Hitachi ZX-3 Fault Codes List PDF [PDF]

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1U1DRT-4-2

Dr. ZX / Fault Code FAULT CODE ZX160-3 to ZX330-3 CLASS For details of trouble analyses, refer to “Technical Manual (Troubleshooting)” for the corresponding models.

T4-1-1

Dr. ZX / Fault Code FAULT CODE LIST MC Controller Hardware Failure Fault Trouble Code 11000-2 Abnormal EEPROM 11001-2 Abnormal RAM 11002-2 Abnormal A/D Conversion 11003-3 Abnormal Sensor Voltage

11004-2

Abnormal CAN Communication

Cause

Influenced Control

Faulty MC Faulty MC Faulty MC Faulty MC Faulty Sensor Faulty Harness

All Control All Control All Control All Control

Faulty MC Faulty CAN Harness

• Heater Control (ZX200-3 to ZX330-3 class) • Speed Sensing Control • Attachment Operation Speed Increase Control • Attachment Operation Speed Limit Control • Attachment Pump Torque Decreases Control (ZX200-3 to ZX330-3 class) • Pump 1 Flow Rate Limit Control • Pump 2 Flow Rate Limit Control • Attachment Flow Rate Control (Optional) • Attachment Valve Selection (Optional) • CAN Cycle Data Communication

T4-1-2

Dr. ZX / Fault Code

Symptoms in Machine Operation When Trouble Occurs. Although the engine control dial is operated, engine speed does not change. • Machine movement is slow. • The work mode alarm is displayed on the monitor unit.

Remedy for Dr. ZX Retrial B Retrial B Retrial B Retrial B

Remark Replace MC Replace MC Replace MC • Check sensor connected to MC • Check Harness • Replace MC • Check CAN Harness • Replace MC

Retrial B

T1V1-05-01-102

T4-1-3

Dr. ZX / Fault Code Engine Failure Fault Trouble Code 11100-2 Abnormal Engine Speed

Cause Engine Speed: more than 4000 -1 min

Influenced Control Speed Sensing Control

11101-3

Abnormal Engine Control Dial Voltage: 4.78 V or higher Sensor High Voltage

Engine Control Dial Control

11101-4

Abnormal Engine Control Dial Voltage: Less than 0.22 V Sensor Low Voltage

Engine Control Dial Control

T4-1-4

Dr. ZX / Fault Code

Symptoms in Machine OperaRemedy for Dr. ZX tion When Trouble Occurs. Machine movement is slow. Retrial B (During speed sensing, torque is reduced.) • Trouble condition with the Retrial B key ON: Engine speed is kept at idle speed. • Trouble condition with the key ON: engine speed is kept at speed immediately before trouble. • Trouble condition with the Retrial B key ON: Engine speed is kept at idle speed. • Trouble condition with the key ON: engine speed is kept at speed immediately before trouble.

T4-1-5

Remark • Check Crank Speed Sensor • Check Cam Angle Sensor • Check Harness • Replace Engine Control Dial

• Check Harness • Replace Engine Control Dial

Dr. ZX / Fault Code Pump Failure Fault Trouble Cause Code 11200-3 Abnormal Pump 1 Delivery Voltage: 4.5 V or higher Pressure Sensor High Voltage

Influenced Control • HP Mode Control • Travel HP Mode Control • E Mode Control • Travel Torque-Up Control • Arm Regenerative Control • Digging Regenerative Control • Auto-Power Lift Control • Travel Motor Swash Angle Control • HP Mode Control • Travel HP Mode Control • E Mode Control • Travel Torque-Up Control • Arm Regenerative Control • Digging Regenerative Control • Auto-Power Lift Control • Travel Motor Swash Angle Control • HP Mode Control • Travel HP Mode Control • E Mode Control • Travel Torque-Up Control • Arm Regenerative Control • Digging Regenerative Control • Travel Motor Swash Angle Control • HP Mode Control • Travel HP Mode Control • E Mode Control • Travel Torque-Up Control • Arm Regenerative Control • Digging Regenerative Control • Travel Motor Swash Angle Control

11200-4

Abnormal Pump 1 Delivery Voltage: Less than 0.25 V Pressure Sensor Low Voltage

11202-3

Abnormal Pump 2 Delivery Voltage: 4.5 V or higher Pressure Sensor High Voltage

11202-4

Abnormal Pump 2 Delivery Voltage: Less than 0.25 V Pressure Sensor Low Voltage

11206-3

Abnormal Pump 1 Pump Voltage: 4.75 V or higher Control Pressure Sensor High Voltage

• E Mode Control • Heater Control (ZX200-3 to ZX330-3 class) • Travel Motor Swash Angle Control

11206-4

Abnormal Pump 1 Pump Voltage: Less than 0.25 V Control Pressure Sensor Low Voltage

11208-3

Abnormal Pump 2 Pump Voltage: 4.75 V or higher Control Pressure Sensor High Voltage

11208-4

Abnormal Pump 2 Pump Voltage: Less than 0.25 V Control Pressure Sensor Low Voltage

• E Mode Control • Heater Control (ZX200-3 to ZX330-3 class) • Travel Motor Swash Angle Control • E Mode Control • Heater Control (ZX200-3 to ZX330-3 class) • Travel Motor Swash Angle Control • E Mode Control • Heater Control (ZX200-3 to ZX330-3 class) • Travel Motor Swash Angle Control

T4-1-6

Dr. ZX / Fault Code Symptoms in Machine Operation When Remedy for Dr. ZX Trouble Occurs. • Combined operation of arm roll-in and Retrial B boom raise or combined operation of arm-roll-in and swing: Arm speed is slow. • Single operation of boom raise: Lifting force is weak. • Travel: Slow speed

Remark • Check Harness • Replace Pump 1 Delivery Pressure Sensor

• Combined operation of arm roll-in and Retrial B boom raise or combined operation of arm-roll-in and swing: Arm speed is slow. • Single operation of boom raise: Lifting force is weak. • Travel: Slow speed

• Check Harness • Replace Pump 1 Delivery Pressure Sensor

• Combined operation of arm roll-in and boom raise or combined operation of arm-roll-in and swing: Arm speed is slow. • Travel: Slow speed

Retrial B

• Check Harness • Replace Pump 2 Delivery Pressure Sensor

• Combined operation of arm roll-in and boom raise or combined operation of arm-roll-in and swing: Arm speed is slow. • Travel: Slow speed

Retrial B

• Check Harness • Replace Pump 2 Delivery Pressure Sensor

• Although speed operating in E mode Retrial B returns to P speed, returning speed becomes low due to this failure. • Travel: Slow speed

• Check Harness • Replace Pump 1 Control Pressure Sensor

• Although speed operating in E mode Retrial B returns to P speed, returning speed becomes low due to this failure. • Travel: Slow speed • Although speed operating in E mode Retrial B returns to P speed, returning speed becomes low due to this failure. • Travel: Slow speed • Although speed operating in E mode Retrial B returns to P speed, returning speed becomes low due to this failure. • Travel: Slow speed

• Check Harness • Replace Pump 1 Control Pressure Sensor • Check Harness • Replace Pump 2 Control Pressure Sensor • Check Harness • Replace Pump 2 Control Pressure Sensor

T4-1-7

Dr. ZX / Fault Code Pilot Failure Fault Trouble Cause Code 11301-3 Abnormal Swing Pilot Pressure Voltage: 4.75 V or higher Sensor High Voltage

Influenced Control • Arm Regenerative Control • Attachment Flow Rate Control • Swing Alarm Control

11301-4

Abnormal Swing Pilot Pressure Voltage: Less than 0.25 V Sensor Low Voltage

• Arm Regenerative Control • Attachment Flow Rate Control • Swing Alarm Control

11302-3

Abnormal Boom Raise Pilot Pressure Sensor High Voltage

Voltage: 4.75 V or higher

• HP Mode Control • Arm Regenerative Control • Digging Regenerative Control • Auto-Power Lift Control • Attachment Flow Rate Control

11302-4

Abnormal Boom Raise Pilot Pressure Sensor Low Voltage

Voltage: Less than 0.25 V

• HP Mode Control • Arm Regenerative Control • Digging Regenerative Control • Auto-Power Lift Control • Attachment Flow Rate Control

11303-3

Abnormal Arm Roll-In Pilot Pressure Sensor High Voltage

Voltage: 4.75 V or higher

• HP Mode Control • Arm Regenerative Control • Digging Regenerative Control • Auto-Power Lift Control

11303-4

Abnormal Arm Roll-In Pilot Pressure Sensor Low Voltage

Voltage: Less than 0.25 V

• HP Mode Control • Arm Regenerative Control • Digging Regenerative Control • Auto-Power Lift Control

T4-1-8

Dr. ZX / Fault Code Symptoms in Machine Operation When Trouble Occurs. • Combined operation of arm-roll-in and swing: Arm speed is slow. • In case of the machine equipped with the swing alarm (optional) and when swing alarm is effective, swing alarm continues to ring. • Combined operation of arm-roll-in and swing: Arm speed is slow. • In case of the machine equipped with the swing alarm (optional) and when swing alarm is effective, swing alarm continues to ring. • During HP control, boom raise speed does not increase. • Combined operation of arm roll-in and boom raise: Arm speed is slow. • During HP control, boom raise speed does not increase. • Combined operation of arm roll-in and boom raise: Arm speed is slow. • During HP control, arm roll-in speed does not increase. • Combined operation of arm roll-in and swing: Arm speed is slow. • During HP control, arm roll-in speed does not increase. • Combined operation of arm roll-in and swing: Arm speed is slow.

Remedy for Dr. ZX

Remark

Retrial B

• Check Harness • Replace Swing Pilot Pressure Sensor

Retrial B

• Check Harness • Replace Swing Pilot Pressure Sensor

Retrial B

• Check Harness • Replace Boom Raise Pilot Pressure Sensor

Retrial B

• Check Harness • Replace Boom Raise Pilot Pressure Sensor

Retrial B

• Check Harness • Replace Arm Roll-In Pressure Sensor

Pilot

• Check Harness • Replace Arm Roll-In Pressure Sensor

Pilot

Retrial B

T4-1-9

Dr. ZX / Fault Code Fault Code 11304-3

11304-4

Trouble

Cause

Abnormal Travel Pilot Pressure Voltage: 4.75 V or higher Sensor High Voltage

Abnormal Travel Pilot Pressure Voltage: Less than 0.25 V Sensor Low Voltage

T4-1-10

Influenced Control • Auto-Idle Control • Idle Speed-Up Control • ECO Control • Travel HP Mode Control • Heater Control (ZX200-3 to ZX330-3 class) • Travel Torque-Up Control • Pump 1 Flow Rate Limit Control • Pump 1 Flow Rate Control Valve at Travel (ZX160-3 Class Only) • Pump 2 Flow Rate Limit Control • Pump 2 Flow Rate Control Valve at Travel (ZX160-3 Class Only) • Travel Motor Swash Angle Control • Attachment Flow Rate Control • Travel Alarm Control • Auto-Idle Control • Idle Speed-Up Control • ECO Control • Travel HP Mode Control • Heater Control (ZX200-3 to ZX330-3 class) • Travel Torque-Up Control • Pump 1 Flow Rate Limit Control • Pump 1 Flow Rate Control Valve at Travel (ZX160-3 Class Only) • Pump 2 Flow Rate Limit Control • Pump 2 Flow Rate Control Valve at Travel (ZX160-3 Class Only) • Travel Motor Swash Angle Control • Attachment Flow Rate Control • Travel Alarm Control

Dr. ZX / Fault Code Symptoms in Machine Operation When Remedy for Dr. ZX Trouble Occurs. • When traveling at idle speed, engine Retrial B speed does not increase to the specification. • When traveling, speed does not return from auto idle speed. • When traveling, speed does not return from ECO speed. • Travel: Slow speed • When operating ATT, the machine mistracks. • In case of the machine equipped with the travel alarm (optional), travel alarm continues to ring.

