EX2500-6 Technical Man. Troubleshooting [PDF]

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



• 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.): Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd. TEL: 81-29-832-7084 FAX: 81-29-831-1162



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



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



• The Operator’s Manual • The Parts Catalog



MANUAL COMPOSITION • This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual. • Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.



• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures. • Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/disassemble procedures.



PAGE NUMBER • Each page has a number, located on the center lower part of the page, and each number contains the following information: Example : T 1-3-5 Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual



W: Workshop Manual



IN-01



INTRODUCTION SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and 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:



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.



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



2



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



this manual. MKSA 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



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 • These are the SAFETY ALERT SYMBOLS. • When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.



• Follow recommended precautions and safe operating practices.



SA-688 001-E01A-0001



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-E01A-1223



SA-1



SA-1223



SAFETY FOLLOW SAFETY INSTRUCTIONS • Carefully read and follow all safety signs on the machine and all safety messages in the operator’s 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.



SA-434 006-E01A-0434



INSPECT MACHINE • Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury.



• In the walk-around inspection, be sure to cover all points described in the “PRE-START INSPECTION” chapter in the operator’s manual.



007-E01A-0435



SA-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.



• Do not leave parts and/or tools lying around the operator’s seat. Store them in their specified locations.



• Avoid storing transparent bottles in the cab. Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire.



• Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine.



• Keep all flammable objects and/or explosives away from the machine.



• After using the ashtray, always cover it to extinguish the match and/or tobacco.



• Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode.



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 handholds. • 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.



009-E01A-0378



SA-5



SA-378



SAFETY FASTEN YOUR SEAT BELT • 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.



SA-237



• We recommend that the seat belt be replaced every three years regardless of its apparent condition. 010-E01A-0237



MOVE AND OPERATE MACHINE SAFELY • Bystanders can be run over. • Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine.



• Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move.



• Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the machine.



SA-426



011-E01A-0426



HANDLE STARTING AIDS SAFELY Starting fluid:



• Starting fluid is highly flammable. • Keep all sparks and flame away when using it. • Keep starting fluid well away from batteries and cables.



• Remove container from machine if engine does not need starting fluid.



• To prevent accidental discharge when storing a pressurized container, keep the cap on the container, and store it in a cool, well-protected location.



• Do not incinerate or puncture a starting fluid container. 036-E01A-0293-3



SA-6



SA-293



SAFETY OPERATE ONLY FROM OPERATOR’S SEAT • Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.



• Start the engine only from 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 lev-



SA-444



ers are in neutral. 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.



SA-032



• Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine.



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 allow the operator on the machine. Keep riders off.



• Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.



SA-379 014-E01B-0379



SA-7



SAFETY INVESTIGATE JOB SITE BEFOREHAND • When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death.



• Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.



• Make a work plan. Use machines appropriate to the work and job site.



• Reinforce ground, edges, and road shoulders as nec-



SA-380



essary. Keep the machine well back from the edges of excavations and road shoulders.



• When working on an incline or on a road shoulder, employ a signal person as required.



• Confirm that your machine is equipped a FOPS cab before working in areas where the possibility of falling stones or debris exist.



• When the footing is weak, reinforce the ground before starting work.



• When working on frozen ground, be extremely alert. As ambient temperatures rise, footing becomes loose and slippery.



• Beware the possibility of fire when operating the machine near flammable objects such as dry grass. 015-E01A-0380



PROTECT AGAINST FALLING STONES AND DEBRIS • Confirm that your machine is FOPS cab equipped before working in areas where the possibility of falling stones or debris exist.



SA-490 015-E01A-0380



SA-8



SAFETY PROVIDE SIGNALS FOR JOBS 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 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. SA-491 017-E01A-0491



SA-9



SAFETY DRIVE MACHINE SAFELY • Before driving the machine, always confirm that the travel levers/pedals direction corresponds to the direction you wish to drive.



• Be sure to detour around any obstructions. • Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine. Do not allow personnel to stay around the machine while traveling. SA-387



• Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death.



• When driving up or down a slope, keep the bucket facing the direction of travel, approximately 0.5 to 1.0 m (A) above the ground.



• If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.



SA-388



SA-441



• Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover. If the direction must be changed, move the machine to level ground, then, change the direction to ensure sage operation.



SA-589



019-E01C-0492



SA-10



SAFETY AVOID INJURY FROM ROLLAWAY ACCIDENTS • Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways: • Select level ground when possible to park machine.



• Do not park the machine on a grade. • Lower the bucket and/or other work tools to the ground.



• Turn the auto-idle switch and the H/P mode switch off.



SA-391



• Run the engine at slow idle speed without load for 5 minutes to cool down the engine.



• Stop the engine and remove the key from the key switch.



• Pull the pilot control shut-off lever to LOCK position. • Block both tracks and lower the bucket to the ground. Thrust the bucket teeth into the ground if you must park on a grade.



• Position the machine to prevent rolling. • Park a reasonable distance from other machines. SA-392 020-E02A-0493



SA-11



SAFETY AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS • If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: • Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR.



• Keep the travel alarm in working condition (if equipped). ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE.



SA-383



• 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. 021-E01A-0494



SA-12



SA-384



SAFETY KEEP PERSON CLEAR FROM WORKING AREA • A person may be hit severely by the swinging front attachment or counterweight and/or may be crushed against an other object, resulting in serious injury or death.



• Keep all persons clear from the area of operation and machine movement.



• Before operating the machine, set up barriers to the sides and rear area of the bucket swing radius to prevent anyone from entering the work area.



SA-386 022-E01A-0386



NEVER POSITION BUCKET OVER ANYONE • Never lift, move, or swing bucket above anyone or a truck cab. Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket.



023-E01A-0487



SA-487



AVOID UNDERCUTTING • In order to retreat from the edge of an excavation if the footing should collapse, always position the undercarriage perpendicular to the edge of the excavation with the travel motors at the rear.



• If the footing starts to collapse and if retreat is not possible, do not panic. Often, the machine can be secured by lowering the front attachment, in such cases.



024-E01A-0488



SA-13



SA-488



SAFETY AVOID TIPPING DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE --- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT



• The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death. To avoid tipping:



SA-012



• Be extra careful before operating on a grade. • Prepare machine operating area flat. • Keep the bucket low to the ground and close to the machine.



• Reduce operating speeds to avoid tipping or slipping. • Avoid changing direction when traveling on grades. • NEVER attempt to travel across a grade steeper than 15 degrees if crossing the grade is unavoidable.



• Reduce swing speed as necessary when swinging loads.



SA-440



• Be careful when working on frozen ground. • Temperature increases will cause the ground to become soft and make ground travel unstable. 025-E01B-0495



NEVER UNDERCUT A HIGH BANK • The edges could collapse or a land slide could occur causing serious injury or death.



SA-489 026-E01A-0489



SA-14



SAFETY DIG WITH CAUTION • Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death.



• Before digging check the location of cables, gas lines, and water lines.



• Keep the minimum distance required, by law, from cables, gas lines, and water lines.



• If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury.



SA-382



• Contact your local “diggers hot line” if available in your area , and/or the utility companies directly. Have them mark all underground utilities. 027-E01A-0382



OPERATE WITH CAUTION • If the front attachment or any other part of the machine hits against an overhead obstacle, such as a bridge, both the machine and the overhead obstacle will be damaged, and personal injury may result as well.



• Take care to avoid hitting overhead obstacles with the boom or arm.



028-E01A-0389



SA-389



AVOID POWER LINES • Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines.



• When operating near an electric line, NEVER move any part of the machine or load closer than 3 m plus twice the line insulator length.



• Check and comply with any local regulations that may apply.



• Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site. SA-381 029-E01A-0381



SA-15



SAFETY OBJECT HANDLING • If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death.



• When using the machine for craning operations, be sure to comply with all local regulations.



• Do not use damaged chains or frayed cables, sables, slings, or ropes.



• Before craning, position the upperstructure with the travel motors at the rear.



SA-014



• Move the load slowly and carefully. Never move it suddenly.



• Keep all persons will away from the load. • Never move a load over a person’s head. • Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground.



• Never attach a sling or chain to the bucket teeth. They may come off, causing the load to fall.



030-E01A-0014



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-16



SA-432



SAFETY PARK MACHINE SAFELY To avoid accidents: • Park machine on a level surface.



• Lower bucket to the ground. • Turn auto-idle switch and H/P mode switch off. • Run engine at slow idle speed without load for 5 minutes.



• Turn key switch to OFF to stop engine. • Remove the key from the key switch. • Pull the pilot control shut-off lever to the LOCK posi-



SA-390



tion.



• Close windows, roof vent, and cab door. • Lock all access doors and compartments.



033-E08B-0390



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 flammable.



SA-018



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



• Securely tighten the fuel and oil filler cap.



SA-019 034-E01A-0496



SA-17



SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents: • Understand service procedures before doing work.



• Keep the work area clean and dry. • Do not spray water or steam inside cab. • Never lubricate or service the machine while it is moving.



• Keep hands, feet and clothing away from power-driven parts. Before servicing the machine: 1. Park the machine on a level surface. SA-028



2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. 4. Run the engine at slow idle speed without load for 5 minutes. 5. Turn the key switch to OFF to stop engine. 6. Relieve the pressure in the hydraulic system by moving the control levers several times. 7. Remove the key from the switch. 8. Attach a “Do Not Operate” tag on the control lever. 9. Pull the pilot control shut-off lever to the LOCK position. 10. Allow the engine to cool.



• If a maintenance procedure must be performed with the engine running, do not leave machine unattended.



• If the machine must be raised, maintain a 90 to 110° angle between the boom and arm. Securely support any machine elements that must be raised for service work.



• Never work under a machine raised by the boom. • 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.



• When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces.



• Disconnect battery ground cable (–) before making adjustments to electrical systems or before performing welding on the machine. 500-E02B-0497



SA-18



SA-527



SAFETY • Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine.



• Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.



SA-037



WARN OTHERS OF SERVICE WORK • Unexpected machine movement can cause serious injury.



• Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever. This tag is available from your authorized dealer.



501-E01A-0287 SA-287



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-026



SA-19



SAFETY 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.



SA-344



• 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



STORE ATTACHMENTS SAFELY • Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death.



• Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas.



504-E01A-0034



SA-20



SA-034



SAFETY PREVENT BURNS Hot spraying fluids:



• After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns.



• To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap.



SA-039



• The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap. Hot fluids and surfaces:



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



• Wait for the oil and components to cool before starting



SA-225



any maintenance or inspection work. 505-E01B-0498



REPLACE RUBBER HOSES PERIODICALLY • Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.



• Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” in the operator’s manual).



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



SA-21



SA-019



SAFETY AVOID HIGH-PRESSURE FLUIDS • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death.



• Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.



• Tighten all connections before applying pressure. • Search for leaks with a piece of cardboard; take care



SA-031



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-292



507-E03A-0499



SA-22



SA-044



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.



SA-019



• 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 each shift or after eight (8) to ten (10) hours operation for loose, kinked, hardened or frayed electrical cables and wires.



• Check before each shift or after eight (8) to ten (10) hours operation for missing or damaged terminal caps.



• DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.. Clean up Flammables: • Spilled fuel, oil, antifreeze fluid and window washer fluid, 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 fire breaks out, failure to stop the engine will escalate 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.



508-E02B-0019



SA-23



SAFETY Check Emergency Engine Stop Switch:



• If a fire breaks out, failure to release pressurized air inside the hydraulic tank will escalate fire, hampering fire fighting. • Check the emergency engine stop switch function every 250 hours: 1)



Start the engine and run it at slow Idle.



2)



Turn the emergency engine stop switch to the EMERG. STOP position.



3)



Confirm that both engines stop and that pressurized air inside the hydraulic oil tank is released (a hissing sound should be heard).



• If any abnormalities are found, be sure to repair them before operating the machine. Check Heat Shields:



• Damaged or missing heat shield may lead to fires. • Damaged or missing heat shields must be repaired or replaced before operating the machine. 508-E02A-0393



EVACUATING IN CASE OF FIRE • If a fire breaks out, evacuate the machine in the following way:



• Stop the engine by turning the key switch to the OFF position if there is time.



• Use a fire extinguisher if there is time. • Exit the machine. • In an emergency, if the cab door or front window cannot be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab. Refer the explanation pages on the Emergency Evacuation Method in the operator’s manual.



SA-393



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 PRECAUTIONS FOR WELDING AND GRINDING • Welding may generate gas and/or small fires. • Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding.



• Only qualified personnel should perform welding. Never allow an unqualified person to perform welding.



• Grinding on the machine may create fire hazards. Store flammable objects in a safe place before starting grinding. • After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.



SA-818



523-E01A-0818



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.



SA-029



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. 511-E01A-0029



BEWARE OF ASBESTOS DUST • Take care not to inhale dust produced in the work site. Inhalation of asbestos fibers may be the cause of lung cancer. • Depending on the wok site conditions, the risk of inhaling asbestos fiber may exist. Spray water to prevent asbestos from becoming airborne. Do not use compressed air.



• When operating the machine in a work site where asbestos might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos.



• Keep bystanders out of the work site during operation. • Asbestos might be present in imitation parts. Use only genuine Hitachi Parts.



SA-26



SA-029



SAFETY 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.



SA-032



• 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-E01B-0032



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



SA-27



SAFETY 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.



SA-309



• See your authorized dealer for MSDS’s (available only in English) on chemical products used with your machine. 515-E01A-0309



DISPOSE OF WASTE PROPERLY • Improperly disposing of waste can threaten the 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, or from your authorized dealer.



516-E01A-0226



SA-28



SA-226



SAFETY 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



SA-435 S517-E01A-0435



SA-29



SAFETY (Blank)



SA-30



SECTION AND GROUP CONTENTS



SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Excavator Test Group 5 Component Test



TECHNICAL MANUAL SECTION 5 TROUBLESHOOTING Group 1 General (Troubleshooting) Group 2 Cross Reference Table Group 3 Component Layout Group 4 Troubleshooting A Group 5 Troubleshooting B Group 6 Troubleshooting C Group 7 Electrical System Inspection



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)2007 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved



TECHNICAL MANUAL (Operational Principle) SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION Group 1 Specifications Group 1 Pump Device Group 2 Component Layout Group 2 Swing Device Group 3 Component Specifications Group 3 Control Valve SECTION 2 SYSTEM Group 4 Control Equipment Group 5 DQR Valve Group 1 Controller Group 6 Travel Device Group 2 Control System Group 7 Others (Upperstructure) Group 3 ELU System Group 8 Others (Undercarriage) Group 4 Hydraulic System Group 5 Electrical System



WORKSHOP MANUAL SECTION 1 GENERAL SECTION 3 UNDERCARRIAGE Group 1 Precautions for DisassemGroup 1 Swing Bearing bling and Assembling Group 2 Travel Device Group 2 Tightening Group 3 Travel Brake Valve Group 3 Painting Group 4 Drive Tumbler Group 4 Bleed Air from Hydraulic Group 5 Center Joint Oil Tank Group 6 Adjuster Cylinder SECTION 2 UPPERSTRUCTURE Group 7 Front Idler Group 8 Upper and Lower Roller Group 1 Cab Group 9 Track Group 2 Counterweight Group 10 Accumulator Group 3 Pump Device Group 11 Welding Repair Procedure Group 4 Control Valve SECTION 4 FRONT ATTACHMENT Group 5 Swing Device Group 6 DQR Valve Group 1 Front Attachment Group 7 Shuttle Valve Group 2 Cylinder Group 8 8-Spool Solenoid Valve Unit Group 3 Bushing and Point Group 9 Oil Cooler Fan Motor Group 10 Compressor Drive Motor Group 11 Air Conditioner Group 12 Lift Cylinder (Fast-Filling/System) Group 13 Lift Cylinder (Sliding Fold-In Ladder)



SECTION 4



OPERATIONAL PERFORMANCE TEST CONTENTS Group 1 Introduction



Group 5 Component Test



Operational Performance Tests ................T4-1-1



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



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



Secondary EHC Valve Pressure ...............T4-5-2 Secondary DQR Valve Pressure ...............T4-5-4



Group 2 Standard



Main Relief Pressure ................................T4-5-6



Operational Performance Standard Table ......................................................T4-2-1 Main Pump P-Q Curve .............................T4-2-6 Main Pump Pi-Q Curve.............................T4-2-8 Oil Cooler Fan Motor Drive Pump P-Q Curve,



Relief Pressure.........................................T4-5-8 Relief Pressure.........................................T4-5-9 Overload Relief Valve Set Pressure ........T4-5-10 Main Pump Flow Rate Measurement ......T4-5-12 Oil Cooler Fan Drive Pump



Oil Cooler Fan Motor Drive Pump Pi-Q Curve .............................................T4-2-9 Electric Lever .........................................T4-2-10



Flow Rate Measurement .......................T4-5-18 Swing Motor Drainage ............................T4-5-24 Travel Motor Drainage ............................T4-5-26



Group 3 Engine Test Engine Speed ...........................................T4-3-1



Group 4 Excavator Test Travel Speed ............................................T4-4-1 Track Revolution Speed ...........................T4-4-2 Mistrack ...................................................T4-4-3 Travel Motor Drift Check...........................T4-4-4 Swing Speed ............................................T4-4-5 Swing Function Drift Check ......................T4-4-6 Swing Motor Leakage ...............................T4-4-8 Maximum Swingable Slant Angle ..............T4-4-9 Swing Bearing Play ................................T4-4-10 Hydraulic Cylinder Cycle Time ................T4-4-12 Dig Function Drift Check ........................T4-4-14 Control Lever Operating Force ...............T4-4-15 Control Lever Stroke...............................T4-4-16 Boom Raise/Swing Combined Operation Check ..................................T4-4-17



18LT-4-1



(Blank)



18LT-4-2



OPERATIONAL PERFORMANCE TEST / Introduction OPERATIONAL PERFORMANCE TEST Use operational performance test procedure to quantitatively check all system and functions on the machine. Purpose of Performance Tests 1. To comprehensively evaluate each operational function by comparing the performance test data with the standard values. 2. According to the evaluation results, repair, adjust, or replace parts or components as necessary to restore the machine’s performance to the desired standard. 3. To economically operate the machine under optimal conditions. Kinds of Tests 1. Base machine performance test is to check the operational performance of each system such as engine, travel, swing, and hydraulic cylinders. 2. Hydraulic component unit test is to check the operational performance of each component such as hydraulic pump, motor, and various kinds of valves. Performance Standards “Performance Standard” is shown in tables to evaluate the performance test data. Precautions for Evaluation of Test Data 1. To evaluate not only that the test data are correct, but also in what range the test data are. 2. Be sure to evaluate the test data based on the machine operation hours, kinds and state of work loads, and machine maintenance conditions. The machine performance does not always deteriorate as the working hours increase. However, the machine performance is normally considered to reduce in proportion to the increase of the operation hours. Accordingly, restoring the machine performance by repair, adjustment, or replacement shall consider the number of the machine’s working hours. Definition of “Performance Standard” 1. Operation speed values and dimensions of the new machine. 2. Operational performance of new components adjusted to specifications. Allowable errors will be indicated as necessary.



T4-1-1



OPERATIONAL PERFORMANCE TEST / Introduction PREPARATION TESTS



FOR



PERFORMANCE



Observe the following rules in order to carry out performance tests accurately and safely. THE MACHINE 1. Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test. TEST AREA AND MEASURING EQUIPMENT 1. Select a hard and flat surface. 2. Secure enough space to allow the machine to run straight more than 20 m (65 ft 7 in), and to make a full swing with the front attachment extended. 3. If required, rope off the test area and provide signboards to keep unauthorized personnel away. 4. Prepare measuring instruments and apparatus suitable to test requirements. 5. Arrange a test weight or an equivalent heavy material. T105-06-01-003



PRECAUTIONS 1. Before starting to test, agree upon the signals to be employed for communication among coworkers. Once the test is started, be sure to communicate with each other using these signals, and to follow them without fail. 2. Operate the machine carefully and always give first priority to safety. 3. While testing, always take care to avoid accidents due to landslides or contact with high-voltage power lines. Always confirm that there is sufficient space for full swings. 4. Avoid polluting the machine and the ground with leaking oil. Use oil pans to catch escaping oil. Pay special attention to this when removing hydraulic pipings. MAKE 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 produced repeatedly. Use mean values of measurements if necessary.



T4-1-2



T105-06-01-004



OPERATIONAL PERFORMANCE TEST / Standard OPERATIONAL DARD TABLE



PERFORMANCE



STAN-



The standard performance values are listed in the table below. Refer to the Groups 3 to 5 for performance test procedures. Values indicated in parentheses are reference values.



The standard measurement conditions are as follows. • Engine Control Lever: Fast Idle Position • Hydraulic Oil Temperature: 50±5 °C (122±9 °F)



The following switch positions shall be selected and the hydraulic oil temperature shall be maintained as indicated below as the preconditions of performance tests unless otherwise instructed in each performance test procedure: Performance Standard



Performance Test Designation



ENGINE SPEED



(min-1)



Fast Idle Speed Slow Idle Speed Auto-Idle Speed



TRAVEL SPEED



T4-4-1



(sec/20 m)



31 45 T4-4-2



(sec/3 rev)



Fast Speed Mode Slow Speed Mode



MISTRACK



77±4 109±5 (mm/20 m)



(With fast and slow travel speed modes)



TRAVEL MOTOR DRIFT CHECK (mm/5 min) SWING SPEED (sec/3 rev) SWING FUNCTION DRIFT CHECK (mm/180) SWING MOTOR LEAKAGE



100 or less



T4-4-3



0 44±5 740 or less



T4-4-4 T4-4-5 T4-4-6



0



T4-4-8



20 or possibly more



T4-4-9



0.5 or less



T4-4-10



(mm/5 min)



MAXIMUM SWINGABLE SLANT ANGLE (deg.)



SWING BEARING PLAY



Reference Page T4-3-1



2050±50 780±50 1400±50



Fast Speed Mode Slow Speed Mode



TRACK REVOLUTION SPEED



Remarks



(mm)



NOTE: BH : Backhoe (9.0 m Boom, 4.2 m Arm, 3 15.0 m (PCSA heaped) Bucket) LD : Loading Shovel



T4-2-1



OPERATIONAL PERFORMANCE TEST / Standard



Performance Standard



Performance Test Designation



HYDRAULIC CYLINDER CYCLE TIME



(sec)



Backhoe Boom Raise Boom Lower Arm Roll-In Arm Roll-Out Bucket Roll-In Bucket Roll-Out Loading Shovel Boom Raise Boom Lower Arm Extend Arm Retract Bucket Tilt-In Bucket Tilt-Out Bucket Open Bucket Close



DIG FUNCTION DRIFT CHECK Backhoe Boom Cylinder Arm Cylinder Bucket Cylinder Bucket Bottom Loading Shovel Boom Cylinder Arm Cylinder Bucket Cylinder Bucket Bottom



Remarks



Reference Page T4-4-12



7.7±0.7 4.7±0.5 7.1±0.5 6.3±0.5 4.7±0.5 3.6±0.5 8.2±0.7 5.0±0.5 3.4±0.5 4.2±0.5 4.0±0.5 2.9±0.5 2.1±0.4 2.5±0.4 T4-4-14



(mm/5 min)



30 or less 60 or less 20 or less 390 or less 25 or less 25 or less 20 or less 300 or less



T4-2-2



OPERATIONAL PERFORMANCE TEST / Standard



Performance Standard



Performance Test



Remarks



CONTROL LEVER OPERATING FORCE (ISO Control Pattern) N (kgf) Boom Lever (Raise / Lower) Arm Lever (Extend / Retract) (HITACHI Control Pattern: Swing Lever (Right / Left)) Bucket Lever (Tilt-in / Tilt-out) Swing Lever (Right / Left) (HITACHI Control Pattern: Arm Lever (Extend / Retract)) Travel Lever



T4-4-15 6.1 to 7.6 (0.6 to 0.8) 5.1 to 6.4 (0.5 to 0.7) 5.1 to 6.4 (0.5 to 0.7) 6.1 to 7.6 (0.6 to 0.8) 5.2 to 6.5 (0.5 to 0.7) 5.9 to 7.4 (0.6 to 0.8) 5.2 to 6.5 (0.5 to 0.7) 5.9 to 7.4 (0.6 to 0.8) 21.6 to 26.3 (2.2 to 2.7) 82 to 100 (8.4 to 10.2)



Bucket Open/Close Pedal



CONTROL LEVER STROKE (ISO Control Pattern)



T4-4-16



mm



Boom Lever Arm Lever (HITACHI Control Pattern: Swing Lever) Bucket Lever Swing Lever (HITACHI Control Pattern: Arm Lever) Travel Lever Bucket Open/Close Pedal



90±10 90±10 90±10 90±10



BOOM RAISE AND SWING COMBINED OPERATION CHECK Time (LD) Time (BH) Bucket Clearance H (LD) Bucket Clearance H (BH)



Reference Page



sec/90° sec/90° mm mm



NOTE: LD: Loading Shovel BH: Backhoe



T4-2-3



110±10 25±5 Bucket: Empty 5.6 5.2 4600 or more 5600 or more



T4-4-17



OPERATIONAL PERFORMANCE TEST / Standard



Performance Standard



Performance Test HYDRAULIC SYSTEM



PRIMARY PILOT PRESSURE



Remarks



MPa (kgf/cm2, psi)



T4-5-1



MPa (kgf/cm2, psi)



Fast Idle



4.4±0.5 (45±5, 640±71) 3.5 (35, 498) or more



Slow Idle



SECONDARY EHC VALVE PRESSURE



T4-5-2



MPa (kgf/cm2, psi)



Fast Idle



4.4±0.5 (45±5, 640±71) 3.5 (35, 498) or more



Slow Idle



SECONDARY DQR VALUE PRESSURE



With Lever Full Stroke With Lever Full Stroke T4-5-4



MPa (kgf/cm2, psi)



Fast Idle Slow Idle



MAIN PUMP DELIVERY PRESSURE MPa (kgf/cm2, psi)



MAIN RELIEF PRESSURE



MPa (kgf/cm2, psi)



Boom, Arm, Bucket, and Bucket Open Circuit Relief Pressure Bucket Close Circuit Relief Pressure



RELIEF PRESSURE



MPa (kgf/cm2, psi)



(When relieving travel)



RELIEF PRESSURE



MPa (kgf/cm2, psi)



(When relieving swing)



OVERLOAD RELIEF VALVE SET PRESSURE MPa (kgf/cm2, psi) Boom, Arm, Bucket, and Bucket Open Circuit Relief Pressure Bucket Close Circuit Relief Pressure



MAIN PUMP FLOW RATE MEASUREMENT



4.3±0.5 (43±5, 619±71) 3.3 (32, 455) or more 29.4±1.0 (300±10, 4266±142) 29.4+1.5−0 +20 (300 −0, 4266+213−0) 16.7+1.5−0 +15 (170 −0, 2417+213−0) 29.4+2.5−0 +25 (300 −0, 4266+360−0) 27.4+2.0−0 +20 (280 −0, 3980+284−0)



With Lever Full Stroke With Lever Full Stroke



T4-5-6



T4-5-10 31.4+1.0−0 +10 (320 −0, 4550+142−0) 16.7+1.0−0 +10 (170 −0, 2417+142−0)



L/min



OIL COOLER FAN DRIVE PUMP FLOW RATE MEASUREMENT L/min SWING MOTOR DRAINAGE L/min (at Constant Swing Speed)



TRAVEL MOTOR DRAINAGE



Reference Page



−



T4-5-12



−



T4-5-18



2.9 or less



T4-5-24



28 or less



T4-5-26



L/min



(While rotating at slow speed with the undercarriage raised off the ground.)



T4-2-4



OPERATIONAL PERFORMANCE TEST / Standard (Blank)



T4-2-5



OPERATIONAL PERFORMANCE TEST / Standard MAIN PUMP P-Q CURVE



EX 2500-5/6 e EX 5500-5/6



• Hydraulic P-Q Control



PN: (YA00003081) 4455484 -1



• Rated Pump Speed: 1547 min (rpm) • Pump Gear Reduction Ratio: 0.86 • Hydraulic Oil Temperature: 50±5 °C (122±9 °F)



Main Pump (1 to 4) P-Q Curve (Power Increase) P (Delivery Pressure) Q (Flow Rate) 2 MPa (kgf/cm , psi) L/min (gpm) G 24.5 (250, 3560) 307 (81.0) H 29.4 (300, 4270) 247 (65.2)



NOTE: Refer to T4-5-12.



Main Pump (1 and 3) P-Q Curve (Power Decrease) P (Delivery Pressure) Q (Flow Rate) 2 MPa (kgf/cm , psi) L/min (gpm) I 9.8 (100, 1420) 363 (95.8) J 14.7 (150, 2140) 281 (74.1) K 19.6 (200, 2850) 231 (61.0) L 24.5 (250, 3560) 181 (47.8) M 29.4 (300, 4270) 130 (34.3)



Main Pump (1 to 4) P-Q Curve (Standard) P (Delivery Pressure) Q (Flow Rate) 2 MPa (kgf/cm , psi) L/min (gpm) A 4.9 (50, 710) 376 (99.2) B 9.8 (100, 1420) 369 (97.4) C 14.7 (150, 2140) 362 (95.5) D 19.6 (200, 2850) 339 (89.4) E 24.5 (250, 3560) 264 (69.7) F 29.4 (300, 4270) 213 (56.2)



Q (Flow Rate) L/min



A



B



C



I



D G E



J



H



K L



F



M



(kgf/cm 2 ) MPa P (Delivery Pressure)



T4-2-6



T18L-04-02-001



OPERATIONAL PERFORMANCE TEST / Standard Main Pump (5 to 6) P-Q Curve (Power Increase) P (Delivery Pressure) Q (Flow Rate) 2 MPa (kgf/cm , psi) L/min (gpm) G 24.5 (250, 3560) 308 (81.3) H 29.4 (300, 4270) 247 (65.2)



Main Pump (5 to 6) P-Q Curve (Standard) P (Delivery Pressure) Q (Flow Rate) 2 MPa (kgf/cm , psi) L/min (gpm) A 4.9 (50, 710) 426 (112.4) B 9.8 (100, 1420) 420 (110.8) C 14.7 (150, 2140) 414 (109.2) D 19.6 (200, 2850) 339 (89.4) E 24.5 (250, 3560) 264 (69.7) F 29.4 (300, 4270) 213 (56.2)



Main Pump (5) P-Q Curve (Power Decrease) P (Delivery Pressure) Q (Flow Rate) 2 MPa (kgf/cm , psi) L/min (gpm) I 9.8 (100, 1420) 363 (95.8) J 14.7 (150, 2140) 281 (74.1) K 19.6 (200, 2850) 231 (61.0) L 24.5 (250, 3560) 170 (44.9) M 29.4 (300, 4270) 130 (34.3)



PN: (YA00003082 ) 4455485



Q (Flow Rate) L/min A



B



C



I



D G E



J



H



K L



F



M



(kgf/cm 2 ) MPa P (Delivery Pressure)



T4-2-7



T18L-04-02-002



OPERATIONAL PERFORMANCE TEST / Standard MAIN PUMP Pi-Q CURVE • Hydraulic Pi-Q Control • Rated Pump Speed: 1547 min-1 (rpm) • Pump Gear Reduction Ratio: 0.86 • Hydraulic Oil Temperature: 50±5 °C (122±9 °F) NOTE: Refer to T4-5-14.



Pi-Q Curve Flow Rate Control Pressure 2 MPa (kgf/cm , psi) 1.3 A (13.4, 190) 2.6 B (27, 380) 2.9 B’ (29.5, 420)



Flow Rate L/min (gpm)



Remarks



100 (26.4) 375 L/min (98.9) 425 L/min (112.1)



Main Pump 1 to 6 Main Pump 1 to 4 Main Pump 5 and 6



Q (Flow Rate) L/min B’



400



B



300 200 A



100 0



10



20



30



Pi (Flow Rate Control Pressure) kgf/cm 2



T4-2-8



OPERATIONAL PERFORMANCE TEST / Standard FAN MOTOR DRIVE PUMP P-Q CURVE



FAN MOTOR DRIVE PUMP Pi-Q CURVE



• Hydraulic P-Q Control



• Hydraulic Pi-Q Control



• Rated Pump Speed: 2232 min-1 (rpm) • Pump Gear Reduction Ratio: 1.089 • Hydraulic Oil Temperature: 50±5 °C (122±9 °F)



• Rated Pump Speed: 2232 min-1 (rpm) • Pump Gear Reduction Ratio: 1.089 • Hydraulic Oil Temperature: 50±5 °C (122±9 °F)



NOTE: Refer to T4-5-20.



NOTE: Refer to T4-5-22.



Oil Cooler Fan Drive Pump P-Q Curve P (Delivery Pressure) Q (Flow Rate) 2 MPa (kgf/cm , psi) L/min (gpm) A 18.4 (188, 2670) 196 (51.7) B 20.6 (210, 2990) 173 (45.6)



Fan Motor Drive Pump Pi-Q Curve P (Delivery Pressure) Q (Flow Rate) 2 MPa (kgf/cm , psi) L/min (gpm) A 0.9±0.2 (9±2, 130±29) 25±3 (6.6±0.8) 2.46±0.2 B 202±5 (53.3±1.3) (25±2, 360±29)



Q (Flow Rate) L/min



Q (Flow Rate) L/min B



200



300



150 100



A



200



50



A



B 0



20



30



kgf/cm 2



Pi (Flow Rate Control Pressure)



100



0



10



100



200



P (Delivery Pressure)



300



kgf/cm 2 T118-04-04-012



T4-2-9



OPERATIONAL PERFORMANCE TEST / Standard ELECTRIC LEVER When moving the electric lever, command current is sent from the controller to ELU according to lever stroke. Boom, Arm, Bucket, Swing 15 to 20°



15 to 20° -



-



Y



+



+



Controller



X



To ELU



Travel, Bucket Open/Close



12.4°±1°



T18G-03-04-001



12.4°±1°



Controller



To ELU T18G-03-04-002



T4-2-10



OPERATIONAL PERFORMANCE TEST / Standard Boom, Arm, Bucket, Swing



Short Zone About 3°



Output Voltage Ratio



90%±2%



50%±1.5%



10%±2%



Center ±15° to ±20° Mechanical Control Angle 2 (Red)



1 (Yellow) Short Zone Resistor for Calibration



4 (White) 30°±5°



3 (Green) Short Zone Resistor for Calibration



Electrical Turning Angle Total Resistance 2 kΩ±15% + Direction on XY Axis



T4-2-11



T18G-03-04-003



OPERATIONAL PERFORMANCE TEST / Standard Travel (Control Curve: 25±5°C) Control Torque



Output Voltage



N⋅m 16.0 15.3±2.3



v



100



12.0



Output Voltage Ratio



8.0 6.5±1.0



0



V OUT



80±7.5 50±5 20±7.5



12.4±1



0



12.4±1 deg



4.0 0



T18M-03-04-004



Neutral Switch Voltage 12.4±1



0



12.4±1 deg T18M-03-04-003



deg T18G-03-04-006



Bucket Open/Close (Control Curve: 25±5°C) Output Voltage



Control Torque N⋅m



v



100



V OUT



16.0 Output Voltage Ratio



12.0



50±5 20±7.5



9.3±1.4 8.0



0



12.4±1



0



12.4±1 deg T18M-03-04-004



4.0 3.9±0.6 0



80±7.5



Neutral Switch Voltage 12.4±1



0



12.4±1 deg T18L-03-04-001



deg T18G-03-04-006



T4-2-12



OPERATIONAL PERFORMANCE TEST / Engine Test ENGINE SPEED Performance Test Conditions: • Hydraulic Oil Temperature: 50±9 °C (122±9 °F) • Ground Conditions: Solid, level ground



Engine Speed Sensor



Measurement: 1. Turn the key switch to the OFF position to stop the engine. 2. Disconnect the engine speed sensor connector (Lower side: For EC and MC). Connect the pulse counter harness to engine speed sensor harness. 3. Start the engine, run it at the specified speeds, and read the pulse counter. Calculate the engine speed using the following formula: -1



Engine speed (min ) = Pulse Number×60/142 Evaluation: Refer to T4-2 Operational Performance Standard Table.



