1



Group 6 Troubleshooting D



Boom Hoist Drum Control Troubleshooting....................................T5-4-48



Troubleshooting D Procedure ...................T5-6-1



Swing System Troubleshooting...............T5-4-50



Fault Code E05 ........................................T5-6-3



Travel System Troubleshooting ..............T5-4-52



Fault Code E20 ........................................T5-6-4



Other Control Troubleshooting................T5-4-55



Fault Code E21 ........................................T5-6-6



Auto-Stop Controller Indicator.................T5-4-60



Fault Code E40, 42...................................T5-6-8 Fault Code E50 ........................................T5-6-9



Group 5 Troubleshooting C



Fault Code E52 ...................................... T5-6-11



Troubleshooting C Procedure ...................T5-5-1



Fault Code E54 ......................................T5-6-12



Malfunction of Coolant Temperature Gauge ..........................T5-5-2 Malfunction of Fuel Gauge .......................T5-5-4 Malfunction of Level Check Switch ...........T5-5-6 Malfunction of Engine Oil Level



Group 7 Electrical System Inspection Precaoutions for Inspection and Maintenance ....................................T5-7-1 Instructions for Disconnecting



Indicator ............................................T5-5-8 Malfunction of Coolant Level



Connectors ....................................T5-7-3 Fuse Continuity Test .................................T5-7-5



Indicator..........................................T5-5-10 Malfunction of Hydraulic Oil



Fusible Link Check ...................................T5-7-7 Voltage and Current Check .......................T5-7-8



Level Indicator ......................................T5-5-12



Continuity Check .................................... T5-7-11



Malfunction of Alternator Indicator ..........T5-5-14



Circuit Check..........................................T5-7-13



Malfunction of Engine Oil Pressure Indicator ................................T5-5-16 Malfunction of Overheat Indicator ...........T5-5-18 Malfunction of Air Filter Restriction Indicator..........................................T5-5-20 Malfunction of Buzzer .............................T5-5-22 Malfunction of Engine Oil Filter Restriction Indicator.......................T5-5-24 Malfunction of Controller Malfunction Indicator ........................................T5-5-26 Malfunction of Brake Unapplied Indicator ........................................T5-5-28 Malfunction of Hydraulic Oil Overheat Indicator ...............................................T5-5-30



24DT-5-2



TROUBLESHOOTING / Diagnosing Procedure INTRODUCTION Inspection procedures for troubleshooting are presented in an orderly fashion in this section so as to enable you locate the source of any problems that may arise. The troubleshooting section consists of 6 groups: the diagnosing procedure, component layout, troubleshooting A (control system), troubleshooting B (base machine operation system), troubleshooting C (monitor system), and electrical system inspection. • Troubleshooting A (Control System) Use this group when a controller failure indicator on the monitor panel is blinking. Example: Abnormal accelerator control. • Troubleshooting B (Base Machine Operation System) Use this group when any trouble exists in the base machine operation system except the main controller and/or auto-stop controller system. Example: Hoist and/or lower function is inoperable. • Troubleshooting C (Monitor System) Use this group when any trouble regarding monitors such as gauges and/or indicators occur. Example: Fuel gauge is inoperable.



• Troubleshooting D (Auto-Stop Controller System) Use this group when any trouble hoist operations (main / aux. / boom hoist) automatically stop, even if they are not auto-stop position. • Electrical System Check Method Refer to this group when precautions and/or inspection data for the electrical system check is required. • Inspection/Measurement Harness Refer to this group for precautions and inspection procedures of the electrical system when or before performing inspections on the electrical system.



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 your star witness --- the operator.



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 details of the trouble? Is the trouble getting worse, or did it appear suddenly for the first time? (d) Did the machine have any other troubles previously? If so, which parts were repaired before? 3. Inspect the machine Before starting the troubleshooting procedure, cheek the machine’s daily maintenance points, as shown in the operator’s manual.



T107-07-01-002



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 noticing a blown fuse, incorrect diagnosis may result along with a large amount of lost time. Be sure to check if any fuse has blown before starting troubleshooting. Fuse failure is often caused by a fine crack in the fuse, and such fine cracks are very hard to detect by visual inspection. Always check fuses using a tester.



T5-1-2



T107-07-01-003



TROUBLESHOOTING / Diagnosing Procedure 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. 5. Perform troubleshooting CAUTION: Never attempt to disconnect harnesses or hydraulic lines while the engine is running. The machine may malfunction or pressurized oil may spout, possibly resulting in personal injury. Be sure to stop the engine before disconnecting harnesses or hydraulic lines.



T324-07-01-002



First identify in which group the trouble is present. Then, perform the troubleshooting, system by system, in accordance with the classification of Troubleshooting A, B, C and D as described in this group. 6. Trace possible causes Before reaching a conclusion, check the most likely causes again. Try to identify the actual cause of the trouble. Based on your conclusion, make a plan for appropriate repairs to avoid consequent malfunctions.



T324-07-01-003



T5-1-3



TROUBLESHOOTING / Diagnosing Procedure (Blank)



T5-1-4



TROUBLESHOOTING / Component Layout MAJOR COMPONENTS Lever Pattern; Joy-Stick Lever



4



9



5 6



30 10



7 8



11



12 13



14



3



2 1



15 16



17



29 28



18 27



19



26



20



25 24



22



23



1234-



Hydraulic Oil Tank Pump Device Muffler Air Cleaner



910 11 12 -



5678-



Engine Radiator Oil Cooler Battery



13 14 15 16 -



T24D-01-02-004



21



Main Hoist Drum Swing Device Aux./Swing Pilot Valve Main/Boom Hoist Pilot Valve Travel Pilot Valve Pilot Shut-off Valve Main Hoist Motor Control Valve



17 18 19 20 -



Swing Bearing Center Joint Aux. Hoist Motor Control Valve



21 - Solenoid Valve 22 - 8-Unit Solenoid Valve 23 - Travel Device



T5-2-1



24 25 26 27 -



Travel Motor Fuel Tank Boom Hoist Drum Counterweight



28 - Main Frame 29 - Aux. Hoist Drum 30 - Control Valve



TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM (INSIDE CAB) Lever Pattern; Joy-Stick Lever 232 130 52 57-1 57-2 145-1 145-2 145-3 127



29-1 218 219 220 196



45-4 29



45-3



28



144 143



38



38-2



42-A 42-B



34 210-1 45-1



55 54



108 98 99 119 112



83



135



47



209 66 184



38-1 48



49 37-2



210-2 42-1 42-2



37



62-1 62-3



114 65



134



37-1



35 126



36



62-5 62 62-2



122 123 138 206 190



24 25 27 109 110 170 190 245 100 243



101 102 103 104



235 236 105 197



106 107 111



124 125 T326-01-02-003



T5-2-2



TROUBLESHOOTING / Component Layout



24 -



Monitor Controller



47 -



Main Host Drum Lock Switch



104 - Aux. Hoist Brake Relay (R7)



25 -



Main Controller



48 -



27 -



EC Controller



49 -



28 -



Monitor Panel



52 -



Aux. Host Drum Lock Switch Boom Hoist Drum Lock Switch Travel Mode Switch



54 -



Cigar Lighter



105 - Aux. Hoist Brake Relay (R8) 106 - Aux. Hoist Brake Relay (R9) 107 - Aux. Brake Hollding Relay (R10) 108 - Horn Relay (R11)



29 -



Auto-Stop Override Switch 29-1 - Override Selection Switch 34 - Key Switch



Wiper Switch (Front and Top Window) 57-1 - Swing Alarm Switch



35 -



Fuse Box



57-2 - Auxillary Switch



36 -



Radio



62 -



37 -



Main Hoist/Boom Hoist Lever 37-1 - Third Speed Selection Switch 37-2 - Horn Switch 38 -



Swing/Aux. Hoist Lever



55 -



Right Stand Control Panel 62-1 - Right Stand Tilt Control Switch 62-2 - Main Hoist Brake Mode Switch



62-3 - Aux. Hoist Brake Mode Switch 62-5 - Superfine Speed Switch



144 -



Aux. Hoist Hook Overhoist Connector Check Switch 145-1 - Auxiliary Switch-1 145-2 - Auxiliary Switch-2 145-3 - Auxillary Switch-3



170 -



109 - Micro-Computer Failure Indicator Relay (R12) 110 - Main Hoist Auto-Brake Indicator Relay (R13) 111 - Aux. Hoist Auto-Brake Indicator Relay (R14) 112 - Work Light Relay (R15)



184 -



114 - Swing Alarm Relay (R17) 119 - Main/Aux. Hoist Brake Unapplied Indicator Relay (R22) 122 - Buzzer (Monitor Alarm)



206 -



123 - Load Dump Prevention Relay (R25) 124 - Bell (Hook Overhoist Alarm) 125 - Buzzer (Boom Overhoist Alarm) 126 - Auto-Brake Circuit Failure Alarm 127 - Cab Light



210-2 - Swing Speed Control Dial 218 - Main Hoist Drum Lock Relay (R33) 219 - Aux. Hoist Drum Lock Relay (R34) 220 - Boom Hoist Drum Lock Relay (R35) 232 - Moment Limiter Mode Indicatior



190 196 197 -



209 -



65 -



Intermittent Wiper Unit



66 -



Swing Brake Indicator



42-A - Accelerator Lever



83 -



Pre-Heat Timer



42-B - Superfine Speed Control Lever (Hoist and Travel) 42-1 - Accelerator Potentiometer 42-2 - Hoist and Travel Speed Control Potentiometer 45-1 - Crawler Extend-Retract Switch



98 -



Swing Brake Relay (R1)



Swing Brake Unapplied Prevention Relay (R2) 100 - Main Hoist Brake Relay (R3) 101 - Main Hoist Brake Relay (R4)



130 - Moment Limiter



235 -



134 - Main Controller Check Switch 135 - Fast Idle Calibration Switch



236 -



45-3 - Work Mode Switch



102 - Main Hoist Brake Relay (R5)



138 -



Engine Oil Pressure Switch Relay (R28)



245 -



45-4 - Boom Slow Stop Switch



103 - Main Brake Holding Relay (R6)



143 -



Main Hoist Hook Overhoist Connector Check Switch



T5-2-3



Engine Emergency Stop Relay (R16) Crawler, Gantry and Jack Relay (R32) Hydraulic Oil Overheat Indicator



210-1 - Swing Mode Switch



38-1 - Third Speed Selection Switch 38-2 - Swing Brake Switch



99 -



Pilot Control Shutt-Off Lever Relay (R24) Boom Hoist Speed Control Dial Swing Lever Sensing Relay (R26) Engine Re-Start Switch



243 -



Brake Pedal Switch Indicator Relay (R37) Brake Pedal Switch Indicator Relay (R38) 3-Winding Layer Prevention Relay (R40) 3-Winding Layer Prevention Relay (R42)



TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM (OUTSIDE CAB) Lever Pattern; Joy-Stick Lever



11



188 40 30



4



26



56



7



174 11



1 10



93



79



6 18



208 43



5 12



171



40



58 60



81



59



9



84



2



82 74 80 77 3 T24D-01-02-005



1 - Coolant Temperature Sensor 2 - Fuel Level Sensor



10 - Oil Filter Restriction Switch



56 - Wiper (Overhead Window)



81 - Glow Plug



11 - Work Light



82 - Current Sensor



3 - Engine Oil Level Switch



12 - Window Washer



4 - Coolant Level Switch



18 - N Sensor (Pump)



5 - Hydraulic Oil Level Switch



26 - Auto-Stop Controller



58 - Motor (Main Hoist Drum Lock) 59 - Motor (Aux. Hoist Drum Lock) 60 - Motor (Boom. Hoist Drum Lock) 74 - Engine Stop Solenoid



6 - Engine Oil Pressure Switch 7 - Overheat Switch



30 - Backup Switch 40 - Interior Speaker



77 - Starter 79 - Alternator



9 - Air Restriction Switch



43 - Antenna



80 - Glow Relay



T5-2-4



84 - Fuel Suction Pump 93 - Wiper (Front Windshield) 171 - Pressure Switch (Pilot Control Shut-Off Lever) 174 - ML (Moment Limiter)Lamp 188 - Switch Box (Brake Mode, Moment Limiter) 208 - Hydraulic Oil Temperature Switch



TROUBLESHOOTING / Component Layout



71 234 89 90 246



75 78 234 85



73



76



86



72



20



19



91 241 240



136



173 159 160 172 214 128



96



94



23 69 225



182



92



87



T24D-01-02-002



17



85



17 - 8-Unit Solenoid Valve



76 - Battery Relay



19 - Limit Switch (First Boom Overhoist) 20 - Limit Switch (Second Boom Overhoist) 23 - Auto-Stop Solenoid Valve (6-Units)



78 - Starter Relay



69 - Pressure Switch (Audio Device for Travel) 71 - Battery



87 - Swing Flasher Relay



159 -Fusible Link (30 A)



89 - Horn (High Sound)



160 -Fusible Link (30 A)



72 - Fusible Link (45 A)



90 - Horn (Low Sound)



172 -Fusible Link (45 A)



73 - Fusible Link (65 A) 75 - Emergency Relay



91 - Tilt Motor (Lever Stand) 92 - Solenoid Valve (Brake Mode Selection)



173 -Fusible Link (65 A) 182 - Solenoid Valve (Crawler Extend/Retract)



85 - Swing Alarm Indicator /Buzzer 86 - Swing Pilot Pressure Switch



94 - Pressure Switch (Main and Aux. Hoist Brake) 96 - Pressure Switch (Main and Aux. Hoist Brake) 128 - Base Machine Relay Box 136 -Engine Control Motor



T5-2-5



196 - Boom Hoist Pressure Switch 214 - Pressure Switch (Boom Hoist) 225 - Solenoid Valve Assembly (3-units, Third Hoist Drum) 234 - Limit Switch (Main and Aux. Hoist Drum and 3-Winding Layer Prevention) 240 - Limit Switch (Main Hoist Brake Pedal) 241 - Limit Switch (Aux. Hoist Brake Pedal) 246 - Limit Switch (Boom Lower Limter)



TROUBLESHOOTING / Component Layout (Blank)



T5-2-6



TROUBLESHOOTING / Component Layout MAJOR COMPONENTS Lever Pattern; Bi-Directional Control Lever



4



5 6 7



9 8



30 10 11



3 2 1



14



15 16 17



29



18 28 27



19 20



26



21



25



22



24



T24D-01-02-006



23



12345678-



Hydraulic Oil Tank Pump Device Muffler Air Cleaner Engine Radiator Oil Cooler Battery



910 11 14 15 16 17 18 -



Main Hoist Drum Swing Device Cab Pilot Shut-off Valve Main Hoist Motor Control Valve Swing Bearing Center Joint



19 20 21 22 23 24 25 -



T5-2-7



Aux. Hoist Motor Control Valve Solenoid Valve 8-Unit Solenoid Valve Travel Device Travel Motor Fuel Tank



26 27 28 29 30 -



Boom Hoist Drum Counterweight Main Frame Aux. Hoist Drum Control Valve



TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM (INSIDE CAB) Lever Pattern; Bi-Directional Control Lever 38-1 38-2



37-1 37-2



130



41-3 41-1 41-2 49 143 34 47 144 52 178 48 55-1 57 45 55-2 145 127 189 29 54 26



62-1 62-2 62-3 184



62-5



210-2 210-1



198 196 135 112



134 113



99 119



98



65



42 108 114 36



197 122



35 83 25 24 27 109



170



110 123 126



100 101 102 104 103 105



111



124



29



125 197 106



107



T24D-01-02-003



T5-2-8



TROUBLESHOOTING / Component Layout



24 -



Monitor Controller



48 -



25 -



Main Controller



49 -



26 -



Auto Stop Controller



52 -



Aux. Host Drum Lock Switch Boom Hoist Drum Lock Switch Travel Mode Switch



27 -



EC Controller



54 -



Cigar Lighter



28 -



Monitor Panel



55 -1 Wiper Switch (Front Window)



107 - Aux. Hoist Brake Relay (R10)



29 -



109 - Micro-Computer Failure Indicator Relay (R12)



170 - Pilot Control Shutt-Off Lever Relay (R24)



35 -



Fuse Box



36 -



Radio



55 -2 Wiper Switch (Top Window) 57 - Drum Speed Sensing Switch (Main and Aux. Hoist) 62 -1 Main Stand Tilt Control Switch 62 -2 Aux. Hoist Brake Mode Switch 62 -3 Main Hoist Brake Mode Switch 62 -5 Superfine Speed Switch



108 - Horn Relay (R11)



34 -



Auto-Stop Override Switch Key Switch



134 - Main Controller Check Switch (Black) 135 - Fast Idle Calibration Switch (White) 143 - Main Hoist Hook Overhoist Connector Check Switch 144 - Aux. Hoist Hook Overhoist Connector Check Switch 145 - Option Switch-1



110 - Main Hoist Auto-Brake Indicator Relay (R13) 111 - Aux. Hoist Auto-Brake Indicator Relay (R14) 112 - Work Light Relay (R15)



178 - Crawler Extend-Retract Switch 184 - Boom Hoist Speed Control Dial 189 - Slow Stop Selector



113 - Hour Meter Relay (R16)



190 - Swing Lever Sensing Relay (R26) 196 - Engine Re-Start Switch



37 -1 Main Hoist Lever 37 -2 Third Speed Selection Switch (Main) 38 -1 Aux. Hoist Lever 38 -2 Third Speed Selection Switch (Aux.)



83 -



Intermittent Wiper Unit (Front and Top Window) Pre-Heat Timer



41 -1 Swing Brake Switch



98 -



Swing Brake Relay (R1)



41 -2 Horn Switch



99 -



41 -3 Potentiometer (Accelerator Grip) 42 - Potentiometer (Accelerator Lever, Superfine) 45 - Work Mode Switch 47 -



Main Host Drum Lock Switch



65 -



103 - Main Hoist Brake Relay (R6) 104 - Aux. Hoist Brake Relay (R7) 105 - Aux. Hoist Brake Relay (R8) 106 - Aux. Hoist Brake Relay (R9)



114 - Swing Alarm Relay (R17) 119 - Main/Aux. Hoist Brake Unapplied Indicator Relay (R22) 122 - Buzzer (Monitor Alarm)



Swing Brake Unapplied Prevention Relay (R2) 100 - Main Hoist Brake Relay (R3) 101 - Main Hoist Brake Relay (R4)



123 - Automatic Brake Circuit Failure Alarm 124 - Bell (Hook Overhoist Alarm) 125 - Buzzer (Boom Overhoist Alarm)



102 - Main Hoist Brake Relay (R5)



126 - Auto-Brake Circuit Failure Alarm 127 - Cab Light



T5-2-9



130 - Moment Limiter



197 - Engine Emergency Stop Relay (R27) 198 - Brake Mode Selection Switch 210 -1 Swing Mode Switch 210 -2 Swing Speed Control Dial



TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM (OUTSIDE CAB) Lever Pattern; Bi-Directional Control Lever



7 79



6



1



11



13 26 56 30



4



10



11



14



18



93



171



208 5



9



60



81



59



16



2



58



15



12



40



43



84



82 74 80



3



77



T24D-01-02-007



(CX500-C/550-C) 76



78 136



172 160 159 75



72



76 (CX700-C)



71



73



89



90



86 20



19 91



173



85



128 96 88 182



23



196



94



92



87 17 85



T24D-01-02-001



T5-2-10



TROUBLESHOOTING / Component Layout



1 - Coolant Temperature Sensor 2 - Fuel Level Sensor



18 -



N Sensor (Pump)



73 -



Fusible Link (65 A)



90 -



Horn (Low Sound)



19 -



74 -



Engine Stop Solenoid



91 -



Tilt Motor (Lever Stand)



3 - Engine Oil Level Switch



20 -



75 -



Emergency Relay



92 -



Solenoid Valve (Brake Mode Selection)



4 - Coolant Level Switch



23 -



76 -



Battery Relay



93 -



5 - Hydraulic Oil Level Switch



26 -



Micro Switch (First Boom Overhoist) Micro Switch (Second Boom Overhoist) Auto-Stop Solenoid Valve (5-Units) Auto-Stop Controller



77 -



Starter



6 - Engine Oil Pressure Switch



30 -



Backup Switch



78 -



Starter Relay



7 - Overheat Switch



40 -



Interior Speaker



79 -



Alternator



9 - Air Restriction Switch 10 - Oil Filter Restriction Switch



43 56 -



80 81 -



Glow Relay Glow Plug



11 - Work Light



58 -



82 -



Current Sensor



160 - Fusible Link (30 A)



12 - Window Washer



59 -



84 -



Fuel Suction Pump



13 - Drum Speed Sensor (Main Hoist)



60 -



85 -



Swing Alarm Indicator /Buzzer



171 - Pressure Switch (Pilot Control Shut-Off Lever) 172 - Fusible Link (45 A)



14 - Drum Speed Sensor (Aux. Hoist) 15 - Third Speed Selection Solenoid Valve (Main Hoist) 16 - Third Speed Selection Solenoid Valve (Aux. Hoist) 17 - 8-Unit Solenoid Valve



71 -



Antenna Wiper (Overhead Window) Motor (Main Hoist Drum Lock) Motor (Aux. Hoist Drum Lock) Motor (Boom. Hoist Drum Lock) Battery



Wiper (Front Windshield) 94 - Pressure Switch (Main and Aux. Hoist Brake) 96 - Pressure Switch (Main and Aux. Hoist Brake) 128 - Base Machine Relay Box 136 - Engine Control Motor 159 - Fusible Link (30 A)



86 -



72 -



Fusible Link (45 A)



87 -



Swing Pilot Pressure Switch Swing Flasher Relay



88 -



Travel Alarm



196 - Boom Hoist Pressure Switch



89 -



Horn (High Sound)



208 - Hydraulic Oil Temperature Switch



T5-2-11



173 - Fusible Link (65 A) 182 - Solenoid Valve (Crawler Extend/Retract)



TROUBLESHOOTING / Component Layout PUMP DEVICE



1



2



5



6



7



3



4



T326-02-02-002



1 - Transmission



3 - Pilot Pump



2 - Pump Section



4 - Third Main Pump (Swing)



T326-02-02-001



5 - First Main Pump (Left Travel, Third Drum (Optional), 2nd (Fast) Aux. Hoist, 1st (Slow) Main Hoist) 6 - Second Main Pump (Right Travel, Boom Hoist, 2nd (Fast) Main Hoist, 1st (Slow) Aux. Hoist)



T5-2-12



7 - Pump Speed Sensor



TROUBLESHOOTING / Component Layout SWING DEVICE 1



2



3



5



4



T326-02-03-001



3



T326-02-03-002



1 - Swing Control Valve 2 - Swing Motor



3 - Reduction Gear



4 - Pinion



T5-2-13



5 - Swing Bearing



TROUBLESHOOTING / Component Layout HOIST DEVICE



Main Hoist Device



Aux. Hook Aux. Hoist Device Main Hook



T324-02-04-001



Main Hoist, Aux. Hoist



1 2 3



4



5 6



T324-02-04-002



1 - Break Drum (Main Hoist, Aux. Hoist) 2 - Hoist Drum (Main Hoist, Aux. Hoist)



3 - Reduction Gear (Two Stage Planetary Gear) 4 - Sequence Valve



5 - Counterbalance Valve



T5-2-14



6 - Hoist Motor (Main Hoist, Aux. Hoist)



TROUBLESHOOTING / Component Layout BOOM HOIST DEVICE



T326-01-02-010



2



1



3



T324-02-05-002



1 - Hoist Motor



2 - Hoist Drum



3 - Reduction Gear (Two-stage Planetary)



T5-2-15



TROUBLESHOOTING / Component Layout CONTROL VALVE 4-Spool Control Valve for Travel Right, Boom Hoist, Aux. Hoist (Slow), and Main Hoist (Fast) Functions 1



2



3



4



Boom Hoist



Travel Right



5



6



Aux. Hoist (Slow)



7



Main Hoist (Fast)



8



Section A



T326-02-06-004



P



9



10 A



B



C T326-02-06-002



Travel (Right)



Boom Hoist



Aux. Hoist (Slow)



Section C



Main Hoist (Fast)



Lowering



T326-02-06-005



11



Hoisting C



T



Section B T326-01-02-011



1 - Main Relief Valve 2 - O-Ring



4 - Spring 5 - Spring



3 - Spring



6 - Spring Seat



7 - Spool 8 - Pressure Compensation Valve 9 - Holding Check Valve



T5-2-16



10 - Plug 11 - Make-Up Valve



T326-02-06-006



TROUBLESHOOTING / Component Layout 4-Spool Control Valve for Travel Left, Third Drum, Aux. Hoist (Fast), and Main Hoist (Slow) Functions 1



2



Aux. Hoist (Fast)



3 Travel Left



Third Drum



4



5 Main Hoist (Slow)



6



9



10



Section A



7 B



11



A



Section B



T326-01-02-012



Travel (Left) Third Drum



Aux. Hoist (Fast)



Main Hoist (Slow) Lowering



C



P



Hoisting T



T326-01-02-013



1 - Main Relief Valve 2 - O-Ring 3 - Spring



4 - Spring 5 - Spring 6 - Spring Seat



7 - Spool 9 - Holding Check Valve



T5-2-17



10 - Plug 11 - Make-Up Valve



TROUBLESHOOTING / Component Layout One (1)-Unit Control Valve: Crawler Extend/Retract



1



12345-



Solenoid Valve Main Relief Valve Pump Port Crawler Extension Port Relief Valve



6789-



2



3



4



5



6



Solenoid Valve Tank Port To Swing Control Valve Crawler Retraction



T326-02-06-007



9



8



7



T326-02-06-008



B1 A1 185K



PP



280K P



T5-2-18



T



T326-02-06-009



TROUBLESHOOTING / Component Layout One (1) -Unit Control Valve: Swing 5



3



6 7 T326-02-06-010



1



T326-02-06-012



2 1



7



2



4 4 6



T326-02-06-011



3 1 - Swing (Right) 2 - Swing (Left)



3 - Pump Port (From Third Main Pump) 4 - Spool



5 - Main Relief Valve 6 - To Tank Port (To Oil Cooler)



T5-2-19



5 7 - Make-Up Valve



T326-02-06-013



TROUBLESHOOTING / Component Layout TRAVEL DEVICE 1



2



3



1 - Travel Speed Mode Selector Valve 2 - Counterbalance Valve 3 - Relief Valve



M326-13-001



SOLENOID VALVE 8-Unit Solenoid Valve 11



10



7



9



6



8



4



5



T328-01-02-005



Auto-Stop Solenoid Valve 18



12



13



14



15



16



19



20



45678910 11 12 13 14 -



15 16 17 -



17



18 19 Front 20 -



T234-05-02-003



T5-2-20



Solenoid Valve SC (Maximum Flow Rate Control) Solenoid Valve SA (Horsepower Decrease) Solenoid Valve SB (Horsepower Increase) Solenoid Valve SH (Superfine Speed) Solenoid Valve SD (Swing Speed Control) Solenoid Valve SE (Travel Mode Selection) Solenoid Valve SF (Auxiliary) Solenoid Valve SI (Swing Brake) Auto-Stop Solenoid Valve (Aux. Hoist Hoisting) Auto-Stop Solenoid Valve (Aux. Hoist Lowering) Auto-Stop Solenoid Valve (Bi-Direction Control Lever-Main Hoist Hoisting Joy-Stick Lever-Main Hoist Lowering) Auto-Stop Solenoid Valve (Boom Hoist Lowering) Auto-Stop Solenoid Valve (Boom Hoist Hoisting) Auto-Stop Solenoid Valve (Bi-direction control lever-Third Drum Hoisting Joy-Stick Lever- Main Hoist Hoisting) Auto-Stop Solenoid Valve (Only used for Joy-Stick Lever-Third Drum Lowering) Auto-Stop Solenoid Valve (Only used for Joy-Stick Lever-Third Drum Hoisting) Solenoid Valve (Only used for Joy-Stick Lever-Auxiliary)



TROUBLESHOOTING / Troubleshooting A TROUBLESHOOTING A PROCEDURE Use Troubleshooting A when a controller malfunction indicator on the monitor panel comes ON or is blinking. When a controller malfunction indicator on the monitor panel comes ON or is blinking, the main controller monitor indicator blinks. According to lightening or blinking of the controller malfunction indicator and the display of the monitor indicator, abnormal input or output of the main controller (MC) is detected.



Controller Malfunction Indicator (on the Monitor Panel)



T324-04-04-001



These Monitor Indicators Come ON When the Service Indicator is OFF (Output System Failure)



When the MC service indicator is ON, the monitor indicators show that input is abnormal. When the MC service indicator is OFF, the monitor indicators show that output is abnormal. Press the service switch to switch the display of Input and Output. Fault codes can be deleted by pushing the service switch while pushing the fast idle calibration switch with the service indicator ON. When a failure occurs, the corresponding monitor indicator starts to blink. Depending on the failure type, the indicator blinks in four patterns such as sequential, single, double, and triple blinking.



