After removing and/or replacing the components as described below for repair and/or inspection, or if error in engine speed is found, readjust engine speed and perform engine learning.
• Removal of the engine, engine control cable, or EC motor
• Replacement of MC Adjustment of Engine Speed:
1. Turn the key switch to the START position to start the engine.
NOTE: Turn the air conditioner OFF.
2. Rotate the engine control dial to the minimum speed position. (The output voltage from the EC sensor is 2.5 V.)
3. Deactivate the auto warming up and ECO control systems by Dr. ZX.
4. When Dr. ZX is not available, keep the engine running for about 15 minutes to warm coolant temperature to more than 30 °C (86 F°) until the auto warming up control system is deactivated.
5. Loosen the bolt holding the control lever to the EC motor output shaft.
6. While monitoring the actual engine speed with Dr.
ZX or the engine speed meter, adjust the control lever so that the minimum speed (slow idle) matches the specification.
Specification: Refer to T4-2 OPERATIONAL PER FORMANCE TEST.
7. Tighten the lever holding bolt to secure the control lever to the motor output shaft.
: 13 N⋅m (1.3 kgf⋅m, 9.4 lbf⋅ft)
NOTE: Don’t lubricate the motor output shaft.
8. Perform engine learning.
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Control Lever
Holding Bolt
NOTE: In case the engine doesn’t stop when the key switch is turned OFF, pull the handle located under the seat to stop the engine.
2. Disconnect Dr. ZX. Wait for 5 seconds.
3. Turn the learning switch ON.
4. Turn the key switch ON. Wait for 5 seconds.
5. Turn the key switch OFF. Wait for 5 seconds.
6. Turn the learning switch OFF.
7. Check the engine speed. T178-01-02-006
T1SM-01-02-006
Dr.ZX Connector to MC Learning Switch
Learning Switch is Turned to Stamp E
Stamp Learning Switch 225 class
(ZAXIS225US)
Dr.ZX Connector to MC
Learning Switch
(Blank)
• Check the fuel cut lever position during cranking.
If the position is normal, the engine unit and/or fuel system may have trouble.
• Governor Lever and Fuel Cut Lever
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1 - Governor Cable (From EC Motor) 2 - Fuel Cut-Off Cable
(Fuel Cut-Off Handle) 3 - Fuel Cut Lever 4 - Governor Lever
1 2 3 4
• Governor Lever Position
A - Key Switch OFF (Engine Stop Position) B - Key Switch ON (Engine Start Position)
T105-07-04-003
• Fuel Cut Lever Position
A - Fuel Cut-Off Handle Pulled Position B - Fuel Cut-Off Handle Returned Position
A
STOP STOP
FULL
FULL B
B A
B
SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 General
Introduction... T5-1-1 Diagnosing Procedure ... T5-1-2 Built-In Diagnosing System Operation ... T5-1-6 Built-In Diagnosing Function Display List .. T5-1-7 Dr. ZX Operation... T5-1-8 Dr. ZX Fault Code List... T5-1-10 Dr. ZX Monitoring Item List ... T5-1-12 Dr. ZX Special Function ... T5-1-14 Dr. ZX Service Mode... T5-1-15 Adjustment Data List... T5-1-25 Initial Setting of Boom Electronic
Cushion... T5-1-27
Group 2 Component Layout
Main Component Layout ... T5-2-1 Electrical Component Layout (Overview) .. T5-2-4 Electrical System
(Relays and Related Equipment) ... T5-2-7 Electrical System
(Monitors and Switches)... T5-2-9 Pump Device ... T5-2-10 Swing Device ... T5-2-10 Control Valve ... T5-2-11 Signal Control Valve... T5-2-11 Solenoid Valve Unit... T5-2-11
Group 3 Troubleshooting A