T4-3-1



T141-04-02-001



OPERATIONAL PERFORMANCE TEST / Engine Test (Blank)



T4-3-2



OPERATIONAL PERFORMANCE TEST / Excavator Test TRAVEL SPEED Summary: 1. Check the overall operational performance of the travel power system (between the hydraulic pumps and travel motors) by measuring time required for the machine to travel the specified distance. Preparation: 1. Equally adjust the track sag on both right and left undercarriages. Track sag (A): 465 to 535 mm (18 to 21 in) 2. Prepare a flat and firm travel test yard 20 m (65.5 ft) long with fringes 3 to 5 m (9.8 to 16.0 ft) on both ends for machine acceleration and deceleration. 3. Empty the bucket and roll in the arm. 4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



Track Frame Bottom A Track Shoe Back Ftace



T145-05-03-001



Backhoe



Deceleration Zone: 3 to 5 m (9.8 to 16.0 ft)



Finish



Travel Test Distance: 20.0 m (65.5 ft)



Measurement: 1. Measure travel time at both fast and slow travel speeds. 2. Engine Control Lever: Maximum Position Auto Idle Switch: OFF 3. Start machine to travel from the rear end of the acceleration zone by moving the travel levers full stroke. 4. Measure the time required to travel the travel test distance 20 m (65.5 ft). 5. After measuring the forward travel time, rotate the machine upperstructure 180°. Then, measure the reverse travel time on the way back to the starting position in the same method. 6. Repeat steps 3 to 5 three times and calculate the average values.



Start



Acceleration Zone: 3 to 5 m (9.8 to 16.0 ft)



T142-05-03-001



Remedy: Refer to T5-5 Troubleshooting B.



Loading Shovel



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



T4-4-1



T145-05-03-006



OPERATIONAL PERFORMANCE TEST / Excavator Test TRACK REVOLUTION SPEED Summary: Check the overall operational performance of the travel power system (between the hydraulic pumps and travel motors) by measuring the track revolution cycle time.



90 to 110°



Preparation: 1. Equally adjust the track sag on both right and left undercarriages. Track sag (A): 465 to 535 mm (18 to 21 in) 2. Mark one shoe with chalk or a piece of cloth on the track to be measured. 3. Rotate the upperstructure 90° to the track and lower the bucket to raise the track to be measured off the ground. Keep the boom and arm angle between 90 to 110° as illustrated.



T142-05-03-011



90 to 110°



CAUTION: Never work under a machine raised and solely supported by the boom. Place blocks under the machine frame to support the machine.



T142-05-03-012



4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Measure the track rotation time at both fast and slow travel speeds. 2. Engine Control Lever : Maximum Position Auto Idle Switch: OFF 3. Operate the travel control lever of the raised track in full forward and reverse. 4. After the track revolution attains to constant speed, measure the time required for the marked shoe to rotate three times in both directions. 5. Raise the other side of the track and repeat the procedure. 6. Repeat steps 3 to 5 three times and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard Table. Remedy: Refer to T5-5 Troubleshooting B.



T4-4-2



Track Frame Bottom



Forward Reverse



A Track Shoe Back Ftace



Travel Device



T145-05-03-001



OPERATIONAL PERFORMANCE TEST / Excavator Test MISTRACK Summary: 1. Check the equilibrium in operational performance between the right and left travel power systems (between the hydraulic pumps and travel motors) by measuring the amount of mistrack found while the machine travels for the specified distance. NOTE: When tested on a concrete surface road, the amount of mistrack may be reduced.



T145-05-03-005



Preparation: 1. Equally adjust the track sag on both right and left undercarriages. Track sag : 465 to 535 mm (18 to 21 in) 2. Prepare a flat and firm travel test yard 20 m (65.5 ft) long with fringes 3 to 5 m (9.8 to 16.0 ft) on both ends for machine acceleration and deceleration. 3. Empty the bucket and set the front attachment in the driving position as illustrated. 4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



Measurement: 1. Measure the amount of mistracking in both fast and slow travel speeds. 2. Engine Control Lever: Maximum Position Auto Idle Switch: OFF 3. Start machine to travel from the rear end of the acceleration zone by moving both travel levers full stroke. 4. Draw a 20 m (65.5 ft) straight line from the travel test start point to the end point as illustrated. Measure the maximum distance (A) between the rut and the straight line. 5. Conduct the measurement in both forward and reverse travel operation in the same method. 6. Repeat steps 3 to 5 three times and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard Table. Remedy: Refer to T5-5 Troubleshooting B.



T4-4-3



T145-05-03-006



Deceleration Zone: 3 to 5 m (9.8 to 16.0 ft)



Maximum Distance (A) 20 m (65.5 ft)



Acceleration Zone: 3 to 5 m (9.8 to 16.0 ft) T115-07-03-005



OPERATIONAL PERFORMANCE TEST / Excavator Test TRAVEL MOTOR DRIFT CHECK Summary: The travel motor parking brake function and drift are measured on a specified slope. Preparation: 1. The test slope surface shall be flat with the gradient of 20 % (11.31°) 2. Put a white line mark on the drive tumbler. 3. With the bucket empty, position the front attachment as follows: Backhoe: Hold the bucket 0.5 to 1.0 m (20 to 40 in) above the ground with the arm and bucket fully rolled in. Loading Shovel: With the arm and bucket cylinders fully extended, hold the bucket 0.5 to 1.0 m (20 to 40 in) above the ground. 4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °C). Measurement: 1. Climb the slope and return the travel lever to neutral. 2. Stop the engine. 3. After the machine stops, put alignment marks on the track link or shoe, and the track side frame. 4. After five minutes have passed, measure the difference between the marks on the track link or shoe, and the track side frame. Evaluation: Refer to T4-2 Operational Performance Standard Table.



T4-4-4



0.5 to 1.0 m (20 to 40 in)



T142-05-03-002



0.5 to 1.0 m (20 to 40 in)



T118-04-03-001



Alignment Marks Put on Track Side Frame and Shoe When Machine Difference after 5 Minutes. T105-06-03-006



OPERATIONAL PERFORMANCE TEST / Excavator Test SWING SPEED Summary: 1. Check the overall operational performance of the swing power system (between the hydraulic pumps and swing motors) by measuring time required for the machine upperstructure to make three complete turns. Preparation: 1. Confirm that the swing gears and bearing are sufficiently greased. 2. Secure a space wide enough for the machine upperstructure to swing on a flat and firm surface. Never attempt to perform this test on a slope. 3. Empty the bucket and position the front attachment as described in the following. Backhoe: With the arm cylinders fully retracted and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height. Loading shobel: With the arm cylinder fully extended and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height. 4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



T145-05-03-007



T145-05-03-008



CAUTION: Prevent personal injury. Always make sure that the area is clear and that coworkers are out of the swing area before starting the measurement. Measurement: 1. Engine Control Lever: Maximum Position Auto Idle Switch: OFF 2. Operate the swing control lever at full stroke. 3. After the swing attains to constant speed, measure the time required for the upperstructure to rotate three times. 4. Measure in both directions (clockwise and counterclockwise). 5. Repeat steps 2 to 4 three times and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard Table. Remedy: Refer to T5-5 Troubleshooting B.



T4-4-5



3 Revolutions



T145-05-03-009



OPERATIONAL PERFORMANCE TEST / Excavator Test SWING FUNCTION DRIFT CHECK Summary: 1. Use the swing drift (measured on the circumference of the swing bearing) when stopping after a 180° full-speed swing, to evaluate the swing brake valve performance. NOTE: The swing motor is equipped with a swing parking mechanical brake. Preparation: 1. Confirm that the swing gears and bearing are sufficiently greased. 2. Secure a space wide enough for the machine upperstructure to swing on a flat and firm surface. Never attempt to perform this test on a slope. 3. Empty the bucket and position the front attachment as described in the following. Backhoe: With the arm cylinders fully retracted and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height. Loading shovel: With the arm cylinder fully extended and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height. 4. Put aligning marks on the outer circumference of the swing bearing and the track frame. 5. Swing the upperstructure 180°. 6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



T4-4-6



T145-05-03-007



T145-05-03-008



OPERATIONAL PERFORMANCE TEST / Excavator Test CAUTION: Prevent personal injury. Always make sure that the area is clear and that coworkers are out of the swing area before starting the measurement. Measurement: 1. Engine Control Lever: Maximum Position Auto Idle Switch: OFF 2. Operate the swing lever full stroke. When the upperstructure rotates 180° back to the original position (when the marks on the swing bearing and track frame aligns with each other), return the swing lever to neutral. 3. After the upperstructure stops, measure the distance between the two marks along the outer circumference of the swing bearing. 4. Align the marks again. Then, measure in the opposite direction. 5. Repeat steps 2 to 4 three times and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard Table.



Return the swing control lever to the neutral position.



Drift Amount



Rotate 180 °



Remedy: Refer to T5-5 Troubleshooting B. T142-05-03-003



T4-4-7



OPERATIONAL PERFORMANCE TEST / Excavator Test SWING MOTOR LEAKAGE Summary: Check for upperstructure drift while suspending a load on a slope. Preparation: 1. Check the lubrication of the swing gear and swing bearing. 2. Load bucket fully. In lieu of loading the bucket, weight (W) of the follwing specification can be used. W = 22500 kg (49600 lb) 3. Position the front attachment as described in the following. Loading shovel: With the arm cylinder fully extended and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height. Backhoe: With the arm cylinders fully retracted and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height. 4. Park the machine on a smooth slope with a gradient of 26.8 % (15°). 5. Swing the upperstructure to position it 90° to the slope. Make aligning marks on the swing bearing periphery and track frame using tape, as illustrated. 6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Stop the engine. After five minutes, measure the difference between the marks along the swing bearing periphery and the track frame. 2. Perform the measurement in both right and left swing directions. 3. Perform the measurement three times in each direction and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard Table.



T142-05-03-004



Measure Difference Between Marks



Marking on the Track Frame Marking on the Swing Bearing



Remedy: Refer to T5-5 Troubleshooting B.



T105-06-03-010



T4-4-8



OPERATIONAL PERFORMANCE TEST / Excavator Test MAXIMUM SWINGABLE SLANT ANGLE Summary: 1. With the upperstructure swung 90° to the slope, check the maximum slant angle on which the upperstructure can swing to the uphill side. Preparation: 1. Check that the swing gear and bearing are well lubricated. 2. Load bucket fully. In lieu of loading the bucket, weight (W) of the following specification can be used. W= 22500 kg (49600 lb) 3. Position the front attachment as described in the following. Loading shovel: With the arm cylinder fully extended and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height. Backhoe: With the arm cylinders fully retracted and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height. 4. Climb a slope and swing the upperstructure 90° to the slope. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Engine Control Lever: Maximum Position Auto Idle Switch: OFF 2. Operate the swing lever to full stroke to swing the upperstructure to the uphill side. 3. If the machine can swing, measure the cab floor slant angle. 4. When the machine can swing, increase the slant angle. Then, repeat the test until the maximum swingable angle is obtained. Check in both clockwise and counterclockwise directions. 5. Perform the measurement three times in each direction and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard Table. Remedy: Refer to T5-5 Troubleshooting B.



T4-4-9



T142-05-03-004



OPERATIONAL PERFORMANCE TEST / Excavator Test SWING BEARING PLAY Summary: 1. Measure the play between the outer and inner races of the swing bearing to check wear on the bearing races and balls. Preparation: 1. Confirm that the swing bearing mounting bolts are securely tightened. 2. Confirm that the swing bearing is well lubricated and rotates smoothly with no noise. 3. Attach a dial gauge on the track frame using a magnetic base. 4. Position the upperstructure so that the boom and bucket center line aligns with that of the track and face toward the front idlers. 5. Position the dial gauge so that its needle point comes into contact with the bottom face of the swing bearing outer race. 6. Empty the bucket.



T4-4-10



Dial Gauge



Magnet Base T105-06-03-015



OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Take measurements of the play at positions A, B, C, and D. 2. Position the front attachment as described in the following. Backhoe: With the arm cylinders fully retracted and the bucket cylinders fully extended, position the arm top pin height is flush with the boom foot pin height. Loading shovel: With the arm cylinder fully extended and the bucket cylinders fully extended, position the arm top pin height is flush with the boom foot pin height. 3. Lower the bucket to the ground and use it to raise the front idler 0.5 m (20 in). Record the dial gauge reading (h2). 4. Calculate bearing play (H) from this data (h1 and h2) as follows: H=h2 - h1



A B



D C



Measure the plays at positions A, B, C and D.



T145-05-03-023



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



Backhoe Front Measurement : (h1 )



Measurement : (h2 )



T142-05-03-006



Loading Shovel Front Measurement : (h1 )



Measurement : (h2 )



T142-05-03-005



T4-4-11



OPERATIONAL PERFORMANCE TEST / Excavator Test HYDRAULIC CYLINDER CYCLE TIME Summary: 1. Check the overall operational performance of the front attachment hydraulic system (between the hydraulic pumps and each cylinder) by measuring the cycle time of the boom, arm, bucket, and bucket dump (open/close) cylinders with the bucket emptied. Preparation: 1. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). 2. Position the front attachment as described in the following. • Backhoe Boom Cylinder: With the bucket cylinder fully extended and the arm cylinder fully retracted, lower the bucket to the ground. Arm Cylinder: With the bucket cylinder fully extended while positioning the center line between the arm and bucket connection pin centers vertical with the arm cylinder extended half stroke. Bucket Cylinder: Adjust the boom and arm cylinder so that the center of full stroke movement of the bucket is positioned vertically. • Loading Shovel Boom Cylinder: With the bucket cylinder and the arm cylinder fully extended, lower the bucket to the ground. Arm Cylinder: With the arm fully retracted, position the bucket so that the rear bucket does not come in contact with the arm stopper. Then, adjust the boom cylinder stroke to position the bucket bottom 1 m (39 in) above the ground. Bucket Cylinder: With the bucket closed and held in a load dump position, adjust the boom cylinder stroke so that bucket bottom height is approx. 1 m (39 in) above the ground. Bucket Dump (Open/Close) Cylinder: With the bucket cylinder and arm cylinder fully extended, adjust the boom cylinder stroke so that the bucket bottom height approx. 1 m (39 in) above the ground.



Backhoe



Boom Cylinder



T145-05-03-012



Arm Cylinder T118-04-03-003



Bucket Cylinder T145-05-03-014



Loading Shovel



Boom Cylinder



T145-05-03-015



Arm Cylinder T145-05-03-016



Bucket Cylinder T145-05-03-017



Dump Cylinder



T145-05-03-018



T4-4-12



OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Select the following lever and switch positions: Engine Control Lever: Maximum Position Auto-Idle Switch: OFF 2. To measure cylinder cycle times: (Cylinder full stroke includes cylinder cushioning zone.) • Boom cylinders: Measure the time it takes to raise the boom, and the time it takes to lower the boom. To do so, position the boom at one stroke end, then move the control lever to the other stroke end as quickly as possible. • Arm cylinder: Measure the time it takes to roll in the arm, and the time it takes to roll out the arm. To do so, position the arm at one stroke end, then move the control lever to the other stroke end as quickly as possible. • Bucket cylinder: Measure the time it takes to roll in the bucket, and the time it takes to roll out the bucket. To do so, position the bucket at one stroke end, then move the control lever to the other stroke end as quickly as possible. • Bucket dump (Open/Close) cylinder: Mesure the time it takes to open the bucket, and the time it takes to close the bucket. To do so, position the bucket dump at one stroke end, then move the bucket open/close pedal to the other stroke end as quickly as possible. 3. Repeat the measurement three times and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard Table. Remedy: Refer to the T5-5 Troubleshooting B.



T4-4-13



OPERATIONAL PERFORMANCE TEST / Excavator Test DIG FUNCTION DRIFT CHECK Summary: 1. Evaluate the internal oil leakage in the control valve, boom, arm, and bucket cylinders by measuring cylinder (dig function) drift with the bucket loaded. NOTE: When checking soon after cylinder replacement, move to full stroke each cylinder to purge air trapped in the cylinders. Preparation: 1. Load bucket fully. In lieu of loading the bucket, weight (W) of the following specification can be used. W = 22500 kg (49600 lb) 2. Position the front attachment as described in the following. Backhoe: With the arm cylinder with rod approx. 50 mm (2 in) extended from the fully retracted position, and bucket cylinder with the rod approx. 50 mm (2 in) retracted from the fully extended position. Loading shovel: With the arm cylinder with the rod approx. 50 mm (2 in) retracted from the fully extended position, and bucket cylinder with the approx. 50 mm (2 in) retracted from the fully extended position. 3. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



T145-05-03-020



T145-05-03-021



BH: Boom and Bucket Cylinders Retraction LD: Boom, Arm and Bucket Cylinders Retraction



Measurement: 1. Stop the engine. 2. After five minutes have passed, measure the retractions of the boom, arm, and bucket cylinders as illustrated 3. Repeat step 2 three times and calculate the average values.



Mark



Mark



T110-06-03-002



BH: Arm Cylinder Extension



Mark



Evaluation: Refer to T4-2 Operational Performance Standard Table. Remedy: Refer to T5-5 Troubleshooting B.



T110-06-03-001



NOTE: BH: Backhoe LD: Loading Shovel



T4-4-14



OPERATIONAL PERFORMANCE TEST / Excavator Test CONTROL LEVER OPERATING FORCE Summary: 1. Measure each control lever stroke play and operating force, and check if it can be moved smoothly. 2. Measure the maximum operating force for the front attachment control levers. 3. Measure operating force at each lever grip top. T18G-04-04-002



Measurement: 1. Stop the engine. 2. Measure all control levers. Evaluation: Refer to T4-2 Operational Performance Standard Table.



T107-06-03-004



T4-4-15



OPERATIONAL PERFORMANCE TEST / Excavator Test CONTROL LEVER STROKE Summary: 1. Measure each control lever stroke and stroke play, and check if it can be moved smoothly. 2. Measure each lever stroke at the lever grip center. 3. If a stroke play is present in the neutral position, add half the value of the play to the one side stroke. Measurement: 1. Stop the engine. 2. Measure the full stroke of the boom, arm, bucket, swing, and travel levers from the neutral position at the lever grip top center. 3. Measure the stroke straight from the neutral position to the stroke end. 4. Repeat each measurement three times and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard Table.



T4-4-16



T107-06-03-005



OPERATIONAL PERFORMANCE TEST / Excavator Test BOOM RAISE/SWING ERATION CHECK



COMBINED



OP-



Summary: 1. Check the combined operation performance while operating the boom raise and swing simultaneously. 2. Run the engine at full speed and check if the boom cylinders move without hesitating.



T142-05-03-007



Preparation: 1. Empty the bucket and position the machine with front attachment positioned as illustrated. 2. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). CAUTION: Prevent personal injury. Always make sure that the area is clear and that co-workers are out of the swing area before starting the measurement.



T142-05-03-008



Measurement: 1. Run the engine at the maximum speed with the auto idle switch OFF. 2. Operate the boom raise and swing levers full stroke. Measure the time required for the machine to swing 90 ° and bucket tooth tip height H raised while swinging. 3. Repeat the measurement in both directions three times and calculate the average values. T142-05-03-009



Evaluation: Refer to T4-2 Operational Performance Standard Table. Remedy: Refer to T5-5 Troubleshooting B.



H



T142-05-03-010



T4-4-17



OPERATIONAL PERFORMANCE TEST / Excavator Test (Blank)



T4-4-18



OPERATIONAL PERFORMANCE TEST / Component Test PRIMARY PILOT PRESSURE Preparation: 1. Stop the engine. CAUTION: The air breather cap may pop off if turned quickly. Slowly turn it to release internal pressure before removing it. 2. Release air from the hydraulic oil tank by loosening the air breather cap at the oil supply port on the hydraulic oil tank. : 4 mm 3. Disconnect the pilot hose from the pilot relief valve. Install tee (ST 6450) and a pressure gauge. : 19 mm, 22 mm Pilot Filter



4. Start the engine. Check for oil leaks from the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Measure the primary pilot pressure at the maximum and minimum engine speeds with the auto-idle switch OFF. 2. Repeat each measurement three times and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard Table.



T4-5-1



Pilot Hose



Pilot Relief Valve T18M-04-05-001



OPERATIONAL PERFORMANCE TEST / Component Test SECONDARY EHC VALVE PRESSURE Preparation: 1. Stop the engine.



Measurement:



CAUTION: The air breather cap may fly off if turned quickly. Slowly turn it to release internal pressure before removing it.



CAUTION: Before starting measurement, check that there are no bystanders and/or obstructions within the swing radius. When measuring the boom lower secondary pilot pressure, the base machine front may be raised off the ground. Take care not to allow the rear of the machine to come in contact with the ground, which may make the machine become unbalanced, possibly resulting in the machine overturning.



2. Release air from the hydraulic oil tank by loosening the air breather cap at the oil supply port on the hydraulic oil tank. : 4 mm 3. Disconnect the hose (1 to 14) which corresponds to the circuit to be checked. Install tee (ST 6450) between the EHC valve and DQR valve 1 or 2. Then, install a pressure gauge to the tee. : 19 mm, 22 mm 4. Start the engine. Check for oil leaks from the pressure gauge connections. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



1. Measure the pilot pressure at the maximum and minimum engine speeds with auto-idle switch OFF. 2. Operate the control lever corresponding to the secondary pilot pressure to be checked. Measure the pressure with the control lever fully stroked. 3. Repeat the measurement three times and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard Table. NOTE: In case the measurement data is abnormal, measure the primary pilot pressure. When the primary pressure is normal, the EHC valve can be determined as faulty.



T4-5-2



OPERATIONAL PERFORMANCE TEST / Component Test



Pilot Panel (Center Side) DQR Valve 1



1 2 3 4 5 6 7



T18L-01-02-009



Pilot Panel (Left Side)



8 9 10 11 12 13 14



T18L-04-05-002



DQR Valve 2



1234-



Bucket Tilt-Out Arm Extent Boom Lower Boom Raise



5678-



Bucket Tilt-In Arm Retract Bucket Open (LD Only) Bucket Close (LD Only)



910 11 12 -



NOTE: LD: Loading Shovel



T4-5-3



Left Travel Forward Left Travel Reverse Right Travel Forward Right Travel Reverse



13 - Left Swing 14 - Right Swing



OPERATIONAL PERFORMANCE TEST / Component Test SECONDARY DQR VALVE PRESSURE Preparation: 1. Stop the engine.



Measurement:



CAUTION: The air breather cap may fly off if turned quickly. Slowly turn it to release internal pressure before removing it.



CAUTION: Before starting measurement, check that there are no bystanders and/or obstructions within the swing radius. When measuring the boom lower secondary pilot pressure, the base machine front may be raised off the ground. Take care not to allow the rear of the machine to come in contact with the ground, which may make the machine become unbalanced, possibly resulting in the machine overturning.



2. Release air from the hydraulic oil tank by loosening the air breather cap at the oil supply port on the hydraulic oil tank. : 4 mm 3. Disconnect the hose (1 to 14) which corresponds to the circuit to be checked. Install a tee between the shuttle valve and DQR valve 1 or 2. Then, install a pressure gauge to the tee. : 22 mm, 27 mm 4. Start the engine. Check for oil leaks from the pressure gauge connections. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).



1. Measure the pilot pressure at the maximum and minimum engine speeds with auto-idle switch OFF. 2. Operate the control lever corresponding to the secondary pilot pressure to be checked. Measure the pressure with the control lever fully stroked. 3. Repeat the measurement three times and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard Table. NOTE: In case the measurement data is abnormal, measure secondary EHC Valve pressure. When secondary EHC Valve pressure is normal, either DQR valve 1 or 2 can be determined as faulty.



T4-5-4



OPERATIONAL PERFORMANCE TEST / Component Test



Pilot Panel (Center Side) DQR Valve 1



1 2 3 4 5 6 7



T18L-01-02-009



Pilot Panel (Left Side)



8 9 10 11 12 13 14



T18L-04-05-002



DQR Valve 2



1234-



Bucket Tilt-Out Arm Extent Boom Lower Boom Raise



5678-



Bucket Tilt-In Arm Retract Bucket Open (LD Only) Bucket Close (LD Only)



910 11 12 -



NOTE: LD: Loading Shovel



T4-5-5



Left Travel Forward Left Travel Reverse Right Travel Forward Right Travel Reverse



13 - Left Swing 14 - Right Swing



OPERATIONAL PERFORMANCE TEST / Component Test MAIN RELIEF PRESSURE Preparation 1. Stop the engine. CAUTION: The breather cap may pop off if turned quickly. Slowly turn it to release internal pressure before removing it. 2



2. Release air from the hydraulic oil tank by loosen the air breather cap. : 4 mm



1



3. Install the pressure gauge in the gauge port located on top of the high pressure strainer, as illustrated. : 6 mm



4 3



4. Start the engine and check for oil leakage from the connections.



6 5



5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement 1. Select the following switch / lever positions: Engine speed control lever : Fast Idle Auto-idle switch : OFF 2. Slowly operate each control lever of boom, arm and bucket functions at full stroke end over relief and measure the pressure. 3. Repeat step (2) three times and calculate the average value. Evaluation Refer to T4-2 Operational Performance Standard Table. NOTE: If any one of the measured pressures is lower than the others, it indicates that the overload relief valve of that circuit is lower than the main relief pressure setting.



T117-05-04-007



Connection of the high pressure strainer High Pressure Main Pump Control Valve Strainer 1 1 Center 2 2 3 3 Right 4 4 5 5 Left 6 6



T4-5-6



OPERATIONAL PERFORMANCE TEST / Component Test Set-Pressure Adjustment of Main Relief Valve IMPORTANT: Do not use these in this section in order to customize the machine illegally. For example; the machine performance is set beyond the specification. Otherwise, the machine life including the components and so on may become short or be broken. Future in addition, a serious trouble may occur.



Main Relief Valve



Adjustment: 1. Loosen lock nut. : 17 mm 2. Adjust the main relief valve set-pressure by turning adjusting screw. : 6 mm



T118-05-02-043



Lock Nut



3. Retighten the lock nut. : 17 mm : 27.5 to 31.4 N⋅m (2.8 to 3.2 kgf⋅m, 20 to 23 lbf⋅ft) 4. Recheck the set-pressure after adjustment. NOTE: Change in pressure setting Adjusting Screw Turns 1/4 1/2 3/4 1 MPa 4.5 8.9 13.4 17.8 Pressure (kgf/cm2) (45.3) (90.5) (135.8) (181) Change (psi) (645) (1285) (1930) (2575)



Adjusting Screw T145-02-03-001



Lock Nut



Pressure Increase



Adjusting Screw



Pressure Decrease W107-02-05-129



T4-5-7



OPERATIONAL PERFORMANCE TEST / Component Test RELIEF PRESSURE (When Relieving Swing) IMPORTANT: Do not use these in this section in order to customize the machine illegally. For example; the machine performance is set beyond the specification. Otherwise, the machine life including the components and so on may become short or be broken. Future in addition, a serious trouble may occur. Adjustment: 1. Loosen the lock nut. : 41 mm



M144-07-012



Swing Relief Valve



2. Adjust the swing relief valve set-pressure by turning the adjusting screw. : 27 mm



Lock Nut



Adjusting Screw



3. Retighten the lock nut. : 41 mm : 19.5 to 29.5 N⋅m (2 to 3 kgf⋅m, 14.5 to 21.5 lbf⋅ft) 4. Recheck the set-pressure after adjustment. T117-02-02-004



NOTE: Change in pressure setting Adjusting Screw Turns 1/4 1/2 3/4 1 Set MPa 2.5 5.0 7.5 10.0 2 Pressure (kgf/cm ) (25.5) (51) (76.5) (102) Change (psi) (363) (725) (1088) (1450)



Adjusting Screw



Pressure Increase



Pressure Decrease



T157-05-04-023



T4-5-8



OPERATIONAL PERFORMANCE TEST / Component Test RELIEF PRESSURE (When Relieving Travel)



Travel Brake Valve



IMPORTANT: Do not use these in this section in order to customize the machine illegally. For example; the machine performance is set beyond the specification. Otherwise, the machine life including the components and so on may become short or be broken. Future in addition, a serious trouble may occur.



T144-03-05-002



Travel Relief Valve



Adjustment: 1. Loosen the lock nut. : 17 mm



Lock Nut



2. Adjust the travel relief valve set-pressure by turning the adjusting screw. : 6 mm 3. Retighten the lock nut. : 17 mm : 34 to 44 N⋅m (3.5 to 4.5 kgf⋅m, 25.5 to 32 lbf⋅ft)



Adjusting Screw



4. Recheck the set-pressure after adjustment. NOTE: Change in pressure setting Adjusting Screw Turns 1/4 1/2 3/4 1 MPa 1.96 3.92 5.88 7.85 Pressure (kgf/cm2) (20) (40) (60) (80) Change (psi) (284) (569) (853) (1138)



T145-05-04-004



Lock Nut



Pressure Increase



Adjusting Screw



Pressure Decrease W107-02-05-129



T4-5-9



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.



T4-5-10



OPERATIONAL PERFORMANCE TEST / Component Test Set-Pressure Adjustment of Overload Relief Valve IMPORTANT: In principle, adjust the overload relief valve set pressure on a test stand.



Overload Relief Valve



Adjustment: 1. Loosen lock nut. : 17 mm 2. Adjust the overload relief valve set-pressure by turning adjusting screw. : 6 mm 3. Retighten lock nut. : 17 mm : 27.5 to 31.4 N⋅m (2.8 to 3.2 kgf⋅m, 20 to 23 lbf⋅ft)



T118-05-02-043



4. Recheck the set-pressure after adjustment. Lock Nut



Adjusting Screw T145-02-03-001



NOTE: Change in pressure setting Adjusting Screw Turns 1/4 1/2 3/4 1 MPa 5.3 10.6 15.9 21.2 Pressure (kgf/cm2) (54) (108) (162) (216) Change (psi) (768) (1536) (2304) (3072)



Adjusting Screw



Pressure Increase



Pressure Decrease W107-02-05-129



T4-5-11



OPERATIONAL PERFORMANCE TEST / Component Test MAIN PUMP FLOW RATE MEASUREMENT • P-Q Line (Torque Adjustment) Summary: In order to check performance of the main pump, measure the main pump flow rate by connecting a hydraulic tester to the delivery hose of the main pump. Measurement Preparation: 1. Stop the engine. 2. Release air from the hydraulic oil tank by loosening the air breather cap at the oil supply port on the hydraulic oil tank. : 4 mm CAUTION: The air breather cap may pop off if turned quickly. Slowly turn it to release internal pressure before removing it. 3. Connect a hydraulic tester and pressure gauge to the delivery hose. Necessary components and parts are as follows: • Pressure gauge • Hydraulic tester • Pressure gauge assembly (ST 6934) • Test hose (Inlet) • Test hose (Outlet) • Pipe • Flange • Split flange



4. Purge air from the main pump. 5. Disconnect pipe from ports (Psv and Pi). Install tee (2) on port Psv of the regulator, then install hose (1) and hose (3) of Psv circuit to tee (2). Connect additional hose (1) to the tee (2). Connect the hose (1) and elbow (4) to port (Pi). Install plug to the disconnected end of hose (Pi). Connecting pump servo assist pressure (Psv) circuit to port Pi allows the pump to be operated by supplying the maximum Pi pressure with the control lever operated full stroke. 6. Disconnect connectors from EHC valve (SD) (power increase solenoid valve) and EHC valve (SF) (power decrease solenoid valve). 7. Connect the pulse meter to the engine speed sensor. 8. Fully open the loading valve of the hydraulic tester. 9. Start the engine and check the line connection for leakage.



Psv (Port Size: G1/4)



1



2



3



Pi



Psv



Psv



4



T4-5-12



Pi (Port Size: G1/4)



T141-04-04-002



OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Measure the maximum flow rate. 2. Auto-idle switch: OFF Engine speed control lever: Fast Idle 3. Measure the pump flow rate and engine speed at the pressure (referring to the table below) while gradually throttling the loading valve of the hydraulic tester. 4. Measure each pressure three times and take the average as the measured figure. Evolution: Connect the measurement results to the date of the pump with the specked speed. QC Q I Np Ne



: Converted Flow Rate : Measured Flow Rate : Pump Speed Ratio (0.86) -1 : Pump Specified Speed (1547 min ) : Measured Engine Speed



Where: Ne=Pulse Number (HZ)×60/142 Qc=(Np×Q)/(i×Ne)



T4-5-13



OPERATIONAL PERFORMANCE TEST / Component Test • Pi-Q Control by Pump Pilot Pressure Signal (Pilot Pressure Characteristics) Summary: In order to check performance of the main pump, measure the main pump flow rate by connecting a hydraulic tester to the delivery hose of the main pump. Preparation: 1. Refer to steps 1 to 3 on page T4-5-12, connect a portable tester to the main pump to be measured. 2. Disconnect hose from regulator port Pi, and attach plug in the disconnected hose. Connect hose (5) on regulator port Pi. 3. Connect adapters (6)(2 used) and adapter (10) to reducing valve (8). Remove plug (1) located on the manifold. Connect adapter (4) to the removed plug port. Connect hose (7) between adapter (4) and adapter (6) to port P1 on reducing valve (8). : 19 mm : 6 mm



Measurement: 1. Measure the main pump flow rate controlled by the pump control pilot pressure signal. 2. Turn the auto-idle switch is OFF position. Operate the engine control lever to fast idle position. 3. Adjust the reducing valve (8) set pressure to the specified pressure shown on the P-Q diagram of the main pump (Pilot Pressure Characteristics). Measure the flow rate and engine speed at each specified pressure shown on the P-Q diagram. 4. Repeat the measurement three times and calculate the average values. Evolution: Convert the measurement results to the flow rate at the specified pump speed by the following formulas:



4. Connect tee (9) to port P2 on reducing valve (8). Connect pressure gauge (3) and hose (5) to tee (9). : 19 mm 5. Connect hose (5) to port T on reducing valve (8). Remove Plug (2) from hydraulic oil tank, and connect adapter (10) and hose (11) to the removed plug (2) hole. : 19 mm. 22 mm 6. Purge air from the main pump. 7. Fully open the loading valve on the portable tester. 8. Start the engine. Check the pressure gauge connection for any oil leakage.



