Hitachi ZAXIS 210-5G & 210LC-5G Excavator Technical Manual PDF

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Hitachi ZAXIS 210-5G & 210LC-5G Hydraulic Excavator Operation Test Technical Manual – PDF DOWNLOAD

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Hitachi ZAXIS 210-5G & 210LC-5G Hydraulic Excavator Operation Test Technical Manual – PDF DOWNLOAD

• P/N: TM13074X19_93
• Language: English
• Division: Hitachi
• Product Lines: Excavators
• Publication Type: Operator’s Manuals
• Associated Models: ZAXIS210-5G
• Serial: 1F9DCDG1_ _C330001—

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TABLE OF CONTENTS:

Hitachi ZAXIS 210-5G & 210LC-5G Hydraulic Excavator Operation Test Technical Manual – PDF DOWNLOAD

Contents 5
General Information 7
Safety 9
Recognize Safety Information 9
Understand Signal Words 9
Follow Safety Instructions 10
Prepare for Emergencies 10
Wear Protective Clothing 11
Protect Against Noise 11
Inspect Machine 11
General Precautions for Cab 12
Use Handholds and Steps 12
Adjust the Operator’s Seat 12
Ensure Safety Before Rising From or Leaving Operator’s Seat 13
Fasten Your Seat Belt 13
Move and Operate Machine Safely 13
Operate Only From Operator’s Seat 14
Jump Starting 14
Keep Riders Off Machine 14
Precautions for Operations 15
Investigate Job Site Beforehand 16
Install OPG Guard 17
Restriction of Attachment Installation 17
Provide Signals for Jobs Involving Multiple Machines 17
Confirm Direction of Machine to be Driven 17
Drive Machine Safely 18
Avoid Injury From Rollaway Accidents 20
Avoid Injury From Back-Over and Swing Accidents 20
Keep Person Clear From Working Area 21
Never Position Bucket Over Anyone 21
Avoid Undercutting 22
Avoid Tipping 22
Never Undercut a High Bank 23
Dig With Caution 23
Operate With Caution 23
Avoid Power Lines 24
Precautions for Lightning 24
Object Handling 25
Protect Against Flying Debris 25
Park Machine Safely 25
Handle Fluids Safely−Avoid Fires 26
Transport Safely 26
Practice Safe Maintenance 27
Warn Others of Service Work 28
Support Machine Properly 28
Stay Clear of Moving Parts 29
Prevent Parts From Flying 29
Avoid Injury from Attachment Falling Accident 30
Store Attachments Safely 30
Prevent Burns 30
Replace Rubber Hoses Periodically 31
Avoid High-Pressure Fluids 31
Prevent Fires 32
Evacuating in Case of Fire 33
Beware of Exhaust Fumes 33
Precautions for Welding and Grinding 34
Avoid Heating Near Pressurized Fluid Lines 34
Avoid Applying Heat to Lines Containing Flammable Fluids 34
Precautions for Handling Accumulator and Gas Damper 34
Remove Paint Before Welding or Heating 35
Beware of Asbestos and Silicon Dust and Other Contamination 35
Prevent Battery Explosions 36
Service Air Conditioning System Safely 36
Handle Chemical Products Safely 36
Dispose of Waste Properly 37
Never Ride Attachment 37
Precautions for Communication Terminal 37
FCC Notifications to User 37
Notes on Protection of Operator’s Station When the Machine Rolls Over 38
Before Returning the Machine to the Customer 39
Diagnostics 44
Main Controller (MCZ) Diagnostic Trouble Codes 45
Main Controller (MCZ) Diagnostic Trouble Codes 45
Controller Area Network 0 (CAN 0) Circuit Diagnostics 45
Controller Area Network 1 (CAN 1) Circuit Diagnostics 45
Interface Controller Area Network (N-CAN) Diagnostics 45
011000 02 — Abnormal EEPROM 45
Abnormal EEPROM Diagnostic Procedure 45
011001 02 — Abnormal RAM 46
Abnormal RAM Diagnostic Procedure 46
011002 02 — Abnormal A/D Converter 47
Abnormal A/D Converter Diagnostic Procedure 47
011003 03 — Abnormal Sensor Voltage 48
Abnormal Sensor Voltage Diagnostic Procedure 48
011006 02 — Engine Controller (ECF) Communication Error 48
011007 02 — (CAN 0) Data Converter Communication Error 1 48
011008 02 — (CAN 1) Data Converter Communication Error 2 49
011009 02 — (CAN 0) Monitor Controller Communication Error 1 49
011010 02 — (CAN 1) Monitor Controller Communication Error 2 49
