Hitachi Ex-150lc-5, Ex160lc-6 PDF

SECTION 1
GENERAL
—CONTENTS—
Group 1 Specification
Specifications .......................................... T1-1-1
Working Ranges and Machine
Dimensions for Transportation ............... T1-1-2
Component Specification ......................... T1-1-3
Group 2 Component Layout

Main Components.................................... T1-2-1
Electrical System (Overall System) .......... T1-2-2
Electrical System (Relays) ....................... T1-2-3
Electrical System
(Monitor and Switch Panels) ................... T1-2-4
Pump and Related Parts .......................... T1-2-5
Other Components .................................. T1-2-6
165T-1-1
(Blank)
165T-1-2
GENERAL / Specifications
SPECIFICATIONS
Model EX150LC-5 Hydraulic Excavator

Type of Front-End Attachment 2.58 m (8 ft 6 in) Standard Arm
3 3 3 3 3
Bucket Capacity (Heaped) m (yd ) PCSA 0.60 m (0.78 yd ), CECE 0.55 m
Operating Weight kg (Ib) 15000 (33100)
Basic Machine Weight kg (Ib) 11800 (26000)
-1
Engine ISUZU A 4BG1T, 74kW (100 PS)/2150 min (rpm)
! 76 kW (104 PS)/2300 min (rpm)
-1
A: Overall Width (Excluding Back Mirrors) mm (ft"in) 2500 (8’2”)

B: Cab Height mm (ft"in) 2800 (9’2”)
C: Rear End Swing Radius mm (ft"in) 2440 (8’0”)
D: Minimum Ground Clearance mm (ft"in) !! 460 (1’8”) (Excluding shoe lug)
E: Counterweight Clearance mm (ft"in) !! 920 (3’0”) (Excluding shoe lug)
F: Engine Cover Height mm (ft"in) 2000 (6’7”)
G: Overall Width of Upperstructure mm (ft"in) 2460 (8’1”)
H: Undercarriage Length mm (ft"in) 3920 (12’10”)
I : Undercarriage Width mm (ft"in) 2490 (8’2”)
J : Sprocket Center to Idle Center mm (ft"in) 3100 (10’2”)
K: Track Shoe Width mm (ft"in) 500 (20”)
(Grouser Shoe)
2
Ground Pressure kPa (kgf/cm ) (psi) 52 (0.53) (7.5)
-1
Swing Speed min (rpm) 13.2 (13.2)
Travel Speed (fast/slow) km/h 5.3/3.1
(mph) (3.3/1.9)
Gradeability degree (%) 35 (70)
A
G
C
E
D
K K J
I H
M165-11-001
NOTE: ! H/P mode

!! The dimensions do not include the
height of the shoe lug.
T1-1-1
WORKING RANGES AND MACHINE
DIMENSIONS FOR TRANSPORTATION
M165-11-002
M165-11-003
Backhoe Face shovel (Reversed hoe bucket)
Working Range
2.58 m (8’6”) Arm 3.10 m (10’2”) Arm

)”A7’ Shovel 2 Backhoe Shovel Backhoe Shovel
A: Maximum Digging Reach mm 8360 B 8460 8900 8990 9360 9460
(ft"in) (27’5”) (27’9”) (29’2”) (29’6”) (30’9”) (31’0”)
B: Maximum Digging Depth mm 5480 5580 6050 6150 6550 6650
(ft"in) (18’0”) (18’4”) (19’10”) (20’2”) (21’6”) (21’10”)
C: Maximum Cutting Height mm 8480 8780 8820 9070 9060 9310
(ft"in) (27’10”) (28’10”) (28’11”) (29’9”) (29’9”) (30’7”)
D: Maximum Dumping Height mm 5810 5710 6100 6030 6340 6270
(ft"in) (19’1”) (18’9”) (20’0”) (19’9”) (20’10”) (20’7”)
E: Transport Height mm !3020 !3020 !2800 !2800 !3040 !3040
(ft"in) !(9’11”) !(9’11”) !(9’2”) !(9’2”) !(10’0”) !(10’0”)
F: Overall Transport Length mm 8620 8620 8540 8540 8550 8550
(ft"in) (28’3”) (28’3”) (28’0”) (28’0”) (28’1”) (28’1”)
G: Minimum Swing Radius mm 3250 3250 2910 2910 2920 2920
(ft"in) (10’8”) (10’8”) (9’7”) (9’7”) (9’7”) (9’7”)
NOTE: ! The dimensions do include the height of

the shoe lug.
T1-1-2
COMPONENT SPECIFICATIONS
ENGINE
MAIN SPECIFICATIONS
Manufacturer ....................................................ISUZU
Model ................................................................A-4BG1T
Type ..................................................................Diesel, 4 cycle, vertical, 4-cylinder inline, water-cooled,
direct injection type
Cyl. No.-bore # stroke.......................................4-105 mm#12 mm (4.13 in#4.92 in)
3 3
Piston displacement .........................................4329 cm (264 in )
-1
Rated output .....................................................73.6 kW/2150 min (100 PS/2150 rpm)
-1
HP Mode: 76.5 kW/2300 min (104 PS/2300 rpm)
Compression ratio ............................................17.0
Dry weight.........................................................360 kg (796 lb)
Firing order .......................................................1-3-4-2
Rotation direction..............................................Clockwise (view from fan side)
COOLING SYSTEM
Cooling fan .......................................................Dia. 540 mm, 8 blades, draw-in type
Fan pulley ratio .................................................Engine rpm#0.89
Thermostat .......................................................Cracking temp. : 82 $C (180 $F)
(under atmospheric pressure) .........................Full open (Stroke: 10 mm or larger) temp. : 95 $C (203 $F)
Water pump ......................................................Centrifugal type, belt driven
LUBRICATION SYSTEM
Lubrication pump type ......................................Gear pump
Oil filter .............................................................Full-flow paper element type with bypass function
Oil cooler ..........................................................Water-cooled, built-in
STARTING SYSTEM
Motor ................................................................Magnetic pinion shift system, reduction type
(with starter relay)
Voltage"Output ..................................................24 V " 4.5 kW
PRE-HEAT SYSTEM
Heating method ................................................Glow plug
ENGINE STOP SYSTEM

Stop method .....................................................Fuel cut
ALTERNATOR
Type ..................................................................AC type (with regulator)
Voltage " Output ................................................24 V " 40 A (Brush-less type)
SUPERCHARGING SYSTEM
Type ..................................................................Exhaust-gas-turbo type TD04H
FUEL SYSTEM
Injection pump model .......................................Bosch A type
Governor...........................................................Centrifugal all speed control RSV
Injection nozzle ................................................Multihole nozzle
T1-1-3
PERFORMANCE
Lubrication oil consumption ..............................Less than 50 mL/h (New engine, at rated horsepower)
-1
Fuel consumption ratio .....................................Less than 241 g/kW"h (177 g/PS"h) @73.6 kW/2150 min
-1
Less than 243 g/kW"h (179 g/PS"h) @76.5 kW/2300 min
Injection timing..................................................12$ before T.D.C.
-1
Max. output torque............................................353 N"m (36 kg"m, 260 lbf"ft) or more at 1600 min
2
Injection pressure .............................................18.1 MPa (185 kgf/cm , 2631 psi)
2
Cylinder compression .......................................3.04 Mpa (31 kgf/cm , 441 psi)
Valve clearance (inlet/exhaust).........................0.4/0.4 mm (when cool)
+50 -1
No load speed ..................................................Min. : 950 -0 min
-1
Max. : 2375%50 min
-1
HP Mode: Max. : 2525%25 min
T1-1-4
Engine Performance Curve (A-4BG1T)
Test Conditions: 1. In conformity with JIS D1005

(Performance test method for
diesel engines used for
construction machinery), under
standard atmospheric pressure.
2. With fan and generator.
Torque
Horse
Power
Fuel
Consumption
Rate
-1 T165-01-01-004
Engine Speed min (rpm)
T1-1-5
ENGINE ACCESSORIES
RADIATOR ASSEMBLY
Type ..................................................................Radiator/Oil cooler tandem type assembly
Weight ..............................................................67 kg (148 lb)
Radiator Oil cooler

Capacity............................................................5.8 L (1.5 US gal) 4.4 L (1.2 US gal)
Air-tight testing pressure...................................88.3 kPa 981 kPa
2 2
(0.9 kgf/cm , 13 psi) (10 kgf/cm , 142 psi)
Cap opening pressure ......................................49 kPa &
2
(0.5 kgf/cm , 7 psi)
BATTERY
Capacity............................................................55 Ah (5 hours)
Voltage..............................................................12 V
Weight ..............................................................19 kg (42 lb)#2
HYDRAULIC DEVICES
MAIN PUMP
Model ................................................................A8V59
Type ..................................................................Variable displacement plunger pump: regulator attached type
Max. flow (Theoritical value).............................126 L/min (33.2 US gpm)#2
PILOT PUMP
Model ................................................................G2-C5Z10NR-10
Type ..................................................................Fixed displacement type gear pump
Max. flow (Theoritical value).............................23.0 L/min (6.07 US gpm)
HP Mode: 24.6 L/min (6.50 US gpm)
CONTROL VALVE
Model ................................................................MVX20
Type ..................................................................Pilot pressure operated type (4-spool+5-spool)
2
Main relief pressure ..........................................34.3 MPa (350 kgf/cm , 4977 psi)
@80 L/min (21 US gpm)
2
Overload relief pressure ..................................37.3 MPa (380 kgf/cm , 5404 psi)
@50 L/min (13.2 US gpm )
(Boom raise/lower, Arm roll-in, Bucket roll-in)
2
39.2 MPa (400 kgf/cm , 5688 psi)
@50 L/min (13 US gpm)
(Arm roll-out, Bucket roll-out)
SWING DEVICE
Type ..................................................................Two-stage planetary reduction type
SWING MOTOR
Model ................................................................M2X146B
Type ..................................................................Swash-plate type, fixed-displacement plunger motor
T1-1-6
SWING BRAKE VALVE
Type .............................................................Non counter balance valve type
2
Relief pressure ............................................31.9 MPa (325 kgf/cm , 4620 psi)
@90 L/min (23.7 US gpm)
SWING PARKING BRAKE

Type .............................................................Multiple-wet-plate negative type
2
Cracking pressure for release .....................2.64 MPa (27 kgf/cm , 384 psi)
TRAVEL DEVICE
Type .............................................................Two-stage planetary reduction gear
TRAVEL MOTOR
Model ...........................................................MSF-85VP
Type .............................................................Swash-plate type, variable displacement plunger motor
TRAVEL BRAKE VALVE

Type .............................................................Counter balance valve type
2
Relief pressure ............................................35.3 MPa (360 kgf/cm , 5120 psi)
TRAVEL PARKING BRAKE

Type .............................................................Multiple-wet-plate negative type
2
Cracking pressure for release .....................1.37 MPa (14 kgf/cm , 199 psi)
CYLINDER
Arm Bucket Bucket
Rod Dia........................................................80 mm (3.15”) 85 mm (3.35”) 75 mm (2.95”)
Cylinder Bore ...............................................110 mm (4.33”) 115 mm (4.52”) 110 mm (4.33”)
Stroke ..........................................................1100 mm (3’8”) 1365 mm (4’6”) 935 mm (3’1”)
Fully retracted length ...................................1650 mm (5’5”) 1905 mm (6’3”) 1460 mm (4’9”)
Plating thickness..........................................30 'm (1.18 'in) 30 'm (1.18 'in) 30 'm (1.18 'in)
or more or more or more
FRONT ATTACHMENT PILOT VALVE

Model ...........................................................HVP04S-040-101
TRAVEL PILOT VALVE

Model ...........................................................HVP05D-040-101
SOLENOID VALVE UNIT

Functions ....................................................."SC : Arm regenerative control
"SE : Speed sensing control
"SI : Travel motor swash angle control
OIL COOLER BYPASS CHECK VALVE

2
Cracking pressure .......................................392 kPa (4 kgf/cm , 57 psi) at 5 L/min (1.3 US gpm)
T1-1-7
ELECTRICAL EQUIPMENT
BATTERY RELAY
Voltage"Current............................................24 V " 100 A
GLOW RELAY
Voltage.........................................................24 V
HORN
Specifications ..............................................24 V " 1.5 A, 113 dB (A)
LIGHT
Specifications ..............................................Work lights : halogen 24 V " 70 W " 60 W
Dome light : 24 V " 10 W
AIR CONDITIONER
Refrigerant...................................................134a
Cooler capacity............................................19.3 MJ/h (4600 kcal/h)
3 3
Cooler air flow..............................................550 m /h (720 yd /h) or more
Heater capacity............................................19.8 MJ/h (4725 kcal/h) or more
Temperature control ....................................Electronic control
T1-1-8
GENERAL / Component Layout
MAIN COMPONENTS
4
5
6
7
8
9
10
19
18
11
17 12
13
14
16
15 T165-01-01-001
1- Bucket Cylinder 6- Swing Device 11 - Engine 16 - Shockless Valve

2- Arm Cylinder 7- Fuel Tank 12 - Radiator 17 - Pilot Shut-Off Valve
3- Boom Cylinder 8- Hydraulic Oil Tank 13 - Oil Cooler 18 - Travel Pilot Valve
4- Center Joint 9- Control Valve 14 - Battery 19 - Front/Swing Pilot Valve
5- Swing Bearing 10 - Pump Device 15 - Travel Device
T1-2-1
ELECTRICAL SYSTEM
(Overall System)
1 2 3
7
28
8
27 9
26 10
25
11, 12
24
23 13
22
At the
21 20 19 18 17 16 bottom of 15 14 T165-01-01-002
the pump
device
1- Wiper Motor 8- Hydraulic Oil Level Switch 15 - N Sensor 22 - Coolant Level Switch
2- Monitor Panel 9- Pressure Switch (Travel) 16 - Engine Oil Pressure Switch 23 - Battery
3- Relays 10 - Solenoid Valve Unit 17 - Engine Oil Level Switch 24 - Air Restriction Switch
4- Work Light 11 - EC Sensor 18 - Alternator 25 - Windshield Washer Tank
5- Fuel Sensor 12 - EC Motor 19 - Overheat Switch 26 - Pressure Switch and
Sensor
6 - Low Fuel Level Switch 13 - PC Pressure Sensor 20 - Coolant Temperature 27 - MC (Main Controller)
Sensor
7 - Pressure Switch (Front) 14 - Pump Delivery Pressure 21 - Battery Relay 28 - Fuse Box
Sensor
T1-2-2
ELECTRICAL SYSTEM (Relays)
1
2
3
4
5
6
7
8
9
13
14
10
11 16 15 T155-01-01-007
12
T157-01-01-007
1- Wiper Relay (R14) 5- Horn Relay (R5) 9- Load Dump Relay (R1) 13 - Fusible Link
2- Wiper Relay (R8) 6- Work Light Relay (R4) 10 - Air Conditioner Relay (R10) 14 - Battery Relay
3- Wiper Relay (R7) 7- Work Light Relay (R3) 11 - Air Conditioner Relay (R11) 15 - Fusible Link
4- Wiper Relay (R6) 8- Windshield Washer Relay 12 - Air Conditioner Relay (R11) 16 - Glow Plug Relay
(R2)
T1-2-3
ELECTRICAL SYSTEM
(Monitor and Switch Panels)
9
23 10
11
1 12
22
13
21
20 14
2 19 15
18 16
17
T157-07-02-001
4
24
3 5
6
7 31
25
26
30
27
29
T157-01-01-009 28 T157-01-01-018
1 - Monitor Panel 9 - Warm Up Complete 17 - Overheat Indicator 25 - Wiper Switch

Indicator
2 - Switch Panel 10 - Fuel Gauge 18 - Alternator Indicator 26 - Travel Mode Switch
3 - Key Switch 11 - E Mode Indicator 19 - Engine Oil Pressure 27 - Work Mode Select Switch
Indicator
4 - Cigar Lighter 12 - Auto-Idle Indicator 20 - Engine Oil Level Indicator 28 - Buzzer Stop Switch
5 - HP Mode Switch 13 - Hydraulic Oil Level 21 - Coolant Level Indicator 29 - Auto-Idle Switch
Indicator
6 - E Mode Switch 14 - Preheat Indicator 22 - HP Mode Indicator 30 - Washer Switch
7 - Engine Control Dial 15 - Air Filter Restriction 23 - Coolant Temperature 31 - Level Check Switch
Indicator Gauge
8 - Air Conditioner Panel 16 - Fuel Level Indicator 24 - Work Light Switch
T1-2-4
PUMP AND RELATED PARTS
1 2 3 4 5 6 7
10
T165-01-01-003
13 12 11
1 - Pump Delivery Pressure 5 - Pump Delivery Pressure 8 - EC Motor 11 - Pump 1

Sensor (Pump 2) Sensor (Pump 1)
2 - Regulator (Pump 2) 6 - PC Pressure Sensor 9 - Pilot Relief Valve 12 - PC Pressure Sensor
(Pump 1) (Pump 2)
3 - Pilot Pump 7 - EC Sensor 10 - Pilot Filter 13 - Pump 2
4 - Regulator (Pump 1)
T1-2-5
OTHER COMPONENTS
Swing Device 1 Shockless Valve

4
5
9
6
7
8 T157-07-03-018
T157-01-01-011
Travel Device Solenoid Valve Unit
Front
2 10
3 11
T155-01-01-013 12
W155-02-11-003
1 - Swing Relief Valve 4 - Shockless Valve 7 - Shockless Valve 10 - Solenoid Valve Unit (SC)
2 - Counterbalance Valve 5 - Pressure Switch 8 - Check Valve 11 - Solenoid Valve Unit (SE)
(Boom Raise)
3 - Travel Relief Valve 6 - Check Valve 9 - Pressure Sensor 12 - Solenoid Valve Unit (SI)
(Arm Roll-In)
T1-2-6
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SYSTEM / Electrical System
OUTLINE
The electrical system is classified into the main circuit,

control circuit, and monitor circuit.
!" Main circuit operates the engine and accessories.
!" Control circuit functions to control operations of the

engine, hydraulic pump, and valves (including
actuators such as solenoid valves, MC (Main
Controller), switch box, sensors, and pressure
switches).
!" Monitor circuit operates the monitor devices

consisting of the monitors, sensors, and switches.
In this group, the functions and construction of the main

circuit are introduced.
!" Electric Power Circuit:

Supplies electric power to all electric system on this
machine.
(Key Switch, Batteries, Fuses (Fuse Box and Fusible
Links), Battery Relay)
!" Bulb Check Circuit:

" Checks for blown indicator bulbs.
" (Key Switch, Battery Relay, Fuses, Monitor)
"
!" Preheat Circuit:
Helps start the engine in cold weather.
(Key Switch, Glow Plug Relay, Glow Plug)
!" Starting Circuit:

Starts the engine.
(Key Switch, Starter, Starter Relay)
!" Charging Circuit:

Recharges batteries and supplies consumption
electricity.
(Alternator, (Regulator) )
!" Surge Voltage Prevention Circuit:

Prevents surge voltage from occurring when the
engine is suddenly stopped.
(Load Dump Relay)
!" Accessory Circuit:

Works with the key switch placed in the ACC
position.
(Key Switch, Battery, Fuses)
!" Engine Stop Circuit:

Stops the engine with the EC motor.
(MC, EC Motor)
T2-3-1
ELECTRIC POWER CIRCUIT
(KEY SWITCH: OFF)
The battery negative terminal is grounded to the vehicle.