T4-5-14



Ne = Pulse Number (Hz) × 60/142 QC = (Np × Q)/(i × Ne) Where: QC : Converted Flow Rate Q : Measured Flow Rate -1 Np : Specified Pump Speed (1547 min ) i : Pump Drive Gear Speed Ratio (0.86) Ne : Measure Engine Speed



OPERATIONAL PERFORMANCE TEST / Component Test Pump Control Panel:



Main Pump: Regulator



Pi Manifold



Pi



1



T141-04-04-004



Hydraulic Oil Tank:



2



T18L-04-05-001



T141-04-04-003



Reducing Valve Port Position



To Hydraulic Oil Tank Plug (2) Hole



Reducing Valve (8)



T 10 3 11



P2



P1



10



5 To Regulator Port Pi



To Manifold Plug (1) Hole



9



6



8



6



7



4 T118-04-04-014



1 - Plug G1/4 2 - Plug G3/8



4 - Adapter UNF7/16×G1/4 (4042037) 5 - Hose UNF7/16×UNF7/16



7 - Hose UNF7/16×UNF7/16 8 - Reducing Valve (4325439)



3 - Pressure Gauge (ST 6931)



6 - Adapter G3/8×UNF7/16 (4200465)



9 - Tee UNF7/16×UNF7/16 ×G1/4 (ST 6451)



T4-5-15



10 - Adapter G3/8×G3/8 (4042031) 11 - Hose G3/8×G3/8 (ST 6961)



OPERATIONAL PERFORMANCE TEST / Component Test Adjustment of Maximum and Minimum Flow Rate The pump flow rate can be adjusted by changing the maximum servo piston stroke. When adjusting the maximum flow rate, loosen nut (1) and adjust screw (2) on the servo piston large chamber side. When adjusting the minimum flow rate, loosen nut (3) and adjust screw (4) on the servo piston small chamber.



: 30 mm : Nut (1), Nut (3) : 13 mm : Screw (2) : 10 mm : Screw (4)



NOTE: Turning screw (2) clockwise decreases the maximum flow rate, and turning counterclockwise increase. 1/4 turn of screw (2) changes the flow rate approx. 7.9 L/min. (2.1 US gal/min) Turning screw (4) clockwise increase the minimum flow rate, and turning counterclockwise decreases. 1/4 turn of screw (4) changes the flow rate approx. 7.9 L/min (2.1 US gal/min). 4



3



1



2



2



1



3



4



T141-04-04-004



(Pump Flow Rate) Q



Maximum Flow Rate Adjustment



(Pump Flow Rate) Q



Pi (Flow Rate Control Pressure)



T4-5-16



Minimum Flow Rate Adjustment



Pi (Flow Rate Control Pressure)



OPERATIONAL PERFORMANCE TEST / Component Test Adjustment for Torque Constant Control The torque constant control is performed by pump delivery pressure Pd. Therefore, the torque constant control is adjusted by changing the set-force of inner spring (2) and outer spring (1). (Before adjust the screws (4) and (6), mark the end of the adjusting screw with a white marker for the record of the original position.) When resetting inner spring (2), loosen nut (5) and adjust screw (6). When resetting outer spring (1), loosen nut (3) and adjust screw (4).



NOTE: When adjusting screw (4) is turned, inner spring (2) set-force varies. Therefore, when adjusting screw (4) is turned, turn adjusting screw (6) 2.17 times the turns of adjusting screw (4) in the opposite direction to keep inner spring (2) set-force unchanged. : 36 mm : Nut (3) : 24 mm : Screw (4) : 13 mm : Nut (5) : 4 mm : Screw (6) 1



2 3



4 5 6



T117-05-04-005



Outer Spring Adjustment Date Adjusting Screw Turn Flow Rate Change Pressure Change Engine Torque Change



1/4 35.4 L/min (9.35 US gal/min) 1.7 MPa (17.8 kgf/cm2, 253 psi) 74.5 N⋅m (7.6 kgf⋅m, 55 lbf⋅ft)



(Pump Flow Rate) Q



Inner Spring Adjustment Date Adjusting Screw Turn Flow Rate Change Pressure Change Engine Torque Change



1/4 16.3 L/min (3.59 US gal/min) 1.8 MPa (18.4 kgf/cm 2, 262 psi) 49.8 N⋅m (5.08 kgf⋅m, 36.7 lbf⋅ft)



(Pump Flow Rate) Q



Pd (Pump Delivery Pressure)



T4-5-17



Pd (Pump Delivery Pressure)



OPERATIONAL PERFORMANCE TEST / Component Test OIL COOLER FAN DRIVE PUMP FLOW RATE MEASUREMENT • Hydraulic P-Q Control (Torque Adjustment) Summary A hydraulic tester to measure the oil cooler pump flow rate is installed on the oil cooler fan pump delivery hose to check pump performance. Preparation 1. Stop the engine. CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may fly off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it.



4. Purge air from the oil cooler fan pump. 5. Disconnect oil cooler fan control solenoid valve both side connectors. 6. Connect a pulse meter to the engine speed sensor. 7. Fully open the loading valve of the hydraulic tester. 8. Start engine and check for oil leaks.



2. Release air pressure from the hydraulic oil tank. : 4 mm 3. Connect a hydraulic tester and pressure gauge to the delivery hose. Necessary components and parts are as follows: • Pressure Gauge • Hydraulic Tester • Pressure Gauge Assembly (ST 6934) • Test Hose (Inlet) • Test Hose (Outlet) • Pipe • Flange • Split Flange Pump Control Panel



Oil Cooler Fan Control Solenoid Valve T18L-04-05-001



T4-5-18



OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Measure the maximum flow rate. 2. Auto-Idle Switch: OFF 3. Engine Control Lever: Fast Idle Position 4. Referring to the table and diagram, measure the pump flow rate and engine speed while gradually throttling the loading valve of the hydraulic tester. 5. Repeat each measurement three times and calculate the average values. Evaluation: Convert the measurement results to the flow rate at the specified pump speed by the following formulas: Ne = Pulse Number (Hz) × 60/142 QC = (Np × Q)/(i × Ne) Where: QC : Converted Flow Rate Q : Measured Flow Rate -1 Np : Specified Pump Speed (2232 min ) i : Pump Drive Gear Speed Ratio (1.089) Ne : Measure Engine Speed



T4-5-19



OPERATIONAL PERFORMANCE TEST / Component Test • Pi-Q Control by Pump Control Pilot Pressure Signal (Pilot Pressure Characteristics) Summary: In order to check performance of the oil cooler fan pump, measure the main pump flow rate by connecting a hydraulic tester to the delivery hose of the oil cooler fan pump. Preparation: 1. Refer to steps 1 to 3 on page T4-5-18, connect a portable tester to the oil cooler fan pump to be measured. 2. Disconnect hose from regulator port Pi, and attach plug in the disconnected hose. Connect hose (5) on regulator port Pi. 3. Connect adapters (6) (2 used) and adapter (10) to reducing valve (8). Remove plug located on the manifold. Connect adapter (4) to the removed plug port. Connect hose (7) between adapter (4) and adapter (6) to port P1 on reducing valve (8). : 19 mm : 6 mm 4. Connect tee (9) to port P2 on reducing valve (8). Connect pressure gauge (3) and hose (5) to tee (9). : 19 mm 5. Connect hose (5) to port T on reducing valve (8). Remove plug (2) from hydraulic oil tank, and connect adapter (10) and hose (11) to the removed plug (2) hole. : 19 mm, 22 mm



Measurement: 1. Measure the oil cooler fan pump flow rate controlled by the pump control pilot pressure signal. 2. Turn the auto-idle switch is OFF position. Operate the engine control lever to fast idle position. 3. Adjust the reducing valve (8) set pressure to the specified pressure shown on the P-Q diagram of the oil cooler fan pump (Pilot Pressure Characteristics). Measure the flow rate and engine speed at each specified pressure shown on the P-Q diagram. 4. Repeat the measurement three times and calculate the average values. Evolution: Convert the measurement results to the flow rate at the specified pump speed by the following formulas: Ne = Pulse Number (Hz) × 60/142 QC = (Np × Q)/(i × Ne) Where: QC : Converted Flow Rate Q : Measured Flow Rate -1 Np : Specified Pump Speed (2232 min ) i : Pump Drive Gear Speed Ratio (1.089) Ne : Measure Engine Speed



6. Purge air from the main pump. 7. Fully open the loading valve on the portable tester. 8. Start the engine. Check the pressure gauge connection for any oil leakage.



T4-5-20



OPERATIONAL PERFORMANCE TEST / Component Test Pump Control Panel:



Oil Cooler Fan Pump:



Manifold



Regulator



1 Pi T118-05-02-026



Hydraulic Oil Tank:



2 T18L-04-05-001



T141-04-04-003



Reducing Valve Port Position



To Hydraulic Oil Tank Plug (2) Hole



Reducing Valve (8) T



10



3 P2



P1



11 10



5 To Regulator Port Pi



To Manifold Plug (1) Hole



9



6



8



6



7



4 T118-04-04-014



1 - Plug G1/4 2 - Plug G3/8



4 - Adapter UNF7/16×G1/4 (4042037) 5 - Hose UNF7/16×UNF7/16



7 - Hose UNF7/16×UNF7/16 8 - Reducing (4325439)



3 - Pressure Gauge (ST 6931)



6 - Adapter G3/8×UNF7/16 (4200465)



9 - Tee UNF7/16×UNF7/16 ×G1/4 (ST 6451)



T4-5-21



10 - Adapter G3/8×G3/8 (4042031) 11 - Hose G3/8×G3/8 (ST 6961)



OPERATIONAL PERFORMANCE TEST / Component Test Adjustment of Maximum and Minimum Flow Rate (Oil Cooler Fan Drive Pump) The pump flow rate can be adjusted by changing the maximum servo piston stroke. When adjusting the maximum flow rate, loosen nut (1) and adjust screw (2) on the servo piston large chamber side. When adjusting the minimum flow rate, loosen nut (3) and adjust screw (4) on the servo piston small chamber side.



NOTE: Turning screw (2) clockwise decreases the maximum flow rate, and turning counterclockwise increases. 1/4 turn of screw (2) changes the flow rate approx. 6.3 L/min (1.7 US gal). Turning screw (4) clockwise increases the minimum flow rate, and turning counterclockwise decreases. 1/4 turn of screw (4) changes the flow rate approx. 5.0 L/min (1.3 US gal). : 30 mm : Nut (1) : 24 mm : Nut (3) : 13 mm : Screw (2) : 8 mm : Screw (4)



4



3



1



2



T118-04-04-007



(Pump Flow Rate) Q



Maximum Flow Rate Adjustment



Pi



(Pump Flow Rate) Q



(Flow Rate Control Pressure)



Minimum Flow Rate Adjustment



Pi



T4-5-22



(Flow Rate Control Pressure)



OPERATIONAL PERFORMANCE TEST / Component Test Adjustment of Flow Rate Control The flow rate control is performed by pump flow rate control pressure Pi. Therefore, the flow rate control is adjusted by resetting the set-force of spring (1). Loosen nut (2) and turn screw (3) to reset the set-force of spring (1). : 13 mm : Nut (2) : 4 mm : Screw (3)



1 2



3



T117-05-04-006



Spring Adjustment Data Adjusting Screw Turn 1/4 Pressure Change (Pi) 0.18 MPa (1.8 kgf/cm 2, 25.6 psi) Flow Rate Change 20 L/min (5.3 US gal/min)



Flow Rate Control (Pump Flow Rate) Q



Pi (Flow Rate Control Pressure)



T4-5-23



OPERATIONAL PERFORMANCE TEST / Component Test SWING MOTOR DRAINAGE Summary: To check swing motor performance, measure the amount of oil draining from the swing motor while swinging the upperstructure. Swing motor while swinging the upperstructure. NOTE: The amount of drain oil from the swing motor will change depending on hydraulic oil temperature. Preparation: 1. Rotate the swing motor to warm the inside of the motor. CAUTION: The breather cap may pop off if turned quickly. Slowly turn it to release internal pressure before removing it. 2. Properly shut down the engine. Slowly loosen air breather cap to release air from the hydraulic oil tank. 3. Disconnect the swing motor drain hose at the hydraulic oil tank end. Install plug (1-1/16-12UN) to the disconnected end. : 30 mm, 36 mm : 176 N⋅m (18 kgf⋅m, 130 lbf⋅ft)



M117-07-082



Drain Hose



CAUTION: Prevent personal injury. Always make sure that the area is clear and that coworkers are out of the swing area before starting machine operation. Also, take care not to fall off the machine while the measurement. Preconditions for Measurement: 1. Engine Control Lever : Fast Idle Position Auto-idle Switch : OFF



T4-5-24



OPERATIONAL PERFORMANCE TEST / Component Test Measurement:



• Amount of Oil Drained While Swinging the Upperstructure • Start the engine. Fully roll out (extend) the arm. Fully roll in (tilt-in) the bucket. Raise the boom so that the arm tip pin height is the same as the boom foot pin height. Be sure that the bucket is empty. • Operate and hold the swing lever full stroke. Start draining oil measurement after the swing speed reaches a constant maximum speed. The measuring time should be more than 20 seconds. • Repeat the measurement at least three times in both clockwise and counterclockwise directions, and calculate the average values.



T145-05-03-008



• Amount of Oil Drained While Relieving Swing Motor Circuit • Start the engine. Thrust the bucket teeth into the ground as illustrated so that the upperstructure does not rotate when the swing lever is operated full stroke. • Operate and hold the swing lever full stroke. Start drain oil measurement when drain oil starts coming out of the drain hose end. The measuring time should be more than 20 seconds. • Repeat the measurement at least three times in both clockwise and counterclockwise directions, and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard Table. * Conversion of the amount of drain oil measured into the per-minute value First measure the amount of drain oil using a calibrated container. Then, convert the measured drain oil into the per-minute value using the formula below: ∆Q = (60 / t) × q Where: ∆Q : Amount of drain oil per minute (L/min) t : Time measured (seconds) q : Total amount of drain oil (L)



T4-5-25



T145-05-03-007



OPERATIONAL PERFORMANCE TEST / Component Test TRAVEL MOTOR DRAINAGE Summary: To check travel motor performance, measure the amount of oil draining from the travel motor, while rotating the travel motor with the measuring side track jacked up. NOTE: The amount of drain oil from the travel motor and the drain oil pressure will change depending on hydraulic oil temperature. CAUTION: Prevent personal injury. Always make sure that the area is clear and that co-workers are out of the swing area before starting machine operation. Preparation: 1. Rotate the travel motor to warm the inside of the motor. CAUTION: The breather cap may pop off if turned quickly. Slowly turn it to release internal pressure before removing it. 2. Properly shut down the engine. Slowly loosen the air breather cap to release air from the hydraulic oil tank.



Drain Hose



3. Disconnect the travel motor drain hose at the hydraulic oil tank end. Install plug (1-1/16-12UN) to the disconnected end. : 30 mm, 36 mm : 176 N⋅m (18 kgf⋅m, 130 lbf⋅ft) Preconditions for Measurement: 1. Engine Control Lever : Fast Idle Position Auto-idle Switch : OFF M117-07-087



T4-5-26



OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Start the engine. Jack up the measuring side track using the front attachment, as illustrated. CAUTION: When working around moving parts is unamoidable, pay special attention to ensure that hands, feet, and clothing do not become entangled. Securely support the raised track using wooden blocks.



90 to 110°



2. Rotate the raised track with the travel lever operated full stroke. Start drain oil measurement after the track rotation speed reaches a constant maximum speed. The measuring time should be more than 20 seconds.



T142-05-03-011



3. Repeat the measurement at least three times in both forward and reverse directions and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard Table. * Conversion of the amount of drain oil measured into the paramount value First measure the amount of drain oil using a calibrated container. Then, convert the measured drain oil into the paramount value using the formula below: ∆Q = (60 / t) × q Where: ∆Q : Amount of drain oil per minute (L/min) t : Time measured (seconds) q : Total amount of drain oil (L)



T4-5-27



90 to 110°



T142-05-03-012



OPERATIONAL PERFORMANCE TEST / Component Test (Blank)



T4-5-28



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



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



SECTION 5



TROUBLESHOOTING CONTENTS Group 1 General



Group 3 Component Layout



Introduction ..............................................T5-1-1



Main Component Layout ...........................T5-3-1



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



Electrical Component Layout ....................T5-3-8



Starting Check Indication..........................T5-1-4



Engine....................................................T5-3-20



Alarm Indication .......................................T5-1-6



Radiator .................................................T5-3-21



Fault Diagnosis Indication ........................T5-1-8



Air Cleaner .............................................T5-3-22



Automatic Snapshot Indication ...............T5-1-10



Pump Device ..........................................T5-3-23



Monitor And Manual Snapshot Indicator..T5-1-12



Control Valve ..........................................T5-3-24



Maintenance History Display ..................T5-1-16



Swing Device..........................................T5-3-27



Life Data Display ....................................T5-1-18



Travel Device .........................................T5-3-28



Machine Information Indication ...............T5-1-20



Center Joint............................................T5-3-28



Various Setup Indication .........................T5-1-22



Oil Cooler ...............................................T5-3-29



Maintenance Setup.................................T5-1-24



EHC Valve (For Main Pump Control) ......T5-3-30 EHC Valve (For Electric Lever Control) ...T5-3-31



Group 2 Cross Reference Table Hydraulic Circuit Diagram .......................T5-2-1 Electrical Circuit Diagram (1/3) .................T5-2-4 Electrical Circuit Diagram (2/3) .................T5-2-6 Electrical Circuit Diagram (3/3) ...............T5-2-10



Sliding Fold-In Ladder ............................T5-3-32 Auto-Lubrication System.........................T5-3-34 Pilot Piping .............................................T5-3-35



Group 4 Troubleshooting A Troubleshooting A Procedure....................T5-4-1 Fault Diagnosis Indication.........................T5-4-2 Fault Code List .........................................T5-4-4



Group 5 Troubleshooting B Troubleshooting B Procedure ...................T5-5-1 How to Read Fault Codes .........................T5-5-2 Fault Code for Engine...............................T5-5-4



18LT-5-1



Group 6 Troubleshooting C Troubleshooting C Procudure ...................T5-6-1 Diagnosis by blinking of Indicator ...........T5-6-14



Group 7 Electrical System Inspection Precautions for Inspection and Maintenance...........................................T5-7-1 Disconnection of Connector......................T5-7-3 Battery Voltage Check ..............................T5-7-4 Fusible Link Inspection .............................T5-7-6 Fuse Continuity Check .............................T5-7-8 Alternator Check ....................................T5-7-15 Voltage Check ........................................T5-7-16 5 Volt Circuit...........................................T5-7-23 Check Using False Signal ......................T5-7-24 Continuity Check ....................................T5-7-25 Circuit Check by Lamp Harness .............T5-7-26



18LT-5-2



TROUBLESHOOTING / General INTRODUCTION Refer to the inspection and troubleshooting procedures after any machine trouble has occurred. The inspection and troubleshooting procedures are presented in an orderly fashion in this section to help you quickly find the cause and solution of the machine trouble. The troubleshooting section in this manual consists of 7 groups; General, Cross Reference Table, Component Layout, Troubleshooting A (base machine diagnosis indicated in the monitor display fault codes), Troubleshooting B (engine diagnosis indicated by the flashing pattern of indicator lights), Troubleshooting C (Air conditioner diagnosis), and Electrical System Inspection.



• General • Cross Reference Table • Component Layout • Troubleshooting A (base machine diagnosis indicated in the monitor display fault codes)



• Troubleshooting B (engine diagnosis relies on the flashing pattern of indicator lights) The engine is diagnosed by referring to the flashing pattern of the engine warning indicator.



• Troubleshooting C (Air conditioner diagnosis) Refer to these procedures when troubleshooting by inspecting abnormal machine operational status. Example: Air conditioner malfunction.



• Electrical System Inspection Refer to this group when required to obtain precautions and/or information for the electrical system inspection. Example: Fuse Inspection



T5-1-1



TROUBLESHOOTING / General 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.



T107-07-01-001



2. Ask the operator Before inspecting, get the full story of malfunctions from your star witness --- the operator. • How is the machine being used? (Find out if the machine is being operated correctly) • When was the trouble noticed, and what types of work the machine doing at that time? • What are the details of the trouble? Is the trouble getting worse, or did it appear suddenly for the first time? • Did the machine have any other troubles previously? If so, which parts were repaired before?



T107-07-01-002



3. Inspect the machine Before starting the troubleshooting procedure, check the machine’s daily maintenance points, as shown in the operator's manual. Also, check the electrical system, including the batteries, as troubles in the electrical system such as low battery voltage, loose connections and blown fuses will result in malfunction of the controllers, causing total operational failure of the machine. If troubleshooting is started without checking for blown fuses, a wrong diagnosis may result, wasting time. Be sure to check for blown fuses before troubleshooting. Even if a fuse looks normal by visual inspection, a fine crack is difficult to find. Always use a tester when checking the fuses. T107-07-01-003



T5-1-2



TROUBLESHOOTING / General 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.



T107-07-01-004



5. Perform troubleshooting CAUTION: If a harness or pipe is disconnected with the engine running, the machine may operate incorrectly, or high pressure oil may spray, causing personal injury. Be sure to disconnect harnesses or pipes after stopping the engine. Perform self-diagnosis by operating the monitor display. In case any fault code has been displayed by diagnosis using the monitor display, check the cause of the trouble by referring to Troubleshooting A in this section. After the machine trouble has been corrected, the fault code will be deleted. If the engine stop indicator and the engine warning indicator in the electrical equipment box start flashing by the ECM diagnosis system, check the cause of the trouble by referring to Troubleshooting B in this section. Therefore, in case problems which are not easily repredicable are encountered, use the built-in self-diagnosing system and ECM diagnosis system to display the fault code.



T107-07-01-006



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.



T107-07-01-007



T5-1-3



TROUBLESHOOTING / General STARTING CHECK INDICATION IDU indicates the starting check information on the monitor display in response to level sensor signals received from each controller through CAN. IMPORTANT: Monitor display can be switched by the keypad.



Indication



Starting Window



Key Pad



T18G-02-01-108



1. When the engine is not running and Meter Window appears on the monitor display, press the ? key to display the Starting Check Window on the monitor display. To return to the Meter Window, press the × key again.



Meter Window



Automatic Transition



T18M-05-01-003



T18M-05-01-001



Starting Check Window



T18M-05-01-002



T5-1-4



TROUBLESHOOTING / General (Blank)



T5-1-5



TROUBLESHOOTING / General ALARM INDICATION IDU indicates the alarm information on the monitor display in response to alarm signals received from each controller through CAN. IMPORTANT: Monitor display can be switched by the keypad.



Key Pad



Indication 1. When the Meter Window appears on the monitor display, press the ← key to display the Current Alarms List Window on the monitor display. To return to the Meter Window, press the × key again.



T18G-02-01-108



Starting Window



Automatic Transition



T18M-05-01-003



Meter Window



2. Select the required item from the list, using the ↑ and ↓ keys, and press the ○ key. The Alarm Explanation Window will appear. (See to next page.) To return the Current Alarms List Window, press the × key again.



T18M-05-01-001



Current Alarm List Window



T18M-05-01-004



T5-1-6



TROUBLESHOOTING / General 3. To display the Detailed Circuit Diagram Window, press the ○ key. To return to the Alarm Explanation Window, press the × key again.



Alarm Explanation Window



T18G-05-01-004



Detailed Circuit Diagram Window



T18G-05-01-005



T5-1-7



TROUBLESHOOTING / General FAULT DIAGNOSIS INDICATION IDU indicates the fault diagnosis results on the monitor display in response to fault signals received from each controller through CAN. IMPORTANT: Monitor display window can be switched by the keypad.



Key Pad



Indication 1. When the Meter Window appears on the monitor display, press the → key to display the Current Faults List Window on the monitor display. To return to the Meter Window, press the × key again.



T18G-02-01-108



Starting Window



Automatic Transition



T18M-05-01-003



Meter Window



2. Select the required item from the list, using the ↑ and ↓ keys, and press the ○ key. The Faults Explanation Window of the selected item will appear. (See to next page.) To return the Current Faults List Window, press the × key again.



T18M-05-01-001



Current Faults List Window



T18M-05-01-005



T5-1-8



TROUBLESHOOTING / General 3. To display the Detailed Circuit Diagram Window, press the ○ key. To return to the Fault Explanation Window, press the × key again.



Faults Explanation Window



T18G-05-01-007



Detailed Circuit Diagram Window



T18G-05-01-027



T5-1-9



TROUBLESHOOTING / General AUTOMATIC SNAPSHOT INDICATION IDU indicates the related snapshot lists on the monitor display on time-series basis in response to event log received from DLU through CAN. IMPORTANT: Monitor display window can be switched by the keypad.



Key Pad



Indication 1. When the Meter Window appears on the monitor display, press the ○ key. Service Menu Window will appear. To return to the Meter Window, press the × key again.



T18G-02-01-108



Starting Window



Automatic Transition



T18M-05-01-003



Meter Window



2. Select Automatic Snapshot List from menu, using the ↑ and ↓ keys, and press the ○ key. Automatic Snapshot List Window will appear. (See to next page.) To return to the Service Menu Window, press the × key again.



T18M-05-01-001



Service Menu Window



T18M-05-01-008



T5-1-10



TROUBLESHOOTING / General 3. Select the required item from the list, using the ↑ and ↓ keys, and press the → key. Snapshot Window of the selected item will be appear. To return the Automatic Snapshot List Window, press the × key again.



Automatic Snapshot List Window



IMPORTANT: If there is no auto snapshot data, reproduction will not appear on the display.



T18M-05-01-011



Snapshot Window



T18M-05-01-015



T5-1-11



TROUBLESHOOTING / General MONITOR AND MANUAL SNAPSHOT INDICATION IDU receives operating status of devices used for the corresponding control from DLU, MC or ELU through CAN, and indicates it on the monitor display, records and reproduce it. IMPORTANT: Monitor display window can be switched by the keypad.



Monitor/Record/Replay Key Pad



Indication



T18G-02-01-108



Starting Window



1. When the Meter Window appears on the monitor display, press the ○ key. Service Menu Window will appear. To return to the Meter Window, press the × key again.



Automatic Transition



2. Select Monitor and Manual Snapshot from menu, using the ↑ and ↓ keys, and press the ○ key. Monitor and Manual Snapshot Menu Window will appear. (See to next page.) To return to the Service Menu Window, press the × key again.



T18M-05-01-003



Meter Window



T18M-05-01-001



Service Menu Window



T18M-05-01-008



T5-1-12



TROUBLESHOOTING / General 3. Select Monitor/Record/Replay from menu, using the ↑ and ↓ keys, and press the ○ key. Monitor/Record/Replay List Window will appear. To return to Monitor and Manual Snapshot Menu Window, press the × key again.



Monitor and Manual Snapshot Menu Window



T18G-05-01-011



4. Select the required item from the list, using the ←, →, ↑ and ↓ keys, and press the ○ key. Snapshot Window of the selected item will appear. To return to Monitor/Record/Replay List Window, press the × key again.



Monitor / Record / Replay List Window



T18M-05-01-006



5. Select an item you want to record from the snapshot, using the ↑ and ↓ keys, and press the ○ key. Data on the selected item will be recorded.



Snapshot Window



T18M-05-01-014



T5-1-13



TROUBLESHOOTING / General Replay IMPORTANT: Monitor display can be switched by the keypad.



Key Pad



T18G-02-01-108



Indication 1. Display Monitor and Manual Snapshot Menu Window. (See T5-1-12.)



Monitor and Manual Snapshot Menu Window



T18G-05-01-011



2. Select Replay from menu, using the ↑ and ↓ keys, and press the ○ key. Replay List Window will appear. To return to Monitor and Manual Snapshot Menu Window, press the × key again.



Replay List Window



3. Select an item you want to display from the list, using the ↑ and ↓ keys, and press the ○ key. The Reproduction Window of the selected item will appear. To return to the Replay List Window, press the × key again. 4. Select the data reproduction item from the Reproduction Window, using the ←, →, ↑ and ↓ keys, and press the ○ key. Data on the selected item will be reproduced.



T18G-05-01-013



Reproduction Window



T18G-05-01-014



T5-1-14



TROUBLESHOOTING / General (Blank)



T5-1-15



TROUBLESHOOTING / General MAINTENANCE HISTORY DISPLAY IDU Indicates the log (maintenance history) at the replacement of air filter, engine oil and hydraulic oil in terms of hourmeter reading, number of replacement and time length until the next replacement. As replacement items are shown in the list, select the required item from the list to record replacement history. IMPORTANT: Monitor display window can be switched by the keypad.



Key Pad



Indication 1. When the Meter Window appears on the Monitor display, press the ○ key. Service Menu Window will appear. To return to the Meter Window, press the × key again.



T18G-02-01-108



Starting Window



Automatic Transition



T18M-05-01-003



Meter Window



2. Select Maintenance History from menu, using the ↑ and ↓ keys, and press the ○ key. Maintenance History List Window will appear. (See to next page.) To return to the Service Menu Window, press the × key again.



T18M-05-01-001



Service Menu Window



T18M-05-01-008



T5-1-16



TROUBLESHOOTING / General 3. Select the required maintenance name from the list, using the ↑ and ↓ keys, and press the ○ key. Maintenance Name, Hourmeter Hours and Maintenance Date Window will appear on the display. To return to the Maintenance History List Window, press the × key again.



Maintenance History List Window



T18G-05-01-015



Maintenance Name, Hourmeter Hours and Maintenance Date Window



T18G-05-01-016



T5-1-17



TROUBLESHOOTING / General LIFE DATA DISPLAY IDU receives cumulative information, including cumulative engine running hours and machine operating hours, from DLU through CAN, and indicates it on the monitor display. IMPORTANT: Monitor display window can be switched by the keypad.



Key Pad



Indication 1. When the Meter Window appears on the monitor display, press the ○ key. Service Menu Window will appear. To return to the Meter Window, press the × key again.



T18G-02-01-108



Starting Window



Automatic Transition



T18M-05-01-003



Meter Window



2. Select Life from menu, using the ↑ and ↓ keys, and press the ○ key. Life Data Window will appear. (See to next page.) To return to the Service Menu Window, press the × key again.



T18M-05-01-001



Service Menu Window



T18M-05-01-008



T5-1-18



TROUBLESHOOTING / General Life Data Window



T18G-05-01-017



T5-1-19



TROUBLESHOOTING / General MACHINE INFORMATION INDICATION IDU indicates controller configuration, as well as hardware and software (version) used in respective controllers. IMPORTANT: Monitor display window can be switched by the keypad.



Key Pad



Indication 1. When the Meter Window appears on the monitor display, press the ○ key. Service Menu Window will appear. To return to the Meter Window, press the × key again.



T18G-02-01-108



Starting Window



Automatic Transition



T18M-05-01-003



Meter Window



2. Select Machine Information from menu, using the ↑ and ↓ keys, and press the ○ key. Machine Information Window will appear. (See to next page.) To return to the Service Menu Window, press the × key again.



T18M-05-01-001



Service Menu Window



T18M-05-01-008



T5-1-20



TROUBLESHOOTING / General Machine Information Window



T18M-05-01-007



T5-1-21



TROUBLESHOOTING / General VARIOUS SETUP INDICATION Maintenance Setup, Event Display Setup, Time Adjust and Setting Put-out Lights Delay Time can be set from the Various Setup window. IMPORTANT: Monitor display window can be switched by the keypad.



Key Pad



Indication 1. When the Meter Window appears on the monitor display, press the ○ key. Service Menu Window will appear. To return to the Meter Window, press the × key again.



T18G-02-01-108



Starting Window



Automatic Transition



T18M-05-01-003



Meter Window



2. Select Various Setup from menu, using the ↑ and ↓ keys, and press the ○ key. Setting Menu Window will appear. (See to next page.) To return to the Service Menu Window, press the × key again.



T18M-05-01-001



Service Menu Window



T18M-05-01-008



T5-1-22



TROUBLESHOOTING / General Setting Menu Window



T18M-05-01-009



T5-1-23



TROUBLESHOOTING / General Maintenance Setup Replacement intervals of air filter, engine oil, hydraulic oil, etc. can be set up on the monitor display. IMPORTANT: Monitor display window can be switched by the keypad.



Key Pad



Indication



T18G-02-01-108



Setting Menu Window



1. Indicate Setting Menu Window. (See T5-1-22.)



T18M-05-01-009



2. Select Maintenance Setup from menu, using the ↑ and ↓ keys, and press the ○ key. Maintenance Setup List Window will appear. To return to the Setup Menu Window, press the × key again.



Maintenance Setup List Window



3. Select an item you want to change from the list, using the ↑, ↓, ← and → keys, and press the ○ key. The selected item will blink, showing its settable state. 4. Select the number, using the ↑, ↓ and × keys, and press the ○ key. Now setup is completed.



T18M-05-01-012



Maintenance Setup Window



↑ : Increase ↓ : Decrease × : Cancellation



T18M-05-01-013



T5-1-24



TROUBLESHOOTING / General Snapshot Setup Initialization of manual snapshot data can be done on the display. IMPORTANT: Monitor display window can be switched by the keypad.



Key Pad T18G-02-01-108



Indication Setting Menu Window



1. Indicate Setting Menu Window. (See T5-1-22.)



T18M-05-01-009



Snapshot Setup Window



2. Select Snapshot Setup from menu, using the ↑ and ↓ keys, and press the ○ key. Snapshot Setup Window will appear. To return to the Setting Menu Window, press the × key again. 3. Press the ○ key to initialize the snapshot data.