Service Indicator These Monitor Indicators Come ON When the Service Indicator is ON (Input System Failure)



T328-05-03-001



Fast Idle Calibration Switch Service Switch



M328-02-002



1280 ms (1 Cycle) 160 ms ON Sequential Blinking OFF



160 ms



Single Blinking Double Blinking Triple Blinking T328-05-03-002



T5-3-1



TROUBLESHOOTING / Troubleshooting A MONITOR INDICATOR FAILURE TYPE Output System



ON



PWM1A



Main Hoist Third Speed PWM2A Pump Superfine Speed PWM2B Swing Pump PWM3A Aux. Hoist Third Speed PWM4A Power Increase PWM4B Power Decrease PWM5A Boom Raise Slow Stop PWM5B Aux. Hoist Lower Slow Stop PWM6A Boom Lower Slow Stop PWM6B Aux. Hoist Upper Slow Stop SOL1 Controller Malfunction Indicator SOL2 Max. Flow Rate Increase PWM1A to PWM6B, SOL1, SOL2 Motor



DISPLAY



Operating



AND



When service indicator is OFF Monitor Indicator Sequential Triple Blinking Double Blinking Blinking Shorted Output Overheat



Single Blinking



OFF



Opened Output



Not Operating



Operating



Shorted Output



Overheat



Opened Output



Not Operating



Operating Operating



Abnormal Feedback Shorted Output Shorted Output



Overheat Overheat



Opened Output Opened Output



Not Operating Not Operating



Operating Operating Operating



Abnormal Feedback Shorted Output Abnormal Feedback Shorted Output Abnormal Feedback Shorted Output



Overheat Overheat Overheat



Not Operating Not Operating Not Operating



Operating



Shorted Output



Overheat



Operating



Abnormal Feedback Shorted Output



Overheat



Operating



Shorted Output



Overheat



Blinking (Abnormal) Shorted Output



Overheat



Opened Output Opened Output Stop/Opened Output Stop/Opened Output Stop/Opened Output Stop/Opened Output Opened Output



Shorted Output



Overheat



ON (Abnormal) Operating



Engine Control (EC Motor)



Disconnected Power Motor Stop at Max. Motor Stop at Speed Stopper Min. Speed Stopper



Motor Stop due to Synchronism Loss



Engine Speed Pulse Arrival of Pulse Input Back-up Battery Backup Commu-nic Serial Interface ation Mode Crane/Bucket Bucket Mode



No Connection / Opened Output Opened Ground



Not Operating Not Operating Not Operating OFF (Normal) Not Operating



Fast Idle Calibration Normal Error



Engine



No Arrival of Pulse Input Normal Normal



Faulty Backup Faulty Serial Reception Start Speed Mode



Crane Mode



When service indicator is ON



Fault Code exists Fault Code exists Operating Fault Code Fault Code Fault Code Fault Code



Abnormal Abnormal Abnormal Abnormal Abnormal



Neutral Normal Normal Normal Normal



Fault Code exists Operating Fault Code exists Selected



Abnormal Abnormal Abnormal Shorted First Input



Normal Stop Normal No Selected



Selected Selected



No Selected Shorted First Input No Selected



DI3



EC Sensor Pressure Sensor (Swing Control Pressure) Swing Speed Control Swing Operation Sensor Relay Engine Control Accelerator Grip Engine Control Accelerator Lever Superfine Speed Control Speed Control Lever Boom Hoist Speed Boom Hoist Speed Control Dial Control Work Mode Control Work Mode Switch Vibration Hammer Swing Speed Control Swing Speed Control Dial Main Hoist Third Speed Main Hoist Third Speed Switch Selection Control Service Request Aux. Hoist Third Speed Aux. Hoist Third Speed Switch Selection Control Slow Stop Control Slow Stop Switch



Monitor Indicator Sequential Blinking Abnormal Normal Abnormal Normal



Selected



No Selected



DI4 DI5 D18 D19



Engine Control Superfine Speed Control Drum Speed Sensing Drum Speed Sensing



Selected Selected Arival of Pulse Input Arival of Pulse Input



No No No No



Input System AI0 AI1



ON



Engine Control Swing Speed Control



AI2 AI3 AI4 AI5 AI6 AI7 AI8 AI9 DI0 DI1 DI2



Fast Idle Calibration Switch Superfine Speed Switch Speed Sensor (Main Hoist) Speed Sensor (Aux. Hoist)



NOTE: When the overhoist prevention switch operates, monitor indicator PWM5A and 5B blink. However the controller malfunction indicator does not come ON.



T5-3-2



exists exists exists exists



OFF



Selected Selected Arival of Pulse Input Arival of Pulse Input



TROUBLESHOOTING / Troubleshooting A FAILURE IN MAIN CONTROLLER SYSTEM When Abnormal MC Monitor Indicator



All indicators are extinguished.



Controller Malfunction Indicator Dimly lights or blinks Blinks Lights Is extinguished Lights



Blinking Blinks



Failure



Symptom



Remedy or Backup Method



Uncontrollable Operation Abnormal Program Memory Abnormal Data Memory Opened Power and ACC Terminals Abnormal EC sensor, EC motor, and Engine Controller (SMC) Abnormal Other Input and/or Output



All controller actuators are inoperable



Engine control is inoperable



Use accelerator pedal



Refer to T5-3-6 or after



System Layout Main Controller



Back-up 0 V (Normal) 24 V (Abnormal)



R12 Service Switch



Fast Idle Calibration Switch



Controller Malfunction Indicator T333-05-03-001



T5-3-3



TROUBLESHOOTING / Troubleshooting A EC Motor System Check • Be sure to inspect wiring connection prior to troubleshooting. Connect EC motor harness end connector terminal #2 YES to #4 using a clip. Check for continuity between EC harness end connector terminals #1 and #2. Disconnect EC. Connect EC motor harness end connector terminal #1 to #3 usYES ing a clip. Check for continuity between EC harness end connector terminals #9 and #10. With key switch OFF, disconnect EC motor. Check if resistance between terminal #1 and #3, and terminal #2 and #4 is 5.7±0.57Ω.



Faulty MC.



YES



Connect EC motor harness end connector terminal #9 to vehicle frame using a clip. Check NO for continuity between EC harness end connector terminal #1 and vehicle frame.



YES Connect EC motor harness end connector terminal #1 to vehicle frame using a clip. Check NO for continuity between EC harness end connector terminal #2 and vehicle frame.



YES



NO



Faulty harness up to engine controller terminal #2.



Faulty harness up to engine controller NO terminal #10.



Faulty harness up to engine controller terminal #10.



Faulty harness up to engine controller terminal #9.



Faulty EC motor. NO



EC Motor Connector (EC motor side connector viewed from the open end side)



EC Motor Connector (Harness end connector viewed from the open end side)



2



1



1



2



4



3



3



4



T5-3-4



EC Connector (Harness end connector viewed from the open end side)



1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18



TROUBLESHOOTING / Troubleshooting A Engine Controller System Check • In case the EC motor is completely inoperatable even if the key switch is turned ON, the engine controller may have failed. • The engine controller is damaged by short circuit in the EC motor. Before replacing the engine controller, be sure to check the resistance in the EC motor (refer to T5-3-4). • Be sure to inspect wiring connection prior to troubleshooting.



YES



Faulty EC.



With key switch OFF, disconnect 12P on the 2 connector side from MC and connector from EC. Check each harness for continuity. ·Check harness between MC terminal #226 and EC terminal #15. ·Check harness between MC terminal #225 and EC terminal #12. ·Check harness between MC terminal #230 and EC terminal #14.



Faulty harness. NO



MC 12 P Connector (Harness end connector viewed from the open end side) 224 223 222 221 220 219 230 229 228 227 226 225



EC Connector (Harness end connector viewed from the open end side) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18



T5-3-5



TROUBLESHOOTING / Troubleshooting A FAILURE IN ENGINE CONTROLLER SYSTEM When Abnormal Monitor Indicator Input AI0 Blinking AI3 Blinking



AI4 Blinking



Failure Abnormal EC sensor voltage Abnormal accelerator grip voltage*



Symptom



Engine slow idle calibration is not stored. Engine speed stays at slow idle speed even if accelerator grip is operated. Abnormal ac- Engine speed celerator lever stays at slow idle speed even if voltage* accelerator lever is operated.



Monitor Indicator Output (Motor)



Remedy Check harness and sensor. Check harness and accelerator grip. Check harness and accelerator lever.



∗ : If a failure occurs once, the fault code is retained. Re-operate the key switch to delete the retained fault code.



Symptom



The EC motor does not move because the disSequential crepancy between the EC Blinking motor position and EC sensor output is too large. The EC motor stops rotatTriple Blinking clockwise as the EC ing sensor output saturates. The EC motor stops rotatDouble Blink- ing counterclockwise as ing the EC sensor output saturates. The fast idle calibration is Single Blinknot stored. ing



Remedy Re-start the engine.



Remove the cause of the EC motor sticking if any. Perform the fast idle calibration.



System Layout Main Controller



EC Sensor Terminals between #1 and #3: 2±0.6 kΩ Accelerator Grip Terminals between # 1 and #3: 2 kΩ Accelerator Lever Terminals between # 1 and #3: 2±0.6 kΩ



2.4 to 4.7V Engine Controller (SMC) 1.0 to 3.0V



0/15 V Pulse



1.0 to 3.8V



Shield



Fast Idle Calibration Switch



EC Motor



T333-05-03-002



T5-3-6



TROUBLESHOOTING / Troubleshooting A EC Sensor System Check • If input voltage from the EC sensor is 4.9 V or higher, faulty EC sensor or discontinuity between MC terminal #22 and sensor side connector terminal B (ground) may be the cause of the trouble. • If input voltage from the EC sensor is 0.1 V or lower, broken harness between the EC sensor and MC, or short circuit of the A5V line to the ground may be the cause of the trouble. • Be sure to inspect wiring connection prior to troubleshooting.



Connect test harness (ST 7129) between EC sensor YES Faulty MC. and base machine harness end conYES nector. With key switch ON, check if voltages at engine Faulty EC sensor. With key switch OFF, slow and fast idle NO connect EC sensor speeds are within harness end conspecification. nector terminal W to · Specification YES vehicle frame using a Slow idle speed: 2.4±0.5 V clip. Check for contiFast idle speed: 4.7±0.3 V nuity between MC · MC normal operation range 24P connector har(Monitor indicator blinks if ness end terminal voltage is outside this With key switch ON, #42 and vehicle range.): 0.1 to 4.9 V check if voltage beframe. Faulty harness up YES tween EC sensor to EC sensor conharness end connecnector terminal W. NO tor terminal R and B is 5±0.5 V. Disconnect EC Faulty harness up YES With key switch ON, sensor with key to EC sensor concheck if voltage beswitch OFF. Check nector terminal B. tween EC sensor if resistance beharness end contween EC sensor NO nector terminal R and Faulty harness up connector terminal to EC sensor convehicle frame is 5±0.5 R and B is 2.0±0.6 NO nector terminal R. V. Ω. Faulty EC sensor.



NO



EC Sensor Connector (EC sensor side connector viewed from the open end side)



R



W



B



EC Sensor Connector (Harness end connector viewed from the open end side)



B



W



MC 24P Connector (Harness end connector viewed from the open end side) 30 29 28 27 26 25 24 42 41 40 39 38 37 36 Red 25 24 23 22 21 20 19 37 36 35 34 33 32 31 Black



R



ST 7129



V



T107-07-03-009



T5-3-7



TROUBLESHOOTING / Troubleshooting A Accelerator Grip System Check • If input voltage from the accelerator grip is 4.9 V or higher, the probable cause is a faulty accelerator grip or discontinuity between MC terminal #33 and accelerator grip side connector terminal #8 (ground). • If input voltage from the accelerator grip is 0.1 volt or lower, the probable cause is discontinuity of the harness between the accelerator grip and MC or short circuit of the A5V line to the ground. • Be sure to inspect wiring connection prior to troubleshooting.



With key switch ON, check if voltage beYES tween accelerator grip harness end connector terminals #6 and #8 is 5 ± 0.5 V. Disconnect accelerator grip with key switch OFF. Check for continuity between accelerator grip connector terminals #6 and #8



With key switch OFF, connect accelerator grip harness end connector terminal #7 to YES vehicle frame using a clip. Remove 24P connector from MC. Check for continuity between 24P connector terminal #29 and vehicle frame.



NO



Faulty accelerator grip.



With key switch OFF, check for continuity between YES accelerator grip harness end connector terminal #8 and vehicle frame.



NO



Faulty harness up to accelerator grip connector terminal #7 YES Faulty main controller Faulty harness up to accelerator grip NO connector terminal #8 Faulty harness up to accelerator grip connector terminal #6 Faulty accelerator grip



NO



30 29 28 27 26 25 24 42 41 40 39 38 37 36



YES Faulty main controller.



·Insert the tester probes into the back of the connector ·Specification Accelerator Grip Slow Idle Speed Side: 1.0 ± 0.05 V Fast Idle Speed Side: 2.4 to 3.1 V ·MC Normal Operation Range (Monitor indicator blinks if voltage is outside this range.): 0.1 to 4.9 V



NO



With key switch ON, check if voltage between accelerator grip harNO ness end connector terminal #6 and vehicle frame is 5 ± 0.5 V



Main Controller 24P Connector (Harness end connector viewed from the open end side)



Reconnect 24P connector to MC. Check if voltage between MC conYES nector terminal #29 and Vehicle frame are within specification.



Accelerator Grip Connector (Harness end connector viewed from the open end side) 4 8



3 7



2 6



1 5



25 24 23 22 21 20 19 37 36 35 34 33 32 31



T5-3-8



TROUBLESHOOTING / Troubleshooting A Accelerator Lever System Check • If input voltage from the accelerator lever sensor is 4.9 V or higher, faulty accelerator sensor or discontinuity between MC terminal #21 and sensor side connector terminal B (ground) may be the cause of the trouble. • If input voltage from the accelerator lever sensor is 0.1 V or lower, broken harness between the accelerator lever sensor and MC, or short circuit of the A5V line to the ground may be the cause of the trouble. • Be sure to inspect wiring connection prior to troubleshooting. With key switch OFF, connect test harness (ST 7129) between accelerator lever YES sensor and harness end connectors. With key switch ON, check if voltages are within specification while operating accelerator lever. With key switch ON, check if voltage between accelerator YES lever sensor harness end connector terminal R and B is 5±0.5 V. Disconnect accelerator lever sensor with key switch OFF. Check if resistance between accelerator lever sensor connector terminal R and B is 2.0±0.6 Ω.



YES



Faulty MC.



NO



Faulty accelerator lever sensor.



·Specification Slow idle speed side: 1.0±0.05 V Fast idle speed side: 3.4 to 3.8 V ·MC normal operation range (Monitor indicator blinks if voltage is outside this range.): 0.1 to 4.9 V



With key switch ON, check if voltage between harness end connecNO tor terminal R and vehicle frame is 5±0.5 V.



With key switch OFF, check for conYES tinuity between harness end connector terminal B and vehicle frame.



Faulty accelerator lever sensor.



NO Accelerator Lever Sensor Connector (Accelerator lever sensor side connector viewed from the open end side)



W



Red



R



Accelerator Lever Sensor Connector (Harness end connector viewed from the open end side)



Black



ST 7129 R



W



NO



Faulty harness up to accelerator lever sensor connector terminal B. Faulty harness up to accelerator lever sensor connector terminal R.



NO



B



YES Faulty MC.



V



B T107-07-03-009



T5-3-9



TROUBLESHOOTING / Troubleshooting A Fast Idle Calibration Switch System Check • If the engine governor lever and EC motor do not operate when the key switch is turned ON while depressing the fast idle calibration switch, the fast idle calibration switch may be faulty. • Be sure to inspect wiring connection prior to troubleshooting.



YES



With switch OFF: No continuity With switch ON: Continuity



With key switch ON, check if voltage between fast idle calibration switch harness end connector terminals #1 and #2 is 5±0.5 V.



With key switch OFF, disconnect fast idle calibration switch. Check for continuity between switch terminal #1 and #2 with fast idle calibration switch OFF or ON.



Faulty MC.



YES Faulty MC. With key switch OFF, check for continuity between YES fast idle calibration switch harness end With key switch ON, connector terminals check if voltage #2 and vehicle between fast idle frame. NO calibration switch NO harness end connector terminals #1 and vehicle frame is 5±0.5 V. NO



Fast Idle Calibration Switch Connector (Fast idle speed calibration switch side connector viewed from the open end side)



2



Fast Idle Calibration Switch Connector (Harness end connector viewed from the open end side)



2



Faulty harness up to fast idle calibration switch connector terminals



Faulty fast idle calibration switch.



With switch OFF: No continuity With switch ON: Continuity



1



Faulty harness up to fast idle calibration switch connector terminals #2



1



T5-3-10



TROUBLESHOOTING / Troubleshooting A MALFUNCTION OF PUMP TORQUE CALIBRATION CONTROL When abnormal Monitor Indicator Output (PWM4A, 4B)



Failure



Symptom



Faulty current feedback circuit for torque calibration control output PWM (Torque Increase/Decrease) Shorted torque calibration control Triple Blinking output PWM (Torque Increase/Decrease) Overheated IC in torque calibration Double Blink- control output PWM circuit or broing ken harness to terminal SOLB (current). Broken harness to terminal SOLB Single Blinking (current) or to SOLG (ground). Sequential Blinking



Current is controlled by open loop.



Check harness to terminal PWM4C.



OFF (Before Torque Increase/Decrease Calibration)



Check harness to terminals PWM4A and 4B or solenoid valves SA and SB for short circuit. Check harness to terminal SOLB for breakage.



OFF (Before Torque Increase/Decrease Calibration) OFF (Before Torque Increase/Decrease Calibration)



NOTE: The pump regulator controls the pump maximum torque in response to the engine speeds. Engine Speed 900 min



-1



1300 min



-1



Monitor Indicator PWM4: ON PWM4: OFF PWM4B: ON PWM4B: OFF



Remedy



Judgment Faulty pump speed sensor or harness. Normal Normal Faulty pump speed sensor or harness.



Check harnesses to terminals PWM4A and 4B or to terminal SOLG for breakage.



Torque



1300 min-1 (rpm)



Torque Increase Control



Torque Decrease Control



Pump Drive Torque before Calibration



900 min-1 (rpm) Engine Speed (Accelerator Command Speed)



System Layout



T333-05-03-003



Main Controller



0.3 to 1.3kHz



PWM: 210 mA (5.9 V) at Fast Idle



Pump Speed Sensor



Solenoid Valve SB (Horsepower Increase) PWM: 410 mA (11 V) at Fast Idle



Solenoid Valve SA (Horsepower Decrease) T333-05-03-004



T5-3-11



TROUBLESHOOTING / Troubleshooting A Pump Speed Sensor System Check • Be sure to inspect wiring connection prior to troubleshooting.



YES



Faulty pump speed sensor or connection.



Disconnect 24P connector from MC and disconnect pump speed sensor. Connect MC 24P harness end connector terminals #19 and #20 to vehicle frame with clips. Check for continuity between pump speed sensor harness end connector terminal #1 and #2. In case terminal #1 has no continuity, harness between pump speed sensor terminal #1 and MC is broken. In case terminal #2 has no continuity, harness between pump speed sensor terminal #2 and MC is broken.



NO



Gear



Pump Speed Sensor Connector (Harness end connector viewed from the open end side)



1



2



Hydraulic Oil Sensing Clearance: 0.5 to 1.0 mm



MC 24P Connector (Harness end connector viewed from the open end side) 30 29 28 27 26 25 24 42 41 40 39 38 37 36



Pump Speed Sensor



T333-05-03-017



25 24 23 22 21 20 19 37 36 35 34 33 32 31



T5-3-12



TROUBLESHOOTING / Troubleshooting A Solenoid Valve SA (Horsepower Decrease) System Check • Be sure to inspect wiring connection prior to troubleshooting.



YES



With key switch OFF, disconnect solenoid valve SA. Check for continuity between solenoid valve terminals #1 and #2.



Remove connected clip from MC harness end connector termiYES nal #208. Check for continuity between Remove 18P connecsolenoid valve SA tor on the 2-connector harness end connecside from MC and distor terminal #1 and connect solenoid valve vehicle frame. SA. Connect 18P harness end connector terminals #208 and YES #217 on the 2-connector side to vehicle frame using clips. Check for continuity between solenoid valve SA harness end terminal #1 and vehicle frame, and terminal #2 and vehicle frame. NO



Shorted harness between solenoid valve SA and MC.



Faulty MC. NO



In case terminal #1 has no continuity, harness between solenoid valve SA terminal #1 and MC is broken. In case terminal #2 has no continuity, harness between solenoid valve SA terminal #2 and MC is broken.



Faulty solenoid valve SA. NO



Solenoid Valve SA Connector (Solenoid valve SA side connector viewed from the open end side)



1



MC 18P Connector (Harness end connector viewed from the open end side) 209 208 207 206 205 204 203 202 201 218 217 216 215 214 213 212 211 210



2



Solenoid Valve SA Connector (Harness end connector viewed from the open end side)



2



1



T5-3-13



TROUBLESHOOTING / Troubleshooting A Solenoid Valve SB (Horsepower Increase) System Check • Be sure to inspect wiring connection prior to troubleshooting.



YES Remove connected clip from MC harness end connector termiYES nal #207. Check for continuity between solenoid valve SB Remove 18P connector harness end connecon the 2-connector side tor terminal #1 and from MC and disconnect vehicle frame. solenoid valve SB. Connect 18P harness end connector terminals YES #207 and #216 on the 2-connector side to vehicle frame using clips. Check for continuity between solenoid valve SB harness end terminal #1 and vehicle frame, and terminal #2 and vehicle frame.



With key switch OFF, disconnect solenoid valve SB. Check for continuity between solenoid valve terminals #1 and #2.



NO



In case terminal #1 has no continuity, harness between solenoid valve SB terminal #1 and MC is broken. In case terminal #2 has no continuity, harness between solenoid valve SB terminal #2 and MC is broken.



MC 18P Connector (Harness end connector viewed from the open end side)



Solenoid Valve SB Connector (Solenoid valve SB side connector viewed from the open end side)



209 208 207 206 205 204 203 202 201 218 217 216 215 214 213 212 211 210



2



Solenoid Valve SB Connector (Harness end connector viewed from the open end side)



2



Faulty MC. NO



Faulty solenoid valve SB.



NO



1



Shorted harness between solenoid valve SB and MC.



1



T5-3-14



TROUBLESHOOTING / Troubleshooting A Main Controller (MC) Power System Check • Be sure to inspect wiring connection prior to troubleshooting.



YES



Faulty MC.



Check for continuity between YES harness end connector terminal #218 (SOLG) and vehicle frame. Remove 2-connector side 18P connector from MC. Check if voltage at harness end connector terminal #209 (SOLB) is 24 V with key switch ON.



Broken ground line. NO



Broken harness up to MC.



NO



MC 18P Connector (Harness end connector viewed from the open end side)



209 208 207 206 205 204 203 202 201 218 217 216 215 214 213 212 211 210



T5-3-15



TROUBLESHOOTING / Troubleshooting A MALFUNCTION OF ESS (ENGINE SPEED SENSING) CONTROL When abnormal Monitor Indicator Input AI4 Blinking



Failure



Symptom



Remedy



Abnormal accelerator lever voltage Deactivated control system (OFF)



Monitor Indicator Output (PWM4A, 4B)



Failure



Check accelerator lever harness and accelerator lever.



Symptom



Remedy



Abnormal current feedback circuit for ESS control output PWM (torque increase/decrease) Shorted ESS control output PWM Triple Blinking (torque increase/decrease)



Current is controlled by open loop.



Check harness to terminal PWM4C.



Control System is deactivated (OFF).



Overheated IC in ESS control outDouble Blink- put PWM (torque increase ing /decrease) circuit or broken harness to terminal SOLB (current). Broken harness to terminal SOLB Single (current) or SOLG (ground). Blinking



Control System is deactivated (OFF).



Check harness to terminals PWM4A and 4B or solenoid valves SA and SB for short circuit. Check harness to terminal SOLB for breakage.



Sequential Blinking



Control System is deactivated (OFF).



NOTE: The speed sensing control only functions when the engine speed is increased to -1 1500 min (rpm) or more by operating the accelerator lever in the bucket mode. When the actual engine runs faster than the speed set by the command signal (pump driving torque control), the present torque allowance is calculated by the MC as speed sensing torque. Then, the pump flow rate is increased by the speed sensing torque so that the actual engine power torque is utilized more efficiently. System Layout



Work Mode Switch



Engine Speed Sensing Torque + +



−



−



∆N= Actual Engine Speed− Command Signal Engine Speed



Torque Engine Speed T324-07-02-007



Main Controller



0 V(Crane) 5 V(Bucket) PMW: 300 mA (7.4 V) at fast idle. No load



0.3 to 1.3kHz Pump Speed Sensor



Accelerator Lever



Check harnesses to terminals PWM4A and 4B or to terminal SOLG for breakage.



Solenoid Valve SB (Horsepower Increase)



1.0 to 3.8V



Solenoid Valve SA (Horsepower Decrease) T333-05-03-021



T5-3-16



TROUBLESHOOTING / Troubleshooting A Work Mode Switch System Check • Although the main controller (MC) and the maximum flow rate control solenoid valve (SC) operate normally, if the actuator speeds don’t change after operating the work mode switch, the mode switch may be faulty. • Check for loose harness connections prior to beginning troubleshooting. YES



Crane mode: No continuity Bucket mode: Continuity



Turn key switch OFF and disconnect work mode switch. Check for continuity between connector terminals #1 and #2 with work mode switch in crane position. Then, check for continuity between connector terminals #1 and #2 with work mode switch in bucket position.



Faulty MC



Turn key switch ON. Check if voltage between work mode switch base machine side harness end connector terminals #1 and #2 is 5 ± 0.5V.



YES Faulty MC



Turn key switch ON. Check if voltage between work mode switch base machine side harNO ness end connector terminals #1 and vehicle frame (ground) is 5 ± 0.5V.



Work Mode Switch Connector (Switch Connector Open End Side)



2



3



4



5



6



Work Mode Switch Connector (Harness End Connector Open End Side)



3



2



1



6



5



4



NO



NO



Faulty harness to work mode switch terminal #2 Faulty harness to work mode switch terminal #1



Faulty work mode switch



Crane mode: Continuity Bucket mode: No Continuity



1



Turn key switch ON. Check for continuity between YES work mode switch base machine side harness end connector terminals #2 and vehicle frame (ground).



T5-3-17



TROUBLESHOOTING / Troubleshooting A Pump Speed Sensor System Check • Be sure to inspect wiring connection prior to troubleshooting.



YES



Faulty pump speed sensor or connection.



Disconnect 24P connector from MC and disconnect pump speed sensor. Connect MC 24P harness end connector terminals #19 and #20 to vehicle frame with clips. Check for continuity between pump speed sensor harness end connector terminal #1 and #2. In case terminal #1 has no continuity, harness between pump speed sensor terminal #1 and MC is broken. In case terminal #2 has no continuity, harness between pump speed sensor terminal #2 and MC is broken.



NO



Gear



Pump Speed Sensor Connector (Harness end connector viewed from the open end side)



1



2



Hydraulic Oil Sensing Clearance: 0.5 to 1.0 mm



MC 24P Connector (Harness end connector viewed from the open end side) 30 29 28 27 26 25 24 42 41 40 39 38 37 36



Pump Speed Sensor



T333-05-03-017



25 24 23 22 21 20 19 37 36 35 34 33 32 31



T5-3-18



TROUBLESHOOTING / Troubleshooting A Accelerator Lever System Check • If input voltage from the accelerator lever sensor is 4.9 V or higher, faulty accelerator sensor or discontinuity between main controller (MC) terminal #21 and sensor side connector terminal B (ground) may be the cause of the trouble. • If input voltage from the accelerator lever sensor is 0.1 V or lower, broken harness between the accelerator lever sensor and MC, or short circuit of the A5V line to the ground may be the cause of the trouble. • Be sure to inspect wiring connection prior to troubleshooting. With key switch OFF, connect test harness (ST 7129) between accelerator lever YES sensor and harness end connectors. With key switch ON, check if voltages are within specification while operating accelerator lever. With key switch ON, check if voltage between accelerator YES lever sensor harness end connector terminal R and B is 5±0.5 V. Disconnect accelerator lever sensor with key switch OFF. Check if resistance between accelerator lever sensor connector terminal R and B is 2.0±0.6 Ω.



YES



Faulty MC.



NO



Faulty accelerator lever sensor.



·Specification Slow idle speed side: 1.0±0.05 V Fast idle speed side: 3.4 to 3.8 V ·MC normal operation range (Monitor indicator blinks if voltage is outside this range.): 0.1 to 4.9 V



With key switch ON, check if voltage between harness end connecNO tor terminal R and vehicle frame is 5±0.5 V.



With key switch OFF, check for conYES tinuity between harness end connector terminal B and vehicle frame.



Faulty accelerator lever sensor.



NO Accelerator Lever Sensor Connector (Accelerator lever sensor side connector viewed from the open end side.)



W



Red



R



Accelerator Lever Sensor Connector (Harness end connector viewed from the open end side.)



Black



ST 7129 R



W



NO



Faulty harness up to accelerator lever sensor connector terminal B. Faulty harness up to accelerator lever sensor connector terminal R.



NO



B



YES Faulty MC.



V



B T107-07-03-009



T5-3-19



TROUBLESHOOTING / Troubleshooting A Solenoid Valve SA (Horsepower Decrease) System Check • Be sure to inspect wiring connection prior to troubleshooting.



YES



With key switch OFF, disconnect solenoid valve SA. Check for continuity between solenoid valve terminals #1 and #2.