Current from the positive terminal flows as follows with
the key switch OFF.
# Glow Plug Relay (Power Source)

Battery # Fusible Link # Key Switch B Terminal No.1 # Backup Power Source
# Load Dump Relay Terminal No.2 # MC (Power Source)
# Fuse Box Terminal No.3 # MC (EC Motor)
Terminal No.9 # Optional
Terminal No.14 # Air Conditioner
Key Switch
Fusible Link
Batteries
Load Dump
Relay
Battery
Relay
Fuse Box
To Monitor
Air Conditioner
Glow Plug Relay Fuse Box
Optional
MC (EC Motor)
MC (Power Source)
Backup Power Source
T157-04-02-001
T2-3-2
BULB CHECK CIRCUIT
(KEY SWITCH: ON)
When the key switch is turned to the ON position, key At the same time, the battery power via the fuse box is
switch terminal B connects with key switch terminals M supplied as power source to the work lights, wiper,
and ACC. heater, MC (solenoid valve power source), and optional
The current from terminal M excites the battery relay. circuits.
Then, the battery power is routed to the monitor through
the battery relay and the fuse box, turning the indicators
on (for bulb check)
Key Switch
Batteries
Battery
Relay
Fuse Box
Heater
Wiper
Work Light
Fuse Box
Optional
Optional
MC
(Solenoid Valve
Power Source)
Monitor
T157-04-02-010
T2-3-3
PREHEAT CIRCUIT
(KEY SWITCH: HEAT)
When the key switch is turned to the Preheat position, Current from the batteries flows to the glow plugs via
the key switch terminal B is connected to terminal G1 in the glow plug relay. Approx. 20 seconds passes after
the switch. After flowing through the fuse box, the preheat is started, the monitor timer turns the preheat
current from terminal G1 magnetizes the glow plug indicator OFF, informing that engine preheating has
relays, operates the monitor, and lights the preheat been completed.
indicator.
Key Switch
Batteries
Battery
Relay
Fuse Box
Glow Plug Relay
Glow Plugs
Monitor
T157-04-02-002
T2-3-4
(Blank)
T2-3-5
STARTING CIRCUIT
(KEY SWITCH: START)
When the key switch is turned to the START position, Starter Relay Operation
terminal B on the key switch is connected to terminals
G2, M, and ST in the switch. The current from terminal • When the key switch is turned to the START
M magnetizes the battery relay, leading the battery position, key switch terminal B and terminal ST
current to terminals B on the starter and starter relay via have continuity in the key switch. Then, the current
the battery relay. flows to the base of transistor (Q2) via resistance
Terminal ST of the key switch is connected to terminal R4 in the starter relay, switching transistor (Q2) ON.
S on the starter relay so that the battery current flows Thereby, the current flows through coil (L), closing
through the coil in the starter relay, allowing the relay to the circuit between starter terminals B and C. Then,
close the circuit. Then, the battery current can flow to the starter begins to rotate.
terminal C on the starter, closing the inner starter relay. • Once the engine is started, the alternator begins to
Thereby, the starter begins to rotate. charge the batteries so that the voltage at starter
Terminal G2 has continuity with terminal G1 by wiring. relay terminal R rises. When the voltage at
Therefore, the battery current flows to the preheat terminal R reaches 21 to 22 V, zener diode (Z)
circuit when the key switch is positioned at START, becomes ON. Accordingly, transistor (Q1) is
leading the current to the glow plugs. switched ON so that the base current to transistor
The current from terminal M flows to the MC, instructing (Q2) is cut, switching transistor (Q2) OFF. At this
that the key switch is positioned at ON or START. When time, continuity between starter terminal B and C is
this signal arrives at the MC, the MC actuates the EC opened. Then, the starter is switched OFF.
motor which moves the governor lever.
Capacitor C1 shown in the figure is used to stabilize
the operating voltage. Diode D4 protects the circuit
from damage when the batteries are inversely
connected.
Starter Relay
S B
D3
(1)
R4 L
C
R3 (2) (1)
C
R2 Z D2
To Alternator R Q2 M B
Terminal L Q1
(2)
C1 C
Starter
E
D4
12V
B
ST Batteries
Key Switch 12V
T107-04-04-003
T2-3-6
Key Switch
Batteries
Battery MC (Key Switch ON Signal)

Relay
Starter
Starter Relay
T157-04-02-003
T2-3-7
CHARGING CIRCUIT (KEY SWITCH: ON)
After the engine starts and the key switch is released, In addition, this current is supplied through the fuse box
the key switch is returned to the ON position. With the as a power source to the solenoid valve, switch box,
key switch kept ON, key switch terminal B is connected hour meter, work lights, wiper, and heater. Current from
to terminals ACC and M. terminal L flows to the monitor to turn off the alternator
After the engine starts, the alternator begins to indicator.
recharge the batteries. Current from terminal B on the
alternator flows to the batteries through the battery
relay recharging the batteries.
Key Switch
Batteries
To Fuse Box
Battery To Fuse Box
Relay
Alternator
Monitor
T157-04-02-011
T2-3-8
Power Generation
The alternator consists of field coil FC, stator coil SC, When the key switch is turned ON, the battery voltage
and diodes D. is applied to base B for transistor T1 in the regulator,
The regulator consists of transistors T1 and T2, allowing current to flow from collector C to emitter E.
zener diode ZD, and resistors R1 and R2. Accordingly, field coil FC is grounded through transistor
T1. Then, when the rotor starts to rotate, alternating
Alternator terminal B is connected to: voltage is generated in stator coil SC due to residual
magnetism in the rotor.
(R)#R1#Base B for Transistor T1 Thereby, the current starts to flow through field coil FC,
B#R#RF magnetizing the rotor further and increasing generating
FC#(F)#Collector C for Transistor T1 voltage.
As generating voltage increases, the flowing current
through field coil FC is increased further, causing the
generating voltage to increase more. Thus, the
batteries are recharged.
Alternator Regulator
B R L
RF
(R) R3 R4 R5
BS
R6
D
ZD
R2
Batteries SC B
E
R1
C
T2
FC B
D1 E
T1
(F)
(E)
E
T157-04-02-008
T2-3-9
Regulator Operation
When the generating voltage increases higher than Then, when the voltage to be applied to zener diode ZD
the set voltage of zener diode ZD, the current from becomes lower than the set voltage of zener diode ZD,
the alternator flows through the zener diode to base B transistor T2 is turned OFF, turning transistor T1 ON
for transistor T2, connecting collector C to emitter E. again. Thus, the current is allowed to flow through field
Accordingly, the current flowing through base B for coil FC to increase the generating voltage by stator coil
transistor T1 is cut so that transistor T1 is turned OFF. SC. As this operation is repeated, the alternator
Thereby, the current flowing through field coil FC is generating voltage is maintained at the specified level.
cut, causing the SC generating voltage to decrease.
RF
R3 R4 R5
BS
R6
ZD
R2
Batteries B
SC
A
E
C
T2
FC B
R1
C E
D1 T1
(F)
(E)
E
T157-04-02-009
T2-3-10
SURGE VOLTAGE PREVENTION CIRCUIT
The surge voltage prevention circuit protects the Thereby, the battery current is supplied to the
electrical parts and components in the controller from magnetizing circuit for the load dump relay to close the
being damaged by the alternator generating surge load dump relay. Accordingly, even if the key switch is
current developed when the engine is suddenly turned OFF while the engine is running, the battery
stopped. current can be supplied through the load dump relay to
While the batteries are being recharged, the generating magnetize the battery relay, holding the battery relay
current from terminal L on the alternator is led to ON until the alternator stops generating.
terminal 42 on the monitor, turning the transistor ON for
terminal 18 on the monitor.
Key Switch
Batteries
Battery
Relay
Load Dump Relay
Alternator
Monitor
Regulator
T157-04-02-005
T2-3-11
ACCESSORY CIRCUIT
(KEY SWITCH: ACC)
When the key switch is turned to the ACC position,

terminal ACC is connected to terminal B in the key
switch.
Then, the battery current flows through the fuse box to
each accessory circuit such as the horn, radio, cigar
lighter, dome light, and to the auxiliary circuit to operate
them.
Key Switch
Batteries
Battery
Relay
Auxiliary
Cab Light
Cigar Lighter
Radio
Horn
T157-04-02-006
T2-3-12
ENGINE STOP CIRCUIT
(KEY SWITCH: OFF)
When the key switch is turned from the ON position to

the OFF position, the signal instructing the MC that the
key switch is ON is cut.
Then, the MC moves the EC motor to the stop position,
causing the engine to stop.
Key Switch
Batteries
Battery
Relay
MC
EC Motor
T157-04-02-007
T2-3-13
(Blank)
T2-3-14
SECTION 3
COMPONENT OPERATION
—CONTENTS—
Group 1 Pump Device Group 4 Pilot Valve
Outline..................................................... T3-1-1 Outline ..................................................... T3-4-1
Main Pump .............................................. T3-1-2 Operation................................................. T3-4-2
Regulator................................................. T3-1-5
Pilot Pump ............................................. T3-1-13 Group 5 Travel Device
N Sensor (Engine Speed Sensor) .......... T3-1-13 Outline ..................................................... T3-5-1
Pump Delivery Pressure Sensor ............ T3-1-13 Travel Reduction Gear ............................. T3-5-2
Travel Motor ............................................ T3-5-3
Group 2 Swing Device Travel Brake Valve................................... T3-5-8
Outline..................................................... T3-2-1 Parking Brake ........................................ T3-5-10
Swing Motor ............................................ T3-2-2
Valve Unit ................................................ T3-2-4 Group 6 Others (Upperstructure)
Swing Parking Brake ............................... T3-2-6 Pilot Shut-Off Valve.................................. T3-6-1
Swing Reduction Gear ............................. T3-2-7 Shockless Valve....................................... T3-6-2
Solenoid Valve Unit.................................. T3-6-4
Group 3 Control Valve Pilot Relief Valve...................................... T3-6-6
Outline..................................................... T3-3-1 EC Motor ................................................. T3-6-6
Hydraulic Circuit ...................................... T3-3-6
Flow Combiner Valve ............................... T3-3-8 Group 7 Others (Undercarriage)
Pump Control Valve ................................. T3-3-9 Swing Bearing.......................................... T3-7-1
Main Relief Valve ....................................T3-3-11 Center Joint ............................................. T3-7-2
Overload Relief Valve Track Adjuster ......................................... T3-7-3
(With Make-Up Function) .......................T3-3-11
Arm Regenerative Valve ........................ T3-3-12
Boom Anti-Drift Valve,
Arm Anti-Drift Valve .............................. T3-3-14
Bucket Flow Control Valve ..................... T3-3-14
Travel Flow Control Valve ...................... T3-3-16
Travel / Boom Lower
Selector Valve....................................... T3-3-16
Boom Regenerative Valve...................... T3-3-18
165T-3-1
(Blank)
165T-3-2
COMPONENT OPERATION / Pump Device
OUTLINE
The pump device consists of two main pumps and a

pilot pump.
Main pumps (1 and 2) are variable displacement,
bent-axis axial plunger type which are incorporated into
a single housing.
Pilot pump (3) is a gear-type pump.
Pump delivery pressure sensor (5) and N sensor (4) are
provided for controlling pumps and valves.
2
1
3 4 T165-03-01-001
T165-03-01-002
1 - Pump 1 3 - Pilot Pump 4 - N Sensor 5 - Delivery Pressure Sensor

2 - Pump 2
T3-1-1
MAIN PUMP
The main pump 1 and 2 supply pressurized hydraulic oil Because rotational force of pump 2 drive disc (1) is also
to actuate hydraulic components such as cylinders and transmitted to pump 1 drive disc (2) via gear parts (6),
motors. disc drive (2) rotates as disc drive (1) rotates,
Rotational force from the engine is transmitted to pump discharging hydraulic oil.
2 drive disc (1). Because drive disc (1) is connected to Each main pump is equipped with pump flow control
cylinder block (5) by seven plungers (4), cylinder block regulator (7).
(5) rotates as drive disc (1) rotates, reciprocating
plungers (4) in and out of cylinder block (5) to draw and
discharge hydraulic oil.
4 7
2
6
T165-03-01-012
1 4 5
5
T165-03-01-011
1 - Drive Disc (Pump 2) 4 - Plunger 6 - Gear Parts 7 - Regulator

2 - Drive Disc (Pump 1) 5 - Cylinder Block
T3-1-2
Engine torque is transmitted to the seven plungers via
the shaft, rotating the cylinder block. Consequently, the
bottom of the cylinder block slides along the surface of
the valve plate.
The plungers reciprocate in cylinder block bores,
drawing and discharging hydraulic oil.
Plunger
Valve Plate
Shaft
Cylinder Block
T105-02-03-002
T3-1-3
Flow Rate Increase / Decrease Operation
Main pump flow rate is controlled by operating servo

piston (6). As servo piston (6) is moved up or down,
the displacement angle of cylinder block (3) is
changed.
Consequently, the stroke of plungers (2) is changed,
changing the flow rate.
Servo piston (6) is connected to valve plate (4) via pin
(5). The end of cylinder block (3) slides along the
surface of valve plate (4).
Maximum displacement angle;

2 2
5
!
3
T105-02-03-021 6 4 3 T165-03-01-013
Minimum displacement angle;
T105-02-03-022
2 - Plunger 4 - Valve Plate 5 - Pin 6 - Servo Piston

3 - Cylinder Block
T3-1-4
REGULATOR
Regulator Construction
Both main pumps (1 and 2) are equipped with a The pilot pressure to large chamber (14) of servo
regulator. The regulator functions to control main piston (15) is controlled by this opening/closing of the
pump flow rate so as not to exceed the engine circuit so as to control the movement of servo piston
horsepower upon receiving various pressures. (15), thus controlling the displacement angle of the
The main components of the regulator are springs cylinder block. As the displacement angle of the
(2), (5), (6), (11), and (12), pistons (3) and (4), spool cylinder block is controlled (changed), the main
(10), rods (7) and (8), barrel (9), and servo piston pump flow rate is controlled (changed).
(15).
Pistons (3) and (4) receive the pump control
pressure, the applicable main pump pressure, the
other main pump pressure, and the pilot pressure
from solenoid valve unit (SE), moving spool (10) via
rod (7) and consequently opening/closing the circuit.
2
3
5 4
6 16
10
15
11
12
14
13
T165-03-01-009
1- Stopper 5- Spring 9- Barrel 13 - Stopper
2- Spring 6- Spring 10 - Spool 14 - Large Chamber
3- Piston 7- Rod 11 - Spring 15 - Servo Piston
4- Piston 8- Rod 12 - Spring 16 - Small Chamber
T3-1-5
Regulator Functions
The regulator has various main pump flow rate

control functions as follows:
• Control by Pump Control Pressure

The pump control valve attached on the control
valve regulates the pump control pressure. Upon Q
receiving this pump control pressure, the regulator
increases/decreases the pump flow rate
accordingly.
When the control valve spool is moved out of the Flow Rate
neutral position, the pump control pressure
increases. As the pump control pressure
increases, the regulator increases the pump flow
rate.
When the control valve spool is returned to the
0 Pi
neutral position, the pump control pressure Pump Control Pressure
decreases. As the pump control pressure
decreases, the regulator decreases the pump flow
rate. (Refer to the Control Valve Group in this
section.)
• Control by Applicable Main Pump Pressure or the

Other Main Pump Pressure
If the average pressure of the two main pumps
Q
exceeds the set P-Q line due to an increase of
Pressure Increase
either main pump pressure, the regulators
decrease both main pumps' flow rates so that the Flow Rate Decrease
P-Q value matches with the one on the set P-Q
line, consequently preventing engine overload.
Since the P-Q line is set using the average Flow Rate
pressure of the two main pump pressures, flow
rate of both pumps are approximately the same.
By the same token, the delivery pressure of one
main pump can be relatively high, i.e. a relatively 0
P
large load is applied, while the delivery pressure of Pressure
the other main pump stays relatively low, i.e. a
relatively small load is applied. (Total Horsepower
Control)
• Control by Pilot Pressure from Solenoid Valve Unit Q

(SE)
After calculating engine target speed and actual
speed, MC (Main Controller) sends signals to
solenoid valve unit (SE). The solenoid valve unit
(SE) sends pilot pressure accordingly. Then, the Flow Rate
regulator decreases the pump flow rate. (Speed
Sensing (Reduced Horsepower) Pump Control)
(Refer to the Control System Group in the
SYSTEM section.)
0 P
Pressure
T3-1-6
Regulator Operation
1
2
3
5 4
6 16
10
15
11
12
14
13
T165-03-01-009
NOTE: Pd1 : Main Pump 1 Delivery Pressure

Pd2 : Main Pump 2 Delivery Pressure
Pi : From the Pump Control Valve
Ps : From the Solenoid Valve SE From the Hydraulic
Oil Tank Pilot Pump
Main Main
Pump 2 Pump 1
Pd2 Pd1
2 2
3 3
Pi Pi
4 4
9 9
10
10 15
15
16
16
14 Ps 14
T165-03-01-010
1- Stopper 5- Spring 9- Barrel 13 - Stopper
2- Spring 6- Spring 10 - Spool 14 - Large Chamber
3- Piston 7- Rod 11 - Spring 15 - Servo Piston
4- Piston 8- Rod 12 - Spring 16 - Small Chamber
T3-1-7
• Flow Rate Control by Pump Control Pressure
Flow Rate Increase:

1. Pump control pressure Pi increases when a 6. At the same time, spring (4) force is reduced.
control valve spool is moved. Servo piston (8) moves until the total force of
2. When pump control pressure Pi overcomes spring springs (4)(7) and pump control pressure Pi
(1), it pushes piston (2) up. Also, spool (6) is balances with spring (1).
moved upward by springs (4) and (7). 7. Subsequently, spool (6) closes the passage
3. As spool (6) moves, the servo piston large between the large chamber and the hydraulic oil
chamber opens to the hydraulic oil tank line. tank line, stopping servo piston (8) movement,
4. Consequently, servo piston (8) moves in the thus stopping the increase of pump flow rate.
direction indicated by the arrow.
5. As servo piston (8) moves, the displacement angle
of the cylinder block changes, increasing the flow
rate.
1
2
3
Decrease of Pump
Control Pressure Pi
Q
4
5 Small Chamber
Flow Rate
0
Pi
Pump Control Pressure Pi 6
Large Chamber
T165-03-01-003
1 - Spring 3 - Piston 5 - Rod 7 - Spring

2 - Piston 4 - Spring 6 - Spool 8 - Servo Piston
T3-1-8
Flow Rate Decrease:
1. Pump control pressure Pi decreases when the 6. At the same time, spring (4) force is increased.
control valve spool returns to neutral. Servo piston (8) moves until the total force of
2. Spring (1) overcomes springs (4) and (7), pushing springs (4)(7) and pump control pressure Pi
piston (2) down. At the same time, spool (6) is balances with spring (1).
pushed downward via piston (3) and rod (5). 7. Subsequently, spool (6) closes the passage
3. As spool (6) moves, the pilot pressure acting on between the large chamber and the hydraulic oil
the small chamber is also routed to the large tank line, stopping servo piston (8) movement,
chamber. thus stopping the decrease of pump flow rate.
4. As a result, servo piston (8) moves in the direction
indicated by the arrow.
5. Subsequently, the displacement angle of the
cylinder block is changed, decreasing the flow
rate.
1
2
3
Decrease of Pump
Control Pressure Pi
Q
4
5 Small Chamber
Flow Rate
0
Pi
Pump Control Pressure Pi
6
Large Chamber
T165-03-01-003

T3-1-9
• Flow Rate Control by Applicable Main Pump
Pressure or the Other Main Pump Pressure
Flow Rate Increase:
(Note that, viewed from a regulator, two main pumps 5. Subsequently, the displacement angle of the
are said to be the applicable main pump and the other cylinder block is changed, increasing the flow rate.
main pump.) 6. At the same time, spring (4) force is reduced.
Servo piston (8) moves until the total force of
Below illustrates the control of main pump 1. springs (4) and (7) balances with the total force of
applicable main pump pressure Pd1 and the other
1. The delivery pressure of the applicable main pump main pump pressure Pd2.
or the other main pump decreases. 7. Subsequently, spool (6) closes the passage
2. As the force to push piston (3) downward reduces, between the large chamber and the hydraulic oil
springs (4) and (7) move spool (6) upward. tank line, stopping servo piston (8) movement,
3. As spool (6) moves, the passage between servo thus stopping the decrease of pump flow rate.
piston (8) and the hydraulic oil tank line opens.
4. As a result, servo piston (8) moves in direction
indicated by the arrow.
1
2
Decrease of Applicable
Main Pump Pressure Pd1
Decrease of the Other

Q
3
Small Chamber
Flow Rate 4
0
Pd
6
(Applicable Main Pump Pressure+
The Other Main Pump Pressure)
Large Chamber
7
To the Hydraulic
Oil Tank
T165-03-01-007

T3-1-10
Flow Rate Decrease:
(Note that, viewed from a regulator, two main pumps 5. Subsequently, the displacement angle of the
are said to be the applicable main pump and the other cylinder block is changed, decreasing the flow rate.
main pump.) 6. At the same time, spring (4) force is increased.
Servo piston (8) moves until the total force of
Below illustrates the control of main pump 1. springs (4) and (7) balances with the total force of
applicable main pump pressure Pd1 and the other
1. The delivery pressure of the applicable main pump main pump pressure Pd2.
or the other main pump increases. 7. Subsequently, spool (6) closes the passage
2. As the force to push piston (3) downward between the large chamber and the hydraulic oil
increases, it overcomes springs (4) and (7), tank line, stopping servo piston (8) movement,
moving spool (6) downward via rod (5). thus stopping the decrease of pump flow rate.
3. As spool (6) moves, the pilot pressure acting on
the small chamber is also routed to the large
chamber.
4. As a result, servo piston (8) moves in the direction
indicated by the arrow. 1
2
Increase of Applicable
Increase of the Other

Q 3
Small Chamber
4
Flow Rate
5
8
0
Pd
(Applicable Main Pump Pressure+ Pilot Pressure

The Other Main Pump Pressure)
Large Chamber
T165-03-01-006

T3-1-11
• Flow Rate Control by Pilot Pressure from Solenoid
Valve Unit (SE)
Flow Rate Decrease:

1. A command from MC (Main Controller) actuates 6. Subsequently, the displacement angle of the
solenoid valve SE, increasing pilot pressure Ps. cylinder block is changed, decreasing the flow
2. This pilot pressure Ps, in addition to the total of two rate.
main pump pressures, acts on piston (3). 7. At the same time, spring (4) force is increased.
3. As the force to push piston (3) downward Servo piston (8) moves until the total force of
increases, it overcomes springs (4) and (7), springs (4) and (7) balances with the total force of
moving spool (6) downward via rod (5). applicable main pump pressure Pd1, the other
4. As spool (6) moves, the pilot pressure acting on main pump pressure Pd2, and pilot pressure Ps.
the small chamber is also routed to the large 8. Subsequently, spool (6) closes the passage
chamber. between the large chamber and the hydraulic oil
5. As a result, servo piston (8) moves in the direction tank line, stopping servo piston (8) movement,
indicated by the arrow. thus stopping the decrease of pump flow rate.
1
2
Increase of Pilot Pressure Ps
Pd1
Pd2
Q 3
Small Chamber
Flow Rate 4
5
8
0 P
Pressure
Large Chamber
7
T165-03-01-008

T3-1-12
PILOT PUMP
Suction Port
The drive gear is rotated via the transmission to drive Driven Gear Drive Gear
the driven gear.
Delivery Port
T137-02-03-005
N SENSOR
4 5
The N sensor detects engine speed. The N sensor is
installed close to the tip of the transmission gear teeth.
The N sensor detects engine speed by converting the
number of teeth passing by the N sensor into electrical
pulse signals.
1 - Coil 4 - Output Terminal

2 - Magnet 5 - Output Terminal
T107-07-02-054
3 - Disc Drive (Gear)
T107-02-03-020
PUMP DELEVERY PRESSURE SENSOR
The pump delivery pressure sensor detects the pump

delivery pressure which is required for various controls.
Oil pressure is received by diaphragm (9).
Depending on the extent of diaphragm deformation, oil
pressure is detected as an electrical signal.
6 - Grounding Terminal 8 - Power Source (5V) T157-02-03-010
7 - Output Terminal 9 - Pressure Receiving 6 7 8 9

Section (Diaphragm)
T3-1-13
(Blank)
T3-1-14
COMPONENT OPERATION / Swing Device
OUTLINE
The swing device consists of the valve unit, the swing

motor unit, and the swing reduction gear unit.
Valve Unit
Swing Motor Unit
Swing Reduction
Gear Unit
T157-02-04-001
T3-2-1
SWING MOTOR
3
The swing motor is a swash-plate-type axial plunger
motor.
The major parts of the motor are: fixed-type swash
plate (5), rotor (9), plungers (8), valve plate (3), motor 9
housing (6), and the parking brake.
The parking brake is a wet-type multiple disc brake,
consisting of plates (1) and friction plates (2).
Shoes (4) are caulked to each plunger (8) and nine 1, 2
plungers with shoes are provided in rotor (9).
Rotor (9) is installed onto shaft (7) with a spline
coupling.
T157-02-04-002
5 7 6
1 - Plate 4 - Shoe 6 - Motor Housing 8 - Plunger

2 - Friction Prate 5 - Fixed-type Swash Plate 7 - Shaft 9 - Rotor
3 - Valve Plate
T3-2-2
Swing speed varies depending on the amount of oil
delivered from the pump. From port A, high pressure oil
is fed so that plunger (3) is pushed from the top to the
bottom.
Shoe (4) then slides along swash plate (5), developing
turning force.
Turning force is transmitted to the swing reduction gear
unit via shaft (6). The return oil flows to outlet port B and
returns to the hydraulic oil tank.
When pressure oil is fed to port B, the motor rotates in
the opposite direction.
4
5
6
T107-02-04-002
1 - Valve Plate 3 - Plunger 5 - Swash Plate 6 - Shaft
2 - Rotor 4 - Shoe
T3-2-3
VALVE UNIT
The valve unit consists of the make-up valve and the

relief valve.
Make-Up Valve Relief Valve

When swing is stopped, if the upperstructure tends to
keep rotating due to swing inertia force, causing the
swing motor to continue rotating further, and to begin
sucking oil from the pump, developing cavitation in Make-Up
the motor. Valve
To make-up valve sucks hydraulic oil through the
return circuit (port C) to compensate for the lack of
Port C
oil, and prevent cavitation.
Control Valve
T107-02-04-013
Relief Valve
Port C
Make-Up Valve
T157-02-04-003
Control Valve
T3-2-4
Relief Valve
When starting or stopping swing operation, oil
pressure in the swing circuit becomes high. The relief
valve prevents the circuit pressure from rising higher
than the specified pressure. Plunger (1) is pushed to
the left by pressure Pp at port (P) and pressure- Relief Valve
receiving area A2.
However, plunger (1) is also pushed back to the right P
by spring (2) force and pressure Pg at chamber (g)
and pressure-receiving area A1.
Chamber (g) is routed to port (P) through orifice (m).
When force acting to the left is higher than that to the
right, the relief valve operates.
C
Control Valve
T107-02-04-013
g 2 1 m
A1 A2 T157-02-04-006
T3-2-5
SWING PARKING BRAKE 1
The parking brake is a wet-type multiple disc brake.

The brake is released only when brake release
pressure enters into brake piston chamber (b),
(negative type brake). When swing and/or front
2
attachment operation is made, brake release pressure
is supplied from the pilot pump.
b
During operations other than swing and/or front, or
while the engine is stopped, brake release pressure is
routed to the hydraulic oil tank and the parking brake is 3
automatically applied by spring (1).
4
!" When the swing and/or front function is operated, the 5

brake is released:
When the swing and/or front control lever is T157-02-04-007
operated, the control valve spool for swing and/or 6

front function is moved from the neutral position,
closing the spool passage for the signal pilot When the brake is released (OFF):
Oil Pressure
pressure circuit. Then, the pilot oil pressure Timer
increases, and the increased pressure pilot oil is sent Brake Release
to the pilot port of the switch valve in the brake Pressure
release circuit. Therefore, the switch valve is opened, Signal
allowing the brake release pilot oil pressure from the Pilot OFF
pilot pump to act on brake piston (2) via the oil Pressure
Circuit
pressure timer check valve. Accordingly, brake
piston (2) is moved up against spring (1), breaking
contact between friction plates (4) and plates (3).
Then, the brake is released. Swing
Motor
Switch Valve
Spool
!" When the swing and/or front function is not operated, T157-02-04-005
the brake is applied:

When the swing and/or front control lever is not
When the brake is applied (ON): Oil Pressure
operated, the control valve spool for swing and/or Timer
front function is in the neutral position, holding the Brake Release
spool passage for the signal pilot pressure circuit Pressure
open. Then, the pilot oil pressure does not increase.
Therefore, the switch valve in the brake circuit is kept ON
closed, allowing the brake release pilot oil pressure
on brake piston (2) to flow out to the hydraulic oil tank Signal Pilot
via the oil pressure timer orifice. Accordingly, brake Pressure
piston (2) is moved down by spring (1) force so that Circuit
friction plates (4) come into contact with plates (3). Swing
As friction plates (4) engage the inner circumference Motor Switch Valve
of motor housing (5) and plates (3) engage the outer
circumference of rotor (6), rotor (6) is braked by Spool
friction force developed between plates (3) and
T157-02-04-004
friction plates (4).
1 - Spring 4 - Friction Plate

2 - Brake Piston 5 - Motor Housing
3 - Plate 6 - Rotor
T3-2-6
SWING REDUCTION GEAR
The swing reduction gear is a two-stage planetary gear Then, rotary power is transmitted to second stage sun
type. Ring gears (2 and 4) in the first and second stages gear (7) via first stage planetary gear (1) and first stage
are provided on the inside of the housing. carrier (8). Second stage sun gear (7) rotates shaft (5)
The housing is bolted to the main frame so that ring via second stage planetary gear (3) and carrier (6).
gears (2 and 4) are held stationary. As shaft (5) meshes with the internal gear of the swing
The motor output shaft of the swing motor drives first bearing bolted to the undercarriage, the upperstructure
stage sun gear (9). is rotated.
8 9
2
7
3
4
6
W157-02-06-002
1 - First Stage Planetary Gear 4 - Second Stage Ring Gear 6 - Second Stage Carrier 8 - First Stage Carrier
2 - First Stage Ring Gear 5 - Shaft (Output Shaft) 7 - Second Stage Sun Gear 9 - First Stage Sun gear
3 - Second Stage Planetary
Gear
T3-2-7
(Blank)
T3-2-8
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COMPONENT OPERATION / Pilot Valve
OUTLINE
The pilot valve controls pilot pressure oil to move the

control valve spools. There are two types of pilot valves.
One is for front operation / swing operation; the other is
for travel operation. Both have four standard oil ports.
An optional two-oil-port type is available.
• Right and left pilot valves

(Front attachment / Swing)
Port No. Hitach Std. ISO Std.

Right Valve 1 Bucket roll-out !
2 Boom lower !
3 Bucket roll-in !
4 Boom raise !
Left Valve 1 Arm roll-in Swing right
2 Swing right Arm roll-out
3 Arm roll-out Swing left
4 Swing left Arm roll-in
P T
1 3 2 4 T107-02-06-032
T105-02-07-020
• Travel pilot valve
Port No. Hitachi Standard/ISO Standard T

1 Left travel forward
P
2 Left travel reverse
3 Right travel reverse
4 Right travel forward
4 1
P T
3 2
1 3 2 4
T105-02-07-020
T154-02-04-001
T3-4-1
OPERATION
• Front and Swing Pilot Valve In neutral

(Corresponding to A to B in the output diagram) :
The lower face of spool (8) head is suspended by the When control lever (1) is in the neutral position (no
upper face of spacer (4); they are kept in contact by pusher stroke), spool (8) completely blocks pressure oil
setting force of balance spring (6). Spacer (4) is from entering port P. Since the delivery port is open to
installed between pusher (3) and spring guide (5) and port T, pressure at the delivery port equals that in the
supported by return spring (7). Piston (9) is located hydraulic oil tank.
inside spool (8). The lower end of piston (9) makes When control lever (1) is slightly moved, cam (2) moves
contact with the plate, preventing the piston from together, pressing down on pusher (3).
moving further downward. Then, pusher (3), spacer (4), and spring guide (5) move
Above piston (9), a chamber is provided and it is led to downward as a unit, compressing return spring (7).
the outside of spool (8) through holes provided in spool The lower face of spool (8) is kept in contact with the
(8). upper face of spacer (4) by setting force of balance
spring (6) and moves downward together with spacer
(4).
However, even if control lever (1) is moved further, until
clearance (A) at section (a) reaches zero, the delivery
port remains open to port T, keeping pressure at the
delivery port equal to that in the hydraulic oil tank.
Delivery Port
Pressure
(Pilot Pressure)
Pusher Stroke
OUTPUT DIAGRAM
Section (a)
Port T
Delivery Port
Port P
T158-03-04-001
1 - Control Lever 4 - Spacer 6 - Balance Spring 8 - Spool
2 - Cam 5 - Spring Guide 7 - Return Spring 9 - Piston
3 - Pusher
T3-4-2
Ready to start operation
(Corresponding to B to C section in the output
diagram) :
When control lever (1) is tilted slightly further from the Once spool (8) moves upward, upper clearance at
position where clearance (A) in section (a) reaches section (a) is opened and lower notch section at section
zero, and pusher (3) is pushed downward, spool (8) is at (b) is closed, leading oil pressure at the delivery port
moved downward, opening notched section (b) to allow to port T, and decreasing oil pressure at the delivery
pressure oil at the port P to flow into the delivery port. port.
This oil pressure is also led to the inside of spool (8) via When oil pressure at the delivery port decreases, the
orifice (10), and acts to push spool (8) upward. Until this force to push up spool (8) is reduced so that balance
oil pressure force reaches the setting force of balance spring (6) stretches to move spool (8) downward,
spring (6), will not be compressed so that spool (8) is closing both the clearance and the notch at sections (a
not moved upward, closing the clearance at section (a), and b).
keeping the notch at section (b) opened, and letting the Thus, original position of spool (8) is kept resumed.
oil pressure to increase at the delivery port. The oil pressure will continue to increase until it is equal
If the oil pressure at the delivery port increases, and the to setting force of balance spring (6) (shown by the
upward-pushing force of spool (8) slightly exceeds the point C in the output diagram).
setting force of balance spring (6), spool (8) moves
upward against setting force of balance spring (6).
Delivery Port
Pressure
(Pilot Pressure)
Pusher Stroke
OUTPUT DIAGRAM
Section (a)
Port T
Clearance (A) Reaches Zero
Delivery Port Section (b)
Port P
T110-02-07-003
1 - Control Lever 6 - Balance Spring 9 - Piston 10 - Orifice
3 - Pusher 8 - Spool
T3-4-3
Operation corresponding to the control lever stroke
(Corresponding to C to D in the output diagram) :
As control lever (1) is moved further to push pusher (3) Accordingly, when compressed by pusher (3), spring
downward, spool (8) is pushed down to open the notch force of balance spring (6) increases in proportion to
at section (b), increasing oil pressure at the delivery the pusher stroke, Then, oil pressure increases to
port. counteract against this spring force.
As pressure increases, the force to push up spool (8)
increases. Then, when force to push up spool (8)
exceeds the setting force of balance spring (6), spool
(8) starts to move upward, compressing balance spring
(6).
When spool (8) moves upward until the clearance at
section (a) opens, the delivery port is opened to port T,
stopping oil pressure increase at the delivery port and
stopping movement of spool (8).
Delivery Port
Pressure
(Pilot Pressure)
Pusher Stroke
OUTPUT DIAGRAM
Section (a)
Port T
Delivery Port
Section (b)
Port P
T110-02-07-004
1 - Control Lever 3 - Pusher 6 - Balance Spring 8 - Spool
T3-4-4
Operation close to pusher stroke end
(Corresponding to D to E in the output diagram) :
As pusher (3) is pressed down, balance spring (6) is Then, oil pressure at the delivery port increases until it
compressed, reducing clearance (B) between pusher reaches port P pressure.
(3) and the top of spool (8) (shown at section (c) ),
finally to zero.
After that, pusher (3) directly pushes spool (8).
Even if oil pressure at the delivery port increases, spool
(8) cannot move upward, closing the oil passage from
the delivery port to port T, and opening the oil passage
from the delivery port to port P.
Delivery Port
Pressure
(Pilot Pressure)
Pusher Stroke
OUTPUT DIAGRAM
Section (c)
Clearance (B) Reaches Zero
Port T
Delivery Port
Port P
T110-02-07-005
3 - Pusher 6 - Balance Spring 8 - Spool
T3-4-5
Full stroke operation
(Corresponding to E to F section in the output
diagram) :
Even if the control lever is tilted further to push down This process corresponds with E to F section in the
pusher (3), spool (8) moves downward along with output diagram.
pusher (3), only widening the notch at lower section (b) The total stroke of the control lever is decided by
of spool (8). dimension C.
Thus, oil pressure at the delivery port is kept same as at

port P. Pusher (3) can be pressed down until spring
guide (5) comes into contact with the shoulder (section
(d)) of the casing.
This position is the stroke end of pusher (3)
(corresponding to F position in the output diagram).
Delivery Port
Pressure
(Pilot Pressure)
Pusher Stroke
OUTPUT DIAGRAM
Section (d)
Port T
Delivery Port
Section (b)
Port P
T110-02-07-006
3 - Pusher 5 - Spring Guide 8 - Spool
T3-4-6
(Blank)
T3-4-7
• Travel Pilot Valve
In neutral
(Corresponding to A to B in the output diagram) : Full stroke operation:
Lever - In Neutral (Pusher Stroke : A to B) Lever - Full Stroke (Pusher Stroke)
In neutral, spool (6) closes port P (the input port) and When the control lever is moved full stroke, pusher (2)
tank port T is connected to delivery port. Through is moved down until spring guide (3) comes into contact
clearance (A). Thus, the pressure at delivery port is the with the shoulder of the valve casing (Lever Stroke
same as that at tank port T. End), opening the notch (B) further to port P.
When the control lever is moved slightly from A to B, The output pressure (pilot pressure to the control valve)
pusher (2) and spring guide (3) together move down remains at the pilot system pressure (the port P
against return spring (5) and balance spring (4). At this pressure).
time, as both oil pressures above and below spool (6) Dimension (C) in the figure right shows the control lever
are the same as the tank pressure, spool (6) moves full stroke.
down together with spring guide (3) until clearance (A)
becomes zero.
Operation corresponding to the control lever stroke

(Corresponding to C to D in the output diagram) :
Lever - Operated
(Pusher Stroke : C to D --- Metering)
When the control lever is moved further to push pusher

(2) down, port P, is connected to delivery port through
notch (B) and passage in spool (6), routing pilot pump Delivery Port
pressure. However, when the pressure applied into Pressure
(Pilot Pressure)
spool (6) overcomes the balance spring forse, spool (6) D
moves up, closing port P. When pusher (2) is moved
further down, compressing return spring (5) and
balance spring (4), the larger the balance spring force;
thus, the output pressure increases in proportion to the C
increase in the balance spring force.
A B Pusher Stroke
OUTPUT DIAGRAM T523-02-05-001
T3-4-8
Pusher Stroke: A to B
1
4
5
Port T
(Clearance A: 0)
(A)
Port P
T154-02-04-003
Delivery Port
T154-02-04-002
Pusher Stroke: C to D Pusher Stroke: Full Stroke
2
2
4
5 (C)
(B)
Port T
Port T
6 3
Port P
Port P
Delivery Port T154-02-04-004

Delivery Port T154-02-04-005
1 - Cam 3 - Spring Guide 5 - Return Spring 6 - Spool

2 - Pusher 4 - Balance Spring
T3-4-9
(Blank)
T3-4-10
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COMPONENT OPERATION / Others (Undercarriage)
SWING BEARING
This bearing is a single-row shear ball-type bearing,

comprising outer race (1), inner race (3), balls (6),
supports (5), and seals (2), (4). Outer race (1) is bolted
to the upperstructure and inner race (3) is bolted to the
undercarriage.
The internal gear of inner race (3) engages with the
output shaft of the swing reduction gear.
T135-03-02-001
1 - Outer Race 3 - Inner Race 5 - Support 6 - Ball

2 - Seal 4 - Seal
T3-7-1
CENTER JOINT
The center joint is a 360! rotating joint. When the

upperstructure is rotated, the center joint avoids
twisting of hoses and allows hydraulic oil to flow
smoothly to or from the travel motors. Spindle (1) is
attached to the main frame, and body (2) is bolted to the
swing center of the undercarriage.
Hydraulic oil flows to the right and left travel motors via
spindle (1) and the oil ports of body (2). Seals (3)
prevent oil leaks between spindle (1) and body (2) into
adjacent passages.
To Left Travel To Right Travel To Left Travel To Right Travel

Motor (Reverse) Motor (Forward) Motor (Forward) Motor (Forward)
To Left Travel To Left Travel To Right Travel

To Right Travel
Motor (Forward) Motor (Reverse) Motor (Reverse)
Motor (Reverse)
1
Pilot Pressure
for Travel Speed Pilot Pressure
Drain
Selection for Travel Speed
Selection
2
Drain
3
Drain
Drain
Forward
Reverse
Pilot Pressure for
Travel Speed Selection
T157-03-02-004
1 - Spindle 2 - Body 3 - Seal
T3-7-2
TRACK ADJUSTER
The track adjuster located on the side frame is

composed of spring (5) and adjuster cylinder (6). Spring
(5) absorbs loads applied to the front idler. Adjuster
1
cylinder (6) adjusts track sag.
Grease Fitting
• Grease is applied through grease fitting into
chamber A of adjuster cylinder (6) as illustrated
below. The pressure of the grease pushes piston
rod (8) out and decreases track sag.
• To increases track sag, loosen valve (1) 1 to 1.5
turns counterclockwise to release grease from the
track adjuster cylinder through the grease
discharge hole.
CAUTION: Do not loosen valve (1) quickly or Grease Discharge Hole

loosen too much since high-pressure grease
M104-07-119
in the adjusting cylinder may spout out.
Loosen carefully, keeping body parts and
face away from valve (1).
Never loosen grease fitting.
1 2 3 4 A 5 6 7 8
W157-03-04-005
1 - Valve 3 - Washer 5 - Spring 7 - Flange

2 - Nut 4 - Spacer 6 - Adjuster Cylinder 8 - Piston Rod
T3-7-3
(Blank)
T3-7-4
SECTION 4
OPERATIONAL
PERFORMANCE TEST
—CONTENTS—
Group 1 Introduction Group 4 Component Test
Operational Performance Tests ............... T4-1-1 Primary Pilot Pressure ............................. T4-4-1
Preparation for Performance Tests .......... T4-1-2 Secondary Pilot Pressure......................... T4-4-3
Solenoid Valve Set Pressure .................... T4-4-4
Group 2 Engine Test Main Pump Delivery Pressure .................. T4-4-6
Engine Speed .......................................... T4-2-1 Main Relief Valve Set Pressure ................ T4-4-7
Engine Compression Pressure ................ T4-2-3 Overload Relief Valve Set Pressure ........T4-4-11
Valve Clearance Adjustment .................... T4-2-4 Main Pump Flow Test............................. T4-4-14
Nozzle Check .......................................... T4-2-6 Swing Motor Drainage............................ T4-4-18
Injection Timing ....................................... T4-2-8 Travel Motor Drainage ........................... T4-4-20
Group 3 Excavator Test Group 5 Standard