T18M-05-01-010



T5-1-25



TROUBLESHOOTING / General Time Adjust Set the world standard time, local standard time and time difference. IMPORTANT: Monitor display window can be switched by the keypad. IMPORTANT: If DLU setting is incorrect, reset the Greenwich Mean Time, Local Standard Time, and Time Difference. When DLU setting is correct, adjust time difference only. Key Pad



Indication



T18G-02-01-108



Setting Menu Window



1. Indicate Setting Menu Window. (See T5-1-22.)



T18M-05-01-009



2. Select Time Adjust from menu, using the ↑ and ↓ keys, and press the ○ key. Time Adjust Window will appear. To return to the Setting Menu Window, press the × key again.



Time Adjust Window



T18G-05-01-022



Adjust Window



3. Press the ○ key to indicate Adjust Window. 4. Select the required item by using the ← and → keys, and adjust time or time difference using the ↑, ↓ and × keys. After adjustment, press the ○ key. Now time or time difference is set up. ↑ : Increase ↓ : Decrease × : Cancellation T18G-05-01-023



T5-1-26



TROUBLESHOOTING / General Setting Put-out Lights Delay Time Select and set up the put-out delay time of light from the setting time. IMPORTANT: Monitor display window can be switched by the keypad.



Key Pad



Indication



T18G-02-01-108



Setting Menu Window



1. Indicate Setting Menu Window. (See T5-1-22.)



T18M-05-01-009



2. Select Setting Put-out Lights Delay Time from menu, using the ↑ and ↓ keys, and press the ○ key. Setting Put-out Lights Delay Time Setting Window will appear. To return to the Setting Menu Window, press the × key again.



Setting Put-out Lights Delay Time Setting Window



3. Select the required time from the list, using the ↑ and ↓ keys, and press the ○ key. Now delay time is set up. T18G-05-01-024



T5-1-27



TROUBLESHOOTING / General (Blank)



T5-1-28



TROUBLESHOOTING / Cross Reference Table HYDRAULIC CIRCUIT DIAGRAM IMPORTANT: The No. indicates the component number in the circuit diagram. Refer to the page and item number in the T5-3 group.



No. 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030



Component Name Accumulator (Pilot Circuit) EHC Valve (For Electric Lever) (Main Frame Left Side) DQR Valve 2 (Main Frame Left Side) Shuttle Valve DQR Valve 1 (Main Frame Center Side) EHC Valve (For Electric Lever) (Main Frame Center Side) Pilot Shut-Off Solenoid Valve Check Valve (Pilot Circuit) Fast Filling Solenoid Valve Check Valve Slow Return Valve Lift Cylinder Travel Mode Solenoid Valve Reducing Valve (Travel Mode Change) Engine Pump Transmission Transmission Oil Filter Oil Cooler Fan Drive Pump Pilot Pump Compressor Pump Transmission Oil Pump Transmission Oil Pump Bypass Check Valve Main Pump 5 Main Pump 6 Main Pump 1 Main Pump 2 Main Pump 3 Main Pump 4 High-Pressure Strainer Pilot Filter



T5-2-1



Page T5-3-1, 4 T5-3-4, 31 T5-3-4 T5-3-1, 26 T5-3-4 T5-3-4, 31 T5-3-4 T5-3-4 T5-3-6, 8 T5-3-6 T5-3-6 T5-3-6 T5-3-4 T5-3-4 T5-3-1, 20 T5-3-3 T5-3-3 T5-3-3 T5-3-3 T5-3-3 T5-3-3 T5-3-3 T5-3-3 T5-3-3 T5-3-3 T5-3-3 T5-3-3 T5-3-3 T5-3-1 T5-3-3



Item No. 25, 2 10 9 27, 4 8 7 5 6 5, 20 2 3 1 4 3 24 4 7 5 5 5 5 6 3 3 1 1 2 2 16 9



Remarks



TROUBLESHOOTING / Cross Reference Table



No. 031 032 033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048 049 050 051 052 053 054 055 056 057 058 059 060



Component Name Pilot Relief Valve EHC Valve (For Main Pump Control) Pump Transmission Cooler Oil Cooler Fan Motor Oil Cooler Fuel Cooler Oil Cooler Bypass Check Valve Bypass Filter Compressor Pump Relief Valve Control Valve (Left) Control Valve (Center) Control Valve (Right) Bypass Check Valve Hydraulic Oil Tank Air Bleeding Solenoid Valve Auto-Lubrication System Motor Pump Unit (Sliding Fold-In Ladder) Valve Unit (Sliding Fold-In Ladder) Sliding Fold-In Ladder Cylinder Check Valve Holding Valve Compressor Motor Travel Motor (Left) Travel Brake Valve Adjuster Cylinder Swing Motor (Rear) Center Joint Pilot Pressure Selector Valve Relief Valve Accumulator (For Adjuster Cylinder)



Page T5-3-3 T5-3-3, 30 T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-29 T5-3-1 T5-3-1, 24 T5-3-1, 24 T5-3-1, 24 T5-3-1 T5-3-1, 8 T5-3-1, 34 T5-3-32 T5-3-32, 33 T5-3-32 T5-3-1 T5-3-1, 28 T5-3-1, 28 T5-3-1, 5 T5-3-1, 27 T5-3-1 T5-3-1, 5 T5-3-1, 5 T5-3-1, 5



T5-2-2



Item No. 8 10 19 20 18 17 5, 7 15 14 14 14 12, 21 13, 6 10 8 9 12 37 30, 1 31, 2 36, 1 9, 1 11 28, 4 32, 7 29/34, 3



Remarks



TROUBLESHOOTING / Cross Reference Table



No. 061 062 063 064 065 066 067 068 069 070 071 072 073 074



Component Name Swing Motor (Front) Travel Motor (Right) Travel Brake Valve Adjuster Cylinder ELU Electric Lever (Left) Electric Lever (Travel) Electric Lever (Right) Electric Lever (Bucket Open / Close) Boom Cylinder Bucket Cylinder Arm Cylinder Dump Cylinder Level Cylinder



Page T5-3-1, 27 T5-3-1, 28 T5-3-1, 28 T5-3-1, 5 T5-3-13 T5-3-13 T5-3-13 T5-3-13 T5-3-13 T5-3-1, 2 T5-3-1, 2 T5-3-1, 2 T5-3-1 T5-3-1



NOTE: LD: Loading Shovel



T5-2-3



Item No. 9, 1 30, 1 31, 2 36, 1 8 1 3 5 2, 4 8, 5 3, 3 1, 4 4 2



Remarks



LD only



LD only LD only



TROUBLESHOOTING / Cross Reference Table ELECTRICAL CIRCUIT DIAGRAM (1/3) No. 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030



Component Name Sliding Fold-In Ladder Emergency Switch Sliding Fold-In Ladder Retract Switch Sliding Fold-In Ladder Extend Switch Sliding Fold-In Ladder Isolation Switch Sliding Fold-In Ladder Beacon / Alarm Ladder Limit Switch Limit Switch (Expansion Slowdown) Limit Switch (Storage Slowdown) Limit Switch (Lock Lever) Limit Switch (Storage Detection) Sliding Fold-In Ladder Relay (4) Sliding Fold-In Ladder Solenoid Valve 2 Limit Switch (Expansion Detection) Sliding Fold-In Ladder Solenoid Valve 1 Sliding Fold-In Ladder Solenoid Valve 3 Sliding Fold-In Ladder Relay (2) Sliding Fold-In Ladder Relay (3) Work Light (Sliding Fold-In Ladder) Motor Pump Unit Lift Pump Drive Solenoid Valve Water In Fuel Sensor Coolant Temperature Sensor (LTA IN) Coolant Temperature Sensor (LTA OUT) Coolant Temperature Sensor (IN) Coolant Temperature Sensor (OUT) Air Temperature Sensor (In Front of Radiator) Emergency Switch 2 (Engine Compartment Front Side) Emergency Switch 3 (Engine Compartment Rear Side) Maintenance Light (Engine Compartment) Air Cleaner Restriction Switch



T5-2-4



Page T5-3-32 T5-3-32 T5-3-32 T5-3-32 T5-3-32 T5-3-32 T5-3-33 T5-3-32 T5-3-33 T5-3-33 T5-3-32 T5-3-32 T5-3-32 T5-3-32 T5-3-21 T5-3-21 T5-3-21 T5-3-21 T5-3-9 T5-3-8 T5-3-8 T5-3-8 T5-3-22



Item No. 11 5 6 12 7 3 13 4 11 6 1 2 10 8 4 9 5 8 2 24 17 10 2



Remarks



TROUBLESHOOTING / Cross Reference Table



No. 031 032 033 034 035 036 037



Component Name Ether Solenoid Valve Work Light (Rear-Left) Coolant Level Sensor Coolant Level Switch (1) Coolant Level Switch (2) Work Light (Rear-Left) Camera 3 (Rear-Left)



Page T5-3-8 T5-3-21 T5-3-21 T5-3-21 T5-3-8 -



T5-2-5



Item No. 23 6 7 7 21 -



Remarks



TROUBLESHOOTING / Cross Reference Table ELECTRICAL CIRCUIT DIAGRAM (2/3) No. 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030



Component Name Contamination Sensor (Main Pump 1) Contamination Sensor (Main Pump 2) Contamination Sensor (Main Pump 3) Contamination Sensor (Main Pump 4) Contamination Sensor (Main Pump 5) Contamination Sensor (Main Pump 6) Pump 1 Drain Pressure Sensor Pump 2 Drain Pressure Sensor Pump 3 Drain Pressure Sensor Pump 4 Drain Pressure Sensor Pump 5 Drain Pressure Sensor Pump 6 Drain Pressure Sensor Pump Transmission Level Switch Pump Transmission Oil Temperature Switch Emergency Switch 5 (Pump Compartment Front Side) Valve Limit Switch (Return 2) Valve Limit Switch (Return 1) EHC Valve (SI) (Main Pump 3, 5, 6 Displacement Control Solenoid Valve) EHC Valve (SF) (Pump Decrease Control Solenoid Valve) EHC Valve (SE) (Main Pump 1, 2, 4 Displacement Control Solenoid Valve) EHC Valve (SD) (Pump Increase Control Solenoid Valve) EHC Valve (SH) (Auxiliary) EHC Valve (SB) (Auxiliary) EHC Valve (SA) (Auxiliary) EHC Valve (SC) (Oil Cooler Fan Control Solenoid Valve) Pressure Sensor (Main Pump 3, 5, 6 Displacement Control) Pressure Sensor (Pump Decrease Control) Pressure Sensor (Main Pump 1, 2, 4 Displacement Control) Pressure Sensor (Pump Increase Control) Pressure Sensor (Oil Cooler Fan Control)



T5-2-6



Page T5-3-19 T5-3-19 T5-3-19 T5-3-19 T5-3-19 T5-3-19 T5-3-23 T5-3-23 T5-3-23 T5-3-23 T5-3-23 T5-3-23 T5-3-23 T5-3-23 T5-3-8 T5-3-8 T5-3-8



Item No. 1 2 3 4 5 6 1 1 3 3 4 4 2 5 9 11 11



T5-3-30



1



T5-3-30



2



T5-3-30



3



T5-3-30 T5-3-30 T5-3-30 T5-3-30 T5-3-30 T5-3-30 T5-3-30 T5-3-30 T5-3-30 T5-3-30



4 8 7 6 5 -



Remarks



TROUBLESHOOTING / Cross Reference Table



No. 031 032 033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048 049 050 051 052 053 054 055 056 057 058 059 060



Component Name Emergency Switch 4 (Pump Compartment Rear Side) Maintenance Light (Pump Compartment) Work Light (Rear-Right) Camera 4 (Rear-Right) Oil Cooler Hydraulic Oil Temperature Sensor (OUT) (1) Oil Cooler Hydraulic Oil Temperature Sensor (OUT) (2) Air Temperature Sensor (1) (In Front of Oil Cooler) Air Temperature Sensor (2) (In Front of Oil Cooler) Oil Cooler Hydraulic Oil Temperature Sensor (IN) (1) Oil Cooler Hydraulic Oil Temperature Sensor (IN) (2) Engine Oil Reserve Tank Fill System Level Switch Engine Oil Reserve Tank Level Switch Engine Oil Reserve Pump Unit Switch Engine Oil Reserve Tank Fill System Valve Switch Prelub Motor Alternator Starter (Upper) Starter (Lower) Prelub Pressure Switch Engine Speed Sensor Engine Oil Level Sensor ECM Bucket Close Solenoid Valve Travel Left Forward Solenoid Valve Travel Left Reverse Solenoid Valve Travel Right Forward Solenoid Valve Auxiliary Travel Right Reverse Solenoid Valve Swing Left Solenoid Valve Swing Right Solenoid Valve



NOTE: LD: Loading Shovel



T5-2-7



Page T5-3-8 T5-3-8 T5-3-8 T5-3-29 T5-3-29 T5-3-9 T5-3-9 T5-3-29 T5-3-29 T5-3-20 T5-3-20 T5-3-20 T5-3-20 T5-3-20 T5-3-20 T5-3-20 T5-3-31 T5-3-31 T5-3-31 T5-3-31 T5-3-31 T5-3-31 T5-3-31 T5-3-31



Item No. 14 12 13 6 8 3 4 2 3 6 3 3 1 2 8 4 10 11 12 13 17 14 15 16



Remarks



LD only



TROUBLESHOOTING / Cross Reference Table



No. 061 062 063 064 065 066 067 068 069 070 071 072 073 074 075 076 077 078 079 080 081 082 083 084 085 086 087 088 089 090



Component Name Pressure Sensor (Bucket Close) Pressure Sensor (Travel Left Forward) Pressure Sensor (Travel Left Reverse) Pressure Sensor (Travel Right Forward) Pressure Sensor (Travel Right Reverse) Pressure Sensor (Swing Left) Pressure Sensor (Swing Right) Fast Filling Panel Solenoid Valve Engine Oil Reserve Tank Filling System Power Switch Engine Oil Reserve Tank Filling System Control Switch Engine Oil Reserve Tank Fill Indicator Engine Oil Reserve Tank Shut-Off Valve Open Indicator Fuel Fill Indicator Fuel Cooler Bypass Solenoid Valve (Optional) Travel Alarm Proximity Switch (Fast Filling System) Air Bleeding Solenoid Valve Hydraulic Oil Level Switch 1 (Level Indicator) Hydraulic Oil Level Switch 2 (Alarm Light) Hydraulic Oil Temperature Sensor Valve Limit Switch (Suction) Work Light (Optional) Boom Lower Solenoid Valve Arm Roll-Out Solenoid Valve Bucket Roll-Out Solenoid Valve Auxiliary Arm Roll-In Solenoid Valve Bucket Roll-In Solenoid Valve Boom Raise Solenoid Valve Bucket Open Solenoid Valve



NOTE: LD: Loading Shovel



T5-2-8



Page T5-3-31 T5-3-31 T5-3-31 T5-3-31 T5-3-31 T5-3-31 T5-3-31 T5-3-8 T5-3-7 T5-3-7 T5-3-7 T5-3-7 T5-3-7 T5-3-8 T5-3-6, 8 T5-3-1, 8 T5-3-8 T5-3-8 T5-3-8 T5-3-8 T5-3-31 T5-3-31 T5-3-31 T5-3-31 T5-3-31 T5-3-31 T5-3-31 T5-3-31



Item No. 20 3 4 1 2 5 18 6, 19 13, 6 7 8 16 22 1 2 3 4 7 8 9 17



Remarks LD only



LD Only



TROUBLESHOOTING / Cross Reference Table



No. 091 092 093 094 095 096 097 098 099 100 101 102 103 104



Component Name Pressure Sensor (Boom Lower) Pressure Sensor (Arm Roll-Out) Pressure Sensor (Bucket Roll-Out) Pressure Sensor (Arm Roll-In) Pressure Sensor (Bucket Roll-In) Pressure Sensor (Boom Raise) Pressure Sensor (Bucket Open) Pilot Shut-Off Pressure Sensor Fuel Level Switch (H) Fuel Level Switch (L) Fuel Level Sensor Pressure Sensor (Travel) Travel Mode Solenoid Valve Pilot Shut-Off Solenoid Valve



Page T5-3-31 T5-3-31 T5-3-31 T5-3-31 T5-3-31 T5-3-31 T5-3-31 T5-3-31 T5-3-8 T5-3-8 T5-3-8 T5-3-26 T5-3-4 T5-3-4



NOTE: LD: Loading Shovel



T5-2-9



Item No. 5 25 25 25 3 4 5



Remarks



LD only



TROUBLESHOOTING / Cross Reference Table ELECTRICAL CIRCUIT DIAGRAM (3/3) No. 001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030



Component Name Camera 2 (Front-Right) (Optional) Work Light (Front-Right) Work Light (Front-Right) Horn (Right) (Optional) Horn Compressor Motor (Optional) Horn Pressure Switch (R1) (Optional) Horn Pressure Switch (R2) (Optional) Auto-Lubrication Solenoid Valve Auto-Lubrication Grease Pressure Switch (Auto) Auto-Lubrication Grease Pressure Switch (Manual) Auto-Lubrication Mode Switch Prelub Timer Relay Fuse (5A) (Prelub Signal) Prelub Relay Starter Relay 1 (Upper) Starter Relay 1 (Lower) Alternator Relay Starter Relay 2 Engine Oil Fill System Relay (1) Engine Oil Fill System Relay (2) Fusible Link (400 A) (Prelub Relay) Circuit Breaker Fuse (30 A) (Zener Diode) Fuse (10 A) (Engine Oil Reserve Tank Valve) Fusible Link 8 (75 A) (Engine Starter Relay) Fusible Link 2 (75 A) (Fuse Box) Fusible Link 3 (75 A) (Fuse Box) Fusible Link 4 (75 A) (Fuse Box) Fusible Link 5 (75 A) (Fuse Box) Fusible Link 6 (75 A) (Fuse Box)



T5-2-10



Page T5-3-8 T5-3-8 T5-3-34 T5-3-10、34 T5-3-10、34 T5-3-10、34 T5-3-10 T5-3-11 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-11 T5-3-10 T5-3-11 T5-3-11 T5-3-11 T5-3-11 T5-3-11 T5-3-11 T5-3-11 T5-3-11



Item No. 4 4 6 16、1 17、2 15、3 5 4 13 7 8 4 6 2 3 3 11 5 6 14 8 9 10 11 12



Remarks



TROUBLESHOOTING / Cross Reference Table



No. 031 032 033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048 049



Component Name Fusible Link 1 (75 A) (Fuse Box) Fusible Link 7 (45 A) (Optional) Battery Relay (1) Battery Relay (2) Battery Relay (3) Fusible Link 9 (45 A) (ECM Main Power) Fusible Link 10 (75 A) (Sliding Fold-In Ladder Relay) Fusible Link (250 A) (Sliding Fold-In Ladder Motor (1)) Fusible Link (250 A) (Sliding Fold-In Ladder Motor (2)) Battery Cover Switch Arm Bottom Pressure Sensor Arm Rod Pressure Sensor Swing Motor Drain Pressure Sensor (Front) Contamination Sensor (Front Swing Motor) Travel Motor Drain Pressure Sensor Contamination Sensor (Travel Motor) Swing Motor Drain Pressure Sensor (Rear) Contamination Sensor (Rear Swing Motor)



T5-2-11



Page T5-3-11 T5-3-11 T5-3-10 T5-3-10 T5-3-10 T5-3-11 T5-3-11 T5-3-11 T5-3-11 T5-3-10 T5-3-10 T5-3-26 T5-3-26 T5-3-27 T5-3-19 T5-3-28 T5-3-19 T5-3-27 T5-3-19



Item No. 7 13 10 9 14 15 16 1 2 12 1 2 1 2 8 4 9 2 7



Remarks



TROUBLESHOOTING / Cross Reference Table (Blank)



T5-2-12



TROUBLESHOOTING / Component Layout MAIN COMPONENT LAYOUT Loading Shovel 7



8



6 5



9



10



11



12 13 14 15 16 17 18 19



1 2



3 4 20



39 38



21 22



37 23



36 24



35 34 33



26



32 31



25



27 30



29



28 T18L-01-02-001



1 - Arm Cylinder 2 - Level Cylinder 3 - Bucket Cylinder 45678-



Dump Cylinder Bucket Arm Boom Boom Cylinder



9 - Swing Device 10 - Auto-Lubrication Device (Lubricator)



11 - Center Joint 12 - Main Hydraulic Oil Tank 13 - Air Bleeding Solenoid Valve 14 - Control Valve 15 - Bypass Filter 16 - High Pressure Strainer 17 - Fuel Cooler 18 - Oil Cooler 19 - Pump Transmission Cooler 20 - Oil Cooler Fan Motor



21 - Sub-Hydraulic Oil Tank 22 - Pump Device 23 - Engine Oil Reserve Tank 24 25 26 27 28 -



Engine Accumulator (Pilot Circuit) Radiator Shuttle Valve (Travel) Pilot Pressure Selector Valve 29 - Accumulator (Adjuster) 30 - Travel Device



T5-3-1



31 - Travel Brake Valve 32 - Relief Valve (Accumulator) 33 - Reducing Valve (Accumulator) 34 - Accumulator (Adjuster) 35 - Swing Bearing 36 - Adjuster Cylinder 37 - Compressor Motor 38 - Compressor (For Air Conditioner) 39 - Washer Tank



TROUBLESHOOTING / Component Layout Backhoe



4



5



3



6



2 1



M18L-01-005



1 - Bucket 2 - Arm



3 - Bucket Cylinder 4 - Arm Cylinder



5 - Boom Cylinder



T5-3-2



6-



Boom



TROUBLESHOOTING / Component Layout Pump and Components 1



2



9



8



7



6



5



4



3 T18L-01-02-003



1 - Main Pump 1 (Transmission Side) Main Pump 2 (Pump End Side) 2 - Main Pump 3 (Transmission Side) Main Pump 4 (Pump End Side) 3 - Main Pump 5 (Transmission Side) Main Pump 6 (Pump End Side)



4-



4-Unit Pump



5 - Transmission Oil Pump Bypass Check Valve



6-



Transmission Oil Filter



8-



7-



Pilot Relief Valve



9 - EHC Valve (Main Pump Control)



T5-3-3



Pilot Filter



TROUBLESHOOTING / Component Layout Pilot Panel (Operation Circuit)



A



2



1



B



3



View A



4



T18L-01-02-008



9



View B



5



T18L-01-02-019



8 1 - Compressor Pump Relief Valve 2 - Accumulator (Pilot Circuit) 3 - Reducing Valve



7 4 - Travel Mode Solenoid Valve 5 - Pilot Shut-Off Solenoid Valve 6 - Check Valve (Pilot Circuit)



10



6 7 - EHC Valve (For Front) 8 - DQR Valve (For Front)



T5-3-4



9-



DQR Valve (For Travel/Swing) 10 - EHC Valve (For Travel/Swing)



TROUBLESHOOTING / Component Layout Undercarriage



7



1



2



6



5



1 - Adjuster Cylinder 2 - Valve



4



3 - Accumulator (For Adjuster Cylinder) 4 - Pilot Pressure Selector Valve



T18L-01-02-016



3



5 - Center Joint 6 - Check Valve



T5-3-5



7 - Relief Valve



TROUBLESHOOTING / Component Layout Fast Filling System 1



2



3



4



A



T18L-01-02-020



View A



6



4



1



5



T18L-01-02-015



1 - Lift Cylinder (2 Used) 2 - Check Valve



3 - Slow Return Valve 4 - Fast-Filling Panel



5 - Fast-Filling Solenoid Valve



T5-3-6



6-



Proximity Switch



TROUBLESHOOTING / Component Layout Fast-Filling Panel



1



2



3



4



5



6



7



8



16



15



9



M18L-01-012



14



1 - Engine Oil Reserve Tank Fill Indicator 2 - Engine Oil Reserve Tank Shut-Off Valve Open Indicator 3 - Engine Oil Reserve Tank Filling System Power Switch 4 - Engine Oil Reserve Tank Filling System Control Switch



13



12



11



10



5 - Fuel Fill Indicator



9 - Grease



6 - Hydraulic Oil



10 - Gear Oil (Rear Side Swing Device)



7 - Gear Oil (Front Side Swing Device)



11 - Fuel



15 - Coolant (Radiator Engine Side)



8 - Pump Transmission Oil



12 - Engine Oil Out (Reserve Tank)



16 - Engine Oil (Engine Oil Pan)



T5-3-7



13 - Coolant (Radiator Outside) 14 - Engine Oil In (Reserve Tank)



TROUBLESHOOTING / Component Layout ELECTRICAL COMPONENT LAYOUT 1



2



3 4 5 6



7



8



9



10



32



11 12 13



31 14



30



15 16 17 29



18 28



19 20



27 26



21



25 24



T18L-01-02-037



23



1 - Work Light (on the Cab) 2 - Entrance Light 3 - Air Conditioner 4 - Work Light (Front Right)



22



9 - Emergency Switch 5 10 - Maintenance Light (Engine Compartment) 11 - Valve Limit Switch (Delivery Circuit) 12 - Maintenance Light (Pump Compartment)



5 - Battery



13 - Work Light (Rear Right)



6 - Air Bleeding Solenoid Valve



14 - Emergency Switch 4



7 - Hydraulic Oil Level Switch 1 (Level Indicator) 8 - Hydraulic Oil Level Switch 2 (Alarm Light)



15 - Engine Oil Reserve Tank Level Switch 16 - Hydraulic Oil Temperature Sensor



17 - Emergency Switch 3 18 - Travel Alarm



25 - Fuel Level Switch 26 - Entrance Light



19 - Proximity Switch (Fast Filling System) 20 - Fast Filling Panel Raise/Lower Solenoid Valve (Fast Filling System) 21 - Work Light (Rear Left)



27 - Maintenance Light (Under Cab Compartment) 28 - Electrical Equipment Box



22 - Valve Limit Switch (Suction Circuit) 23 - Work Light (Rear Left) 24 - Emergency Switch 2



T5-3-8



29 - Receiver-Dryer Condenser Fan Control Pressure Switch 30 - Work Light (Front Left) 31 - Condenser (Fan Motor) 32 - Horn



TROUBLESHOOTING / Component Layout Electrical Component



T18L-01-02-041



T18L-01-02-040



3 1



1 - Air Temperature Sensor (Outside of Cab)



T18L-01-02-042



2-



2



4



T18L-01-02-043



T18L-01-02-044



Air Temperature Sensor (In Front of Radiator)



3-



T5-3-9



Air Temperature Sensor (1) (In Front of Oil Cooler)



4-



Air Temperature Sensor (2) (In Front of Oil Cooler)



TROUBLESHOOTING / Component Layout Battery Compartment 1



2



3



4



A



5



6



7



8



B



9 14



10



13



11



12



Cross Section A



Cross Section B



T18L-01-02-036



16 15 17



M18L-07-042



1 - Cover Switch 2 - Engine Oil Fill System Relay (1) 3 - Engine Oil Fill System Relay (2) 4 - Alternator Relay



6 - Starter Relay 2 7 - Starter Relay 1 (Upper)



10 - Battery Relay (1) 11 - Circuit Breaker



8 - Starter Relay 1 (Lower)



12 - Battery



9 - Battery Relay (2)



13 - PRELUB Relay



5 - PRELUB Timer Relay



T5-3-10



14 - Battery Relay (3) 15 - Auto-Lubrication Mode Switch 16 - Auto-Lubrication Grease Pressure Switch 17 - Auto-Lubrication Grease Pressure Switch (Manual)



TROUBLESHOOTING / Component Layout Battery Compartment (Fusible Link)



A



Cross Section A



B



Cross Section B



C



1



3 5



4 2



6



T18L-01-02-045



Cross Section C



7



8



9



10



13



14



15



16



11



12



T18L-01-02-046



1 - Fusible Link (250 A) (Sliding Fold-In Ladder Motor (Front)) 2 - Fusible Link (250 A) (Sliding Fold-In Ladder Motor (Rear)) 3 - Fusible Link (400 A) (PRELUB Relay) 4 - Fusible Link (5 A) (PRELUB Signal)



5 - Fusible Link (30 A) (Zener Diode)



9 - Fusible Link 3 (75 A) (Fuse Box)



13 - Fusible Link 7 (45 A) (Optional)



6 - Fusible Link (10 A) (Engine Oil Reserve Tank Valve) 7 - Fusible Link 1 (75 A) (Fuse Box) 8 - Fusible Link 2 (75 A) (Fuse Box)



10 - Fusible Link 4 (75 A) (Fuse Box)



14 - Fusible Link 8 (75 A) (Engine Starter Relay)



11 - Fusible Link 5 (75 A) (Fuse Box) 12 - Fusible Link 6 (75 A) (Fuse Box)



15 - Fusible Link 9 (45 A) (ECM Main Power) 16 - Fusible Link 10 (75 A) (Sliding Fold-In Ladder Relay)



T5-3-11



TROUBLESHOOTING / Component Layout Cab Inside



1



2



T18G-01-02-053



T18M-01-02-004



29



3



4



5



28



6



27



7 8



26



9



25



10



24



11



23 22



12



21



13



20



14



19



18



17



16



15



13



T18M-01-02-005



1 - Monitor Display



9 - Dome Light Switch



16 - Travel Speed Switch



2 - Hour Meter 3 - Left Control Lever/Horn Switch 4 - Right Control Lever/Horn Switch 5 - Pilot Control Shutoff Lever 6 - Emergency Switch



10 - Entrance Light Switch 11 - Auto-Idle Switch



17 - Maintenance Switch 18 - Work Light Switch



23 - Air Conditioner Control (Front) 24 - Wiper/Washer Switch 25 - Wiper Interval Switch



12 - Fast Filling System Switch



19 - Engine Stop Switch



26 - Display Contrast Switch



13 - Auxiliary 14 - Key Switch



7 - Engine Control Dial



15 - Buzzer Stop Switch



20 - Radio 21 - Air Conditioner Control (Rear) 22 - Air Conditioner Control (Side)



27 - Key Pad 28 - Engine Warning Lamp (Yellow) 29 - Engine Stop Lamp (Red)



8 - Engine Start Switch



T5-3-12



TROUBLESHOOTING / Component Layout 1



2



3



4



5



M18M-01-006



6



7



8



1 - Electric Lever (Left) 2 - Electric Lever (Bucket Close) (LD Only)



3 - Electric Lever (Travel) 4 - Electric Lever (Bucket Open) (LD Only)



5 - Electric Lever (Right) 6 - Monitor Display



NOTE: LD: Loading Shovel



T5-3-13



T18M-01-02-006



7 - IDU 8 - ELU



TROUBLESHOOTING / Component Layout



1



A



A



T18G-01-02-030



M18M-01-007



2



3



4



5



6



7



Cross Section A-A



8 9 10



13



12



11



T18G-01-02-026



Layout of Power Source Terminal 1 - Fuse Box (Cab) 2 - DC/DC Converter 3 - Cigar Lighter 4 - ORBCOMM (Optional)



5-



Data Link Connector (Auxiliary) 6 - Data Link Connector (ECM) 7 - Data Link Connector (DLU) 8 - Buzzer



9-



DC/DC Converter



10 - Power Source Terminal 11 - DLU 12 - Data Link Connector (MMS)



T5-3-14



13 - Controller (View Camera)



T146-01-03-023



TROUBLESHOOTING / Component Layout Electrical Equipment Box



T18L-01-02-038



10



11



12



13



9 8



7 6 5



Relay Arrangement (Refer to T1-2-16 to 17.)



4 3 2 1



T18M-01-02-007



1 - Fuse Box 2 2 - Fuse Box 1 3 - Fuse Box 4 4 - Fuse Box 3



5 - Auto Lubricator Interval Switch 6 - Engine Fault Indicator 7 - MC 8 - Engine Diagnostic Switch



9-



Fault code INC/DEC Switch 10 - HMU 11 - CSU 12 - Limit Switch (Box Light)



T5-3-15



13 - Box Light



TROUBLESHOOTING / Component Layout Relay Arrangement in Electrical Equipment Box



1



2



3



4



5



6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21



40 39 38 37 36 35 34 33



22 23 24



25 26 32



T5-3-16



31



30



29



28



27



T18M-01-02-007



TROUBLESHOOTING / Component Layout



1 - Wiper Relay 3（Slow Speed Control)



(L5) 11 - Work Light Relay 3 (Upper Cab Work Light (L)(R)) (L6) 12 - Work Light Relay 4 (Right Frame Front Work Light (L)(R)) (L1) 13 - Work Light Relay 5 (Engine Frame Rear Work Light (L)(R)) (L2) 14 - Work Light Relay 6 (Center L/R Side Work Light) (L3) 15 - Entrance Light Relay



(3)



(L4) 16 - Maintenance Light Relay (Engine Room)



(8)



7 - A/C Main Relay (Side) (L7) 17 - Fast Filling Panel Position Relay (Store Signal) 8 - A/C Main Relay (L8) 18 - Delayed Power Off (Rear) Relay 9 - Work Light Relay 1 (1) 19 - Travel Speed Select (Left Frame Front Relay Work Light (L)) (2) 20 - Fast Filling Device 10 - Work Light Relay 2 Relay (Left Frame Front Work Light (R))



(13)



2 - A/C Main Relay (Front) 3 - Air Horn Compressor Relay (L1) 4 - Air Horn Compressor Relay (R1) (Optional) 5 - Wiper Relay 1（Slow Speed Control） 6 - Wiper Relay 2（Slow Speed Control）



(21) 31 - ELU PWM Power Relay 1 （Key ON Signal） 22 - A/C Fan Relay (Front) (22) 32 - ELU Pilot Solenoid Relay



(26)



(5)



23 - A/C Fan Relay (Side)



(23) 33 - Air Horn Compressor Relay (L2)



(17)



(6)



24 - A/C Fan Relay (Rear) (24) 34 - Air Horn Compressor Relay (R2) (Option)



(18)



(7)



25 - Sliding Fold-In Ladder Alarm and Flash Light Relay 2 26 - Sliding Fold-In Ladder Alarm and Flash Light Relay 1 27 - Engine Oil Reserve Tank Pumping Unit Relay 28 - Sliding Fold-In Ladder Relay 29 - ELU PWM Power Relay 3 (Emergency Switch Signal) 30 - ELU PWM Power Relay 2 （Gate Lock Switch Signal）



(32) 35 - Horn Relay



(19)



(31) 36 - Wiper Relay 4 （Fast Speed Control）



(20)



(30) 37 - Maintenance Light Relay (Pump Room and Radiator Room) (29) 38 - Maintenance Light Relay (Cab Bed) (28) 39 - Maintenance Light Relay (Control Valve and Oil Cooler Room) (27) 40 - Charge Signal Relay



(9)



(4)



(14) (15)



(16)



21 - Washer Motor Relay



NOTE: Numbers in parentheses correspond to the numbers used in the electric circuit diagram.