011100 02 — Abnormal Engine Speed 49
Abnormal Engine Speed Diagnostic Procedure 49
011101 03 — Engine Control Dial Sensor Circuit High Input 50
Engine Control Dial Sensor Circuit High Input Diagnostic Procedure 50
011101 04 — Engine Control Dial Sensor Circuit Low Input 51
Engine Control Dial Sensor Circuit Low Diagnostic Procedure 51
011200 03 — Pump 1 Delivery Pressure Sensor Circuit High Input 53
Pump 1 Delivery Pressure Sensor Circuit High Input Diagnostic Procedure 53
011200 04 — Pump 1 Delivery Pressure Sensor Circuit Low Input 55
Pump 1 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure 55
011202 03 — Pump 2 Delivery Pressure Sensor Circuit High Input 57
Pump 2 Delivery Pressure Sensor Circuit High Input Diagnostic Procedure 57
011202 04 — Pump 2 Delivery Pressure Sensor Circuit Low Input 59
Pump 2 Delivery Pressure Sensor Circuit Low Input Diagnostic Procedure 59
011206 03 — Pump 1 Flow Control Pressure Sensor Circuit High Input 61
Pump 1 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure 61
011206 04 — Pump 1 Flow Control Pressure Sensor Circuit Low Input 62
Pump 1 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure 62
011208 03 — Pump 2 Flow Control Pressure Sensor Circuit High Input 64
Pump 2 Flow Control Pressure Sensor Circuit High Input Diagnostic Procedure 64
011208 04 — Pump 2 Flow Control Pressure Sensor Circuit Low Input 65
Pump 2 Flow Control Pressure Sensor Circuit Low Input Diagnostic Procedure 65
011301 03 — Swing Pilot Pressure Sensor Circuit High Input 67
Swing Pilot Pressure Sensor Circuit High Input Diagnostic Procedure 67
011301 04 — Swing Pilot Pressure Sensor Circuit Low Input 68
Swing Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure 68
011302 03 — Boom Up Pilot Pressure Sensor Circuit High Input 70
Boom Up Pilot Pressure Sensor Circuit High Input Diagnostic Procedure 70
011302 04 — Boom Up Pilot Pressure Sensor Circuit Low Input 71
Boom Up Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure 71
011303 03 — Arm In Pilot Pressure Sensor Circuit High Input 72
Arm In Pilot Pressure Sensor Circuit High Input Diagnostic Procedure 72
011303 04 — Arm In Pilot Pressure Sensor Circuit Low Input 74
Arm In Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure 74
011304 03 — Travel Pilot Pressure Sensor Circuit High Input 75
Travel Pilot Pressure Sensor Circuit High Input Diagnostic Procedure 75
011304 04 — Travel Pilot Pressure Sensor Circuit Low Input 76
Travel Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure 76
011307 03 — Front Attachment Pilot Pressure Sensor Circuit High Input 78
Front Attachment Pilot Pressure Sensor Circuit High Input Diagnostic Procedure 78
011307 04 — Front Attachment Pilot Pressure Sensor Circuit Low Input 79
Front Attachment Pilot Pressure Sensor Circuit Low Input Diagnostic Procedure 79
011400 02 — Pump 2 Flow Rate Limit Solenoid Valve Abnormal Feedback 81
Pump 2 Flow Rate Limit Solenoid Valve Abnormal Feedback Diagnostic Procedure 81
011400 03 — Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current 83
Pump 2 Flow Rate Limit Solenoid Valve Feedback High Current Diagnostic Procedure 83
011400 04 — Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current 85
Pump 2 Flow Rate Limit Solenoid Valve Feedback Low Current Diagnostic Procedure 85
011401 02 — Torque Control Solenoid Valve Abnormal Feedback 87
Torque Control Solenoid Valve Abnormal Feedback Diagnostic Procedure 87
011401 03 — Torque Control Solenoid Valve Feedback High Current 89
Torque Control Solenoid Valve Feedback High Current Diagnostic Procedure 89
011401 04 — Torque Control Solenoid Valve Feedback Low Current 91
Torque Control Solenoid Valve Feedback Low Current Diagnostic Procedure 91
011402 02 — 3-Spool Solenoid Valve Unit (SF) Abnormal Feedback 93
3-Spool Solenoid Valve Unit (SF) Abnormal Feedback Diagnostic Procedure 93
011402 03 — 3-Spool Solenoid Valve Unit (SF) Feedback High Input 95