Travel Speed ........................................... T4-3-1 Operational Performance Standard
Track Revolution Speed........................... T4-3-2 Table ...................................................... T4-5-1
Mistrack Check ........................................ T4-3-3 Main Pump P-Q Diagram ......................... T4-5-4
Travel Parking Function Check ................ T4-3-4 Injection Pump......................................... T4-5-5
Swing Speed ........................................... T4-3-5
Swing Function Drift Check...................... T4-3-6
Swing Motor Leakage .............................. T4-3-7
Swing Bearing Play.................................. T4-3-8
Maximum Swingable Slant Angle ............. T4-3-9
Hydraulic Cylinder Cycle Time ............... T4-3-10
Dig Function Drift Check .........................T4-3-11
Control Lever Operating Force............... T4-3-12
Control Lever Stroke.............................. T4-3-13
Combined Boom Raise/Swing
Function Check .................................... T4-3-14
165T-4-1
(Blank)
165T-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedures to

quantitatively check all systems and functions on the
machine.
Purpose of Performance Tests Precautions for Evaluation of Test Data
1. To evaluate not only that the test data are correct,

1. To comprehensively evaluate each operational but also in what range the test data are.
function by comparing the performance test data
with the standard values. 2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
2. According to the evaluation results, repair, adjust, loads, and machine maintenance conditions.
or replace parts or components as necessary to
restore the machine's performance to the desired The machine performance does not always
standard. deteriorate as the working hours increase. However,
the machine performance is normally considered to
3. To economically operate the machine under reduce in proportion to the increase of the operation
optimal conditions. hours.
Accordingly, restoring the machine performance by
repair, adjustment, or replacement shall consider the
Kinds of Tests number of the machine's working hours.
1. Base machine performance test is to check the Definition of “Performance Standards”

operational performance of each system such as
engine, travel, swing, and hydraulic cylinders. 1. Operation speed values and dimensions of the
new machine.
2. Hydraulic component unit test is to check the
operational performance of each component such 2. Operational performance of new components
as hydraulic pump, motor, and various kinds of adjusted to specification. Allowable errors will be
valves. indicated as necessary.
Performance Standards
“Performance Standards” is shown in tables to

evaluate the performance test data.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out

performance tests accurately and safely.
1. THE MACHINE
Repair any defects and damage found, such as oil
or water leaks, loose bolts, cracks and so on,
before starting to test.
2. TEST AREA
(1) Select a hard, flat surface.
(2) Secure enough space to allow the machine to
run straight more than 20 m (65 ft 7 inch), and
to make a full swing with the front attachment
extended.
(3) If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.
3. PRECAUTIONS
(1) Before starting to test, agree upon the signals to
be employed for communication among
coworkers. Once the test is started, be sure to
communicate with each other using these T105-06-01-003
signals, and to follow them without fail.
(2) Operate the machine carefully and always give
first priority to safety.
(3) While testing, always take care to avoid
accidents due to landslides or contact with
high-voltage power lines. Always confirm that
there is sufficient space for full swings.
(4) Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil.
Pay special attention to this when removing
hydraulic pipings.
4. MAKE PRECISE MEASUREMENTS

(1) Accurately calibrate test instruments in
advance to obtain correct data.
(2) Carry out tests under the exact test conditions T105-06-01-004
prescribed for each test item.
(3) Repeat the same test and confirm that the test
data obtained can be procured repeatedly.
Use mean values of measurements if
necessary.
T4-1-2
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary:
1. Use Dr.EX. If Dr.EX is not available, use an engine 1

tachometer.
2. Measure the engine speeds in each mode.
NOTE: Measure the engine speed before

performing all other tests to check that the
engine speed meets specification. Because,
if the engine speed is not adjusted correctly,
all other performance data will be unreliable.
Preparation:
T107-06-02-001
1. Connect Dr.EX to the diagnosing connector beside
the fuse box located behind the operator's seat,
and select the monitor function. When using an
2
engine tachometer, install speed pickup (2) to
injection pipe (3).
3
2. Warm up the machine until the engine coolant
temperature reaches 50 !C (122 !F) or more, and
hydraulic oil is 50"5 !C (122"9 !F).
NOTE: Never attempt to readjust stopper (1).
T107-06-02-002
T4-2-1
Measurement:
1. No Load Engine Speed

1-1. Measure the engine start speed (Start Idle),
slow idle speed, fast idle speed (in normal
mode), and fast idle speeds (in both E and HP
modes). HP Mode E Mode
Switch Switch
1-2. Select the switch positions as shown below.
1-3. Start measurement from the start idle speed.
1-4. Measure while changing the engine control dial,
E mode switch, and HP mode switch.
Engine E HP Auto-Idle Work

Control mode Mode Switch Mode
Dial Switch Switch Switch
General
Start Idle OFF OFF OFF Purpose
Mode
General
Slow Idle OFF OFF OFF Purpose
Mode
Fast Idle General
(Normal OFF OFF OFF Purpose
Mode) Mode
Fast Idle General
(E Mode) ON OFF OFF Purpose
Mode
Fast Idle General
Engine Control
(HP OFF ON OFF Purpose Dial T157-07-02-002
Mode) Mode
2. No Load Auto-Idle Speed

2-1. Select the switch positions as shown below.
Engine E HP Auto-Idle Work

Control mode Mode Switch Mode
Dial Switch Switch Switch
General
Fast Idle OFF OFF ON Purpose
Mode Work
Mode
Auto-Idle Switch
2-2. Start the engine and operate the bucket lever.
Switch
2-3. Return the lever to the neutral position. Wait
approx. 4 seconds until the engine speed is
automatically reduced. Then, measure the
reduced engine speed.
Evaluation:
Refer to the Performance Standard Table in Group
T4-5. T157-01-01-018
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-2-2
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in the cylinders to
check for a decline in engine power.
2. Check exhaust gas color and the amount of blow-

by gas from the crankcase. Keep track of engine
oil consumption.
3. Check for abnormalities in the intake system,

including the air filter.
Preparation:
1. Confirm that valve clearances are correct.
2. Confirm that the batteries are charged properly.
3. Run the engine until the coolant temperature

gauge reaches the operating range.
4. Stop the engine. Remove glow plugs from each

cylinder.
5. Install an adaptor and compression gauge in place T157-05-02-001

of the glow plug in one cylinder. (Be sure to
sufficiently tighten the adaptor and compression
gauge to prevent air leakage.)
Measurement:
1. Turn the starter to crank the engine. Record the
compression pressure of each cylinder.
2. Repeat measurement three times for each

cylinder and calculate the mean values.
Evaluation:
T4-5.
Remedy:
Refer to engine shop manual.
T4-2-3
VALVE CLEARANCE ADJUSTMENT
Summary:
1. Perform the measurement when the engine is

cold.
2. Before starting work, clean the head cover

mounting area to avoid contamination in the
engine.
Preparation :
TDC Mark
1. Locate the top dead center (TDC) in the
compression stroke.
Align the TDC mark on the crank pulley with the Pointer
pointer located on the timing gear case as
illustrated. Piston No.1 (or piston No.4) is now Timing Gear Case
positioned at the TDC in its compression stroke.
2. Remove the head cover. Crank Pulley
3. Move push rods for the intake and exhaust valves

on the No.1 cylinder up and down by hand. If any
clearances on the both ends of the push rods are
T157-05-02-002
found, piston No.1. is positioned at TDC in the
compression stroke. (If the exhaust valve of
cylinder No.1 is pushed down, piston No.4 is
positioned at TDC in the compression stroke.
Start measurement from the cylinder (No.1 or
No.4) positioned at TDC in the compression
stroke.
Measurement:
1. Insert a thickness gauge into the clearance

between the rocker arm and the valve stem end to
measure the valve clearance.
NOTE: The cylinders are aligned from No.1 to No.4

in that order, as viewed from the fan side .
T107-02-12-005
T4-2-4
2. When the measurement is started from No.1
cylinder, perform the same measurement to all
valves indicated with the mark “!” in the table
below. (When the measurement is started from
No.4 cylinder, perform the measurement in the
valves shown with mark “#”.)
Cylinder No. No.1 No.2 No.3 No.4

Valve locations I E I E I E I E
When the measurement is
started from No.1 cylinder
! ! ! !
When the measurement is
# # #
started from No.4 cylinder
3. Rotate the crankshaft 360!.

Align the TDC mark with the pointer. Then,
continue measurement of other valves in the same
way.
Evaluation:
Standard Valve Clearance:
• Intake valve : 0.40 mm (0.0157 in)
• Exhaust valve : 0.40 mm (0.0157 in)
Adjustment:
If the measurement results are out of specification,
adjust the valve clearance in the same order of
measurement.
1. Loosen the adjusting screw lock nuts for the rocker

arms. Insert the thickness gauge set at 0.4 mm,
adjust the adjusting screws.
2. After adjusting, retighten the lock nuts to the

specification.
Recheck the valve clearance after the lock nuts
are tightened.
: 25.5"4.9 N$m
(2.6"0.5 kgf$m, 18.8"3.6 lbf$ft)
T4-2-5
NOZZLE CHECK
Summary:
1. Check the injection pressure and the spray pattern
with a nozzle tester.
2. Before starting work, clean the nozzle holder
mounting area to avoid contamination in the
engine.
Preparation:
1. Remove the nozzle holders.
Remove all nozzle holders and fuel injection
pipings from the engine.
2. Attach a nozzle holder to the nozzle tester.
Measurement:
CAUTION: Never touch spray directly. The

fuel spray from the nozzle may penetrate the
skin, resulting in serious injury. If fuel
penetrates into the blood stream, it may
cause blood toxication.
1. Injection pressure
After attaching the nozzle holder to the nozzle
tester, strongly make several strokes of the tester
to inject fuel. Then, while operating the tester at
approx. 60 time strokes a minute, measure the T107-06-02-006
fuel injection pressure.

If adjustment is required, loosen the lock nuts and
adjust the adjusting screws. Turn clockwise to
increase the pressure, and counterclockwise to
decrease the pressure.
2. Spray pattern
For this test, turn the pressure tester knob to
bypass the pressure gauge. Attach the nozzle
holder to the nozzle tester. Strongly make several
strokes of the tester and check the fuel spray
pattern.
NOTE: Use clean diesel oil.
T4-2-6
Evaluation:
1. Standard Injection Pressure:
2
18.1 MPa (185 kgf/cm , 2 630 psi) Normal
2. Spray Pattern
%& Large-size spray should not be visible to the naked
eye.
&
%& No stray sideways sprays should be seen.
&
%& During initial injection stage, spray size should be fine
and injected intermittently.
&
%& There should be no drips found. T102-02-11-005
&
%& Injection spray angle must be normal. Abnormal
T102-02-11-006
Adjustment:
%& To adjust the injection pressure, loosen the lock nuts.

Adjust the adjusting screw.
& Turn clockwise to increase the pressure, and
counterclockwise to decrease the pressure.
&
%& After adjusting, retighten the lock nuts.
T107-06-02-007
T4-2-7
INJECTION TIMING
Timing Mark
Inspection: TDC Mark
1. Position No.1 piston to the top dead center. Turn
the crank pulley in the direction of rotation
Pointer
(clockwise as seen from the front of the engine) to
set a “TDC” mark on the crank pulley under the
“pointer”, located on the timing gear case. Timing Gear Case
2. Remove the timing check hole cover on the front Crank Pulley
section of the fuel injection pump.
When the mark on the injection pump is set under
the projection of the gear case, No.1 piston is
positioned at the top dead center. If the mark is not
set under the projection, keep turning to adjust. T157-05-02-002
3. Turn the crank pulley at approx. 30 degrees Gear Case

counterclockwise. Projection
4. Remove the injection piping from No.1 cylinder.
5. Remove the delivery valve holder for No.1 cylinder

from the injection pump to pull the delivery valve
and the spring out. Reinstall the delivery valve
holder. Injection Pump
Alignment Mark
: 39 to 43 N$m
(4.0 to 4.4 kg$m, 28.9 to 31.8 lbf$ft) T107-02-12-007
Gear Case
Projection
6. While supplying fuel with the feed pump, turn the
crank pulley slowly clockwise just until fuel cannot
be seen from the top of the delivery valve hole.
This is the position where the injection starts.
7. Check the timing mark, located on the crank pulley

for what degrees the pointer indicates.
Adjustment:
1. Turn the crank pulley so that the pointer comes Injection Pump
Alignment Mark
just above the correct timing position (12 degrees
T107-02-12-008
before the TDC) on the crank pulley.
2. Loosen the mounting nuts of the injection pump.
3. When advancing timing, tilt the injection pump

outward against the cylinder block.
When delaying timing, tilt the injection pump
inward against the cylinder block.
T107-02-12-009
T4-2-8
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary:
Measure the time required for the excavator to travel a
10 m (32.8 ft) test track.
Preparation:
1. Adjust the track sag on both side tracks equally.
2. Prepare a flat and solid test track 20 m (65.5 ft) in
length with extra length of 3 to 5 m (9.8 to 16 ft) on
Arm Rolled-In, Bucket Rolled-In
both ends for machine acceleration and decelera- End
tion. Bucket Height: 0.3 to 0.5 m
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above the
ground with the arm and bucket rolled in. Start
20 m Deceleration
4. Maintain hydraulic oil temperature at 50!5 "C Zone
(122!9 "F). 3 to 5 m
Acceleration
Measurement: Zone
3 to 5 m
1. Measure both the slow and fast speeds of the
machine. T105-06-03-001
2. Select the following switch positions:
Travel Engine Work
E Mode HP Mode Auto-Idle
Mode Control Mode
Switch Switch Switch
Switch Dial Switch
General
Slow Fast
OFF OFF Purpose OFF
Mode Idle
Mode
General
Fast Fast
OFF OFF Purpose OFF
Mode Idle
Mode
3. Start traveling the machine in the acceleration

zone with the travel levers to full stroke.
4. Measure the time required to travel 20 m (65.5 ft).
5. After measuring the forward travel speed, turn the
upperstructure 180" and measure the reverse
travel speed.
6. Repeat steps 4. to 5. three times in each direction
and calculate the average values.
Evaluation:
T4-5.
Remedy:
T4-3-1
TRACK REVOLUTION SPEED
Summary:
Measure the track revolution cycle time with the track
raised off ground.
Preparation:
1. Adjust the track sag of both side tracks to be
equal.
2. On the track to be measured, mark one shoe with
chalk. 90 to 110"
3. Swing the upperstructure 90" and lower the bucket
to raise the track off ground. Keep the boom-arm
angle between 90 to 110" as shown. Place blocks
under the machine frame.
M104-07-067
Mark
CAUTION: Securely support the raised track
using wooden blocks.
4. Maintain the hydraulic oil temperature at 50!5 "C

(122!9 "F).
Measurement:
Travel Engine E Mode HP Mode Work Auto-Idle
Mode Control Mode Switch
Switch Dial Switch Switch Switch
Slow Fast General
OFF OFF Purpose OFF
Mode Idle Mode
Fast Fast General
OFF OFF Purpose OFF
Mode Idle Mode
2. Operate the travel control lever of the raised track

to full stroke.
3. Measure the time required for 3 revolutions in both
directions after a constant track revolution speed
is obtained.
4. Raise the other side and repeat the above
procedures.
5. Repeat steps 2. to 4. three times and calculate the
average values.
Evaluation:
T4-5.
NOTE: The measurement data obtained through

the raised track revolution test may have
wide variations. Therefore, the evaluation
based on the results obtained from the 20 m
travel speed check described before is
more rec-ommendable.
Remedy:
T4-3-2
MISTRACK CHECK
Summary:
1. Allow the machine to travel 20 m (65.5 ft). Measure
the maximum tread deviation from the tread chord
line drawn between the travel start and end points Maximum Distance
to check the performance equilibrium between
both sides of the travel device systems (from the
main pump to the travel motor). Acceleration
2. If measured on a concrete surface, the tread Zone:
deviation has a trend to decrease. 3 to 5 m
20 m
Preparation:
1. Adjust the track sag of both tracks to be equal.
2. Provide a flat, solid test yard 20 m (65.5 ft) in
length, with extra length of 3 to 5 m (9.8 to 16 ft) on
both ends for machine acceleration and T105-06-03-022
deceleration.
ground with the arm and bucket rolled in.
(122!9 "F).
Measurement:
1. Measure the amount of mistracking in both fast,
and slow travel speeds.
Travel Engine E Mode HP Mode Work Auto-Idle
Mode Control Mode
Switch Dial Switch Switch Switch Switch
Slow Fast General
OFF OFF Purpose OFF
Mode Idle Mode
Fast Fast General
OFF OFF Purpose OFF
Mode Idle Mode
3. Start traveling the machine in the acceleration

zone with the travel levers at full stroke.
4. Measure the maximum distance between a
straight 20 m (65.5 ft) tread chord line and the
tread made by the machine.
5. After measuring the tracking in forward travel, turn
the upperstructure 180" and measure in reverse
travel.
average values.
Evaluation:
T4-5.
Remedy:
T4-3-3
TRAVEL PARKING FUNCTION CHECK
Summary:
To measure the parking brake function on a specified
slope.
Preparation:
1. The surface of the test slope shall be even with a
gradient of 20 % (11.31").
0.2 to 0.3 m
2. Mark a white line on the travel device cover.
ground with the arm and bucket fully rolled in.
(122!9 "F).
T105-06-03-004
Measurement:
1. Measure in the fast travel mode.
2. Select the following switch positions: Position where the machine
Travel Engine E Mode HP Mode Work Auto-Idle comes to a stop.
Mode Control Mode Position when the travel
Switch Dial Switch Switch Switch Switch levers are in neutral.
Fast Fast General Displacement
OFF OFF Purpose OFF (Revolution Angle)
Mode Idle Mode Mark
3. Measure the displacement (revolution angle) of

the travel device cover until the parking brake is
applied.
3-1. Climb the slope and place the travel levers in
neutral. T107-06-03-002
3-2. Measure the displacement from the mark
position on the travel device cover when the
levers are placed in neutral to that position
when the machine stops moving.
4. Measure the travel parking brake slip amount
while parked.
4-1. Climb the slope and place the travel levers in
neutral.
4-2. Stop the engine.
4-3. After the machine stops, put alignment marks Alignment marks on the track
on a track link or shoe, and the track side side frame and shoe when the
machine comes to a stop.
frame.
Displacement measured
4-4. After 5 minutes, measure the distance between after 5 minutes.
the marks on the track link or shoe and the T105-06-03-006
track side frame.
Evaluation:
T4-5.
T4-3-4
SWING SPEED
Summary:
Measure the time required to swing three complete
turns.
Preparation:
1. Check the lubrication of the swing gear and swing
bearing.
2. Place the machine on flat, solid ground with ample
space for swinging. Do not conduct this test on
slopes.
3. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
the same as the boom foot pin. The bucket must The same height as the
be empty. boom foot pin height
(122!9 "F). T105-06-03-013
CAUTION: Prevent personal injury. Always

make sure that the area is clear and that co-
workers are out of the swing area before
starting the measurement.
Measurement:
Engine E Mode HP Mode Work Auto-Idle
Control Mode
Dial Switch Switch Switch Switch
General
Fast Idle OFF OFF Purpose OFF
Mode
2. Operate swing control lever fully.