Remove 18P connector on the 2-connector side from MC and disconnect solenoid valve SA. Connect 18P harness end connector terminals #208 and YES #217 on the 2-connector side to vehicle frame using clips. Check for continuity between solenoid valve SA harness end terminal #1 and vehicle frame, and terminal #2 and vehicle frame.



Remove connected clip from MC harness end connector termiYES nal #208. Check for continuity between solenoid valve SA harness end connector terminal #1 and vehicle frame.



Shorted harness between solenoid valve SA and MC.



Faulty MC. NO



In case terminal #1 has no continuity, harness between solenoid valve SA terminal #1 and MC is broken. In case terminal #2 has no continuity, harness between solenoid valve SA terminal #2 and MC is broken.



NO



Faulty solenoid valve SA. NO



Solenoid Valve SA Connector (Solenoid valve SA side connector viewed from the open end side)



1



MC 18P Connector (Harness end connector viewed from the open end side) 209 208 207 206 205 204 203 202 201 218 217 216 215 214 213 212 211 210



2



Solenoid Valve SA Connector (Harness end connector viewed from the open end side)



2



1



T5-3-20



TROUBLESHOOTING / Troubleshooting A Solenoid Valve SB (Horsepower Decrease) System Check • Be sure to inspect wiring connection prior to troubleshooting.



YES



Remove 18P connector on the 2-connector side from MC and disconnect solenoid valve SB. Connect 18P harness end connector terminals YES #207 and #216 on the 2-connector side to vehicle frame using clips. Check for continuity between solenoid valve SB harness end terminal #1 and vehicle frame, and terminal #2 and vehicle frame.



With key switch OFF, disconnect solenoid valve SB. Check for continuity between solenoid valve terminals #1 and #2.



Remove connected clip from MC harness end connector termiYES nal #207. Check for continuity between solenoid valve SB harness end connector terminal #1 and vehicle frame.



In case terminal #1 has no continuity, harness between solenoid valve SB terminal #1 and MC is broken. In case terminal #2 has no continuity, harness between solenoid valve SB terminal #2 and MC is broken. Faulty solenoid valve SB.



NO



MC 18P Connector (Harness end connector viewed from the open end side)



Solenoid Valve SB Connector (Solenoid valve SB side connector viewed from the open end side)



209 208 207 206 205 204 203 202 201 218 217 216 215 214 213 212 211 210



2



Solenoid Valve SB Connector (Harness end connector viewed from the open end side)



2



Faulty MC. NO



NO



1



Shorted harness between solenoid valve SB and MC.



1



T5-3-21



TROUBLESHOOTING / Troubleshooting A (Blank)



T5-3-22



TROUBLESHOOTING / Troubleshooting A MALFUNCTION OF PUMP SUPERFINE SPEED CONTROL When abnormal Monitor Indi-cator Failure Symptom Input AI5 Sequen- Abnormal superfine speed control lever OFF (Minimum Superfine tial Blinking voltage Speed) Monitor Indi-cator Output Failure (PWM2A) Triple Shorted pump superfine speed control Blinking output PWM. Overheated IC in output PWM circuit or Double broken harness to terminal SOLB Blinking (Current). Single Broken harness to terminal SOLB Blinking (Current) or to terminal SOLG (Ground).



Remedy Check superfine speed control lever and harness.



Symptom



Remedy



OFF (Minimum Superfine Speed) OFF (Minimum Superfine Speed)



Check harness to terminal PWM2A or solenoid valve SH for short circuit. Check harness to terminal SOLB for breakage.



OFF (Minimum Superfine Speed)



Check harnesses to terminals PWM2A and SOLG for breakage.



Current (mA)



NOTE: Superfine Speed Mode Switch Check Switch ON



Monitor Indicator D15 ON



OFF



OFF ON OFF



1.251 2.346 2.815 3.128



Judgment Normal Faulty switch or broken harness. Faulty switch or broken harness. Normal



NOTE: The pump superfine speed control system controls the hoist pump control pressure by means of solenoid valve SH in response to command signals from the superfine speed control lever. System Layout



Superfine Speed Control Lever Resistance between #1 and #3: 2.0±0.6 kΩ



V V V V



(178.4 (224.9 (234.7 (262.1



mA) mA) mA) mA)



Input Side Superfine Speed Command Voltage T333-05-03-022



Main Controller



When superfine speed control lever is full stroke: 260 mA (6 V)



1.2 to 4.0V



Solenoid Valve SH (Pump Superfine Speed)



Superfine Speed Mode Switch



∗ Refer to the electrical circuit diagram for details of the backup box.



Backup Box



∗



T333-05-03-008



T5-3-23



TROUBLESHOOTING / Troubleshooting A Superfine Speed Control Lever and Superfine Speed Switch System Check



• Be sure to inspect wiring connection prior to troubleshooting.



Red



Turn key switch ON. Check if voltage YES between superfine speed control lever harness end connector terminals R and B is 5.0±0.5 V.



Black ST 7129



V



T107-07-03-009



Reconnect superfine speed switch. Remove 18P connector YES from MC. Check for continuity Disconnect between MC 18P superfine harness end speed switch. connector termiCheck for nal #3 and vehicontinuity cle frame with YES between susuperfine speed With key switch perfine speed OFF, disconswitch ON. switch connect superfine nector termispeed control nals #1 and lever. Check if #2 with suresistance beperfine speed tween superswitch ON. fine speed control lever connector terNO minals R and B is 2.0±0.6 kΩ.



Connect test harness (ST 7129) between superfine speed control lever and base machine harness end conYES nector. Check if voltage is equal to specification when superfine speed control lever is moved from slow speed side to fast speed side with key switch ON. · Specification: Slow speed side: 4.0 V Fast speed side: 1.2 V · MC normal operation range (Monitor indicator blinks if voltage is outside this range.): 0.1 to 4.9 V



Turn key switch ON. Connect MC 24P connector terminal #21 to #23 by inserting NO a clip from the connector back side. Check if voltage between terminals #21 and #23 is 5.0±0.5 V.



NO



NO MC 18P Connector (Harness end connector viewed from the open end side)



Superfine Speed Control Lever Connector (Speed control lever side connector viewed from the open end side)



9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10



Superfine Speed Switch (Hoist) Connector (Switch side connector viewed from the open end side) 1



2



3



4



B



W



R



Superfine Speed Control Lever Connector (Harness end connector viewed from the open end side)



R



T5-3-24



W



B



TROUBLESHOOTING / Troubleshooting A



YES



NO



Faulty harness up to terminal W or faulty MC.



Faulty superfine speed control lever.



Faulty harness between MC terminal #23 and superfine speed control lever terminal R or between MC terminal #21 and speed control lever terminal B.



YES



Faulty MC. NO Broken harness between superfine speed switch terminal #2 and MC or broken ground line of superfine speed switch. Faulty superfine speed switch. Faulty superfine speed control lever.



MC 24P Connector (Harness end connector viewed from the open end side)



30 29 28 27 26 25 24 42 41 40 39 38 37 36



25 24 23 22 21 20 19 37 36 35 34 33 32 31



T5-3-25



TROUBLESHOOTING / Troubleshooting A Solenoid Valve SH System Check • Be sure to inspect wiring connection prior to troubleshooting.



YES



With key switch OFF, disconnect solenoid valve SH. Check for continuity between solenoid valve terminals #1 and #2.



Remove 18P connector on the 2-connector side from MC. Connect 18P harness end connector terminals #203 on the 2-connector YES side to vehicle frame using clips. Check for continuity between solenoid valve SH harness end terminal #1 and vehicle frame, and terminal #2 and vehicle frame.



Remove connected clip from MC harness end connector YES terminal #203. Check for continuity between solenoid valve SH harness end connector terminal #1 and vehicle frame.



NO



Shorted harness between solenoid valve SH and MC.



Faulty MC. NO



In case terminal #1 has no continuity, harness between solenoid valve SH terminal #1 and MC is broken. In case terminal #2 has no continuity, ground line between solenoid valve SH terminal #2 and vehicle frame is broken.



Faulty solenoid valve SH. NO



MC 18P Connector (Harness end connector viewed from the open end side)



Solenoid Valve SH Connector (Solenoid valve SH side connector viewed from the open end side)



1



209 208 207 206 205 204 203 202 201 218 217 216 215 214 213 212 211 210



2



Solenoid Valve SH Connector (Harness end connector viewed from the open end side)



2



1



T5-3-26



TROUBLESHOOTING / Troubleshooting A (Blank)



T5-3-27



TROUBLESHOOTING / Troubleshooting A MALFUNCTION OF BOOM HOIST SPEED CONTROL When abnormal Monitor Indicator Failure Symptom Input AI6 Sequen- Abnormal boom hoist speed control OFF (Minimum Superfine Speed) tial Blinking dial voltage Monitor Indicator Output



Failure



Remedy



Check boom hoist speed control dial and harness.



Symptom



(PWM5A, 6A)



Remedy



Sequential Abnormal current feedback for boom hoist speed control Blinking (hoist/lower) output PWM. Shorted boom hoist speed control Triple output PWM. Blinking



Current is controlled by open loop.



Check terminals PWM5C and 6C.



OFF (Minimum Superfine Speed)



Overheated IC in output PWM circuit or broken harness to terminal SOLB (Current). Broken harness to terminal SOLB (Current) or to terminal SOLG (Ground).



OFF (Minimum Superfine Speed)



Check harness to terminal PWM5A and 6A or boom hoist auto-stop solenoid valve for short circuit. Check harness to terminal SOLB for breakage.



OFF (Minimum Superfine Speed)



Check harnesses to terminals PWM and SOLG for breakage.



Double Blinking Single Blinking



Current



NOTE: The boom hoist speed control system controls the boom hoist control valve pressure by means of solenoid valve in response to command signals from the boom hoist speed control dial.



Superfine Speed Command Voltage T333-05-03-009



System Layout



Boom Hoist Speed Control Dial



Main Controller



Auto-Stop Solenoid Valve (Boom Hoist)



1.1 to 3.9V



∗ Refer to the electrical circuit diagram for details of the auto-stop controller and backup box.



Backup ∗ Box



Auto-Stop ∗ Controller



Auto-Stop Solenoid Valve (Boom Lower)



T333-05-03-010



T5-3-28



TROUBLESHOOTING / Troubleshooting A Boom Hoist Speed Control Dial System Check



• Be sure to inspect wiring connection prior to troubleshooting. Connect test harness (ST 7129) between boom hoist speed control dial and base machine harness end connector. Check YES if voltage is equal to specification when boom hoist speed control dial is turned from slow speed side to fast speed side with key switch ON.



Red



Black ST 7129



V



Turn key switch ON. Check if voltage between boom hoist speed control dial harness end connector terminals R and B is 5.0±0.5 V.



With key switch OFF, disconnect boom hoist speed control dial. Check if resistance between boom hoist speed control dial connector terminals R and B is 8 kΩ.



NO



Faulty boom hoist speed control dial.



· Specification: Slow speed side: 1.1 V Fast speed side: 3.9 V · MC normal operation range (Monitor indicator blinks if voltage is outside this range.): 0.1 to 4.9 V



T107-07-03-009



YES



YES Faulty harness up to terminal W or faulty MC.



YES



NO



Turn key switch ON. Connect MC 24P connector terminal #21 to #23 by inserting a clip from the connector back side. Check if voltage between terminals #21 and #23 is 5.0±0.5 V.



Faulty harness between MC terminal #23 and speed control lever terminal R or between MC terminal #21 and speed control lever terminal B.



Faulty MC. NO



Faulty boom hoist speed control dial.



NO



MC 24P Connector (Harness end connector viewed from the open end side)



Boom Hoist Speed Control Dial Connector (Boom hoist speed control dial side connector viewed from the open end side) B



30 29 28 27 26 25 24 42 41 40 39 38 37 36



25 24 23 22 21 20 19 37 36 35 34 33 32 31



W



R



Boom Hoist Speed Control Dial Connector (Harness end connector viewed from the open end side) R



T5-3-29



W



B



TROUBLESHOOTING / Troubleshooting A Auto-Stop Solenoid Valve System Check



• If overhoisted, normally the monitor indicator blinks and the drum rotation stops.



• If the auto-stop function operates though not overhoisted, refer to Troubleshooting D.



• Be sure to inspect wiring connection prior to troubleshooting.



Reconnect the connector. Remove 2-connector side 12P connector from MC. Check for continuity beYES tween harness end connector terminal #219 (PWM5A) and vehicle frame, and terminal #223 (PWM6A) and vehicle frame.



Remove clips from harness end connector. Check for continuity between MC 2-connector YES side 12P connector harness end terminal #219 (PWM5A) and vehicle frame, and terminal #223 (PWM6A) and vehicle frame.



· Disconnect 24P connector from auto-stop controller. Connect harness end connector terminals #6 (PWMBH) and #8 (PWMBD) to vehicle frame using a clip.



With key switch OFF, disconnect auto-stop solenoid valve. Check if resistance between auto-stop solenoid valve connector terminals #1 and #2 is 17.5 Ω at 20 °C.



NO



Shorted harness beYES tween MC and auto-stop controller.



Connect MC 2-connector side 12P connector harness end terminals #228 (PWM5C) and #229 (PWM6C) to vehicle frame using clips. NO Disconnect auto-stop solenoid valves (boom/jib hoist and lower). Check for continuity between harness end connector terminal #2 and vehicle frame.



Broken harness between MC and auto-stop controller.



Faulty auto-stop solenoid valve.



NO



T5-3-30



TROUBLESHOOTING / Troubleshooting A



YES



YES



Remove 24P connector from auto-stop controller and connect harness end connector terminals #7 (NBHS) and #9 (NBDS) to vehicle frame YES using clips. Disconnect harness end connector terminal #1 from auto-stop solenoid valve. Check for continuity between harness end connector and vehicle frame.



Reconnect connectors. Disconnect harness end connector terminal #2 from auto stop solenoid valve. Check for continuity between harness end connectors and vehicle frame. NO



Faulty auto-stop controller or MC.



Broken harness between auto-stop solenoid valve and MC.



Broken harness between auto-stop controller and auto-stop solenoid valve.



NO



Broken harness between MC and auto-stop solenoid valve.



NO



Auto-Stop Solenoid Valve Connector (Harness end connector viewed from the open end side)



2



Auto-Stop Controller 24P Connector (Harness end connector viewed from the open end side)



1



12 11 10 9 8 7 6 24 23 22 21 20 19 18



Auto-Stop Solenoid Valve Connector (Auto-stop solenoid valve side connector viewed from the open end side)



1



7 6 5 4 3 2 1 19 18 17 16 15 14 13



MC 12P Connector (Harness end connector viewed from the open end side)



2



224 223 222 221 220 219 230 229 228 227 226 225



T5-3-31



TROUBLESHOOTING / Troubleshooting A Main Controller (MC) Power System Check



• Be sure to inspect wiring connection prior to troubleshooting.



YES



Faulty MC.



Check for continuity between YES harness end connector terminal #218 (SOLG) and vehicle frame. Remove 2-connector side 18P connector from MC. Check if voltage at harness end connector terminal #209 (SOLB) is 24 V with key switch ON.



Broken ground line. NO



Broken harness up to MC.



NO



MC 18P Connector (Harness end connector viewed from the open end side)



209 208 207 206 205 204 203 202 201 218 217 216 215 214 213 212 211 210



T5-3-32



TROUBLESHOOTING / Troubleshooting A (Blank)



T5-3-33



TROUBLESHOOTING / Troubleshooting A MALFUNCTION OF SLOW STOP CONTROL When abnormal Monitor Indicator Input



Failure



Symptom



Communi- Communication error from moment Inoperative slow stop cation Blink- limiter control ing Monitor Indicator Output



Failure



(PWM5A, 5B, 6A, and 6B)



Symptom



Sequential Abnormal current feedback circuit Blinking for slow stop control output PWM. Shorted slow stop control output Triple PWM. Blinking Double Blinking Single Blinking



Overheated IC in output PWM circuit or broken harness to terminal SOLB (Current). Broken harness to terminal SOLB (Current) or to terminal SOLG (Ground).



Current is controlled by open loop. OFF (Stop) OFF (Stop) OFF (Stop)



Remedy



Check communication harness from moment limiter.



Remedy



Check terminals PWM5C and 6C. Check harness to terminals PWM5A/5B and 6A/6B or auto-stop solenoid valve for short circuit. Check harness to terminal SOLB for breakage. Check harnesses to terminals PWM and SOLG for breakage.



NOTE: Monitor indicators (PWM5B and 6B) do not blink sequentially as they have no feedback circuit. NOTE: Slow Stop Switch Check Switch ON



Monitor Indicator DI3 ON OFF ON



OFF



OFF



Judgment Normal Faulty switch or broken harness. Faulty switch or short circuited harness. Normal



System Layout 5 V (Not Selected) 0 V (Selected)



Main Controller Auto-Stop ∗ Controller



Slow Stop Switch



Auto-Stop Solenoid (Boom Hoist) Auto-Stop Solenoid (Boom Lower) Auto-Stop Solenoid (Aux. Hoist) Auto-Stop Solenoid (Aux. Lower)



Moment Limiter



Hook Overhoist ∗ Refer to the electrical circuit diagram for details of the auto-stop controller and backup box.



Backup ∗ Box



5 V(Overhoisted) 0 V(Not Overhoisted) T333-05-03-023



T5-3-34



TROUBLESHOOTING / Troubleshooting A Moment Limiter Communication Harness Check



• Be sure to inspect wiring connection prior to troubleshooting.



With key switch OFF, remove 10P connector from moment limiter. Connect harness end connector terminals TX, CTS, RX, RTS, and DGND to vehicle frame using clips. Check for continuity between vehicle frame and each of MC 3-connector side terminals #6 (RX), #7 (RTS), #15 (TX), #16 (CTS), and #17 (DGND).



YES



Faulty harness. NO



Moment Limiter 10P Connector (Harness end connector viewed from the open end side) CASEG DGND GND CTS TX DGND Acc RTS RX B



Faulty moment limiter or MC.



MC 18P Connector (Harness end connector viewed from the open end side)



9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10



T5-3-35



TROUBLESHOOTING / Troubleshooting A Auto-Stop Solenoid Valve System Check



• If overhoisted, normally the monitor indicator blinks and the drum rotation stops.



• If the auto-stop function operates though not overhoisted, refer to Troubleshooting D.



• Be sure to inspect wiring connection prior to troubleshooting.



Reconnect the connector. Remove 2-connector side 12P connector from MC. Check for continuity beYES tween vehicle frame and each of harness end connector terminals #219 (PWM5A), #227 (PWM5B), #223 (PWM6A), and #224 (PWM6B).



Remove clips from harness end connector. Check for continuity between vehicle frame and YES each of MC 2-connector side 12P connector harness end terminal #219 (PWM5A), #227 (PWM5B), #223 (PWM6A), and #224 (PWM6B).



Shorted harness beYES tween MC and auto-stop controller.



Connect MC 2-connector side 12P connector harness end terminals #228 (PWM5C) and #229 (PWM6C) to vehicle frame using clips. DisNO connect auto-stop solenoid valves (boom/jib hoist and lower). Check for continuity between harness end connector terminal #1 and vehicle frame.



· Disconnect 24P con-



nector from auto-stop controller. Connect harness end connector terminals #6 (PWMBH), #8 (PWMBD), #4 (PWMAH), and #10 (PWMAD) to vehicle frame using clips.



With key switch OFF, disconnect auto-stop solenoid valve. Check if resistance between auto-stop solenoid valve connector terminals #1 and #2 is 17.5 Ω at 20 °C.



NO



Broken harness between MC and auto-stop controller.



Faulty auto-stop solenoid valve.



NO



T5-3-36



TROUBLESHOOTING / Troubleshooting A



YES



Remove 24P connector from auto-stop controller and connect harness end connector terminals #7 (NBHS), #9 (NBDS), #5 (NAHS), and #11 (NADS) to vehicle frame YES using clips. Disconnect each harness end connector terminal #2 from auto-stop solenoid valves. Check for continuity between harness end connector and vehicle frame.



Reconnect connectors. Disconnect each harness end connector terYES minal #1 from auto stop solenoid valves (aux. hoist and lower). Check for continuity between harness end connectors and vehicle frame. NO



Faulty auto-stop controller or MC.



Broken ground line of auto-stop solenoid valve.



Broken harness between auto-stop controller and auto-stop solenoid valve.



NO



Broken harness between MC and auto-stop solenoid valve.



NO



Auto-Stop Solenoid Valve Connector (Harness end connector viewed from the open end side)



2



Auto-Stop Controller 24P Connector (Harness end connector viewed from the open end side)



1



12 11 10 9 8 7 6 24 23 22 21 20 19 18



Auto-Stop Solenoid Valve Connector (Auto-stop solenoid valve side connector viewed from the open end side)



1



7 6 5 4 3 2 1 19 18 17 16 15 14 13



MC 12P Connector (Harness end connector viewed from the open end side)



2



224 223 222 221 220 219 230 229 228 227 226 225



T5-3-37



TROUBLESHOOTING / Troubleshooting A Slow Stop Switch System Check (Open Circuit)



• Be sure to inspect wiring connection prior to trou-



YES Faulty MC.



bleshooting.



Connect MC 3-connector side 18P-harness end connector terminal #2 YES to vehicle frame using a clip. Disconnect Turn key switch OFF slow stop switch. and slow stop switch Check for continuity ON. Disconnect between harness end 3-connector side connector terminal #1 18P connector from and vehicle frame. MC. Check for continuity between harness end terminal #2 (DI3) and vehicle frame.



Turn slow stop switch ON. Check for continuity beYES tween slow stop switch side connector terminals #1 and #2.



Check for continuity between slow YES stop switch side connector terminals #2 and vehicle frame.



Broken line of slow NO stop switch.



Open circuit in slow stop switch.



NO



Broken harness between MC and slow stop switch.



NO



Faulty switch or harness.



NO



Slow Stop Switch System Check (Short Circuit) NO



• Be sure to inspect wiring connection prior to troubleshooting. NO



NO Turn key switch OFF and slow stop switch ON. Disconnect 3-connector side 18P



Disconnect slow stop switch. Check for continuity between harness end connector terminal #1 and vehicle frame.



Turn slow stop switch OFF. Check for continuity between slow stop switch side connector terminals #1 and #2. Shorted slow stop YES switch.



connector from MC. Check for continuity between harness end terminal #2 (DI3) and vehicle frame.



YES



1 3



Broken harness between MC and slow stop switch.



Faulty switch or harness.



YES Slow Stop Switch Connector (Harness end connector viewed from the open end side)



Faulty MC.



Slow Stop Switch Connector (Slow stop switch side connector viewed from the open end side)



2



2



1



4



4



3



T5-3-38



MC 18P Connector (Harness end connector viewed from the open end side) 9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10



TROUBLESHOOTING / Troubleshooting A Main Controller (MC) Power System Check



• Be sure to inspect wiring connection prior to troubleshooting.



YES



Faulty MC.



Check for continuity between YES harness end connector terminal #218 (SOLG) and vehicle frame. Remove 2-connector side 18P connector from MC. Check if voltage at harness end connector terminal #209 (SOLB) is 24 V with key switch ON.



Broken ground line. NO



Broken harness up to MC.



NO



MC 18P Connector (Harness end connector viewed from the open end side)



209 208 207 206 205 204 203 202 201 218 217 216 215 214 213 212 211 210



T5-3-39



TROUBLESHOOTING / Troubleshooting A MALFUNCTION OF HOIST THIRD SPEED SELECTION CONTROL When abnormal Monitor Indicator Input



DI0, DI2 Blinking



Failure



When power is ON, third speed switch is short circuited.



Monitor Indicator Output (PWM1A, and 3A)



Triple Blinking Double Blinking Single Blinking



Symptom



OFF (Normal Speed)



Failure



Shorted third speed control output.



ON



Remedy



OFF (Normal Speed)



Overheated IC in third speed control OFF (Normal Speed) output circuit or broken harness to terminal SOLB (Current). Broken harness to terminal SOLB OFF (Normal Speed) (Current) or to terminal SOLG (Ground).



Monitor Indicator DI0 and DI2 ON



OFF



OFF ON OFF



Check third speed switch and harness for short circuit.



Symptom



NOTE: Third Speed Switch Check Switch



Remedy



Check harness to terminals PWM1A/3A or third speed selector solenoid valve for short circuit. Check harness to terminal SOLB for breakage. Check harnesses to terminals PWM1A/3A and SOLG for breakage.



NOTE: Third speed selector solenoid valve is operatable only on crane mode.



Judgment Normal Faulty switch or broken harness. Faulty switch or short circuited harness. Normal



System Layout Main Controller Mode Selector Switch



Main Hoist Third Speed Switch



0V(Crane) 5V(Bucket)



24V(Third Speed)



Aux. Hoist Third Speed Switch



Main Hoist Third Speed Selector Solenoid Valve



Main Hoist Motor



Aux. Hoist Third Speed Selector Solenoid Valve



Aux. Hoist Motor



0V(Normal Speed)



5 V (OFF) 0 V (ON)



T326-05-03-022



T5-3-40



TROUBLESHOOTING / Troubleshooting A Main and Aux. Hoist Third Speed Selector Solenoid Valve System Check



• Be sure to inspect wiring connection prior to troubleshooting. YES



Remove 2-connector side 18P connector from MC. Check for conYES tinuity between vehicle frame and each of MC 2-connector side 18P connector harness end terminals #201 and #205. With key switch OFF, disconnect main and aux. Third speed selector solenoid valves. Check if resistance between solenoid valve side plug connector terminal and vehicle frame is 33.9 Ω at 20 °C.



Shorted harnesses between MC and main and aux. hoist third speed selector solenoid valves.



Reconnect 18P connector to MC and plug connectors to Main and aux. Faulty main and hoist third speed YES aux. hoist third selector solenoid speed selector valves. With key solenoid valves. switch ON, insert tester probes into YES the back of MC 18P Connect each of harness end conMC 2-connector nector terminal side 18P connector Faulty MC. #201 and #205 to harness end termimeasure voltage. NO nals #201 and #205 Check if voltage is to vehicle frame 24 V and 0V when using clips. Check NO for continuity bethird speed mode switch is ON and tween solenoid OFF respectively. valve harness end Broken harnesses plug connector terbetween MC and minals. main and aux. hoist third speed NO selector solenoid valves. Faulty main and aux. hoist third speed selector solenoid valves.



NO



MC 18P Connector (Harness end connector viewed from the open end side)



209 208 207 206 205 204 203 202 201 218 217 216 215 214 213 212 211 210



T5-3-41



TROUBLESHOOTING / Troubleshooting A Third Speed Switch System Check



• Joy-Stick Lever • Be sure to inspect wiring connection prior to troubleshooting.



NO



With key switch OFF, remove 3-connector side 18P connector from MC. With third speed switches ON, check for continuity between vehicle frame and each of harness end connector terminals #10 (DI0) and #11 (DI2).



With key switch and third speed switch OFF, check for continuity beYES tween vehicle frame and each of harness end connector terminals #10 (DI0) and #11 (DI2).



Disconnect the connectors located under both right and left control levers. Check if continuity between connector terminal #2 under right control lever and conNO troller 18P connector terminal #10 (D10), and between connector terminal #4 under left control lever and controller 18P connector terminal #11 (D12) exists.



MC 18P Connector (Harness end connector viewed from the open end side)



Faulty MC.



Faulty third speed switch.



YES Check if continuity between connector YES terminals #4 and 5 under right and left control levers and vehicle frame exists.



YES



Faulty third speed switch.



Broken ground line.



NO



Broken harness between third speed switch and MC.



NO



Connector under Right control Lever (Harness end connector viewed from the open end side)



9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10



1



2



3



4



Connector under Left Control Lever (Harness end connector viewed from the open end side)



T5-3-42



1



2



3



4



5



6



TROUBLESHOOTING / Troubleshooting A Third Speed Switch System Check



• Bi-Directional Control Lever • Be sure to inspect wiring connection prior to troubleshooting.



NO



With key switch OFF, remove 3-connector side 18P connector from MC. With third speed switches ON, check for continuity between vehicle frame and each of harness end connector terminals #10 (DI0) and #11 (DI2).



With key switch and third speed switch OFF, check for continuity beYES tween vehicle frame and each of harness end connector terminals #10 (DI0) and #11 (DI2).



Disconnect the connectors located under main hoist and aux. hoist levers. Check if continuity between connector terminal A under main NO hoist and aux. hoist levers, and main controller 18P connector terminal #10 (D10), and #11 (D12) exists.



Faulty MC.



Faulty third speed switch.



YES YES



Check if continuity between connector YES terminal B under main hoist and aux. hoist levers, and vehicle frame exists.



Faulty third speed switch.



Broken ground line.



NO



Broken harness between third speed switch and MC.



NO



Connector under main hoist and aux. hoist lever (Harness end connector viewd from the open end side.)



MC 18P Connector (Harness end connector viewed from the open end side)



E



A



D



B



9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10



C



T5-3-43



TROUBLESHOOTING / Troubleshooting A MALFUNCTION OF DRUM SPEED SENSING • Joy-Stick Lever (Optional) When abnormal Monitor Indi-cator Output (PWM1B, and 3B) Triple Blinking Double Blinking Single Blinking



Failure



Symptom



Shorted drum speed sensing output circuit.