• When traveling at idle speed, engine Retrial B speed does not increase to the specification. • When traveling, speed does not return from auto idle speed. • When traveling, speed does not return from ECO speed. • Travel: Slow speed • When operating ATT, the machine mistracks. • In case of the machine equipped with the travel alarm (optional), travel alarm continues to ring.

T4-1-11

Remark • Check Harness • Replace Travel Pilot Pressure Sensor

• Check Harness • Replace Travel Pilot Pressure Sensor

Dr. ZX / Fault Code Fault Code 11307-3

11307-4

Trouble

Cause

Influenced Control

Abnormal Front Attachment Pi- Voltage: 4.75 V or higher lot Pressure Sensor High Voltage

• Auto-Idle Control • Idle Speed-Up Control • ECO Control • Travel HP Mode Control • Heater Control (ZX200-3 to ZX330-3 class) • Travel Motor Swash Angle Control

Abnormal Front Attachment Pi- Voltage: Less than 0.25 V lot Pressure Sensor Low Voltage

• Auto-Idle Control • Idle Speed-Up Control • ECO Control • Travel HP Mode Control • Heater Control (ZX200-3 to ZX330-3 class) • Travel Motor Swash Angle Control

T4-1-12

Dr. ZX / Fault Code Symptoms in Machine Operation When Remedy for Dr. ZX Trouble Occurs. • When operating the front attachment at Retrial B idle speed, engine speed does not increase to the specification. • When operating the front attachment, speed does not return from auto idle speed. • When operating the front attachment, speed does not return from ECO speed. • Although the front attachment is operated, travel becomes fast. • When operating the front attachment at Retrial B idle speed, engine speed does not increase to the specification. • When operating the front attachment, speed does not return from auto idle speed. • When operating the front attachment, speed does not return from ECO speed. • Although the front attachment is operated, travel becomes fast.

T4-1-13

Remark • Check Harness • Replace Front Pilot Pressure Sensor

• Check Harness • Replace Front Pilot Pressure Sensor

Dr. ZX / Fault Code Proportional Solenoid Valve Failure Fault Trouble Code 11400-2 Abnormal Current Feedback of Maximum Pump 2 Flow Rate Limit Control Solenoid Valve 11400-3 Abnormal Feedback High Current of Maximum Pump 2 Flow Rate Limit Control Solenoid Valve

11400-4

11401-2

11401-3

11401-4

11402-2

11402-3

11402-4

11403-2

11403-3

11403-4

Cause

Influenced Control

Current: Both of Higher than 920 mA or Less than 60 mA Current: Higher than 920 mA

• Pump 2 Flow Rate Limit Control • Pump 2 Flow Rate Control Valve at Travel (ZX160-3 class only) • Pump 2 Flow Rate Limit Control • Pump 2 Flow Rate Control Valve at Travel (ZX160-3 class only)

Current: Less than 56 • Pump 2 Flow Rate Limit Control mA • Pump 2 Flow Rate Control Valve at Travel (ZX160-3 class only) Current: Both of Higher • Speed Sensing Control than 920 mA or Less • Travel Torque-Up Control than 60 mA • Attachment Pump Torque Decrease Control (ZX200-3 to ZX330-3 class) Abnormal Feedback High Current of Current: Higher than • Speed Sensing Control Torque Control Solenoid Valve 920 mA • Travel Torque-Up Control • Attachment Pump Torque Decrease Control (ZX200-3 to ZX330-3 class) Abnormal Feedback Low Current of Current: Less than 56 • Speed Sensing Control Torque Control Solenoid Valve mA • Travel Torque-Up Control • Attachment Pump Torque Decrease Control (ZX200-3 to ZX330-3 class) Abnormal Current Feedback of So- Current: Both of Higher Digging Regenerative Control lenoid Valve Unit (SF) (Digging than 920 mA or Less Regeneration) than 60 mA Abnormal Feedback High Current of Current: Higher than Digging Regenerative Control Solenoid Valve Unit (SF) (Digging 920 mA Regeneration) Abnormal Feedback Low Current of Current: Less than 56 Digging Regenerative Control Solenoid Valve Unit (SF) (Digging mA Regeneration) Abnormal Current Feedback of So- Current: Both of Higher Arm Regenerative Control lenoid Valve Unit (SC) (Arm than 920 mA or Less Regeneration) than 60 mA Abnormal Feedback High Current of Current: Higher than Arm Regenerative Control Solenoid Valve Unit (SC) (Arm Re- 920 mA generation) Abnormal Feedback Low Current of Current: Less than 56 Arm Regenerative Control Solenoid Valve Unit (SC) (Arm Re- mA generation) Abnormal Feedback Low Current of Maximum Pump 2 Flow Rate Limit Control Solenoid Valve Abnormal Current Feedback of Torque Control Solenoid Valve

T4-1-14

Dr. ZX / Fault Code Remedy for Dr. ZX Retrial B

• Check Harness

Actual Operation of Proportional Valve during High Current: • Travel mistakes. • Boom raise operation is slow. • Arm operation is slow. • Swing operation is slow.

Retrial B

• Check Harness

Actual Operation of Proportional Valve during Low Current: • In case ATT flow rate is limited, it cannot be limited.

Retrial B

• Check Harness

Machine overall operation is slow.

Retrial B

• Check Harness

Actual Operation of Proportional Valve during High Current: • The engine is stalled at Low idle speed. • Engine Speed: Middle to Fast: Engine Stall or Large Lug Down

Retrial B

• Check Harness

Actual Operation of Proportional Valve during Low Current: • Machine overall operation is slow.

Retrial B

• Check Harness

During digging, arm speed is slow. (As deceleration rate is low, this state is not easy to find.)

Retrial B

• Check Harness

Actual Operation of Proportional Valve during High Current: • Combined operation of boom raise and arm roll-in during lifting/precision: The boom raise operation is not smooth. Actual Operation of Proportional Valve during Low Current: • During digging, arm speed is slow. (As deceleration rate is low, this state is not easy to find.) Combined operation of boom raise and arm roll-in with the front attachment over ground, the boom is not raised smoothly and the arm roll-in full-speed is slow. Actual Operation of Proportional Valve during High Current: • Digging force (arm) becomes weak.

Retrial B

• Check Harness

Retrial B

• Check Harness

Retrial B

• Check Harness

Retrial B

• Check Harness

Actual Operation of Proportional Valve during Low Current: • Combined operation of boom raise and arm roll-in with the front attachment over ground, the boom is not raised smoothly and the arm roll-in full-speed is slow.

Retrial B

• Check Harness

Symptoms in Machine Operation When Trouble Occurs. In case ATT flow rate is limited, it cannot be limited.

T4-1-15

Remark

Dr. ZX / Fault Code Fault Code 11404-2

Trouble

Cause

Influenced Control

Abnormal Current Feedback of So- Current: Both of Higher • Power Digging Control lenoid Valve Unit (SG) (Relief than 920 mA or Less • Auto-Power Lift Control Pressure Control) than 60 mA • Travel Pressure Increasing Control Abnormal Feedback High Current of Current: Solenoid Valve Unit (SG) (Relief 920 mA Pressure Control)

11404-4

Abnormal Feedback Low Current of Current: Less than 56 • Power Digging Control Solenoid Valve Unit (SG) (Relief mA • Auto-Power Lift Control Pressure Control) • Travel Pressure Increasing Control

11405-2

Current: Both of Higher than 920 mA or Less than 60 mA Current: Higher than 920 mA

Abnormal Current Feedback of Solenoid Valve Unit (SI) (Travel Motor Fast Speed Selection) 11405-3 Abnormal Feedback High Current of Solenoid Valve Unit (SI) (Travel Motor Fast Speed Selection) 11405-4 Abnormal Feedback Low Current of Solenoid Valve Unit (SI) (Travel Motor Fast Speed Selection) 11410-2 Abnormal Current Feedback of (ZX160-3 Maximum Pump 1 Flow Rate Limit class only) Control Solenoid Valve 11410-3 Abnormal Feedback High Current of (ZX160-3 Maximum Pump 1 Flow Rate Limit class only) Control Solenoid Valve

Higher

than • Power Digging Control • Auto-Power Lift Control • Travel Pressure Increasing Control

11404-3

Travel Motor Swash Angle Selection Control Travel Motor Swash Angle Selection Control

Current: Less than 56 Travel Motor Swash Angle Selection mA Control Current: Both of Higher than 920 mA or Less than 60 mA Current: Higher than 920 mA

• Pump 1 Flow Rate Limit Control • Pump 1 Flow Rate Control Valve at Travel • Pump 1 Flow Rate Limit Control • Pump 1 Flow Rate Control Valve at Travel

11410-4 Abnormal Feedback Low Current of Current: Less than 56 • Pump 1 Flow Rate Limit Control (ZX160-3 Maximum Pump 1 Flow Rate Limit mA • Pump 1 Flow Rate Control Valve class only) Control Solenoid Valve at Travel

T4-1-16

Dr. ZX / Fault Code Remedy for Dr. ZX Retrial B

• Check Harness

Actual Operation of Proportional Valve during High Current: • Pressure always increases.

Retrial B

• Check Harness

Actual Operation of Proportional Valve during Low Current: • Pressure increasing is impossible.

Retrial B

• Check Harness

Travel motor is always slow.

Retrial B

• Check Harness

Operation of Proportional Valve during High Current: • Travel motor is always slow.

Retrial B

• Check Harness

Operation of Proportional Valve during Low Current: • Travel motor is always slow.

Retrial B

• Check Harness

In case ATT flow rate is limited, it cannot be limited.

Retrial B

• Check Harness

Actual Operation of Proportional Valve during High Current: • Travel mistakes. • Boom raise operation is slow. • Arm operation is slow. • Bucket operation is slow.

Retrial B

• Check Harness

Actual Operation of Proportional Valve during Low Current: • In case ATT flow rate is limited, it cannot be limited.

Retrial B

• Check Harness

Symptoms in Machine Operation When Trouble Occurs. Pressure increasing is impossible.

T4-1-17

Remark

Dr. ZX / Fault Code CAN Data Reception Failure Fault Trouble Code 11910-2 Actual Engine Speed Received from ECM

Cause Faulty Harness

• Speed Sensing Control • Send to ICF • Attachment Operation Speed Increase Control • Attachment Operation Speed Limit Control • Attachment Pump Torque Decrease Control (ZX200-3 to ZX330-3 class) • Pump 1 Flow Rate Limit Control • Pump 2 Flow Rate Limit Control • Attachment Flow Rate Control • Attachment Valve Selection (Optional) Theft Prevention Engine Speed, Engine Torque Fuel Flow Rate

11918-2

Work Mode Received from Monitor Unit

Faulty Harness

11911-2

Security Signal Received from Monitor Unit Fuel Flow Rate Received from ECM Radiator Coolant Temperature Received from ECM

Faulty Harness

11920-2 11914-2

Influenced Control

Faulty Harness Faulty Harness

T4-1-18

Radiator Coolant Temperature Auto-Warming Up Control

Dr. ZX / Fault Code Remedy for Dr. ZX Machine operation speed is slow. (During speed sensing, torque Retrial B is decreased.) During e-service, the engine is stalled. • Digging Mode: Lock Retrial B In case flow rate is decreased and speed decreases during ATT, stop this control, or Digging is not changed into ATT mode. • Work Mode Alarm is displayed on the monitor unit. Symptoms in Machine Operation When Trouble Occurs.