3-Spool Solenoid Valve Unit (SF) Feedback High Input Diagnostic Procedure 95
011402 04 — 3-Spool Solenoid Valve Unit (SF) Feedback Low Input 97
3-Spool Solenoid Valve Unit (SF) Feedback Low Input Diagnostic Procedure 97
011403 02 — 3-Spool Solenoid Valve Unit (SC) Abnormal Feedback 99
3-Spool Solenoid Valve Unit (SC) Abnormal Feedback Diagnostic Procedure 99
011403 03 — 3-Spool Solenoid Valve Unit (SC) Feedback High Input 101
3-Spool Solenoid Valve Unit (SC) Feedback High Input Diagnostic Procedure 101
011403 04 — 3-Spool Solenoid Valve Unit (SC) Feedback Low Input 103
3-Spool Solenoid Valve Unit (SC) Feedback Low Input Diagnostic Procedure 103
011404 02 — 3-Spool Solenoid Valve Unit (SG) Abnormal Feedback 105
3-Spool Solenoid Valve Unit (SG) Abnormal Feedback Diagnostic Procedure 105
011404 03 — 3-Spool Solenoid Valve Unit (SG) Feedback High Input 107
3-Spool Solenoid Valve Unit (SG) Feedback High Input Diagnostic Procedure 107
011404 04 — 3-Spool Solenoid Valve Unit (SG) Feedback Low Input 109
3-Spool Solenoid Valve Unit (SG) Feedback Low Input Diagnostic Procedure 109
011457 02 — 2-Speed Activation Solenoid Disconnected or Not Present 111
2-Speed Activation Solenoid Disconnected or Not Present Diagnostic Procedure 111
011458 02 — Selector Valve Solenoid Valve Disconnected or Not Present 113
Selector Valve Solenoid Valve Disconnected or Not Present Diagnostic Procedure 113
011901 03 — Hydraulic Oil Temperature Sensor Circuit High Input 115
Hydraulic Oil Temperature Sensor Circuit High Input Diagnostic Procedure 115
011901 04 — Hydraulic Oil Temperature Sensor Circuit Low Input 116
Hydraulic Oil Temperature Sensor Circuit Low Input Diagnostic Procedure 116
Engine Controller (ECF) Diagnostic Trouble Codes 119
Engine Controller (ECF) Diagnostic Trouble Codes 119
011600 02 — Abnormal EEPROM 119
Abnormal EEPROM Diagnostics Procedure 119
011601 02 — Abnormal RAM 119
Abnormal RAM Diagnostics Procedure 119
011602 02 — Abnormal A/D Conversion 119
Abnormal A/D Conversion Diagnostics Procedure 120
011603 03 — Abnormal Sensor Voltage 120
Abnormal Sensor Voltage Diagnostic Procedure 120
011604 02 — Abnormal CAN Communication 120
016605 02 — Abnormal Engine Speed 120
Abnormal Engine Speed Diagnostic Procedure 121
016606 03 — Abnormal EC Angle Sensor High Voltage 122
Engine Control (EC) Sensor High Voltage Diagnostic Procedure 122
016606 04 — Abnormal EC Angle Sensor Low Voltage 123
Engine Control (EC) Sensor Low Voltage Diagnostic Procedure 123
016607 02 — Target Engine Speed Sent From Main Controller 124
Monitor Controller (DSZ) Diagnostic Trouble Codes 125
Monitor Controller (DSZ) Diagnostic Trouble Codes 125
013002 02 — Engine Controller (ECF) Communication Error 125
013003 02 — Main Controller (MCZ) Communication Error 1 125
013004 02 — Main Controller (MCZ) Communication Error 2 125
013005 02 — Monitor Controller (DSZ) Communication Error 1 125
013006 02 — Monitor Controller (DSZ) Communication Error 2 125
013007 02 — Machine Controller (BCZ) Communication Error 125
013303 02 — Abnormal Monitor Internal Temperature Sensor 125
Monitor Internal Temperature Sensor Diagnostic Procedure 125
013304 02 — Alternator Alarm 126
Alternator Alarm Diagnostic Procedure 126
013310 03 — Shorted Circuit in Coolant Temperature Sensor 126
Shorted Circuit in Coolant Temperature Sensor Diagnostic Procedure 126
013311 03 — Fuel Level Sensor Open Circuit 128
Fuel Level Sensor Open Circuit Diagnostic Procedure 128
013311 04 — Fuel Level Sensor Shorted Circuit 129
Fuel Level Sensor Shorted Circuit Diagnostic Procedure 129
014001 02 — Flash Memory Read/Write Error 131
Flash Memory Read/Write Error Diagnostic Procedure 131
014002 02 — External RAM Read/Write Error 131
External RAM Read/Write Error Diagnostic Procedure 131
014003 02 — Abnormal EEPROM 132
Abnormal EEPROM Diagnostics Procedure 132
014006 02 — Communication Terminal:Communication Error 132