OFF



Overheated IC in drum speed sensing output circuit or broken harness to terminal SOLB (Current). Broken harness for drum speed sensing output or to terminal SOLG (Ground).



OFF



NOTE: Drum Speed Sensor Check Monitor IndiJudgment Drum cator DI8 and DI9 Rotating



ON OFF ON



Stop



OFF



OFF



Remedy



Check harness to terminals PWM1B/3B or drum speed sensing solenoid for short circuit. Check harness to terminal SOLB for breakage. Check harnesses to terminals PWM1B/3B and SOLG for breakage.



NOTE: Drum Speed Sensing ON-OFF Switch Check Switch



Normal



Faulty sensor or broken harness. Faulty switch or short circuited harness. Normal



Drum Speed Sensing Sole-noid



Monitor Indica-tor PWM1B and 3B



ON



Activated



OFF



ON Deactivated



ON OFF ON



OFF



Deactivated



OFF Single Blinking



System Layout



Judgment Normal Faulty switch or solenoid, or broken harness. Faulty switch or solenoid, or short circuited harness.



Normal



Faulty switch or solenoid, or broken harness. Faulty switch or solenoid, or short circuited harness.



Normal



Main Controller



PWM Pulse 0 to 65 mA



Main Hoist Speed Sensor



Main Hoist Speed Sensing Solenoid Main Hoist Drum Speed Sensing ON-OFF Switch Aux. Hoist Drum Speed Sensing ON-OFF Switch



Aux. Hoist Speed Sensor PWM Pulse 0 to 65 mA



Aux. Hoist Speed Sensing Solenoid



T333-05-03-020



T5-3-44



TROUBLESHOOTING / Troubleshooting A Drum Speed Sensing Solenoid Check • Joy-Stick Lever (Optional) • Be sure to inspect wiring connection prior to troubleshooting. With key switch OFF, disconnect drum speed sensing solenoid. Check if resistance between drum speed sensing solenoid connector terminals 1 and 2 is 44.8±4.5 Ω.



Drum Speed Sensing Solenoid Connector (Drum speed sensing solenoid connector viewed from the open end side)



Check electrical circuit parts and harnesses other than drum speed sensing solenoid.



YES



• Be sure to inspect wiring connection prior to troubleshooting.



·Connect drum speed sensing solenoid harness end connector terminal 1 to vehicle frame using a clip.



Drum Speed Sensing Solenoid Connector (Harness end connector viewed from the open end side)



Check for continuity between drum speed YES sensing solenoid harness end connector terminal 2 and vehicle frame.



1



YES



Broken harness to drum speed sensing solenoid termiNO nal 2. YES Broken harness between MC and drum speed sensing solenoid.



Disconnect drum speed sensing ON-OFF switch with NO the switch ON. Check for continuity between switch connector terminals #1 and #2.



Faulty drum speed sensing ON-OFF NO switch.



• Be sure to inspect wiring connection prior to troubleshooting.



NO



Disconnect drum speed sensing ON-OFF switch with YES the switch OFF. Check for continuity between switch connector terminals #1 d #2



2



Faulty MC.



Drum Speed Sensing Solenoid Harness and Drum Speed Sensing ON-OFF Switch Check (Short Circuit)



With key switch OFF, disconnect drum speed sensing solenoid. With drum speed sensing ON-OFF switch ON, remove 2-connector side 18P connector from MC. Check for continuity between terminal #202 (PWM1B) and vehicle frame, and terminal #206 (PWM3B) and vehicle frame.



1



Faulty drum speed sensing solenoid.



NO



Drum Speed Solenoid Harness and Drum Speed Sensing ON-OFF Switch Check (Discontinuity)



With key switch OFF, disconnect drum speed sensing solenoid. With drum speed sensing ON-OFF switch ON, remove 2-connector side 18P connector from MC. Check for continuity between terminal #202 (PWM1B) and vehicle frame, and terminal #206 (PWM3B) and vehicle frame.



2



Faulty MC.



Short circuited harYES ness between MC and drum speed sensing solenoid. Faulty drum speed sensing ON-OFF NO switch.



T5-3-45



MC 18P Connector (Harness end connector viewed from the open end side) 209 208 207 206 205 204 203 202 201 218 217 216 215 214 213 212 211 210



Drum Speed Sensing ON-OFF Switch Connector 1 2



TROUBLESHOOTING / Troubleshooting A MALFUNCTION OF DRUM SPEED SENSING • Bi-Directional Control Lever When abnormal Monitor Indicator Output (PWM1B, and 3B) Triple Blinking Double Blinking Single Blinking



Failure



Symptom



Shorted drum speed sensing output circuit.



OFF



Overheated IC in drum speed sensing output circuit or broken harness to terminal SOLB (Current). Broken harness for drum speed sensing output or to terminal SOLG (Ground).



OFF



NOTE: Drum Speed Sensor Check Monitor IndiJudgment Drum cator DI8 and DI9 Rotating



ON OFF ON



Stop



OFF



OFF



Remedy



Check harness to terminals PWM1B/3B or drum speed sensing solenoid for short circuit. Check harness to terminal SOLB for breakage. Check harnesses to terminals PWM1B/3B and SOLG for breakage.



NOTE: Drum Speed Sensing ON-OFF Switch Check Switch



Normal



Faulty sensor or broken harness. Faulty switch or short circuited harness. Normal



Drum Speed Sensing Sole-noid



Monitor Indica-tor PWM1B and 3B



ON



Activated



OFF



ON Deactivated



ON OFF ON



OFF



Deactivated



OFF Single Blinking



System Layout



Judgment Normal Faulty switch or solenoid, or broken harness. Faulty switch or solenoid, or short circuited harness.



Normal



Faulty switch or solenoid, or broken harness. Faulty switch or solenoid, or short circuited harness.



Normal



Main Controller



PWM Pulse 0 to 65 mA



Main Hoist Speed Sensor



Main Hoist Speed Sensing Solenoid Main Hoist Drum Speed Sensing ON-OFF Switch Aux. Hoist Drum Speed Sensing ON-OFF Switch



Aux. Hoist Speed Sensor PWM Pulse 0 to 65 mA



Aux. Hoist Speed Sensing Solenoid



T326-05-03-023



T5-3-46



TROUBLESHOOTING / Troubleshooting A Drum Speed Sensing Solenoid Check • Bi-Directional Control Lever • Be sure to inspect wiring connection prior to troubleshooting. With key switch OFF, disconnect drum speed sensing solenoid. Check if resistance between drum speed sensing solenoid connector terminals D and C is 44.8±4.5 Ω.



Drum Speed Sensing Solenoid Connector (Drum speed sensing solenoid connector viewed from the open end side)



Check electrical circuit parts and harnesses other than drum speed sensing solenoid.



YES



• Be sure to inspect wiring connection prior to troubleshooting.



·Connect drum speed sensing solenoid harness end connector terminal D to vehicle frame using a clip.



YES



B



D



Check for continuity between drum speed sensing solenoid harness end connector terminal C and vehicle frame.



Disconnect drum speed sensing ON-OFF switch with NO the switch ON. Check for continuity between switch connector terminals #1 and #2.



YES



E



A



D



B



Faulty MC. C



Broken harness to drum speed sensing solenoid termiNO nal C. YES Broken harness between MC and drum speed sensing solenoid. Faulty drum speed sensing ON-OFF NO switch.



• Be sure to inspect wiring connection prior to troubleshooting.



NO



Disconnect drum speed sensing ON-OFF switch with YES the switch OFF. Check for continuity between switch connector terminals #1 d #2



C Drum Speed Sensing Solenoid Connector (Harness end connector viewed from the open end side)



Drum Speed Sensing Solenoid Harness and Drum Speed Sensing ON-OFF Switch Check (Short Circuit)



With key switch OFF, disconnect drum speed sensing solenoid. With drum speed sensing ON-OFF switch ON, remove 2-connector side 18P connector from MC. Check for continuity between terminal #202 (PWM1B) and vehicle frame, and terminal #206 (PWM3B) and vehicle frame.



E



Faulty drum speed sensing solenoid.



NO



Drum Speed Solenoid Harness and Drum Speed Sensing ON-OFF Switch Check (Discontinuity)



With key switch OFF, disconnect drum speed sensing solenoid. With drum speed sensing ON-OFF switch ON, remove 2-connector side 18P connector from MC. Check for continuity between terminal #202 (PWM1B) and vehicle frame, and terminal #206 (PWM3B) and vehicle frame.



A



Faulty MC.



Short circuited harYES ness between MC and drum speed sensing solenoid. Faulty drum speed sensing ON-OFF NO switch.



T5-3-47



MC 18P Connector (Harness end connector viewed from the open end side) 209 208 207 206 205 204 203 202 201 218 217 216 215 214 213 212 211 210



Drum Speed Sensing ON-OFF Switch Connector 1 2



TROUBLESHOOTING / Troubleshooting A Drum Speed Sensor System Check • Be sure to inspect wiring connection prior to troubleshooting. YES



YES With key switch OFF, disconnect drum speed sensor (main or aux. hoist). Turn key switch ON. Check if voltage between drum speed sensor harness end connector terminals #2 and #3 is 15 V. NO



Check if drum speed sensor operation check LED blinks with drum rotating.



Turn key switch ON. Check if voltage between drum speed sensor harness end connector terminals #2 and vehicle frame is 15 V.



Drum Speed Sensor Connector (Harness end connector viewed from the open end side)



1



A: 1.0±0.5 mm



2



3



Faulty MC.



YES Faulty drum speed sensor. Check if clearance between drum speed senNO sor and gear teeth is 1.0±0.5 mm.



YES



NO



Poor installation of drum NO speed sensor. Faulty harness to drum speed sensor terminal #3. Faulty harness to drum speed sensor terminal #2.



MC 10P Connector (Harness end connector viewed from the open end side)



105 104 103 102 101 110 109 108 107 106



17 mm Drum Speed Sensor



Drum Speed Sensor Operation Check LED



T331-05-03-003 T331-05-03-002



T5-3-48



TROUBLESHOOTING / Troubleshooting A (Blank)



T5-3-49



TROUBLESHOOTING / Troubleshooting A MALFUNCTION OF SWING SPEED CONTROL When abnormal Monitor Indicator Input AI9 Blinking AI1 Blinking Communication Blinking Monitor Indicator Output (PWM2B) Sequential Blinking Triple Blinking Double Blinking Single Blinking



Failure



Symptom



Abnormal swing speed control dial voltage Abnormal pressure sensor (swing control pressure) Abnormal communication from moment limiter



Remedy



Minimum delivery flow rate No control pressure feedback Minimum swing speed



Check swing speed control dial and harness. Check pressure sensor (swing control pressure) and harness. Check moment limiter communication harness.



Failure



Symptom



Remedy



Abnormal swing pump PWM output current feedback. Short circuit in swing constant speed control PWM output circuit. Overheated output IC in swing constant speed control PWM output circuit or opened SOLB current terminal. Opened swing constant speed control PWM output circuit or SOLG terminal.



Current is controlled by open loop. OFF (Minimum delivery flow rate) OFF (Minimum delivery flow rate)



Check harness to terminal PWM2C.



OFF (Minimum delivery flow rate)



Check harnesses to terminals PWM2B and SOLG for discontinuity.



Check harness to terminal PWM2B or to solenoid valve for short circuit. Check harness to terminal SOLB for discontinuity.



NOTE: Swing Sensing Relay Check Monitor InJudgment Operation dicator AI2 ON Normal Rotating Faulty relay or broken harness. OFF Neutral



ON OFF



Faulty relay or short circuited harness.



Normal



System Layout



Main Controller 5 V (Stationary) 0 V (Swing) 419 mA (9 to 10 V) in swing lever neutral



Swing Sensing Relay



Solenoid Valve SD Backup* Box



Swing Mode Switch



0.4 to 1.7KHz



Swing Speed Control Dial



Speed Sensor



Pressure sensor (Swing Control Pressure)



Pump



* Refer to the electrical circuit diagram for backup box details.



0.66 to 3.7V



Moment Limiter



T326-05-03-024



T5-3-50



TROUBLESHOOTING / Troubleshooting A Swing Speed Control Dial System Check • Be sure to inspect wiring connection prior to troubleshooting.



Connect test harness (ST 7129) between swing speed control dial and base machine harness end connector. Turn key switch ON and place swing speed mode switch to normal/constant YES swing speed position. Check if voltage matches the specified value when swing speed control dial is operated from the slow to fast position.



Red



Black V



ST 7129



T107-07-03-009



YES



NO ·Specification: Normal swing: 5 V Constant speed swing: 0.9 to 4.1 V ·MC normal operation range (Monitor indicator blinks if voltage is outside this range.): 0.1 to 4.9 V



Reconnect swing mode switch. Turn key Disconnect switch ON and YES swing mode place swing switch. Check mode switch to for continuity the constant Turn key between swing swing speed switch ON. mode switch position. Check Check if voltconnector terif voltage beage between minal #3 and tween swing swing speed swing speed speed control control dial YES control dial dial harness NO harness end harness end end connector With key switch connector connector terterminals R and OFF, disconterminals R minal B with B is 5±0.5V. nect swing and vehicle swing speed speed control frame is mode switch in dial. Check if 5±0.5V. the constant resistance beswing speed tween swing position. speed control NO dial terminals R and B is 5 kΩ.



With key switch OFF, remove MC 24P connector. Connect harness end connector terYES minal #21 to vehicle frame using a clip. Check for continuity between swing speed control dial harness end connector terminal B and vehicle frame.



NO



R



B



Swing Speed Control Dial Connector (Harness end connector viewed from the open end side) B



2



3



4



5



6



Broken harness between swing mode switch terminal #3 and swing speed control dial terminal B or broken harness NO to swing mode switch terminal #2. Broken harness up to terminal R.



Faulty swing speed control dial.



W



Swing Mode Switch Connector (Switch connector viewed from the open end side) 1



YES Faulty MC.



Swing Speed Control Dial Connector (Swing speed control dial connector viewed from the open end side)



30 29 28 27 26 25 24 42 41 40 39 38 37 36



25 24 23 22 21 20 19 37 36 35 34 33 32 31



Faulty swing speed control dial.



Faulty swing mode switch.



NO MC 24P Connector (Harness end connector viewed from the open end side)



Faulty harness up to terminal W or faulty MC.



R W



T5-3-51



TROUBLESHOOTING / Troubleshooting A Main Controller (MC) Power System Check • Be sure to inspect wiring connection prior to troubleshooting.



YES



Faulty MC.



Check for continuity between YES harness end connector terminal #218 (SOLG) and vehicle frame. Remove 2-connector side 18P connector from MC. Check if voltage at harness end connector terminal #209 (SOLB) is 24 V with key switch ON.



Broken ground line. NO



Broken harness up to MC.



NO



MC 18P Connector (Harness end connector viewed from the open end side)



209 208 207 206 205 204 203 202 201 218 217 216 215 214 213 212 211 210



T5-3-52



TROUBLESHOOTING / Troubleshooting A Moment Limiter Communication Harness Check • Be sure to inspect wiring connection prior to troubleshooting.



With key switch OFF, remove 10P connector from moment limiter. Connect harness end connector terminals TX, CTS, RX, RTS, and DGND to vehicle frame using clips. Check for continuity between vehicle frame and each of MC 3-connector side terminals #6 (RX), #7 (RTS), #15 (TX), #16 (CTS), and #17 (DGND).



YES



Faulty harness. NO



Moment Limiter 10P Connector (Harness end connector viewed from the open end side) CASEG DGND GND CTS TX DGND Acc RTS RX B



Faulty moment limiter or MC.



MC 18P Connector (Harness end connector viewed from the open end side)



9 8 7 6 5 4 3 2 1 18 17 16 15 14 13 12 11 10



T5-3-53



TROUBLESHOOTING / Troubleshooting A Solenoid Valve SD System Check • Be sure to inspect wiring connection prior to troubleshooting.



YES



Remove 2-connector side 18P connector from MC. Connect MC 2-connector side 18P harness end connector YES terminals #204 and #213 to vehicle frame using clips. Check for continuity between vehicle frame and each of solenoid valve SD harness end connector terminals #1 and #2.



With key switch OFF, disconnect solenoid valve SD. Check for continuity between solenoid valve connector terminals #1 and #2.



Remove clips from MC harness end connector terminal #204. Check YES for continuity between solenoid valve SD harness end connector terminal #1 and vehicle frame.



Shorted harness between solenoid valve SD and MC.



Faulty MC. NO



NO



If terminal #1 does not have continuity, harness between solenoid valve SD terminal #1 and MC is broken. If terminal #2 does not have continuity, harness between solenoid valve SD terminal #2 and MC is broken.



Faulty solenoid valve SD. NO



Solenoid Valve SD Connector (Solenoid valve SD connector viewed from the open end side)



1



MC 18P Connector (Harness end connector viewed from the open end side) 209 208 207 206 205 204 203 202 201 218 217 216 215 214 213 212 211 210



2



Solenoid Valve SD Connector (Harness end connector viewed from the open end side)



2



1



T5-3-54



TROUBLESHOOTING / Troubleshooting A Swing Sensing Relay System Check (Discontinuity) • Be sure to inspect wiring connection prior to troubleshooting. NO



With key switch OFF, replace swing sensing relay with jack sensing relay. Check if machine operates normally. ·Engine: Running ·Pilot control shut-off lever: UNLOCK position ·Swing lever: Operated



Faulty swing sensing relay.



With key switch OFF, disconnect swing sensing relay and connect harness end connector terminal #5 to vehiYES cle frame using a clip. Check for continuity between MC 24P connector terminal #41 (AI2) and vehicle frame.



YES



Faulty MC.



Broken harness. NO



Swing Sensing Relay System Check (Short Circuit) • Be sure to inspect wiring connection prior to troubleshooting. NO



Faulty swing sensing relay.



With key switch OFF, replace swing sensing relay with jack sensing relay. Check if machine operates normally.



YES



·Engine: Running ·Pilot control shut-off lever: UNLOCK position ·Swing lever: operated



With key switch OFF, disconnect swing sensing relay. Check for continuity between YES MC 24P connector terminal #41 (AI2) and vehicle frame.



Short-circuited harness.



Faulty MC. NO MC 24P Connector (Harness end connector viewed from the open end side)



Swing Sensing Relay Connector (Harness end connector viewed from the open end side) 1 3



30 29 28 27 26 25 24 42 41 40 39 38 37 36



2 5 4



25 24 23 22 21 20 19 37 36 35 34 33 32 31



T5-3-55



TROUBLESHOOTING / Troubleshooting A Pressure Sensor (Swing Control Pressure) System Check • Be sure to inspect wiring connection prior to troubleshooting. 2



NOTE: 1kgf/cm = 98.07 kPa



With key switch OFF, disconnect pressure sensor (swing control pressure). Turn key switch ON. Check if voltage between pressure sensor (swing control pressure) harness end connector terminals R and B is 5 V



Reconnect pressure sensor (swing control YES pressure).Insert tester probe into MC 24P conYES nector terminal #30 (AI1) from connector back side without removing connector. Check if voltage matches the specified NO l ·Specification When gantry raise/lower, crawler extend/retract, and/or 2 jack is not being operated: 3.8 V at 41 kgf/cm When gantry raise/lower, crawler extend/retract, and/or 2 jack is being operated: 1.4 V at 12 kgf/cm ·MC Normal Operation Range (Monitor indicator blinks if voltage is outside this range.): 0.66 to 4.9 V



Turn key switch ON. Check if voltage between pressure sensor (swing NO control pressure) harness end connector terminal R and vehicle frame is 5 V.



Check for continuity between pressure YES sensor (swing control pressure) harness end connector terminal B and vehicle frame.



Faulty MC.



Faulty pressure sensor (swing control pressure).



YES



Faulty MC.



NO



Broken harness to terminal B.



Broken harness to terminal R.



NO



MC24P Connector (Harness end connector viewed from the open end side)



30 29 28 27 26 25 24 42 41 40 39 38 37 36



Pressure sensor (swing control pressure) (Harness end connector viewed from the open end side)



Pressure vs Voltage Characteristics of Pressure Sensor 4.5 V



R



W



25 24 23 22 21 20 19 37 36 35 34 33 32 31



B



0.5 V 0



T5-3-56



50 kgf/cm 2



TROUBLESHOOTING / Troubleshooting A MALFUNCTION OF WORK MODE CONTROL (Bucket mode is inoperable) Monitor Indicator Input A17 Blinking



Problem Faulty mode switch or harness (Abnormal voltage)



Monitor Indicator Output (SOL2) Triple Blinking



Double Blinking



Single Blinking



Symptom



Corrective Measures



Crane mode remains unchanged. • Maximum pump flow rate does not change in two stages (Less flow rate is kept unchanged.)



• Check the mode switch or harness.



Problem



Symptom



Corrective Measures



Short-circuited output of the maximum flow rate two stage control solenoid valve SC. Overheated output IC of the above solenoid valve or broken harness to terminal SOLB (current). Broken harness to terminal SOLB (current) or to terminal SOLG (ground).



OFF (Less flow rate is kept unchanged.)



Check harness to terminal SOL2 or solenoid valve SC for short circuit.



OFF (Less flow rate is kept unchanged.)



Check harness to terminal SOL2 for discontinuity.



OFF (Less flow rate is kept unchanged.)



Check harness to terminal SOL2 or to terminal SOLG for discontinuity.



NOTE: Two-Stage Maximum Flow Rate Control Shift to the smaller maximum flow rate: 0 V output (OFF) Shift to the larger maximum flow rate: 24 V output (ON) Diagram Main Controller (MC) 15 A



24 V (ON) Work Mode Switch



0 V (OFF)



0 V (Crane) 5 V (Bucket)



Solenoid Valve SC (Maximum Flow Rate Control)



T333-05-03-024



T5-3-57



TROUBLESHOOTING / Troubleshooting A Work Mode Switch System Check • Although the main controller (MC) and the maximum flow rate control solenoid valve (SC) operate normally, if the actuator speeds don’t change after operating the work mode switch, the mode switch may be faulty. • Check for loose harness connections prior to beginning troubleshooting. YES



Crane mode: No continuity Bucket mode: Continuity



Turn key switch OFF and disconnect work mode switch. Check for continuity between connector terminals #1 and #2 with work mode switch in crane position. Then, check for continuity between connector terminals #1 and #2 with work mode switch in bucket position.



Turn key switch ON. Check if voltage between work mode switch base machine side harness end connector terminals #1 and #2 is 5 ± 0.5V.



YES Faulty MC



Turn key switch ON. Check if voltage between work mode switch base machine side harNO ness end connector terminals #1 and vehicle frame (ground) is 5 ± 0.5V.



Work Mode Switch Connector (Switch Connector Open End Side)



2



3



4



5



6



Work Mode Switch Connector (Harness End Connector Open End Side)



3



2



1



6



5



4



Turn key switch ON. Check for continuity between YES work mode switch base machine side harness end connector terminals #2 and vehicle frame (ground).



NO



NO



Faulty harness to work mode switch terminal #2 Faulty harness to work mode switch terminal #1



Faulty work mode switch



Crane mode: Continuity Bucket mode: No continuity



1



Faulty MC



T5-3-58



TROUBLESHOOTING / Troubleshooting A Solenoid Valve SC (Maximum Flow Rate Control) System Check • Check for loose harness connections prior to beginning troubleshooting.



Turn key switch OFF and disconnect solenoid valve SC. Check for continuity between solenoid valve connector terminals #1 and #2.



Disconnect 12P connector on MC 2-connection end-point side and solenoid valve SC. Using a clip, connect 12P harness end connector terminal YES #222 on MC 2-connection end-point side to vehicle frame. Check for continuity between solenoid valve SC harness end connector terminals #1 and #2, and vehicle frame respectively.



Disconnect clip from MC harness end connector terminal #222. YES Check for continuity between solenoid valve SC harness end connector terminal #1 and vehicle frame.



YES Short-circuited harness between solenoid valve and MC



NO



In case terminal #1 has no continuity, harness between solenoid valve SC terminal #1and MC is broken. In case terminal #2 has no continuity, harness between solenoid valve SC terminal #2 and vehicle frame (ground) is broken.



NO



Faulty solenoid valve SC



NO



Solenoid Valve SC Connector (Valve Connector Open End Side)



2



MC 12P Connector (Harness End Connector Open End Side)



224 223 222 221 220 219 230 229 228 227 226 225



1



Solenoid Valve SC Connector (Harness End Connector Open End Side)



1



Faulty MC



2



T5-3-59



TROUBLESHOOTING / Troubleshooting A (Blank)



T5-3-60



TROUBLESHOOTING / Troubleshooting B TROUBLESHOOTING B PROCRDURE Use troubleshooting B in case the machine operates abnormally although no monitor controller malfunction indicators are blinking and the auto-stop system operates normally.



• How to Read the Troubleshooting Flow Charts YES(OK)



・



(2) After checking or measuring in step (1), select either YES (OK) or NO (NOT OK) and proceed to step (2) or (3), as appropriate.



(1) NO (NOT OK)



・ · Key switch: ON



・



(3)



Special instructions or reference items are indicated under the flow chart box as required. Incorrect measuring or checking methods will render troubleshooting impossible, and may damage components. Descriptions inside thick-line boxes state the cause of the trouble. Possible trouble location can be focused by scanning only the descriptions in the thick-line boxes.



NOTE: For all connector drawings illustrated in this group, harness end connector terminals are seen from the open end side.



Wire Harness Side Open End Side Harness End Connector T158-05-03-001



T5-4-1



TROUBLESHOOTING / Troubleshooting B TROUBLESHOOTING LIST Trouble Location



Engine



Actuator Control System



Hook Hoist Drum System



E-1 E-2 E-3 E-4 E-5 E-6 A-1 A-2 A-3 M-1 M-2 M-3 M-4 M-5



Boom Hoist Drum System Swing System



B-1 S-1 T-1



Travel System T-2 O-1 O-2 Other Control O-3



Symptom Starter does not rotate. Although starter rotates, engine does not start. Engine is hard to start at low ambient temperature (without preheating). Engine stalls in several seconds after engine starts. Faulty engine speed. Engine does not stop. More than one actuator do not move. Actuator does not stop even if control lever is in neutral. Superfine speed mode does not operate. Drum does not rotate. Drum speed becomes fast but does not increase to third speed range. Lifted load is lowered when hoist lever is returned to neutral (in the auto-brake mode). Auto-brake green indicator does not come ON even if brake mode switch is turned to the auto-brake mode position. Free fall is inoperable even if brake mode switch is turned to the free mode position. Drum does not rotate. Swing speed is slow or swing is inoperable. One-side track does not move, moves slowly, or machine cannot travel straight (mistracks). Travel mode does not change. Drum lock does not operate. Stand does not tilt. Joy-Stick Lever: Right Stand Bi-Directional Control Lever: Main Stand Crawler does not extend and/or retract (by operating pendant switch)



T5-4-2



TROUBLESHOOTING / Troubleshooting B (Blank)



T5-4-3



TROUBLESHOOTING / Troubleshooting B ENGINE TROUBLESHOOTING YES



Engine Does Not Start E-1 Starter Does not Rotate First, check that all brake mode switches are turned to AUTO BRAKE position and that the swing brake switch is in the ON position.



Voltage at terminal B is 0 volts when key switch is turned to ON or START position, or while engine is running.



Tracing Procedure: Measure each voltage in order, shown in the following table. The electronic control system, such as the engine controller, is not involved with the failure of the starter to rotate.



Is battery voltage and electrolyte density normal? Normal Values: Voltage is 24 V or more Density is 1.26 or more



YES



· Key switch: ON ↔ START · Engine: Running Voltage at terminal C is not 24 V when key switch is turned to START position.



Is the voltage at each starter terminal normal (as shown in table below) when key switch is turned to ON or START position?



Starter Relay Terminal Voltage Unit: Volts Key Switch ON



B C E N Sw



Unit: Volts Key Switch START



Terminal



C B M



0 24 0



24 24 24



START



Terminal



Starter Terminal Voltage ON



Is voltage at each starter relay terminal normal (as shown in the table below) when key switch is turned to ON or START position, or while engine is running ?



ENG. RUNNING



(0) (24) (0)



24 0 0 0 0



24 24 0 0 24



ENG. RUNNING



(24) (0) (0) (12) (0)



NO



Voltage at terminal M is not 24 V when key switch is turned to START position. NO (If the voltage at terminal B is 18 volts or less when the key switch is turned to the START position, batteries are faulty.)



T5-4-4



TROUBLESHOOTING / Troubleshooting B Failure of starter or disconnection of starter grounding wire. Check if a click can be heard from battery relay when key switch is turned OFF from ON position.



YES



Voltage at starter relay terminal Sw is · Key switch: ON ↔ OFF not 24 V when key switch is turned to START position. Voltage at key switch terMeasure voltages Check if slow blow minal No.4: 0 V at key switch terfuse No.1 (45A) is minal No.1 and normal (if fuse is No.4. not blown). · Key switch: START



Failure of harness between battery relay and starter Check battery relay function.



NO OK



Failure of harness between slow blow fuse and key switch



NOT OK Voltage at key switch terminal No.4: 24 V Voltage at key switch terminal No.1: 0 V



Voltage at key switch terminal No.4: 24 V Voltage at key switch terminal No.1: 24 V



A



Voltage at main drum brake relay (R3) terminal No.3: 24 V



· Key switch: START



Voltage at at swing-brake-unapplied relay (R2) terminal No.5: 24 V



Measure voltages at swing-brake-unappli ed relay (R2) ter· Key switch: START



Failure of key switch



Voltage at main drum brake relay (R3) terminal No.3: 0 V



Measure voltage at main drum brake relay (R3) terminal No.3.