Remark • Check Harness

• Check Harness

T1V1-05-01-102

In case theft prevention is turned ON by Dr. ZX, engine speed is Retrial B kept at Minimum speed and pump torque is kept Minimum. When the monitor setting is displayed fuel consumption at mo- Retrial B ment, engine display at moment is “----“. Heater Control: Ineffective Retrial B

T4-1-19

• Check Harness • Check Harness • Check Harness

Dr. ZX / Fault Code Other Failures Fault Trouble Code 11901-3 Hydraulic Oil Temperature Sensor High Voltage

Cause

Influenced Control

Voltage: 4.52 V or higher

• Hydraulic Oil Temperature Auto-Warming Up Control • Arm Regenerative Control • Digging Regenerative Control

Voltage: Less than 0.23 V

• Hydraulic Oil Temperature Auto-Warming Up Control • Arm Regenerative Control • Digging Regenerative Control

11901-4

Hydraulic Oil Temperature Sensor Low Voltage

11905-3

Abnormal Boom Bottom Pres- Voltage: 4.5 V or higher sure Sensor High Voltage (Optional)

• Overload Alarm

11905-4

Abnormal Boom Bottom Pres- Voltage: Less than 0.25 V sure Sensor Low Voltage (Optional)

• Overload Alarm

T4-1-20

Dr. ZX / Fault Code Remedy for Dr. ZX Retrial B

• Check Harness

When temperature is low (hydraulic oil temperature is less than 0 °C), the auto-warming up control is inoperable.

Retrial B

• Check Harness

When overload alarm is used. • Overload alarm buzzer rings. • The overload alarm is displayed on the monitor unit.

Retrial B

• Check Harness • Replace Boom Pressure Sensor

Bottom

• Check Harness • Replace Boom Pressure Sensor

Bottom

Symptoms in Machine Operation When Trouble Occurs. When temperature is low (hydraulic oil temperature is less than 0 °C), the auto-warming up control is inoperable.

Remark

T1V1-05-02-002

When overload alarm is used. • Overload alarm buzzer rings. • The overload alarm is displayed on the monitor unit.

T1V1-05-02-002

T4-1-21

Retrial B

Dr. ZX / Fault Code ECM Fault Code 100-3 100-4 102-3 102-4 105-3

105-4 108-3 108-4 110-0

110-3 110-4

Trouble

Cause

Abnormal Engine Oil Pressure Sensor (Abnormal Low Voltage) Abnormal Engine Oil Pressure Sensor (Abnormal High Voltage) Abnormal Boost Pressure Sensor (Abnormal Low Voltage) Abnormal Boost Pressure Sensor (Abnormal High Voltage) Abnormal Boost Temperature Sensor (Abnormal High Voltage)

Voltage at the engine oil pressure sensor is below 0.1 V. Voltage at the engine oil pressure sensor is beyond 4.85 V. Voltage at the boost pressure sensor is below 0.1 V

Abnormal Coolant Temperature Sensor (Abnormal High Voltage) Abnormal Coolant Temperature Sensor (Abnormal Low Voltage)

Voltage at the coolant temperature sensor is beyond 4.85 V. Voltage at the coolant temperature sensor is below 0.1 V

Voltage at the boost pressure sensor is beyond 4.9 V.

Voltage at the boost temperature sensor is beyond 4.95 V over 5 minutes after the engine starts or when coolant temperature is beyond 50 °C (122 °F). Abnormal Boost Temperature Sensor Voltage at the boost temperature sensor is below 0.1 (Abnormal Low Voltage) V. Abnormal Atmospheric Pressure Sensor Voltage at the atmospheric pressure sensor is below (Abnormal Low Voltage) 0.5 V. Abnormal Atmospheric Pressure Sensor Voltage at the atmospheric pressure sensor is beyond (Abnormal High Voltage) 3.8 V. Overheating Coolant temperature is beyond 120 °C (248 °F) when operating the engine.

157-0

Abnormal common rail pressure (First Common rail pressure is beyond 185 MPa. stage)

157-0

Abnormal common rail pressure (Second stage)

The first stage “Abnormal common rail presure” is approved and common rail pressure is beyond 190 MPa.

157-2

Abnormal common rail pressure (Pump over-pressure)

157-3

Abnormal Common Rail Pressure Sensor (Abnormal High Voltage) Abnormal Common Rail Pressure Sensor (Abnormal Low Voltage)

When DUTY to the suction control valve is 40 % or more, or target pressure to the suction control valve is 3 90 mm /sec or less, actual rail pressure is 40 MPa 2 (410 kgf/cm , 5820 psi) higher than the target rail pressure. Voltage at the common rail pressure sensor is beyond 4.5 V. Voltage at the common rail pressure sensor is below 0.7 V.

157-4

T4-1-22

Dr. ZX / Fault Code

Presumptive Symptoms in Real Machine Assumptive Conditions at Backup Operation There is no influence when operating the ma- Nothing special chine.

Fault Code (Tech 2) P0522 P0523

Dark smoke occurs.

Boost pressure cannot be corrected.

P0237 P0238

There is no influence when operating the ma- Nothing special chine.

P1112

P1113 Dark smoke occurs at high altitude.

2

Atmospheric pressure 80 kPa (0.8 kgf/cm , 12 psi) (2000 m above the sea)

P0107 P0108

There is no influence when operating the ma- Nothing special (The history of overheating is chine. recorded.)

P1173

When starting: -20 °C (-4 °F) (Start the engine although what state.) When operating: 80 °C (176 °F) (Operate normally.)

P0118

Normal temperature: When starting, dark smoke may occur and engine combustion sound may be become loud. While warming up with fresh air in low temperature: Rough idle, engine stall or while smoke may be occur. Vibration of the engine may be large, Rough idle, output power decrease may occur, faulty increasing of rotation speed, dark smoke may occur, output power may be too large.

P0117

Prevention the junection system (pump) from damage (Protect the RP sensor by over-pressure)

P0088

Vibration of the engine may be large, Rough idle, Prevention the junection system from damage output power decrease may occur, faulty in- (Pressure is too much as PR is clogged.) creasing of rotation speed, dark smoke may occur, output power may be too large.

P0088

Vibration of the engine may be large, Rough idle, Prevention the junection system (pmp) from output power decrease may occur, faulty in- damage creasing of rotation speed, dark smoke may (Protect the RP sensor by over-pressure) occur, output power may be too large.

P0089

The engine may be stalled. The output power decreases.

P0193

The supply pump can not be controlled.

P0192

T4-1-23

Dr. ZX / Fault Code

Fault Code 172-3

Trouble

Cause Voltage at the intake-air temperature sensor is beyond 4.95 V in 3 minutes after the engine starts. Voltage at the intake-air temperature sensor is below 0.1 V. Voltage at the fuel temperature sensor is beyond 4.85 V in 3 minutes after the engine starts. Voltage at the fuel temperature sensor is below 0.1 V.

190-0

Abnormal Intake-Air Temperature Sensor (Abnormal High Voltage) Abnormal Intake-Air Temperature Sensor (Abnormal Low Voltage) Abnormal Fuel Temperature Sensor (Abnormal High Voltage) Abnormal Fuel Temperature Sensor (Abnormal Low Voltage) Overrunning

In case the engine speed is beyond 2500 min

628-2 633-7

Abnormal ROM Pressure limiter open

ROM is broken. The pressure limiter is open.

636-2

Abnormal Cam Angle Sensor (No Signal)

172-4 174-3 174-4

636-2 636-7

639-2 639-3 651-3 652-3 653-3 654-3 655-3 (ZX330-3 class only) 656-3 (ZX330-3 class only)

-1

Although the crank signal is present, the cam signal is not present. Abnormal Cam Angle Sensor (Abnormal The pulse of cam signal is not matched. Signal) Phase Mismatch of Cam Angle Sensor The right cam pulse is not present at the gap in the crank. Abnormal CAN Bus Line Abnormal CAN Time Out

Detect the bus line off. In case the CAN data reception is not approved in prescribedtime Open circuit in injection nozzle ＃1 drive No input signal of injector 1 monitor. system Open circuit in injection nozzle ＃2 drive No input signal of injector 2 monitor. system Open circuit in injection nozzle ＃3 drive No input signal of injector 3 monitor. system Open circuit in injection nozzle #4 drive No input signal of injector 4 monitor. system Open circuit in injection nozzle #5 drive No input signal of injector 5 monitor. system Open circuit in injection nozzle #6 drive No input signal of injector 6 monitor. system

T4-1-24

Dr. ZX / Fault Code

Presumptive Symptoms in Real Machine Operation Nothing special

Nothing special

Engine speed of the excavator may not increase -1 2500 min or more. The engine stops. Output power decrease

Assumptive Conditions at Backup When starting: -10 °C (14 °F) (Start the engine although what state.) When operating: 25 °C (77 °F) (Operate normally.) When starting: -20 °C (-4 °F) (Start the engine although what state.) When operating: 70 °C (158 °F) (Operate normally.) Mistake of gear change, etc.

Data of ROM cannot be read. Rial pressure is beyond the allowable pressure. • While the engine runs, there is nothing abnor- While the engine runs, operate according to standard of the crank sensor. When the enmal with machine operation. • After the engine is stalled, the re-start is im- gine stops, the start is impossible (in order to prevent the engine from damaging). possible. • While the engine runs, there is nothing abnor- The timing chain and the belt does not turn smoothly but turn in reverse. mal with machine operation. • After the engine is stalled, the re-start is impossible. Speed is turnd into idle speed. CAN communication is operable.

Fault Code (Tech 2) P0113 P0112 P0183 P0182 P0219 P0601 P1095 P0340 P0341 P1345

U2104 U2106

Vibration of the engine is large, Rough idle, out- #1 injector cannot be controlled. put power decrease, faulty increasing of → Stop drive pulse output of #1 injector. rotation speed, output power decrease #2 injector cannot be controlled. → Stop drive pulse output of #2 injector. #3 injector cannot be controlled. → Stop drive pulse output of #3 injector. #4 injector cannot be controlled. → Stop drive pulse output of #4 injector. #5 injector cannot be controlled. → Stop drive pulse output of #5 injector.

P0201

#6 injector cannot be controlled. → Stop drive pulse output of #6 injector.

P0206

T4-1-25

P0202 P0203 P0204 P0205

Dr. ZX/ Fault Code

Fault Code

Trouble

Cause

723-2

Although the cam signal is present, the crank signal is not present. The pulse of crank signal is not matched.

987-3

Abnormal Crank Speed Sensor (No Signal) Abnormal Crank Speed Sensor (Abnormal Signal) Abnormal check engine lamp

1077-2

Abnormal IC for CPU watching

No change of RUN-SUB pulse in 20 msec

1079-2

Abnormal 5 V Power Source 1 When battery volate is between 16 V and 32 V, voltage of Voltage IGKEY power source is 5.5 V or more or 4.5 V or less.

1080-2

Abnormal 5 V Power Source 2 When battery volate is between 16 V and 32 V, voltage of Voltage IGKEY power source is 5.5 V or more or 4.5 V or less.

1239-1

No pressure to pump (Fuel leakage)

When pressure to the suction control valve is 900 min , 2 actual rail pressure is 15MPa (150 kgf/cm , 2180 psi) or less.