T5-3-17



(25)



(10) (11)



(12)



TROUBLESHOOTING / Component Layout LEDs for Contamination Sensor Amplifier 2 1



4 3



6 5



Auxiliary



Auxiliary



7



9 8 Auxiliary



T146-05-02-049



T18M-01-02-007



1 - Main Pump 1 2 - Main Pump 2 3 - Main Pump 3



4 - Main Pump 4 5 - Main Pump 5



67-



T5-3-18



Main Pump 6 Front Swing Motor



89-



Rear Swing Motor Travel Motor



TROUBLESHOOTING / Component Layout Contamination Sensors Layout 1



3



4



2



5 6



Machine Front



A T18L-01-02-006



T18L-01-02-021



View A



7



Cross Section B



8



9



B



T18L-01-02-007



T18L-01-02-017



1 - Contamination Sensor (Main Pump 1) 2 - Contamination Sensor (Main Pump 2) 3 - Contamination Sensor (Main Pump 3)



4 - Contamination Sensor (Main Pump 4) 5 - Contamination Sensor (Main Pump 5)



6 - Contamination Sensor (Main Pump 6) 7 - Contamination Sensor (Rear Swing Motor)



T5-3-19



8-



Contamination Sensor (Front Swing Motor) 9 - Contamination Sensor (Travel Motor)



TROUBLESHOOTING / Component Layout ENGINE 1



2



3 5



9



4



8



7



T18L-01-02-031



6 T18L-01-02-032



1 - PRELUB Pressure Switch 2 - Engine Speed Sensor 3 - Starter (Cummins)



4 - Cummins ECM 5 - Fuel Filter (3 Used)



67-



T5-3-20



Alternator (Cummins) Coolant Filter (2 Used)



8 - Engine Oil Level Sensor 9 - Engine Oil Filter (4 Used)



TROUBLESHOOTING / Component Layout RADIATOR 1



A



4



B



5



3



2



T18L-01-02-025



C Cross Section A



View B



Cross Section C



7



6



8



9 T18L-01-02-026



1 - Water Tank 2 - LTA Cooler



4 - Coolant Temperature Sensor (LTA In) 5 - Coolant Temperature Sensor (Radiator In)



6-



Coolant Level Sensor



7-



Coolant Level Switch



3 - Radiator



T5-3-21



8-



Coolant Temperature Sensor (Radiator Out) 9 - Coolant Temperature Sensor (LTA Out)



TROUBLESHOOTING / Component Layout AIR CLEANER



1



2



T18L-01-02-027



1 - Air Cleaner



2-



Air Cleaner Restriction Switch



T5-3-22



TROUBLESHOOTING / Component Layout PUMP DEVICE 1



2



3



4



A



T18L-01-02-003



View A



5



T18L-01-02-029



1 - Pump 1 Drain Pressure Sensor (Transmission Side) Pump 2 Drain Pressure Sensor (Pump End Side) 2 - Pump Transmission Level Switch



3 - Pump 3 Drain Pressure Sensor (Transmission Side) Pump 4 Drain Pressure Sensor (Pump End Side)



4-



T5-3-23



Pump 5 Drain Pressure Sensor (Transmission Side) Pump 6 Drain Pressure Sensor (Pump End Side)



5-



Pump Transmission Oil Temperature Switch



TROUBLESHOOTING / Component Layout CONTROL VALVE NOTE: This drawing indicates the arrangement viewed from the base machine front.



Control Valve (Lower-Right)



1



2



3



4



5



6



7



8



Control Valve (Upper)



18



19



22



20 21



Control Valve (Lower-Left)



23



24



31 32 33 34 35



36



37



T18L-01-02-005



9



10 11 12



13



14



15



16 17 25



26



T5-3-24



27



28



29



30



38 39 40 41 42



43



TROUBLESHOOTING / Component Layout Control Valve (Lower-Right) 12345678910 11 12 13 14 15 16 17 -



Control Valve (Upper)



Overload Relief Valve (Boom Raise) Make-Up Valve (Boom Raise) Overload Relief Valve (Bucket Tilt-In) Make-Up Valve (Bucket Tilt-In) Overload Relief Valve (LD: Arm Extend, BH: Arm Roll-In) Make-Up Valve (LD: Arm Extend, BH: Arm Roll-In) Overload Relief Valve (Right Swing) Make-Up Valve (Right Swing) Make-Up Valve (Boom Lower) Overload Relief Valve (Boom Lower) Make-Up Valve (Bucket Tilt-Out) Overload Relief Valve (Bucket Tilt-Out) Make-Up Valve (BH: Arm Roll-Out) Overload Relief Valve (BH: Arm Roll-Out) Make-Up Valve (Left Swing) Overload Relief Valve (Left Swing) Main Relief Valve



18 19 20 21 22 23 24 25 26 27 28 29 30 -



Main Relief Valve Overload Relief Valve (Boom Raise) Make-Up Valve (Boom Raise) Overload Relief Valve (LD: Bucket Open, BH: Bucket Roll-In) Make-Up Valve (LD: Bucket Open, BH: Bucket Roll-In) Overload Relief Valve (LD: Arm Extend, BH: Arm Roll-In) Make-Up Valve (LD: Arm Extend, BH: Arm Roll-In) Make-Up Valve (Boom Lower) Overload Relief Valve (Boom Lower) Overload Relief Valve (LD: Bucket Close) Overload Relief Valve (LD: Bucket Close, BH: Bucket Roll-Out) Make-Up Valve (LD: Arm Retract, BH: Arm Roll-Out) Overload Relief Valve (LD: Arm Retract, BH: Arm Roll-Out)



Control Valve (Lower-Left) 31 32 33 34 35 36 37 38 39 40 41 42 43 -



Main Relief Valve Overload Relief Valve (LD: Arm Extend, BH: Arm Roll-In) Make-Up Valve (LD: Arm Extend, BH: Arm Roll-In) Overload Relief Valve (Boom Raise) Make-Up Valve (Boom Raise) Overload Relief Valve (Bucket Tilt-In) Make-Up Valve (Bucket Tilt-In) Make-Up Valve (LD: Arm Retract, BH: Arm Roll-Out) Overload Relief Valve (LD: Arm Retract, BH: Arm Roll-Out) Make-Up Valve (Boom Lower) Overload Relief Valve (Boom Lower) Make-Up Valve (Bucket Tilt-Out) Overload Relief Valve (Bucket Tilt-Out)



NOTE: LD: Loading Shovel BH: Backhoe



T5-3-25



TROUBLESHOOTING / Component Layout A



1



2 View A



T18L-01-02-033



B View B



4



1 - Arm Rod Pressure Sensor



2-



3



Arm Bottom Pressure Sensor



T18L-01-02-028



3-



T5-3-26



Pressure Sensor (Travel)



4-



Shuttle Valve (Travel)



TROUBLESHOOTING / Component Layout SWING DEVICE



3



4



1



T18L-01-02-007



2 1 - Swing Motor



2-



Swing Motor Drain Pressure Sensor



3-



T5-3-27



Relief Valve



4-



Make-Up Valve



TROUBLESHOOTING / Component Layout TRAVEL DEVICE



1



2



3



T18L-01-02-011



CENTER JOINT



4



T18L-01-02-017



1 - Travel Motor



2 - Brake Valve



3 - Travel Reduction Gear



T5-3-28



4 - Travel Motor Drain Pressure Sensor



TROUBLESHOOTING / Component Layout OIL COOLER Machine Front Side



1 2



A



3 4 B



Cross Section A



Cross Section B



1



4



5



7



8



6



T18L-01-02-047



1 - Oil Cooler (Front)



2 - Oil Cooler Hydraulic Oil Temperature Sensor (1) (IN)



3 - Oil Cooler Hydraulic Oil Temperature Sensor (2) (IN) 4 - Oil Cooler (Rear)



5 - Oil Cooler Bypass Check Valve (Front)



7 - Oil Cooler Bypass Check Valve (Rear)



6 - Oil Cooler Hydraulic Oil Temperature Sensor (1) (OUT)



8 - Oil Cooler Hydraulic Oil Temperature Sensor (2) (OUT)



T5-3-29



TROUBLESHOOTING / Component Layout EHC VALVE (FOR MAIN PUMP CONTROL) 1



2



8 7 3



6



5



4



T18L-01-02-004



1 - Main Pump Displacement Control (No.3, 5, 6 Main Pump) 2 - Power Decrease Control



3 - Main Pump Displacement Control (No.1, 2, 4 Main Pump) 4 - Power Increase Control



5 - Oil Cooler Fan Control



7 - Auxiliary



6 - Auxiliary



8 - Auxiliary



T5-3-30



TROUBLESHOOTING / Component Layout EHC VALVE CONTROL)



(FOR



ELECTRIC LEVER EHC Valve (Left Side)



EHC Valve (Center Side) 1



9



2



8



3



7



4



5



6



1 - Boom Lower



6 - Auxiliary



2 - Arm Extend 3 - Bucket Tilt-Out 4 - Auxiliary



7 - Arm Retract 8 - Bucket Tilt-In 9 - Boom Raise



T18L-01-02-023



10



11



12



13



17



16



15



14



10 - LD: Bucket Close BH: Auxiliary 11 - Left Travel Forward 12 - Left Travel Reverse 13 - Right Travel Forward



5 - Pilot Shut-Off Pressure Sensor



NOTE: LD: Loading Shovel BH: Backhoe



T5-3-31



T18L-01-02-022



14 - Right Travel Reverse 15 - Left Swing 16 - Right Swing 17 - LD: Bucket Open BH: Auxiliary



TROUBLESHOOTING / Component Layout SLIDING FOLD-IN LADDER 4 5



1



6



2



7



3 8 Cross Section A-A



Cross Section C-C



A



View B



9 10



B



A



11



12



C



C



13



14



T18L-01-02-039



1 - Sliding Fold-In Ladder Relay (2) 2 - Sliding Fold-In Ladder Relay (3) 3 - Sliding Fold-In Ladder Relay (4) 4 - Limit Switch (Expansion Detection)



5-



Limit Switch (Expansion Slowdown) 6 - Limit Switch (Storage Slowdown) 7 - Limit Switch (Storage Detection) 8 - Motor Pump Unit



9-



Valve Unit



10 - Work Light (Sliding Fold-In Ladder) 11 - Sliding Fold-In Ladder Beacon/Alarm



T5-3-32



12 - Limit Switch (Lock Lever) 13 - Sliding Fold-In Ladder Cylinder 14 - Lock Lever



TROUBLESHOOTING / Component Layout Valve Unit (For Sliding Fold-In Ladder) 1



2



4



3



5



6



7 8 14



9



13



12



11



10



15 3



2



11



T18L-01-02-034



6



14



P3



B A1 A2



P1



8 4



P2



12 10



A3



5



7 M



T 1 - Overload Relief Valve (For Cylinder Bottom Side) 2 - Orifice



1



15



13



PF



5 - Check Valve



9 - Check Valve 10 - Throttle Valve



3 - Check Valve



6 - Sliding Fold-In Ladder Solenoid Valve 3 7 - Main Relief Valve



4 - Check Valve



8 - Check Valve



11 - Sliding Fold-In Ladder Solenoid Valve 1 12 - Check Valve



T5-3-33



9



T18L-01-02-035



13 - Sliding Fold-In Ladder Solenoid Valve 2 14 - Slow Return Valve 15 - Overload Relief Valve (For Cylinder Rod side)



TROUBLESHOOTING / Component Layout AUTO-LUBRICATION SYSTEM Grease Tank



Lubricator Panel



4 1



3



6



2 5



M18L-07-015



T146-01-03-026



7



T18L-01-02-024



T18M-03-07-006



1 - Pressure Switch (Auto Lubrication) 2 - Pressure Switch (Manual Lubrication)



3 - Auto-Lubrication ON/OFF Switch 4 - Vent Valve



5 - Grease Pump 6 - Auto-Lubrication Solenoid Valve



T5-3-34



7 - Auto-Lubrication Interval Switch



TROUBLESHOOTING / Component Layout PILOT PIPING Manifold 1 This manifold is a pilot line connection block from manifold 2, EHC valve (for pump control), pilot relief valve and manifold 3. No. 1 2 3 4



Connecting Point Manifold 2 EHC Valve Pilot Relief Valve Manifold 3



Primary pilot Primary pilot Primary pilot Primary pilot



Remarks pressure pressure pressure pressure



Upper Side



2 1



Rear Side



Front Side



3



4



Lower Side EHC Valve T117-06-02-037



Manifold 2



3



Cross Section A



Pilot Relief Valve



2 1



4



T117-06-02-034



Cross Section B T18L-05-03-001



T5-3-35



TROUBLESHOOTING / Component Layout Manifold 2 This manifold is a pilot line connection block of pump control pressure. No. 1 2 3 4 5 6 7 8 9 10 11 12 13



Connecting Point EHC Valve (SI) EHC Valve (SF) EHC Valve (SE) EHC Valve (SD) EHC Valve (SC) Manifold 1 (1) Main Pump 3 (1), 5 (1), 6 (5) Main Pump 1 (2), 2 (2), 4 (2) Main Pump 1 (5), 2 (5), 4 (1) Main Pump 1 (7), 2 (4), 3 (7), 4 (4), 5 (7), 6 (4) Fan Motor Drive Pump (2) Main Pump 1 (6), 2 (2), 3 (6), 4 (2), 5 (6), 6 (2) Fan Motor Drive Pump (1)



1



Remarks Flow rate control pressure Pi for main pump Horspower decrease pressure Pf for main pump Flow rate control pressure Pi for main pump Hosepower increase pressure Pz for main pump Flow rate control pressure Pi for fan motor drive pump Primary pilot pressure Flow rate control pressure Pi for main pump Horspower decrease pressure Pf for main pump Flow rate control pressure Pi for main pump Hosepower increase pressure Pz for main pump Flow rate control pressure Pi for fan motor drive pump Pump servo assist pressure Psv for main pump Pump servo assist pressure Psv for fan motor drive pump



7 Upper Side



2 8



3



Rear Side



9



4



10



5



Front Side



Lower Side



11



6



12 13



T117-06-02-038



11



Cross Section A



13 7 to 12



1 to 6



Cross Section B T141-05-02-007



T18L-05-03-001



T5-3-36



TROUBLESHOOTING / Component Layout Manifold 3 This manifold is a pilot line connection block from manifold 2, fast filling system, auto-lubrication system, pilot shut-off solenoid valve, DQR valve 1 and DQR valve 2.



No. 1 2 3 4



Connecting Point Manifold 2 (4) Fast Filling System (Fast Filling Solenoid Valve) Auto-Lubrication System Pilot Shut-Off Solenoid Valve (4), DQR Valve 1 (9), DQR Valve 2 (8)



Remarks Primary pilot pressure Primary pilot pressure Primary pilot pressure Primary pilot pressure



DQR Valve 1 Pilot Shut-Off Solenoid Valve



1 2 To DQR Valve 2



3 4



T5-3-37



Manifold 3 T18L-01-02-009



TROUBLESHOOTING / Component Layout Pilot Shut-Off Solenoid Valve This valve opens and closes the pilot pressure oil circuit.



No. 1 2 3 4



Connecting Point EHC Valve 1 to EHC Valve 2 Manifold 4 (2) Hydraulic Oil Tank Connection Pipe



Remarks Primary pilot pressure Primary pilot pressure Return oil to hydraulic oil tank Primary pilot pressure



1



2



Manifold 4



EHC Valve 1



3



4 T18L-01-02-009



T5-3-38



TROUBLESHOOTING / Component Layout Manifold 4 This manifold is a pilot line connection block from pilot shut-off solenoid valve, swing motor and travel mode change solenoid valve. No. 1 2 3



Connecting Point Swing Motor Pilot Shut-Off Solenoid Valve (2) Travel Mode Change Solenoid Valve (3)



1



X



Remarks Pilot pressure for swing parking brake release Primary pilot pressure Travel parking brake release pressure / Travel speed change pressure



2 Upper Side



Left Side



3 T117-06-02-012



Right Side



Lower Side



View X



1



3 Cross Section B



1 2



T18L-05-03-002



Cross Section A



T117-06-02-028



T5-3-39



TROUBLESHOOTING / Component Layout Travel Mode Change Solenoid Valve No. 1 2 3 4



Connecting Point Reducing Valve (2) Hydraulic Oil Tank Manifold 4 (3)



Remarks Control pressure of reducing valve Return oil to hydraulic oil tank Travel parking brake release pressure / Travel speed change pressure Travel parking brake release pressure / Travel speed change pressure



Reducing Valve (3)



Upper Side



Left Side



Right Side



1



Lower Side



2



4



T18L-05-03-002



3



T117-06-02-018



Reducing Valve (For Travel Mode Change) No. 1



Connecting Point Center Joint to Travel Motor



2 3



Travel Mode Change Solenoid Valve (2) Travel Mode Change Solenoid Valve (4)



4



Hydraulic Oil Tank



Remarks Travel parking brake release pressure / Travel speed change pressure Control pressure of reducing valve Travel parking brake release pressure / Travel speed change pressure Return oil to hydraulic oil tank



Upper Side



Left Side



Right Side



2



Lower Side



3



1



4



T141-05-02-012



T18L-05-03-002



T5-3-40



TROUBLESHOOTING / Component Layout DQR Valve 1 DQR valve 1 controls the pilot pressure from EHC valve 1. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16



Connecting Point EHC Valve 1 (SE) EHC Valve 1 (SF) EHC Valve 1 (SI) EHC Valve 1 (SA) EHC Valve 1 (SB) EHC Valve 1 (SH) EHC Valve 2 (SH) Hydraulic Oil Tank Connection Pipe Manifold 5 (5) Manifold 6 (6) Manifold 6 (5) Manifold 6 (8) Manifold 6 (7) Manifold 5 (8) Manifold 5 (7)



Remarks Bucket roll-out pilot pressure Arm roll-out pilot pressure Boom lower pilot pressure Boom raise pilot pressure Bucket roll-in pilot pressure Arm roll-in pilot pressure Bucket open pilot pressure (LD only) Return oil to hydraulic oil tank Primary pilot pressure Bucket open pilot pressure (LD only) Arm roll-in pilot pressure Bucket roll-in pilot pressure Boom raise pilot pressure Boom lower pilot pressure Arm roll-out pilot pressure Bucket roll-out pilot pressure



NOTE: LD: Loading Shovel



Pilot Panel (Center Side) 1



3



2



4



16 15 14 13 12 11 10



9



8



7



6



5 T18L-01-02-009



T5-3-41



TROUBLESHOOTING / Component Layout DQR Valve 2 DQR valve 2 controls the pilot pressure from EHC valve 2.



No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16



Connecting Point Manifold 5 (6) Shuttle Valve (7) Shuttle Valve (8) Shuttle Valve (5) Shuttle Valve (6) Manifold 7 (3) Manifold 7 (4) Connection Pipe Hydraulic Oil Tank EHC Valve 2 (SB) EHC Valve 2 (SA) EHC Valve 2 (SC) EHC Valve 2 (SD) EHC Valve 2 (SE) EHC Valve 2 (SF) EHC Valve 2 (SI)



Remarks Bucket close pilot pressure (LD only) Travel left forward pilot pressure Travel left reverse pilot pressure Travel right forward pilot pressure Travel right reverse pilot pressure Left swing pilot pressure Right swing pilot pressure Primary pilot pressure Return oil to hydraulic oil tank Right swing pilot pressure Left swing pilot pressure Travel right reverse pilot pressure Travel right forward pilot pressure Travel left reverse pilot pressure Travel left forward pilot pressure Bucket close pilot pressure (LD only)



NOTE: LD: Loading Shovel



Pilot Panel (Left Side)



1 2



16



3



15



4



14 13



5



12



6



11



7



10 9



T5-3-42



8



T18L-04-05-002



TROUBLESHOOTING / Component Layout Manifold 5 No. 1 2 3 4 5 6 7 8



Connecting Point Left Control Valve (26) Left Control valve (30) Center Control Valve(6) Center Control Valve DQR Valve 2 (1) DQR Valve 1 (10) DQR Valve 1 (16) DQR Valve 1 (15)



Remarks Arm roll-out pilot pressure Bucket roll-out pilot pressure Bucket open pilot pressure (LD only) Bucket close pilot pressure (LD only) Bucket close pilot pressure (LD only) Bucket open pilot pressure (LD only) Bucket roll-out pilot pressure Arm roll-out pilot pressure



NOTE: LD: Loading Shovel



1



2



3



4 Upper Side



Left Side



Right Side



Lower Side T18L-05-03-003



8



7



6



5



Manifold 5



T141-05-02-008



T5-3-43



TROUBLESHOOTING / Component Layout Manifold 6 No. 1 2 3 4 5 6 7 8



Connecting Point Manifold 8 (11) Left Control Valve (28) Manifold 8 (12) Manifold 8 (10) DQR Valve 1 (12) DQR Valve 1 (11) DQR Valve 1 (14) DQR Valve 1 (13)



Remarks Boom raise pilot pressure Boom lower pilot pressure Arm roll-in pilot pressure Bucket roll-in pilot pressure Bucket roll-in pilot pressure Arm roll-in pilot pressure Boom lower pilot pressure Boom raise pilot pressure



1



3



2



4



Upper Side



Left Side



Right Side



Lower Side



8 T18L-05-03-004



7



6



5



T141-05-02-008



Manifold 6



T5-3-44



TROUBLESHOOTING / Component Layout Shuttle Valve No. 1 2 3 4 5 6 7 8



Connecting Point Left Control Valve (4) Left Control Valve (24) Center Control Valve (19) Center Control Valve (8) DQR Valve 2 (4) DQR Valve 2 (5) DQR Valve 2 (2) DQR Valve 2 (3)



1



2



3



Travel Travel Travel Travel Travel Travel Travel Travel



Remarks left reverse pilot pressure left forward pilot pressure right reverse pilot pressure right forward pilot pressure right forward pilot pressure right reverse pilot pressure left forward pilot pressure left reverse pilot pressure



4 Upper Side



Left Side



8



Right Side



Lower Side T18L-05-03-004



7



6



5



T141-05-02-008



Shuttle Valve



T5-3-45



TROUBLESHOOTING / Component Layout Manifold 7 No. 1 2 3 4



Connecting Point Right Control Valve (9) Right Control Valve (18) DQR Valve 2 (6) DQR Valve 2 (7)



1



Remarks Right swing pilot pressure Left swing pilot pressure Left swing pilot pressure Right swing pilot pressure



2



Upper Side



Left Side



Right Side



Lower Side



4



3



T18L-05-03-005



T141-05-02-008



Manifold 7



T5-3-46



TROUBLESHOOTING / Component Layout Manifold 8 No. 1 2 3 4 5 6 7 8 9 10 11 12



Connecting Point Right Control Valve (11) Left Control Valve (1) Right Control Valve (12) Center Control Valve (7) Right Control Valve (10) Center Control Valve (5) Center Control Valve (6) Left Control Valve (2) Left Control Valve (3) Manifold 6 (4) Manifold 6 (1) Manifold 6 (3)



Remarks Bucket roll-in pilot pressure Bucket roll-in pilot pressure Boom raise pilot pressure Boom raise pilot pressure LD: Arm extend pilot pressure, BH: Arm roll-in pilot pressure LD: Arm extend pilot pressure, BH: Arm roll-in pilot pressure Bucket roll-in pilot pressure Boom raise pilot pressure LD: Arm extend pilot pressure, BH: Arm roll-in pilot pressure Bucket roll-in pilot pressure Boom raise pilot pressure LD: Arm extend pilot pressure, BH: Arm roll-in pilot pressure



NOTE: LD: Loading Shovel BH: Backhoe



1



2



3



4



5 6



Upper Side



Left Side



7



8



9



10



11



12



Right Side



Lower Side



T18L-05-03-006



T141-05-02-008



T5-3-47



TROUBLESHOOTING / Component Layout Control Valve No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30



Connecting Point Manifold 8 (2) Manifold 8 (8) Manifold 8 (9) Shuttle Valve (1) Manifold 8 (6) Manifold 8 (7) Manifold 8 (4) Shuttle Valve (4) Manifold 7 (1) Manifold 8 (5) Manifold 8 (1) Manifold 8 (3) Left Control Valve (27) Center Control Valve (20) Left Control Valve (29) Center Control Valve (21) Center Control Valve (23) Manifold 7 (2) Shuttle Valve (3) Right Control Valve (14) Right Control Valve (16) Left Control Valve (25) Right Control Valve (17) Shuttle Valve (2) Center Control Valve (22) Manifold 5 (1) Right Control Valve (13) Manifold 6 (2) Right Control Valve (15) Manifold 5 (2)



Remarks Bucket roll-in pilot pressure Boom raise pilot pressure LD: Arm extend pilot pressure, BH: Arm roll-in pilot pressure Travel left reverse pilot pressure LD: Arm extend pilot pressure, BH: Arm roll-in pilot pressure LD: Bucket open pilot pressure, BH: Bucket roll-in pilot pressure Boom raise pilot pressure Travel right forward pilot pressure Right swing pilot pressure LD: Arm extend pilot pressure, BH: Arm roll-in pilot pressure Bucket roll-in pilot pressure Boom raise pilot pressure Boom lower pilot pressure Boom lower pilot pressure Bucket roll-out pilot pressure Bucket roll-out pilot pressure BH: Arm roll-out pilot pressure Left swing pilot pressure Travel right reverse pilot pressure LD: Bucket tilt-in pilot pressure, BH: Boom lower pilot pressure LD: Bucket close pilot pressure, BH: Bucket roll-out pilot pressure LD: Arm retract pilot pressure, BH: Arm roll-out pilot pressure LD: Arm retract pilot pressure, BH: Arm roll-out pilot pressure Travel left forward pilot pressure LD: Arm retract pilot pressure, BH: Arm roll-out pilot pressure LD: Arm retract pilot pressure, BH: Arm roll-out pilot pressure Boom lower pilot pressure Boom lower pilot pressure Bucket roll-out pilot pressure Bucket roll-out pilot pressure



NOTE: LD: Loading Shovel BH: Backhoe



T5-3-48



TROUBLESHOOTING / Component Layout



1



2



3



4



5



6



7



8



9



10



11



12



T18L-01-02-028



30



29



28



27



26



25



24



23



22 21



T5-3-49



20



19



18



17



16 15



14



13



TROUBLESHOOTING / Component Layout Main Pump No. 1 2 3 4 5 6 7



Manifold Manifold Manifold Manifold Manifold Manifold Manifold



2 2 2 2 2 2 2



Connecting Point (7, 9) (8) (12) (10) (7, 9) (12) (10)



1



Remarks Flow rate control pressure Pi Horsepower decrease pressure Pf Pump servo assist pressure Psv Horsepower increase pressure Pz Flow rate control pressure Pi Pump servo assist pressure Psv Horsepower increase pressure Pz



2



3



4



Upper Side



Rear Side



Front Side



Lower Side



7



6



T141-05-02-013



5



Fan Motor Drive Pump No. 1 2



Connecting Point



Remarks Pump servo assist pressure Psv Flow rate control pressure Pi



Manifold 2 (13) Manifold 2 (11)



1 Upper Side



Rear Side



Front Side



Lower Side



2 T118-05-02-026



T5-3-50



TROUBLESHOOTING / Troubleshooting A TROUBLESHOOTING A PROCEDURE Refer to troubleshooting A procedure in case any fault codes are displayed after diagnosing the controller using Monitor Display.



Cummins Code is the fault code of Cummins Inc..



HCM Code is the fault code of Hitachi Construction Machinery Co.,Ltd.



T18M-05-01-005



T5-4-1



TROUBLESHOOTING / Troubleshooting A FAULT DIAGNOSIS INDICATION IDU indicates the fault diagnosis results on the monitor display in response to fault signals received from each controller through CAN. IMPORTANT: Monitor display window can be switched by the keypad. IMPORTANT: Only when malfunction or alarm occurs, Fault or Alarm is displayed on the Meter Window by blinking. Item Alarm (←) Fault (→) Menu ({)



Abnormal Not abnormal Blinking Not displayed Blinking Not displayed Always displayed



Key Pad



T18G-02-01-108



Meter Window



Indication 1. When the Meter Window appears on the monitor display, press the → (or ←) key to display the Current Faults (or Alarm) List Window on the monitor display. To return to the Meter Window, press the × key.



T18M-05-01-001



Current Faults (or Alarm) List Window



T18M-05-01-005



T5-4-2



TROUBLESHOOTING / Troubleshooting A 2. Select the required item from the list, using the ↑ and ↓ keys, and press the { key. The Fault (or Alarm) Explanation Window of the selected item will appear. To return the Current Faults (or Alarm) List Window, press the × key.



Current Faults (or Alarm) List Window



T18M-05-01-005



3. To display the Detailed Circuit Diagram Window, press the { key. To return to the Fault (or Alarm) Explanation Window, press the × key.



Faults (or Alarm) Explanation Window



T18G-05-01-007



Detailed Circuit Diagram



T18G-05-01-027



T5-4-3



TROUBLESHOOTING / Troubleshooting A FAULT CODE LIST HCM CODE 00006-000 00006-003 00006-004 00006-016 00007-001 00007-003 00007-004 00007-018 00008-001 00008-003 00008-004 00009-000 00009-003 00009-004 00009-016 00011-001 00011-003 00011-004 00011-018 00012-003 00012-004 00012-016 00014-016 00015-000 00015-003 00015-004 00021-000 00021-003 00021-004 00021-010 00021-016 00022-000 00022-003 00022-004 00022-010 00022-016



Cummins CODE 00151 00144 00145 00146 00235 00195 00196 00197 00228 00231 00232 00266 00263 00265 00261 00415 00135 00141 00143 00212 00213 00421 01362 00556 01843 01844 00155 00153 00154 00783 00488 00158 00156 00157 02157 01984



Description High Coolant Temperature Coolant Temperature Sensor Failed High Coolant Temperature Sensor Failed Low Coolant Temperature Above Normal Low Coolant Level Coolant Level Sensor Failed High Coolant Level Sensor Failed Low Coolant Level Below Normal Very Low Coolant Pressure Coolant Pressure Sensor Failed High Coolant Pressure Sensor Failed Low High Fuel Temperature (Most Sever Level) Fuel Temperature Sensor Failed High Fuel Temperature Sensor Failed Low High Fuel Temperature (Moderate Level) Very Low Oil Pressure Oil Pressure Sensor Failed High Oil Pressure Sensor Failed Low Low Oil Pressure Engine Oil Temperature Sensor Failed High Engine Oil Temperature Sensor Failed Low Engine Oil Temperature Above Normal High Lube Oil Filter Restriction High Crankcase Pressure Crankcase Pressure Sensor Failed High Crankcase Pressure Sensor Failed Low High Inlet Manifold Temperature 1 Inlet Manifold Temperature 1 Sensor Failed High Inlet Manifold Temperature 1 Sensor Failed Low Rapid Rise Inlet Manifold Temperature 1 High Intake Manifold Temperature High Inlet Manifold Temperature 2 Inlet Manifold Temperature 2 Sensor Failed High Inlet Manifold Temperature 2 Sensor Failed Low Rapid Rise Inlet Manifold Temperature 2 Inlet Manifold Temperature 2 Above Normal



T5-4-4



Warning Buzzer Yes No No Yes Yes No No No Yes No No Yes No No Yes Yes No No No No No Yes No Yes No No Yes No No No Yes Yes No No No Yes



Related Controller ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM



TROUBLESHOOTING / Troubleshooting A HCM CODE 00041-000 00041-003 00041-004 00041-018 00043-003 00043-004 00046-000 00046-002 00048-003 00048-004 00048-008 00096-003 00096-004 00097-003 00097-004 00098-003 00098-004 00100-003 00100-004 00120-016 00121-016 00122-016 00123-016 00124-016 00125-016 00126-016 00127-016 00128-016 00129-016 00130-016 00131-016 00132-016 00133-016 00134-016 00135-016 00188-003 00188-004 00227-005 00227-006



Cummins CODE 00449 00451 00452 00559 00221 00222 00234 00689 01358 01359 01514



02121 02131 02122 02132 02123 02133 02124 02134 02125 02135 02126 02136 02127 02137 02128 02138



Description High Rail Pressure Rail Pressure Sensor Failed High Rail Pressure Sensor Failed Low Rail Pressure 1 Below Normal Ambient Air Pressure Failed High Ambient Air Pressure Failed Low Engine Overspeed Engine Crankshaft Speed Erratic Axel Pedal Sensor 1 Sensor Failed High Axel Pedal Sensor 1 Sensor Failed Low Axel Pedal Position Sensor 1 Freq Issue Temperature Sensor Fault (Inlet Air) High Temperature Sensor Fault (Inlet Air) Low Temperature Sensor Fault (Radiator Outlet) High Temperature Sensor Fault (Radiator Outlet) Low Pressure Sensor Fault (Cooler Fan Motor Inlet) High Pressure Sensor Fault (Cooler Fan Motor Inlet) Low Pressure (Cooler Fan Motor Negative Control) High Pressure (Cooler Fan Motor Negative Control) Low High Exhaust Temperature Cylinder 1 High Exhaust Temperature Cylinder 2 High Exhaust Temperature Cylinder 3 High Exhaust Temperature Cylinder 4 High Exhaust Temperature Cylinder 5 High Exhaust Temperature Cylinder 6 High Exhaust Temperature Cylinder 7 High Exhaust Temperature Cylinder 8 High Exhaust Temperature Cylinder 9 High Exhaust Temperature Cylinder 10 High Exhaust Temperature Cylinder 11 High Exhaust Temperature Cylinder 12 High Exhaust Temperature Cylinder 13 High Exhaust Temperature Cylinder 14 High Exhaust Temperature Cylinder 15 High Exhaust Temperature Cylinder 16 Level Sensor Fault (Fuel) High Level Sensor Fault (Fuel) Low EHC Valve Current Low (Radiator Fan) EHC Valve Current High (Radiator Fan)



T5-4-5



Warning Buzzer No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No



Related Controller ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM MC MC MC MC MC MC MC MC ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM MC MC MC MC



TROUBLESHOOTING / Troubleshooting A HCM CODE 00231-000 00231-003 00231-004 00231-010 00231-016 00232-000 00232-003 00232-004 00232-010 00232-016 00233-003 00233-004 00233-016 00234-003 00234-004 00234-016 00239-003 00239-004 00249-003 00249-004 00250-003 00250-004 01001-003 01001-004 01003-000 01003-001 01003-005 01003-006 01005-003 01005-004 01007-000 01007-001 01007-005 01007-006



Cummins CODE 00162 00159 00161 02158 01985 00165 00163 00164 02159 01986 02242 02243 01987 02246 02247 01988