3. Measure the time required to swing 3 turns in one
direction.
4. Operate swing control lever fully in the opposite
direction and measure the time required for 3
turns.
average values.
Evaluation:
T4-5.
Remedy:
T4-3-5
SWING FUNCTION DRIFT CHECK
Summary:
Measure the swing drift on the bearing outer
circumference when stopping after a 180" full-speed
swing.
Preparation:
bearing.
2. Place the machine on flat, solid ground with ample
space for swinging. Do not conduct this test on a Two Check Marks
slope.
T105-06-03-008
the same as the boom foot pin. The bucket must
be empty.
4. Make two chalk marks: one on the swing bearing
and one directly below it on the track frame.
5. Swing the upperstructure 180".
(122!9 "F).

make sure that the area is clear and that co- T105-06-03-009

Measure Difference Between Marks
Measurement:
Control Mode
General
Fast Idle OFF OFF Purpose OFF Marking on the Track Frame
Mode
Marking on the Swing Bearing
2. Operate the swing control lever fully and return it
to the neutral position when the mark on the T105-06-03-010
upperstructure aligns with that on the track frame
after swinging 180".
3. Measure the distance between the two marks.
4. Align the marks again, swing 180", then test in the
opposite direction.
5. Repeat steps 3. to 5. three times each and
calculate the average values.
Evaluation:
T4-5.
Remedy:
T4-3-6
SWING MOTOR LEAKAGE
Summary:
Check for upperstructure drift while suspending a load
on a slope.
Preparation:
bearing.
2. Park the machine on a smooth slope with a
gradient of 26.8 %,
3. Load bucket fully. In lieu of loading the bucket,
weight (W: tons) of the following specification can
be used.
W=M#1.5
where: M=Bucket heaped capacity (CECE: m3) T105-06-03-011
1.5=Soil specific gravity
4. With the arm rolled out, and bucket rolled in,

position the arm top pin height to be level with the
boom foot pin.
5. Swing the upperstructure to position it 90" to the
slope. Make aligning marks on the swing bearing
periphery and track frame using tape, as
illustrated.
(122!9 "F).
Measurement:
1. Select the following switch position:
E Mode HP Mode Work Mode Auto-Idle Measure Difference Between Marks
Switch Switch Switch Switch
General
OFF OFF Purpose OFF
Mode
2. Maintain the engine at slow idle. After five minutes, Marking on the Track Frame
measure the difference between the marks along
the swing bearing periphery and the track frame. Marking on the Swing Bearing
3. Perform the measurement in both right and left
swing directions. T105-06-03-010
4. Perform the measurement three times in each
direction and calculate the average values.
Evaluation:
T4-5.
Remedy:
T4-3-7
SWING BEARING PLAY
Summary:
Measure the swing bearing play using a dial gauge to
check the wear of bearing races and balls.
Preparation:
1. Check swing bearing mounting bolts for loose-
ness.
2. Check the lubrication of the swing bearing. Con-
firm that bearing rotation is smooth and without
noise.
3. Install a dial gauge on the track frame as shown,
T105-06-03-014
using a magnetic base.
4. Position the upperstructure so that the boom
aligns with the tracks facing towards the front
idlers.
5. Position the dial gauge so that its needle point
comes into contact with the bottom face of the
bearing outer race.
6. Bucket should be empty.
Measurement:
the same as the boom foot pin. Record the dial
T105-06-03-015
gauge reading (h1).
2. Lower the bucket to the ground and use it to raise
the front idler 0.5 m (20 in). Record the dial gauge
reading (h2).
3. Calculate bearing play (H) from this data (h1 and
h2) as follows:
H=h2-h1
Measurement: (h2)
Measurement: (h1)
The same height as the

boom foot pin height
T105-06-03-017
T105-06-03-013
Evaluation:
T4-5.
T4-3-8
MAXIMUM SWINGABLE SLANT ANGLE
Summary:
With the upperstructure swung 90" to the slope, check
the maximum slant angle on which the upperstructure
can swing to the uphill side.
Preparation:
1. Check that the swing gear and bearing are well
lubricated.
2. Load bucket fully. In lieu of loading the bucket,
weight (W: tons) of the following specification can
be used.
W=M#1.5
3
where: M=Bucket heaped capacity (CECE: m )
3. With the arm cylinder fully retracted and the bucket T105-06-03-011
cylinder fully extended, hold the arm top pin to the
position flush with the boom foot pin height.
4. Climb a slope and swing the upperstructure 90" to
the slope.
(122!9 "F).
Measurement:
Control Mode
General
Mode
2. Operate the swing lever to full stroke to swing the

upperstructure to the uphill side.
3. If the machine can swing, measure the cab floor
slant angle.
4. Increase the slope angle and repeat steps 2. and 3.
Check both clockwise and counterclockwise.
5. Perform the measurement three times.
Evaluation:
T4-5.
Remedy:
T4-3-9
HYDRAULIC CYLINDER CYCLE TIME
Measure the cycle time of the boom, arm, and bucket

cylinders.
Preparation:
1. To measure the cycle time of the boom cylinders:
With the arm rolled out and the empty bucket
rolled in, lower the bucket to the ground, as shown.
2. To measure the cycle time of the arm cylinder:
With the empty bucket rolled in, position the arm T105-06-03-018
so that it is vertical to the ground. Lower the boom
until the bucket is 0.5 m (20 in) above the ground.
3. To measure the cycle time of the bucket cylinder:
The empty bucket should be positioned at mid-
stroke between roll-in and roll-out, so that the
sideplate edges are vertical to the ground.
(122!9 "F).
0.5 m
Measurement:
1. Select the following switch positions: T105-06-03-019
Control Mode
General
Mode
2. To measure cylinder cycle times:

(Cylinder full stroke includes cylinder cushioning
zone.)
(1) Boom cylinders:
Measure the time it takes to raise the boom, and
the time it takes to lower the boom. To do so,
position the boom at one stroke end, then move
the control lever to the other stroke end as quickly T105-06-03-020
as possible.
(2) Arm cylinder:
Measure the time it takes to roll in the arm, and
the time it takes to roll out the arm. To do so,
position the arm at one stroke end, then move the
control lever to the other stroke end as quickly as
possible.
(3) Bucket cylinder:
Measure the time it takes to roll in the bucket, and
the time it takes to roll out the bucket. To do so, Evaluation:
position the bucket at one stroke end, then move Refer to the Performance Standard Table in Group
the control lever to the other stroke end as quickly T4-5.
as possible.
Remedy:
3. Repeat each measurement three times and
T4-3-10
DIG FUNCTION DRIFT CHECK
Summary:
Measure dig function drift, which can be caused by oil
leakage in the control valve and boom, arm, and
bucket cylinders, with the loaded bucket.
NOTE: When testing the dig function drift just after

cylinder replacement, slowly operate each
cylinder to its stroke end to purge air.
Extended
Preparation: Retracted
Distance
Distance
1. Load bucket fully. In lieu of loading the bucket, Retracted
weight (W: tons) of the following specification can Distance
be used.
W=M#1.5 Same Height
3
where: M=Bucket heaped capacity (CECE: m )
2. Position the arm cylinder with the rod 50 mm (2 in) Bucket Bottom
extended from the fully retracted position.
3. Position the bucket cylinder with the rod 50 mm (2
T105-06-03-021
in) retracted from the fully extended position.
4. With the arm rolled out and the bucket rolled in, Arm Cylinder Extension
hold the bucket so that the height of the bucket pin
is the same as the boom foot pin.
(122!9 "F).
Measurement: Mark
1. Stop the engine.
2. Five minutes after the engine has been stopped,
measure the change in the position of the bottom
of the bucket, as well as the boom, arm and bucket
cylinders.
3. Repeat step (2) three times and calculate the
T110-06-03-001
average values.
Boom and Bucket Cylinder Retraction
Evalution:
Refer to the Performance Standard Table in Group Mark Mark
T4-5.
Remedy:
T110-06-03-002
T4-3-11
CONTROL LEVER OPERATING FORCE
Summary:
Use a spring scale to measure the maximum
resistance of each control lever as illustrated.
Preparation:
Maintain the hydraulic oil temperature at 50!5 "C
(122!9 "F).
Measurement:
1. Start the engine.
Control Mode
Dial Switch Switch Switch Switch T107-06-03-003
General
Mode

3. Operate each boom, arm, bucket and swing lever

to at full stroke and measure the maximum
operating force for each.
4. Lower the bucket to the ground to raise one track
off the ground. Operate the travel lever to full
stroke and measure the maximum operating force
T107-06-03-004
required. When finished, lower the track and then
jack-up the other track.
average values.
Evalution:
T4-5.
T4-3-12
CONTROL LEVER STROKE
Summary:
Measure each lever stroke at the lever top using a
ruler.
NOTE: When the lever has play, take a half of this

value and add it to the measured stroke.
Preparation:
Maintain the hydraulic oil temperature at 50!5 "C
(122!9 "F).
Measurement:
T107-06-03-005
1. Stop the engine.
2. Measure each lever stroke at the lever top from

neutral to the stroke end using a ruler.
3. Repeat step (2) three times and calculate the

average values.
Evalution:
T4-5.
T4-3-13
COMBINED BOOM RAISE/SWING FUNC-
TION CHECK
Summary:
Check boom raise and swing movement and speeds
while operating both functions simultaneously.
Preparation:
1. Start the engine and run it at fast idle. Operate the
boom raise function and check to be sure that the
cylinder movement is smooth, with out sticking.
T107-06-03-009
2. With the arm fully rolled out and bucket fully rolled
in, lower the bucket to the ground. The bucket
must be empty.
(122!9 "F).

Measurement:
Engine E Mode HP Mode Work Auto-Idle T107-06-03-010
Control Mode
General
Mode
2. Raise the boom and swing simultaneously, both at

full stroke.
3. When the upperstructure rotates 90", release the
control levers to stop both functions. Measure the H
time required to swing 90" and the height(H) of the
bucket teeth.
average values.
T107-06-03-011
Evalution:
T4-5.
Remedy:
T4-3-14
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Install tee (ST 6450) between the pilot filter and
hose 1. Install adapter (ST 6069) and pressure
gauge (ST 6942) on the tee.
: 22 mm, 27 mm ST 6942
ST 6450
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection. Hose 1
(122!9 "F).
Measurement: T165-04-04-006
ST 6069
Engine Work
Control Mode
Dial Switch
General
Fast Idle/
OFF OFF Purpose OFF
Slow Idle
Mode
2. Measure the pilot pressure in each specified

setting above.
3. Repeat the measurement three times and
Evaluation:
T4-5.
T4-4-1
Primary Pilot Pressure Adjustment Procedure
Adjustment:
Adjust the setting pressure of relief valve (1) (the
primary pilot pressure) as necessary.
: 22 mm
T154-01-01-005
2 3
1. Remove plug (3).
2. Install the estimated necessary numbers of shims

(2).
3. Tighten plug (3).

T157-05-04-007
: 24.5 N#m (2.5 kgf#m, 18 lbf#ft)
4. Check the relief pressure of relief valve (1).
(Reference) Standard Change in Relief Presssure

Shim Thickness
0.25 0.5 1.0
(mm)
kPa 78 157 304
2
kgf/cm 0.8 1.6 3.1
psi 11 23 44
T4-4-2
SECONDARY PILOT PRESSURE
1
Preparation:
3. Install pressure gauge (ST 6942) and tee (ST
6450) to the end of pilot line (1) at the respective
control valve spool end, as illustrated.
: 14 mm, 17 mm

observed at the pressure gauge connection.
(122!9 "F).
Measurement:
Engine Work
Control Mode
Dial Switch W155-04-01-003
General
Fast Idle/
OFF OFF Purpose OFF
Slow Idle
Mode
2. Measure the pilot pressure in each specified

setting above with the corresponding control lever
operated full stroke.
Evaluation:
T4-5.
Remedy: T157-05-04-011
T4-4-3
SOLENOID VALVE SET PRESSURE
Measure solenoid valve set pressure with both the

Dr.EX and the pressure gauge.
Preparation:
3. Disconnect line (1) from the solenoid valve to be
measured. Install hose (Parts Number: 4216453),
tee (ST 6451), adapter (ST 6461), and pressure
gauge (ST 6942) to the disconnected end at the
solenoid valve side, as illustrated.
1
: 17 mm, 19 mm, 22 mm
Connect Dr.EX to the machine for solenoid valve W155-02-11-003

set pressure monitoring.
Solenoid Valve
observed at the pressure gauge connection. Pressure Gauge
(122!9 "F).
Measurement:
Engine Work Travel

E Mode HP Mode
Control Mode Mode Hose Tee Adapter T157-05-04-002
Switch Switch
Dial Switch Switch
O General Fast
Fast Idle OFF FF Purpose Speed
Mode Mode
2. Operate as instructed below for each measuring

solenoid valve:
Solenoid Valve SG: Repeat pressing and releasing
of the power boost switch.
Solenoid Valve SD: Perform a combined operation.
Relieve both actuators.
Solenoid Valve SC: Perform a combined operation
of boom raise and arm roll-in.
Solenoid Valve SI: Drive the machine, then stop
the machine.
3. Read the values on both Dr.EX and the pressure
gauge.
Evaluation:
The average value read on the pressure gauge shall
be within !0.2 MPa (!2 kgf/cm2, !28 psi) of the value
indicated on Dr.EX.
T4-4-4
Solenoid Valve Set Pressure Adjustment
Procedure
IMPORTANT: Do not loosen the adjusting screw

excessively.
The O-ring on the threads may come
off the sealing surface, causing oil
leakage.
The distance between the lock

nut end and screw end should be
1. Mark the end of the adjusting screw with a white 4.0 mm (0.157 in) or less.
marker for the record of the original position. (Take
care not to touch any part of the screw threads with T107-06-04-020
the white marker.)
2. Loosen lock nut (7). Turn adjusting screw (8) to
adjust the set pressure of the solenoid valve.
3. Retighten lock nut (7).
: 13 mm
: 4 mm
: 8.8 N#m ( 0.9 kgf#m, 6.5 lbf#ft )
8 7
(Reference) Standard Change in Relief Presssure T107-06-05-001
Screw Turns 1/4 1/2 3/4 1

kPa 98 196 294 392
2
kgf/cm 1 2 3 4
psi 14 28 43 57 Adjusting Screw
4. Check the set pressure of the solenoid valve.
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-4-5
MAIN PUMP DELIVERY PRESSURE
The main pump delivery pressure can also be

measured with Dr.EX.
Preparation:
3. Remove the plug from the main pump delivery port.
Install adapter (ST 6069), and pressure gauge (ST
6941) on the port.
: 6 mm
Or connect Dr.EX to the machine for main pump T165-04-04-001

delivery pressure monitoring.
(122!9 "F).
Measurement:
Engine Work
Control Mode
Dial Switch
General
Mode
2. Measure the pressure with the control levers in

neutral.
Evaluation:
T4-5.
Remedy:
T4-4-6
MAIN RELIEF VALVE SET PRESSURE
Summary:
Measure the main relief valve setting pressure at the
main pump delivery port.
The main relief pressure can also be measured with
Dr.EX.
Preparation:
6941) on the port.
: 6 mm
Or connect Dr.EX to monitor the main pump

delivery pressure.
4. Start the engine. Confirm that no oil leakage is T165-04-04-001

(122!9 "F).
Measurement:
Engine Work
E Mode HP Mode
Control Mode
Switch Switch
Dial Switch
General
Fast Idle OFF OFF Purpose
Mode
2. Relieve each actuator to measure main relief

pressures.
First, slowly operate bucket, arm, and boom
control levers to the stroke end to relieve each
function one at a time.
3. As for the swing function, secure the upper-
structure so it is immovable. Slowly operate the
swing lever to relieve the swing function.
4. As for the travel function, secure the tracks against
an immovable object. Slowly operate the travel
levers to relieve the travel function.
Evaluation: Reference:
Refer to the Performance Standard Table in Group If the measure pressures for all functions are lower
T4-5. than the specified range, the probable cause is a
decrease of the main relief valve setting pressure.
If the relief pressure of a particular function is lower,

the probable cause is other than main relief valve.
T4-4-7
Main Relief Pressure Setting Adjustment
Procedure
Adjustment:
Adjust the main relief pressure setting as follows:
1. Loosen lock nut (2).

2. Turn adjusting screw (3) to adjust the relief
pressure setting referring to the table below.
: 17 mm
: 19.5 N#m (2 kgf#m, 14.5 lbf#ft)
Main Relief Valve

W155-04-01-004
2 3
4. Recheck the set pressures.
W105-02-05-151
Adjusting Screw
(Reference) Standard Change in Relief Presssure Pressure

Pressure
Screw Turns 1/4 1/2 3/4 1 Decrease
Increase
kPa 2.79 5.59 8.36 11.2
2
kgf/cm 28.5 57 85.2 114
psi 405 810 1210 1620
T105-06-05-002
T4-4-8
Swing Relief Pressure Setting Adjustment Swing
Procedure Relief
Valve
Adjustment:
Adjust the pressure setting of the swing relief valve
using adjusting screw (1) after loosening lock nut (2).
1. Loosen lock nut (2).
2. Turn adjusting screw (1) adjust the pressure

setting referring to the table below.
4. Recheck the set pressure.
: 24 mm, 32 mm
: 177 N#m (18 kgf#m, 130 lbf#ft)

T158-01-01-001
1 2
(Reference) Standard Change in Relief Presssure T157-02-04-006

kPa 2.9 5.8 8.7 11.7
2
kgf/cm 30 59.5 89 119 1
psi 430 850 1270 1690
Pressure Pressure
Increase Decrease
T157-05-04-023
T4-4-9
Travel Relief Pressure Setting Adjustment
Procedure
Adjustment:
: 19 mm
: 6 mm
1. Loosen lock nut (2). Travel Relief Valve
2. Turn adjusting screw (1) to adjust the pressure

setting referring to the table below. T155-01-01-013
3. Retighten lock nut (2). 2
: 44 N#m (4.5 kgf#m, 32.5 lbf#ft)
T133-06-04-002
(Reference) Standard Change in Relief Presssure

Screw Turns 1
kPa 8.6
2
kgf/cm 88 Adjusting Screw
psi 1250
Pressure
Pressure
Decrease
Increase
W107-02-05-129
T4-4-10
OVERLOAD RELIEF VALVE SET PRES-
SURE
Summary: Measurement:
1. The circuit pressure must be increased by 1. Select the following switch positions:
applying an external force while blocking the return
circuit from the control valve. This measuring Engine Work
E Mode HP Mode
method is hazardous and the results obtained with Control Mode
Switch Switch
this method are unreliable. Dial Switch
2. Pressure setting of the overload relief valve must General
be made at a specified oil flow rate normally far Fast Idle OFF OFF Purpose
smaller than the main pump delivery flow rate. Mode
Accordingly, even if the main relief valve set
pressure can be reset higher than the overload 2. Slowly operate bucket, arm, and boom control
relief valve set pressure, the main pump supplies levers to the stroke ends to relieve each function
too much oil to correctly measure the setting one at a time.
pressure of the overload relief valve. 3. Read the pressures on the pressure gauge while
For this reason, in order to correctly measure the releasing the front functions.
set pressure of the overload relief valve, the 4. Perform the measurement for the bucket, arm,
overload relief valve unit must be removed from and boom, in that order.
the machine and tested on a test stand. 5. Repeat the measurement three times and
3. If the overload relief valve performance must be calculate the average value for each front function.
checked on the machine, however, measure the
main relief pressure while releasing each front Evaluation:
function respective to the measuring overload 1. Performance of the overload relief valves are
relief valve. And, assume that the overload relief normal if the measured main relief pressures are
valve is functioning correctly if the obtained main within the specified value range.
relief pressure is within the specified value range. Refer to the Performance Standard Table in Group
Measure the main pressure of the front functions T4-5.
as follows:
Preparation:
6941) on the port.
: 6 mm
Or connect Dr.EX to the machine for main pump

delivery pressure monitoring.
observed at the pressure gauge connection. T165-04-04-001

(122!9 "F).
T4-4-11
Overload Relief Valve Set Pressure Adjusting
Procedure
NOTE: In principle, adjust the overload relief valve

set pressure on a test stand.
Adjustment:
Adjust the pressure setting of the overload relief
valve using adjusting screw (2) after loosening lock
nut (1).
1. Remove cap (3). Loosen lock nut (1).
2. Turn adjusting screw (2) to adjust the pressure

setting referring to the table below.
: 17 mm
T105-06-05-006
: 31.5 N#m (3.2 kgf#m, 23 lbf#ft)
4. Recheck the set pressure.
(Reference) Standard Change in Relief Presssure Adjusting Screw

kPa 2.8 5.6 8.4 11.2
2 Pressure
kgf/cm 28.5 57 85.2 114 Pressure
Decrease
Increase
psi 405 810 1210 1620
T105-06-05-002
T4-4-12
(Blank)
T4-4-13
MAIN PUMP FLOW TEST
Summary:
To check the main pump performance, measure the 5. Disconnect the vacuum pump. Loosen plug K on
pump flow rate by connecting a portable tester at the the pump housing to bleed air from the pump until
delivery port of the main pump of which the flow rate oil comes out of plug K clearance.
is to be measured. Dr.EX or a pressure gauge is 6. Connect a tachometer to the injection pipe.
used for pressure reading purpose in the Disconnect N senser connector. Fully open the
measurement. loading valve on the portable tester.
7. Start the engine. Check the pressure gauge
Preparation: connection for any oil leakage. Connect the Dr. EX
1. Properly shut down the engine. Press the air to the machine to monitor pressure.
release valve on top of the hydraulic oil tank to
release any remaining pressure. Connect a Measurement:
vacuum pump to the oil filler on the hydraulic oil
tank. 1. Maintain the hydraulic oil temperature at 50!5 "C
(122!9 "F).
NOTE: Operate the vacuum pump while connecting
the portable tester to the main pump.
Engine Travel Work
Control Mode Mode
2. Disconnect delivery hoses A or B from the main Switch Switch Switch
Dial Switch Switch
pump to be measured. Install flange (6), split Fast General
flange C, and bolt D on the disconnected hose. Fast Idle Speed OFF OFF Purpose OFF
Remove plug E and install adapter (10). Mode Mode
: 41 mm : 10 mm
3. Adjust the main relief valve to obtain each
3. Install pipes (4) and (5), split flange C, bolt D, test specified pressure on the P-Q curve shown page
hoses (3) and (12), block (7), portable tester (2), T4-5-4.
and adapters (8), (9), and (11). Do not connect the 4. Relieving arm roll in circuit, gradually close the
end of pipe (4) or (5) to the main pump which is not loading valve on the portable tester to obtain the
to be measured. specified pressure on the P-Q curve, and measure
Instead, plug the pipe end by installing flange (6) the flow rate and engine speed. Repeat steps 3
and split flange C with bolt D. and 4 for all specified pressure points on the P-Q
Straighten hose (3), which is connected to the curve.
plugged pipe (4) or (5), as much as possible, and 5. Repeat the measurement three times and
secure the plugged pipe (4) or (5), to restrict any calculate the average values.
movement of hose (3).
4. When Dr.EX is not available, remove plug J from

the main pump delivery port section. Connect
adapter (15) to pump 1 and 2. Connect pressure
gauge (1).
: 22 mm : 6 mm
T4-4-14
Evaluation:
1. Conversion 2. Specified Pump Flow Rate
Convert the measured pump flow rate into the one Refer to the Performance Standard Table in Group
for the rated pump speed using the following T4-5.
formula.
Converted Pump Flow Rate (Qc) = Ns $ Q / Ne