1240-1

No pressure to pump (Fuel leakage)

When DUTY to the suction control valve is 33 % or less, or 3 pressure to the suction control valve is 28000 mm /sec or -1 more and 1200 min , actual rail pressure is 50 MPa (510 2 kgf/cm , 7270 psi) lower than the target rail pressure.

1347-0

Open circuit in suction control valve The suctioncontrol valve drive current is beyond 2400 mA or drive system, Shorted circuit in + B or below 50 mA. Or, difference between the tartget current and GND actual current is 1000 mA or more.

1485-2

Abnormal main relay system

723-2

No monitor signal of the check engine lamp

-1

Voltage in the main relay system is 1 V or less with the main relay coil output ON. Although the main relay coil output is turned OFF, the main relay is kept ON.

10001-3

Abnormal EGR Position (Brushless The condition which the output signal of EGR position cannot spec.) be present in.

10002-2

Abnormal EGR valve control

Difference between the target valve lift and actual position is beyond 20%.

T4-1-26

Dr. ZX/ Fault Code

Presumptive Symptoms in Real Machine Operation

Assumptive Conditions at Backup

• The output power may decrease, white smoke Operate according to standard of the cam sensor. may occur and vibration may occur. • The engine may be stalled. (If the cam senor is normal, the engine can re-start.)

Fault Code (Tech 2) P0335 P0336

There is no influence when operating the Nothing special machine.

P0650

Output power decrease

Sub CPU is broken.

P0606

Same as Abnormal accelerator Sensor

←

P1631

Same as Abnomal atmospheric and in-take ← temperature sensors

P1632

Vibration of the engine may be large, Rough idle, output power decrease may occur, faulty increasing of rotation speed, dark smoke may occur, output power may be too large. Vibration of the engine may be large, Rough idle, output power decrease may occur, faulty increasing of rotation speed, dark smoke may occur, output power may be too large. The engine may be stalled and the rotation speed increases automatically and abnormally according to open or shorted circuit condition. Dark smoke occurs. Output power is too large.

Fuel leakage is too much. Actual rail pressure does not increase to the required pressure.

P0087

Fuel leakage is too much. Difference between target rail pressure and actual rail pressure is larger than the specification. (Large deflection) The supply pump cannot be controlled. → Prevent the engine from increasing the rotation speed automatically and abnormally (Protect the engine).

P1093

The engine cannot start.

Nothing

Electrical power is kept supplying to the Nothing machine. There is influence to exhaust gas.

There is influence to exhaust gas.

As the sensor input is not certain, it cannot be controlled. Exhaust gas becomes bad. Operate the engine with EGR valve fully open. EGR cannot be controlled. As exhaust gas becomes bad, EGR stops.

T4-1-27

P0090

P1625 P0487

P0488

Dr. ZX/ Fault Code

Fault Code 10003-2

10004-2

Trouble

Cause

Abnormal Injection Nozzle Common ZX160-3 to ZX270-3 class 1 Drive System No monitor siganals of injectors 1, 4 ZX330-3 class No monitor siganals of injectors 1, 3, 5 Abnormal Injection Nozzle Common ZX160-3 to ZX270-3 class 2 Drive System No monitor siganals of injectors 2, 3 ZX330-3 class No monitor siganals of injectors 2, 4, 6

10005-1

Abnormal Charge Circuit

(Bank 1)

In case voltage at bank 1 of charge circuit in ECM is low

10006-1

Abnormal Charge Circuit

(Bank 2)

In case voltage at bank 2 of charge circuit in ECM is low

10007-2

Abnormal CPU

10008-2 10009-2

Abnormal A/D Conversion A/D conversion cannot be done. Abnormal 5 V Power Source 3 When battery voltage is between 16 V and 32 V, voltage of Voltage IGKEY power source is 5.5 V or more or 4.5 V or less.

10010-2

Abnormal 5 V Power Source 4 When battery voltage is between 16 V and 32 V, voltage of Voltage IGKEY power source is 5.5 V or more or 4.5 V or less.

10011-2

Abnormal 5 V Power Source 5 When battery voltage is between 16 V and 32 V, voltage of Voltage IGKEY power source is 5.5 V or more or 4.5 V or less.

10013-2

Abnormal EEPROM

Within 100 msec after the key switch is turned ON, failure of main CPU is detected by sub CPU. (Sub CPU resets CPU.)

EEPROM is broken.

T4-1-28

Dr. ZX/ Fault Code

Presumptive Symptoms in Real Machine Operation

Assumptive Conditions at Backup

Vibration of the engine may be large, Rough idle, output power decrease may occur, faulty increasing of rotation speed may occur, the engine may be stalled.

The injector cannot be controlled. → Stop output of drive signal at broken common side (Protect the engine from damage)

Fault Code (Tech 1) P1261

P1262

Vibration of the engine may be large, Rough idle, output power decrease may occur, faulty increasing of rotation speed may occur, the engine may be stalled.

The injector cannot be controlled. → Stop output of drive signal at broken common side (Protect the engine from damage)

P0612

Output power decrease

CPU is broken.

P0606

P0611

The engine cannot start.

P0606

Output power decrease, dark smoke occur. All analogue sensor cannot be used. Same as Abnomal coolant temperature, fuel ← temperature and hydraulic oil pressure sensors

P1630 P1633

Same as Abnomal boost pressure and boost ← temperature sensors

P1634

Same as Abnomal rail pressure and EGR ← position sensors

P1635

There is no influence when operating the Data cannot be written to EEPROM. machine.

P0630

T4-1-29

Dr. ZX/ Fault Code ICF Fault Code

Trouble

Cause

14000-2

Abnormal CAN Communication

Data cannot be received due to the noise on the CAN bus line.

14001-2

ICF: Flash Memory: Read / Write In case the internal memory is abnormal when the key is Error turned ON

14002-2

ICF: External RAM: Read / Write In case the internal memory is abnormal when the key is Error turned ON

14003-2

ICF: EEPROM: Sum Check Error

14006-2

ICF: Satellite Communication In case communication to the satellite terminal cannot be Terminal: Communication Error done over 30 seconds.

14008-2

ICF: Abnormal Internal RAM

In case the internal memory is abnormal when the key is turned ON

In case the internal memory is abnormal when the key is turned ON

T4-1-30

Dr. ZX/ Fault Code

Fault Code

Remedy

14000-2

Check for CAN communication bus line.

14001-2

After initializng the information C/U by using Dr. ZX, re-try in the troubleshooting. If the error code is displayed after re-try, ICF may be broken. Replace ICF. NOTE: When initialising the information C/U, all stored data is deleted.

14002-2

After initializng the information C/U by using Dr. ZX, re-try in the troubleshooting. If the error code is displayed after re-try, ICF may be broken. Replace ICF. NOTE: When initialising the information C/U, all stored data is deleted.

14003-2

As ICF may be broken, replace ICF.

14006-2

Check for the items below. 1. Check if the communication line is abnormal. 2. Check if the electrical power source of communication terminal is abnormal. • Electrical power source • Fuses 3. Check if the satellilte terminal is broken.

14008-2

Re-try in the troubleshooting by using Dr.ZX. If the error code is displayed after re-try, ICF may be broken.

T4-1-31

Dr. ZX/ Fault Code SATELLITE TERMINAL Fault Code

Trouble

Cause

14100-2

Satellite Communication Terminal: Data cannot be received due to the noise on the CAN bus Abnormal EEPROM line.

14101-2

Satellite Communication Terminal: In case the internal memory is abnormal when the key is Abnormal IB/OB Queue turned ON

14102-2

Satellite Communication Terminal: In case the internal memory is abnormal when the key is Abnormal Local Loop Back turned ON

14103-2

Satellite Communication Terminal: In case the internal memory is abnormal when the key is The satellite is not found. turned ON

14104-2

Satellite Communication Terminal: In case communication to the satellite terminal cannot be Fail 1 of Remote Loop Back done over 30 seconds.

14105-2

Satellite Communication Terminal: In case the internal memory is abnormal when the key is Fail 2 of Remote Loop Back turned ON

14106-2

Satellite Communication Terminal: In case sending and receiving data are unmatched. Sending and receiving data are mistached.

T4-1-32

Dr. ZX/ Fault Code

Fault Code

Remedy

14100-2

Replace the controller.

14101-2

Replace the controller.

14102-2

• Check communication aerial of satellite terminal.

14103-2

• Check communication aerial of satellite terminal.

14104-2

Replace the controller.

14105-2

Replace the controller.

14106-2

Replace the controller.

T4-1-33

Dr. ZX/ Fault Code MONITOR UNIT Fault Code

Trouble

Cause

13303-2

Abnormal Thermister Temperature

Thermister temperature is 85 °C (185 °F) or higher.

13304-2

Abnormal REG Input H Level

During REG input H level

13306-2

Abnormal EEPROM

When failure reading EEPROM occurs

13308-2

Abnormal CAN Communication

Bus off occurs beyond five times.

13310-3

Shorted circuit Temperature Sensor

13311-3

Shorted circuit in Fuel Leverl Sensor The state, input 3±1 Ω or less, is kept over 60 seconds.

13311-4

Open circuit in Fuel Leverl Sensor

in

Coolant The state, input 105±30 Ω or less, is kept over 60 seconds.

The state, input 135±20 Ω or less, is kept over 60 seconds.

T4-1-34

Dr. ZX/ Fault Code

Fault Code

Remedy

13303-2

Cool the monitor unit and so on until temperature inside the monitor unit is less than 85 °C (185 °F).

13304-2

(Refer to the Troubleshooting flow chart.)

13306-2

If this fault code is displayed after retarial, replace the monitor unit.

13308-2

Refer to “Check CAN Harness”.

13310-3

Check coolant temperature sensor and harness.

13311-3

Check fuel level sensor and harness.

13311-4

Check fuel level sensor and harness.

T4-1-35

Dr. ZX/ Fault Code (Blank)

T4-1-36

Dr. ZX / Fault Code FAULT CODE ZX450-3 TO ZX850-3 CLASS For details of trouble analyses, refer to “Technical Manual (Troubleshooting)” for the corresponding models.

T4-2-1

Dr. ZX / Fault Code FAULT CODE LIST MC

Fault Code 11000-2

Trouble

Cause

Influenced Control

Abnormal EEPROM

Faulty MC

• All Control

11001-2

Abnormal RAM

Faulty MC

• All Control

11002-2

Abnormal A/D Converter

Faulty MC

• All Control

11003-3

Abnormal Sensor Voltage

Faulty MC

• All Control

11004-2

CAN Communication Error

Faulty MC Shorted Circuit in CAN Bus Line

11101-3

EC Dial sensor Circuit High Input EC Dial sensor Circuit Low Input

Voltage: 4.75 V or higher

• Engine Control • Work Mode Control • Attachment Mode Control • Horsepower (Speed Sensing) Control • Fan Pump Flow Rate Control • CAN Cycle Data Communication • Overheat Prevention Control • Engine Control Dial Control

Voltage: Less than 0.25 V

• Engine Control Dial Control • HP Mode Control • Horsepower Control • Relief Flow Rate Reducing Control (Relief Cut Off) • Auto-Power Lift Control • HP Mode Control • Horsepower Control • Relief Flow Rate Reducing Control (Relief Cut Off) • Auto-Power Lift Control

11101-4 11200-3

Pump 1 Delivery Pressure Sensor Circuit High Input

Voltage: 4.75 V or higher

11200-4

Pump 1 Delivery Pressure Sensor Circuit Low Input

Voltage: Less than 0.25 V

11202-3

Pump 2 Delivery Pressure Sensor Circuit High Input

Voltage: 4.75 V or higher

11202-4

Pump 2 Delivery Pressure Sensor Circuit Low Input

Voltage: Less than 0.25 V

T4-2-2

• HP Mode Control • Horsepower Control • Relief Flow Rate Reducing Control (Relief Cut Off) • HP Mode Control • Horsepower Control • Relief Flow Rate Reducing Control (Relief Cut Off)

Dr. ZX / Fault Code

Symptoms in Machine Operation When Trouble Occurs.