Communication Terminal:Communication Error Diagnostic Procedure 132
014008 02 — Abnormal Internal RAM 133
Abnormal Internal RAM Diagnostic Procedure 133
014021 02 — Communication Terminal Security Error 133
014022 02 — SIM Card Error 133
014023 02 — Security Error 134
020100 02 — Overheat Alarm 134
Overheat Alarm Diagnostic Procedure 134
020101 02 — Engine Warning Alarm 136
Engine Warning Alarm Diagnostic Procedure 136
020102 02 — Engine Oil Pressure Alarm 137
020105 02 — Hydraulic Oil Filter Restriction Alarm 137
Hydraulic Oil Filter Restriction Alarm Diagnostic Procedure 137
020106 02 — Air Cleaner Restriction Alarm 138
Air Cleaner Restriction Alarm Diagnostic Procedure 138
020109 02 — Pilot Control Shutoff Lever Alarm 139
Pilot Control Shutoff Lever Alarm Diagnostic Procedure 139
020113 02 — System Error Alarm 140
020114 02 — Overheat Alarm 140
Overheat Alarm Diagnostic Procedure 140
Air Conditioner Controller (ACF) Diagnostic Trouble Codes 143
Air Conditioner Controller (ACF) Diagnostic Trouble Codes 143
11 — Open Circuit in Air Recirculation Sensor 143
Open Circuit in Air Recirculation Sensor Diagnostic Procedure 143
12 — Short-Circuited Air Recirculation Sensor 144
Short-Circuited Air Recirculation Sensor Diagnostic Procedure 144
13 — Open Circuit in Ambient Air Temperature Sensor 145
Open Circuit in Ambient Air Temperature Sensor Diagnostics Procedure 145
14 — Short-Circuited Ambient Air Temperature Sensor 147
Short-Circuited Ambient Air Temperature Sensor Diagnostic Procedure 147
18 — Short-Circuited Solar Radiation Sensor 148
Short-Circuited Solar Radiation Sensor Diagnostic Procedure 148
21 — Open Circuit in Air Conditioner Freeze Control Switch 149
Open Circuit In Air Conditioner Freeze Control Switch Diagnostic Procedure 150
22 — Short-Circuited Air Conditioner Freeze Control Switch 151
Short-Circuited Air Conditioner Freeze Control Switch Diagnostic Procedure 151
43 — Abnormal Air Conditioner and Heater Blower Port Change Servomotor 152
Abnormal Air Conditioner and Heater Blower Port Change Servomotor Diagnostic Procedure 152
44 — Abnormal Air Conditioner and Heater Mixer Servomotor 154
Abnormal Air Conditioner and Heater Mixer Servomotor Diagnostic Procedure 154
51 — Abnormal Air Conditioner High/Low Pressure Switch 155
Abnormal Air Conditioner High/Low Pressure Switch Diagnostic Procedure 155
91 — Communication Error 156
Communication Error Diagnostic Procedure 156
92 — CAN Bus Off Error 157
CAN Bus Off Error Diagnostic Procedure 157
Operational Checkout Procedure 159
Operational Checkout Procedure 161
Operational Checkout Procedure 161
Diagnostic Trouble Code Check 161
Operational Checks—Key Switch Off, Engine Off Checks 161
Operational Checks—Key Switch On, Engine Off Checks 164
Operational Checks—Key Switch On, Engine On Checks 176
Engine 213
Theory of Operation 215
Isuzu Engine 215
Engine Fuel System Component Location 217
Engine Cooling System Component Location 224
Cold Weather Starting Aid 225
Engine Speed Control System Operation 226
Diagnostic Information 229
Isuzu Engine 229
Adjustments 231
Isuzu Engine 231
Engine Learning Procedure 231
Engine Speed Adjustment 232
Engine Fuel Shutoff Adjustment 233
Tests 235
Isuzu Engine 235
Electrical System 239
System Information 241
Electrical Diagram Information 241
System Diagrams 247
Explanation of Wire Markings 247
Fuse and Relay Specifications 247
System Functional Schematic, Component Location, and Wiring Diagram Master Legend 253
System Functional Schematic 259
Cab Harness (W1) Component Location 289
Cab Harness (W1) Wiring Diagram 297
Machine Harness (W2) Component Location 310
Machine Harness (W2) Wiring Diagram 311
Monitor Harness (W3) Component Location 332
Monitor Harness (W3) Wiring Diagram 334
Pump Harness (W8) Component Location 335
Pump Harness (W8) Wiring Diagram 336
Pilot Shutoff Switch Harness (W11) Component Location 337
Pilot Shutoff Switch Harness (W11) Wiring Diagram 339