NOTE: Pipe (4) is installed on the pump 2 for
Where: measuring the pump 2 in the drawing.
Qc : Converted Pump Flow Rate
Q : Measured Pump Flow Rate
Ns : Rated Engine Speed (2150 min-1)
Ne : Measured Engine Speed
K
A C, D 6
B 6 C, D
4 5
C, D
10
12 E
17
1
13 1 13
M165-07-030
3
7
3
8
2
11
12
9
T165-04-04-007
J
M165-07-034
1 - Pressure Gauge 5 - Pipe B (ST 6192) 8 - PF1$PF1 Adapter 11 - PF1$UNF1-7/8

(ST 6941) (ST 6003) Adapter (ST 6146)
2 - Portable Tester 6 - Flange (ST 6190) 9 - PF1$UNF1-7/8 12 - Test Hose (ST 6145)
(ST 6299) (3 Used) Adapter (ST 6003) (2 Used)
3 - Test hose (ST 6145) 7 - Block (ST 6289) 10 - PF3/4$PF1 Adapter 13 - Adapter (ST 6069)
(3 Used) PF1$PT1 Adapter (ST 6635)
(ST 6012 ) (3 Used)
4 - Pipe E (ST 6192)
T4-4-15
Regulator Adjustment
4 3 1 2
T165-04-04-004
1 - Lock Nut 2 - Adjusting Screw 3 - Lock Nut (For P-Q Line 4 - Adjusting Screw (For P-Q
(For Pilot Pressure (For Pilot Pressure Adjustment) Line Adjustment)
Characteristic Characteristic
Adjustment) Adjustment)
T4-4-16
Adjustment Item Adjustment Procedure Remarks

1. Pilot Pressure Charact- Loosen lock nut (1) and turn ad- 1) Securely retighten lock nut
eristics (Pi-Q Line) justing screw (2). (1) after the adjustment.
Rotating adjusting screw (2) 1/4 a
Q
turn clockwise decreases the flow
rate by 3.0 cm3/rev. (0.18 in3/rev).
Pi
2. P-Q Line Loosen lock nut (3) and turn 1) Rotate the adjusting screws
(Torque Adjustment) adjusting screw (4). watching the engine per-
Rotating adjusting screw (4) 1/4 a formance.
turn clockwise increases the 2) Securely retighten lock nut
Q
maximum pump flow rate by 6.5 (3) after the adjustment.
cm3/rev. (0.40 in3/rev).
T4-4-17
SWING MOTOR DRAINAGE
Summary:
To check swing motor performance, measure the
amount of oil draining from the swing motor while
swinging the upperstructure.
NOTE: The amount of drain oil from the swing

motor will change depending on hydraulic
oil temperature.
Maintain hydraulic oil temperature at 50!5
"C (122!9 "F). 1
Preparation:
1. Maintain hydraulic oil temperature at 50!5 "C
(122!9 "F). Rotate the swing motor to warm the
inside of the motor.
2. Properly shut down the engine. Press the air

release any remaining pressure.
3. Disconnect the swing motor drain hose (1) at the

hydraulic oil tank end. Install plug (ST 6213) to the
disconnected end on the hydraulic oil tank.
: 22 mm
: 39 N#m (4 kgf#m, 29 lbf#ft)

Also, take care not to fall off the machine
while the measurement. T107-06-06-002
Preconditions for Measurement:

Engine Work
Control Mode
Dial Switch
General
Mode
T4-4-18
Measurement:
1. Amount of Oil Drained While Swinging the
Upperstructure
(1) Fully retract the arm cylinder. Fully extend the
bucket cylinder. Raise the boom so that the arm
tip pin height is the same as the boom foot pin
height. Be sure that the bucket is empty.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start draining oil measurement The same height as
boom foot pin height
after the swing speed reaches a constant
maximum speed. The measuring time should be
T105-06-03-013
more than 45 seconds.
(3) Repeat the measurement at least three times in
both clockwise and counterclockwise directions,
2. Amount of Oil Drained While Relieving Swing

Motor Circuit
(1) Thrust the bucket teeth into the ground as
illustrated so that the upperstructure does not
T107-06-06-005
rotate when the swing lever is operated full
stroke.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start drain oil measurement
when drain oil starts coming out of the drain hose
end. The measuring time should be more than
45 seconds.
(3) Repeat the measurement at least three times in
both clockwise and counterclockwise directions,
Evaluation:
T4-5.
T107-06-05-008
* Conversion of the amount of drain oil measured
into the per-minute value
First measure the amount of drain oil using a

calibrated container. Then, convert the measured
drain oil into the per-minute value using the
formula below:
%Q & 60 $ q / t
Where:
%Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-4-19
TRAVEL MOTOR DRAIN OIL PRESSURE
Summary:
To check travel motor performance, measure the
drain oil pressure, while rotating the travel motor with
the measuring side track jacked up.
NOTE: The amount of drain oil from the travel motor

and the drain oil pressure will change
depending on hydraulic oil temperature.
Maintain hydraulic oil temperature at 50!5
"C (122!9 "F).
Preparation:
1. Main hydraulic oil temperature at 50!5 "C (122!9
"F). Rotate the travel motor to warm the inside of
the motor.
2. Properly shut down the engine. Press the air

release any remaining pressure.
3. Remove plug (1) and install pressure gauge (ST

6925) and adapter (ST 6053).
: 10 mm
Preconditions for Measurement: 1

1. Preconditions for Measurement:
T133-06-04-003
Engine Travel
Control Mode
Dial Switch
Fast
Fast Idle OFF OFF Speed OFF
Mode
T4-4-20
Measurement:
1. Start the engine. Jack up the measuring side track
using the front attachment, as illustrated.
CAUTION: Securely support the raised track

90 to 110"
using wooden blocks.
2. Rotate the raised track with the travel lever

operated full stroke. Measure the drain oil
pressure. M104-07-067
Evaluation:
T4-5.
NOTE: Operational performance of the travel motor

should be totally evaluated taking test
results on the travel speed and mistrack into
consideration.
T4-4-21
(Blank)
T4-4-22
OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE STAND-
ARD TABLE
The standard performance values are listed in the table

below. Engine Work
E Mode HP Mode Hydraulic Oil
Refer to the Groups 2 to 4 for performance test Control Mode
Switch Switch Temperature
procedures. Values indicated in parentheses are Dial Switch
reference values. General
50!5 "C
Fast Idle OFF OFF Purpose
(122!9 "F)
The following switch positions shall be selected and the Mode
hydraulic oil temperature shall be maintained as
indicated below as the preconditions of performance
tests unless otherwise instructed in each performance
test procedure:
EX150LC-5
Performance Test Designation (Performance Remarks
Standard)
-1
ENGINE SPEED (min )
Fast Idle Speed with E and HP Modes OFF 2 350!50 Value indicated on
Dr.EX is permissible.
Fast Idle Speed with E Mode ON 2 000!50 #
Fast Idle Speed with HP Mode ON 2 250 or more Extend the arm cylinder
to relieve the arm roll-in
circuit.
Slow Idle Speed 950!100 Value indicated on
Dr.EX is permissible.
Auto-Idle Speed 1 200!100 #
2
ENGINE COMPRESSION PRESSURE (kgf/cm ) 31
(After engine warm-up)
VALVE CLEARANCE (IN, EX) (mm) 0.4 With the engine cold
2
NOZZLE INJECTION PRESSURE (kgf/cm ) 185
INJECTION TIMING (Degrees before TDC) (deg.) 12"
TRAVEL SPEED (sec/20 m)
FAST SPEED 13.6!0.9
SLOW SPEED 23.3!2.5
TRACK REVOLUTION SPEED (sec/3 rev) 28.9!3.0
MISTRACK (mm/20 m) 200 or less
(With fast and slow travel speed modes)
TRAVEL PARKING FUNCTION CHECK (rev) 1/6 or less
TRAVEL MOTOR LEAK (mm/5 min) 0
SWING SPEED (sec/3 rev) 13.1!0.9
SWING FUNCTION DRIFT CHECK ( mm/180") 800 or less 2.6 m arm, 0.6 m3
(PCSA heaped) bucket
SWING MOTOR LEAKAGE (mm/5 min) 0 2.6 m arm, 0.6 m3
SWING BEARING PLAY (mm) 1.1 or less Limit of Use: 3.7
2
NOTE: 1 kgf/cm =98.07 kPa
T4-5-1
EX150LC-5
Standard)
MAXIMUM SWINGABLE SLANT ANGLE (deg.) 20" or more 2.6 m arm, 0.6 m3
HYDRAULIC CYLINDER CYCLE TIME (sec) 2.6 m arm, 0.6 m3
Boom Raise 3.0!0.3
Boom Lower 2.5!0.3
Arm Roll-In 3.5!0.3
Arm Roll-Out 2.6!0.3
Bucket Roll-In 3.8!0.3
Bucket Roll-Out 2.2!0.3
DIG FUNCTION DRIFT CHECK (mm/5 min) 2.6 m arm, 0.6 m3
Boom Cylinder 10 or less
Arm Cylinder 20 or less
Bucket Cylinder 15 or less
Bucket Bottom 150 or less
CONTROL LEVER OPERATING FORCE (kgf)
Boom Lever 2.0 or less
Arm Lever 1.7 or less
Bucket Lever 1.7 or less
Swing Lever 2.0 or less
Travel Lever 2.5 or less
CONTROL LEVER STROKE (mm)
Boom Lever 105!10
Arm Lever 83!10
Bucket Lever 83!10
Swing Lever (mm) 105!10
Travel Lever 115!10
NOTE: 1 kgf=98.07 N
T4-5-2
EX150LC-5
Standard)
(sec)
BOOM RAISE/SWING (Bucket Empty) 3.4!0.3 2.6 m arm, 0.6 m3
( mm)
(Bucket Teeth Height: H) 5 900 or more
2 +10
PRIMARY PILOT PRESSURE (kgf/cm ) 40 -5
(Engine: Fast Idle)
SECONDARY PILOT PRESSURE (kgf/cm2) (34 to 40) Value indicated on Dr.EX
(Engine: Fast Idle and Slow Idle) (Lever: Full Stroke)
2
SOLENOID VALVE SET PRESSURE (kgf/cm ) Value Indicated on
Dr.EX!2
2
MAIN PUMP DELIVERY PRESSURE (kgf/cm ) 23!10 Value indicated on Dr.EX
2
MAIN RELIEF VALVE SET PRESSURE (kgf/cm )
+20
Boom, and Arm 350 -0 Value indicated on Dr.EX
+25
Bucket 350 -0 Value indicated on Dr.EX
+20
Swing 345 -5 Value indicated on Dr.EX
+25
Travel 350 -5 Value indicated on Dr.EX
OVERLOAD RELIEF VALVE SET PRESSURE (kgf/cm2) (Reference values at
50 L/min)
+10
Boom (Raise/Lower), Arm Roll-In, and Bucket Roll-In 380 -0
+10
Arm Roll-Out, Bucket Roll-Out 400 -0
MAIN PUMP FLOW TEST (L/min) $ Refer to page T04-05-04.
SWING MOTOR DRAINAGE
With constant maximum speed (L/min) 0.2 to 1.0 Limit of Use: 2.0
With the motor relieved (L/min) 8 Limit of Use: 16
TRAVEL MOTOR DRAINAGE OIL PRESSURE
2
Continuous Pressure (kgf/cm ) (2.0) Measured at Test Stand
2
Maximum Instantaneous Pressure (kgf/cm ) (5.0) Measured at Test Stand
2
NOTE: 1 kgf/cm =0.09807 Mpa
T4-5-3
* MAIN PUMP P-Q DIAGRAM (EX150LC-5)
(REFERENCE: Measured at Test Stand)
• Rated Engine Speed : 2 150 min-1 (rpm)

• Hydraulic Oil Temperature : 50!5 "C
NOTE: Refer to T04-04-14.
2
NOTE: 1 kgf/cm =0.09807 MPa
L/min
Flow
Rate
2
Delivery Pressure Kgf/cm T165-04-04-005
T4-5-4
INJECTION PUMP
Test conditions : NOTE: The nozzle test injection pressure is 17.2

Injection pump: PES4A 101041-8620 2
MPa (175 kgf/cm ). However, actual
Governor: EP/RSV 105419-2380 machine injection pressure is 18.1 MPa
Nozzle and nozzle holder assembly: 105780-8140 2
(185 kgf/cm ).
(Bosch No. EF8511/9A)
Nozzle: 105780-0000 (Bosch No. DN12SD12T)
Nozzle holder : 105780-2080 (Bosch No. EF8511/9)
2
Nozzle opening pressure: 17.2 MPa (175 kgf/cm )
Test fuel: ISO 4113 or SAE J967d
2
Transfer pump pressure: 0.16 MPa (1.6 kgf/cm )
Injection pipe: Inner Dia. 2 mm, Outer Dia. 6 mm,
Length 600 mm (0.079, 0.23, 23.6 in)
Fuel temperature: 40+5 "C (104+9 "F)
Overflow valve opening pressure: 127 kPa (1.3
2
kgf/cm )
Average injection Maximum vari-

Adjusting Pump speed Rack posi-
-1 Strokes rate ance between Fixed Remarks
Point (min ) tion (mm) 3
(cm /1000 Strokes) cylinders (%)
A 1160 8.8 87.5!1.1 !2 Lever
C 475 Approx. 6.0 8.8!1.4 !14 Rack
Governor adjustment
Above 14.0
13.0
Idle-sub spring setting
9.5!0.1 Governor spring setting
9.4
Rack position 8.8
(mm)
6.4 8.3!0.1
6.0 C
5.5!0.3 8.7-0.5
(1160)
0 1265
300
350 475 1170
135!30 (450)
T165-04-05-001
-1
Pump speed min (rpm)
T4-5-5
(Blank)
T4-5-6
6(&7,21ýè
7528%/(6+227,1*
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TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Use troubleshooting A procedure when fault codes are

shown on Dr.EX.
!" How to Read the Troubleshoting Flow Charts
YES(OK)
(2) After checking or measuring item (1), select either Yes (OK) or No
(NOT OK) and proceed to item (2) or (3), as appropriate.
• (1)
(3)
NO(NOT OK)
• Special instructions or reference item are indicated in the spaces under the box. Incorrect
measuring or checking methods will render troubleshooting impossible, and may damage
!"
Key switch: ON components as well.
• Explanation of how to use lamp harness kit required. Refer to “Harness Check” Group
(Group 7) in this section.
• Use Dr. EX function.
• Causes are stated in a thick-line box. Scanning through thick-line boxes, possible causes
can be seen without going through the flow chart.
NOTE: For all connector drawings illustrated in this

group, harness end connector terminals
seen from the open end side are shown.
Wire Harness Side
Open End Side

Harness End Connector
T158-05-03-001
T5-3-1
FAULT CODE
FAULT CODE TROUBLE CORRECTIVE ACTION

01 EC sensor failure 1) Perform “Retrial B”.
2) Check harness.
3) Replace EC sensor.
02 Pump 1 delivery pressure sensor failure 1) Perform “Retrial B”.
03 Pump 2 delivery pressure sensor failure 2) Check harness.
3) Replace the pump delivery pressure sensor.
04 Pump 1 control pressure sensor failure 1) Perform “Retrial B”.
05 Pump 2 control pressure sensor failure 2) Check harness.
3) Replace the pump control pressure sensor.
06 Arm roll-in pilot pressure sensor failure 1) Perform “Retrial B”.
2) Check harness.
3) Replace the arm roll-in pilot pressure sensor.
07 Engine control dial failure 1) Perform “Retrial B”.
2) Check harness.
3) Replace the engine control dial.
T5-3-2
(Blank)
T5-3-3
FAULT CODE 01 (EC SENSOR FAILURE)
NO Faulty MC
Check if breakage or
short circuit exists !"
After replacement, refer
YES between MC 22P to page T5-4-60.
connector terminal
No.D15 and EC
sensor terminal No.2. Harness failure between
Disconnect EC sensor MC and EC sensor.
connector. Check if YES
voltage between
YES
harness end connector
terminals No.1 and Harness breakage
Disconnect EC sensor No.3 is 5#0.5 V. YES
between MC and EC
connector. Check if Check if voltage sensor terminal No.3.
resistance between EC between harness end
sensor side connector !"
Key switch: ON
connector terminals
terminals No.1 and No.3 is No.1 and vehicle frame
1.7#0.4 k$. NO
is 5#0.5 V. Harness breakage
Connect test harness
between EC sensor between MC and EC
connector halves. Turn !"
Key switch: ON NO sensor terminal No.1.
engine control dial and
check if voltage changes
as specified. Faulty EC sensor
!"
Test harness: ST 7129 NO
!"
Refer to page T5-3-9 for !"
the voltage change to page T5-4-60.
standard values.
Connector (harness end connector terminals seen from the open end side)
Main Controller (22P): “D” is added for each terminal number in the text.
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
EC Sensor
1 2 3
T5-3-4
FAULT CODE 02
(PUMP 1 DELIVERY PRESSURE SENSOR
FAILURE)
FAULT CODE 03
(PUMP 2 DELIVERY PRESSURE SENSOR
FAILURE)
Checking Instruction:
• It is unlikely for both pump delivery pressure
sensors (for pumps 1 and 2) to fail simultaneously.
For this reason, if faults codes 2 and 3 are
indicated, the probable cause is harness failure.
Harness failure between

Check if breakage or YES MC and pump delivery
short circuit exists pressure sensor.
between MC 22P
YES connector terminal No.
D16 (pump 1)/No. D17
(pump 2) and pump Faulty MC
delivery pressure sensor
Disconnect the pump terminal No.2. NO
delivery pressure !"
sensor connector. to page T5-4-60.
NO Check if voltage
between harness end Harness breakage
connector terminals between MC and pump
No.1 and No.3 is 5#0.5 YES delivery pressure sensor
Switch pump delivery V.
pressure sensors (for Check if voltage terminal No. 3.
pumps 1 and 2) with !"
Key switch: ON between harness end
each other. connector terminals
Perform “RETRIAL.” NO No.1 and vehicle frame Harness breakage
Check if indicated fault is 5#0.5 V. between MC and pump
code changes to the delivery pressure sensor
one for the other pump !"
Key switch: ON NO
terminal No. 1.
delivery pressure
sensor.
Faulty pump delivery
YES pressure sensor.
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
Pump Delivery Pressure Sensor
1 2 3
T5-3-5
FAULT CODE 04
(PUMP 1 CONTROL PRESSURE SENSOR
FAILURE)
FAULT CODE 05
(PUMP 2 CONTROL PRESSURE SENSOR
FAILURE)
Checking Instruction:
• It is unlikely for both pump control pressure
sensors (ones in 4-spool side and in 5-spool side
control valves) to fail simultaneously. For this
reason, if faults codes 04 and 05 are indicated, the
probable cause is harness failure.