Remedy for Dr. ZX

Remedy

Retry Diagnostic Procedure B

• Replace MC

Retry Diagnostic Procedure B

• Replace MC

Retry Diagnostic Procedure B

• Replace MC

• Engine speed is kept at backup -1 speed (1200 min ).

Retry Diagnostic Procedure B

• Replace MC • Check Harness (Sensor Power) • Check Sensor to connected to MC

• No Speed sensing • All abnormal signals via CAN communication • Engine speed is kept at slow idle speed.

Retry Diagnostic Procedure B

• Replace MC • Check CAN Harness

• Target engine speed is kept at -1 1200 min . • Target engine speed is kept at -1 1200 min . • Increasing speed at HP mode is difficult. • Less flow rate at 19.6 MPa • Relief cut is not operated. • Auto-power lift does not function. • Increasing speed at HP mode is difficult. • Less flow rate at 19.6 MPa • Relief cut is not operated. • Auto-power lift does not function.

Retry Diagnostic Procedure B

• Check Harness • Replace Engine Control Dial • Check Harness • Replace Engine Control Dial • Check Harness • Replace Pump 1 Delivery Pressure Sensor

-

Retry Diagnostic Procedure B Retry Diagnostic Procedure B

Retry Diagnostic Procedure B

• Check Harness • Replace Pump 1 Delivery Pressure Sensor

• Increasing speed at HP mode is difficult. • Less flow rate at 19.6 MPa

Retry Diagnostic Procedure B

• Check Harness • Replace Pump 2 Delivery Pressure Sensor

• Increasing speed at HP mode is difficult. • Less flow rate at 19.6 MPa

Retry Diagnostic Procedure B

• Check Harness • Replace Pump 2 Delivery Pressure Sensor

T4-2-3

Dr. ZX / Fault Code Fault Code 11301-3

Trouble

Cause

Influenced Control

Swing Pilot Pressure Sensor Circuit High Input

Voltage: 4.75 V or higher

• Engine Control • Relief Flow Rate Reducing Control (Relief Cut Off) • Swing Horsepower Reducing Control • Boom Mode Selector Control

11301-4

Swing Pilot Pressure Sensor Circuit Low Input

Voltage: Less than 0.25 V

• Engine Control • Relief Flow Rate Reducing Control (Relief Cut Off) • Swing Horsepower Reducing Control • Boom Mode Selector Control

11302-3

Boom Raise Pilot Pressure Sensor Circuit High Input

Voltage: 4.75 V or higher

• Engine Control • HP Mode Control • Auto-Power Lift Control • Boom Mode Selector Control

T4-2-4

Dr. ZX / Fault Code Symptoms in Machine Operation Remedy for Dr. ZX When Trouble Occurs. • Cut off override is not impossible. Retry Diagnostic Procedure B • A/I cannot be released by swing operation. • Flow rate of lever regulated pump control becomes maximum by swing operation. • Reducing operation of swing torque is impossible. • Boom mode selector control is impossible by swing operation. • Engine speed is lower than speed at E mode.

Remedy • Check Harness • Replace Swing Pilot Pressure Sensor

• Cut off override is not impossible. Retry Diagnostic Procedure B • A/I cannot be released by swing operation. • Flow rate of lever regulated pump control becomes maximum by swing operation. • Reducing operation of swing torque is impossible. • Boom mode selector control is impossible by swing operation. • Engine speed is lower than speed at E mode.

• Check Harness • Replace Swing Pilot Pressure Sensor

Retry Diagnostic Procedure B • Speed at HP mode does not increase by boom raise operation. • A/I cannot be released by boom raise operation. • Flow rate of lever regulated pump control becomes maximum by boom raise operation. • Boom mode selector control is impossible by boom raise operation. • Auto-power lift does not function by boom raise operation. • Boom flow rate control valve control is not operated. • Engine speed is lower than speed at E mode.

• Check Harness • Replace Boom Raise Pilot Pressure Sensor

T4-2-5

Dr. ZX / Fault Code Fault Code 11302-4

Trouble

Cause

Influenced Control

Boom Raise Pilot Pressure Sensor Circuit Low Input

Voltage: Less than 0.25 V

• Engine Control • HP Mode Control • Auto-Power Lift Control • Boom Mode Selector Control

11303-3

Arm Roll-in Pilot Pressure Sensor Circuit High Input

Voltage: 4.75 V or higher

• Engine Control • HP Mode Control • Boom Mode Selector Control • Boom Flow Rate Control Valve Control • Auto-Power Lift Control

11303-4

Arm Roll-in Pilot Pressure Sensor Circuit Low Input

Voltage: Less than 0.25 V

• Engine Control • HP Mode Control • Boom Mode Selector Control • Boom Flow Rate Control Valve Control • Auto-Power Lift Control

T4-2-6

Dr. ZX / Fault Code Symptoms in Machine Operation When Trouble Occurs. • Speed at HP mode does not increase by boom raise operation. • A/I cannot be released by boom raise operation. • Flow rate of lever regulated pump control becomes maximum by boom raise operation. • Boom mode selector control is impossible by boom raise operation. • Auto-power lift does not function by boom raise operation. • Boom flow rate control valve control is not operated. • Engine speed is lower than speed at E mode.

Remedy for Dr. ZX

Remedy

Retry Diagnostic Procedure B

• Check Harness • Replace Boom Raise Pilot Pressure Sensor

• Speed at HP mode does not increase by arm roll-in operation. • A/I cannot be released by arm roll-in operation. • Flow rate of lever regulated pump control becomes maximum by arm roll-in operation. • Boom mode selector control is impossible by arm roll-in operation. • Auto-power lift does not function by arm roll-in operation. • Boom flow rate control valve control is not operated. • Engine speed is lower than speed at E mode.

Retry Diagnostic Procedure B

• Check Harness • Replace Arm Roll-In Pilot Pressure Sensor

• Speed at HP mode does not increase by arm roll-in operation. • A/I cannot be released by arm roll-in operation. • Flow rate of lever regulated pump control becomes maximum by arm roll-in operation. • Boom mode selector control is impossible by arm roll-in operation. • Auto-power lift does not function by arm roll-in operation. • Boom flow rate control valve control is not operated. • Engine speed is lower than speed at E mode.

Retry Diagnostic Procedure B

• Check Harness • Replace Arm Roll-In Pilot Pressure Sensor

T4-2-7

Dr. ZX / Fault Code Fault Code 11400-3

Trouble

Cause

Influenced Control

Pump 2 Regulator Valve FB High Current Pump 2 Regulator Valve FB Low Current Boom Flow Control Valve FB High Current Boom Flow Control Valve FB Low Current Power Boost P/S Valve FB High Current

Current: Higher than 920 mA

• All Pump Controls

Current: Less than 56 mA

• All Pump Controls

Current: Higher than 920 mA

• All Pump Controls

Current: Less than 56 mA

• All Pump Controls

Current: Higher than 920 mA

• Counterweight Removal and Installation Control • Pressure Increase Selection Control When Traveling • Power Digging Control • Auto-Power Lift Control

11404-4

Power Boost P/S Valve FB Low Current

Current: Less than 56 mA

• Counterweight Removal and Installation Control • Pressure Increase Selection Control When Traveling • Power Digging Control • Auto-Power Lift Control

11405-3

Travel Swash Angle P/S Valve FB High Current Travel Swash Angle P/S Valve FB Low Current Pump 1 Regulator Valve FB High Current Pump 1 Regulator Valve FB Low Current Hyd. Fan P/S Valve FB High Current Hyd. Fan P/S Valve FB Low Current Boom Bottom Pressure Sensor Circuit High Input

Current: Higher than 920 mA

Current: Higher than 920 mA

• Travel Motor Swash Angle Selection Control • Travel Motor Swash Angle Selection Control • All Pump Controls

Current: Less than 56 mA

• All Pump Controls

Current: Higher than 920 mA

• Fan Pump Flow Rate Control

Current: Less than 56 mA

• Fan Pump Flow Rate Control

Voltage: 4.5 V or higher

• Overload Alarm Control

11802-4

Boom Bottom Pressure Sensor Circuit Low Input

Voltage: Less than 0.25 V

• Overload Alarm Control

11901-3

Hyd. Oil Temp Sensor Circuit High Input

Intake air temperature: 21 °C or higher (higher than 20 °C) Voltage: 4.10 V or higher This condition is continued beyond 30 seconds.

• Engine Control • Overheat Prevention Control • Fan Pump Flow Rate Control

11901-4

Hyd. Oil Temp Sensor Circuit Low Input

Voltage: Less than 0.23 V This condition is continued beyond 30 seconds.

• Engine Control • Overheat Prevention Control • Fan Pump Flow Rate Control

11400-4 11402-3 11402-4 11404-3

11405-4 11410-3 11410-4 11412-3 11412-4 11802-3

Current: Less than 56 mA

T4-2-8

Dr. ZX / Fault Code Symptoms in Machine Operation When Trouble Occurs. • Pump 2 control is impossible.

Remedy for Dr. ZX

Remedy

Retry Diagnostic Procedure B

• Check Harness

• Pump 2 control is impossible.

Retry Diagnostic Procedure B

• Check Harness

• Boom flow rate control valve control is not operated. • Boom flow rate control valve control is not operated. • Increasing pressure selection is impossible.

Retry Diagnostic Procedure B

• Check Harness

Retry Diagnostic Procedure B

• Check Harness

Retry Diagnostic Procedure B

• Check Harness

• Increasing pressure selection is impossible.

Retry Diagnostic Procedure B

• Check Harness

• Travel mode selection is impossible. • Travel mode selection is impossible. • Pump 1 control is impossible.

Retry Diagnostic Procedure B

• Check Harness

Retry Diagnostic Procedure B

• Check Harness

Retry Diagnostic Procedure B

• Check Harness

• Pump 1 control is impossible.

Retry Diagnostic Procedure B

• Check Harness

• Fan control is impossible.

Retry Diagnostic Procedure B

• Check Harness

• Fan control is impossible.

Retry Diagnostic Procedure B

• Check Harness

Retry Diagnostic Procedure B

• Check Harness • Replace Boom Bottom Pressure Sensor

Retry Diagnostic Procedure B

• Check Harness • Replace Boom Bottom Pressure Sensor

• Overheat prevention control of hydraulic oil is impossible. • Maximum fan speed • Drive torque of pump is reduced.

Retry Diagnostic Procedure B

• Check Harness • Replace Hydraulic Oil Temperature Sensor

• Overheat prevention control of hydraulic oil is impossible. • Maximum fan speed • Drive torque of pump is reduced.