Voltage at at swing-brake-unappli ed relay (R2) terminal No.5: 0 V



Voltage at starter relay terminal B is 0 V.



Failure of slow blow fuse (45A)



Failure of harness between key switch terminal No.1 and relay (R3) terminal No.3 A Failure of harness between swing-brake-unapplie d relay (R2) terminal No.5 and starter relay terminal Sw



Check functions of main/auxiliary brake relays (R3 and R7), main/auxiliary brake mode switches, swing-brake-unapplied relay (R2), and swing brake switch. Check harnesses between them. Failure of slow blow fuse (65A) or harness.



Voltage at starter terminal C is 0 V but voltage at starter relay terminal C is 24 V when key switch is turned to START position. ・



Failure of harness between starter relay terminal C and starter terminal C.



Voltages at starter relay terminals except terminal C are normal (voltage at terminal C is not 24).



Failure of starter relay Failure of starter relay or disconnection of starter grounding wire. Failure of batteries.



T5-4-5



TROUBLESHOOTING / Troubleshooting B Starter Voltage Check B



1. Check starter voltage with key switch turned to the ON or START position, or engine running. 2. Contact negative (-) probe of circuit tester to machine (ground to unpainted areas like a bolt head) and positive (+) probe to terminal C, B, and M on starter to measure voltages.



M



C



Starter Terminal Voltage



T108-07-04-001



Key Switch



ON



START



C B M



0 24 0



24 24 24



Terminal



Unit: Volts ENG. RUNNING (0) (24) (0)



B C



M



T108-07-04-002



C



Starter Relay Voltage Check



B



1. Check starter relay voltage with key switch turned to the ON or START position, or with engine running.



E



2. Measure voltages at starter relay terminal B, C, E, N, and Sw with connector and wire connected. N



Starter Relay Terminal Voltage Key Switch



ON



START



B C E N Sw



24 0 0 0 0



24 24 0 0 24



Terminal



Sw



Harness Connector (View from harness side)



Unit: Volts ENG. RUNNING (24) (0) (0) (12) (0)



T108-07-04-004



T5-4-6



TROUBLESHOOTING / Troubleshooting B Key Switch Voltage Check 1. Remove key switch (1) from console panel. 2. Turn key switch ON. 3. With key switch connected, measure voltages at terminal No.1 and No.4 from harness side. 1 Joy-Stick Lever



T326-04-03-018



1



Bi-Directional Control Lever



M326-02-005



A



View A T324-07-03-003



T5-4-7



TROUBLESHOOTING / Troubleshooting B E-2 Although Starter Rotates, Engine Does Not Start.



• Be sure to inspect wiring connections prior to troubleshooting. Check position of governor and fuel shut-off levers with key switch turned to the ON or START position. If positioning of both levers is correct, the problem may be in engine or fuel system. YES



YES



Failure of engine. · Refer to engine shop manual.



Check if fuel shut-off lever is at the start position when key switch is turned to the ON or START position. · Key switch: ON or START NO



Check if governor lever moves to start position when the key switch is turned ON.



Failure of emergency relay



YES



Check if fuel shut-off lever moves to the start position when engine stop solenoid terminal is removed. Failure of engine stop solenoid



NO



· Key switch: ON



· Check that all levers and links move



Check EC motor driving circuit.



NO



1 3



• Governor Lever and Fuel Shut-Off Lever



123456-



Governor Rod Governor Lever Fuel Shut-off Lever Rod Slow Idle stopper Bolt Fast Idle Stopper Bolt



2 4



6



5 T324-07-03-002



T5-4-8



TROUBLESHOOTING / Troubleshooting B • Governor Lever Position A: B:



FULL



Key Switch OFF (Engine Stop Position) Key Switch ON (Engine Start Position)



STOP B A



T324-07-03-002



• Fuel Shut-Off Lever Switch A: B:



Key Switch OFF (Engine Stop Position) Key Switch START (Engine Start Position)



NOTE: When the key switch is turned OFF from the ON or Start position, the fuel shut-off lever is moved to position A. The lever then moves to position B after approximately 10 seconds by the engine stop solenoid spring force.



B



A



T324-07-03-004



T5-4-9



TROUBLESHOOTING / Troubleshooting B E-3 Engine is Hard to Start at Low Ambient Temperature



• Be sure to inspect wiring connections prior to troubleshooting. Check if electricity is conducted to the glow plugs and/or check for failure of the glow plugs.



20 V



Measure resistance of each glow plug. (Refer to T5-4-12.)



A



· Key switch: OFF · Remove copper plates connecting each glow plug to measure the resistance. Measure voltage at glow plug for No.1 cylinder. (Refer to T5-4-12.) · Key switch: HEAT (Even if the key switch is turned to the HEAT position, the circuit is automatically cut off after five seconds. · Measure the voltage as soon as possible.)



OK (24 V)



0V



Check voltage at glow plug relay terminal Sw. · Key switch: HEAT · With the glow plug relay connected, measure voltage from the harness side. NOT OK (0



Measure voltage at the glow plug timer terminal in the order shown in the table below. (Refer to T5-4-12.) · With the glow plug timer connected, measure voltage from the harness side. · Key switch: OFF/HEAT/START



Glow Plug Timer Terminal Voltage Unit: Volts Order of Measurement



(1) (2) (3) (4) (5)



Key Switch Position Nos. of Glow Plug Timer



6 4 9 3 2



B



OFF



HEAT



START



24 0 0 0 0



24 Over 20 Over 20 Over 20 24



24 0 Over 20 Over 20 24



T5-4-10



C



TROUBLESHOOTING / Troubleshooting B



NOT OK (∞ Ω)



Replace glow plug.



A Failure of engine OK (10 Ω) · Refer to engine shop manual.



Failure of glow plug relay, or discontinuity of harnesses between slow blow fuse No.1 (45A) and glow plug relay, and/or between glow plug relay and glow plug.



B



Failure of harness between slow blow fuse No.1 (45A) and glow plug timer terminal No.6.



Voltage at glow plug timer terminal No.6 is not 24 V.



(1)



· Key switch: OFF/HEAT/START



· Recheck fuse No.1.



C NOT OK (0 V) Voltage at glow plug timer terminal No.4 is not 20 V or more.



(2)



· Key switch: HEAT



(3), (4)



Check voltage at key switch terminal No.2. · Key switch: HEAT



Voltage at glow plug timer terminal No.3 or 9 is not 20 V or more.



OK (20 V)



Failure of key switch (Replace key switch) Discontinuity of harnesses between key switch terminal No.2 and glow plug timer terminal No.4. Discontinuity of current sensor circuit



· Key switch: HEAT (5)



Voltage at glow plug timer terminal No.2 is less than 24 V.



Failure of glow plug timer (Replace)



· Key switch: OFF → HEAT (Within 5 seconds)



T5-4-11



TROUBLESHOOTING / Troubleshooting B Glow Plug Voltage and Resistance Check Resistance:



Voltage: · Check voltage without disconnecting the copper plate · Key switch: OFF→HEAT



· Check resistance after disconnecting the copper plate



V



Ω



Copper Plate



T108-07-04-007



T108-07-04-008



Less than 10 Ω (Normal)



20 Volts or More (Normal)



Glow Plug Timer Rear Console in Operator’s cab



Glow Plug Timer Voltage Check Without disconnecting the connector from the glow plug timer, check voltages at terminal No. 6, 4, 9, 3 and 2 with key switch OFF, HEAT and START positions.



Glow Plug Timer Terminal Voltage



T324-07-04-002



Unit: Volts Order of Measurement



(1) (2) (3) (4) (5)



Key Switch Position Nos. of Glow Plug Timer



6 4 9 3 2



OFF



HEAT



START



24 0 0 0 0



24 20 or more 20 or more 20 or more 24



24 0 20 or more 20 or more 24



View A



A



6 2



10 3 9 5



4



7



T108-07-04-009



T5-4-12



TROUBLESHOOTING / Troubleshooting B E-4 Engine Stalls in Several Seconds After Engine Starts In case engine oil pressure does not rise (the engine oil pressure indicator stays ON), the engine stalls in about 20 seconds after the engine starts. In case the generative voltage of the alternator is reduced (does not rise to the specification), the engine stalls in about six seconds after the engine starts.



YES (5 V)



Is voltage at terminal of OK engine oil pressure switch about 5 V ?



Engine stalls in about 20 seconds after engine starts. Check if engine oil level is normal.



· Engine: Running · Measure voltage with connector attached



Check if engine oil YES pressure switch is normal.



NO (0 V)



· Engine: Running



Failure (faulty grounding) of harness between engine oil pressure switch and emergency relay, or harness between engine oil pressure switch and monitor controller. Failure of engine oil pressure switch, or engine oil pump.



NO



Replenish engine oil.



NO



Engine stalls in about 6 seconds after engine starts. Is voltage at terminal N of alternator about 12 V?



Failure of emergency relay.



Discontinuity of harnesses between terminals N of starter relay and alternator emergency relay.



YES (12 V)



· Engine: Running Failure of alternator



NO (0 V)



Engine Oil Pressure Switch Check 1. Remove the connector from the engine oil pressure switch.



Ω



2. Check for continuity between the switch terminal and ground while the engine is not running. T108-07-04-012



3. Check that no continuity exists between the switch terminal and ground while the engine is running.



T5-4-13



TROUBLESHOOTING / Troubleshooting B E-5 Faulty Engine Speed When the engine speed is faulty, incorrect adjustment of the EC motor, and links and levers, or faulty fuel injection pump may be the cause of the trouble. OK



NO



Slow idle speed is too fast or slow.



Check if length of control cable connecting governor lever and EC motor is correct.



Check if engine governor lever comes in contact with slow idle stopper. · Key switch: ON · Place accelerator grip or lever in the low idle position. · Perform visual inspection.



NOT OK



YES



NO



NO



Fast idle speed is too slow.



Check if fast idle position has been calibrated.



Check if engine governor lever comes in contact with fast idle stopper. · Engine: Running · Place accelerator grip or lever in the fast idle position. · Perform visual inspection.



YES



YES



Check if engine governor lever or rod is deYES formed. NO



T5-4-14



TROUBLESHOOTING / Troubleshooting B



Incorrect adjustment of accelerator pedal cable length.



Incorrect adjustment of control cable length between EC motor and governor lever. Incorrect adjustment of engine governor lever.



Calibrate fast idle position.



NO Check if the length of control cable connecting EC motor and governor lever is correct. YES



Incorrect length of control cable connecting EC motor and governor lever.



Incorrect adjustment of accelerator pedal cable. Failure of governor lever and rod. · Deformations of lever and rods Faulty engine or fuel system.



T5-4-15



TROUBLESHOOTING / Troubleshooting B E-6 Engine Does Not Stop



• Be sure to inspect wiring connections prior to troubleshooting. In case the engine does not stop , move the fuel shut-off lever manually to the stop position, and check and adjust after the engine comes to a complete stop.



Engine stop is made by the engine stop solenoid. If the engine does not stop, either the engine stop solenoid or the key switch sending stop signal to engine stop solenoid may have a trouble (even if the key switch is OFF, voltage at terminal No. 6 may be 24 volts).



Failure of fuel injection pump



YES



· Refer to engine shop manual. OK YES



Check engine stop solenoid. Refer to T5-4-17.



Check if fuel shut-off lever is in the stop position.



NOT OK



Failure of emergency relay



Failure of engine stop solenoid



· Key switch: ON → OFF Check if voltage at terminal No.6 is 0 NO V. Failure of key switch or emergency relay (replace)



· Key switch: OFF NO (24 V)



How To Stop Engine Manually Pull the engine stop solenoid rod to manually move the fuel shut-off lever to the engine stop position. Engine Stop Position



Fuel Shut-Off Lever Rod



T324-07-03-005



T5-4-16



TROUBLESHOOTING / Troubleshooting B Engine Stop Solenoid Check 1. Start the engine. 2. Turn the key switch OFF to stop the engine. In case the engine does not stop, move the fuel shut-off lever manually to the stop position, and start checking after the engine comes to a complete stop. 3. Measure voltage between (+) terminal (yellow color wire) and (-) terminal (black color wire) on the engine stop solenoid. Standard Voltage: Approximately 24 volts



NOTE: The engine stop solenoid is activated for about 10 seconds when key switch is turned from ON (engine running) to OFF. So measure the voltage quickly. Key Switch Position And Voltage Between Terminals On Engine Stop solenoid . Key Switch Position OFF ON START ON (START) → OFF



Voltage between Terminals 0V 0V 0V 24 V (within about 10 seconds)



V



T108-07-04-014



T5-4-17



TROUBLESHOOTING / Troubleshooting B ACTUATOR CONTROL SYSTEM TROUBLESHOOTING A-1 More than One Actuator Do Not Move



• The pilot system (such as the pilot pump and pilot shut-off valve) and pilot relief valve system may have failed. • If the hook raise/lower and boom lower functions are inoperable, refer to the troubleshooting D or auto-stop controller indicators (T5-4-60).



YES YES



Check if main relief pressure is normal. · Refer to the Operational Performance Test.



YES



Check if primary pilot pressure is normal.



Faulty main relief valve pressure setting.



NO NO



· Refer to the Operational Performance Test.



Check if pilot control shut-off lever is in the UNLOCK position.



NO



Faulty main pump and/or transmission.



Faulty pilot pump.



Disassemble and adjust pilot relief valve. Check if pilot relief valve is normal. YES



Faulty pilot relief valve. Move pilot control shut-off lever to the UNLOCK position.



NO



A-2 Actuator Does Not Stop Even If Control Lever Is in Neutral



• Either the pilot valve spool or control valve spool may have seized.



YES



Faulty pilot valve. · Even if control lever is in neutral, pilot pressure is routed up to control valve spool end.



Check if actuator stops when pilot control shut-off lever is moved to the LOCK position.



Faulty control valve. NO · Although pilot pressure is not routed up to control valve spool end, oil passage is kept opened due to seizure of spool.



T5-4-18



TROUBLESHOOTING / Troubleshooting B A-3 Superfine Speed Mode Does Not Operate



• Find out whether the control system or hydraulic system is faulty.



• If controller malfunction indicators are lighting or blinking, refer to the Troubleshooting A. NOTE: 1 MPa = 145 psi Faulty pump regulator.



YES Check pressure at superfine speed YES switch valve port A is 0.5 MPa 2 (5 kgf/cm ) or more.



Disconnect pipe from shuttle valve. Install In all operations pressure gauge to port E. Check if pressure is 4.9 2 MPa (50 kgf/cm ) Check if superfine when operated. NO speed mode is unavailable in all operations.



In only specific operations



Check if signal pressure from solenoid valve NO SH is 0.5 MPa 2 (5kgf/cm ) or more.



NO Faulty superfine speed switch valve.



Faulty solenoid YES valve SH. Faulty shuttle valve.



Disconnect corresponding pipe from shuttle valve. Install pressure gauge to disconnected pipe. Check if pressure 2 is 4.9 MPa (50 kgf/cm ) when operated. · 1- Hook Hoist · 3- Travel · 4- Boom Hoist



YES



Faulty shuttle valve.



NO



Faulty shuttle valve corresponding to operation.



Port A



Port E



Superfine Speed Switch Valve



T326-05-04-001



T5-4-19



Shuttle Valve



T326-05-04-002



TROUBLESHOOTING / Troubleshooting B HOIST DRUM SHOOTING



CONTROL



TROUBLE-



M-1 Drum Does Not Rotate



• Be sure to inspect wiring connections prior to troubleshooting.



• In case the pilot pump and/or pilot relief valve is faulty, not only the drum but also the travel and swing functions become inoperable. • If overhoisted, the drum stops. Check for troubleshooting D or auto-stop controller indicator (T5-4-60). NOTE: 1 MPa = 145 psi



NO



Faulty pilot valve.



YES



Check if secondary pilot pressure is normal.



Main



· Refer to the Performance Check section.



Conduct the troubleshooting D.



Check if auto-stop solenoid valve resistance is 32 Ω at 20 C°.



Faulty auto-stop solenoid valve.



NO



YES



Check which drum does not rotate, main or auxiliary.



Normal



Aux.



Check for outputs from monitor indicators (PWM5B and 6B). · Refer to T5-3-34.



T5-4-20



Check if current to auto-stop solenoid valve matches specification.



· Slow stop switch: OFF · Crane: 679 mA · Tower: 517 mA Faulty auto-stop Abnormal solenoid valve · Refer to T5-3-36.



TROUBLESHOOTING / Troubleshooting B



Auto-Stop Solenoid Valve Connector (Auto-stop solenoid valve connector viewed from the open end side)



1



NO



2



Perform Troubleshooting A. · Refer to T5-3-36. NO



YES



Faulty auto-stop solenoid valve.



Disconnect output line from auto-stop solenoid valve. Install pressure gauge. Check if pressure is 2 4.9 MPa (50 kgf/cm ).



Faulty hoist motor. YES



T5-4-21



TROUBLESHOOTING / Troubleshooting B M-2 Drum Speed Becomes Fast But Does Not Increase to Third Speed Range YES



• Be sure to inspect wiring connections prior to troubleshooting.



Check if third speed mode solenoid valve operates correctly (check if a click sound is heard.). · Key switch: ON · Third speed mode switch: ON



YES



Disconnect third speed mode solenoid valve. Check if voltage at harness end connector terminals #2 is 24 V. · Key switch: ON



Disconnect connectors from both main hoist and aux. hoist lever grips. Check if continuity between main hoist lever grip connector terminals # 2 and 4, and between aux. hoist lever grip connector terminals # 4 and 5 exists. · Key switch: ON · Third speed mode switch: ON



NO



NO YES YES



(H)



Check if pilot pressure (from shuttle valve to third speed selector solenoid valve) to hoist motor sequential valve is 2 1.3 MPa (13 kgf/cm ) or more. · Engine: Running · Hoist lever: 2nd speed · Third speed mode switch: ON



NO



NO Main Hoist Lever Grip Connector (Grip side connector seen from the open end side)



1



2



3



4



Third Speed Mode Solenoid Valve Connector (Harness end connector seen from the open end side)



1



2



Aux. Hoist Lever Grip Connector (Grip side connector seen from the open end side)



1



2



3



4



5



6



T5-4-22



Is aux. hoist drum displaying any trouble ?



TROUBLESHOOTING / Troubleshooting B



to (H)



YES



Perform Troubleshooting A.



Is machine with crane YES attachment displaying any trouble?



· Refer to T5-3-40.



Third speed mode is not applicable to tower aux. hoist drum operation.



NO



Perform Troubleshooting A.



NO



· Refer to T5-3-40. Faulty Third speed mode switch. Disassemble hoist motor sequence valve. Check if sequence valve is abnormal.



YES



Faulty hoist motor sequence valve. Faulty hoist motor.



NO Faulty shuttle valve.



Perform Troubleshooting A. · Refer to T5-3-40.



Pilot Pressure Check Port



T326-05-04-003



T5-4-23



TROUBLESHOOTING / Troubleshooting B M-3 Lifted Load Is Lowered When Hoist Lever Is Returned to Neutral (In the Auto-Brake Mode)



• Check whether the hoist drum brake or hoist motor multi-disc brake may be unapplied. NOTE: 1 MPa = 145 psi



YES YES



Check if hoist drum brake slips.



Check if brake band indicator is in normal range with brake pedal released. (Refer to Operator’s Manual for checking method.)



· Engine: Running at slow idle · Pilot primary pressure: More than 4.4 ± 0.5 MPa (45 ± 5 2 kgf/cm ). · Pilot control shut-off lever: UNLOCK position.



NO



NO



YES



Check if hoist motor multi-disc brake release pressure is 0 2 kgf/cm . NO



T5-4-24



Check brake lining for oil contamination.



Adjust brake band.



Faulty hoist motor multi-disc brake.



Faulty hoist motor brake release valve (oil leak).



TROUBLESHOOTING / Troubleshooting B (Blank)



T5-4-25



TROUBLESHOOTING / Troubleshooting B M-4 Auto Brake Green Indicator Does Not Come ON Even If Brake Mode Switch Is Turned to the Auto-Brake Mode Position



• Be sure to inspect wiring connections prior to



NOTE: Brake Pedal Joy-Stick Lever: After changing the out side cab brake mode switch to the “Bucket” mode, depress the brake pedal fully. Bi-Directional Control Lever: Locked Position.



troubleshooting.



YES



YES



Check if green indicator light is burnt out.



Check if buzzer stops 2 to 3 seconds after brake mode switch is turned to auto brake position. · Engine: Running · Brake mode switch: FREE MODE position → AUTO-BRAKE MODE position · Hoist lever: Neutral · Brake Pedal: See NOTE NO



Check if hoist drum is allowed to free fall when brake pedal is released.



Check if buzzer stops when pressure switch (auto-brake pressure sensing) is disconnected. · Engine: Running · Brake mode switch: AUTO-BRAKE MODE position



· Engine: Running · Brake mode switch: AUTO-BRAKE MODE position · Hoist lever: Neutral YES



NO



Check if voltage at brake mode selection solenoid valve terminal #1 is 0 V. · Engine: Running · Brake mode switch: FREE MODE position → AUTO-BRAKE MODE NO position · Hoist lever: Neutral · Brake pedal: See NOTE



T5-4-26



TROUBLESHOOTING / Troubleshooting B



OK



Check if voltage at main hoist brake relay (R13) (aux. hoist brake relay (R14)) terminal #3 is 24 V. · Engine: Running · Brake mode switch: AUTO-BRAKE MODE position



YES



Check if voltage at main hoist brake relay (R13) (aux. hoist brake relay (R14)) terminal #4 is 24 V.



YES



Faulty harness (broken harness) between green indicator and relay (R13) (aux. hoist relay (R14))



· Engine: Running · Brake mode switch: AUTO-BRAKE MODE position



NO



Faulty relay (R13) (aux. hoist relay (R14)).



NO



Faulty harness (broken harness) between brake mode switch and relay (R13) (aux. hoist relay (R14)). Burnt out green indicator.



NOT OK



Faulty pressure switch (auto-brake pressure sensing).



YES



Faulty harness between pressure switch (auto-brake pressure sensing) and relay (R13) (aux. hoist relay (R14)).



NO



Faulty adjustment of brake system.



Main Hoist Brake Relay (R13) and Aux. Hoist Brake Relay (R14) Connector (Harness end connector seen from the open end side)



1



Brake Mode Selection Solenoid Valve Connector (Harness end connector seen from the open end side)



2 1 2



3 5 4



T5-4-27



Faulty harness (short-circuited harness) between brake mode selection solenoid valve and relay (R4) (aux. hoist relay (R8)).



TROUBLESHOOTING / Troubleshooting B M-5 Free Fall is inoperable Even If Brake Mode Switch is Turned to the Free Mode Position



• Be sure to inspect wiring connections prior to troubleshooting.



• When the hoist brake selection key is in the LOCK position, free mode is not selected.



• Check fuses #16, 17, and 18 at the same time. YES



NOTE: • Brake pedal Joy-Stick lever: After changing the out side cab brake mode switch to the “Bucket” mode, depress the brake pedal fully. Bi-directional control lever: Locked position. YES



Check if brake mode indicators correctly operate. Green Indicator: OFF Red Indicator: ON



Check if primary pilot pressure is normal. · Engine: Running · Refer to the Performance Test section. NO



· Engine: Running · Brake mode switch: FREE MODE · Pilot control shut-off Lever: UNLOCK position · Brake pedal: See NOTE. · Drum Lock: Engaged



Re-select brake mode in the correct procedure.



NO



Check if brake mode was selected in the correct proNO Green And Red cedure. Indicators: OFF · Engine: Running · Brake pedal: See NOTE. YES · Pilot control shut-off lever: UNLOCK position · Brake mode switch: AUTO-BRAKE MODE→ FREE MODE



Brake Mode Selection Solenoid Valve Connector (Harness end connector seen from the open end side)



Check pilot pump and/or relief valve.



Disconnect hoist auto-brake selection key. Check if red free mode indicator comes ON when harness end connector terminal #1 is connected to #2.



Pilot Control Shut-Off Lever Pressure Switch Connector (Harness end connector seen from the open end side)



YES



OK



Faulty hoist auto-brake selection key.



Is aux. hoist drum displaying any trouble?



Pilot Control Shut-Off Lever Pressure Relay Connector (Harness end connector seen from the open end side)



1 3 5



2 1



1 2



2 4



Hoist Auto-Brake Selection Key Connector (Harness end connector seen from the open end side)



2 1 4 3



Auto-Stop Controller 18 P Connector (Harness end connector seen from the open end side)



209



208



207



206



205



204



203



202



201



218



217



216



215



214



213



212



211



210



T5-4-28



TROUBLESHOOTING / Troubleshooting B



YES



Check if auto-brake release cylinder inlet pressure is normal.



NO Brake Unit



YES



· Engine: Running NO · Check visually. · Pilot control shut-off lever: UNLOCK position · Brake mode switch: FREE MODE position YES



Brake Release Cylinder Inlet Pressure Check Position



· Engine: Running 3.9 MPa 2 (40 kgf/cm ) or higher at slow idle speed) · Pilot control shut-off lever: UNLOCK position · Brake mode switch: FREE MODE position



Check if auto-brake release cylinder extends to compress auto-brake spring.



Check if voltage at brake mode selection solenoid valve terminal #1 is 24 V.



· Engine: Running · Check visually. · Pilot control shut-off lever: UNLOCK position · Brake mode switch: FREE MODE position



NO



YES T328-05-04-004



YES YES YES Is the machine with crane attachment?



Check if FRONT indicator on auto-stop controller displays CRANE.



Remove 18P connector with 6 cables from auto-stop controller. Connect harness end connector terminal #201 to #202 using a clip. Check if free mode is selected.



Brake Mode Switch Connector (Harness end connector seen from the open end side)



4 3 2 1 8 7 6 5



Faulty harness (broken) between brake mode selection solenoid valve and relay (R4) (aux. hoist relay (R8)). Faulty auto-stop controller.



Free mode is not applicable to tower aux. hoist drum operation. Faulty pilot control shut-off lever pressure switch.



YES



· Engine: Running



Faulty brake mode selection solenoid valve (stuck).



Incorrectly connected tower overhoist connector.



NO



NO



Faulty brake unit (seized).



To be continued to (A) on this page.



NO



Disconnect pilot control shut-off lever pressure switch. Check if free mode red inNO dicator comes ON by connecting (A) harness end connector terminals #1 to #2.



Faulty adjustment of brake system.



Check if voltage at pilot control shut-off lever relay (R24) terminal #5 is 24 V.



NO



Check if voltage at pilot control shut-off lever relay (R24) terminals #1 and #3 is 24 V. · Engine: Running



· Engine: Running · Pilot control shut-off lever: UNLOCK position



Check if voltage at brake mode switch terminal #3 is 24 V.



YES · Engine: Running · Pilot control shut-off lever: UNLOCK position · Brake mode switch: FREE MODE position



T5-4-29



YES



Faulty pilot control shut-off lever relay (R24).



Broken harness between fuse No. 16 or No. 18 and NO pilot control (Either or shut-off lever relay Both) (R24). NO To be continued to (B) on next page.



YES



To be continued to (C) on next page.



TROUBLESHOOTING / Troubleshooting B



YES



(B)



Check if voltage at brake mode switch terminal #2 is 24 V. · Engine: Running NO



YES NO



(C)



Check if voltage at brake relay (R5) (aux. hoist (R9)) terminal #3 is 24 V. · Key switch: ON



Check if voltage at brake relay (R5) (aux. hoist (R9)) terminal #4 is 24 V · Engine: Running



NO



NO



YES



Check if switch valve located under brake pedal is fully pushed. · Engine: Running · Brake pedal: See NOTE. (T5-4-29)



YES



After disconnecting pressure switch (booster pressure sensing), connect harness end plug terminals. Check if red indicator comes ON. · Engine: Running · Brake pedal: See NOTE. (T5-4-29) · Pilot control shut-off lever: UNLOCK position



Brake Mode Switch Connector (Harness end connector seen from the open end side)



Brake Relays (R5 and R9) Connector (Harness end connector seen from the open end side)



4 3 2 1



1



2



8 7 6 5



3 5 4



T5-4-30



TROUBLESHOOTING / Troubleshooting B



Faulty brake mode switch.



Broken harness between brake mode switch and pilot control shut-off lever relay (R24).



Faulty brake relay (R5) (aux. hoist (R9)). Broken harness between brake relay (R5) (aux. hoist (R9)) and fuse No.17. Adjust brake pedal lever and stopper. Readjust switch valve stroke to specification. Faulty pressure switch (booster pressure sensing).



YES



Faulty harness (broken) between pressure switch (booster pressure sensing) and brake relay (R4) (aux. hoist (R8)).



NO



NO



Check if voltage at brake relay (R4) (aux. hoist (R8)) terminal #1 is 24 V. · Engine: Running · Brake pedal: See NOTE. (T5-4-29) · Pilot control shut-off lever: UNLOCK position



YES



YES



Check if voltage at brake relay (R4) (aux. hoist (R8)) terminal #5 is 24 V.