Check if breakage or YES MC and pump control
short circuit exists pressure sensor.
between MC 22P
YES connector terminal No.
D14 (4-spool side)/No.
D19 (5-spool side) and Faulty MC
pump control pressure
Disconnect pump sensor terminal No.2. NO
control pressure !"
sensor connector. to page T5-4-60.
NO Check if voltage
between harness end
connector terminals Harness breakage
Switch pump control No.1 and No.3 is 5#0.5 YES between MC and pump
pressure sensors (ones V. control pressure sensor
Check if voltage terminal No.3.
for 4-spool side and for !"
5-spool side control
valves ) with each other. connector terminals
NO No.1 and vehicle frame Harness breakage
Perform “RETRIAL”
is 5#0.5 V. between MC and pump
Check if the indicated
control pressure sensor
fault code changes to the !"
Key switch: ON NO
terminal No. 1.
one for the other pump
control pressure sensor.
Faulty pump control

YES pressure sensor.
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
Pump Control Pressure Sensor
1 3
2
T5-3-6
FAULT CODE 06
(ARM ROLL-IN PILOT PRESSURE
SENSOR FAILURE)

YES MC and pilot pressure
short circuit exists sensor.
between MC 22P
YES
connector terminal
No.D18 and pilot
pressure sensor Faulty MC
Disconnect pilot terminal No.2. NO
pressure sensor !"
connector. Check if to page T5-4-60.
NO voltage between
harness end connector
terminals No.1 and Harness breakage
No.3 is 5#0.5 V. YES between MC and pilot
pressure sensor
Check if voltage terminal No.3.
Replace pilot pressure !"
sensor with pump control
connector terminals
pressure sensor. Harness breakage
Perform “RETRIAL” NO No.1 and vehicle frame
is 5#0.5 V. between MC and pilot
Check if fault code pressure sensor
disappears. !"
Key switch: ON NO
terminal No.1.
Faulty pilot pressure

YES sensor (arm roll-in).
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
Pilot Pressure Sensor
1 3
2
T5-3-7
FAULT CODE 07
(ENGINE CONTROL DIAL FAILURE)

YES MC and engine control
short circuit exists dial.
between MC 22P
YES
connector terminal
No.D21 and engine
control dial terminal Faulty MC
Disconnect engine No.6. NO
control dial connector. !"
Check if voltage to page T5-4-60.
YES between harness end
connector terminals
Disconnect engine control No.5 and No.7 is 5#0.5 Harness breakage
dial connector. Check if V. YES between MC and engine
resistance between engine control dial terminal
control dial side terminals !"
Key switch: ON Check if voltage No.7.
No.5 and No.7 is 5#0.5 k$. between harness end
With the engine control connector terminals
dial connected, insert test NO No.5 and vehicle frame Harness breakage
probe from back of engine is 5#0.5 V. between MC and engine
control dial terminal
control dial. Turn engine !"
Key switch: ON NO
No.5.
control dial and check if
voltage changes as
specified.
Faulty engine control
!"
Refer to page T5-3-9 for NO dial.
the voltage change
standard values.
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
Engine Control Dial
4 3 2 1
5 6 7 8 9
T5-3-8
SENSOR OPERATING RANGE LIST
1. Preconditions for measurement
• Hydraulic Oil Temperature: 50#5 %C (122#9 %F) E Mode

• Unless otherwise instructed, set the switches as HP Mode Switch
Switch
follows:
Engine E Mode Work

Auto-Idle
Control Switch/HP Mode
Switch
Dial Mode Switch Switch
General
Max.
OFF Purpose OFF
Position
Mode
• Monitor using the Dr.EX.
Engine Control Dial

T157-07-02-002
2. Sensor Operating Range
Item Required Control/Switch Operation

Engine Control Dial At minimum speed position 0.3 to 1.0 V
At maximum speed position 4.0 to 4.7 V
EC Sensor Engine control dial at Min. position 2.5 to 2.7 V
Engine control dial at Max. position with HP 3.3 to 3.7 V
mode switch turned OFF
Engine control dial at Max. position with HP 0.1 V or more larger than the voltage
mode switch turned ON obtained above (with the engine
control dial at Max. position with HP
mode switch turned OFF)
2
Pump Delivery Control Levers: Neutral 18#10 kgf/cm
Pressure Sensor
+20 2
Boom Raised and Cylinder Relieved 350 -10 kgf/cm
2
Pilot Pressure Sensor Control Levers: Neutral 0 to 1.0 kgf/cm
Pilot Control Shut-Off Lever:
Locked Position
2
Control Lever: Full Stroke 34 to 40 kgf/cm
Pilot Control Shut-Off Lever:
Unlocked Position
2
Pump Control Pressure Control Levers: Neutral 5 to 15 kgf/cm
Sensor
2
One Track Jacked-Up Travel Lever (Raised 30 to 40 kgf/cm
track side): Full Stroke
2
NOTE: 1 kgf/cm =0.09807 MPa=14.22 psi
T5-3-9
(Blank)
T5-3-10
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault code Start the troubleshooting with more probable causes
is displayed on the Dr.EX although the machine’s selected by referring to these tables.
operation is abnormal.
On the front section pages of this group T5-4, are
tables indicating the relationship between machine
trouble symptoms and related parts which may cause
such trouble if failed.
!" How to Read the Troubleshoting Flow Charts
YES(OK)
(2)
• After checking or measuring item (1), select either Yes (OK) or
• (1) No (NOT OK) and proceed to item (2) or (3), as appropriate.
(3)
NO(NOT OK)
• Special instructions or reference item are indicated in the spaces under the box.
• Incorrect measuring or checking methods will render troubleshooting impossible,
!"
Key switch: ON and may damage components as well.
• Explanation of how to use lamp harness kit required. Refer to “Harness Check” Group
• (Group 7) in this section.
• Use Dr.EX function.

•
• Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
•
causes can be seen without going through the flow chart.
T5-4-1
RELATIONSHIP BETWEEN MACHINE This table indicates the probable machine trouble
TROUBLE SYMPTOMS AND PARTS IN symptoms by part item when each part is failed and
TROUBLE procedures to determine if the part has failed.
EC Motor EC Sensor Engine Control Dial
!"
To operate governor lever. !"
To detect the slow-idle speed !"To instruct the engine target
governor lever position (2.5 V). speed governor lever position.
Part function
!"
Governor lever does not move. !"
Whenever key switch is ON, gover- !"
Even if engine control dial is
nor lever position is learned as in operated, engine speed is
the slow idle speed position differ- unchanged.
Control System ing from the correct position. Ac- !"If harness to engine control dial
Trouble cordingly, engine speed is con- is broken, target speed 1600
trolled afterward with the discrep- min-1 is used as the backup
ancy which occurred at this time. value.
!"
Even if engine control dial is op- !"
If the discrepancy occurred to the !" Engine speed is constantly held
erated, engine speed does not slower side, engine speed is at 1 600 min-1.
increase from slow speed range. changed by engine control dial. (Auto-idle function operates,
!"
Starter rotates but engine fails to However, engine speed control and engine can be stopped by
start occasionally. range stays slower than normal. turning key switch.)
!"
While engine is running at a
(Note: If the discrepancy occurred
to the faster side, when engine con-
faster than specific speed, if har-
trol dial is turned to the fastest
ness to EC motor is broken, en-
position, EC motor continues mov-
Machine Symptom gine stalls.
ing. However, EC motor is a worm
!"
While engine is running at a gear type so that governor lever is
slower than specific speed, if kept holding at the full stroke posi-
harness to EC motor is broken, tion. If engine control dial is turned
engine becomes uncontrollable. to the slowest position, governor
Engine does not stop even if key lever returns to the slow idle posi-
switch is turned OFF. tion.)
!"
When engine is started, engine
speed fluctuates.
!"
Engine start may become difficult.
By Dr.EX Self- Fault code 01 is displayed. Fault code 07 is displayed.
Diagnosing -
Function
By Dr.EX Monitor Item: EC angle Monitor item:
Monitor Target engine speed
Trouble Function -
Shooting
Proce- By Lamp!" Install lamp harness (ST7125).
Harness Then, check output signal from
dures - -
Check EC and check if harness is nor-
mal.
By Other
Check/ - - -
Measurements
!"
Engine is stopped by EC motor. !" If EC sensor is failed, engine learn-
No engine stop motor is provided. ing operation becomes impossible.
However, a fuel cutoff cable is in-
stalled.
-
Note
Descriptions in T2-1 T2-1 T2-1

(Operational Prin-
ciple)Technical
Manual
T5-4-2
Pump Control Pump Delivery

N Sensor Solenoid Valve Unit (SE)
Pressure Sensor Pressure Sensor
!"
To detect pump control valve !"To detect both right and left !" To detect engine speed to con- !"
To reduce pump swash angle
pressure in control valve to pump delivery pressures to trol speed sensing system. by guiding pilot pressure to
control the travel motor swash control speed sensing system, regulator to operate the speed
angle. HP mode circuit, arm regen- sensing control system.
erative circuit, and travel motor
swash angle.
!"
Sensor output is reduced to !"
When pump delivery pressure !"Speed sensing system does !"
Pilot pressure is not fed to
zero and travel motor swash sensor output is 0 V or 5 V, the not function. regulator.
angle is held to the maximum following symptoms appear.
angle.
!"
Even if travel mode switch is !" Engine stalls when the ma- !"
Travel speed is changed to the !" Engine may stall under heavy
turned to the fast mode posi- slow speed range. However, chine is operated at a high alti- conditions such as operation at
tion, travel speed does not automatic up shifting to the fast tude or under heavy operating a high altitude.
change to the fast range. speed range from slow speed conditions.
" range is impossible.
!"
HP mode does not work.
!"
When combined operation is
made, arm speed is slow (when
delivery pressure sensor for
pump 2 has failed).
"
Fault codes 04 and 05 are Fault codes 02 and 03 are dis-

displayed. played. - -
Monitor items: Monitor item: Monitor item:

Pump 1 and 2 control pressure - Actual engine speed Pump proportional solenoid
(engine speed is not measured) valve output
!"
Install lamp harness (ST7123).
- - - Then, check output signal from
MC and check if harness is
normal.
- - - -
!"
Evaluation by Dr.EX
0.25 V or Less: Discontinuity
4.75 V or More: Short Circuit
- - -
T2-1 T2-1 T2-1 T2-1
T5-4-3
Solenoid Valve Unit (SC) Solenoid Valve Unit (SI) Pressure Switch (Travel)
!"
When arm is rolled in, arm speed !"
To increase travel speed by de- !"To detect that travel spool is
is increased by guiding return oil creasing travel motor swash angle operated (for auto-idle opera-
from arm cylinder rod side to bot- when fast travel mode is selected tion and travel motor swash an-
Part function tom side. and pump delivery pressure is low. gle control).
!"
If solenoidvalve unit (SC) is not !"
Travel speed is held in slow speed !"
No signal is sent to MC.
energized, pilot pressure at port range.
SC is 0 MPa (0 kgf/cm2).
Control System Thereby, arm regenerative func-
Trouble tion does not work.
!"
When leveling, arm speed be- !"
Travel speed does not increase !" Even if machine is traveled with
comes very slow. even if travel mode switch is turned auto-idle switch ON, engine
to the fast travel speed position. speed does not increase.
!"
When traveling on a flat area in
the fast travel mode, travel
speed is slow.
Machine Symptom
By Dr.EX Self-
Diagnosing - - -
Function
By Dr.EXMonitor item: Monitor item: Monitor item: Pressure switch
Monitor Arm regenerative proportional so- Travel motor displacement angle While traveling, monitor to check
Function lenoid valve output change output if pressure switch is ON or OFF.
Trouble
Shooting By Lamp!"
Install lamp harness (ST7123). !"
Install lamp harness (ST7123).
Harness Then, check output signal from Then, check output signal from MC
Proce- Check MC and check if harness is nor- and check if harness is normal. -
dures mal.
By Other - - -
Check/
Measurements
!"
It is possible to check if pres-
sure switch has failed or if a port
is clogged by switching the
pressure switch with an adja-
Note - - cent one (for front).

(Operational Prin-
ciple)Technical
Manual
T5-4-4
Pressure Switch Pilot Pressure Sensor

Pressure Switch (Front) Learning Switch
(Boom Raise) (Arm Roll-In)
!"
To detect that front and/or !"
To detect boom raise pilot !" To detect arm roll-in pilot pres- !"
To start learning engine control
swing spool is operated (for pressure (for arm regenerative sure (for HP mode control and
auto-idle operation). control). arm regenerative control). ON: 0 V # Learning
OFF: 5 V # Normal Control
!"
No signal is sent to MC. !"
Engine learning does not func-
" tion.
!"
Even if either front or swing !"
As arm generative function !"
When the combined operation !" If trouble is caused by circuit
control lever is operated with does not work, when boom is of swing and arm roll-in is discontinuity, engine control
auto-idle switch ON, engine raised and arm is rolled in, arm made, arm regenerative func- system operates normally.
speed does not increase. speed is slower than normal tion does not work so that arm (Only engine learning function
(difficult to discern). speed is slow when starting to fails.)
!"
When beginning to level a roll in (difficult to discern). !"
If trouble is caused by a short
ground surface, bucket is !"Arm speed is slow when level- circuit, the learning mode op-
slightly lowered into the ing. erates when key switch is
ground. !"
HP mode does not function turned ON. Therefore, engine
when arm is rolled in. may stall 5 seconds after en-
gine starts.
Fault code 06 is displayed.

- - -
Monitor item: Pressure switch Monitor item: Pressure switch Monitor item: Monitor item:
While operating front or swing Arm roll-in pilot pressure Engine learning control
function, monitor to check if
pressure switch is ON or OFF.
- - - -
- - - -
!"
It is possible to check if pres-
sure switch has failed or if a
port is clogged by switching the
pressure switch with an adja-
cent one (for travel). - - -
T2-1 T2-1 T2-1 T2-1
T5-4-5
HP Mode Switch E Mode Switch Travel Mode Switch
!"
To control HP mode operation !"
To select E mode. !"
To change travel speed at two
stages.
Part function ON: 0 V # HP Mode. ON: 0 V # E Mode Fast Travel Mode:

OFF: 5 V # Standard Mode. OFF: 5 V # Standard Mode 0 V # Traveling at fast speed
Slow Travel Mode: 5 V
!"
Discontinuityin Switch: Travel
speed is kept in slow range (5
V).
Control System
- -
Trouble
!"
Broken Wire: Even if HP mode !"
Broken Wire: Even if E mode !" Even if travel mode switch is
switch is depressed, HP mode switch is depressed, engine turned to the fast travel mode
does not operate. runs at full speed. position, travel speed is un-
!"
Short Circuit: Even if HP mode !"
Short Circuit: Engine speed is changed.
switch is turned OFF, HP mode not increased up to full speed.
is not deactivated.
Machine Symptom
By Dr.EX Self-
Diagnosing - - -
Function
By Dr.EXMonitor item: HP mode switch Monitor item: E mode switch Monitor item:
Monitor Selected travel mode switch
Trouble Function
shooting
Proce- By Lamp
Harness
dures Check - - -
By Other
Check/ - - -
Measurements
Note - - -

(Operational Prin-
ciple)Technical
Manual
T5-4-6
Pump Control Restriction in Arm 1

MC Flow Combiner Valve
Valve Parallel Passage
!"
To To develop pump control pres- !"
control engine, pump, and !" To supply hydraulic oil to both !"To ensure lateral thrust force of
valve operations. sure in response to the oil flow right and left travel spools from the front by swing function.
rate passing through the center pump 1 when the combined
bypass passage in the control operation of travel and
valve. front/swing is made.
"
!"
Problems may differ depending !"
If the pump control valve spool !"
When the combined operation !" If the restriction is clogged,
on the trouble. (Machine trou- is seized, or the spring is bro- of travel and front/swing is hydraulic oil does not flow
bles shown below signify that ken, pump control pressure made, hydraulic oil is not sup- through the arm 1 parallel cir-
the logic circuit in MC has does not change. plied to the left travel spool, or cuit.
some faults.) oil flow to the left travel spool is
insufficient.
!"
Even if key switch is turned to !"
When the 5-spool side pump !" While traveling straight, the !"
Arm speed is slow when level-
the ON position, EC motor control valve is faulty: machine mistrack when the ing.
does not rotate to the start po- "1.Left track travel speed only is swing lever is operated.
sition so that engine cannot slow.
start. Or, even if engine is "2.Swing function is also slow.
started, engine speed does not "3.Arm speed is slow when lev-
increase. eling.
!"Pump swash angle is held to a "4.Single operation of bucket,
minimum, all function speeds boom, or arm is almost nor-
are slow. mally performed.
!"
When 4-spool side pump con-
trol valve is faulty:
"1.Bucket single operation
speed is very slow.
"2.Boom is not raised when lev-
eling.
"3.Right track travel speed only
is slow.
"4.Single operation of boom,
arm, or swing is almost nor-
mally performed.
Procedures may differ
depending on the locations of - - -
failures.
Monitor item:
- Pump 1 and 2 control pressure - -
- - - -
- - - -
!"
Before suspecting a failure in
MC, check the fuse in this con-
trol circuit.
- - -
T3-3 T3-3 T3-3

-
T5-4-7
Check Valve and Restriction in Arm Regenerative

Travel Flow Control Valve
4-Spool Side Parallel Circuit Control Valve
!"
To supply hydraulic oil from pump !"
To increase arm speed by allowing !"
To reduce the shock load devel-
1 to arm 1 spool in pump 2 side. the return oil from the arm cylinder oped when single travel opera-
rod side to flow into the arm cylinder tion is switched to the combined
bottom side when the valve is operation of travel and front by
Part function switched by pilot pressure oil led gradually restricting oil flow in
from solenoid valve unit (SC) the travel parallel circuit.
!"
If the check valve is seized and !"Arm regenerative function does not !"
Oil flow is not restricted prop-
kept closed, or the restriction is operate. erly.
clogged, hydraulic oil does not
Control System flow from pump 1 to arm 1 spool.
Trouble !"
If the check valve is seized and
kept opened, hydraulic oil from
pump 2 flows to the pump 1 side.
!"
!"
When check valve is kept closed, !"
Arm speed is very slow when level- !"
When fully closed:
or restriction is clogged: ing. Great shock is felt when
Arm speed is slow when leveling. changed from travel single op-
!"
When check valve is kept eration to travel combined op-
opened: eration.
Left travel speed is slow. !"
When fully opened:
The boom is not raised when
the combined operation of
Machine Symptom travel down a slope and boom
raise with the bucket loaded is
made. (Boom is raised when
boom single operation is per-
formed.)
By Dr.EX Self-
Diagnosing - - -
Function
By Dr.EX
Monitor
Trouble Function - - -
shooting
Proce- By Lamp
Harness
dures Check - - -
By Other
Check/ - - -
Measurements
Note - - -

(Operational Prin-
ciple)Technical
Manual
T5-4-8
Travel and Boom Lower

Arm Anti-Drift Valve Boom Anti-Drift Valve Boom Regenerative Valve
Selector Valve
!"
To ensure the boom lower force !"
To prevent the arm drift caused !"
To prevent the boom drift !" To prevent boom hesitation
when the combined operation by inner leakage of hydraulic caused by inner leakage of hy- when lowering boom by allow-
of travel and boom lower is oil in control valve. Only when draulic oil in control valve. Only ing the return oil from the boom
made. arm roll-in operation is made, when boom lower operation is cylinder bottom side to flow
anti-drift valve (check valve) in made, anti-drift valve (check into the boom cylinder rod side.
the arm cylinder return circuit valve) in the boom cylinder re-
is forcibly opened so that the turn circuit is forcibly opened
arm is rolled in. so that boom is lowered.
!"
Boom 2 spool does not move !"
Check valve does not open if !"
Check valve does not open if !"
With check valve kept closed,
when the combined operation the changeover valve is the switch valve is seized. boom lower speed becomes
of travel and boom lower is seized. slow.
made. !"
With check valve kept opened,
!"
Boom 2 spool is moved even if the track of the base machine
the single operation of boom is not raised off the ground by
lower is made. lowering the boom.
!"
When fully opened: !"
If check valve does not open !" If check valve does not open, !"Same as described in the
Boom lower speed is very fast. fully, arm roll-in speed is slow. boom is not lowered. above column.
With swing lever fully stroked, !"If check valve is kept opened, !"If check valve is kept opened,
swing speed is slow when the arm drift increases due to the boom drift increases due to the
combined operation of swing control valve inner leakage. control valve inner leakage.
and boom lower is made. !"
According to the degree of sei- !"
According to the degree of sei-
!"
When fully closed: zure in check valve, arm roll-in zure in check valve, boom
With the front lowered while operation becomes jerky, or lower operation becomes jerky,
traveling, the track of the base slower. or slower.
machine is not raised off the
ground.
- - - -
- - - -
- - - -
- - - -
- - - -
T3-3 T3-3 T3-3 T3-3
T5-4-9
Bucket Flow Control Valve

!"
To restrict the bucket circuit to
assist boom to raise when the
combined operation of bucket,
arm roll-in, and boom raise is
Part function made.
!"
Bucket circuit is always re-
stricted if the switch valve is
seized.
Control System
Trouble
!"
Bucket speed is slow if poppet
valve is seized and kept closed,
or switch valve is seized so that
the poppet valve is closed.
!"
Boom is not raised when the
combined operation of bucket,
arm roll-in, and boom raise is
Machine Symptom made with poppet valve fully
opened, or if the switch valve is
seized so that the poppet valve
is fully opened.
By Dr.EX Self-
Diagnosing -
Function
By Dr.EX
Monitor
Trouble Function -
shooting
Proce- By Lamp
Harness
dures Check -
By Other
Check/ -
Measurements
Note -
Descriptions in T3-3
(Operational Prin-
ciple)Technical
Manual
T5-4-10
(Blank)
T5-4-11
CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
Engine Control Pump/Valve Control

EC EC Eng. Sol. Pump Pump N Arm Pres.
Motor Sensor Cont. Valve Delivery Delivery Sensor Roll-In Sw.
Dial Unit Pres. Pres. Sensor (Travel)
(SE) Sensor Sensor
(Pump 2) (Pump 1)
E-1 Starter does not rotate.
E-2 Although starter rotates, engine does

# $
not start
E-3 Engine runs slower than normal at all
operation speeds.
#
Slow idle speed is faster or slower
than normal.
E-4 Even if engine control dial is turned,
# #
engine speed is unchanged.
E-5 Even if HP mode switch is depressed,
HP mode does not operate. $ # # #
E-6 Engine does not stop even if key

$ $
switch is turned OFF.
E-7 Auto-idle function does not function.
$ #
E-8 Engine speed does not change, even
if E mode switch is depressed.
E-9 Engine stalls several seconds after
engine starts
E-10 Engine stalls when machine is
operated at high altitude or under # #
adverse conditions.
E-11 Engine is hard to start at low ambient
temperature.
Engine Control Pump Control Valve

Eng. Gover Main Pilot Spool Pump Pump Main
Unit nor Pump Pump Cont. Cont. Relief
Unit Valve Valve Valve
(5-Spool (4-Spool
Side) Side)
A-1 All actuators speeds are slow.