Retry Diagnostic Procedure B

• Check Harness • Replace Hydraulic Oil Temperature Sensor

-

-

T4-2-9

Dr. ZX / Fault Code Fault Code 11910-2 11911-2

Trouble

Cause

Actual Engine Speed Receive Error Security Signal receive Error

Faulty Harness

Influenced Control -

Faulty Harness -

11914-2 11918-2

Radiator Water Temp Receive Error Work Mode Receive Error

Faulty Harness

11920-2

Fuel Flaw Receive Error

Faulty Harness

11976-3

Auxiliary Valve 2 FB High Current Auxiliary Valve 2 FB Low Current Auxiliary Valve 1 FB High Current Auxiliary Valve 1 FB Low Current ATT Relief Change Valve FB High Current ATT Relief Change Valve FB Low Current Fan Reverse Valve 2 FB High Current Fan Reverse Valve 2 FB Low Current Fan Reverse Valve 1 FB High Current Fan Reverse Valve 1 FB Low Current Intake Air Temperature Receive Error Boost Temperature Receive Error Boom Mode Control Valve FB High Current Boom Mode Control Valve FB Low Current

Current: Higher than 920 mA

11976-4 11977-3 11977-4 11980-3 11980-4 11981-3 11981-4 11982-3 11982-4 11983-2 11984-2 11989-3 11989-4

Faulty Harness

Current: Less than 56 mA Current: Higher than 920 mA Current: Less than 56 mA Current: Higher than 920 mA Current: Less than 56 mA Current: Higher than 920 mA Current: Less than 56 mA Current: Higher than 920 mA Current: Less than 56 mA

• Overheat Prevention Control • Fan Pump Flow Rate Control • Work Mode Control • Attachment Mode Control -

Faulty Harness

• Fan Pump Flow Rate Control

Faulty Harness

• Fan Pump Flow Rate Control

Current: Higher than 920 mA

• Boom Mode Selector Control

Current: Less than 56 mA

• Boom Mode Selector Control

T4-2-10

Dr. ZX / Fault Code Symptoms in Machine Operation When Trouble Occurs. • Stop speed sensing. • Pump learning is impossible. • When engine control security and pump control security are turned ON, security is activated.

Remedy for Dr. ZX

Remedy

Retry Diagnostic Procedure B

• Check Harness

Retry Diagnostic Procedure B

• Check Harness

Retry Diagnostic Procedure B

• Check Harness

Retry Diagnostic Procedure B

• Check Harness

Retry Diagnostic Procedure B

• Check Harness

Retry Diagnostic Procedure B

• Check Harness

Retry Diagnostic Procedure B

• Check Harness

Retry Diagnostic Procedure B

• Check Harness

Retry Diagnostic Procedure B

• Check Harness

• Attachment relief selection is impossible. • Attachment relief selection is impossible. • Fan reverse is impossible.

Retry Diagnostic Procedure B

• Check Harness

Retry Diagnostic Procedure B

• Check Harness

Retry Diagnostic Procedure B

• Check Harness

• Fan reverse is impossible.

Retry Diagnostic Procedure B

• Check Harness

• Fan reverse is impossible.

Retry Diagnostic Procedure B

• Check Harness

• Fan reverse is impossible.

Retry Diagnostic Procedure B

• Check Harness

• Maximum fan speed (with blower motor relay ON) • Maximum fan speed

Retry Diagnostic Procedure B

• Check Harness

Retry Diagnostic Procedure B

• Check Harness

Retry Diagnostic Procedure B

• Check Harness

Retry Diagnostic Procedure B

• Check Harness

• Maximum fan speed • Drive torque of pump is reduced. • The value received last time is effective. • The value received last time is effective. -

• Boom mode selector control is impossible. • Boom mode selector control is impossible.

T4-2-11

Dr. ZX / Fault Code Fault Code

Trouble

Cause

Influenced Control

Right Travel Pilot Pressure Sensor Circuit High Input

Voltage: 4.75 V or higher

• Travel Speed Increase Control • Relief Flow Rate Reducing Control (Relief Cut Off) • Swing Horsepower Reducing Control • Pressure Increase Selection Control When Traveling • Rear Monitoring Display Selection Control • Travel Alarm Control • Engine Control

Right Travel Pilot Pressure Sensor Circuit Low Input

Voltage: Less than 0.25 V

• Travel Speed Increase Control • Relief Flow Rate Reducing Control (Relief Cut Off) • Swing Horsepower Reducing Control • Pressure Increase Selection Control When Traveling • Rear Monitoring Display Selection Control • Travel Alarm Control • Engine Control

11991-3

11991-4

T4-2-12

Dr. ZX / Fault Code Symptoms in Machine Operation When Trouble Occurs. • Increasing travel speed is impossible by right travel operation. • A/I cannot be released by right travel operation. • Cut off override is impossible by right travel operation. • Boom mode selector control is impossible by right travel operation. • Pressure increase when traveling is impossible by right travel operation. • Rear monitoring display selection is impossible by right travel operation. • Travel alarm outputs. • Engine speed is lower than speed at E mode. • Increasing travel speed is impossible by right travel operation. • A/I cannot be released by right travel operation. • Cut off override is impossible by right travel operation. • Boom mode selector control is impossible by right travel operation. • Pressure increase when traveling is impossible by right travel operation. • Rear monitoring display selection is impossible by right travel operation. • Travel alarm outputs. • Engine speed is lower than speed at E mode.

Remedy for Dr. ZX

Remedy

Retry Diagnostic Procedure B

• Check Harness • Replace Right Travel Pilot Pressure Sensor

Retry Diagnostic Procedure B

• Check Harness • Replace Right Travel Pilot Pressure Sensor

T4-2-13

Dr. ZX / Fault Code Fault Code 11992-3

11992-4

Trouble

Cause

Influenced Control

Pump 2 Regulator Pressure Sensor Circuit High Input

Voltage: 4.75 V or higher

• Pump 2 Flow Rate Control • Pump 2 Regulator Pressure Learning

Pump 2 Regulator Pressure Sensor Circuit Low Input

Voltage: Less than 0.25 V

• Pump 2 Flow Rate Control • Pump 2 Regulator Pressure Learning

Left Travel Pilot Pressure Sensor Circuit High Input

Voltage: 4.75 V or higher

• Travel Speed Increase Control • Relief Flow Rate Reducing Control (Relief Cut Off) • Swing Horsepower Reducing Control • Pressure Increase Selection Control When Traveling • Rear Monitoring Display Selection Control • Travel Alarm Control • Engine Control

Left Travel Pilot Pressure Sensor Circuit Low Input

Voltage: Less than 0.25 V

• Travel Speed Increase Control • Relief Flow Rate Reducing Control (Relief Cut Off) • Swing Horsepower Reducing Control • Pressure Increase Selection Control When Traveling • Rear Monitoring Display Selection Control • Travel Alarm Control • Engine Control

11993-3

11993-4

T4-2-14

Dr. ZX / Fault Code Symptoms in Machine Operation When Trouble Occurs. • No secondary pressure feedback of pump 2 proportional solenoid valve (bad response) • Pump learning is impossible.

Remedy for Dr. ZX

Remedy

Retry Diagnostic Procedure B

• Check Harness • Replace Pump 2 Regulator Pressure Sensor

• No secondary pressure feedback of pump 2 proportional solenoid valve (bad response) • Pump learning is impossible.

Retry Diagnostic Procedure B

• Check Harness • Replace Pump 2 Regulator Pressure Sensor

• Increasing travel speed is impossible by left travel operation. • A/I cannot be released by left travel operation. • Cut off override is impossible by left travel operation. • Boom mode selector control is impossible by left travel operation. • Pressure increase when traveling is impossible by left travel operation. • Rear monitoring display selection is impossible by left travel operation. • Travel alarm outputs. • Engine speed is lower than speed at E mode. • Increasing travel speed is impossible by left travel operation. • A/I cannot be released by left travel operation. • Cut off override is impossible by left travel operation. • Boom mode selector control is impossible by left travel operation. • Pressure increase when traveling is impossible by left travel operation. • Rear monitoring display selection is impossible by left travel operation. • Travel alarm outputs. • Engine speed is lower than speed at E mode.

Retry Diagnostic Procedure B

• Check Harness

Retry Diagnostic Procedure B

• Check Harness

T4-2-15

Dr. ZX / Fault Code Fault Code 11994-3

11994-4

Trouble

Cause

Influenced Control

Pump 1 Regulator Pressure Sensor Circuit High Input

Voltage: 4.75 V or higher

• Pump 1 Flow Rate Control • Pump 1 Regulator Pressure Learning

Pump 1 Regulator Pressure Sensor Circuit Low Input

Voltage: Less than 0.25 V

• Pump 1 Flow Rate Control • Pump 1 Regulator Pressure Learning

Arm Roll-Out Pilot Pressure Sensor Circuit High Input

Voltage: 4.75 V or higher

• Boom Mode Selector Control • Boom Flow Rate Control Valve Control • Engine Control

Arm Roll-Out Pilot Pressure Sensor Circuit Low Input

Voltage: Less than 0.25 V

• Boom Mode Selector Control • Boom Flow Rate Control Valve Control • Engine Control

11995-3

11995-4

T4-2-16

Dr. ZX / Fault Code Symptoms in Machine Operation When Trouble Occurs. • No secondary pressure feedback of pump 1 proportional solenoid valve (bad response) • Pump learning is impossible.

Remedy for Dr. ZX

Remedy

Retry Diagnostic Procedure B

• Check Harness • Replace Pump 1 Regulator Pressure Sensor

• No secondary pressure feedback of pump 1 proportional solenoid valve (bad response) • Pump learning is impossible.

Retry Diagnostic Procedure B

• Check Harness • Replace Pump 1 Regulator Pressure Sensor

• A/I cannot be released by arm roll-out operation. • Flow rate of lever regulated pump control becomes maximum by arm roll-out operation. • Boom mode selector control is impossible by arm roll-out operation. • Boom flow rate control valve control is not operated. • Engine speed is lower than speed at E mode.

Retry Diagnostic Procedure B

• Check Harness • Replace Arm Roll-Out Pilot Pressure Sensor

• A/I cannot be released by arm roll-out operation. • Flow rate of lever regulated pump control becomes maximum by arm roll-out operation. • Boom mode selector control is impossible by arm roll-out operation. • Boom flow rate control valve control is not operated. • Engine speed is lower than speed at E mode.

Retry Diagnostic Procedure B

• Check Harness • Replace Arm Roll-Out Pilot Pressure Sensor

T4-2-17

Dr. ZX / Fault Code Fault Code 11997-3

Trouble

Cause

Influenced Control

Bucket Roll-Out Pilot Pressure Sensor Circuit High Input

Voltage: 4.75 V or higher

• Boom Mode Selector Control • Boom Flow Rate Control Valve Control • Engine Control

11997-4

Bucket Roll-Out Pilot Pressure Sensor Circuit Low Input

Voltage: Less than 0.25 V

• Boom Mode Selector Control • Boom Flow Rate Control Valve Control • Engine Control

11998-3

Boom Lowering Pilot Pressure Sensor Circuit High Input

Voltage: 4.75 V or higher

• Boom Mode Selector Control • Boom Flow Rate Control Valve Control • Engine Control

11998-4

Boom Lowering Pilot Pressure Sensor Circuit Low Input

Voltage: Less than 0.25 V

• Boom Mode Selector Control • Boom Flow Rate Control Valve Control • Engine Control

T4-2-18

Dr. ZX / Fault Code Symptoms in Machine Operation When Trouble Occurs. • A/I cannot be released by bucket roll-out operation. • Flow rate of lever regulated pump control becomes maximum by bucket roll-out operation. • Boom mode selector control is impossible by bucket roll-out operation. • Boom flow rate control valve control is not operated. • Engine speed is lower than speed at E mode.