NO



Check if voltage at brake relay (R4) (aux. hoist (R8)) terminal #3 is 24 V NO



YES Check if red indiYES cator is burnt out.



Broken harness between brake mode switch and brake relay (R4) (aux. hoist (R8)).



Burnt out red indicator.



Broken NO



T5-4-31



Faulty brake relay (R4) (aux. hoist (R8))



harness



between



red



indicator



and



b



l



k



TROUBLESHOOTING / Troubleshooting B BRAKE SYSTEM SET DIMENSIONS AND CHECKING PROCEDURES. • Joy-Stick Lever NOTE: 1. When the booster valve spool is pulled by hand, play (D) is removed and dimension (B) should be 67 ± 0.5 mm. 2. Accumulator rod dimension (C) (28 mm) will vary according to the extend of the brake band adjustment. With the brake pedal stepped until lower stopper limit bolt clearance (e) becomes zero. Adjust the brake band so that dimension (C) is 29 mm or less. 3. The switch valve stroke is 5 mm. The switch valve is pushed 5 mm by the lever when the brake pedal is depressed with the switch valve stroked fully, slightly touch adjusting bolt (12) to lever (11). Then, tighten adjusting bolt (12) one more turn to set dimension (e) to approx. 4 mm. 4. 1 mm=0.03937 in



CAUTION: Before checking, lower a lifted load, and/or lifting accessories to the ground for safety. Engage the drum lock. Set Dimensions IMPORTANT: • The brake system is adjusted to the dimensions shown in the table below before shipping from the factory. Never adjust the rods unless a system failure occurs. If rod adjustment is required, be sure to determine the cause first. • After changing the outside cab brake mode switch to the “Bucket” mode, be sure to turn the brake mode to the “FREE” mode.



Legend



Inspection Item



With Brake Pedal Raised (mm)



With Brake Pedal Fully Depressed (mm)



－ －



A



Brake Pedal Height



176 to 180



B C D



Booster Valve Spool Accumulator Rod Slit and Pin Play



Approx. 66 (See NOTE 1) 28 1 to 2



28 (See NOTE 2)



－ Pin Center



Pin Center



E



Indicator and Pin Locations



Red



White



Blue



Yellow M324-10-161



White



Red



Blue



Yellow



M324-10-162



a



Band Return Spring Rod



Approx. 40



b



Pedal Unlock Spring Brake Pedal Return-Spring Rod Pedal Lower Limit Stopper Bolt Switch Valve



Approx. 158



－ －



Approx. 22



Approx. 22



－



12 to 15



－



Approx. 4 (See NOTE 3)



c d e



T5-4-32



TROUBLESHOOTING / Troubleshooting B Set Dimensions



a



E



A c



b



D d B C 11



e 12 T24D-05-04-001



T5-4-33



TROUBLESHOOTING / Troubleshooting B Checking Procedure. 1. After checking the drum lock is engaged, turn the out side cab brake mode switch to BUCKET MODE. 2. With brake pedal fully depressed, turn brake mode switch to FREE MODE. 3. Release the brake pedal to loosen the brake band. 4. Confirm that brake pedal height (A) is 176 to 180 mm. Confirm that the pedal lever is in contact with stopper (10).



Out-Side Cab Brake Mode Switch



M24F-01-001



5. Confirm that booster valve dimension (B) is approximately 66 mm. 6. Having the correct dimension (B), confirm that play (D) between the slit and pin is 1 to 2 mm.



Brake Mode Switch



7. Confirm that center of pin (2) is in the white zone on indicator (1). 8. If the dimensions and location in steps (3) to (6) are correct, the brake system dimensions are normal. NOTE: If any of the above mentioned dimensions and location are not correct, find the cause first before attempting to adjust. 1 mm=0.03937 in



T5-4-34



M324-01-045



TROUBLESHOOTING / Troubleshooting B Checking Procedures



a



2



1



A



10



b



D



B T24D-05-04-002



T5-4-35



TROUBLESHOOTING / Troubleshooting B CHECK AND ADJUST HOIST BRAKE • Joy-Stick Lever Precautions for Check and Adjustment CAUTION: Be sure to lower the hooks and lifting accessories onto the ground. Return all control levers to NEUTRAL and engage all brake and drum locks.



6



1. Run the engine at a medium speed. Check the pilot pressure at pressure gauge (1). Correct Pilot Pressure Range : 3.9 to 4.9 MPa (40 2 to 50 kgf/cm ) with the hydraulic oil temperature at 30 to 80 °C. 2. Reduce the engine speed to slow idle. 3. Move pilot control shut-off lever (6) to the UNLOCK position.



5



1



Check Brake Band Tightness IMPORTANT: 1. Check brake band tightness daily at the brake band tightness indicator before starting operation.



M333-01-051



2. Be sure to check the indicator when the brake mode is in “FREE” mode. If the brake mode is in “AUTOMATIC” mode, an incorrect reading will result as pin (3) postion is altered from that in “FREE” mode. After turning the outside cab brake mode switch to the Bucket mode, depress the brake pedal continuously and turn the brake mode switch to the Free position. When the brake band is correctly adjusted, the center of pin (3) should be in the Normal Brake Operating Range on indicator (2) as illustrated to the right. In case the center of pin (3) is in the red range behind the Normal Brake Operating Range on indicator (2), the lining has worn. Adjust the brake band.



2



White



Red Blue Yellow



3



M324-10-024



Normal Brake Operating Range Center of Pin



White



Red



2 Blue



T5-4-36



Yellow



M324-10-142



TROUBLESHOOTING / Troubleshooting B Adjust Brake Band (when the lining has worn) CAUTION: Before checking, lower a lifted load, and/or lifting accessories to the ground for safety. IMPORTANT: Be sure to adjust both bolts (4 and 5) at the same time. If bolts (4) are not tightened sufficiently, hunting may occur in free fall operation. If bolts (4) are tightened excessively, the brake may not work effectively. 1. Check that the drum lock is engaged. 2. After turning the outside cab brake mode switch to the BUCKET mode, and turn brake mode switch (1) to the Free position with the brake pedal depressed. 3. Loosen brake band nuts (3) and bolts (4). : 36 mm 4. Loosen nut (6) on brake band adjusting bolt (5). : 46 mm 5. Release brake pedal (2) to loosen the brake band. 6. Check clearance (a) on the dead brake band. In case clearance (a) (between the drum and lining) is more than approx. 0.5 mm, tighten bolt (7) to adjust clearance to approx. 0.5 mm. : 24 mm 7. Gradually, retighten nut (8). 8. Depress brake pedal (2) fully. Check indicator (9) at this time. 6



8



3



4



M24F-01-001



1



M324-01-045



5



11



12



Live Brake Band



7 Dead Brake Band a



10



9



2



T24D-05-04-003



T5-4-37



TROUBLESHOOTING / Troubleshooting B 9. Repeat steps (7 and 8) until the center of pin (10) comes to the center of the blue range on indicator (9). 10. Securely tighten nut (6). 11. With brake pedal (2) depressed fully, turn bolts (4) by hand until the bolt heads come in contact with each other. Further tighten bolts (4) approx. 1/6 turn. Lock bolts (4) with nuts (3). NOTE: After disengaging the drum lock and returning brake pedal, check that free fall operation can be performed properly. If not, adjust lifting springs (11 and 12). [Clearance between the drum and lining around the circle should be approx. 0.8 mm except for at the end of the dead brake band.] : 13 mm



2



White



Red Blue Yellow



Adjust Brake Band (Adjustment to meet Bucket Works)



3



M324-10-024



Center of Pin



CAUTION: Before checking, lower a lifted load, and/or lifting accessories to the ground for safety. If the brake band is loosened until the center of pin enters the red range on the indicator, the brake will not work with the brake pedal half stroked.



White



Red



9



Blue Yellow



IMPORTANT: 1. Before shipping the machine, the brake band is adjusted so that the center of the pin is located to near the center of the blue range on the indicator. In free fall operations such as bucket or lifting magnet work, if the brake works more effectively, a large reaction force will act on the machine as impact loads. Loosen the brake band corresponding to the bucket weight in the normal brake operating range to reduce impact loads (the pin moves to the yellow range when the brake band is loosened). 2. In free fall operations, adjustment interval of the brake band is shortened due to wear on the lining. Refer to “Adjust Brake Band (when the lining has worn)” on the previous pages for adjustment. However, be sure to retighten nut (8) slowly as described in 7.



M324-10-162



Normal Brake Operating Range Center of Pin



Red



White



2 Blue



T5-4-38



Yellow



M324-10-142



TROUBLESHOOTING / Troubleshooting B (Blank)



T5-4-39



TROUBLESHOOTING / Troubleshooting B BRAKE SYSTEM SET DIMENSIONS AND CHECKING PROCEDURES. • Bi-Directional Control Lever NOTE: 1. When the booster valve spool is pulled by hand, play (D) is removed and dimension (B) should be 67 ± 0.5 mm. 2. Accumulator rod dimension (C) (28 mm) will vary according to the extend of the brake band adjustment. With the brake pedal stepped until lower stopper limit bolt clearance (e) becomes zero. Adjust the brake band so that dimension (C) is 29 mm or less. 3. The switch valve stroke is 5 mm. The switch valve is pushed 5 mm by the lever when the brake pedal lock is engaged, slightly touch adjusting bolt (12) to lever (11). Then, tighten adjusting bolt (12) one moret tall turn to set dimension (e) to approx. 4 mm. 4. 1 mm=0.03937 in



CAUTION: Before checking, lower a lifted load, and/or lifting accessories to the ground for safety. Engage the drum lock. Set Dimensions IMPORTANT: • The brake system is adjusted to the dimensions shown in the table below before shipping from the factory. Never adjust the rods unless a system failure occurs. If rod adjustment is required, be sure to determine the cause first. • Before checking, turn the brake mode selection key to the unlock position. Then, turn the brake mode to the “FREE” mode.



Legend



Inspection Item



When Brake Pedal is Unlocked (mm)



When Brake Pedal is Locked (mm)



－ －



A



Brake Pedal Height



176 to 180



B C D



Booster Valve Spool Accumulator Rod Slit and Pin Play



Approx. 66 (See NOTE 1) 28 1 to 2



28 (See NOTE 2)



－ Pin Center



Pin Center



E



Indicator and Pin Locations



Red



White



Blue



Yellow M324-10-161



White



Red



Blue



Yellow



M324-10-162



a



Band Return Spring Rod



Approx. 40



b



Pedal Unlock Spring Brake Pedal Return-Spring Rod Pedal Lower Limit Stopper Bolt Switch Valve



Approx. 158



－ －



Approx. 22



Approx. 22



－



12 to 15



－



Approx. 4 (See NOTE 3)



c d e



T5-4-40



TROUBLESHOOTING / Troubleshooting B Set Dimensions



a



E



A c



b



D d



B C 11



e 12 M326-08-032



T5-4-41



TROUBLESHOOTING / Troubleshooting B Checking Procedures IMPORTANT: 1. If the position and dimensions mentioned above are outside the specified range, trace the cause before adjusting the brake.



Brake Mode Switch



2. In case the brake malfunctions although the position and dimensions mentioned above are inside the specified range, the cause of the trouble may be other than setting the dimension. 1. After checking the drum lock is engaged, turn the brake mode selection key to the UNLOCK position. Then turn the brake mode switch to the Free mode position. 2. Unlock the brake pedal to loosen the brake band. 3. Check that pin center (2) is in the white range of indicator (1). 4. Check that brake pedal height (A) is within the range shown below. At the same time, check that the pedal lever comes in contact with stopper (10). Brake Pedal Height (A): 176 to 180 mm 5. Check that booster valve spool dimension (B) is approx. 66 mm. 6. At this time, check that play (D) between slit end and the pin is 1 to 2 mm. 7. When the position and dimensions described in steps (3) to (6) are in the specified range, the brake system should be normal. NOTE: 1 mm = 0.03937 in



T5-4-42



M324-02-008



Brake Pedal



TROUBLESHOOTING / Troubleshooting B Checking Procedures



2



1 10



A



D



B



M234-01-029



T5-4-43



TROUBLESHOOTING / Troubleshooting B CHECK AND ADJUST HOIST BRAKE • Bi-Directional Control Lever



4



Precautions for Check and Adjustment CAUTION: Be sure to lower the hooks and lifting accessories onto the ground. Return all control levers to NEUTRAL and engage all brake and drum locks.



6



1. Run the engine at a medium speed. Check the pilot pressure at pressure gauge (1). Correct Pilot Pressure Range : 3.9 to 4.9 MPa 2 (40 to 50 kgf/cm ) with the hydraulic oil temperature at 30 to 80 °C. 2. Reduce the engine speed to slow idle. 3. Move pilot control shut-off lever (6) to the UNLOCK position.



5



1



M324-01-001



Check Brake Band Tightness IMPORTANT: 1. Check brake band tightness daily at the brake band tightness indicator before starting operation. 2. Be sure to check the indicator when the brake mode is in “FREE” mode. If the brake mode is in “AUTOMATIC” mode, an incorrect reading will result as pin (3) postion is altered from that in “FREE” mode. After checking that the dram lock is engaged, turn the brake mode selection key to the UNLOCK position. Then, Turn the brake mode switch (4) to Free position. When the brake band is correctly adjusted, the center of pin (3) should be in the Normal Brake Operating Range on indicator (2) as illustrated to the right. In case the center of pin (3) is in the red range behind the Normal Brake Operating Range on indicator (2), the lining has worn. Adjust the brake band.



2



White



Red Blue Yellow



3



M324-10-024



Normal Brake Operating Range Center of Pin



White



Red



2 Blue



T5-4-44



Yellow



M324-10-142



TROUBLESHOOTING / Troubleshooting B Adjust Brake Band (when the lining has worn) CAUTION: Before checking, lower a lifted load, and/or lifting accessories to the ground for safety. IMPORTANT: Be sure to adjust both bolts (4 and 5) at the same time. If bolts (4) are not tightened sufficiently, hunting may occur in free fall operation. If bolts (4) are tightened excessively, the brake may not work effectively.



1



1. Check that the drum lock is engaged. 2. After checking that brake pedals (2) are locked, turn the brake mode selection key to the UNLOCK position. Then, turn brake mode switch (1) to FREE Mode Position. 3. Loosen brake band nuts (3) and bolts (4). : 36 mm 4. Loosen nut (6) on brake band adjusting bolt (5). : 46 mm 5. Release brake pedal (2) to loosen the brake band. 6. Check clearance (a) on the dead brake band. In case clearance (a) (between the drum and lining) is more than approx. 0.5 mm, tighten bolt (7) to adjust clearance to approx. 0.5 mm. : 24 mm 7. Gradually, retighten nut (8). 8. With brake pedal (2) locked, check indicator (9). 6



8



3



4



M333-01-005



5



11



12



Live Brake Band



7 Dead Brake Band a



10



9



2



T24D-05-04-004



T5-4-45



TROUBLESHOOTING / Troubleshooting B 9. Repeat steps (7 and 8) until the center of pin (10) comes to the center of the blue range on indicator (9). 10. Securely tighten nut (6). 11. With brake pedal (2) locked, turn bolts (4) by hand until the bolt heads come in contact with each other. Further tighten bolts (4) approx. 1/6 turn. Lock bolts (4) with nuts (3). NOTE: After disengaging the drum lock and returning brake pedal, check that free fall operation can be performed properly. If not, adjust lifting springs (11 and 12). [Clearance between the drum and lining around the circle should be approx. 0.8 mm except for at the end of the dead brake band.] : 13 mm



2



White



Red Blue Yellow



Adjust Brake Band (Adjustment to meet Bucket Works)



3



M324-10-024



Center of Pin



CAUTION: Before checking, lower a lifted load, and/or lifting accessories to the ground for safety. If the brake band is loosened until the center of pin enters the red range on the indicator, the brake will not work with the brake pedal half stroked.



White



Red



9



Blue Yellow



IMPORTANT: 1. Before shipping the machine, the brake band is adjusted so that the center of the pin is located to near the center of the blue range on the indicator. In free fall operations such as bucket or lifting magnet work, if the brake works more effectively, a large reaction force will act on the machine as impact loads. Loosen the brake band corresponding to the bucket weight in the normal brake operating range to reduce impact loads (the pin moves to the yellow range when the brake band is loosened). 2. In free fall operations, adjustment interval of the brake band is shortened due to wear on the lining. Refer to “Adjust Brake Band (when the lining has worn)” on the previous pages for adjustment. However, be sure to retighten nut (8) slowly as described in 7.



M324-10-162



Normal Brake Operating Range Center of Pin



Red



White



2 Blue



T5-4-46



Yellow



M324-10-142



TROUBLESHOOTING / Troubleshooting B (Blank)



T5-4-47



TROUBLESHOOTING / Troubleshooting B BOOM HOIST DRUM CONTROL TROUBLESHOOTING B-1 Drum Does Not Rotate



• Be sure to inspect wiring connections prior to troubleshooting.



• If the pilot pump and/or pilot relief valve fails, not only drum rotation but also travel and swing functions become inoperable. • If overhoisted, the drum stops rotating. Check the troubleshooting D or the auto-stop controller indicator (refer to T5-4-60). NOTE: 1 MPa = 145 psi NO



Faulty pilot valve. NO



Check if secondary pilot pressure is normal. · Refer to Operational Performance Test section.



Check if current value to auto-stop solenoid valve conforms to specification.



Normal



YES



Check for monitor indicator outputs (PWM5A and 6A).



· Slow Stop Switch: OFF · Specification: 679 mA · Boom Hoist Speed Control Dial: Fast Speed



· Refer to T5-3-28.



Abnormal



Auto-Stop Solenoid Valve Pressure Check Position



(A) (B) T333-05-04-003



T5-4-48



YES



TROUBLESHOOTING / Troubleshooting B



Auto-Stop Solenoid Valve Connector (Auto-stop solenoid valve connector viewed from the open end side)



Auto-Stop Controller 24P Connector (Harness end connector viewed from the open end side) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24



1



2



Perform troubleshooting A. · Refer to T5-3-28.



· · · ·



Remove output pipe from auto-stop solenoid valve and install pressure gauge. Check if pressure is 2.5 2 MPa (25 kgf/cm ). Engine: Running Boom hoist lever: Fully stroked Boom hoist hoisting (A) position Boom hoist lowering (B) position



Faulty boom hoist motor. Faulty auto-stop solenoid valve. Perform troubleshooting A. · Refer to T5-3-28.



Secondary Pilot Pressure Check Position



T333-05-04-007



T5-4-49



TROUBLESHOOTING / Troubleshooting B SWING SYSTEM TROUBLESHOOTING S-1 Swing Speed Is Slow or Swing Is Inoperable.



• Be sure to inspect wiring connections prior to troubleshooting.



Check for monitor indicator output YES (PWM2B) and /or inputs (AI1 and AI9).



NO



Faulty swing pilot valve.



· Refer to T5-3-50



Check if swing brake YES release pressure is normal.



Check if secondary pilot pressure to swing control valve is normal.



· Standard: 3.9 MPa 2 (40 kgf/cm ) · Swing lever: Operating · Swing brake: OFF



· Refer to the Operational Performance Check section.



YES Check if swing motor drain oil amount is normal.



Check if swing relief pressure is YES normal. · Swing circuit: Relieving · Swing lock lever: Engaged · Swing brake: ON



With swing brake solenoid valve disconnected, check if voltage at harness end connector terminal #1 NO is 24 V.



· Refer to the Operational Performance Check section.



· Swing lock lever: Engaged · Swing brake: OFF NO



Faulty swing motor Faulty swing relief valve.



NO



T5-4-50



TROUBLESHOOTING / Troubleshooting B Faulty swing speed control dial system.



Abnormal AI9



· Refer to T5-3-51. Faulty pressure sensor (swing control pressure) system.



Abnormal AI1



· Refer to T5-3-56. Abnormal PWM



Faulty solenoid valve SD (swing speed) system. · Refer to T5-3-54.



Faulty swing reduction gear.



YES With swing mode switch positioned in the constant swing speed, check if swing speed changes while operating dial.



Normal



Faulty third main pump (swing).



NO



Faulty solenoid valve SI (swing brake).



YES



NO



Disconnect swing brake relay. Check if voltage at harness end connector terminal #3 is 24 V.



Faulty swing brake relay or harness between swing brake relay and solenoid valve SI (swing brake).



YES



· Swing lock lever: Engaged · Swing brake : OFF



Faulty swing brake switch.



NO



Solenoid Valve SI (Swing Brake) Connector (Harness end connector seen from the open end side)



Swing Brake Relay Connector (Harness end connector seen from the open end side)



1



2 1



2



3 5 4



T5-4-51



TROUBLESHOOTING / Troubleshooting B TRAVEL SYSTEM TROUBLESHOOTING T-1 One Side Track Does Not Move, Moves Slowly, or Machine Cannot Travel Straight (Mistracks)



• If one side system only does not operate, pilot valve, control valve, travel motor, center joint, or pump may be faulty. YES



YES



NO



Check if symptom is reversed after switching the right and left travel line hoses connected to top of the center joint.



Check if secondary pilot pressure is normal.



Check if travel relief pressure in slow speed side is normal.



NO



· Refer to the Operational Performance Check section.



YES



Switch rear and front or right and left travel relief valves. Check if symptom is reversed. Seized control valve spool. Faulty pilot valve.



NO



Secondary Pilot Pressure Check Position T333-05-04-010



T5-4-52



TROUBLESHOOTING / Troubleshooting B



Disassemble and clean travel motor counterbalance. Check if the same problem occurs again.



YES



YES



Disassemble and clean travel motor servo piston. Check if the same problem occurs again.



NO



3



Faulty travel motor servo piston.



NO



Faulty counter-balance



YES



Faulty center joint.



NO



Faulty travel relief valve.



Front



2



Faulty travel motor or travel reduction gear.



4 1 1234-



T333-05-04-011



T5-4-53



Right Travel (Reverse) Left Travel (Forward) Left Travel (Reverse) Right Travel (Forward)



TROUBLESHOOTING / Troubleshooting B T-2 Travel Mode Does Not Change



• Be sure to inspect wiring connections prior to troubleshooting. NOTE: 1 MPa=145 psi



Faulty swash plate angle control mechanism in travel motor.



YES YES Disconnect solenoid valve SE. Check if voltage at harness end connector terminal #1 is 24 V.



Check if travel mode control signal pressure is 3.9 2 MPa (40 kgf/cm ). · Travel mode switch: Fast



Faulty solenoid valve SE.



NO



· Travel mode switch: Fast NO



Disconnect travel mode switch. Check for continuity between terminals.



YES



· Travel mode switch: Fast



NO



Broken harness or blown fuse #21.



Faulty travel mode switch.



Travel Mode Control Pressure Check Position



Solenoid Valve SE Connector (Harness end connector viewed from the open end side)



Center Joint



2 1



T333-05-04-006



T5-4-54



TROUBLESHOOTING / Troubleshooting B OTHER CONTROL TROUBLESHOOTING O-1 Drum Lock Does Not Operate



• Be sure to inspect wiring connections prior to troubleshooting.



• Check that the drum lock tooth is disengaged. NOT OK



Replace fuse.



Broken harness between fuse and drum lock motor.



NO Check for fuses #23, #24, and #25. · Key switch: ON



OK



OK



Disconnect drum lock motor. Check OK for continuity of harness end connector.



Disconnect drum lock motor. Check if voltage at harness end connector terminal #4 is 24 V. · Key switch: ON YES Disconnect drum lock switch. Check for continuity of switch.



· Drum lock switch: ON ↓ Continuity between terminals #2 and #3 exists. · Drum lock switch: OFF ↓ Continuity between terminals #1 and #2 exists.



Faulty drum lock motor.



Broken harness between drum lock · Key switch: ON NOT motor and drum · Drum lock switch: ON lock switch. OK ↓ Continuity between terminals #1 and #2 exists. · Drum lock switch: OFF ↓ Continuity between terminals #1 and #3 exists. Faulty drum lock switch. NOT OK



Drum Lock Relay (Harness end connector viewed from the open end side)



Drum Lock Switch (Drum lock switch connector seen from the open end side)



1



3 2 1



2



3 5



Drum Lock Motor (Harness end connector seen from the open end side)



4



3 2 1 6 5 4



T5-4-55



TROUBLESHOOTING / Troubleshooting B O-2 Stand Does Not Tilt Joy-Stick Lever: Right Stand Bi-Directional Control Lever: Main Stand



• Be sure to inspect wiring connections prior to troubleshooting. NOT OK



Replace fuse.



Broken harness between fuse and tilt switch.



NO Check fuse #27.



Faulty tilt switch.



NOT OK



OK Disconnect tilt switch. Check if voltage at harness end connector terminal #1 is 24 V. · Key switch: ON



OK



YES With tilt switch disconnected, check for continuity of switch. · Turn tilt switch forward: #1 and #4 · Turn tilt switch rearward: #1 and #3



Tilt Switch (Tilt switch connector seen from the open end side)



With tilt motor disconnected, check OK for continuity of vehicle side harness. · Turn tilt switch forward: NOT between yellow harOK ness and vehicle · Turn tilt switch rearward: between green harness and vehicle



Tilt Switch (Harness end connector seen from the open end side)



1 2



2 1



3 4



4 3



T5-4-56



Faulty tilt motor.



Faulty harness between tilt switch and tilt motor.



TROUBLESHOOTING / Troubleshooting B (Blank)



T5-4-57



TROUBLESHOOTING / Troubleshooting B O-3 Crawler Does Not Extend And/Or Retract (By Operating Switch in Cab)



• In case swing function is also slow, the third main pump (swing) may have failed.



• Be sure to inspect wiring connections prior to troubleshooting. YES



NOTE: 1 MPa=145 psi



YES



Disconnect either extend or retract side connector from crawler spool solenoid valve on left control valve. Check if voltage at harness end connector terminal #1 is 24 V. · Crawler extend/retract switch: Extend or retract position · Pilot control shut-off lever: UNLOCK position



Check if oil pressure in crawler extend/retract cylinder is 18.0 MPa (185 2 kgf/cm ) while extending and 27.5 2 MPa (280 kgf/cm ) while retracting.



YES



Check control valve spool for any abnormality. NO YES



NO



· Refer to the Operational Performance Test section.



Check if crawler extend/retract cylinder operates normally. NO



Faulty/ crawler extend-retract switch or broken harness between crawler extend-retract switch and solenoid valve.



NO



T5-4-58



TROUBLESHOOTING / Troubleshooting B



Faulty control valve spool. Faulty cylinder or throttle valve. Faulty solenoid valve.



Faulty main relief valve for left control valve.



T5-4-59



TROUBLESHOOTING / Troubleshooting B AUTO-STOP CONTROLLER INDICATOR



T331-05-04-008



T5-4-60



TROUBLESHOOTING / Troubleshooting C TROUBLESHOOTING C (TROUBLESHOOTING FOR MONITOR) PROCEDURE Use troubleshooting C when any monitors, such as gauges or indicators malfunction.



• How to Read Troubleshooting Flow Charts YES(OK)



・



(2)



• After checking or measuring item (1), select either YES (OK) or NO (NOT OK) and proceed to item (2) or (3), as appropriate.



(1) NO(NOT OK)



(3)



• Special instructions or reference item are indicated in the spaces under the box.



・ · Key switch: ON



Incorrect measuring or checking methods will render troubleshooting impossible, and may damage components as well.



• Causes are stated in a thick-line box. Scanning through thick-line boxes, possible



・



causes can be seen without going through the flow chart. NOTE: For all connector drawings illustrated in this group, harness end connector terminals seen from the open end side are shown.



Wire Harness Side



Open End Side



Harness End Connector T158-05-03-001



T5-5-1



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF PERATURE GAUGE



COOLANT



TEM-



• Be sure to inspect wiring connections prior to troubleshooting.



Gauge needle does not swing at all.



YES



Check if coolant temperature sensor terminal is correctly connected.



Disconnect coolant temperature sensor. YES Check if needle swings to (H) side when harness end terminal #1 is grounded to vehicle frame. · Key switch: ON



With coolant temperature sensor disconnected, disconnect 12P connector from monitor panel. Check for contiNO nuity between harness end connector terminal #24 and coolant temperature sensor terminal.



NO



YES



Gauge needle swings over scale.



Check if needle returns when coolant temperature sensor terminal is disconnected. · Key switch: ON



Gauge needle swings unstably.



Check if coolant temperature sensor terminal is correctly connected.



With coolant temperature sensor disconnected, disconnect 12P connector from monitor NO panel. Check for continuity between harness end connector terminal #24 and vehicle frame.



Disconnect coolant temperature sensor. Check if needle swings YES to (H) side and stays in that position when harness end terminal #1 is grounded to vehicle frame. · Key switch: ON



NO



T5-5-2



Continuity



No continuity



YES



NO



TROUBLESHOOTING / Troubleshooting C



Faulty coolant temperature sensor. Continuity



Connector (Harness end connector viewed from the open end side)



Faulty monitor panel.



Coolant Temperature Sensor



Monitor Panel (12P)



No continuity



Broken harness between monitor panel and coolant temperature sensor.



25 24 23 22 21 32 31 30 29 28 27 26



1 2



Faulty coolant temperature sensor terminal connection. Coolant Temperature and Electrical Resistance Coolant Temperature Electrical Resistance °C (°F) Ω 50±0.2 (122±0.4) (112.4±10) 80±0.2 (176±0.4) 41.8±2.5 100±0.3 (212±0.5) 23.6±0.9 120±0.3 (248±0.5) (14.2±0.3)



Faulty coolant temperature sensor.