Troubleshooting A Procedure ...T5-3-1 Fault Code List ...T5-3-2 Fault Code 01, 02, 03...T5-3-3 Fault Code 04...T5-3-3 Fault Code 06...T5-3-4 Fault Code 07...T5-3-5 Fault Code 08...T5-3-6 Fault Code 10, 11 ...T5-3-7 Fault Code 12, 13...T5-3-8 Fault Code 14, 15, 16, 18...T5-3-9 Fault Code 19...T5-3-10
Group 4 Troubleshooting B
Troubleshooting B Procedure...T5-4-1 Relationship between Machine Trouble
Symptoms and Related Parts ...T5-4-2 Correlation between Trouble
Symptoms and Part Failures ...T5-4-24 Engine System Troubleshooting...T5-4-37 All Actuator System Troubleshooting ...T5-4-58 Front Attachment System
Troubleshooting...T5-4-67 Swing System Troubleshooting ...T5-4-82 Travel System Troubleshooting ...T5-4-87 Other System Troubleshooting ...T5-4-94
Malfunction of Coolant
Temperature Gauge ... T5-5-2 Malfunction of Fuel Gauge ... T5-5-4 Malfunction of Indicator Light
Check System... T5-5-6 Malfunction of Preheat Indicator ... T5-5-7 Malfunction of Engine Oil Level
Indicator ... T5-5-8 Malfunction of Coolant Level
Indicator ... T5-5-10 Malfunction of Alternator Indicator ... T5-5-12 Malfunction of Engine Oil Pressure
Indicator ... T5-5-14 Malfunction of Overheat Indicator ... T5-5-16 Malfunction of Air Filter Restriction
Indicator ... T5-5-18 Malfunction of Buzzer ... T5-5-20 Malfunction of LCD ... T5-5-22 Malfunction of Hour Meter... T5-5-23 Malfunction of Hydraulic Oil Filter
Indicator (Optional) ... T5-5-24
Group 6 Electrical System Inspection
Precautions for Inspection and
Maintenance ... T5-6-1 Instructions for Disconnecting
Connectors ... T5-6-3 Fuse Inspection ... T5-6-4 Fusible Link Inspection ... T5-6-5 Battery Voltage Check ... T5-6-6 How to Troubleshoot Alternator
Malfunctions... T5-6-7 Continuity Check... T5-6-8 Voltage and Current Measurement ... T5-6-11 Check by False Signal ... T5-6-15
ICX Fault Code List ...T5-7-8 Satellite Terminal Fault Code List ...T5-7-8 Fault Code 1 to 4 and 6...T5-7-9 Fault Code 7 to 10...T5-7-9 Some Parts of Data in Daily Report,
Frequency Distribution, Cumulative
Operation Hours are not Recorded...T5-7-10
INTRODUCTION
Refer to the inspection and troubleshooting proce-dures after any machine trouble has occurred. The inspection and troubleshooting procedures are pre-sented in an orderly fashion in this section to quickly find the cause of the machine trouble and solution.
The troubleshooting section in this manual consists of 7 groups; General, Component Layout, Troubleshoot-ing A (base machine diagnosis usTroubleshoot-ing fault codes), Troubleshooting B (base machine diagnosis starting with inspection of abnormal operational status), Trou-bleshooting C (monitor diagnosis), Electrical System Inspection, and ICX.
• General
• Component Layout
• Troubleshooting A (base machine diagnosis using fault codes)
Refer to these procedures if any fault codes are displayed when the main controller (MC) is diag-nosed with Dr. ZX (or the built-in diagnosing sys-tem).
(MC self-diagnosing function retains a record of the electrical signal system malfunction in the form of fault codes.)
Example: Fault Code 06: Abnormal EC Sensor
• Troubleshooting B (base machine diagnosis start-ing with inspection of abnormal operational status)
Refer to these procedures when no fault codes are displayed after diagnosing the machine with Dr. ZX (or the built-in diagnosing system). Trace the cause of trouble based on the inspected re-sult of the abnormal symptom.