Remedy for Dr. ZX

Remedy

Retry Diagnostic Procedure B

• Check Harness • Replace Bucket Roll-Out Pilot Pressure Sensor

• A/I cannot be released by bucket roll-out operation. • Flow rate of lever regulated pump control becomes maximum by bucket roll-out operation. • Boom mode selector control is impossible by bucket roll-out operation. • Boom flow rate control valve control is not operated. • Engine speed is lower than speed at E mode.

Retry Diagnostic Procedure B

• Check Harness • Replace Bucket Roll-Out Pilot Pressure Sensor

• Speed at HP mode does not increase by boom lower operation. • A/I cannot be released by boom lower operation. • Boom mode selector control is impossible by boom lower operation. • Boom flow rate control valve control is not operated. • Engine speed is lower than speed at E mode. • Speed at HP mode does not increase by boom lower operation. • A/I cannot be released by boom lower operation. • Boom mode selector control is impossible by boom lower operation. • Boom flow rate control valve control is not operated. • Engine speed is lower than speed at E mode.

Retry Diagnostic Procedure B

• Check Harness • Replace Boom Lower Pilot Pressure Sensor

Retry Diagnostic Procedure B

• Check Harness • Replace Boom Lower Pilot Pressure Sensor

T4-2-19

Dr. ZX / Fault Code Fault Code

Trouble

Cause

Influenced Control

11999-3

Bucket Roll-In Pilot Pressure Sensor Circuit High Input

Voltage: 4.75 V or higher

• Boom Mode Selector Control • Boom Flow Rate Control Valve Control • Engine Control

11999-4

Bucket Roll-In Pilot Pressure Sensor Circuit Low Input

Voltage: Less than 0.25 V

• Boom Mode Selector Control • Boom Flow Rate Control Valve Control • Engine Control

20062-0 (ZX850-3 class Only)

Hydraulic Oil Overheat Alarm

Hydraulic Oil Temperature: 100 °C or higher

• Overheat Prevention Control • Engine Control

T4-2-20

Dr. ZX / Fault Code Symptoms in Machine Operation When Trouble Occurs. • A/I cannot be released by bucket roll-in operation. • Flow rate of lever regulated pump control becomes maximum by bucket roll-in operation. • Boom mode selector control is impossible by bucket roll-in operation. • Boom flow rate control valve control is not operated. • Engine speed is lower than speed at E mode.

Remedy for Dr. ZX

Remedy

Retry Diagnostic Procedure B

• Check Harness • Replace Bucket Roll-In Pilot Pressure Sensor

• A/I cannot be released by bucket roll-in operation. • Flow rate of lever regulated pump control becomes maximum by bucket roll-in operation. • Boom mode selector control is impossible by bucket roll-in operation. • Boom flow rate control valve control is not operated. • Engine speed is lower than speed at E mode.

Retry Diagnostic Procedure B

• Check Harness • Replace Bucket Roll-In Pilot Pressure Sensor

• Alarm is displayed on the monitor unit • Pump driving torque decrease. • Max. pump flow rate decrease.

Retry Diagnostic Procedure B

• Check Harness • Check Oil Cooler

T4-2-21

Dr. ZX / Fault Code ECM Fault Code

Trouble

Cause

91-2

Accelerator Sensor 1-2 Comparison Fault

• Difference in opening angle between accelerator sensors 1-2 is 45 % or more.

100-3

Engine Oil Pressure Sensor Fault (Low Voltage: Less than 0.1 V Voltage Fault) Engine Oil Pressure Sensor Fault (High Voltage: More than 4.85 V Voltage Fault) Boost Pressure Sensor Fault (Low Volt- Voltage: Less than 0.1 V age Fault)

100-4 102-3

102-4

Boost Pressure Sensor Fault (High Voltage Fault)

105-3

Boost Temperature Sensor Fault (High Voltage: More than 4.94 V Voltage Fault) Boost Temperature Sensor Fault (Low Voltage: Less than 0.1 V Voltage Fault) Barometric Pressure Sensor Fault (Low Voltage: Less than 0.5 V Voltage Fault)

105-4 108-3

108-4

Voltage: More than 4.9 V

Barometric Pressure Sensor Fault (High Voltage: More than 3.8 V Voltage Fault)

T4-2-22

Dr. ZX / Fault Code

Presumptive Symptoms in Real Machine Operation

Assumptive Conditions at Back-up

Fault Code (Tech 2)

• 1 system fault: No back-up • 2 system fault: Accelerator opening angle is controlled to 0 %.

• 1 system fault: No back-up • 2 system fault: Accelerator opening angle is controlled to 0 %.

P1271

• Operationality is not affected.

• No back-up

P0522

• Operationality is not affected.

• No back-up

P0523

• Operationality is affected

• Boost pressure default setting (200 kPa) • Boost pressure correction/ EGR stopped

P0237

• Black smoke emission

• Boost pressure default setting (200 kPa) • Boost pressure correction/ EGR stopped

P0238

• Operationality is affected.

• No back-up

P1113

• Operationality is affected.

• No back-up

P1112

• Black smoke emitted at high altitude • Output shortage at low altitude

• Barometric pressure default setting 80 kPa (equivalent to altitude 2500 m)

P0107

• Black smoke emitted at high altitude • Output shortage at low altitude

• Barometric pressure default setting 80 kPa (equivalent to altitude 2500 m)

P0108

T4-2-23

Dr. ZX / Fault Code Fault Code

Trouble

Cause

110-3

Engine Coolant Temperature Fault (High Voltage Fault)

Sensor

Voltage: More than 4.85 V

110-4

Engine Coolant Temperature Fault (Low Voltage Fault)

Sensor

Voltage: Less than 0.1 V

157-0

Common Stage)

157-0

Common Rail Pressure Fault (Second Stage)

Common rail pressure fault (first stage) + rail pressure: More than 155 MPa or higher

157-2

Common Rail Pressure Fault (Excessive Pressure Feed in Pump)

Actual rail pressure higher than target rail pressure for 10 MPa or more holds 8 seconds or more. Or actual rail pressure higher than target rail pressure for 10 MPa or more holds 8 seconds or more, during indication of no pressure feed.

157-3

Common Rail Pressure Sensor Fault (High Voltage Fault)

Voltage: More than 4.5 V

157-3

Common Rail Pressure Sensor Fault (Low Voltage Fault)

Voltage: Less than 0.7 V.

Rail

Pressure

Fault

(First

Rail pressure: More than 150 MPa

T4-2-24

Dr. ZX / Fault Code Presumptive Symptoms in Real Machine Operation

Assumptive Conditions at Back-up

Fault Code (Tech 2)

• At normal temperature: Black • Coolant temperature default setting. (at starting: -20 °C, at running: 80 °C) smoke emission at starting, greater engine combustion noise are possible. • During idling at atmospheric temperature: Rough idling, engine stall, white smoke emission

P0118

• Start ability deteriorates at low temperature • Black smoke emission is possible • Output lowering depending on conditions • Intense engine vibration • Rough idling • Output lowering • Blow up fault • Black smoke emission • Excessive output

• Coolant temperature default setting. (at starting: -20 °C, at running: 80 °C)

P0117

• Limited injection amount 3 (Multi-injection stopped) • Target rail pressure: Upper limit (80 MPa)

P0088

• Intense engine vibration • Rough idling • Output lowering • Blow up fault • Black smoke emission • Excessive output

• Limited injection amount 3 (Multi-injection stopped) • Target rail pressure: Upper limit (80 MPa)

P0088

• Intense engine vibration • Rough idling • Output lowering • Blow up fault • Black smoke emission • Excessive output

• Limited injection amount 3 (Multi-injection stopped) • Target rail pressure: Upper limit (80 MPa)

P0089

• Output lowering • Black smoke emission • Engine stall is possible.

• Actual rail pressure default setting (80 MPa) • Rail pressure feedback control stopped • Limited injection amount 2 (Multi-injection stopped)

P0193

• Engine blow up

• Actual rail pressure default setting (80 MPa) • Rail pressure feedback control stopped • Limited injection amount 2 (Multi-injection stopped)

P0192

T4-2-25

Dr. ZX / Fault Code Fault Code

Trouble

Cause

172-3

Intake Air Temperature Sensor Fault Voltage: More than 4.95 V (High Voltage Fault)

172-4

Intake Air Temperature Sensor Fault (Low Voltage: Less than 0.1 V. Voltage Fault)

174-3

Fuel Temperature Sensor Fault (High Voltage Fault)

174-4

Fuel Temperature Sensor Fault (Low Voltage: Less than 0.1 V. Voltage Fault)

190-0

Overrun

Engine Speed: More than 1970 min

628-2

ROM Fault

633-7

Pressure Limiter Open

ROM is faulty. Re-flash failure Pressure limiter is opened.

636-2

Cam Angle Sensor Fault (No Signal)

The crank signal exists but no cam angle sensor signal.

636-2

Cam Angle Sensor Fault (Signal Fault)

Number of pulse for cam angle sensor signal is mismatched.

636-7

Cam Angle Sensor out of Phase

Correct cam angle sensor pulse does not exist in crank gap position.

Voltage: More than 4.85 V

-1

T4-2-26

Dr. ZX / Fault Code Presumptive Symptoms in Real Machine Operation

Assumptive Conditions at Back-up

Fault Code (Tech 2)

• White smoke emission is possible when starting at low temperature.

• Intake air temperature default setting (at starting: -10 °C, at running: 25 °C)

P0113

• White smoke emission is possible when starting at low temperature.

• Intake air temperature default setting (at starting: -10 °C, at running: 25 °C)

P0112

• Not in particular

• Fuel temperature default setting (at starting: -20 °C, at running: 70 °C)

P0183

• Operationality is affected.

• Fuel temperature default setting (at starting: -20 °C, at running: 70 °C)

P0182

• Output lowering

• Limited injection amount 1 (Limitation is lifted if the speed decreases.)

P0219

• Engine stopped

• Engine stopped

P0601

• Output lowering • Limited injection amount 1 • Hunting • Symptom does not change during • Engine running based on crank when crank is normal • After engine stops: Unable to identify cylinder (unable engine running. to restart) • After engine stalls, engine will not start.

P1095

• Symptom does not change during • Engine running based on crank when crank is normal • After engine stops: Unable to identify cylinder (unable engine running. to restart) • After engine stalls, engine will not start.

P0341

• Symptom does not change during • Engine running based on crank when crank is normal • After engine stops: Unable to identify cylinder (unable engine running. to restart) • After engine stalls, engine will not start.

P1345

T4-2-27

P0340

Dr. ZX / Fault Code Fault Code

Trouble

Cause

639-2

CAN Bus Fault

Bus-off is detected.

639-3

CAN Timeout Fault

CAN data reception does not complete at a set time.

651-3

Open Circuit in Injection Nozzle #1 Drive No injector 1 monitor input signal exists. System

652-3

Open Circuit in Injection Nozzle #2 Drive No injector 2 monitor input signal exists. System

653-3

Open Circuit in Injection Nozzle #3 Drive No injector 3 monitor input signal exists. System

654-3

Open Circuit in Injection Nozzle #4 Drive No injector 4 monitor input signal exists. System

655-3

Open Circuit in Injection Nozzle #5 Drive No injector 5 monitor input signal exists. System

656-3

Open Circuit in Injection Nozzle #6 Drive No injector 6 monitor input signal exists. System

723-2

Crank Revolution Sensor Fault (No Signal)

Cam angle sensor signal exists but no crank signal.

723-2

Crank Revolution Sensor Fault (Signal Fault)

Number of pulse for crank signal is mismatched.