NOTE: Values in (



Short-circuited harness between monitor panel and coolant temperature sensor.



Faulty monitor panel.



Faulty coolant temperature sensor.



Faulty monitor panel.



Faulty coolant temperature sensor terminal connection.



T5-5-3



) are reference only.



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF FUEL GAUGE • Be sure to inspect wiring connections prior to troubleshooting. Disconnect fuel sensor. Short-circuit harness end connector termiYES nals #1 and #2. Check if gauge pointer swings to the F side. Gauge pointer does not move at all.



· Key switch: ON · Use a clip to short-circuit.



Check if fuel sensor is correctly connected.



YES



With fuel sensor disconnected, disconnect 12 P connector from monitor panel. Check NO for continuity between harness end connector terminal #25 and fuel sensor terminal #1.



NO



YES



Gauge pointer swings over scale.



With fuel sensor disconnected, check if pointer swings back to zero. · Key switch: ON



Continuity With fuel sensor disconnected, disconnect 12 P connector from monitor panel. Check for continuNO ity between harness end connector terminal #1 and vehicle frame. No Continuity



YES Disconnect fuel sensor. Short-circuit harness YES end connector terminals #1 and #2. Check if gauge pointer stably swings to the F side. Gauge pointer swings unstably.



· Key switch: ON · Use a clip to short-circuit.



Check if fuel sensor is correctly connected.



NO



T5-5-4



NO



TROUBLESHOOTING / Troubleshooting C



Faulty fuel sensor.



Continuity



No Continuity



Faulty monitor panel.



Connector (Harness end connector seen from the open end side) Fuel Sensor



Broken harness between monitor panel and fuel sensor.



2



Monitor Panel (12P) 25 24 23 22 21 32 31 30 29 28 27 26



1



Incorrectly connected fuel sensor.



Float



FULL 3/4



Faulty fuel sensor.



Fuel Sensor



257 mm 138.5 mm



22° R370



33°



70.5



Short-circuited harness between monitor panel and fuel sensor.



228 mm



1/2



27° 28° Electrical Resistor



1/4 338 mm



Faulty monitor panel. EMPTY



T107-04-03-020



NOTE: 1 mm = 0.03937 in Faulty fuel sensor.



Float Position VS. Electrical Resistance Float Position Resistance ( Ω ) 1.0 Full 10± 0.5 3/4 (19.5) 1/2 32±3 1/4 (49.5) Empty 80±2



Faulty monitor panel.



Incorrectly connected fuel sensor.



T5-5-5



TROUBLESHOOTING / Troubleshooting C MALFUNCTION SWITCH



OF



LEVEL



CHECK



• This troubleshooting is applied when only the level check switch malfunctions. If power is not supplied at all when the key switch is turned ON, or the indicator does not come ON when indicator light check is conducted, perform troubleshooting for these failure first. • Be sure to inspect wiring connections prior to troubleshooting. Disconnect 12P connector from switch YES panel. Check voltage at switch panel harness end connector terminal #6. · Key switch: ON · Level check switch: ON



All indicators do not come ON. Check if oil and coolant levels are correct.



Indicator does not come ON even if level check switch is depressed. · Engine oil level indicator · Coolant level indicator · Hydraulic oil level indicator



Check if all indicators do not come ON.



NO



· Key switch: ON · Level check switch: ON Only one indicator does not come ON.



T5-5-6



TROUBLESHOOTING / Troubleshooting C



0 to 0.5 V



Faulty switch panel (level check switch)



0 to 0.5 V



4.5 to 5 V



Faulty harness between monitor controller and switch panel.



Check voltage at monitor controller 16P connector terminal #32. · Insert tester terminal from behind monitor controller connector. · Key switch: ON · Level check switch: ON



4.5 to 5 V



Faulty monitor controller.



Refill engine oil, hydraulic oil, or coolant.



Refer to the troubleshooting for individual indicator which does not come ON.



Connector (Harness end connector viewed from the open end side) Switch Panel (12P)



Monitor Controller (16P)



5 4 3 2 1 12 11 10 9 8 7 6



28 27 26 25 24 23 22 21 36 35 34 33 32 31 30 29



T5-5-7



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE OIL LEVEL INDICATOR • Indicator light is not burned out. • Other indicators work correctly. • Be sure to inspect wiring connections prior to troubleshooting. Continuity



NO



Indicator does not come ON even if level check switch is depressed. · Engine oil level is higher than Lo level.



With engine oil level switch disconnected, ground harness end connector red line terminal to vehicle frame. Check if indicator comes ON. · Key switch :ON · Level check switch: ON



With engine oil level switch red line terminal grounded to vehicle frame, disconnect 20P connector from monitor controller. Check for continuity between harness end connector terminal #18 and vehicle frame.



Reconnect connector. Check if voltage at monitor controller 20P connector terminal #5 is lower than 1 V. · Key switch :ON · Level check switch: ON · Insert tester terminal from behind monitor controller connector.



No Continuity



YES



Continuity With engine oil level switch disconnected, disconnect 20P connector from monitor YES controller. Check for continuity between connector terminal #18 and vehicle frame.



Indicator comes ON even if engine oil level is lower than specified level when level check switch is depressed.



No Continuity



Disconnect engine oil level switch. Check if indicator comes ON.



Short-circuited harness between engine oil level switch and monitor controller.



Faulty monitor controller.



· Key switch :ON · Level check switch: ON



Engine Oil Level Switch



H L



ON



3 mm



OFF



NO T166-05-05-001



T5-5-8



Faulty engine oil level switch.



TROUBLESHOOTING / Troubleshooting C Disconnect 12P connector from monitor panel. YES Check if voltage at harness end connector terminal #26 is lower than 1 V.



YES



· Key switch :ON · Level check switch: ON



NO



Faulty monitor panel.



Faulty harness between monitor controller and monitor NO panel.



Connector (Harness end connector seen from the open end side) Monitor Panel (12P) 25 24 23 22 21 32 31 30 29 28 27 26



Monitor Controller (20P)



Faulty monitor controller.



10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



Broken harness between engine oil level switch and monitor controller. Faulty engine oil level switch.



T5-5-9



Engine Oil Level Switch(2P)



2



1



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF COOLANT LEVEL INDICATOR • Indicator light is not burned out. • Other indicators work correctly. • Be sure to inspect wiring connections prior to troubleshooting. Reconnect connector. Continuity Check if voltage at monitor controller terminal #6 is lower than 1 V.



NO



Indicator does not come ON even if level check switch is depressed. · Coolant level is higher than Low level.



With coolant level switch disconnected, short-circuit harness end terminals #1 and #2. Check if indicator comes ON.



With coolant level switch terminals short-circuited, disconnect 20P connector from monitor controller. Check for continuity between harness end connector terminal #19 and vehicle frame.



· Key switch :ON · Level check switch: ON · Insert tester terminal from behind monitor controller connector.



No Continuity



· Key switch :ON · Level check switch: ON



YES



Continuity With coolant level switch disconnected, disconnect 20P connector from YES monitor controller. Check for continuity between harness end connector terminal #19 and vehicle frame. Indicator comes ON even if coolant level is lower than specified level when level check switch is depressed.



No Continuity



Disconnect coolant level switch. Check if indicator comes ON. · Key switch :ON · Level check switch: ON NO Reserve Tank



ON FULL LOW Radiator



OFF Coolant Level Switch T107-04-03-012



T5-5-10



TROUBLESHOOTING / Troubleshooting C



YES Faulty monitor panel. Remove 12P conYES nector from monitor panel. Check if voltage at harness end connector terminal #27 is lower than 1 V. · Key switch :ON · Level check switch: ON



NO (24 V)



Connector (Harness end connector seen from the open end side)



NO (24 V)



Faulty harness between monitor controller and monitor panel.



Monitor Panel (12P) 25 24 23 22 21 32 31 30 29 28 27 26



Monitor Controller (20P)



Faulty monitor controller.



10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



Broken harness between coolant level switch and monitor controller.



Coolant Level Indicator (Harness end connector viewed from the open end side)



Faulty coolant level switch.



3 1



Short-circuited harness between coolant level switch and monitor controller.



Faulty monitor controller



Faulty coolant level switch.



T5-5-11



2



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF LEVEL INDICATOR



HYDRAULIC



OIL



• Indicator light is not burned out. • Other indicators work correctly. • Be sure to inspect wiring connections prior to troubleshooting.



Indicator does not come ON even if level check switch is depressed. · Hydraulic oil level is higher than Low level.



With hydraulic oil level switch disconnected, short-circuit harness end terminals #1 and #2. Check if indicator comes ON.



Reconnect connector. Continuity Check if voltage at monitor controller terminal #7 is lower than 1 With hydraulic oil level V. switch terminals · Key switch :ON short-circuited, discon· Level check switch: ON NO nect 20P connector · Insert tester terminal from monitor controller. from behind monitor Check for continuity controller connector. between harness end connector terminal #20 and vehicle frame. No Continuity



· Key switch :ON · Level check switch: ON



YES



Continuity



Indicator comes ON even if hydraulic oil level is lower than specified level when level check switch is depressed.



With hydraulic oil level switch disconnected, disconnect 20P connector from monitor YES controller. Check for continuity between harness end connector terminal #20 and vehicle frame. Disconnect hydraulic oil level switch. Check if indicator comes ON. · Key switch :ON · Level check switch: ON



No Continuity



NO



Hydraulic Oil Level Switch T137-04-04-001



T5-5-12



TROUBLESHOOTING / Troubleshooting C YES Remove 12P connector from monitor panel. Check if voltYES age at harness end connector terminal #28 is lower than 1 V. · Key switch :ON · Level check switch: ON



NO (24 V)



NO (24 V)



Faulty monitor panel.



Faulty harness between monitor controller and monitor panel.



Connector (Harness end connector seen from the open end side) Monitor Panel (12P) 25 24 23 22 21 32 31 30 29 28 27 26



Faulty monitor controller. Monitor Controller (20P)



Broken harness between hydraulic oil level switch and monitor controller. Faulty hydraulic oil level switch.



Short-circuited harness between hydraulic oil level switch and monitor controller.



Faulty monitor controller



Faulty hydraulic oil level switch.



T5-5-13



10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ALTERNATOR INDICATOR • Be sure to inspect wiring connections prior to troubleshooting.



YES (10 V or lower) Check if voltage at YES starter relay terminal N is lower than 10 V. Even if power generation is insufficient, alternator indicator does not come ON. · Key switch: ON · Engine: Stopped



· Key switch: ON · Engine: Stopped



Check if alternator indicator comes ON when key switch is turned from OFF to ON. (Indicator light check)



NO (10 V or higher)



· Key switch: OFF ⇔ ON NO



YES Check if voltage at YES monitor controller terminal #4 is higher than 15 V. Alternator indicator does not go OFF after engine is running.



Check if voltage at starter relay terminal N is higher than 15 V.



· Engine: Running



· Engine: Running



· Engine: Running · Insert tester terminal from behind monitor controller connector.



NO



T5-5-14



NO



TROUBLESHOOTING / Troubleshooting C



Connector (Harness end connector seen from the open end side) Monitor Panel (12P)



Faulty monitor controller.



25 24 23 22 21 32 31 30 29 28 27 26



Monitor Controller (20P) 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



Faulty regulator.



Starter Relay



Faulty alternator indicator.



E SW



Faulty monitor controller.



Broken harness between alternator and monitor controller.



Faulty alternator.



T5-5-15



N



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR YES



• Be sure to inspect wiring connections prior to troubleshooting.



Disconnect engine oil pressure switch. Check YES if indicator comes ON by connecting terminal #1 to vehicle frame. · Key switch: ON



Although engine oil level is lower, indicator does not come ON. · Key switch: ON · Engine: Stopped



Disconnect 16P connector from monitor controller. Check for continuity between harNO ness end connector terminal #21 and vehicle frame.



Check if indicator comes ON when key switch is turned from OFF to ON position. (Indicator light check) · Key switch: OFF⇔ON



· After checking, be sure to reconnect the removed connector.



NO



YES



Indicator goes OFF after engine starts. · Check for oil filter clogging. (Engine oil restriction indicator comes ON if filter is clogged.)



Check if indicator goes OFF when engine oil pressure switch is disconnected. · Key switch: ON · Engine: Stopped



Continuity



NO



Remove engine oil pressure switch terminal and monitor controller 16P connector. Then, check for continuity between harness end connector terminal #21 and vehicle frame. No continuity



Engine Oil Pressure Switch Pressure Operation Approx. 39 kPa 2 (0.4 kgf/cm , 5.7 psi) or ON lower Approx. 39 kPa 2 (0.4 kgf/cm , 5.7 psi) or OFF Higher



T5-5-16



TROUBLESHOOTING / Troubleshooting C



Faulty engine oil pressure switch. YES



Faulty monitor controller.



NO



Broken harness between monitor controller and monitor panel.



Ground monitor controller YES 20P connector terminal #9 to vehicle frame. Check if indicator comes ON. Reconnect connector. Ground monitor panel 12P Continuity connector terminal #30 to vehicle frame. Check if indicator comes ON. · Key switch: ON · Without disconnecting the connector, ground terminal to vehicle using a clip from behind connector.



· Key switch: ON · Without disconnecting the connector, ground terminal to vehicle using a clip from behind connector.



Faulty monitor panel.



NO



Broken harness between monitor controller and engine oil pressure switch.



No Continuity



Burned out indicator light.



Faulty engine oil pressure switch or engine oil lubrication system.



Short-circuited harness between pressure switch and monitor controller.



Reconnect connector. Disconnect monitor panel 12 P connector and monitor controller 20P connector. Check for continuity between monitor panel harness end connector terminal #30 and vehicle frame.



Short-circuited harness between monitor controller and monitor panel.



Continuity



Faulty monitor controller. No Continuity



Connector (Harness end connector seen from the open end side) Monitor Controller (16P)



Monitor Controller (20P)



28 27 26 25 24 23 22 21 36 35 34 33 32 31 30 29



10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



Monitor Panel (12P)



T5-5-17



25 24 23 22 21 32 31 30 29 28 27 26



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF OVERHEAT INDICATOR YES



• Be sure to inspect wiring connections prior to troubleshooting.



YES



Disconnect overheat switch. Check if indicator comes ON by connecting terminal #1 to #2. · Key switch: ON



Indicator does not come ON even if engine overheats.



Check if indicator comes ON when key switch is turned from OFF to ON (indicator light check). · Key switch: OFF ⇔ ON



With overheat switch terminals #1 and #2 connected to vehicle frame, disconnect 16P connector from monitor NO controller. Check for continuity between harness end connector #22 and vehicle frame.



NO



YES



Indicator comes ON even if coolant temperature is low.



Check if indicator goes OFF when overheat switch is disconnected.



Continuity



· Key switch: ON NO



With overheat switch and monitor controller 16P connector disconnected, check for continuity between harness end connector terminal #22 and vehicle frame. No Continuity



Overheat Switch Coolant Temperature Lower than 101 °C (214 °F) 101 °C (214 °F) or higher



Operation OFF ON



T5-5-18



TROUBLESHOOTING / Troubleshooting C



Faulty overheat switch.



Reconnect connector. Continuity Ground monitor panel connector terminal #31 to vehicle. Check if indicator comes ON. · Key switch: ON · Without disconnecting the connector, ground terminal to vehicle using a clip from behind connector.



YES



Faulty monitor controller.



NO



Broken harness between monitor controller and monitor panel.



Ground monitor controller YES 20P connector terminal #10 to vehicle frame. Check if indicator comes ON · Key switch: ON · Without disconnecting the connector, ground terminal to vehicle using a clip from behind connector.



Faulty monitor panel.



NO



Broken harness between monitor controller and overheat switch.



No Continuity



Burned out indicator light.



Faulty overheat switch.



Short-circuited harness between monitor controller and overheat switch. Reconnect connector. Disconnect monitor panel 12 P connector and monitor controller 20P connector. Check for continuity between monitor panel harness end connector terminal #31 and vehicle frame.



Short-circuited harness between monitor controller and monitor panel.



Continuity



Faulty monitor controller. No Continuity



Connector (Harness end connector seen from the open end side) Monitor Controller (16P)



Monitor Controller (20P)



28 27 26 25 24 23 22 21 36 35 34 33 32 31 30 29



10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



T5-5-19



Monitor Panel (12P) 25 24 23 22 21 32 31 30 29 28 27 26



Overheat SW 1 2



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF AIR FILTER RESTRICTION INDICATOR • Be sure to inspect wiring connections prior to troubleshooting.



YES



Disconnect air filter restriction switch and YES ground harness end +terminal to vehicle frame. Check if indicator comes ON. · Key switch: ON



Indicator does not come ON even if air filter is clogged.



Check if indicator comes ON when key switch is turned from OFF to ON (indicator light check). · Key switch: OFF ⇔ ON



With air filter restriction switch terminal connected to vehicle, disconnect 16P connector from monitor controller. NO Check for continuity between harness end connector #26 and vehicle frame.



NO



YES



Indicator comes ON even if air filter is not clogged. · Disassemble and visually check. · Check if air filter is moist.



Check if indicator goes OFF when air filter restriction switch is disconnected.



Continuity



· Key switch: ON NO



With air filter restriction switch and monitor controller 16P connector disconnected, check for continuity between harness end connector terminal #26 and vehicle frame.



Air Filter Restriction Switch



Pressure 5.1 kPa or Lower (520 mmH2O or Lower) 6.2 kPa or Higher (630 mmH2O or Higher)



Operation OFF ON



T5-5-20



No Continuity



TROUBLESHOOTING / Troubleshooting C



Faulty air filter restriction switch.



Reconnect connector. Ground monitor panel conContinuity nector terminal #33 to vehicle frame. Check if indicator comes ON. · Key switch: ON · Without disconnecting the connector, ground terminal to vehicle using a clip from behind connector.



Ground monitor controller 20P connector terminal YES #13 to vehicle frame. Check if indicator comes ON. · Key switch: ON · Without disconnecting the connector, ground terminal to vehicle using a clip from behind connector.



YES



Faulty monitor controller.



NO



Broken harness between monitor controller and monitor panel.



Faulty monitor panel.



NO Broken harness between monitor controller and air filter restriction switch.



No Continuity



Burned out indicator light.



Faulty air filter restriction switch.



Short-circuited harness between monitor controller and air filter restriction switch. Reconnect connector. Disconnect monitor panel 12 P connector and monitor controller 20P connector. Check for continuity between monitor panel harness end connector terminal #33 and vehicle frame.



Continuity



Short-circuited harness between monitor controller and monitor panel. Faulty monitor controller.



No Continuity



Connector (Harness end connector seen from the open end side) Monitor Controller (16P)



Monitor Controller (20P)



Monitor Panel (12P)



28 27 26 25 24 23 22 21 36 35 34 33 32 31 30 29



10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



25 24 23 22 21 32 31 30 29 28 27 26



T5-5-21



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF BUZZER • Be sure to inspect wiring connections prior to troubleshooting. YES



Buzzer keeps sounding after engine is running. · Engine: Running



Check if engine oil pressure indicator is ON. · Engine: Running



YES



Check if overheat indiNO cator is ON. · Engine: Running NO



NO



Buzzer does not sound even if engine oil pressure indicator or overheat indicator comes ON. · Engine: Running



Disconnect buzzer. Check if voltage at buzzer harness end terminal #1 is 24 V. · Engine: Running



Check if buzzer sounds YES when buzzer connector terminal #2 is grounded to vehicle frame. · Engine: Running · Without disconnecting the connector, insert tester terminal from behind monitor controller connector.



YES



NO (1 V or Lower)



MALFUNCTION OF HOUR METER • Be sure to inspect wiring connections prior to troubleshooting. YES



Hour meter does not count operating hours when engine is running.



Check if alternator indicator is ON.



· Engine: Running



· Engine: Running



NO (24 V) Check if voltage at monitor controller terminal #34 is lower than NO 1 V. · Engine: Running · Without disconnecting the connector, insert tester terminal from behind monitor controller connector.



T5-5-22



Disconnect 12P connector from monitor panel. Check if voltage YES between harness end connector terminal #23 is lower than 1 V. · Engine: Running



TROUBLESHOOTING / Troubleshooting C



Faulty engine oil pressure system



Connector (Harness end connector seen from the open end side) Buzzer



Overheating of engine. 2



YES



Faulty monitor controller.



NO



Short-circuited harness between monitor controller and buzzer or faulty buzzer.



Check if buzzer stops sounding when 20P connector is disconnected from monitor controller. · Engine: Running



Faulty monitor controller.



1



Monitor Controller (16P) 28 27 26 25 24 23 22 21 36 35 34 33 32 31 30 29



Monitor Controller (20P) 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11



Broken harness between monitor controller and buzzer.



Monitor Panel (12P) 25 24 23 22 21 32 31 30 29 28 27 26



Faulty power line harness.



Faulty alternator indicator or alternator. (Refer to MALFUNCTION OF ALTERNATOR INDICATOR: Alternator indicator does not go OFF after engine is started.) Faulty Monitor controller. NO (24 V)



YES



Broken harness between monitor controller and monitor panel. Faulty monitor panel (hour meter).



T5-5-23



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE OIL FILTER RESTRICTION INDICATOR • Be sure to inspect wiring connections prior to troubleshooting.



• The engine oil pressure indicator comes on if the engine oil filter is clogged. YES



YES



Indicator does not come ON even if engine oil filter is clogged.



Disconnect engine oil restriction switch and ground harness end terminal to vehicle frame. Check if indicator comes ON. · Key switch: ON



Check if indicator comes ON when key switch is turned from OFF to ON (indicator light check).



Reconnect connector. Ground monitor panel 12P connector terminal #32 to vehicle frame. Check if indicator NO comes ON. · Key switch: ON · Without disconnecting the connector, ground terminal to vehicle using a clip from behind connector.



· Key switch: OFF ⇔ ON



NO



YES



Indicator comes ON even if engine oil filter is not clogged.



Check if indicator goes OFF when engine oil restriction switch is disconnected. · Key switch: ON NO



With engine oil restriction switch and monitor panel 12P connector disconnected, check for continuity between harness end connector terminal #32 and vehicle frame.



T5-5-24



Continuity



No Continuity



TROUBLESHOOTING / Troubleshooting C



Faulty engine oil restriction switch.



Connector (Harness end connector seen from the open end side) Monitor Panel (12P)



YES



Broken harness between monitor panel and engine oil restriction switch.



Faulty monitor panel. NO



Burned out indicator light.



Faulty engine oil restriction switch. Short-circuited harness between monitor panel and engine oil restriction switch.



Faulty monitor panel.



T5-5-25



25 24 23 22 21 32 31 30 29 28 27 26



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF CONTROLLER MALFUNCTION INDICATOR NO



• Be sure to inspect wiring connections prior to troubleshooting.



YES Check if voltage at MC 12P connector terminal #221 is 24 V.



Indicator does not blink or comes ON even if MC monitor indicator displays abnormal status.



Check if indicator comes ON when key switch is turned from OFF to ON (indicator light check).



· Refer to T5-3-3. The controller malfunction indicator does not always come ON in all cases.



· Key switch: OFF⇔ON



· Key switch: ON · #221 Output 24 V: Normal 0 V: Abnormal · Without disconnecting the connector, insert tester terminal from behind monitor controller connector.



Disconnect controller malfunction indicator relay (R12). Check if voltage at YES harness end connector terminal #1 is 24 V. · Key switch: ON



NO NO (24 V)



Indicator comes ON even if MC monitor indicator does not display abnormal status. · Key switch: ON



Check if voltage at MC 12P connector terminal #221 is 0 V. · Key switch: ON



YES Check if indicator goes OFF when controller malfunction indicator relay YES (R12) is disconnected. · Key switch: ON



T5-5-26



Disconnect 6P connector from monitor panel. Check for contiNO nuity between harness end connector terminal #35 and vehicle frame.



TROUBLESHOOTING / Troubleshooting C



Faulty MC.



Broken harness between MC terminal #221 and controller malfunction indicator relay (R12) terminal #1.



NO



Broken ground line of controller malfunction indicator relay (R12) terminal #2.



No Continuity Check for continuity between controller malfunction indicator relay (R12) harness end terminal #2 and YES vehicle frame.



Faulty controller malfunction indicator relay (R12).



YES



Check if indicator comes ON when controller malfunction indicator relay (R12) Continuity harness end terminal #3 is grounded to vehicle frame. · Key switch: ON



Check if indicator comes ON when monitor panel terminal #35 is grounded to NO vehicle frame. · Key switch: ON · Without disconnecting the connector, ground terminal to vehicle using a clip from connector back side.



YES



Broken harness between monitor panel and controller malfunction indicator relay (R12). Faulty monitor panel.



NO



Faulty indicator.



Faulty MC.



Faulty controller malfunction indicator relay (R12). Short-circuited harness between monitor panel and controller malfunction indicator relay (R12).



Continuity



Faulty monitor panel. No Continuity



Connector (Harness end connector viewed from the open end side) MC (12P) 224 223 222 221 220 219 230 229 228 227 226 225



Monitor Panel (6P)



Controller Malfunction Indicator Relay (R12)



34 33 38 37 36 35



1 3



2 5 4



T5-5-27



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF BRAKE UNAPPLIED INDICATOR • Be sure to inspect wiring connections prior to



NO



troubleshooting. Indicator Lightening Condition When the key switch is turned to START with one of three switches positioned as described bellow, the indicator comes ON without starting the engine. • Swing Brake Switch → FREE MODE • Main Hoist Brake Mode Switch → FREE MODE YES • Aux. Hoist Brake Mode Switch → FREE MODE



Indicator does not come ON under indicator lightening condition. · Key switch: START



Disconnect brake unapplied indicator relay (R22). Check if voltage at connector terminal #1 is 24 V. · Key switch: START · Swing brake switch: ON · Main hoist brake mode switch: FREE MODE position · Aux. hoist brake mode switch: AUTOMATIC BRAKE MODE position



Check if indicator comes ON when key switch is turned from OFF to ON (indicator light check). · Key switch: OFF ⇔ ON



NOTE: Check beforehand that the engine can start with swing brake switch ON, and the main and aux. hoist brake mode switches placed in the AUTOMATIC BRAKE MODE.



Check if voltage at brake unapplied indicator relay (R22) terYES minal #1 is 24 V. · Key switch: START · Swing brake switch: ON · Main hoist brake mode switch: AUTOMATIC BRAKE MODE position · Aux. hoist brake mode switch: FREE MODE position



NO



YES



Indicator does not go OFF after engine is running. · Engine: Running · Key switch: ON



Indicator goes OFF when brake unapplied indicator relay (R22) is disconnected.



Continuity



· Key switch: ON NO



Disconnect 6P connector from monitor panel. Check for continuity between harness end connector terminal #36 and vehicle frame. No Continuity



T5-5-28



TROUBLESHOOTING / Troubleshooting C



Broken harness between brake unapplied indicator relay (R22) and main hoist brake relay (R3). Broken harness between brake unapplied indicator relay (R22) and aux. hoist brake relay (R7).



NO



Broken harness between brake unapplied indicator relay (R22) and swing brake relay (R2).



NO Check if voltage at brake unapplied indicator relay (R22) YES connector terminal #1 is 24 V.



Check if indicator comes ON when brake unapplied indicator relay (R22) · Key switch: START harness end conYES nector terminal #3 is · Swing brake switch: OFF · Main and aux. hoist brake grounded to vehicle mode switches: AUTOMATIC frame. BRAKE MODE position · Key switch: ON



YES



Faulty brake unapplied indicator relay (R22).



Check if indicator comes ON when monitor panel termiNO nal #36 is grounded to vehicle frame. · Key switch: ON · Without disconnecting the connector, ground terminal to vehicle using a clip from behind connector.



Broken harness between YES monitor panel and brake unapplied indicator relay (R22). Faulty monitor panel. NO



Burned out indicator light.



Faulty brake unapplied indicator relay (R22). Short-circuited harness between monitor panel and brake unapplied indicator relay (R22).



Faulty monitor panel.



Connector (Harness end connector seen from the open end side) Monitor Panel (6P) 34 33 38 37 36 35



Brake Unapplied Indicator Relay (R22) 1 3



2 5 4



T5-5-29



TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF HYDRAULIC OVERHEAT INDICATOR



OIL YES Faulty hydraulic oil temperature switch.



• Be sure to inspect wiring connections prior to troubleshooting.



NO



Disconnect hydraulic oil temperature switch. Check if indicator comes ON when harness is grounded to vehicle frame. · Key switch: ON



Indicator does not come ON even when hydraulic oil temperature is higher than 92 °C (198 °F).



Broken harness between indicator and hydraulic oil NO temperature switch.



Check if buzzer is sounding.



Burned out indicator light or broken indicator harness.



YES



YES



YES



Check if indicator goes OFF when hydraulic oil temperature switch is disconnected. · Key switch: ON



Indicator comes ON even when hydraulic oil temperature is lower than 92 °C (198 °F).



Faulty hydraulic oil temperature switch.



NO



Check if buzzer is sounding.



Short-circuited harness between indicator and hydraulic oil temperature switch.



Short-circuited indicator or indicator harness.