Example: Even if the engine control dial is oper-ated, engine speed remains unchanged.
• Troubleshooting C (monitor diagnosis)
Refer to these procedures when gauges and/or indicators are malfunctioning.
Example: Malfunction of fuel gauge
• Electrical System Inspection
Refer to this group when required to obtain pre-cautions and/or information for the electrical sys-tem inspection.
Example: Fuse Inspection
• ICX
Refer to these procedures after any fault code is displayed after diagnosing ICX (Information Con-troller) or the satellite terminal (optional) with Dr.
ZX. (The controller self-diagnosing function re-tains a record of the electrical signal system mal-function in the form of fault codes.)
Example: ICX Fault Code 7: MC Communication Time Out
In addition, information on the following items is described in this group.
1. Trouble shooting and setting procedures of ICX and satellite terminal using Dr. ZX.
2. Information on the satellite communication system
These six basic steps are essential for efficient troubleshooting:
1. Study the System
Study the machine’s technical manuals. Know the system and how it works, and what the construction, functions and specifications of the system components are.
2. Ask the operator
Before inspecting, get the full story of malfunctions from your star witness … the operator.
(a) How is the machine being used? (Find out if the machine is being operated correctly) (b) When was the trouble noticed, and what
types of work the machine doing at that time?
(c) What are the details of the trouble? Is the trouble getting worse, or did it appear suddenly for the first time?
(d) Did the machine have any other troubles previously? If so, which parts were repaired before?
T107-07-01-001
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.
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.
T107-07-01-003
harnesses or hydraulic lines while the engine is running. The machine may malfunction or pressurized oil may spout, possibly resulting in personal injury. Be sure to stop the engine before disconnecting harnesses or hydraulic lines.
Perform diagnosis by connecting Dr. ZX to the machine or by operating the built-in diagnosing system. In case any fault code has been dis-played by diagnosis using Dr. ZX (or the built-in diagnosing system), delete the fault code once and retry self-diagnosis again. If the fault code is displayed again, check the cause of the trouble by referring to Troubleshooting A in this section.
After the machine trouble has been corrected, the fault code (displayed by the built-in diagnosing function) will be deleted. Therefore, in case prob-lems, which are not easily re-predicable are encountered, use Dr. ZX to display the fault code.
In case no fault codes are displayed, check all re-lated parts/component operating condition using the monitor function of Dr. ZX (or the built-in di-agnosing system) while referring to troubleshoot-ing B in this section.
※Note that the fault codes displayed do not necessarily indicate machine trouble. The controller stores even temporary electrical malfunctions, such as a drop in battery output voltage or disconnections of the switches, sensors, etc., for inspections.
For this reason, the “RETRIAL” is required to erase the accumulated fault codes from the controller memory and to confirm if any fault codes are indicated after the “RETRIAL”.
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.
T107-07-01-005
T107-07-01-006
T107-07-01-007
(Blank)
IMPORTANT: This system is to be operated by the HITACHI Dealer Only. Don’t explain this system function to the cus-tomer.
In the service mode, the monitor LCD displays the diagnosing items, fault codes and monitored results (not all of them) without using Dr. ZX.
Built-In Diagnosing System Activation
1. While pressing the monitor SET switch, turn the key switch ON.
Built-In Diagnosing System Operation
1. Each time the display selection switch is pressed, the displayed item will be changed as shown on next page.
NOTE: The fault code is indicated in the display order 8. All fault codes (Dr. ZX fault code list) can be indicated. In case more than one fault code is indicated, they will be dis-played with an interval of 1 second in order.
After the machine malfunction has been repaired, the fault codes are automatically deleted. Accordingly, if any trouble, which is not reproducible, is encountered, it is recommended to use Dr. ZX.
• The built-in diagnosing system displays only the item No. on the left and the monitored result on the right. The item description is not displayed.
T178-01-01-003
SET Switch Display Selection Switch
LCD