987-3

Check Engine Lamp Fault

No check engine lamp monitor signal exists.

T4-2-28

Dr. ZX / Fault Code Presumptive Symptoms in Real Machine Operation

Assumptive Conditions at Back-up

Fault Code (Tech 2)

Vary depending on setting

Switched to drive control by accelerator sensor input voltage

U2104

Vary depending on setting

Switched to drive control by accelerator sensor input voltage

U2106

• Intense engine vibration • Rough idling • Output lowering • Blow up fault

• Injection for cylinder #5

P0201

• Intense engine vibration • Rough idling • Output lowering • Blow up fault

• Injection for cylinder #3

P0202

• Intense engine vibration • Rough idling • Output lowering • Blow up fault

• Injection for cylinder #6

P0203

• Intense engine vibration • Rough idling • Output lowering • Blow up fault

• Injection for cylinder #2

P0204

• Intense engine vibration • Rough idling • Output lowering • Blow up fault

• Injection for cylinder #4

P0205

• Intense engine vibration • Rough idling • Output lowering • Blow up fault

• Common 1 stop (#1, #2, #3 cylinders stopped)

P0206

• Output lowering • White smoke emission • Intense engine vibration is possible. • Engine stall is possible (restart is possible when G sensor is normal.)

• Control based on cam angle sensor when cam angle sensor is normal

P0335

• Output lowering • White smoke emission • Intense engine vibration is possible. • Engine stall is possible (restart is possible when G sensor is normal.)

• Control based on cam angle sensor when cam angle sensor is normal

P0336

• Operationality is not affected.

• No back-up

P0650

T4-2-29

Dr. ZX / Fault Code Fault Code

Trouble

Cause

1077-2

CPU Fault

Sub-CPU detects main CPU fault in 100 msec after key switch ON. (Sub-CPU resets CPU.)

1079-2

Voltage Fault in 5 V Power Supply 1

1080-2

Voltage Fault in 5 V Power Supply 2

5 V 1 power supply voltage: 5.5 V or more, 4.5 V or less 5 V 2 power supply voltage: 5.5 V or more, 4.5 V or less

1239-1

No Pump Pressure Feed (First Stage)

Actual rail pressure lower than target rail pressure for 10 MPa or more holds 8 seconds or more. Or pressure feed indication is limit +1 °C or less, and actual rail pressure lower than target rail pressure for 10 MPa or more holds 8 seconds or more.

1240-1

No Pump Pressure Feed (Second Stage)

Actual rail pressure lower than target rail pressure for 10 MPa or more holds 8 seconds or more, when judgment of “No pump pressure feed (first stage)” is completed. Or pressure feed indication is limit +1 °C or less, and actual rail pressure lower than target rail pressure for 10 MPa or more holds 8 seconds or more.

1347-0

PCV1 Open Circuit or Ground Short

PCV1 monitor signal is fixed to Low side.

1347-4

PCV1+B Short Circuit

PCV1 monitor signal is fixed to High side.

1348-0

PCV2 Open Circuit or Ground Short

PCV2 monitor signal is fixed to Low side.

1348-4

PCV2+B Short Circuit

PCV2 monitor signal is fixed to High side.

1485-2

Main Relay System Fault

10001-3 10002-2

Main relay voltage is 1 V or less. In spite of relay OFF command, relay is connected. EGR Position Sensor Fault (Brushless EGR position output signal is abnormal. Specification) EGR Valve Control Fault Difference between target valve lift and actual position is more than 20 %.

T4-2-30

Dr. ZX / Fault Code Presumptive Symptoms in Real Machine Operation

Assumptive Conditions at Back-up

Fault Code (Tech 2)

Output lowering

• Limited injection amount 2 (Multi-injection stopped) • Sub-CPU stops control.

P0606

Accelerator opening angle is controlled to 0 %. • Black smoke emitted at high altitude • Output lowest at low altitude

Same to accelerator sensor fault

P1631

• Same to barometric pressure and intake air temperature sensor fault

P1632

• Intense engine vibration • Rough idling • Output lowering • Blow up fault

• Limited injection amount 3 (Multi-injection stopped) • Target rail pressure upper limit (80 MPa)

P1094

• Intense engine vibration • Rough idling • Output lowering • Blow up fault • Black smoke emission • Engine stall

• Limited injection amount 3 (Multi-injection stopped) • Target rail pressure upper limit (80 MPa)

P1093

• Intense engine vibration • Rough idling • Output lowering • Blow up fault • Black smoke emission

• Limited injection amount 3 (Multi-injection stopped) • Target rail pressure upper limit (80 MPa)

P0091

• Intense engine vibration • Rough idling • Output lowering • Blow up fault • Black smoke emission

• PCV1 stop

P0092

• Intense engine vibration • Rough idling • Output lowering • Blow up fault • Black smoke emission

• Limited injection amount 3 (Multi-injection stopped) • Target rail pressure upper limit (80 MPa)

P1291

• Intense engine vibration • Rough idling • Output lowering • Blow up fault • Black smoke emission

• PCV2 stop

P1292

Engine does not start.

No back-up

P1625

• Operationality is not affected.

• Instruction to fully close EGR valve

P0487

• Operationality is not affected.

• Instruction to fully close EGR valve

P0488

T4-2-31

Dr. ZX / Fault Code Fault Code

Trouble

Cause

10003-2

Injection Nozzle Common 1 Drive System No injector 1, 2, 3 monitor input signal exists. Fault

10004-2

Injection Nozzle Common 2 Drive System No injector 4, 5, 6 monitor input signal exists. Fault

10005-1

Charge Circuit Fault (Bank 1)

When charge circuit bank 1 voltage inside ECM is low.

10006-1

Charge Circuit Fault (Bank 2)

When charge circuit bank 2 voltage inside ECM is low.

10007-2

CPU Monitoring IC Fault

10008-2

A/D Conversion Fault

RUN-SUB pulse does not change for 20 msec or more. A/D conversion failure

10009-2

Voltage Fault in 5 V Power Supply 3

5 V 3 power supply voltage: 5.5 V or more, 4.5 V or less

10010-2

Voltage Fault in 5 V Power Supply 4

10011-2

Voltage Fault in 5 V Power Supply 5

5 V 4 power supply voltage: 5.5 V or more, 4.5 V or less 5 V 5 power supply voltage: 5.5 V or more, 4.5 V or less

10013-2

EEPROM Fault

EEPROM is faulty.

T4-2-32

Dr. ZX / Fault Code Presumptive Symptoms in Real Machine Operation

Assumptive Conditions at Back-up

Fault Code (Tech 2)

• Intense engine vibration • Rough idling • Output lowering • Blow up fault • Engine stall is possible.

• Common 1 stop (#1, #2, #3 cylinders stopped)

P1261

• Intense engine vibration • Rough idling • Output lowering • Blow up fault • Engine stall is possible.

• Common 2 stop (#4, #5, #6 cylinders stopped)

P1262

• Intense engine vibration • Rough idling • Output lowering • Blow up fault • Engine stall is possible.

• Common 1 stop (#1, #2, #3 cylinders stopped)

P0611

• Intense engine vibration • Rough idling • Output lowering • Blow up fault • Engine stall is possible.

• Common 2 stop (#4, #5, #6 cylinders stopped)

P0612

• Output lowering

• Limited injection amount 1

P0606

• Output lowering • Black smoke emission

• Analog sensor system default processing • Limited injection amount 3 (Multi-injection stopped) • Target rail pressure upper limit (80 MPa)

P1630

• Deterioration of start ability • Black smoke emission is possible. • Operationality is affected.

• Same to oil pressure, coolant temperature, and combustion temperature sensor fault

P1633

• Operationality is affected.

• Same to boost pressure sensor fault

P1634

• Engine blow up • Output lowering • Black smoke emission • Engine stall is possible.

• Same to rail pressure sensor fault and EGR position sensor fault

P1635

• Operationality is not affected.

• No back-up

P0603

T4-2-33

Dr. ZX / Fault Code ICF Fault Code

Trouble

Cause

Remedy

14000-2

Abnormal CAN Data cannot be received due to the Check for CAN communication bus line. Communicanoise on the CAN bus line. tion

14001-2

Flash Memory: In case the internal memory is ab- After initializing the information C/U by using Read / Write normal when the key is turned ON Dr. ZX, retry in the troubleshooting. Error If the error code is displayed after retry, ICF may be broken. Replace ICF. NOTE: When initializing the information C/U, all stored data is deleted.

14002-2

External RAM: In case the internal memory is ab- After initializing the information C/U by using Read / Write normal when the key is turned ON Dr. ZX, retry in the troubleshooting. Error If the error code is displayed after retry, ICF may be broken. Replace ICF. NOTE: When initializing the information C/U, all stored data is deleted.

14003-2

EEPROM: In case the internal memory is ab- Retry in the troubleshooting by using Dr.ZX. Sum Check normal when the key is turned ON If the error code is displayed after retry, ICF Error may be broken. Replace ICF.

14006-2

In case communication to the satel- Check for the items below. Satellite lite terminal cannot be done over 30 1. Check if the communication line is abCommunicanormal. tion Terminal: seconds. 2. Check if the electrical power source of Communicacommunication terminal is abnormal. tion Error • Electrical power source • Fuses 3. Check if the satellite terminal is broken.

14008-2

Abnormal In- In case the internal memory is ab- Retry in the troubleshooting by using Dr.ZX. ternal RAM normal when the key is turned ON If the error code is displayed after retry, ICF may be broken. Replace ICF.

T4-2-34

Dr. ZX / Fault Code SATELLITE TERMINAL Fault Code

Trouble

Remedy

Cause

14100-2

Abnormal EEPROM

In case the internal memory is ab- Replace the controller. normal.

14101-2

Abnormal IB/OB Queue

In case the internal memory is ab- Replace the controller. normal.

14102-2

Abnormal Lo- In case the data cannot receive from Check the transmitting cal Loup Back the satellite, antenna of satellite.

and

receiving

14103-2

The satellite is In case the satellite is not found. not found.

and

receiving

14104-2

Fail 1 of Re- In case communication to the satel- Replace the controller. mote Loup lite terminal cannot be done. Back

14105-2

Fail 2 of Re- In case communication to the satel- Replace the controller. mote Loup lite terminal cannot be done, Back

14106-2

Sending and In case sending and receiving data Replace the controller. receiving data are unmatched. are mismatched.

T4-2-35

Check the transmitting antenna of satellite.

Dr. ZX / Fault Code MONITOR UNIT Fault Code

Trouble

Remedy

Cause

Thermistor temperature is 85 °C Cool the monitor unit and so on until (185 °F) or higher. temperature inside the monitor unit is less than 85 °C (185 °F).

13303-2

Abnormal Thermistor Temperature

13304-2

Abnormal REG During REG input H level Input H Level

13306-2

Abnormal EEPROM

13308-2

Abnormal CAN Bus off occurs beyond five times. Communication

13310-2

Shorted circuit The state, input 105±30 Ω or less, is Check coolant temperature sensor and in Coolant kept over 60 seconds. harness. Temperature Sensor

13311-2

Shorted circuit The state, input 3±1 Ω or less, is Check fuel level sensor and harness. in Fuel Level kept over 60 seconds. Sensor

13311-4

Open circuit in The state, input 135±20 Ω or less, is Check fuel level sensor and harness. Fuel Level kept over 60 seconds. Sensor

(Refer to the Troubleshooting flow chart.)

When failure reading EEPROM oc- If this fault code is displayed after retarial, curs replace the monitor unit.

T4-2-36

Refer to “CAN Harness Check”.

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