Description High Inlet Manifold Temperature 3 Inlet Manifold Temperature 3 Sensor Failed High Inlet Manifold Temperature 3 Sensor Failed Low Rapid Rise Inlet Manifold Temperature 3 Inlet Manifold Temperature 3 Above Normal High Inlet Manifold Temperature 4 Inlet Manifold Temperature 4 Sensor Failed High Inlet Manifold Temperature 4 Sensor Failed Low Rapid Rise Inlet Manifold Temperature 4 Inlet Manifold Temperature 4 Above Normal Inlet Manifold Temperature 5 Sensor Failed High Inlet Manifold Temperature 5 Sensor Failed Low Inlet Manifold Temperature 5 Above Normal Inlet Manifold Temperature 6 Sensor Failed High Inlet Manifold Temperature 6 Sensor Failed Low Inlet Manifold Temperature 6 Above Normal Temperature Sensor Fault (Radiator Inlet) High Temperature Sensor Fault (Radiator Inlet) Low Temperature Sensor Fault (LTA Radiator Inlet) High Temperature Sensor Fault (LTA Radiator Inlet) Low Temperature Sensor Fault (LTA Radiator Outlet) High Temperature Sensor Fault (LTA Radiator Outlet) Low Pressure Sensor Fault (Positive Control 1) High Pressure Sensor Fault (Positive Control 1) Low EHC Valve Stick/High Pressure (Positive Control 1) EHC Valve Stick/Low Pressure (Positive Control 1) EHC Valve Current Low (Positive Control 1) EHC Valve Current High (Positive Control 1) Pressure Sensor Fault (Positive Control 2) High Pressure Sensor Fault (Positive Control 2) Low EHC Valve Stick/High Pressure (Positive Control 2) EHC Valve Stick/Low Pressure (Positive Control 2) EHC Valve Current Low (Positive Control 2) EHC Valve Current High (Positive Control 2)



T5-4-6



Warning Buzzer Yes No No No Yes Yes No No No Yes No No No No No No No No No No No No No No No No No No No No No No No No



Related Controller ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM MC MC MC MC MC MC ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU



TROUBLESHOOTING / Troubleshooting A HCM CODE 01050-000 01051-000 01052-000 01053-000 01054-000 01055-000 01056-000 01057-000 01066-000 01068-003 01068-004 01070-005 01070-006 01072-003 01072-004 01074-005 01074-006 01102-003 01102-004 01104-000 01104-001 01104-005 01104-006 01106-003 01106-004 01108-000 01108-001 01108-005 01108-006 01110-003 01110-004 01112-000 01112-001 01112-005 01112-006 01114-003 01114-004 01116-000 01116-001 01116-005 01116-006



Cummins CODE



Description Contamination Alarm (CH1) Contamination Alarm (CH2) Contamination Alarm (CH3) Contamination Alarm (CH4) Contamination Alarm (CH5) Contamination Alarm (CH6) Contamination Alarm (CH7) Contamination Alarm (CH8) Contamination Alarm (Travel Motor CH21) Pressure Sensor Fault (Power Increase) High Pressure Sensor Fault (Power Increase) Low EHC Valve Current Low (Power Increase) EHC Valve Current High (Power Increase) Pressure Sensor Fault (Power Reduction) High Pressure Sensor Fault (Power Reduction) Low EHC Valve Current Low (Power Reduction) EHC Valve Current High (Power Reduction) Pressure Sensor Fault (Positive Control 3) High Pressure Sensor Fault (Positive Control 3) Low EHC Valve Stick/High Pressure (Positive Control 3) EHC Valve Stick/Low Pressure (Positive Control 3) EHC Valve Current Low (Positive Control 3) EHC Valve Current High (Positive Control 3) Pressure Sensor Fault (Positive Control 1) High Pressure Sensor Fault (Positive Control 1) Low EHC Valve Stick/High Pressure (Positive Control 1) EHC Valve Stick/Low Pressure (Positive Control 1) EHC Valve Current Low (Positive Control 1) EHC Valve Current High (Positive Control 1) Pressure Sensor Fault (Positive Control 2) High Pressure Sensor Fault (Positive Control 2) Low EHC Valve Stick/High Pressure (Positive Control 2) EHC Valve Stick/Low Pressure (Positive Control 2) EHC Valve Current Low (Positive Control 2) EHC Valve Current High (Positive Control 2) Pressure Sensor Fault (Positive Control 3) High Pressure Sensor Fault (Positive Control 3) Low EHC Valve Stick/High Pressure (Positive Control 3) EHC Valve Stick/Low Pressure (Positive Control 3) EHC Valve Current Low (Positive Control 3) EHC Valve Current High (Positive Control 3)



T5-4-7



Warning Buzzer No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No



Related Controller CSU CSU CSU CSU CSU CSU CSU CSU CSU MC MC MC MC MC MC MC MC ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU



TROUBLESHOOTING / Troubleshooting A HCM CODE 02001-003 02001-004 02003-003 02003-004 03006-000 03007-000 03008-000 03009-000 05006-013 05008-013 05009-013 05010-013 05011-013 07000-003 07000-004 08008-003 08008-004 08011-005 08011-006 10017-012 10018-012 11001-003 11001-004 11003-000 11003-001 11003-005 11003-006 11006-003 11006-004 11008-000 11008-001 11008-005 11008-006 11011-003 11011-004 11013-000 11013-001 11013-005 11013-006



Cummins CODE



Description Pressure Sensor Fault (Travel) High Pressure Sensor Fault (Travel) low Pressure Sensor Fault (Adjuster Cylinder) High Pressure Sensor Fault (Adjuster Cylinder) Low Contamination Alarm (Swing Motor CH17) Contamination Alarm (Swing Motor CH18) Contamination Alarm (Swing Motor CH19) Contamination Alarm (Swing Motor CH20) Boom Raise Cylinder End Memory Error Arm Roll-In Cylinder End Memory Error Arm Roll-Out Cylinder End Memory Error Bucket Roll-In Cylinder End Memory Error Bucket Roll-Out Cylinder End Memory Error Temperature Sensor Fault (Hydraulic Oil) High Temperature Sensor Fault (Hydraulic Oil) Low Pressure (Cooler Fan Motor Negative Control) High Pressure (Cooler Fan Motor Negative Control) Low EHC Valve Current Low (Oil Cooler Fan) EHC Valve Current High (Oil Cooler Fan) Temperature Sensor Fault (Radiator Inlet) High Travel Operation Signal to MC Fault Pressure Sensor Fault (Boom Raise) High Pressure Sensor Fault (Boom Raise) Low EHC Valve Stick/High Pressure (Boom Raise Operation) EHC Valve Stick/Low Pressure (Boom Raise Operation) EHC Valve Current Low (Boom Raise Operation) EHC Valve Current High (Boom Raise Operation) Pressure Sensor Fault (Boom Lower) High Pressure Sensor Fault (Boom Lower) Low EHC Valve Stick/High Pressure (Boom Lower Operation) EHC Valve Stick/Low Pressure (Boom Lower Operation) EHC Valve Current Low (Boom Lower Operation) EHC Valve Current High (Boom Lower Operation) Pressure Sensor Fault (Bucket Roll-In) High Pressure Sensor Fault (Bucket Roll-In) Low EHC Valve Stick/High Pressure (Bucket Roll-In Operation) EHC Valve Stick/Low Pressure (Bucket Roll-In Operation) EHC Valve Current Low (Bucket Roll-In Operation) EHC Valve Current High (Bucket Roll-In Operation)



T5-4-8



Warning Buzzer No No No No No No No No No No No No No No No No No No No No No No No Yes Yes No Yes No No Yes Yes No Yes No No Yes Yes No Yes



Related Controller MC MC ELU ELU CSU CSU CSU CSU ELU ELU ELU ELU ELU MC MC MC MC MC MC ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU



TROUBLESHOOTING / Troubleshooting A HCM CODE 11016-003 11016-004 11018-000 11018-001 11018-005 11018-006 11021-003 11021-004 11023-000 11023-001 11023-005 11023-006 11026-003 11026-004 11028-000 11028-001 11028-005 11028-006 11031-003 11031-004 11033-000 11033-001 11033-005 11033-006 11036-003 11036-004 11038-000 11038-001 11038-005 11038-006 11041-003 11041-004 11043-000 11043-001 11043-005 11043-006 11046-003 11046-004



Cummins CODE



Description Pressure Sensor Fault (Bucket Roll-Out) High Pressure Sensor Fault (Bucket Roll-Out) Low EHC Valve Stick/High Pressure (Bucket Roll-Out Operation) EHC Valve Stick/Low Pressure (Bucket Roll-Out Operation) EHC Valve Current Low (Bucket Roll-Out Operation) EHC Valve Current High (Bucket Roll-Out Operation) Pressure Sensor Fault (Bucket Open) High Pressure Sensor Fault (Bucket Open) Low EHC Valve Stick/High Pressure (Bucket Open Operation) EHC Valve Stick/Low Pressure (Bucket Open Operation) EHC Valve Current Low (Bucket Open Operation) EHC Valve Current High (Bucket Open Operation) Pressure Sensor Fault (Bucket Close) High Pressure Sensor Fault (Bucket Close) Low EHC Valve Stick/High Pressure (Bucket Close Operation) EHC Valve Stick/Low Pressure (Bucket Close Operation) EHC Valve Current Low (Bucket Close Operation) EHC Valve Current High (Bucket Close Operation) Pressure Sensor Fault (Arm Roll-Out) High Pressure Sensor Fault (Arm Roll-Out) Low EHC Valve Stick/High Pressure (Arm Roll-Out Operation) EHC Valve Stick/Low Pressure (Arm Roll-Out Operation) EHC Valve Current Low (Arm Roll-Out Operation) EHC Valve Current High (Arm Roll-Out Operation) Pressure Sensor Fault (Arm Roll-In) High Pressure Sensor Fault (Arm Roll-In) Low EHC Valve Stick/High Pressure (Arm Roll-In Operation) EHC Valve Stick/Low Pressure (Arm Roll-In Operation) EHC Valve Current Low (Arm Roll-In Operation) EHC Valve Current High (Arm Roll-In Operation) Pressure Sensor Fault (Right Swing) High Pressure Sensor Fault (Right Swing) Low EHC Valve Stick/High Pressure (Right Swing Operation) EHC Valve Stick/Low Pressure (Right Swing Operation) EHC Valve Current Low (Right Swing Operation) EHC Valve Current High (Right Swing Operation) Pressure Sensor Fault (Left Swing) High Pressure Sensor Fault (Left Swing) Low



T5-4-9



Warning Buzzer No No Yes Yes No Yes No No Yes Yes No Yes No No Yes Yes No Yes No No Yes Yes No Yes No No Yes Yes No Yes No No Yes Yes No Yes No No



Related Controller ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU



TROUBLESHOOTING / Troubleshooting A HCM CODE 11048-000 11048-001 11048-005 11048-006 11051-003 11051-004 11053-000 11053-001 11053-005 11053-006 11056-003 11056-004 11058-000 11058-001 11058-005 11058-006 11061-003 11061-004 11063-000 11063-001 11063-005 11063-006 11066-003 11066-004 11068-000 11068-001 11068-005 11068-006 11100-003 11100-004 11100-013 11101-003 11101-004 11101-013 11103-003 11103-004 11103-013 11104-003 11104-004 11104-013



Cummins CODE



Description EHC Valve Stick/High Pressure (Left Swing Operation) EHC Valve Stick/Low Pressure (Left Swing Operation) EHC Valve Current Low (Left Swing Operation) EHC Valve Current High (Left Swing Operation) Pressure Sensor Fault (Right Travel Forward) High Pressure Sensor Fault (Right Travel Forward) Low EHC Valve Stick/High Pressure (Right Travel Forward) EHC Valve Stick/Low Pressure (Right Travel Forward) EHC Valve Current Low (Right Travel Forward) EHC Valve Current High (Right Travel Forward) Pressure Sensor Fault (Right Travel Reverse) High Pressure Sensor Fault (Right Travel Reverse) Low EHC Valve Stick/High Pressure (Right Travel Reverse) EHC Valve Stick/Low Pressure (Right Travel Reverse) EHC Valve Current Low (Right Travel Reverse) EHC Valve Current High (Right Travel Reverse) Pressure Sensor Fault (Left Travel Forward) High Pressure Sensor Fault (Left Travel Forward) Low EHC Valve Stick/High Pressure (Left Travel Forward) EHC Valve Stick/Low Pressure (Left Travel Forward) EHC Valve Current Low (Left Travel Forward) EHC Valve Current High (Left Travel Forward) Pressure Sensor Fault (Left Travel Reverse) High Pressure Sensor Fault (Left Travel Reverse) Low EHC Valve Stick/High Pressure (Left Travel Reverse) EHC Valve Stick/Low Pressure (Left Travel Reverse) EHC Valve Current Low (Left Travel Reverse) EHC Valve Current High (Left Travel Reverse) Right Lever (F/R) Signal Fault (High) Right Lever (F/R) Signal Fault (Low) Right Lever (F/R) Interlock Right Lever (F/R) Center Signal Fault (High) Right Lever (F/R) Center Signal Fault (Low) Right Lever (F/R) Center Signal Out of Range Right Lever (L/R) Signal Fault (High) Right Lever (L/R) Signal Fault (Low) Right Lever (L/R) Interlock Right Lever (L/R) Center Signal Fault (High) Right Lever (L/R) Center Signal Fault (Low) Right Lever (L/R) Center Signal Out of Range



T5-4-10



Warning Buzzer Yes Yes No Yes No No Yes Yes No Yes No No Yes Yes No Yes No No Yes Yes No Yes No No Yes Yes No Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes



Related Controller ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU



TROUBLESHOOTING / Troubleshooting A HCM CODE 11106-003 11106-004 11106-013 11107-003 11107-004 11107-013 11109-003 11109-004 11109-013 11110-003 11110-004 11110-013 11112-003 11112-004 11112-013 11114-013 11115-003 11115-004 11115-013 11117-013 11118-003 11118-004 11118-013 11120-013 11121-003 11121-004 11121-013 11123-013 11124-013 11125-013 11126-013 11126-019 12037-003 12037-004 12037-018 12038-012 12039-019



Cummins CODE



Description Left Lever (F/R) Signal Fault (High) Left Lever (F/R) Signal Fault (Low) Left Lever (F/R) Interlock Left Lever (F/R) Center Signal Fault (High) Left Lever (F/R) Center Signal Fault (Low) Left Lever (F/R) Center Signal Out of Range Left Lever (L/R) Signal Fault (High) Left Lever (L/R) Signal Fault (Low) Left Lever (L/R) Interlock Left Lever (L/R) Center Signal Fault (High) Left Lever (L/R) Center Signal Fault (Low) Left Lever (L/R) Center Signal out of range Bucket Pedal (Open) Signal Fault (High) Bucket Pedal (Open) Signal Fault (Low) Bucket Pedal (Open) Interlock Bucket Pedal (Open) Center Signal Fault Bucket Pedal (Close) Signal Fault (High) Bucket Pedal (Close) Signal Fault (Low) Bucket Pedal (Close) Interlock Bucket Pedal (Close) Center Signal Fault Travel Pedal (Right) Signal Fault (High) Travel Pedal (Right) Signal Fault (Low) Travel Pedal (Right) Interlock Travel Pedal (Right) Center Signal Fault Travel Pedal (Left) Signal Fault (High) Travel Pedal (Left) Signal Fault (Low) Travel Pedal (Left) Interlock Travel Pedal (Left) Center Signal Fault Multi-Lever Selection Abnormalities Front Attachment Selection Abnormalities Machine Selection Abnormalities Machine Information Reception Failure Pressure Sensor Fault (Pilot Shut-Off Valve) High Pressure Sensor Fault (Pilot Shut-Off Valve) Low Below Normal Operation Pressure (Pilot Shut-Off Valve) Pilot Shut-Off Signal Output Fault Communication Error ELU-MC



T5-4-11



Warning Buzzer Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No No No No Yes No



Related Controller ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU



TROUBLESHOOTING / Troubleshooting A HCM CODE 13011-003 13011-004 13015-001 14000-000 14005-000 14009-001 14009-002 14009-003 14013-000 14015-000 14017-000 14049-000 14051-000 14052-000 14053-000 14055-000 15038-031 20000-019 20600-019 20610-012 20611-003 20611-004 20612-003 20612-004 20613-003 20613-004 20614-003 20614-004 20615-003 20615-004 20616-003 20616-004 20618-003 20618-004 20800-019 21000-019 21200-019 21800-019 23000-019 23200-019



Cummins CODE



Description Temperature sensor fault (Pump Lube Oil) High Temperature sensor fault (Pump Lube Oil) Low Pump Transmission Oil Level Low Alternator Charge Fault Hydraulic Oil Level Low Auto-Lubrication OFF Manual-Lubrication Auto-Lubrication Alarm Emergency Switch ON Air Cleaner Restriction Hydraulic Oil Temperature High Fast Fill Panel Low Ladder Limit Switch Tension Indicator Valve Close (Suction Piping) Valve Close (Return Piping) Control Box Door Open MC Communication Error ELU Communication Error ELU Internal Memory Error ELU 5V Output (Travel/Bucket) High ELU 5V Output (Travel/Bucket) Low ELU 5V Output (Front/Swing) High ELU 5V Output (Front/Swing) Low ELU 5V Output (Angle Sensor/Pressure Sensor) High ELU 5V Output (Angle Sensor/Pressure Sensor) Low ELU PWM Power High ELU PWM Power Low ELU SOL Power High ELU SOL Power Low ELU Sensor 24V Output High ELU Sensor 24V Output Low ELU Main Power High ELU Main Power Low DLU Communication Error HMU Communication Error CSU Communication Error ECM Communication Error (Parent) ECM Communication Error (Child 1) ECM Communication Error (Child 2)



T5-4-12



Warning Buzzer No No Yes No Yes No No No No No No Yes Yes No Yes Yes No No No Yes Yes Yes Yes Yes No No Yes Yes No No No No Yes Yes No No No No No No



Related Controller MC MC MC MC MC MC MC MC MC MC MC MC MC ELU MC MC MC MC ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU ELU DLU HMU CSU ECM ECM ECM



TROUBLESHOOTING / Troubleshooting A HCM CODE 30001-004 30002-016 30003-003 30003-004 30006-013 30007-009 30010-003 30010-004 30011-002 30012-002 30015-009 30015-013 30020-003 30020-004 30021-003 30021-004 30022-003 30022-004 30022-018 30100-012 30101-031 30102-005 30103-005 30104-005 30105-005 30106-005 30107-005 30108-005 30109-005 30110-005 30111-005 30112-005 30113-005 30114-005 30115-005 30116-005 30117-005



Cummins CODE 01361 01852 00224 00223 00342 00781 02377 00245 01257 00431 00285 00286 02265 02266 00272 00271 00546 00547 02215 00351 02311 00322 00331 00324 00332 00323 00325 01548 01549 01622 01551 01552 01553 01554 01555 01556 01557



Description Remote Accelerator Pedal 1 Circuit Failed High Water Indicator Above Normal Sentinel Burn Valve Above Normal Sentinel Burn Valve Below Normal Calibration Incompatibility Error J1939 Data Link 2 cannot Transmit Fan Control Circuit Failed High Fan Control Circuit Failed Low Module ID Input State Error Idle Validation Invalid J1939 PGN Timeout Error J1939 Configuration Error Lift Pump Supply Circuit Failed High Lift Pump Supply Circuit Failed Low Fuel Pump Pressure 1 Circuit Failed High Fuel Pump Pressure 1 Circuit Failed Low Fuel Del Pressure Circuit Failed High Fuel Del Pressure Circuit Failed Low Fuel Pump Pressure Below Normal Injector Power Supply Failed Fuel Injection Valve Circuit Error Injector Solenoid Driver Cylinder 1 Below Normal Injector Solenoid Driver Cylinder 2 Below Normal Injector Solenoid Driver Cylinder 3 Below Normal Injector Solenoid Driver Cylinder 4 Below Normal Injector Solenoid Driver Cylinder 5 Below Normal Injector Solenoid Driver Cylinder 6 Below Normal Injector Solenoid Driver Cylinder 7 Below Normal Injector Solenoid Driver Cylinder 8 Below Normal Injector Solenoid Driver Cylinder 9 Below Normal Injector Solenoid Driver Cylinder 10 Below Normal Injector Solenoid Driver Cylinder 11 Below Normal Injector Solenoid Driver Cylinder 12 Below Normal Injector Solenoid Driver Cylinder 13 Below Normal Injector Solenoid Driver Cylinder 14 Below Normal Injector Solenoid Driver Cylinder 15 Below Normal Injector Solenoid Driver Cylinder 16 Below Normal



T5-4-13



Warning Buzzer No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No No



Related Controller ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM ECM



TROUBLESHOOTING / Troubleshooting A (Blank)



T5-4-14



TROUBLESHOOTING / Troubleshooting B TROUBLESHOOTING B PROCEDURE Troubleshooting B is used for executing troubleshooting of the engine by use of the Engine Fault Indicator inside the electrical equipment box below the cab. In case the engine control system suffers a fault, the Engine Fault Indicator is lit. Each warning lamp means the following. • Engine Stop Lamp (Red) Stop the engine immediately, and repair the defective portion.



• Engine Warning Lamp (Amber) Working can be continued for a while, but repair the defective portion within 24 hours.



• Engine Maintenance Lamp (Yellow) Further operation can be allowed, but repair the defective portion in the next periodic maintenance. NOTE: Fault codes related to the Engine Stop Lamp (Red) and the Engine Warning Lamp (Amber) can be confirmed by the monitor display also. Therefore, in case the monitor display is functioning normally, execute troubleshooting utilizing Troubleshooting A.



T18L-01-02-038



Electrical Equipment Box



Engine Fault Indicator



NOTE: Fault codes related to the Engine Maintenance Lamp (Yellow) cannot be confirmed by the monitor display. Therefore, periodically examine whether the Engine Maintenance Lamp (Yellow) is lit or not, and in case it is lit, read the fault code(s), and repair the portion(s) needing remedy in the next periodic maintenance.



T18M-05-04-002



Engine Stop Lamp (Red)



Engine Maintenance Lamp (Yellow)



T5-5-1



Engine Warning Lamp (Amber)



T18M-05-04-003



TROUBLESHOOTING / Troubleshooting B HOW TO READ FAULT CODES 1. Stop the engine, and turn the key switch ON. 2. In case a fault code exists, the Engine Warning Lamp (Amber) alone is lit, but in case no fault code exists, none of the lamps are lit. 3. Turn the Engine Diagnostic Switch ON. 4. The Engine Warning Lamp (Amber) flickers once, and in a second, the Engine Stop Lamp (Red) indicates the fault code at stake twice consecutively, which is repeated. 5. A Fault code has four digits at the maximum. A numeral is indicated by the number of times of flickering of the Engine Stop Lamp (Red) for each digit, and remains unlit for 1 second between digit change. 6. When the key switch is turned off, indication of the fault code is finished. NOTE: In case a plural number of fault codes are in existence, the Engine Warning Lamp (Amber) flickers once each time indication of a fault code is over, and a second later, the Engine Stop Lamp (Red) indicates the next fault code twice, which is repeated. NOTE: When indication of all the fault codes is over, the Engine Warning Lamp (Amber) flickers once, and a second later, the Engine Stop Lamp (Red) repeats indication of the fault codes from the first one.



Engine Diagnostic Switch



Fault Code INC/DEC Switch



Engine Stop Lamp (Red) Engine Maintenance Lamp (Yellow)



T18M-05-04-003



Engine Warning Lamp (Amber)



Example: Flickering of Engine Stop Lamp (Red) in case of Fault Code 132 100s digit



10s digit



1s digit



Lit



Unlit



NOTE: IN case the Fault Code INC/DEC Switch is moved toward INC once, indication of the next fault code begins. In case the Fault Code INC/DEC Switch is moved toward DEC once, indication is changed to the previous fault code.



T5-5-2



1 second



1 second



T141-05-03-004



TROUBLESHOOTING / Troubleshooting B (Blank)



T5-5-3



TROUBLESHOOTING / Troubleshooting B FAULT CODE FOR ENGINE Cummins Warning HCM Description Code Lamp Color Code 115 Red 30036-002 Speed Signal Lost



122 123 124 135 141 143



144



Effect On Engine Fueling to the injectors is disabled and the engine cannot be started.



Amber 00016-003 Intake Manifold Pressure 1 Circuit Failed High Amber 00016-004 Intake Manifold Pressure 1 Circuit Failed Low Amber 00016-016 High Intake Manifold Press 1 Amber 00011-003 Oil Press Circuit Failed High None on performance. No engine protection for oil pressure. Amber 00011-004 Oil Press Circuit Failed Low None on performance. No engine protection for oil pressure. Amber 00011-018 Low Oil Pressure Calibration dependent progressive power derate and calibration dependent engine shutdown with increasing time after alert. Amber 00006-003 Coolant Temperature Circuit Failed Possible white smoke. No engine protection High for engine coolant temperature.



145



Amber 00006-004 Coolant Temperature Circuit Failed Possible white smoke. No engine protection Low for engine coolant temperature.



146



Amber 00006-016 Coolant Temperature Above Normal



151



153



154



155



156 157



158



Red



00006-000 High Coolant Temperature



Progressive power derate increasing in severity from time of alert.



Calibration dependent progressive power derate and calibration dependent engine shutdown with increasing time after alert.



Amber 00021-003 Intake Manifold Temperature 1 Circuit Possible white smoke. No engine protection for intake manifold air Failed High temperature. Amber 00021-004 Intake Manifold Temperature 1 Circuit Possible white smoke. No engine protection for intake manifold air Failed Low temperature. Red 00021-000 High Intake Manifold Temperature 1 Calibration dependent progressive power derate and calibration dependent engine shutdown with increasing time after alert. Amber 00022-003 Intake Manifold Temperature 2 Circuit Possible white smoke. No engine protection Failed High for intake manifold air temperature. Amber 00022-004 Intake Manifold Temperature 2 Circuit Possible white smoke. No engine protection for intake manifold air Failed Low temperature. Red 00022-000 High Intake Manifold Temperature 2 Calibration dependent progressive power derate and calibration dependent engine shutdown with increasing time after alert.



T5-5-4



TROUBLESHOOTING / Troubleshooting B



Instruction 1



Instruction 2



Inspect the engine harness connectors for correct connec- If the warning continues to be on afterward, report tions. Make sure the engine crankshaft speed/position sensor it to your local Cummins dealer along with all exand engine camshaft speed/position sensor are connected to isting Cummins fault codes and any symptoms. the engine wiring harness correctly.



Fix it as soon as possible within 12 hours. Make sure engine oil level is optimal and re-fill if not. Fix it as soon as possible within 12 hours. Make sure engine oil level is optimal and re-fill if not. Shut the engine off. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms Fix them as soon as possible within 12 hours. And monitor radiator inlet temperature if the operation continues under this condition Fix them as soon as possible within 12 hours. And monitor radiator inlet temperature if the operation continues under this condition Run the engine at High idle speed or auto idle speed to cool down the engine. Stop the engine after cooling down and check radiator for restriction and clean fins. Run the engine at high idle speed or auto idle speed to cool If the warning continues to be on afterward, report down the engine. it to your local Cummins dealer along with all exStop the engine after cooling down and check radiator for re- isting Cummins fault codes and any symptoms. striction and clean fins. Check also coolant level. Fix it as soon as possible within 12 hours. Make sure LTA outlet temperature is at optimal. Keep an eye on other three. Fix it as soon as possible within 12 hours. Make sure LTA outlet temperature is at optimal. Keep an eye on other three. Check LTA radiator for restrictions. Clean the radiator thor- If the warning continues to be on afterward, report it to your local Cummins dealer along with all exoughly. If all four temperatures are high, there may be restrictions on isting Cummins fault codes and any symptoms. radiators, If a single one is high, internal problem may exist. Fix it as soon as possible within 12 hours. Make sure LTA outlet temperature is at optimal. Keep an eye on other three. Fix it as soon as possible within 12 hours. Make sure LTA outlet temperature is at optimal. Keep an eye on other three. Check LTA radiator for restrictions. If the warning continues to be on afterward, report Clean the radiator thoroughly. it to your local Cummins dealer along with all exIf all four temperatures are high, there may be restrictions on isting Cummins fault codes and any symptoms. radiators, If a single one is high, internal problem may exist.



T5-5-5



TROUBLESHOOTING / Troubleshooting B Cummins Warning HCM Description Effect On Engine Code Lamp Color Code 159 Amber 00231-003 Intake Manifold Temperature 3 Circuit Possible white smoke. No engine protection for intake manifold air Failed High temperature. 161 Amber 00231-004 Intake Manifold Temperature 3 Circuit Possible white smoke. No engine protection for intake manifold air Failed Low temperature. 162 Red 00231-000 High Intake Manifold Temperature 3 Calibration dependent progressive power derate and calibration dependent engine shutdown with increasing time after alert. 163



164



165



Amber 00232-003 Intake Manifold Temperature 4 Circuit Possible white smoke. No engine protection for intake manifold air Failed High temperature. Amber 00232-004 Intake Manifold Temperature 4 Circuit Possible white smoke. No engine protection for intake manifold air Failed Low temperature. Red 00232-000 High Intake Manifold Temperature 4 Calibration dependent progressive power derate and calibration dependent engine shutdown with increasing time after alert.



187



Amber 21812-004 Sensor Supply 2 Circuit Failed Low



Multiple sensor faults possible. Loss of sensor functionality.



195



Amber 00007-003 Coolant Level Circuit Failed High



None on performance.



196



Amber 00007-004 Coolant Level Circuit Failed Low



None on performance.



197 212



Amber 00007-018 Coolant Level Below Normal Amber 00012-003 Oil Temperature Circuit Failed High



213



Amber 00012-004 Oil Temperature Circuit Failed Low



221 222 223



Amber 00043-003 Ambient Air Pressure Failed High Amber 00043-004 Ambient Air Pressure Failed Low Amber 30003-004 Sentinel Burn Valve Below Normal



224



Amber 30003-003 Sentinel Burn Valve Above Normal



227



Amber 21812-003 Sensor Supply 2 Circuit Failed High



231



Amber 00008-003 Coolant Press Circuit Failed High



None on performance. No engine protection for engine oil temperature. No engine protection for engine oil temperature. Power derate may occur. Power derate may occur. ECM turns off the engine oil burn valve solenoid driver supply voltage and the system is disabled. ECM turns off the engine oil burn valve solenoid driver supply voltage and the system is disabled. Multiple sensor faults possible. Loss of sensor functionality. Calibration dependent progressive power derate and calibration dependent engine shutdown with increasing time after alert. No engine protection for coolant pressure.



232



Amber 00008-004 Coolant Press Circuit Failed Low



No engine protection for coolant pressure.



228



Red



00008-001 Very Low Coolant Pressure



T5-5-6



TROUBLESHOOTING / Troubleshooting B Instruction 1



Instruction 2



Fix it as soon as possible within 12 hours. Make sure LTA outlet temperature is at optimal. Keep an eye on other three. Fix it as soon as possible within 12 hours. Make sure LTA outlet temperature is at optimal. Keep an eye on other three. Check LTA radiator for restrictions. Clean the radiator thor- If the warning continues to be on afterward, report oughly. it to your local Cummins dealer along with all exIf all four temperatures are high, there may be restrictions on isting Cummins fault codes and any symptoms. radiators, If a single one is high, internal problem may exist. Fix it as soon as possible within 12 hours. Make sure LTA outlet temperature is at optimal. Keep an eye on other three. Fix it as soon as possible within 12 hours. Make sure LTA outlet temperature is at optimal. Keep an eye on other three. Check LTA radiator for restrictions. Clean the radiator thor- If the warning continues to be on afterward, report oughly. it to your local Cummins dealer along with all exIf all four temperatures are high, there may be restrictions on isting Cummins fault codes and any symptoms. radiators, If a single one is high, internal problem may exist. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Check on wires for damages and connections. Fix them as soon as possible within 12 hours. Check on wires for damages and connections. Fix them as soon as possible within 12 hours. Check for wire damages and connections. Fix them as soon as possible. Check for wire damages and connections. Fix them as soon as possible. Look for damages on wiring and connectors. Look for damages on wiring and connectors. Check for wire damages and connections. Call your Cummins dealer to fix them as soon as possible.



Call your local Cummins dealer along with all existing Cummins fault codes. Call your local Cummins dealer along with all existing Cummins fault codes. If there are no damages, call your Cummins If there are no damages, call your Cummins



Check for wire damages and connections. Call your Cummins dealer to fix them as soon as possible.



Check coolant level add coolant water if it is at low level.



Check for wire damages and connections. Call your Cummins dealer to fix them as soon as possible. Check for wire damages and connections. Call your Cummins dealer to fix them as soon as possible.



T5-5-7



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. If the warning continues to be on afterward, report it to your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



TROUBLESHOOTING / Troubleshooting B Cummins Warning HCM Description Code Lamp Color Code 234 Red 00046-000 Engine Over speed



235



Red



00007-001 Low Coolant Level



Amber 30008-002 Multi Unit Synchronization Error Amber 21813-004 Sensor Supply 3 Circuit Failed Low



245



Amber 30010-004 Fan Control Circuit Failed Low



261



Amber 00009-016 High Fuel Temperature (Moderate Level)



263



Amber 00009-003 Fuel Temperature Circuit Failed High



265



Amber 00009-004 Fuel Temperature Circuit Failed Low Red



Fuel injection disabled until engine speed falls below the over speed limit. Calibration dependent progressive power derate and calibration dependent engine shutdown with increasing time after alert.



237 238



266



Effect On Engine



00009-000 High Fuel Temperature (Most Sever Level)



Multiple sensor faults possible. Loss of sensor functionality. The fan can possibly stay on continuously or not run at all. Calibration dependent progressive power derate and calibration dependent engine shutdown with increasing time after alert. ECM will set a default value for fuel temperature. No other action taken by ECM. ECM will set a default value for fuel temperature. No other action taken by ECM. Calibration dependent progressive power and speed derate and calibration dependent engine shutdown with increasing time after alert. Engine will run poorly at idle. Engine will have low power. Fuel pressure will be higher than commanded. Engine will not run or engine will run poorly.



271



Amber 30021-004 Fuel Pump Pressure 1 Circuit Failed Low



272



Amber 30021-003 Fuel Pump Pressure 1 Circuit Failed High Amber 30015-009 J1939 PGN Timeout Error One or more multiplexed devices will not operate properly. One or more symptoms will occur. Amber 30015-013 J1939 Configuration Error At least one multiplexed devices will not operate properly. Red 21822-014 Aux Pressure 1 Exception Yellow 30016-002 Real Time Clock Data Erratic None on performance. Data in the ECM will not have accurate time and date information. Amber 30102-005 Injector Solenoid Driver Cylinder 1 Engine can misfire or possibly run rough. Below Normal Amber 30106-005 Injector Solenoid Driver Cylinder 5 Engine can misfire or possibly run rough. Below Normal Amber 30104-005 Injector Solenoid Driver Cylinder 3 Engine can misfire or possibly run rough. Below Normal Amber 30107-005 Injector Solenoid Driver Cylinder 6 Engine can misfire or possibly run rough. Below Normal Amber 30103-005 Injector Solenoid Driver Cylinder 2 Engine can misfire or possibly run rough. Below Normal Amber 30105-005 Injector Solenoid Driver Cylinder 4 Engine can misfire or possibly run rough. Below Normal Red 30006-013 Calibration Incompatibility Error Hard to start or no start.