Auxiliary Fuse Box Harness (W13) Component Location 341
Auxiliary Fuse Box Harness (W13) Wiring Diagram 343
Multi-Function Pilot Control Lever Harness (W15) Component Location 346
Multi-Function Pilot Control Lever Harness (W15) Wiring Diagram 349
Travel Alarm Cancel Switch Harness (W16) Component Location 351
Travel Alarm Cancel Switch Harness (W16) Wiring Diagram 351
Attachment Harness (W17) Component Location 352
Attachment Harness (W17) Wiring Diagram 355
Attachment Interface Harness (W18) Component Location 358
Attachment Interface Harness (W18) Wiring Diagram 360
Rear Camera Harness (W19) Component Location 361
Rear Camera Harness (W19) Wiring Diagram 362
9-Pin Service ADVISOR™ Connector (W20) Component Location 362
9-Pin Service ADVISOR™ Connector (W20) Wiring Diagram 363
Pilot Shutoff Solenoid Harness (W21) Component Location 364
Pilot Shutoff Solenoid Harness (W21) Wiring Diagram 365
Auxiliary 3-Button Cancel Switch Harness (W22) Component Location 365
Auxiliary 3-Button Cancel Switch Harness (W22) Wiring Diagram 366
Travel Alarm Cancel Switch Sub Harness (W25) Component Location 366
Travel Alarm Cancel Switch Sub Harness (W25) Wiring Diagram 368
Travel Alarm Harness (W26) Component Location 369
Travel Alarm Harness (W26) Wiring Diagram 370
Solenoid Harness (W28) Component Location 370
Solenoid Harness (W28) Wiring Diagram 371
Starter Switch Harness (W29) Component Location 371
Starter Switch Harness (W29) Wiring Diagram 372
Data Converter Harness (W30) Component Location 373
Data Converter Harness (W30) Wiring Diagram 376
Data Converter Interface Harness (W31) Component Location 380
Data Converter Interface Harness (W31) Wiring Diagram 382
2-Speed Harness (W32) Component Location 385
2-Speed Harness (W32) Wiring Diagram 386
Heater and Air Conditioner Harness (W41) Component Location 388
Heater and Air Conditioner Harness (W41) Wiring Diagram 389
Auxiliary Solenoid Harness (W61) Component Location 392
Auxiliary Solenoid Harness (W61) Wiring Diagram 394
Rear Cab Light Switch Harness (W84) Component Location 396
Rear Cab Light Switch Harness (W84) Wiring Diagram 397
Rear Cab Light Relay Harness (W85) Component Location 397
Rear Cab Light Relay Harness (W85) Wiring Diagram 398
Rear Cab Light Harness (W86) Component Location 398
Rear Cab Light Harness (W86) Wiring Diagram 399
Fuel Tank Overflow Shutoff Switch Harness (W89) Component Location—If Equipped 400
Fuel Tank Overflow Shutoff Switch Harness (W89) Wiring Diagram—If Equipped 401
Satellite (SAT) Harness (W6003) Component Location 401
Satellite (SAT) Harness (W6003) Wiring Diagram 402
JDLink™ Harness (W6004) Component Location 403
JDLink™ Harness (W6004) Wiring Diagram 405
Sub-System Diagnostics 409
Controller Area Network (CAN) Theory of Operation 409
Starting and Charging Circuit Theory of Operation 413
Monitor Controller (DSZ) Circuit Theory of Operation 417
Engine Controller (ECF) Circuit Theory of Operation 429
Main Controller (MCZ) Circuit Theory of Operation 433
Travel Alarm Circuit Theory of Operation 443
Machine Controller (BCZ) Circuit Theory of Operation 444
Windshield Wiper and Washer Circuit Theory of Operation 445
Lighting Circuit Theory of Operation 449
Pilot Shutoff Circuit Theory of Operation 453
Attachment Control Circuit Theory of Operation 456
Monitor Operation 465
Service Menu 465
Troubleshooting 465
Monitoring 466
Controller Version 469
Issued Warning Record 469
Operation 470
Machine Setting 471
Monitor Setting 475
Alarm Setting 477
Maintenance Mode 477
Rear View Camera Troubleshooting 478
Rear View Camera Troubleshooting Procedure 478
References 481
Reading Diagnostic Trouble Codes with Monitor Display 481
Service ADVISOR™ Diagnostic Application 481
Service ADVISOR™ Connection Procedure 482
Reading Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application 483
Clearing Engine Diagnostic Trouble Codes 485
MPDr Application 490