NO



T5-5-30



TROUBLESHOOTING / Troubleshooting D TROUBLESHOOTING D (TROUBLESHOOTING FOR MOMENT LIMITER) PROCEDURE Use troubleshooting D when the moment limiter displays any fault codes. (HL-9A) The following list shows the fault codes to be displayed on the moment limiter when troubleshooting is performed and the manual pages describing the causes and troubleshooting methods corresponding to the displayed fault code(s). Fault Code E02 E03 E04 E05



E20 E21 E40 E41



Failure Location Arithmetic Unit



Others



Boom Angle Detector Signal Cassette



E42 E43



Cause of Failure Memory Error in Arithmetic Unit Lower Boom Angle Detector Power Voltage than Specification. Overly High Detector Voltage Underly Low Detector Voltage Memory Error in Cassette Mishandling Memory Error in Cassette Mishandling



E54



Load Detector Signal



Low Load Detector Voltage Mishandling High Load Detector Voltage Over Powered Detector Voltage than Specification Under Powered Detector Voltage than Specification



Precautions for Troubleshooting • Use a digital voltage meter for measuring voltage and resistance. • When instructed as “ Measure XX between A and B” in the troubleshooting flow charts, contact A to the digital volt meter red probe and B to the black one.



Remarks Replace the Arithmetic unit



− T5-6-3



T5-6-4, 5 T5-6-6, 7 T5-6-8 −



Turn the main/aux. switch to the main hoist side.



T5-6-8 −



E44 E50 E51 E52 E53



Page to be Referred.



T5-6-9, 10 − T5-6-11 −



Replace the cassette with the crane cassette. Press the crane operation key. Recheck the ML setting. Replace the Arithmetic unit



T5-6-12 Connector



Receptacle



T331-05-07-001



• When measuring, check if the connector side is to be measured or the receptacle side is to be measured. • Before disconnecting connectors, be sure to turn the key switch and the moment limiter power switch OFF T331-05-07-002



T5-6-1



TROUBLESHOOTING / Troubleshooting D (Blank)



T5-6-2



TROUBLESHOOTING / Troubleshooting D FAULT CODE E05



Arithmetic Unit (Moment Limiter)



E05



Base Machine Terminal Box



Disconnect angle detector connector (5P) from base machine terminal box.



Check if fault code E05 disappears



NO



YES Boom Angle Detector



Replace boom angle detector.



Boom Angle Detector Connector Reconnect angle detector connector (5P) to base machine terminal box. Disconnect connector (24P) from the back of moment limiter.



NO



Check if fault code E05 disappears YES



Replace arithmetic unit.



Replace base machine terminal box.



T5-6-3



T331-05-07-003



TROUBLESHOOTING / Troubleshooting D FAULT CODE E20



Arithmetic Unit (Moment Limiter)



E20



Base Machine Terminal Box



Check actual boom angle.



Within allowable load radius.



Check if boom angle is within allowable load radius.



Beyond allowable load radius. Lower boom until boom angle is within allowable load radius.



Check if fault code E20 disappears.



Remains.



Boom Angle Detector



T331-05-07-003



Disappeared. End.



After re-setting actual boom angle to approx. 60°, disconnect angle detector connector (5P) from base machine terminal box. Measure resistance value between terminals A and B on the disconnected connector.



NO



Check if measured resistance value is 0.5 to 1.0 kΩ. YES Measure resistance value between terminals A and C on the disconnected connect



∞ 2.5 kΩ or More.



Measured resistance value is …. Less than 2.5 kΩ.



Replace boom angle detector.



A



T5-6-4



Angle Detector Connector T331-05-07-004



TROUBLESHOOTING / Troubleshooting D A



Arithmetic Unit (Moment Limiter)



Reconnect angle detector connector (5P) to base machine terminal box. Disconnect connector (24P) from the back of moment limiter. Measure resistance value between terminals A5V and A1 on disconnected connector.



Check if measured resistance value is 0.5 to 1.0 kΩ.



T331-05-07-005



Arithmetic Unit (Moment Limiter)



Base Machine Terminal Box



Outside the Range



YES Measure resistance value between terminals A1 and AGND on disconnected connector.



Measured resistance value is …



∞ 2.5 kΩ or More.



Less than 2.5 kΩ. Replace arithmetic unit.



Replace base machine terminal box.



Boom Angle Detector T331-05-07-003



T5-6-5



TROUBLESHOOTING / Troubleshooting D FAULT CODE E21



Arithmetic Unit (Moment Limiter)



E21



Base Machine Terminal Box



Check if angle detector connector (5P) is connected to base machine terminal box.



YES



Is connector connected ? NO



Boom Angle detector



Connect connector.



Check if fault code E21 disappears. Disappears.



Remains. Boom Angle Detector Connector



Check harness between connector and angle detector for any damage.



YES



Is harness damaged ? NO Check actual boom angle.



Check if boom angle is within allowable load radius.



Within allowable load radius.



Beyond is within allowable load radius. Raise boom until boom angle is within allowable load radius.



Disappeared.



Check if fault code E21 disappears.



Remains.



B



End.



T5-6-6



T331-05-07-003



TROUBLESHOOTING / Troubleshooting D



Arithmetic Unit (Moment Limiter) B



T331-05-07-005



Arithmetic Unit (Moment Limiter) After re-setting actual boom angle to approx. 60°, disconnect angle detector connector (5P) from base machine terminal box. Measure resistance value between terminals A and B on the disconnected connector.



Measured resistance value is …



∞



Base Machine Terminal Box



0.5 to 1.0 kΩ



Boom Angle Detector



Measure resistance value between terminals B and C on disconnected connector.



0Ω



The measured resistance value is … T331-05-07-003



0.5 to 1.0 kΩ



Replace angle detector.



∞ 0.5 ~1.0kΩ



Reconnect angle detector connector (5P) to base machine terminal box. Disconnect connector (24P) from back of moment limiter. Measure resistance value between terminals A5V and A1 on disconnected connector.



T331-05-07-004



Measured resistance value is … 0.5 to 1.0 kΩ Measure resistance value between terminals A1 and AGND on disconnected connector.



0Ω



Measured resistance value is … 0.5 to 1.0 kΩ



Replace harness.



Boom Angle Detector Connector



Replace arithmetic unit.



T5-6-7



TROUBLESHOOTING / Troubleshooting D FAULT CODE E40, E42 E40



E42



Re-insert cassette.



Check if fault code disappears. Remains.



Disappears.



End.



Insert a different cassette.



Check if fault code disappears.



Disappears.



Remains. Replace arithmetic unit.



Replace cassette.



T5-6-8



TROUBLESHOOTING / Troubleshooting D FAULT CODE E50 Connector to Load Detector Amplifier



E50



Load Detector



Connector to Load Detector Base Machine Terminal Box



Check if load detector connector (7P) is connected to the base machine terminal



YES



Is connector connected ? NO Connect connector.



Arithmetic Unit (Moment Limiter) Check if fault code E50 disappears.



Base Machine Terminal Box



Remains. T331-05-07-006



Disappears.



Check harness between base machine terminal box and load detector for any damage.



Is harness damaged ?



YES



NO Check if load detector connector (7P) is connected to amplifier.



Is connector connected ?



Replace harness between base machine terminal box and load detector



YES



NO Connect connector.



Disappears.



Check if fault code E50 disappears.



Remains.



C



End.



T5-6-9



TROUBLESHOOTING / Troubleshooting D Connector to Load Detector Amplifier



C



Load Detector



Remove cover of amplifier from load detector. Measure and record voltage values between + and ground, and Out and ground on amplifier measurement terminals.



Disconnect load detector harness both end connectors from amplifier (4P) and base machine terminal box (7P). Measure resistance values between terminals D and D, A and A, and either A and C on harness both end connectors.



Resistance value between terminals D and D, and A and A should be 0 Ω. Check if resistance value between terminals either A and C on harness both and connectors is ∞.



One or more values are incorrect. Replace harness.



One or more values are incorrect.



Load Detector Amplifier Side Connector



Connector to Load Detector Base Machine Terminal Box



Base Machine Terminal Box Load Detector Side Connector



Base Machine Terminal Box



Arithmetic Unit (Moment Limiter)



T326-05-06-002



All values are incorrect.



Arithmetic Unit (Moment Limiter)



After connecting load detector side connector to amplifier, disconnect connector (24P) from the back of moment limiter with base machine terminal box connector disconnected. Measure resistance values between terminals A10V and D, WT1and A, and either WT1 and AGNDL or A and C on disconnected connector and base machine terminal box load sensor receptacle.



T331-05-07-005



Resistance value between terminals A10V and D, WT1and A should be 0 Ω. Check if resistance value between terminals either WT1 and AGNDL or A and C is ∞.



All values are incorrect.



Replace base machine box.



Voltage values measured at first step in this page are as follows. Terminal + and ground: 9.786 to 10.206 V Terminal Out and ground: 1.5 to 4.5 V



YES Replace arithmetic unit.



T5-6-10



NO



Replace load detector



TROUBLESHOOTING / Troubleshooting D FAULT CODE E52 E52



Connector to Load Detector Amplifier Load Detector



Remove cover of amplifier from load detector. Measure and record voltage values between + and ground, and Out and ground on amplifier measurement terminals.



Load Detector Amplifier Side Connector



Connector to Load Detector Base Machine Terminal Box



Disconnect load detector both end connectors from amplifier (4P) and base machine terminal box (7P). Measure resistance value between terminals C and C, and either D and A on harness both end connectors.



Base Machine Terminal Box Load Detector Side Connector



Arithmetic Unit (Moment Limiter)



Base Machine Terminal Box



T326-05-06-002



Is resistance value between terminals C and C 0 Ω ? Are resistance values between either terminals D and A on harness both end connectors.



One or more values are incorrect Replace harness.



One or more values are incorrect.



Replace base machine terminal box.



All values are correct Arithmetic Unit (Moment Limiter)



After connecting load detector side connector to amplifier, disconnect connector (24P) from the back of moment limiter with base machine terminal box connector disconnected. Measure the resistance value between terminals AGNDL and C on and either D and A, or A10VL and AGNDL disconnected connector and base machine terminal box load detector receptacle.



T331-05-07-005



Is resistance value 0 Ω ? Resistance value between terminal AGNDL and C should be 0 Ω. Check if resistance value between terminals either D and A or A10VL and AGNDL is ∞.



All values are correct.



Voltage values measured at first step in this page are as follows. Terminal + and ground: 9.786 to 10.206 V Terminal Out and ground: 1.5 to 4.5 V



YES Replace arithmetic unit.



T5-6-11



NO



Replace load detector.



TROUBLESHOOTING / Troubleshooting D FAULT CODE E54 E54



Connector to Load Detector Amplifier Load Detector



Remove cover of amplifier from load detector. Measure and record voltage values between + and ground, and out and ground on amplifier measurement terminals.



Load Detector Amplifier Side Connector



Connector to Load Detector Base Machine Terminal Box



Disconnect both load detector harness end connectors from amplifier (4P) and base machine terminal box (7P). Measure resistance values between terminals C and D on both disconnected connectors.



Base Machine Terminal Box Load Detector Side Connector



Arithmetic Unit (Moment Limiter)



Base Machine Terminal Box



T326-05-06-002



Is measured resistance value ∞ Ω ?



OK



NOT OK Replace harness.



NOT OK



After connecting load detector side connector to amplifier, disconnect connector (24P) from back of moment limiter with base machine terminal box connector disconnected. Measure resistance values between terminals AGNDL and A10VL or C and D on disconnected connector and base machine terminal box load sensor receptacle.



Arithmetic Unit (Moment Limiter)



T331-05-07-005



Is measured resistance value ∞ Ω ?



All values are correct. Replace base machine terminal box. Voltage values measured at first step in this page are as follows. Terminal + and ground: 9.786 to 10.206 V Terminal Out and ground: 1.5 to 4.5 V



YES Replace arithmetic unit.



T5-6-12



NO



Replace load detector.



TROUBLESHOOTING / Electrical System Inspection PRECAUTIONS FOR INSPECTION AND MAINTENANCE 1. Disconnect the power source. Be sure to remove the negative terminals from the batteries 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. Refer to the table on the right for the wire harness color codes. When a harness is indicated with two different color codes in the electrical diagram, the left initial stands for the base color, while the right initial stands for the marking color. NOTE: 1) Code BW indicates a black base wire with white fine-line marking. 2) Initials “O” and “Or” both stand for the color orange. 3) Longitudinal color stripes printed on wire indicate the kinds of wire (AVS). 3. Precautions for connecting and disconnecting terminal connectors. 1) When disconnecting harnesses, grasp them by their connectors. Do not pull on the wire itself. Be sure to release the lock first before attempting to separate connectors, if a lock is provided. (Refer to T5-7-3 “INSTRUCTIONS FOR DISCONNECTING CONNECTORS”.) 2) Water-resistant connectors keep water out so that if water enters them, water will not easily drain from them. When checking 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. 3) Before connecting terminal connectors, check that no terminals are bent or coming off. In addition, as most connectors are made of brass, check that no terminals are rusting. 4) When connecting terminal connectors provided with a lock, be sure to insert them together until the lock “clicks.”



T5-7-1



Code R L Or Y Br Gr



Color Red Blue Orange Yellow Brown Gray



Code W G Lg B P V



Right



Color White Green Light green Black Pink Violet



Wrong



T107-07-06-001



Right Rust Wrong (Deformation) Wrong (Separation) T107-07-06-002



TROUBLESHOOTING / Electrical System Inspection 4. Precaution for using a circuit tester. 1) Before using a circuit tester, refer to the instructions in the circuit tester manual. Then, set the circuit tester to meet the object to be measured, voltage range and current polarity. 2) 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 standard probe size is too large to be used for testing, wind a fine piece of sharpened wire or a pin around the probe to make the test easier.



T5-7-2



Wind a Piece of Wire



Tester Probe



Sharpen the end of the Wire T107-07-06-003



TROUBLESHOOTING / Electrical System Inspection INSTRUCTIONS CONNECTORS



FOR



DISCONNECTING



1. Push down on the lock to release it, then pull the connector apart. NOTE: 1. Avoid pulling the connector while pushing down on the lock which will make it difficult to disconnect the connector. 2. Be sure to pull the connector after pushing down on the lock. The lock is provided on the harness end T107-04-05-002



Devices using this type of connector: Fuel Level Sensor Engine Oil Level Switch Coolant Level Switch



Radio Radio Speaker Swing Lever



Alternator Glow Relay Current Sensor



Hydraulic Oil Level Switch



Accelerator Lever



Glow Timer



Engine Overheat Switch



Superfine Speed Control Lever Work Mode Switch



Swing Alarm Lamp



EC Sensor EC Motor Superfine Speed Control Solenoid Hook Overhoist Prevention Harness Connector Check Switch Option Switch



Flusher Relay



Relay Harness in Cab



Drum Lock Switch Travel Mode Switch Overhead Window Wiper



Horn Brake Mode Switch Windshield Wiper



Drum Speed Sensing Switch Drum lock Motor



Pressure Switch (1) Universal Relay



Air Conditioner Auto-Stop Controller



Hoist Lever Junction Harness Pressure Switch (3)



Buzzer Main Controller Check Switch



Monitor Panel



Travel Alarm Pressure Switch



Moment Limiter



Starter Switch



Audio Output Unit



Fast Idle Set Switch



Tilt Harness Main/Auxiliary Brake Harness Superfine Speed Control Harness Auxiliary Harness Pilot Control Shut-Off Lever Pressure Switch Optional Indicator Connector Optional Power Outlet Connector First Boom Overhoist Prevention Switch Second Boom Overhoist Prevention Switch



Engine Oil Filter Restriction Switch Pump Speed Sensor Auto-Stop Solenoid Stepping Motor Controller (SMC) Monitor Controller Main Controller (MC)



2. Pull up on the lock to release it, then pull the connector apart. Devices using this type of connector: Emergency Relay



T107-04-05-003



T5-7-3



TROUBLESHOOTING / Electrical System Inspection 3. Grasp both sides firmly with the fingers, and pull. Devices using this type of connector: Proportional Solenoid Valve Solenoid Valve



T107-04-05-004



4. Push from the both sides, then pull the connector apart. Devices using this type of connector: Main Drum Sensor Auxiliary Drum Sensor Swing Function Operation Switch



T324-04-05-007



T5-7-4



TROUBLESHOOTING / Electrical System Inspection FUSE CONTINUITY TEST Fuse failures are often caused by a fine crack in the fuse, and such fine cracks are very hard to detect by visual inspection. Checking fuse continuity with a tester is considered standard practice industry wide. 1. Turn the key switch ON. 2. In doing so, the battery relay is activated by current from terminal B of the key switch suppling electric power to all circuits. (See the circuit diagram.) 3. Remove the fuse box cover and set the tester to the correct voltage measurement range. (Measurement Range: 0 to 30 V) Connect the negative probe to the vehicle ground, and touch the outside terminal of each fuse with the positive probe of the tester. When normal continuity of a fuse is intact, the tester will indicate 20 to 25 volts.



Fuse Box 2



Fuse Box 1



M324-10-092



Fuse Box 1



20 19 18 8 17 7 16 6 15 5 4 14 3 13 12 2 11 1 10



9



* All the inside terminals of the fuses in the fuse box are connected to the power source, while the outside terminals are connected to the accessories. Test all fuses using the same method.



M104-07-055



Fuse Box 1



Fuse Capacity No.



Connected to



Fuse Capacity No.



Connected to



1



5A



Heater



11



15A



Work Light



2



1A



Switch, Backup



12



5A



Front Washer



3



5A



Cab Light



13



5A



Roof Wiper, Roof Washer



4



1A



Radio



14



20A



Air-Conditioner



5



10A



Horn



15



15A



Fuel Pump



6



10A



Cigar Lighter



16



5A



Brake



7



5A



Moment Limiter



17



5A



Brake Relay



8



10A



Main Controller Engine Controller



18



5A



Pilot Control Shut-Off Lever



9



15A



Main Controller



19



10A



Auto-Stop Controller



10



5A



Auto-Stop Controller



20



10A



Switch Box, Relay Box



T5-7-5



TROUBLESHOOTING / Electrical System Inspection



Fuse Box 2



Fuse Capacit No. y



Continued to



Fuse Capacit No. y



Continued to



21



5A



Swing Brake, Travel Fast/Slow



31



5A



Optional



22



5A



Brake Light



32



5A



Optional



23



10A



Main Hoist Drum Lock



33



5A



Optional



24



10A



Aux. Hoist Drum Lock



34



5A



Front Wiper



25



10A



Boom Hoist Drum Lock



35



10A



Pendant Switch



26



10A



Third Drum Lock (Optional)



36



5A



Pendant Switch



27



5A



Tilt Switch



37



5A



Optional



28



10A



Swing Alarm



38



5A



Optional



29



5A



Optional



39



5A



Engine Re-Start Switch



30



5A



Optional



40



5A



Auto-Stop Controller



Fuse Box 2



40 30 39 29 38 28 37 27 36 26 35 25 24 34 23 33 32 22 31 21



M324-10-093



T5-7-6



TROUBLESHOOTING / Electrical System Inspection FUSIBLE LINK CHECK Open fusible link caps to remove fuses. Visually check fuses.



Fuse No. 1 2 3 4 5 6



T324-04-05-002



Capacity



Color



Continued to



45A 65A 45A 30A 30A 65A



Red Black Red Green Green Black



Fuse Box 1, 2 Alternator Fuse Box 1 Fuse Box 2 Fuse Box 1, 2 Emergency Engine Stop Relay



1



2



3 Front



4 5 6



T333-05-07-002



T5-7-7



TROUBLESHOOTING / Electrical System Inspection VOLTAGE AND CURRENT CHECK Turn the related switch (es) ON so that the specified voltage (current) is applied to the point to be checked. Judge if the specified voltage or current is applied.



Engine Power Source Circuit Stopped Stopped Stopped Stopped Stopped Stopped Pre-Heat Circuit Stopped Stopped Stopped Stopped Starting Circuit Started Started Started Started



24 Voltage Circuit Start checking in order, up to the point where voltage is measured from either power source or actuator side. Thereby, the faulty circuit can be found. Black Probe (Minus) of Tester: To vehicle ground. Red Probe (Plus) of Tester: To location to be measured.



Key Switch



Check Point



Standard



OFF OFF OFF OFF OFF OFF



Between (2) and (1): One Battery Between (3) and (2): One Battery Between (3) and (1): Two Batteries Between (4) and Ground: Battery Relay Between (5) and Ground: Fusible Link Between (1) and Ground: Backup Current*



10 to 12.5 V 10 to 12.5 V 20 to 25 V 20 to 25 V 20 to 25 V 6 mA



HEAT HEAT HEAT HEAT



Between (3) and Ground: Battery Between (5) and Ground: Fusible Link Between (6) and Ground: Key Switch Between (7) and Ground: Glow Plug



20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V



START START START START



Between (3) and Ground: Battery Between (8) and Ground: Key Switch Between (5) and Ground: Fusible Link Between (9) and Ground: Battery Relay



20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V



Started Started Started



START START START



Between (10) and Ground: Battery Relay Between (11) and Ground: Starter (C) Between (12) and Ground: Starter (B)



20 to 25 V 20 to 25 V 20 to 25 V



Started Started Charging Circuit Fast Speed Fast Speed Fast Speed Fast Speed Fast Speed



START START



Between (13) and Ground: Starter Relay (C) Between (14) and Ground: Starter Relay (SW)



20 to 25 V 20 to 25 V



ON ON ON ON ON



Between (3) and Ground: Battery Between (10) and Ground: Alternator Changing Voltage Between (15) and Ground: Alternator Changing Voltage (B) Between (16) and Ground: Alternator (N) Between (17) and Ground: Emergency Relay



26 to 30 V 26 to 30 V 26 to 30 V 13 to 15 V 26 to 30 V



* After disconnecting the battery negative cable, begin measuring.



T5-7-8



TROUBLESHOOTING / Electrical System Inspection



Engine Surge Voltage Prevention Circuit Slow Idling Slow Idling Slow Idling Accessory Circuit Stopped Stopped Stopped Stopped Stopped Stopped Stopped Stopped



Key Switch



Check Point



Standard



ON ON ON



Between (17) and Ground: Emergency Relay (B) Between (18) and Ground: Emergency Relay (N) Between (9) and Ground: Battery Relay



26 to 30 V 13 to 15 V 26 to 30 V



ON ON ON ON ON ON



Between (9) and Ground: Battery Relay Between (19) and Ground: Radio Between (20) and Ground: Horn Between (21) and Ground: Cigar Lighter Between (22) and Ground: Cab Light Between (23) and Ground: Engine Controller, Main Controller Between (24) and Ground: Main Controller Between (25) and Ground: Switch Panel, Monitor Panel, Monitor Controller



20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V



ON ON



T5-7-9



20 to 25 V 20 to 25 V



TROUBLESHOOTING / Electrical System Inspection



Engine Stop Solenoid



17



Emergency Relay Key Switch



18



1



2



3



4



5



6



8



Battery



9



10 11 12



Starter



14



Battery Relay



13



Starter Relay



Each Component Power Source



Alternator



19 15



20 21 22



23 24



Each Component Power Source



25



Switch Panel (ACC), Monitor Panel (ACC), Monitor Controller Power Source Main Controller Power Source (SOL) Engine Controller (MB), Main Controller (ACC)



16



7



Glow Plug Relay Current Sensor Glow Timer



Glow Plug T326-05-07-001



T5-7-10



TROUBLESHOOTING / Electrical System Inspection CONTINUITY CHECK Harness



Single-line continuity check Disconnect both end connectors of the harness and check continuity between both ends: If the ohm-meter reading is: 0 Ω = Continuity ∞ Ω = Discontinuity NOTE: When the one end connector is far apart from the other, connect one end of connector (A) to the vehicle frame using a clip. Then, check continuity of the harness through the vehicle frame as illustrated.



A



Ω



Connect to the vehicle frame.



Ω



Single-line short-circuit check Disconnect both end connectors of the harness and check continuity between one end connector of the harness and the vehicle frame: If the ohm-meter reading is: 0 Ω = Short circuit is present. ∞ Ω = No short circuit is present. Multi-line continuity check Disconnect both end connectors of the harness, and short-circuit two terminals, (A) and (B), at one end connector, as illustrated. Then, check continuity between terminals (a) and (b) at the other connector. If the ohm-meter reading is ∞ Ω, either line (A) - (a), or (B) - (b) is in discontinuity. To find out which line is discontinued, conduct the single line continuity check on both lines individually, or, after changing the short-circuit terminals from (A) - (B) to (A) - (C), check continuity once more between terminals (a) and (c). NOTE: By conducting the multi-line continuity check twice, it is possible to find out which line is discontinued. With terminals (A) and (C) short-circuited, check continuity between terminals (a) and (c). If the ohm-meter reading is: 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 check continuity between terminals (A) and (B) or (C). If the ohm-meter reading is: 0 Ω = Short-circuit exists between the lines. ∞ Ω = No short-circuit exists between the lines.



T5-7-11



a



A



Connect to the vehicle frame.



If the ohm-meter reading is: 0 Ω = Continuity ∞ Ω = Discontinuity



a



a



A ×



Short-circuit between the harness and the vehicle frame



Ω



T107-07-05-003



First short-circuit



A B C



a b c



Second short-circuit



Ω



T107-07-05-004



Short-circuit between harnesses. A B C



×



a b c



Ω



T107-07-05-005



TROUBLESHOOTING / Electrical System Inspection 5 Voltage Circuit



• Voltage between terminal No.1 and the vehicle frame (ground) With the key switch turned OFF, disconnect the sensor connector. Measure the voltage between terminal No.1 on the machine harness side connector and the vehicle (ground) under the following conditions.



Signal or ground



Power source



Two polarities



2



1



V



• Key switch position: ON • Tester black terminal (negative): Connected to the vehicle (ground)



• Tester red terminal (positive): Connected to terminal No.1



T107-07-05-006



Evaluation: If the measuring voltage is within 5±0.5 volts, the circuit up to terminal No.1 is normal.



Three polarities



Power source Signal Ground 1 2 3



V



• Voltage between terminal No.1 and the ground terminal With the key switch turned OFF, disconnect the sensor connector. Measure the voltage between terminal No.1 on the machine harness side connector and the ground terminal (terminal No.2 for two polarities, or terminal No.3 for three polarities) under the following conditions.



T107-07-05-007



Two polarities 1



2



V



• Key switch position: ON • Tester black terminal (negative): Connected to the ground terminal (terminal No.2 or 3) • Tester red terminal (positive): Connected to terminal No.1



T107-07-05-008



Three polarities 1



Evaluation: If the measuring voltage is within 5±0.5 volts, the circuit up to terminal No.1 or the ground terminal is normal.



2



3



V



T107-07-05-009



T5-7-12



TROUBLESHOOTING / Electrical System Inspection CIRCUIT CHECK Connect the lamp harness kit between connectors. Then, check if the circuit is normal or abnormal depending on whether the lamp comes ON or goes OFF during operation. Parts Number 4283594 (ST 7126) Use when checking the continuity (discontinuity or voltage) of a single wire.



To check point.



During Operation: Lamp comes ON.



To ground. T107-07-05-012



Parts Number 4283594 (ST 7126)



Parts Number 4274587 (ST 7123) Use when checking solenoid valves. • Solenoid Valves SA, SB, SH, and SD When operating the corresponding control lever and/or switch: Lamp comes ON • Solenoid Valve SE When traveling in the fast mode: Lamp comes ON.



4 3 1



50



150



2



50



50



2



1 T107-07-05-012



Parts Number 4274587 (ST 7123)



Parts Number 4274589 (ST 7125) Use when checking the EC motor circuit.



• EC Motor Circuit When the accelerator grip or lever is operated: When both side lamps come ON: Normal If only one side lamp comes ON: Check for continuity in the lamp extinguish circuit. If both lamps Stay OFF: Check the harness including the relay.



5 6 50 1



2



3



4



150



Parts Number 4284347 (ST 7129) Use when measuring the signal cable voltage (between terminal No.2 and 3) in the EC sensor circuit.



50 50



2



1



4



3



50



7 8



Parts Number 4274589 (ST 7125)



T107-07-06-024



(Red)



(Black)



V



Parts Number 4284347 (ST 7129)



T5-7-13



T107-07-03-009



TROUBLESHOOTING / Electrical System Inspection (Blank)



T5-7-14



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Hitachi Construction Machinery Co. Ltd



Hitachi Ref. No.



Attn: Publications, Marketing & Product Support Fax: 81-298-31-1162



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THE ATTACHED DIAGRAM LIST (The following diagrams are attached to this manual.) CX550-C/700-C ELECTRICAL CIRCUIT DIAGRAM (LEVER PATTERN; JOY-STICK LEVER) CX500-C/550-C/700-C ELECTRICAL CIRCUIT DIAGRAM (LEVER PATTERN; BI-DIRECTIONAL CONTROL LEVER) CX550-C HYDRAULIC CIRCUIT DIAGRAM (LEVER PATTERN; JOY-STICK LEVER) CX500-C/550-C HYDRAULIC CIRCUIT DIAGRAM (LEVER PATTERN; BI-DIRECTIONAL CONTROL LEVER) CX700-C HYDRAULIC CIRCUIT DIAGRAM (LEVER PATTERN; JOY-STICK LEVER) CX700-C HYDRAULIC CIRCUIT DIAGRAM (LEVER PATTERN; BI-DIRECTIONAL CONTROL LEVER)