285



286 296 319



322 323 324 325 331 332 342



T5-5-8



TROUBLESHOOTING / Troubleshooting B Instruction 1



Instruction 2



Check on operating conditions.



Look for any external leaks and fix them if there are any. And fill up coolant water.



If the condition has not changed, report it to your local Cummins dealer along with all existing Cummins fault codes and any symptoms. If you cannot find any leaks, report it your Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Wiring problem should be fixed. Monitor coolant temperature. Check for fuel cooler restrictions and clean it.



Shut down engine as soon as possible. Check for fuel cooler restrictions and clean it.



If the warning continues to be on afterward, report it to your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call Hitachi Dealer for investigation.



Let your Cummins dealer set dates and time.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



T5-5-9



TROUBLESHOOTING / Troubleshooting B Cummins Warning HCM Description Code Lamp Color Code 343 Amber 21800-012 ECM Hardware Issue Non Mission Disabling 349 Amber 30035-016 Trans Output Shaft Speed Above Normal 351 Amber 30100-012 Injector Power Supply Failed 352 Amber 21811-004 Sensor Supply 1 Circuit Failed Low 386 415



Amber 21811-003 Red



00011-001



Yellow 30002-015



421



Amber 00012-016



426 431



Yellow 30015-002 Amber 30012-002



432 441



Red 30012-013 Idle Validation Calibration Error Amber 21817-018 Low Battery Voltage



442



Amber 21817-016 High Battery Voltage



Red



Possible none on performance, or severe derate. Engine will run off of a default auxiliary speed.



Multiple sensor faults possible. Loss of sensor functionality. Sensor Supply 1 Circuit Failed High Multiple sensor faults possible. Loss of sensor functionality. Very Low Oil Pressure Calibration dependent progressive power derate and calibration dependent engine WIF Indicator Warning Possible white smoke, loss of power, or hard starting. Engine Oil Temperature Above Nor- Severity based torque derate. mal J1939 Data link Can Not Transmit Idle Validation Invalid Engine will run at idle.



418



449



Effect On Engine



00041-000 High Rail Pressure



Engine will run at idle. ECM voltage supply approaching level at which unpredictable operation will occur. Possible electrical damage to all electrical components. Fuel injection noise.



451



Amber 00041-003 Rail Press Circuit Failed High



Power and or speed derate.



452



Amber 00041-004 Rail Press Circuit Failed Low



Power and or speed derate.



487 488



Amber 30000-018 Ether Bottle Empty Amber 00021-016 High Intake Manifold Temperature



Ether Injection is disabled. Calibration dependent progressive power derate and calibration dependent engine shutdown with increasing time after alert.



489 497 527 529 546



Amber Amber Amber Amber Amber



555 556



AXG Speed Low Error Multi Unit Synchronization Error Dual Output A Failed High Dual Output B Failed High Fuel Delivery Pressure Circuit Failed No action taken by the ECM. High Amber 30022-004 Fuel Delivery Pressure Circuit Failed No action taken by the ECM. Low Amber 00015-016 Crankcase Pressure Above Normal Red 00015-000 High Crankcase Pressure Ramps to full derate in 20 seconds.



559



Amber 00041-018 Rail Pressure 1 Below Normal



547



30005-018 30033-002 21920-003 21921-003 30022-003



T5-5-10



Low Power, possible shutdown, or no start.



TROUBLESHOOTING / Troubleshooting B Instruction 1



Instruction 2 Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Shut the engine off immediately. Drain the water from the fuel filter. Make sure coolant water is not overheating.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Check OEM wirings for any damages. If these damages are not causes, call your Cummins dealer.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms if there is no damage to the OEM wiring.



Check on alternator and battery capacity. Check battery voltage on the display. It must be below 32VDC. Change alternator. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Replace ether bottle. Inspect the following item: -Plugged LTA radiator fins -Coolant level



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Shut the engine off immediately.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



T5-5-11



TROUBLESHOOTING / Troubleshooting B Cummins Warning HCM Description Effect On Engine Code Lamp Color Code 599 Red 30009-014 Aux Commanded Dual Output Shutdown 611 Yellow 30032-031 Engine Hot Shutdown 621 Yellow 00120-017 Low Power Cylinder 1 Possible power loss. 622



Yellow 00122-017 Low Power Cylinder 3



Possible power loss.



623



Yellow 00124-017 Low Power Cylinder 5



Possible power loss.



624



Yellow 00126-017 Low Power Cylinder 7



Possible power loss.



625



Yellow 00128-017 Low Power Cylinder 9



Possible power loss.



626



Yellow 00130-017 Low Power Cylinder 11



Possible power loss.



627



Yellow 00132-017 Low Power Cylinder 13



Possible power loss.



628



Yellow 00134-017 Low Power Cylinder 15



Possible power loss.



631



Yellow 00121-017 Low Power Cylinder 2



Possible power loss.



632



Yellow 00123-017 Low Power Cylinder 4



Possible power loss.



633



Yellow 00125-017 Low Power Cylinder 6



Possible power loss.



634



Yellow 00127-017 Low Power Cylinder 8



Possible power loss.



635



Yellow 00129-017 Low Power Cylinder 10



Possible power loss.



636



Yellow 00131-017 Low Power Cylinder 12



Possible power loss.



637



Yellow 00133-017 Low Power Cylinder 14



Possible power loss.



638



Yellow 00135-017 Low Power Cylinder 16



Possible power loss.



671



Yellow 00120-004 Exhaust Temperature Low Cylinder 1 Yellow 00122-004 Exhaust Temperature Low Cylinder 3 Yellow 00124-004 Exhaust Temperature Low Cylinder 5 Yellow 00126-004 Exhaust Temperature Low Cylinder 7 Yellow 00128-004 Exhaust Temperature Low Cylinder 9 Yellow 00130-004 Exhaust Temperature Low Cylinder 11 Yellow 00132-004 Exhaust Temperature Low Cylinder 13



672 673 674 675 676 677



Circuit Failed Loss of urement. Circuit Failed Loss of urement. Circuit Failed Loss of urement. Circuit Failed Loss of urement. Circuit Failed Loss of urement. Circuit Failed Loss of urement. Circuit Failed Loss of urement.



T5-5-12



exhaust gas temperature measexhaust gas temperature measexhaust gas temperature measexhaust gas temperature measexhaust gas temperature measexhaust gas temperature measexhaust gas temperature meas-



TROUBLESHOOTING / Troubleshooting B Instruction 1



Instruction 2



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



T5-5-13



TROUBLESHOOTING / Troubleshooting B Cummins Warning HCM Description Effect On Engine Code Lamp Color Code 678 Yellow 00134-004 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measLow Cylinder 15 urement. 689 Amber 00046-002 Engine Crankshaft Speed Erratic Engine can run rough. Possibly poor starting capability. Engine runs using backup speed sensor. Engine power is reduced. 697 Amber 30013-003 ECM Temperature Circuit Failed 698 Amber 30013-004 ECM Temperature Circuit Failed Low 721 Yellow 00121-004 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measLow Cylinder 2 urement. 722 Yellow 00123-004 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measLow Cylinder 4 urement. 723 Yellow 00125-004 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measLow Cylinder 6 urement. 724 Yellow 00127-004 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measLow Cylinder 8 urement. 725 Yellow 00129-004 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measLow Cylinder 10 urement. 726 Yellow 00131-004 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measLow Cylinder 12 urement. 727 Yellow 00133-004 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measLow Cylinder 14 urement. 728 Yellow 00135-004 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measLow Cylinder 16 urement. 731 Amber 30036-007 Engine Speed Cam/Crank Mis- Engine will run derate. Excessive smoke, hard start, and rough idle alignment possible. 781 Amber 30007-009 J1939 Data link 2 Can Not Transmit Engine will lose power or stop running. 783



1117 1135 1256 1257



Red



00021-010 Rapid Rise Intake Manifold Tem- Calibration dependent progressive power and speed derate and calibration dependent perature 1 engine shutdown with increasing time after alert. Yellow 30100-002 Power Lost with Ignition On Red 30007-009 J1939 Data link 2 Can Not Transmit Engine will lose power or stop running. Amber 30011-002 Module ID Input State Error Low Power, possible shutdown, or no start. Red



30011-002 Module ID Input State Error



1357



Amber 30027-018



1358



Amber 00048-003



1359



Amber 00048-004



1361



Amber 30001-004



Hard to start or no start. Lose power. Remote Oil Level Below Normal No action taken by ECM. Possible damage to engine if left unresolved (SENTINEL application only). Accelerator Pedal Sensor 1 Sensor Calibration dependent power and speed derate. Failed High -1 Engine speed will be locked to 1000 min Accelerator Pedal Sensor 1 Sensor Calibration dependent power and speed derate. Failed Low -1 Engine speed will be locked to 1000 min Remote Accelerator Pedal 1 Circuit Calibration dependent power and speed Failed High derate.



T5-5-14



TROUBLESHOOTING / Troubleshooting B Instruction 1



Instruction 2 Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Shut the engine off immediately.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Look for any damage on the throttle dial and its stopper. Also look for any worn on harness. Look for any damage on the throttle dial and its stopper. Also look for any worn on harness. Check for wire damages and connections. Fix them as soon as possible.



T5-5-15



TROUBLESHOOTING / Troubleshooting B Cummins Warning HCM Description Code Lamp Color Code 1362 Amber 00014-016 High Lube Oil Filter Restriction



1363



Effect On Engine Calibration dependent progressive power derate and engine shutdown with increasing time after alert.



1371



Yellow 00016-017 Intake Manifold Pressure 1 Below Normal Yellow 30026-003 Pre Filter Oil Press Circuit Failed High Yellow 30026-004 Pre Filter Oil Press Circuit Failed Low Yellow 21820-003 Aux Temperature Input 1 Circuit Failed High Yellow 21822-003 Aux Press Input 1 Circuit Failed High



1372



Yellow 21822-004 Aux Press Input 1 Circuit Failed Low None on performance.



1373



Yellow 30004-011 Ether Injection Circuit Failed



Ether injection feature is disabled. Hard to start in cold temperatures.



1374



Yellow 30037-003 Turbo Speed Sensor Circuit Failed High Yellow 30037-004 Turbo Speed Sensor Circuit Failed Low Yellow 30036-002 Engine Speed Cam/Crank data Erratic Yellow 30031-003 Post Filter Oil Press Circuit Failed High Yellow 30031-004 Post Filter Oil Press Circuit Failed Low Yellow 21820-014 Aux Temperature Input 1 Circuit Exception



Possible performance influence.



1367 1368 1369



1375 1376 1377 1378 1381



1383



Yellow 00016-003



1384



Yellow 00016-004



1385



Yellow 00017-003



1386



Yellow 00017-004



1387



Yellow 30017-031



1411 1412 1418 1427



Amber Amber Amber Amber



1428



Amber 30031-031



30031-003 30031-003 30031-003 30031-031



Possible low power. None on performance. None on performance. None on performance. None on performance.



Possible performance influence. Possible poor starting. Engine power derate. None on performance. None on performance.



Calibration-dependent progressive power and speed derate and engine shutdown with increasing time after alert. (Not included in HCM application?) Intake Manifold Pressure 1 Failed Possible performance influence. High Intake Manifold Pressure 1 Failed Possible performance influence. Low Intake Manifold Pressure 2 Failed Possible performance influence. High Intake Manifold Pressure 2 Failed Possible performance influence. Low J1939 Engine Commanded Shutdown Gen Output Freq Circuit Failed High Droop Adjust Circuit Failed High Gain Adjust Circuit Failed High Over Speed Shutdown Relay Driver Error Low Oil Pressure Shutdown Relay Driver Error



T5-5-16



TROUBLESHOOTING / Troubleshooting B Instruction 1



Instruction 2



Replace filters and at the same time cut open filters and in- If there are coolant or metals, do not start engine spect for coolant and metals. and ｃall your local Cummins dealer along with all Do not start engine until the inspection is made. existing Cummins fault codes and any symptoms. Check air filters for restrictions and replace them if they are clogged. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Check ether injection system.



If there is no external problem, call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



T5-5-17



TROUBLESHOOTING / Troubleshooting B Cummins Warning HCM Description Code Lamp Color Code 1429 Amber 30031-031 High Engine Temperature Shutdown Relay Driver Error 1431 1432 1435 1514



1516 1517



1518



1519



1521 1522 1523 1524 1525 1526 1527 1529 1531 1532 1533 1534 1535 1536



Effect On Engine



Amber 30031-031 Oil Pressure Relay Driver Error Amber 30031-031 High Engine Temperature Relay Driver Error Amber 30030-031 Engine Cold Potential Starting Issue Amber 00048-008 Accelerator Pedal Position Sensor 1 Engine operates at idle. Frequency Issue Yellow 00046-015 Engine Crankshaft Speed Above Normal Red 21800-031 ECM Detects Most Severe Fault Dependent on particular faults from ECM 1 and/or ECM 2 that triggered Fault Code 1517. Amber 21800-031 ECM Detects Moderately Severe Dependent on particular faults from ECM 1 and/or ECM 2 that triggered Fault Code Fault 1518. Yellow 21800-031 ECM Detects Least Severe Fault Dependent on particular faults from ECM 1 and/or ECM 2 that triggered Fault Code 1518. Yellow 00122-003 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measHigh Cylinder 3 urement. Yellow 00124-003 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measHigh Cylinder 5 urement. Yellow 00126-003 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measHigh Cylinder 7 urement. Yellow 00128-003 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measHigh Cylinder 9 urement. Yellow 00130-003 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measHigh Cylinder 11 urement. Yellow 00132-003 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measHigh Cylinder 13 urement. Yellow 00134-003 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measHigh Cylinder 15 urement. Yellow 00121-003 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measHigh Cylinder 2 urement. Yellow 00125-003 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measHigh Cylinder 6 urement. Yellow 00127-003 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measHigh Cylinder 8 urement. Yellow 00129-003 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measHigh Cylinder 10 urement. Yellow 00131-003 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measHigh Cylinder 12 urement. Yellow 00133-003 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measHigh Cylinder 14 urement. Yellow 00135-003 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature measHigh Cylinder 16 urement.



T5-5-18



TROUBLESHOOTING / Troubleshooting B Instruction 1



Instruction 2



Check OEM wirings for any damages. If these damages are not causes, call your Cummins dealer.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms if there is no damage to the OEM wiring.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Look if any other faults are apparent.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Look if any other faults are apparent.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



T5-5-19



TROUBLESHOOTING / Troubleshooting B Cummins Warning HCM Description Code Lamp Color Code 1544 Yellow 21821-014 Aux Pressure Sensor Input 1 Exception 1548 Amber 30108-005 Injector Solenoid Driver 7 Below Normal 1549 Amber 30109-005 Injector Solenoid Driver 8 Below Normal 1551 Amber 30111-005 Injector Solenoid Driver 10 Below Normal 1552 Amber 30112-005 Injector Solenoid Driver 11 Below Normal 1553 Amber 30113-005 Injector Solenoid Driver 12 Below Normal 1554 Amber 30114-005 Injector Solenoid Driver 13 Below Normal 1555 Amber 30115-005 Injector Solenoid Driver 14 Below Normal 1556 Amber 30116-005 Injector Solenoid Driver 15 Below Normal 1557 Amber 30117-005 Injector Solenoid Driver 16 Below Normal 1595 Amber 30001-003 Remote Accelerator Pedal 1 Circuit Failed High 1596 Yellow 21820-004 Aux Temperature Sensor Input 1 Circuit Failed Low 1597 Yellow 21800-012 ECM Critical Internal Failure 1618



1843 1844 1845



Yellow 00120-003 Exhaust Temperature Circuit Failed High Cylinder 1 Yellow 00123-003 Exhaust Temperature Circuit Failed High Cylinder 4 Amber 30110-005 Injector Solenoid Driver 9 Below Normal Amber 00017-016 Intake Manifold Pressure 2 Above Normal Yellow 00017-017 Intake Manifold Pressure 2 Below Normal Amber 00015-003 Crankcase Press Circuit Failed High Amber 00015-004 Crankcase Press Circuit Failed Low Yellow 30002-003 WIF Indicator Circuit Failed High



1846



Yellow 30002-004 WIF Indicator Circuit Failed Low



1619 1622 1634 1638



1847 1852 1888



Red



Effect On Engine Possible engine power derate. Engine can misfire or possibly run rough. Engine can misfire or possibly run rough. Engine can misfire or possibly run rough. Engine can misfire or possibly run rough. Engine can misfire or possibly run rough. Engine can misfire or possibly run rough. Engine can misfire or possibly run rough. Engine can misfire or possibly run rough. Engine can misfire or possibly run rough.



None on performance. Engine will possibly not start. Loss of exhaust gas temperature measurement. Loss of exhaust gas temperature measurement. Engine can misfire or possibly run rough.



Possible low power. No engine protection. No engine protection. None on performance. No water in fuel warning available. None on performance. No water in fuel warning available.



00006-014 Engine Coolant Temperature Exception Amber 30002-016 WIF Indicator Above Normal Possible white smoke, loss of power, or hard starting. Yellow 00048-019 J1939 Accelerator Pedal Error Engine could possibly only idle or engine will not accelerate to full speed.



T5-5-20



TROUBLESHOOTING / Troubleshooting B Instruction 1



Instruction 2



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Check air filters for restrictions and replace them if they are clogged.



Check wires and connections from a filter to the engine connection. Check wires and connections from a filter to the engine connection.



Drain water from all filters. Check pedals for any damages.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



T5-5-21



TROUBLESHOOTING / Troubleshooting B Cummins Warning HCM Description Effect On Engine Code Lamp Color Code 1889 Yellow 30001-019 J1939 Remote Accelerator Pedal Engine will not respond to the remote throttle. Error Engine could possibly only idle. The primary or cab accelerator could possi1891 Amber 30025-031 Engine Oil Change Interval Exceeded 1911 Amber 00041-000 Injector Rail Pressure Above Normal Engine performance derate. 1978 1979 1984



Amber 30014-003 Load Bias Circuit Failed High Amber 30014-004 Load Bias Circuit Failed Low Amber 00022-016 Intake Manifold Temperature Above Normal



1985



Amber 00231-016 Intake Manifold Above Normal



Temperature



1986



Amber 00232-016 Intake Manifold Above Normal



Temperature



1992 2121



Red 00046-016 Engine Speed Above Normal Amber 00120-016 High Exhaust Temperature Cylinder Possible engine smoke and engine damage. 1



2122



Amber 00122-016 High Exhaust Temperature Cylinder Possible engine smoke and engine damage. 3



2123



Amber 00124-016 High Exhaust Temperature Cylinder Possible engine smoke and engine damage. 5



2124



Amber 00126-016 High Exhaust Temperature Cylinder Possible engine smoke and engine damage. 7



2125



Amber 00128-016 High Exhaust Temperature Cylinder Possible engine smoke and engine damage. 9



2126



Amber 00130-016 High Exhaust Temperature Cylinder Possible engine smoke and engine damage. 11



T5-5-22



2 Calibration dependent progressive power derate and calibration dependent engine shutdown with increasing time after alert. 3 Calibration dependent progressive power derate and calibration dependent engine shutdown with increasing time after alert. 4 Calibration dependent progressive power derate and calibration dependent engine shutdown with increasing time after alert.



TROUBLESHOOTING / Troubleshooting B Instruction 1



Instruction 2 Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Shut the engine off.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Inspect the following item: - Plugged LTA radiator fins - Coolant level Inspect the following item: - Plugged LTA radiator fins - Coolant level Inspect the following item: - Plugged LTA radiator fins - Coolant level Inspect the following items: - Restricted air flow through the exhaust manifold or exhaust system - Air Cleaner Restriction Warning - LTA output temperature Inspect the following items: - Restricted air flow through the exhaust manifold or exhaust system - Air Cleaner Restriction Warning - LTA output temperature Inspect the following items: - Restricted air flow through the exhaust manifold or exhaust system - Air Cleaner Restriction Warning - LTA output temperature Inspect the following items: - Restricted air flow through the exhaust manifold or exhaust system - Air Cleaner Restriction Warning - LTA output temperature Inspect the following items: - Restricted air flow through the exhaust manifold or exhaust system - Air Cleaner Restriction Warning - LTA output temperature Inspect the following items: - Restricted air flow through the exhaust manifold or exhaust system - Air Cleaner Restriction Warning - LTA output temperature



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



T5-5-23



TROUBLESHOOTING / Troubleshooting B Cummins Warning HCM Description Effect On Engine Code Lamp Color Code 2127 Amber 00132-016 High Exhaust Temperature Cylinder Possible engine smoke and engine damage. 13



2128



Amber 00134-016 High Exhaust Temperature Cylinder Possible engine smoke and engine damage. 15



2131



Amber 00121-016 High Exhaust Temperature Cylinder 2 Possible engine smoke and engine damage.



2132



Amber 00123-016 High Exhaust Temperature Cylinder 4 Possible engine smoke and engine damage.



2133



Amber 00125-016 High Exhaust Temperature Cylinder 6 Possible engine smoke and engine damage.



2134



Amber 00127-016 High Exhaust Temperature Cylinder 8 Possible engine smoke and engine damage.



2135



Amber 00129-016 High Exhaust Temperature Cylinder Possible engine smoke and engine damage. 10



2136



Amber 00131-016 High Exhaust Temperature Cylinder Possible engine smoke and engine damage. 12



2137



Amber 00133-016 High Exhaust Temperature Cylinder Possible engine smoke and engine damage. 14



2138



Amber 00135-016 High Exhaust Temperature Cylinder Possible engine smoke and engine damage. 16



T5-5-24



TROUBLESHOOTING / Troubleshooting B Instruction 1



Instruction 2 Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Inspect the following items: - Restricted air flow through the exhaust manifold or exhaust system - Air Cleaner Restriction Warning - LTA output temperature Inspect the following items: - Restricted air flow through the exhaust manifold or exhaust system - Air Cleaner Restriction Warning - LTA output temperature Inspect the following items: - Restricted air flow through the exhaust manifold or exhaust system - Air Cleaner Restriction Warning - LTA output temperature Inspect the following items: - Restricted air flow through the exhaust manifold or exhaust system - Air Cleaner Restriction Warning - LTA output temperature Inspect the following items: - Restricted air flow through the exhaust manifold or exhaust system - Air Cleaner Restriction Warning - LTA output temperature Inspect the following items: - Restricted air flow through the exhaust manifold or exhaust system - Air Cleaner Restriction Warning - LTA output temperature Inspect the following items: - Restricted air flow through the exhaust manifold or exhaust system - Air Cleaner Restriction Warning - LTA output temperature Inspect the following items: - Restricted air flow through the exhaust manifold or exhaust system - Air Cleaner Restriction Warning - LTA output temperature Inspect the following items: - Restricted air flow through the exhaust manifold or exhaust system - Air Cleaner Restriction Warning - LTA output temperature Inspect the following items: - Restricted air flow through the exhaust manifold or exhaust system - Air Cleaner Restriction Warning - LTA output temperature



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



T5-5-25



TROUBLESHOOTING / Troubleshooting B Cummins Warning HCM Description Effect On Engine Code Lamp Color Code 2157 Red 00022-010 Rapid Rise Intake Manifold Tem- Calibration dependent progressive power and speed derate and calibration dependent perature 2 engine shutdown with increasing time after alert. 2158 Red 00231-010 Rapid Rise Intake Manifold Tem- Calibration dependent progressive power and speed derate and calibration dependent perature 3 engine shutdown with increasing time after alert. 2159 Red 00232-010 Rapid Rise Intake Manifold Tem- Calibration dependent progressive power and speed derate and calibration dependent perature 4 engine shutdown with increasing time after alert. 2185 Amber 21820-003 Sensor Supply 4 Circuit Above Nor- Multiple sensor faults possible. Loss of sensor functionality. mal It may cause throttle problem. 2186 Amber 21820-004 Sensor Supply 4 Circuit Below Nor- Multiple sensor faults possible. Loss of sensor functionality. mal It may cause throttle problem. 2215 Amber 30022-018 Fuel Pump Pressure Below Normal Low power.



2261



Yellow 30022-015 Fuel Pump Delivery Pressure Above Low power or engine smoke. Normal



2262



Yellow 30022-017 Fuel Pump Delivery Pressure Below Low power. Normal



2265



Amber 30020-003 Lift Pump Supply Circuit Failed High



Engine can be difficult to start.



2266



Amber 30020-004 Lift Pump Supply Circuit Failed Low



Engine can be difficult to start.



2311



Amber 30101-031 Fuel Injection Valve Circuit Error



Possible low power.



2321



Yellow 00046-002 Engine Crankshaft Speed - Data Erratic Yellow 30036-002 Engine Camshaft Speed Data Erratic Amber 30010-003 Fan Control Circuit Failed High The fan can possibly stay on continuously or not run at all. Amber 21960-003 Aux PWM Driver 1 Circuit Failed Amber 21960-004 Aux PWM Driver 1 Circuit Failed Low Yellow 00006-015 Engine Coolant Temperature Above Normal Yellow 00021-015 Intake Manifold Temperature 1 Above Normal



2322 2377 2557 2558 2963 2964



T5-5-26



TROUBLESHOOTING / Troubleshooting B Instruction 1



Instruction 2



Shut the engine off immediately.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Shut the engine off immediately.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Shut the engine off immediately.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Check for fuel restriction and high 1st stage filter restriction.



Inspect the following items: - Stage 2 fuel filter restriction - Fuel quality If there are restrictions, change all filters.



If no restriction is found, call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Inspect the following items: - High stage 1 fuel filter restriction - High fuel inlet restriction - Fuel quality If there are restrictions, change all filters.



Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms



Look for any wiring damages.



If there are no damages or mis-connection, call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms. Call your local Cummins dealer along with all existing Cummins fault codes and any symptoms.



Look for any wiring damages.



Wiring problem should be fixed. Monitor coolant temperature.



T5-5-27



TROUBLESHOOTING / Troubleshooting B (Blank)



T5-5-28



TROUBLESHOOTING / Troubleshooting C TROUBLESHOOTING C PROCEDURE Fault Diagnosis C is used for the failure of the air conditioner.



T5-6-1



TROUBLESHOOTING / Troubleshooting C Air conditioner malfunction.



• When the air conditioner system control panel indicator flashes, see T5-6-14.



• When reporting the malfunction of the air conditioner to HITACHI, use the Air Conditioner Trouble Report form shown on page T5-6-16. Cooling Circuit Refrigerant pressure in both high and low pressure sides is low.



Bubbles can be seen in sight glass.



Piping and/or parts are stained with oil, respond to gas detector. No oil stain is found or gas detector doesn’t respond. Refrigerant has not been refilled for longer than one season.



No bubbles are seen in sight glass.



After cooling at fast speed continuously, cooling power is reduced. Air flow volume remains unchanged. Air flow volume is reduced. Refrigerant pressure in low pressure side is high. Insufficient Cooling Power



Bubbles can be seen in sight glass.



Compressor cylinder is not hot. (Refrigerant returns into compressor in liquid form.)



Refrigerant pressure in high pressure side is low.



Compressor cylinder is extremely hot, emitting a smell.



Heater unit emits hot air.



Refrigerant pressure in high pressure side is high.



Bubbles can be seen in sight glass.



Refrigerant pressure in low pressure side is low.



Condenser is stained and clogged. Even if condenser is sprayed with water, few bubbles appear. Receiver dryer temperature is low.



After cooling at fast speed continuously, cooling power is reduced. Air flow volume is reduced.



Frost forms.



Thermistor doesn’t cool. Thermistor cools.



T5-6-2



TROUBLESHOOTING / Troubleshooting C



Gas leaks from pipe joints and/or parts.



Re-tighten or replace parts.



Normal leakage of refrigerant from hoses.



Refill refrigerant.



Improper adjustment (excessive restriction) of expansion valve.



Readjust or replace expansion valve.



Clogged expansion valve.



Remove clog, or replace receiver and/or expansion valve.



Clogged low pressure circuit and/or evaporator.



Remove clog, or replace parts.



Frozen expansion valve or water in circuit.



After evacuation, refill refrigerant and/or replace receiver dryer.



Gas leaks from case.



Seal gaps using vinyl tape or packing compound.



Poor contact of expansion valve temperature sensor.



Make good contact. Replace temperature sensing stay.



Improper adjustment (excessive open) of expansion valve.



Readjust or replace.



Insufficient compressor discharge (faulty gasket and/or valve).



Replace.



Improper water stop valve wire adjustment and/or faulty stop valve.



Check and readjust or replace.



Poor airtight fitting of outside air damper (outside air induction type).



Repair. Remove clog, or replace parts.



Clogged high pressure circuit before receiver dryer.



Clean Condenser.



Excessive refrigerant.



Remove excessive refrigerant to proper level.



Air is mixed in system.



After evacuation, refill refrigerant and/or replace receiver dryer.



Incorrect thermistor location.



Correct thermister location.



Gas leaks from case.



Seal gaps using vinyl tape or packing compound.



Faulty thermistor (stays ON).



Disconnected thermister cord.



Even if function and performance are normal, when air-conditioner is kept operated for a long time with thermistor in max. cooling position and air flow in M or L mode, frost may form.



Instruct user correct air-conditioner operation. (Reset thermistor to either minimum or middle cooling position or increase air flow.)



T5-6-3



TROUBLESHOOTING / Troubleshooting C Cooling Circuit



Case connection.



Louver resonance.



Fan contacts case, or foreign matter enters case. Blower fan connection. Brush friction noise, metal and/or thrust washer contact noise.



Noise



Gas blowing sound (roaring).



Gas vibration noise (compressor discharge and/or suction gas noise).



Expansion valve connection, whistle sound, gas blowing sound.



Abnormal noise from expansion valve (Expansion valve is normally functioning.).



Faulty clutch bearing, and/or idle pulley bearing. Clutch disengaging sound. Contact of clutch amature due to resonance, or loose belt and/or screws. Noisy compressor. Compressor rotating sound. Vibration and/or loose screws due to excessive drive belt looseness. Broken heater core and/or hose. Water leak and/or splash. Clogged case drain port and/or drain hose.



Others Abnormal smell.



Absorbed cigarette and dust smell on evaporator fins.



T5-6-4



TROUBLESHOOTING / Troubleshooting C



Repair or replace.



Remove foreign matter. Readjust fan motor location.



Slight noise is unavoidable. Replace if loud.



No functional problem exists. Provide silencer if intolerable.



Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.



Replace.



Repair or replace clutch. Re-tighten screws.



Repair or replace.



Re-adjust drive belt.



Replace.



Clean. -1



Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min in L mode for more than 10 minutes, flush smell out by condensed water.



T5-6-5



TROUBLESHOOTING / Troubleshooting C Electrical Circuit



Both clutch and (1) blower don’t operate.



Not blown. Check fuses. Blown.



Not drawn. Only (2) clutch is not activated.



Directly connect battery to clutch terminal.



Directly connect battery only to thermostat (relay), and clutch circuit.



Drawn.



Blower doesn’t rotate. Only (3)blower doesn’t rotate.



Directly connect battery to blower motor positive terminal. Blower rotates.



Connect blower switch terminals L, M, and H directly to terminal B.



Fan doesn’t rotate. Electric fan (4) doesn’t rotate.



Directly connect battery to fan motor positive terminal.



Check for voltage between fan motor relay connectors terminal #1 and #2. Fan rotates.



24 V (12 V) Short circuit between relay connectors terminal #3 and #5.



Check air gap. Clutch



(5)slips.



Measure clutch drawing voltage (16 v on 24 V-system circuit). Check if compressor shaft rotates smoothly.



T5-6-6



TROUBLESHOOTING / Troubleshooting C



Move to steps (2 and 3). Short-circuited clutch and/or blower circuit (Incorrect power input terminal)).



Repair. Follow instructions.



Faulty clutch.



Replace.



Clutch is drawn.



Faulty parts (thermostat and/or relay).



Replace.



Clutch is not drawn.



Broken clutch system harness.



Blower rotates.



Faulty blower motor.



Replace.



Faulty blower switch.



Replace.



Broken blower system harness. Blower doesn’t rotate.



Repair.



Repair.



Faulty resister.



Replace.



Faulty motor.



Replace.



0V



Broken signal circuit harness.



Fan rotates.



Faulty relay.



Fan doesn’t rotate.



Broken fan motor power circuit harness.



Repair. Replace.



T5-6-7



Repair.



TROUBLESHOOTING / Troubleshooting C Electronic Thermo



Clutch stays ON.



Clutch stays OFF.



Clutch chatters.



Short-circuited thermistor.



Check thermistor connector resistance with tester.



Short-circuited thermo volume.



Thermo volume is turned OFF.



Poor relay contact and/or faulty amplifier.



Disconnect thermistor.



Faulty thermistor.



Check for thermistor connector resistance with tester.



Broken circuit in thermo volume.



Check for thermo volume terminal resistance with tester.



Faulty thermostat (or broken harness to thermo volume).



Check for resistance with tester after turning switch ON (continuity check).



Poor relay contact and/or faulty amplifier.



Disconnect thermistor. Ground amplifier connector.



Poor thermostat contact.



Check for continuity at volume switch terminal with tester.



Faulty soldering in amplifier.



Disconnect thermistor. Ground amplifier side connector.



Poor connector contact.



Temperature is not sufficiently cooled (clutch operates ON/OFF).



Vibrate connectors.



Faulty thermistor.



Replace thermistor.



Improper thermistor location.



Locate thermistor in evaporator center.



Failure in amplifier.



Replace thermistor.



Temperature is not sufficiently cooled (clutch stays ON).



Trouble exists outside electronic ※Standard Thermistor Temperature Characteristics: thermo. (Refer to the troubleshooting 0 °C (32 °F): approx. 7.2 kΩ 25 °C (77 °F): approx. 2.2 kΩ tables on previous pages.)



Noisy relay (chattering)



Poor ground line contact.



Check for ground line contact.



T5-6-8



TROUBLESHOOTING / Troubleshooting C



Replace thermistor.



Resistance is small. (When resistance is approx. 2 kΩ at 25 °C (77 °F), thermistor is normal.) Clutch is turned OFF.



Replace thermo volume.



Clutch is not turned OFF.



Replace amplifier.



Resistance is 7 kΩ or more.



Replace thermistor. Check amplifier.



Resistance is infinite.



Replace thermo volume.



Normal when resistance is 0.



Replace thermo volume.



Abnormal when resistance is infinite. Clutch stays OFF.