MPDr Connection Procedure 491
Fuse Test 492
Relay Test 499
Pressure Sensor Test 500
Solenoid Test 501
Temperature Sensor Test 502
Alternator Test 503
Controller Area Network (CAN) Circuit Test 505
Controller Area Network (CAN) Diagnostics 507
Electrical Component Checks 510
Component Checks 510
Battery Remove and Install 518
Rear Cover Remove and Install 520
Main Controller (MCZ) Remove and Install 521
Machine Controller (BCZ) Remove and Install 522
Engine Controller (ECF) Remove and Install 524
Data Converter Remove and Install 525
Monitor Controller (DSZ) Remove and Install 526
Air Conditioner Controller (ACF) Remove and Install 527
Key Switch Remove and Install 527
Right Switch Console Remove and Install 528
Left Switch Console Remove and Install 530
Travel Alarm Remove and Install 531
Disconnect Tab Retainer Connectors 531
Disconnecting Spring Wire Clip Connectors 532
Replace DEUTSCH™ Connectors 532
Replace DEUTSCH™ Rectangular or Triangular Connectors 533
Install DEUTSCH™ Contact 534
Replace WEATHER PACK™ Connector 536
Install WEATHER PACK™ Contact 537
Replace (Pull Type) Metri-Pack™ Connectors 538
Replace (Push Type) Metri-Pack™ Connectors 539
Replace CINCH™ Connectors 539
Install CINCH™ Contact 541
Repair 32 and 48 Way CINCH™ Connectors 542
Remove Connector Body from Blade Terminals 544
Power Train 545
Theory of Operation 547
Track Adjuster and Recoil Spring Operation 547
Travel Gear Case Operation 548
Diagnostic Information 551
Noisy or Loose Track Chain 551
Noisy or Loose Track Chain Diagnostic Procedure 551
Tight Track Chain 551
Tight Track Chain Diagnostic Procedure 551
Frequent Track Chain Sag Adjustment Required 552
Frequent Track Chain Sag Adjustment Required Diagnostic Procedure 552
Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers 552
Excessive Oil Leakage From Front Idler, Track Rollers, or Carrier Rollers Diagnostic Procedure 552
Bent Track Shoes 552
Bent Track Shoes Diagnostic Procedure 552
“Popping” of Track 553
“Popping” of Track Diagnostic Procedure 553
Cracked Track Link 553
Cracked Track Link Diagnostic Procedure 553
Chipped Link Rails 554
Chipped Link Rails Diagnostic Procedure 554
Individual Undercarriage Component Wear 555
Individual Undercarriage Component Wear Diagnostic Procedure 555
Measure Swing Bearing Wear 556
Hydraulic System 559
Theory of Operation 561
Hydraulic System Operation 561
Pilot System Operation 561
Pilot Pump, Pressure Regulating Valve, and Filter Operation 562
Pilot Shutoff Solenoid Valve Operation 563
Pilot Control Valve Operation 566
Travel Pilot Control Valve Operation 568
Pilot Operation of Control Valve Operation 571
Pilot Signal Manifold Operation 574
Pump 1, Pump 2, and Drive Gear Case Operation 586
Pump 1 and Pump 2 Regulator Operation 589
Engine Speed Sensing Control Circuit Operation 594
Control Valve Operation 596
Control Valve Check Valves Identification and Operation 614
Main Relief Valve Circuit Operation 617
Circuit Relief and Anticavitation Valve Operation 621
Travel Flow Combiner Valve Operation 622
Auxiliary Flow Combiner Valve and Bypass Shutoff Valve Operation 625
Boom Lower Meter-In Cut Valve Operation 629
Boom Regenerative Valve Circuit Operation 631
Dig Regenerative Valve Circuit Operation 633
Arm Regenerative Valve Circuit Operation 637
Bucket Regenerative Valve Circuit Operation 642
Boom and Arm Reduced Leakage Valves Operation 646
Arm 1 Flow Rate Control Valve Circuit Operation 649
Arm 2 Flow Rate Control Valve Circuit Operation 653
Bucket Flow Rate Control Valve Circuit Operation 657
Boom Flow Rate Control Valve Circuit Operation 661
Auxiliary Flow Rate Control Valve Circuit Operation 666
Swing Reduction Gear Case Operation 669
Swing Motor, Crossover Relief Valve, and Make-Up Check Valve Operation 670
Swing Motor Damper Valve 673
Swing Motor Park Brake Release Circuit Operation 680
Center Joint Operation 681
Travel Motor and Park Brake Valve Operation 682
Travel Motor Speed Circuit Operation 691
Cylinder Operation 695
Return Filter Operation 696
Auxiliary System Operation 697
Auxiliary Pilot Control Valve Operation 697
Flow Rate Select Solenoid Valve Operation 708
Flow Rate Pressure Reducing Valve Operation 709
Secondary Auxiliary Relief Valve Solenoid Valve Operation 709
Secondary Auxiliary Relief Control Valve Operation 710
Secondary Auxiliary Relief Valve Operation 710
Selector Valve Solenoid Valve Operation 711
Selector Valve Operation 711
Auxiliary Shuttle Valve Operation 712
Auxiliary High Flow Line Kit Operation 713
Two Way Solenoid Kit Operation 717
Two Pump Combined Flow Kit Operation 721
Secondary Auxiliary Relief Kit Operation 726
Low Flow Kit Operation 729
Diagnostic Information 737
All Hydraulic Functions Slow 737
All Hydraulic Functions Slow Diagnostic Procedure 737
Hydraulic Oil Overheats 739
Hydraulic Oil Overheats Diagnostic Procedure 739
No Hydraulic Functions 741
No Hydraulic Functions Diagnostic Procedure 741
Poor Combined Operation 742
Poor Combined Operation Diagnostic Procedure 742
All Functions Cannot Be Operated 743
All Functions Cannot Be Operated Diagnostic Procedure 743
Function Does Not Stop When Control Lever Released 744
Function Does Not Stop When Control Lever Released Diagnostic Procedure 744
Some Functions Cannot Be Operated, All Others Are Normal 745
Some Functions Cannot Be Operated, All Others Are Normal Diagnostic Procedure 745
All Functions Slow 746
All Functions Slow Diagnostic Procedure 746
Functions Move in Opposite Direction 747
Functions Move in Opposite Direction Diagnostic Procedure 747
All Dig Functions Slow or No Power 748
All Dig Functions Slow or No Power Diagnostic Procedure 748
Some Dig Functions Slow (Not All) 748
Some Dig Functions Slow (Not All) Diagnostic Procedure 748
Load Drifts Down When Control Lever is in Neutral Position 750
Load Drifts Down When Control Lever is in Neutral Position Diagnostic Procedure 750
Load Falls When Control Valve is Actuated to Raise Load With Engine Running at Slow Idle 751
Load Falls When Control Valve is Actuated to Raise Load With Engine Running at Slow Idle Diagnostic Procedure 751
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal 751
H/P (High Power) Function Does Not Operate, PWR (Power) Mode is Normal Diagnostic Procedure 752
Swing Speed Slow in Both Directions 754
Swing Speed Slow in Both Directions Diagnostic Procedure 754
Swing Speed Slow or Does Not Operate in One Direction 755
Swing Speed Slow or Does Not Operate in One Direction Diagnostic Procedure 755
Upperstructure Drift With Swing Valve in Neutral 756
Upperstructure Drift With Swing Valve in Neutral Diagnostic Procedure 756
Swing Function Does Not Operate 758
Swing Function Does Not Operate Diagnostic Procedure 758
Travel Park Brakes Do Not Apply 759
Travel Park Brakes Do Not Apply Diagnostic Procedure 759
Track Will Not Move in One Direction 760
Track Will Not Move in One Direction Diagnostic Procedure 760
Track Will Not Move in Either Direction 761
Track Will Not Move in Either Direction Diagnostic Procedure 761
Machine Mistracks at All Speeds in Both Directions 762
Machine Mistracks at All Speeds in Both Directions Diagnostic Procedure 762
Slow Travel Speed or Low Power 764
Slow Travel Speed or Low Power Diagnostic Procedure 764
Combined Travel and Dig Functions Slow or No Power 765
Combined Travel and Dig Functions Slow or No Power Diagnostic Procedure 765
Travel is “Jerky” 766
Travel is “Jerky” Diagnostic Procedure 766
Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline 767
Machine Will Not Hold Back and Park Brakes Engage and Disengage When Traveling Down an Incline Diagnostic Procedure 767
Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs 767
Machine Will Not Turn Smoothly in One Direction or Park Brake Grabs Diagnostic Procedure 767
Pump 1, Pump 2, and Pilot Pump Line Identification 768