Replace amplifier.



Tester needle moves when thermo volume is vibrated.



Replace thermo volume.



Normal if tester needle is unmoving when thermo volume is vibrated. Clutch chatters when amplifier is vibrated.



Replace amplifier.



Clutch chatters.



Faulty connector.



Repair connector.



Temperature is cooled.



Faulty thermistor.



Replace thermistor.



Temperature is not cooled.



Faulty thermistor.



Replace thermistor.



Normal when cooled.



Faulty cooling function.



Temperature is not cooled.



Faulty amplifier.



Replace amplifier.



Normal.



Faulty amplifier.



Replace.



Poor connection.



Repair.



T5-6-9



TROUBLESHOOTING / Troubleshooting C Compressor Compressor doesn’t rotate.



Clutch terminal voltage is normal 24 V.



Clutch terminal voltage is low. Clutch terminal voltage is 0 V.



Inoperable cooling system



Bubbles exist even after refrigerant is refilled. Both high and low side pressures are low. Both compressor and blower motor rotate.



Check for oil and refrigerant leaks from parts other than compressor and pipe joints using gas detector. Check for oil and refrigerant leaks from compressor (no leaks from parts other than compressor) using gas detector.



Stain on exterior



Refer to NOTE 1 and 2 on page T5-6-13. Refrigerant has not been refilled for longer than one season. Refrigerant is discharged within 1 to 2 months after being recharged. Check for refrigerant leaks using gas detector. Refrigerant is kept charged for longer than 2 years.



Compressor cylinder is not hot. (Refrigerant returns to compressor in liquid form.) High pressure side is slightly low and low pressure side is high.



No refrigerant returns in liquid form. High pressure side is low.



Bubbles can be seen through sight glass.



Others Refer to the Cooling Circuit Troubleshooting Table on page T5-6-4.



High pressure side is high. Temperature is not cooled when compressor is operated at fast speed continuously. Air flow from blower is insufficient.



Over-hea ting is suscep-ti ble to occur.



Compressor rotation is abnormally draggy.



Trouble other than compressor



Refer to the Cooling Circuit Troubleshooting Table on page T5-6-4.



T5-6-10



TROUBLESHOOTING / Troubleshooting C



Seized clutch.



Replace.



Improper gap between am Broken or short-circuited core cable. Shaft doesn’t rotate (internally locked).



Replace.



Replace.



Refer to the Electrical Circuit Troubleshooting Table on page T5-6-6.



Refer to the Cooling Circuit Troubleshooting Table on page T5-6-4.



Faulty mechanical seal, gasket, and/or charge valve. Replace. Oil leaks from oil plug. Oil and refrigerant leaks from front housing, and/or cylinder block joint. Normal leaks from hoses.



Replace. Charge refrigerant.



No leaks (normal).



Refer to the Cooling Circuit Troubleshooting Table on page T5-6-4. Broken valve (See NOTE 3 on page T5-6-13.). Replace. Blown gasket (See NOTE 3 on page T5-6-13.).



Check and adjust oil level.



Excessive oil. Broken clutch bearing due to overly tightened belt.



Replace.



Shaft doesn’t rotate. Replace.



Shaft rotates draggy.



T5-6-11



TROUBLESHOOTING / Troubleshooting C Compressor



Noise is heard when clutch is OFF.



Abnormal noise



Noise is heard when clutch is ON.



T5-6-12



TROUBLESHOOTING / Troubleshooting C



Broken clutch bearing. Replace Contact or slip due to poor air gap. Faulty idle pulley bearing. Refer to the Cooling Circuit Troubleshooting Table on page T5-6-4.



Saggy belt. Loose screws.



Broken valve. Replace Blown gasket. Abnormal internal noise.



Replace



Vibration due to saggy belt. Refer to the Cooling Circuit Troubleshooting Table on page T5-6-4.



Loose screws.



NOTE: 1. Don’t quickly decide that oil is leaking when a stain around the clutch and/or gasket is found. A slight oil seepage will appear due to the seal construction. However, this oil seepage will not cause malfunction. Be sure to accurately check whether oil is leaking or seeping only. 2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose surface may be detected. As long as the specified rubber hoses are used, the problem should not occur. (In case a large leaks is detected, the hose may be broken.) 3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between 2 high pressure side and low pressure side is 0.49 MPa (5 kgf/cm , 71 psi) or less. When the clutch is turned OFF, the pressure difference between high pressure side and low pressure side will disappear within about 10 seconds.



T5-6-13



TROUBLESHOOTING / Troubleshooting C DIAGNOSIS BY BLINKING OF INDICATOR The air conditioner system has a function to detect the abnormality of the system by blinking of the indicator IMPORTANT: Once abnormality is detected, the detection state remains even after normal state resumes. To release this detection state, turn OFF the key switch, or stop the air conditioner with ON/OFF switch on the control panel. Notice that the limitation of M/A (motor actuator) can be released only when the key switch is OFF. Abnormal Communication



Open-Circuit Detection



• Blinking of HOT Mark



• Blinking of Temperature Control Bar Frame



When the power is ON, HOT mark blinks if the harness of the air mix M/A disconnects or shorts. The air mix M/A remains disabled until the power is turned ON again.



• Blinking of Inside/Outside Air Mark When the main key power is ON, the inside/outside air mark blinks if the harness of the inside/outside air selection M/A disconnects or shorts. The inside/outside air selection M/A remains disabled until the power is turned ON again.



• Blinking of A/C Mark (Open- or Short-Circuit of Evaporation Sensor and Its Input Circuit) The A/C mark blinks if the harness disconnects or shorts. At this time, compressor control is not made, and the compressor clutch is always turned OFF. Notice that anti-fretting control is made.



1. If communication between control panel and control amplifier fails, thus disabling reception, the control panel makes the temperature control bar frame blink about 30 seconds later. 2. At this time, the control amplifier makes all outputs turn OFF. 3. Even when is blinking, the control panel receives all switch inputs. 4. When reception resumes, the temperature control bar frame is turned ON instead of blinking state, and the control panel and control amplifier resume.



T5-6-14



TROUBLESHOOTING / Troubleshooting C



Control Panel ON/OFF Switch



A/C Mark Inside/Outside Air Mark



HOT Mark



Temperature Control Bar Frame



T18G-05-06-001



T5-6-15



TROUBLESHOOTING / Troubleshooting C ÚPlease fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to the related post / after experiencing a problem with your machine’s air conditioning system.



< AIR CONDITIONER TROUBLE REPORT >



File No.



(1) What Checked by: Model (Serial No. ) Operation Type Manual Semi-Auto Full-Auto Delivery Date Year Month (2) When Date Year Month Day Operating Hour ( h) Time Morning Daytime Evening Night Frequency Every Day Once a Week Once a Month Times per (3) Where Job Site Address State County Town Access Road Condition Paved Not Paved (Gravel Sand Soil) (4) How (Operating Conditions) Weather Fine Cloudy Rain Snow Atmospheric Temperature Very Hot Hot Cold Very Cold Operating Conditions Parking Traveling Working Temperature Control Paint blanks equal to red indicators. / Fill in set-temperature when full-auto operation A/C ON OFF Air Induction Re-Circulation Fresh Air Circulation Control AUTO ON OFF Not Available Panel Fill following items when operated in manual mode or when manual control type unit is used. Vent Position Front Front / Rear Foot Front / Rear and Foot Fan First Second Third Fourth Fifth Sixth (5) How (Problem Symptom) Abnormal Compressor Operation



Symptom Not turned ON (1) Is problem reproducible ? Not turned OFF Others Reproducible Uncontrollable air temperature Not reproducible Symptom No cool air (1) Pressure (To be measured at gauge No warm air manifold) Others Low Pressure Uncontrollable air volume High Pressure Symptom Air flows in Hi mode only (1) Which parts have been replaced ? No air flows 1 Small air volume Others Uncontrollable vent hole 2 Symptom Vent hole isn’t selected Others ∗ Before replacing the control amplifier, Abnormal panel indication Faulty Indi- Vent Hole be sure to check that the connectors are cator A/C correctly connected while repeatedly AUTO disconnecting and reconnecting conFresh Air Circulation nectors. Fan OFF Fan (Lo • •• Hi) Temperature Control Symptom Stays OFF Stays ON Blinks Others



T5-6-16



TROUBLESHOOTING / Troubleshooting C Refrigerant Quantity....................... 1400±50 g 3 Compressor Oil Quantity................ 320 cm



T5-6-17



TROUBLESHOOTING / Troubleshooting C (Blank)



T5-6-18



TROUBLESHOOTING / Electrical System Inspection PRECAUTIONS FOR INSPECTION AND MAINTENANCE 1. Disconnect 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 circuit. 2. Color Coding of Wire Harnesses The color codes of the wire harnesses in the electrical system are shown in the table on the light. In some cases, where two colors are indicated for one wire, the left initial stands for the base color, while the right initial stands for the marking color. Code



R



W



L



G



Y



B



Color



Red



White



Blue



Green



Yellow



Black



Code



Or



Lg



Br



p



Gr



V



Orange



Light Green



Brown



Pink



Gray



Violet



Color



NOTE: • • •



Code BW indicates a black base wire with white fine-line marking. Initials “O” and “Or” both stand for the color orange. Wires with longitudinal stripes printed on them are not color coded. Be sure not to confuse them with color coded wires.



T5-7-1



TROUBLESHOOTING / Electrical System Inspection 3. Precautions for Connecting and Disconnecting Terminal Connectors • 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. • Water-resistant connectors keep water out so that if water enters the connector, water will not easily drain. When checking water-resistant connectors, take extra care not to allow water to enter these types of connectors. In case water should enter this connector, reconnect only after thoroughly drying the connector. • Before connecting terminal connectors, check that no terminals are bent or missing. In addition, as most connectors are made of brass, check that no terminals are corroding. • When connecting terminal connectors provided with a lock, be sure to insert them together until the lock “clicks”. 4. Precaution for Using a Circuit Tester • Before using a circuit tester, refer to the instructions in the circuit tester manual. Then, set the circuit tester to meet the object to be measured, voltage range and current polarity. • Before starting the connector test, always check the connector terminal numbers, referring to the circuit diagram. When the connector size is very small, and the 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



Correct



Incorrect



T107-07-06-001



Correct Rust Bending Separation T107-07-06-002



Wind wire around the probe.



Probe



Sharpen the tip of wire. T107-07-06-003



TROUBLESHOOTING / Electrical System Inspection DISCONNECTION OF CONNECTOR • Connector with a lock to press NOTE: 1. Press the lock first, then pull the connector. The lock is difficult to press after the connector is pulled. 2. The lock is located on the female (harness) end of the connector.



T107-04-05-002



• Connector to pull apart NOTE: Remove locks (if any) using a needle nose pliers before pulling the connector.



T107-04-05-004



• Connector to pull apart Use a 10 mm wrench to tighten the screw until the torque mark (convex) appears when re-tightening.



Screw Convex



T107-04-05-005



T5-7-3



TROUBLESHOOTING / Electrical System Inspection BATTERY VOLTAGE CHECK 1. Turn the key switch OFF. Check voltage between the battery positive terminal and the vehicle frame. Normal Voltage:Between 24 to 26 V NOTE: If voltage is abnormal, recharge or replace the battery (ies). 2. Start the engine. Check charging voltage between the battery positive terminal and the vehicle frame. Normal Voltage:Between 26 to 28 V NOTE: If voltage is abnormal, check the charging system.



V



T157-07-06-007



T5-7-4



TROUBLESHOOTING / Electrical System Inspection (Blank)



T5-7-5



TROUBLESHOOTING / Electrical System Inspection FUSIBLE LINK INSPECTION • Fusible Link 1 Pull off the fusible link to visually inspect.



A



Cross Section A



B



Cross Section B



C



T18L-01-02-045



Cross Section C



1



2



3



4



7



8



9



10



5



6



T18L-01-02-046



No. 1 2 3 4 5 6 7 8 9 10



Part Name Fusible Link 1 Fusible Link 2 Fusible Link 3 Fusible Link 4 Fusible Link 5 Fusible Link 6 Fusible Link 7 Fusible Link 8 Fusible Link 9 Fusible Link 10



Capacity 75A 75A 75A 75A 75A 75A 45A 75A 45A 75A



Connected to Fuse Box 1,3 (Fuse No.1,2,4 to 12,55) Fuse Box 2,4 (Fuse No.31 to 33,69,70) Fuse Box 2,3,4 (Fuse No.30,34 to 36,48 to 50,73) Fuse Box 2,3,4 (Fuse No.37 to 39,44 to 47,53,59,60,67,68,77 to 79) Fuse Box 4 (Fuse No.61 to 66) Fuse Box 3,4 (Fuse No.41,51,52,75,76) Option Terminal Engine Starter Relay ECM Main Power Sliding Fold-In Ladder Relay



T5-7-6



TROUBLESHOOTING / Electrical System Inspection • Fusible Link2 Check continuity between both ends of the fusible link.



A



Cross Section A



1



B



Cross Section B



3



2



T18L-01-02-045



T183-05-08-001



No. 1 2 3



Part Name Fusible Link 250A Fusible Link 250A Fusible Link 400A



Capacity 250A 250A 400A



Connected to Sliding Fold-In Ladder Motor (Rear) Sliding Fold-In Ladder Motor (Front) Engine Pre-Lube Relay



T5-7-7



TROUBLESHOOTING / Electrical System Inspection FUSE CONTINUITY CHECK The fuse failure is 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 far superior to visual inspection. 1. Turn the key switch ON. In doing so, the battery relay is activated by the current from terminal M of the key switch, and electric power is supplied to all circuits. 2. Remove the fuse box cover and set the correct voltage measurement range (0 to 30 V) of the tester. 3. Connect the negative probe to the machine for grounding, and touch the accessory (downstream) side terminal of each fuse with the positive probe of the tester. If voltage (battery voltage) of approx. 20 to 25 V is observed at the tester, fuse is not blown.



Power Source Side (Positive)



NOTE: 1.The inside terminals of the fuses in the fuse box 1 and 2 are connected to the power source, while the outside terminals are connected to the accessory (downstream) side. 2.The left side terminals of the fuses in the fuse box 3 are connected to the power source, while the right side terminals are connected to the accessory (downstream) side. 3.The upper side terminals of the fuses in the fuse box (cab) are connected to the power source, while the lower side terminals are connected to the accessory (downstream) side.



T5-7-8



Accessory Side (Negative)



T105-07-01-008



TROUBLESHOOTING / Electrical System Inspection Fuse Box (Cab)



20 19 18 17 16



15 14 13 12 11



T18G-01-02-030



10 9



8



7



6



T18G-01-02-028



Fuse Box (Cab) No.



Part Name



Capacity



Connected to



1



Main Power Key SW



20A



Key Switch B Terminal



2



ELU Main Power



5A



ELU



3



IDU Main Power



5A



IDU



4



DLU Main Power



5A



DLU



5



ORBCOMM Battery Power



5A



ORBCOMM Unit (Optional)



6



Radio Backup



5A



Radio



7



ELU Key ON Sig.



5A



ELU



8



IDU Key ON Sig.



5A



IDU



9



DLU Key ON Sig.



5A



DLU



10



Buzzar



5A



BUZZAR



11



Key ON Sig. (Control Box)



5A



Fuse Box 1 (Fuse No.13)



12



ECM Key ON Sig.



5A



ECM



13



Radio (ACC)



5A



Radio



14



Air Horn Comp. ACC Sig.



5A



Air Horn Compressure Relay, Horn Relay



15



Lighter



10A



Radio, Ciger Lighter



16



Terminal (ACC)



10A



Terminal 1



17



Terminal (12V)



15A



Terminal 1



18



−



19



Monitor Control Unit



5A



−



Monitor Display



−



20



Pilot Control Shut-Off Lever SW.



5A



Pilot Control Shut-Off Lever SW



T5-7-9



5



4



3



2



1



TROUBLESHOOTING / Electrical System Inspection Fuse Box 1



1



2



3



4



5



6



7



8



9 10



T18G-05-07-001



11 12 13 14 15 16 17 18 19 20



T18M-05-06-002



Fuse Box 1 Connection Table No.



Part Name



Capacity



Connected to



1



MC Main Power



5A



MC



2



Delayed Power OFF Relay



5A



Delayed Power Off Relay



3



−



4



MMS Back-up



5A



MMS (Optional)



5



HMU Main Power



5A



HMU



6



Air Horn Compressor (L)



30A



Air Horn Compressor Relay (L)



7



Air Horn Compressor (R)



30A



Air Horn Compressor Relay (R)



8



Sliding Fold-In Ladder Sol. (A)



10A



Sliding Fold-In Ladder Solenoid (A)



9



BOX LIGHT



5A



Box Light



10



Cab.Battery Power



30A



Fuse Box (Cab) Fuse #1, 2, 3, 4, 5 ,6



11



Opt. C/U Main Power



10A



Oprion Control Unit



12



Opt. C/U Main Power



10A



Oprion Control Unit



13



Opt. C/U Key ON Sig.



5A



Oprion Control Unit



−



−



14



Opt. C/U Key ON Sig.



5A



Oprion Control Unit



15



MC Key ON Sig.



5A



MC



16



ELU PWM Power Relay



5A



ELU PWM Power Relay



17



DLU Key SW ON Sig.



5A



DLU



18



−



19



ECM SW Power



5A



−



Engine Diagnostic Switch



−



20



HMU Key ON Sig.



5A



HMU



T5-7-10



TROUBLESHOOTING / Electrical System Inspection Fuse Box 2 21 22 23 24 25 26 27 28 29 30



T18G-05-07-001



31 32 33 34 35 36 37 38 39 40



T18M-05-06-002



Fuse Box 2 Connection Table No.



Part Name



Capacity



Connected to



21



Washer Motor Relay



5A



22



Travel Speed Select relay



5A



Washer Motor Relay Travel Speed Select Relay



23



A/C Main Relay (Front)



5A



A/C Main Relay (Front)



24



A/C Main Relay (Side)



5A



A/C Main Relay (Side)



25



A/C Main Relay (Rear)



5A



A/C Main Relay (Rear)



26



Battery Relay



5A



Battery Relay



27



A/C Control AMP (Front)



5A



A/C Control AMP (Front)



28



A/C Control AMP (Side)



5A



A/C Control AMP (Side)



29



A/C Control AMP (Rear)



5A



A/C Control AMP (Rear)



30



Motion Alarm



5A



Motion Alarm



31



A/C Main Power (Front)



15A



A/C Main Power (Front)



32



A/C Main Power (Side)



15A



A/C Main Power (Side)



33



A/C Main Power (Rear)



15A



A/C Main Power (Rear)



34



A/C Condenser Fan (Front)



20A



Air Compressure Fan Relay (FRONT)



35



A/C Condenser Fan (Side)



20A



Air Compressure Fan Relay (SIDE)



36



A/C Condenser Fan (Rear)



20A



Air Compressure Fan Relay (REAR)



37



DLU Service Tool



5A



DLU



38



ORBCOMM Main Power



5A



ORBCOMM Unit (Optional)



39



MMS Main Power



5A



MMS (Optional)



40



Charge Signal



5A



Alternator



T5-7-11



TROUBLESHOOTING / Electrical System Inspection Fuse Box 3 41 42 43 44 45 46 47 48 49 50



T18G-05-07-001



51 52 53 54 55 56 57 58 59 60



T18M-05-06-002



Fuse Box 3 Connection Table No.



Part Name



Capacity 15A



Connected to



41



Suspention Seat Air Compressor



42



−



−



Suspention Seat Air Compressure



43



−



−



44



Travel Speed Select Sol.



5A



Travel Speed Select Relay



45



Sliding Fold-In Ladder Sol.



5A



Sliding Fold-In Ladder Solenoid Valve B



46



Dome LED Light



5A



Dome LED Light in the Cab



47



Air Breather Sol.



5A



Air Breather Solenoid Valve



− −



48



Terminal (24V)



15A



Terminal



49



DC/DC Converter1



15A



DC-DC Converter 1



50



DC/DC Converter2



15A



DC-DC Converter 2



51



MC Sol. Power



10A



MC



52



MC PWM. Power



10A



MC



53



ELU Sol. Power



15A



ELU PWM.Power Relay, ELU



54



−



55



ECM Power



−



56



−



−



−



57



−



−



−



58



−



−



59



Engine Oil Reserve Tank Pump



15A



Engine Oil Reserve Tank Pump



60



Oil Pump



20A



Air Release Solenoid Valve



15A



− ECM



−



T5-7-12



TROUBLESHOOTING / Electrical System Inspection Fuse Box 4 61 62 63 64 65 66 67 68 69 70



T18G-05-07-001



71 72 73 74 75 76 77 78 79 80



T18M-05-06-002



Fuse Box 4 Connection Table No.



Part Name



Capacity



Connected to



61



Wark Light (1)



10A



Work Light Relay (1)



62



Wark Light (2)



10A



Work Light Relay (2)



63



Wark Light (3)



10A



Work Light Relay (3)



64



Wark Light (4)



10A



Work Light Relay (4)



65



Wark Light (5)



10A



Work Light Relay (5)



66



Wark Light (6)



10A



Work Light Relay (6)



67



Maintenance Light (1)



10A



Maintenance Light Relay (1)



68



Maintenance Light (2)



10A



Maintenance Light Relay (2)



69



Maintenance Light (3)



10A



Maintenance Light Relay (3)



70



Maintenance Light (4)



10A



Maintenance Light Relay (4)



71



−



−



72



−



−



73



Entrarce Light



10A −



− − Entrarce Light Relay



74



−



75



Wipir Motor (Slow Speed)



30A



Wipir Motor Relay (Slow Speed)



76



Wipir Motor (Fast Speed)



30A



Wipir Motor Relay (Fast Speed)



77



Washer Motor



10A



Washer Motor Relay



78



Fast Filling System Sol.



5A



Fast Filling System Relay



79



CSU Main Power



5A



CSU



80



−



−



−



−



T5-7-13



TROUBLESHOOTING / Electrical System Inspection Fuse Check Continuity between both ends of the fuse.



A



Cross Section A



B



Cross Section B



2



1



3



T18L-01-02-045



No.



Part Name



Connected to IDU (Prelube Signal)



1



Fuse 5A



2



Fuse 30A



Zener Diode



3



Fuse 10A



Engine Oil Reserve Tank Valve



T5-7-14



TROUBLESHOOTING / Electrical System Inspection ALTERNATOR CHECK The alternator indicator should go off after the engine is started. If the alternator indicator stays (comes) on while the engine is running, the alternator may be failed.



Terminal R Terminal B



Measurement of Generating Voltage Start the engine. Measure voltage at terminals R and B. If the voltage at terminal R is 1.0 V or higher, and if that at the terminal B is approximately 28 V, the alternator is normal.



T18M-05-06-001



T5-7-15



TROUBLESHOOTING / Electrical System Inspection VOLTAGE CHECK The voltage check is performed not only for determination of the voltage values at the measurement point, but also for the confirmation of the electrical validity between the measurement point and power supply. 24 Volt Circuit Before voltage check, turn appropriate switch ON to apply voltage at the measurement line. Measurement Example 1: When current is not flowing Black Negative (-) Probe: Vehicle Frame Red Positive (+) Probe: Each Measurement Point If the rated voltage (battery voltage) is measured, probably the circuit from the battery (alternator) to the measurement point is in good condition. However, if the current flowing through the circuit, the voltage may not be reached the rated value (this voltage drop is caused by resistance of electrical components).



Measurement Point



T141-05-06-002



If the rated voltage is not measured, faulty power supply, short-circuited circuit and/or broken line on circuit may be suspected. In this case, the faulty parts in the circuit can be found out by checking each parts in order of the circuit from the upstream (or downstream).



Measured Voltage 24 V: The circuit from power source to the measurement point is normal. 0 V: There is open or short circuit between power supply and the measurement point.



Rated Voltage (with normal power source): When engine is not running: Battery voltage approx. 25.5 V When engine is running: Alternator generated voltage approx. 28 V



Measurement Example 2: When power flows 2



1



3 T141-05-06-003



Measurement Point Measured Value 1 24 V 2 20 V 3 0V The measurement voltage does not become same to the power supply value because of voltage drops by resistance of the electrical components. However, if the voltage is measured, it can be decided that there are no open wires in the upstream circuit from measurement point.



T5-7-16



TROUBLESHOOTING / Electrical System Inspection



Engine Power Source Circuit Stopped Stopped Stopped Stopped Stopped Accessory Circuit Stopped Stopped Stopped Stopped Stopped Stopped



Key Switch



Check Point



Standard



OFF OFF OFF OFF OFF



Between (2) and (1): One Battery Between (3) and (2): One Battery Between (3) and (1): Two Battery Between (4) and Ground: Power Source Between (5) and Ground: Fusible Link 1



10 to 12.5 V 10 to 12.5 V 20 to 25 V 20 to 25 V 20 to 25 V



ACC ACC



Between (6) and Ground: Radio, Cigarette Lighter Between (7) and Ground: Air Horn Compress Relay (L2) Between (8) and Ground: Air Horn Compress Relay (R2) Between (9) and Ground: Horn Relay



20 to 25 V 20 to 25 V



Between (10) and Ground : Pre-Lube Timer Relay (#2) Between (11) and Ground : Pre-Lube Timer Relay (#5) Between (12) and Ground : Starter Relay (Upper) (Switch) Between (13) and Ground : Starter Relay (Upper) (Coil) Between (14) and Ground : Starter Relay (Lower) (Switch) Between (15) and Ground : Starter Relay (Lower) (Coil) Between (16) and Ground : Safety Relay (Switch) Between (17) and Ground : Starter Motor (Upper) (S) Between (18) and Ground : Starter Motor (Lower) (S)



20 to 25 V 20 to 25 V 20 to 25 V



Between (19) and Ground: Alternator Generating Voltage (B) Between (20) and Ground: Battery Relay (B)



26 to 30 V



Between (21) and Ground: Delayed Power Off Relay (Coil) Between (22) and Ground: Battery Relay (Coil)



20 to 25 V



ACC ACC



Starting Circuit Engine Start Switch: ON Started Started Started



ON ON ON



Started



ON



Started



ON



Started



ON



Started Started Started Charging Circuit Running



ON ON ON



Running Surge Voltage Prevention Circuit Running−Stopped



ON



Running−Stopped



ON - OFF



ON



ON – OFF



T5-7-17



20 to 25 V 20 to 25 V



20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V



20 to 25 V



20 to 25 V



TROUBLESHOOTING / Electrical System Inspection Power Source Circuit Limit Switch (Box light switch)



Fuse Box (Cab)



LED



To MC Delayed Power OFF Relay Terminals #1 and #3 To MMS Communication Unit



To HUM



To ELU To IDU To DLU ORBCOMM Terminal #2 (Option)



Sliding Fold-In Ladder Relay (1) Terminal #3 Sliding Fold-In Ladder Relay Alarm Flash Light (1) #12



Air Horn Compressor Relay (L1) Terminal #3 Air Horn Compressor Relay (R1) Terminal #3



C/U Main Power Source Terminal #1 (Option)



To Radio



C/U (Ke-CAN) Terminal #1 (Option)



Fuse Box 1



Key Switch ECM (Datalink)



Fuse Box 3



Sliding Fold-In Ladder Relay (2)



5



Sliding Fold-In Ladder Relay (3)



Fusible Link #9



Fusible Link 1 Fusible Link #10 Fusible Link (250A)



Fusible Link (250A) Battery Relay 1



4



Battery Relay 2



4



Battery Relay 3



4



3



2



Sliding Fold-In Ladder Motor 1



Sliding Fold-In Ladder Motor 2



Battery



1 T18M-02-05-001



T5-7-18



TROUBLESHOOTING / Electrical System Inspection Accessory Circuit



Fuse Box 1 Fuse #7 Fuse #6



Fuse Box (Cab)



Fuse Box 1 Fuse #10



Air Horn Compressor Relay (L2)



Key Switch To Radio



Air Horn Compressor Relay (L1)



Cigarette Lighter



Fusible Link 1



7 6 8



Air Horn Compressor Relay (R2)



9



Power Source Terminal (1)



Air Horn Compressor Relay (R1)



Horn Relay



Horn Switch



Horn (R)



Horn (L)



Air Horn Compressor (R1)



Air Horn Compressor (L1) Battery Horn Pressure Switch (L1)



Horn Pressure Switch (R1)



Horn Pressure Switch (L2)



Horn Pressure Switch (R2)



T18M-02-05-002



T5-7-19



TROUBLESHOOTING / Electrical System Inspection Starting Circuit From Key Switch Terminal M



Engine Start Switch



11



Prelube Timer



10



Charge SIG Relay Starter Relay (Upper)



12 13



Engine Oil Reserve Pump Unit Relay



Fuse Box 3 Fuse #59



Starter Relay (Lower)



14 15



Charge Relay



16



Safety Relay



Fusible Link 4



ECM



Alternator



Engine Oil Reserve Pump Unit Switch From EHU Fuse Box 2 Fuse #40



Battery Relay (1)



Fuse Box 2 Fuse #26



Battery Relay (2) Battery Relay (3)



17



18



Crank Speed Sensor



Starter (1) (Upper)



Fuse Box (Cab)



From Battery Key Switch



Starter (2) (Lower)



T18M-02-05-006



T5-7-20



TROUBLESHOOTING / Electrical System Inspection Power Source Circuit To T2-5-15, 17, 19, 21



Fusible Link Terminal (Main)



Fusible Link 9



Terminal (Sub) Circuit Braker (200A)



20 20 20



19



Battery 1



Relay



Battery 2



Relay



Battery 3



Relay



From Alternator Terminal B From Key Switch Terminal M



Sliding Fold-In Ladder Relay (2)



Sliding Fold-In Ladder Relay (3) ECM Battery



Sliding Fold-In Ladder Motor 2



Sliding Fold-In Ladder Motor 1 T18M-02-05-008



T5-7-21



TROUBLESHOOTING / Electrical System Inspection Surge Voltage Prevention Circuit Fuse Box (Cab)



Fuse #11 Fuse #1 Key Switch Fuse Box 1



Fuse #2 Delayed Power Off Relay



21



Fuse Box 2 Fuse #26



Fuse #15 Fuse #10



MC



Fusible Link 1



Battery Relay 1



22



Battery Relay 2



22



Battery Relay 3



22 Alternator (L)



Battery



T18M-02-05-016



T5-7-22



TROUBLESHOOTING / Electrical System Inspection 5 Volt Circuit Voltage between terminal No.1 and the machine chassis (Ground): With the key switch turned OFF, disconnect the sensor connector. Measure the voltage between terminal No.1 of the harness side connector and the vehicle frame under the following conditions



Power Source Signal or Ground 2 1 Two Polarities



V



• Key switch position: ON • Tester black probe (negative): Connected to the vehicle frame (ground)



• Tester red probe (positive):



T107-07-05-006



Connected to terminal No.1 Evaluation: If the measured voltage is within 5±0.5 volts, the circuit up to terminal No.1 is normal.



Power Source Signal Ground 2 3 1 Three Polarities



V



T107-07-05-007



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 of the harness side connector and the ground terminal (terminal No.2 for two polarities, or terminal No.3 for three polarities) under the following conditions.



1



2



Two Polarities



V



• Key switch position: ON • Tester black probe (negative): Connected to the ground terminal (terminal No.2 or 3) • Tester red probe (positive): Connected to terminal No.1 Evaluation: If the measured voltage is within 5±0.5 volts, the circuit lines up to terminal No.1 and the ground terminal are normal.



T107-07-05-008



1



2



3



Three Polarities



V



T107-07-05-009



T5-7-23



TROUBLESHOOTING / Electrical System Inspection CHECK USING FALSE SIGNAL With the key switch turned OFF, disconnect the sensor connector. Connect terminal No.1 (power source) and No.2 (signal) of the harness side connector to supply the power source voltage as a false signal to the controller. This makes it to create the same situation as the extreme situation on the sensor input signal. If the machine and/or gauge actuate with the maximum signal accordingly, the related harness is considered to be normal. On the pressure switch, the switch indicates "ON" status.



2



1



Two Polarities



Connect



T107-07-05-010



IMPORTANT: On three-polarity connectors, do not connect terminals No.1 and No.2 to No.3 or the machine chassis (ground).



Three Polarities



1



2



3



Connect



T107-07-05-011



T5-7-24



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 machine chassis using a clip. Then, check continuity of the harness through the vehicle frame as illustrated. If the ohm-meter reading is: 0 Ω = Continuity ∞ Ω = Discontinuity



A



Ω Connect To Machine Chassis.



A



Connect To Machine Chassis.



a



Ω



A



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 connect 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).



a



a ×



Ω Short-Circuit Between Harness and Machine Chassis



T107-07-05-003



First Terminal Connection



A B C



a b c



Second Terminal Connection



NOTE: By conducting the multi-line continuity check twice, it is possible to find out which line is discontinued. With terminals (A) and (C) connected, 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.



T5-7-25



Ω



T107-07-05-004



Short-Circuit Between Harness A B C



×



a b c



Ω



T107-07-05-005



TROUBLESHOOTING / Electrical System Inspection CIRCUIT CHECK BY LAMP HARNESS Check the power at the measurement point using a lamp harness. #4283594 (ST 7126) Used for single line inspection (an open, voltage). Light should come on when the line is activated. NOTE: On the PWM signal circuit, the lamp does not show light if the ON signal duration ratio is too small.



To measurement point



Connect an end of the lamp harness to the measurement point, and connect the other end to the ground. Turn ON the circuit to be measured. Check the circuit conditions with the lamp flashing simultaneously with the system operation.



T5-7-26



#4283594(ST 7126)



Grounding



T107-07-05-012



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



Hitachi Construction Machinery Co. Ltd Attn: Publications, Marketing & Product Support Fax: 81-29-831-1162



Hitachi Ref. No.



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ATTACHED DIAGRAM LIST (The following diagrams are attached to this manual) 1. EX2500-6 ELECTRICAL CIRCUIT DIAGRAM (1/3) EX2500-6 ELECTRICAL CIRCUIT DIAGRAM (2/3) 2. EX2500-6 ELECTRICAL CIRCUIT DIAGRAM (3/3) EX1900-6, EX2500-6, EX3600-6 ELECTRICAL CIRCUIT DIAGRAM (CAB) 3. EX1900-6, EX2500-6, EX3600-6 ELECTRICAL CIRCUIT DIAGRAM (ELECTRICAL EQUIPMENT BOX 1/2) EX1900-6, EX2500-6, EX3600-6 ELECTRICAL CIRCUIT DIAGRAM (ELECTRICAL EQUIPMENT BOX 2/2) 4. EX1900-6, EX2500-6, EX3600-6, EX5500-6 CONNECTORS 5. EX2500-6 HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL) EX2500-6 HYDRAULIC CIRCUIT DIAGRAM (BACKHOE)