Control Valve Line Identification 769
Swing Motor Line Identification 772
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Excavator Pattern 773
Pilot Control Valve-to-Pilot Signal Manifold Component Location—Backhoe Pattern 777
Pilot Signal Manifold-to-Control Valve Line Connection 780
Travel System Component Location 784
Travel Hydraulic System Line Connection 785
Auxiliary Attachment Schematic 789
Auxiliary System Line Connections 815
Hydraulic System Schematic 823
Hydraulic System Component Location 844
Hydraulic System Line Connections 845
Tests 849
JT05800 Digital Thermometer Installation 849
JT02156A Digital Pressure and Temperature Analyzer Kit Installation 849
General Hydraulic Oil Cleanup Procedure 850
Hydraulic Component Failure Cleanup Procedure 852
Hydraulic Oil Tank Pressure Release Procedure 853
Hydraulic Oil Warm-Up Procedure 855
Pilot Pressure Regulating Valve Test and Adjustment 857
Control Valve Spool Actuating Pilot Pressure Test 859
Dig Regenerative Solenoid Valve Test and Adjustment 861
Arm Regenerative Solenoid Valve Test and Adjustment 863
Power Dig Solenoid Valve Test and Adjustment 865
Torque Control Solenoid Valve Test and Adjustment 867
Pump Control Pilot Pressure Signal Test 870
Main Relief and Power Dig Valve Test and Adjustment 872
Circuit Relief Valve Test and Adjustment 875
Swing Motor Crossover Relief Valve Test and Adjustment 878
Travel Motor Crossover Relief Valve Test and Adjustment 880
Pump Regulator Test and Adjustment—Minimum Flow 883
Pump Regulator Test and Adjustment—Maximum Flow 885
Pump Flow Test 887
Comprehensive Pump Flow Test 890
Swing Motor Leakage Test 895
Travel Motor Leakage Test 896
Cylinder Drift Test—Boom, Arm, and Bucket 898
Heating and Air Conditioning 901
Theory of Operation 903
Air Conditioning System Cycle of Operation 903
Diagnostic Information 905
No Air Flow From Heater and Air Conditioner Vents 905
No Air Flow From Heater and Air Conditioner Vents Diagnostic Procedure 905
Air Conditioning System Does Not Operate 908
Air Conditioning System Does Not Operate Diagnostic Procedure 908
Air Conditioning Does Not Cool Interior of Cab 909
Air Conditioning Does Not Cool Interior of Cab Diagnostic Procedure 909
Air Conditioning Runs Constantly, Too Cold 910
Air Conditioning Runs Constantly, Too Cold Diagnostic Procedure 910
Interior Windows Continue to Fog Using Air Conditioner 911
Interior Windows Continue to Fog Using Air Conditioner Diagnostics Procedure 911
Heater System Does Not Operate 912
Heater System Does Not Operate Diagnostic Procedure 912
Heater Does Not Warm Interior of Cab 915
Heater Does Not Warm Interior of Cab Diagnostic Procedure 915
Interior Windows Continue to Fog Using Heater 916
Interior Windows Continue to Fog Using Heater Diagnostic Procedure 916
Heater and Air Conditioner Component Location 919
Tests 923
Refrigerant Cautions and Proper Handling 923
Heater and Air Conditioner Operational Checks 923
Visual Inspection of Components 923
Air Conditioner Compressor Clutch Test 925
Refrigerant Leak Test 926
Refrigerant Hoses and Tubing Inspection 926
Air Conditioner Compressor Belt Check 926
Air Conditioner High/Low-Pressure Switch Test 927
Air Conditioner Freeze Control Switch Test 928
R134a Air Conditioning System Test 929
Operating Pressure Diagnostic Chart 930
Dealer Fabricated Tools 931
Dealer Fabricated Tools 933
DFT1218 Split Flange Hose Cap 933
Page Number 5
Section 9000 7
Group 01 9
Section 9001 44
Group 10 45
Group 20 119
Group 30 125
Group 40 143
Section 9005 159
Group 10 161
Section 9010 213
Group 05 215
Group 15 229
Group 20 231
Group 25 235
Section 9015 239
Group 05 241
Group 10 247
Group 15 409
Group 16 465
Group 20 481
Section 9020 545
Group 05 547
Group 15 551
Section 9025 559
Group 05 561
Group 15 737
Group 25 849
Section 9031 901
Group 05 903
Group 15 905
Group 25 923
Section 9900 931
Group 99 933

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