$ $ # # $ $ $
A-2 When single travel operation is made,
left side track is slow but right side
track is normal. Single swing
operation is slow. Bucket operation is # #
normal. Arm speed is slow when
leveling. All above symptoms
occurred at the same time.
A-3 When single travel operation is made,
right side track is slow but left side
track is normal. Single bucket
operation is slow. Single swing # #
operation is normal. Boom hardly
raises when leveling. All the above
symptoms occurred at the same time.
A-4 Actuator does not stop, even after

control lever is in the neutral position. #
T5-4-12
Switch Panel Engine Pump

Pres. Auto- Lear- HP E Key MC Eng. Eng. Gover Main
Sw. Idle ning Mode Mode Sw. Elec. Unit nor Pump
(Front) Sw. Sw. Sw. Sw. Parts Unit
# #
# # # #
# # #
# # #
$ $ $
# # $
# #
Others
Pilot Pilot
Valve Relief NOTE: The above table shows the correlation
Valve between machine operation trouble and
related parts which may cause trouble.
However, the correlations in this table are
described based on the condition supposing
#
that each trouble occurs independently. If
any other trouble occur at the same time,
find out the faulty parts causing the trouble
by checking all suspected parts in each
symptom.
#: being liked closely. Checking the part is sequined.

$: being linked, but if this part is faulty another type of
trouble will be prominent. Therefore, this part may not
be the main cause of the trouble.
T5-4-13
Pump/Valve Control Control Valve

Sol. Pump Arm Pres. Spool Main Over- Load Boom Re-
Valve Delivery Roll- Sw. Relief load Check Regen. stric-
Unit Pres. In (Boom Valve Relief Valve Valve tion
(SC) Sensor Sensor Raise) Valve (Arm 1
(Pump Paral-
2) lel)
F-1 All front attachment function

#
are weak.
F-2 Some cylinders do not move
# #
or speeds are slow.
F-3 Boom lower single operation
is fast.
F-4 Arm speed is slow in a
combined operation.
# # # # #
Arm speed is slow in leveling
operation.
F-5 Bucket digging single
operation is slightly slow.
Bucket digging single
operation is jerky.
F-6 Arm starting speed is slow
during combined operations.
Arm operation is jerky.
During arm roll-in single
operation, arm starting speed
is slightly slow.
F-7 Boom staring speed is slow
during combined operations.
Boom operation is jerky.
#
Boom starting speed is
slightly slow during boom
lower single operations.
F-8 When operating the control
lever to raise boom or to roll-
out arm, boom or arm starts to #
move after slightly moving in
the reverse direction.
F-9 Front attachment cylinder drift
# #
is large.
S-1 Swing speed is slow or swing
#
function does not operate.
S-2 Swing speed is slow during
combined operation with
boom lower.
NOTE: The above table shows the correlation #: being liked closely. Checking the part is sequined.
between machine operation trouble and $: being linked, but if this part is faulty another type of
related parts which may cause trouble. trouble will be prominent. Therefore, this part may
However, the correlations in this table are not be the main cause of the trouble.
described based on the condition supposing
that each trouble occurs independently. If
any other trouble occur at the same time,
find out the faulty parts causing the trouble
by checking all suspected parts in each
symptom.
T5-4-14
Control Valve Others

Check Arm Travel/ Arm Boom Bucket Swing Shock Pilot Cylin-
Valve / Regen. Boom Anti- Anti- Flow Device -less Valve der
Restric. Valve Lower Drift Drift Cont. Valve
(4-Spool Select. Valve Valve Valve
Paral- Valve
lel)
# # #
# #
# # #
# # # #
# #
T5-4-15
Sw.
Pump/Valve Control Panel Control Valve
Sol. PC PC Pump Pump Pres. Travel Spool Load Flow
Valve Pres. Pres. Delivery Delivery Sw. Mode Check Com-
Unit Sensor Sensor Pres. Pres. (Trav- Sw. Valve biner
(SI) (5- (4- Sensor Sensor el) Valve
Spool Spool (Pump (Pump
Side) Side) 2) 1)
T-1 Both right and left side tracks

do not move or move slowly.
T-2 When a single travel operation
is shifted to a combined
operation with front functions,
a shock load is felt.
T-3 One side track does not move
or moves slowly. Or the
#
machine cannot travel
straight (mistracks).
T-4 During a combined operation
of travel and front attachment
# #
function, the machine
mistracks
T-5 Steering power and
Gradeability are insufficient in # $ $
the fast travel mode.
T-6 Travel function does not
change to the fast speed
range. Or, shifting function
# $ $ # # # #
from the slow speed range to
the fast speed range does not
work.
O-1 The wiper does not operate,
or will not retract.
T5-4-16
Control Valve
Travel/ Travel Center Pilot
Boom Device Joint Valve
lower
Selector
Valve
# # #
T5-4-17
ENGINE TROUBLESHOOTING
E-1 Starter Does Not Rotate.
Related Fault Code: None
YES
Checking Instructions
• Measure each voltage by referring to the table be-
low.
• Electronic system such as MC has nothing to do
with the trouble obstructing the rotation of starter.
Regardless of key switch

With key switch positioned as position ON or START, voltage
shown in table below, check if at terminal B is 0 volts.
YES
each terminal voltage on
starter and starter relay is
Check if battery voltage and normal. !"
Key switch: ON$START
electrolyte density are normal.
Unit: V
!"
Voltage : 24 volts or more
!"
Density : 1.26 or more
Terminal ON START
B 24 24 With key switch positioned at

START, voltage at terminal S
NO does not increase to 24 volts.
C 0 24
S 0 24
!"
Key switch: START
R 0 to 5 0 to 5
With key switch positioned at

START, voltages at terminals
B, C, and S do not increase to
24 volts.
NO (When key switch is turned to the START position, if voltage at

terminal B is lower than 18 volts, battery may be faulty.)
!" Starter Terminal Voltage Check

C
White-Green Black-White
T157-07-04-009
T5-4-18
Faulty starter or disconnected

starter ground line.
YES Faulty harness between

battery relay and starter.
When key switch is turned
from the ON position to the
OFF position, check if battery
relay sounds.
Check battery relay or diode
!"
Key switch: ON$START NO D2.
YES Faulty harness between

Check if fusible link fusible link and key switch.
Voltage at terminal No.1: 0 V
(40 A) is normal.
Measure each voltage at Faulty fusible link.

terminal No.1 and No.6 on key NO
switch. Voltage at terminal No.1: 24 V
Faulty key switch.
!"
Key switch: START
Voltage at terminal No.6: 24 V Faulty harness between key
switch terminal No.6 and
starter relay terminal S.
Faulty starter relay.
Faulty battery.
!" Key Switch Voltage Check
NOTE: Remove the key switch from the console.
View A
ST G1 ACC
V
B G2 M
T105-07-04-002
T5-4-19
E-2 Although Starter Rotates, Engine Does Not
Start.
• Check the governor lever position and the fuel cut
lever position while the engine is cranking. If they
are in normal position, the engine and the fuel
system may be faulty.
YES
Faulty engine.
!"
Refer to engine shop
With key switch ON, check if manual.
governor lever moves to the
starting position.
!"Key switch: ON
Check EC motor activating

NO circuit.
!" Governor Lever and Fuel Cut Lever
1 2 3 4
T105-07-04-003
1 - Governor Cable
(From EC Motor)
2 - Fuel Cut-Off Cable
(Fuel Cut Handle)
3 - Fuel Cut Lever
4 - Governor Lever
T5-4-20
!" Governor Lever Position
A- Key Switch OFF (Engine Stop Position)

B- Key Switch ON (Engine Start Position)
A B
STOP FULL
FULL
T105-07-04-003
STOP
!" Fuel Cut Lever Position
A- Fuel Cut Handle Pulled Position

B- Fuel Cut Handle Returned Position
A
B
T105-07-04-003
T5-4-21
E-3 Engine Runs Slower than Normal at All
Operation Speeds.
Slow Idle Speed is Faster or Slower than
Normal.
Related Fault Code: 01
• Before the engine learning operation is carried out,
or when the engine learning operation is made in a
wrong procedure, the engine may run slower at all
operation speeds.
• If the EC sensor is faulty, the governor lever
position which is located when the key switch is
turned ON, is learned as the idle position. Then,
the engine is controlled based on this engine
learning operation. Accordingly, the engine runs
with discrepancy from the standard control speed.
Further more, this trouble may not reemerge as
the extent of discrepancy in the governor lever
position differs each time when the key switch is
turned ON.
• Refer to the Control System Group titled “Engine
Learning Control” in the SYSTEM Section in the
Operational Principle book (Technical Manual).
• Even if the EC motor control becomes abnormal,
the governor lever position is constantly kept at the
full stroke end since the EC motor is a worm gear
type. Accordingly, the engine does not stall.
Return fuel control

NO lever to the original
position.
Check if fuel cut
YES Faulty EC sensor.
lever is fully
operated.
Check if fault code
01 is displayed. !"
After replacement, YES End.
YES refer to T5-4-60.
Check if the trouble

is reconditioned
NO
after engine
learning operation Monitor the engine
is conducted. learning operation.
NO
!"
Refer to T5-4-60.
!"
Monitor item:
!"
Engine learning
control
T5-4-22
YES Faulty engine or

Check if governor
lever comes in fuel system.
OK contact with the
stopper when Faulty control
conducting engine cable. Faulty
learning operation. engine governor
NO lever adjustment.
!"
Refer to T5-4-60.
Failure in MC.
NOT OK Faulty learning
switch, or harness
between learning
switch and MC.
!"
After replacement,
refer to T5-4-60.
T5-4-23
E-4 Even If Engine Control Dial is Turned, Engine
Speed is Unchanged.
Related Fault Code: 07
• Refer to the Control System group titled “Engine
Learning Control” in the SYSTEM Section in the
Faulty engine control dial or

YES broken harness between
engine control dial and MC.
Check if fault code 07 is

displayed. YES Faulty EC motor.
Connect Lamp Harness (ST
7125) to EC motor. Check if !"
After replacement, refer to
NO the lamp comes ON when T5-4-60.
engine control dial is turned.
Failure in MC or broken
NO harness between MC and EC
motor.
!"
T5-4-60.
T5-4-24
E-5 Even If HP Switch is Depressed, HP Mode
Does NOT Operate.
(Standard Mode Operates Normally.)
Related Fault Codes: 02, 03, and 06
• The pressure switches check if the HP mode is
requested so that if these pressure switches fail,
the HP mode does not operate.
• Refer to the Control System group titled “HP Mode
Control” in the SYSTEM Section on the
Faulty HP mode
NO switch, or broken
Monitor HP mode harness between
switch. Check if HP mode switch
indication of “HP” is and MC.
displayed or
NO deleted on Dr.EX
screen by
operating the HP
mode switch on the
right console ON or Check if governor YES
OFF. lever comes into Faulty engine or
Check if fault code contact with full- poor quality fuel.
is displayed. !"
Monitor item: speed side stopper
!"
HP mode switch YES when hydraulic oil
pressure is relieved
by arm roll-in Failure in MC.
Faulty sensors, or operation. NO
broken harness
between MC and
!"
After replacement,
YES refer to T5-4-60.
sensors.
!"
Fault codes:
Pump 1 delivery pressure sensor: 02
Pump 2 delivery pressure sensor: 03
Pilot pressure sensor (arm roll-in): 06
T5-4-25
E-6 Engine Does Not Stop Even If Key Switch is
Turned OFF.
(When the engine does not stop, be sure to
stop the engine by pulling the fuel cut handle
located under the seat stand before
checking.)
Related Fault Codes: 01 and 07
Checking Instruction
• Trouble symptoms such as “Engine runs slower
than normal at all operation speed.” or “Even if
engine control dial is turned, engine speed is
unchanged” are sure to exist at the same time.
Perform the troubleshooting of all symptoms.
E-7 Auto-Idle Function Does Not Function.
• When trouble corresponding to E-1 to E-6 exist,
perform the troubleshooting of them beforehand.
• Refer to the Control System group titled “Auto-Idle
Control” in the SYSTEM Section in the Operational
Principle book (Technical Manual).
Faulty pressure switches

(travel, and front
NO attachment).
Faulty harness between MC
and pressure switches.
Monitor pressure switches
Filter in the pilot signal circuit
(travel and front attachment).
is clogged.
Check if indication of “Tr” and
YES “Fr” is displayed or deleted on
Dr.EX screen by operating NOTE: Pressure switches
each of the travel and front (travel, and front
control levers. attachment) are
Monitor auto-idle switch. installed on the
Check if indication of “AI” is control valve.
displayed or deleted on !"
Monitor item:
Dr.EX screen by operating !"
Pressure switch
the auto-idle switch on the
right panel ON or OFF.
Failure in MC
!"Monitor item: Faulty auto-idle switch, or YES
!"Auto-idle switch broken harness between !"
After replacement,
! NO auto-idle switch and MC. refer to T5-4-60.
T5-4-26
E-8 Engine Speed Does Not Change, Even If E
Mode Switch is Depressed.
• If trouble corresponding to E-1 to E-7 exist,
perform the troubleshooting of them beforehand.
• Refer to the Control System group titled “E Mode
Control” in the SYSTEM Section in the Operational
Principle book (Technical Manual).
Monitor E mode Faulty E mode switch,

switch. Check if or broken harness
NO between E mode
indication of “E” or “P”
is displayed alternately switch and MC.
on Dr.EX screen by
operating the E mode
switch on the right
console ON or OFF. Failure in MC.
YES
!"
After replacement,
refer to T5-4-60.
E-9 Engine Stalls Several Seconds After Engine

Starts.
• Refer to the Control System group titled “Engine
Learning Control” in the SYSTEM Section on the Rear Console
• If engine learning switch is set to the engine
learning side, engine comes to a stop 5 seconds Fuse Box
after engine is started.
YES Return the switch End.

to neutral.
Check if engine
learning switch is Faulty learning
turned ON. switch, or short
circuit of harness
NO between learning
Engine Learning
switch and MC. Or,
Side
check if the fuel
system is clogged.
Neutral Position T157-07-04-001
(OFF)
T5-4-27
E-10 Engine Stalls When Machine is Operated at
High Altitude, or under Adverse Conditions.
• If speed sensing control does not function, engine
may stall under adverse operating conditions. Disconnect
harness from
Monitor output solenoid valve unit
signal from (SE) and connect
solenoid valve unit test harness (ST
(SE). With a NO 7123) between
pressure gauge solenoid valve unit
installed to port SE, (SE) and the
compare the disconnected
pressure gauge harness. Check if
NO reading with the the lamp comes
monitored pressure ON.
by Dr.EX. Check if
pressure values
indicated on both
the pressure gauge Disassemble and
and the Dr.EX vary YES check regulator.
identically.
Monitor engine
NO speed. Check if
engine runs at
abnormal speed. !"
Monitor item:
Check if fault code "Pump proportional
is displayed. !"
Monitor item: "solenoid valve
"Actual engine speed !"
Refer to Operational
Performance Test
section.
Referring to the
Faulty N sensor or
displayed fault
faulty harness
code, check
YES YES between N sensor
suspectable parts.
and MC.
T5-4-28
YES Faulty solenoid

valve unit (SE).
Broken harness
NO between solenoid
valve and MC.
T5-4-29
E-11 Engine is Hard to Start at Low Ambient
Temperature.
(Even if preheated, engine is hard to start
or does not start at a low ambient tempera-
ture or in a cold climate district.)
• Check if electricity is conducted to glow plugs and
10 $ or less Faulty engine.
glow plugs are normal.
!"
Refer to engine shop manual.
20 to 24 V Measure each glow plug !"
resistance value. T5-4-60.
・
!"
Key switch: OFF
Measure voltage at engine !"
After removing copper
Replace glow plugs.
No.1 cylinder glow plug. plates connecting each
plug, measure the plug #$
!"
Key switch: HEAT resistance values.
Check if glow plug relay

0V functions correctly.
!" Measurement of Glow Plug Voltage and Resistance
Remove
Copper
Plates.
Standard: 20 to 24 V Standard: 10ƒ¶or Less
T105-07-04-006 T105-07-04-007
T5-4-30
(Blank)
T5-4-31
ACTUATOR CONTROL SYSTEM TROU-
BLESHOOTING
A-1 All Actuator Speeds are Slow.
• In case the speed is increased if load is reduced,
main relief valve may be faulty (F-1). If only the
speed is too slow, pump control system may have
malfunction (A-2, or A-3) and pilot system also
may be faulty.
• If N sensor is faulty, it does not show a small
divergence in speed but show an abnormal value
such as 0 min-1 (rpm).
NO Check if pilot
primary pressure is
YES normal.
Select general Monitor engine
purpose mode. actual speed. !"
Arm: Fully rolled in.
NO !"
Monitor item:
Check if abnormal
speed is Arm roll-in pilot pressure
Check if precision
monitored.
work mode is
selected. !"
Monitor item: Faulty N sensor or
Actual engine speed broken harness in
Check if fault code YES N sensor circuit.
NO is displayed.
Referring to the
displayed fault
YES code, check
suspected parts.
T5-4-32
End.
NO (Faulty pilot relief
valve)
After
disassembling,
cleaning, and
NO adjusting pilot relief
valve, check if an
abnormal condition
still remains.
Faulty pilot pump
or clogged pilot
YES filter.
Trace the causes

YES of trouble by
checking other
symptoms.
T5-4-33
A-2 When Single Travel Operation is Made, Left
Side Track is Slow But Right Side Track is
Normal.
Single Swing Operation is Slow. Single
Bucket Operation is Normal.
Arm Speed is Slow When Leveling.
(all above symptoms occurred at the same
time.)
• Due to some reasons, pump 2 delivery rate is
reduced to the minimum (approx. 20 L/min).
Accordingly, left side track and swing function
speeds are too slow as they are actuated by
pressure oil from pump 2.
• Arm and boom cylinders are also actuated by
pressure oil from pump 1 so that arm and boom
speed is slightly reduced when the single
operation of arm or boom is made. However, when
the level crowding operation is made, oil flow to
boom cylinders has priority over arm cylinder.
Then, almost no oil flow is supplied to arm cylinder,
reducing arm speed.
• Refer to “Control Valve” and “Pump Device”
groups in COMPONENT OPERATION Section in
the Operational Principle book (Technical Manual).
Reconnect
correctly.
Check if pump
NO control pipe lines
are correctly Faulty pump
NO
connected. control valve (5
spool side).
Check if fault code
Monitor pump
is displayed.
control pressure by
NO operating control
Referring to the lever.
displayed fault Check if pump
code, check sus- control pressure
pected parts. increases. Check regulator for
pump 2.
!"
Swing or travel left
!"
Monitor item:
Pump 2 control pressure
T5-4-34
A-3 When Single Travel Operation is Made, Right
Side Track is Slow But Left Side Track is
Normal.
Single Bucket Operation is Slow. Single
Swing Operation is Normal.
Boom Hardly Raises When Leveling.
(All the above symptoms occurred at the
same time.)
• Due to some reasons, pump 1 delivery rate is
reduced to the minimum (approx. 20 L/min).
Accordingly, right side track and bucket function
speeds are too slow as they are actuated by
pressure oil from pump 1.
• Arm and boom cylinders are also actuated by
pressure oil from pump 2 so that arm and boom
speed is slightly reduced when the single
operation of arm or boom is made. However, when
the level crowding operation is made, oil flow to
arm cylinder has priority over boom cylinders.
Then, almost no oil flow is supplied to boom
cylinders, causing boom to become immovable.
• Refer to “Control Valve” and “Pump Device”
groups in COMPONENT OPERATION Section in
YES Reconnect
correctly.
Check if pump
NO control pipe lines
Faulty pump
are correctly NO
control valve (4
connected.
spool side).
Check if fault code
Monitor pump
is displayed.
control pressure by
NO operating control
Referring to the lever. Check if
displayed fault pump control
YES
YES code, check sus- pressure
pected parts. increases. Check regulator for
pump 1.
!"
Bucket or travel right. YES
!"
Monitor item:
Pump 1 control pressure
T5-4-35
A-4 Actuator Does Not Stop Even After Control
Lever is Returned to Neutral.
• Sticking of pilot valve spool or control valve main
spool may be the cause of the trouble.
YES Faulty Pilot Valve.
!"
When control lever is in
neutral, pilot pressure is
Check if actuator stops when guided to control valve
pilot control shut-off lever is spool.
raised.
Faulty Control Valve.

NO
!"
Pilot pressure is not guided
to control valve spool.
However, control valve is
kept open as spool is stuck.
!"
T5-4-36
(Blank)
T5-4-37
FRONT ATTACHMENT CONTROL SYSTEM
TROUBLESHOOTING
F-1 All Front Cylinder Functions are Weak.
• If motion speed is normal and power is weak, main
relief valve may be faulty (F-1). If motion speed is 2
NOTE: 1 kgf/cm =98.07 kPa
too slow, pump control system may have
malfunction (A-2, or A-3) and pilot system also Main Relief Valve
may be faulty. is normal. Trace
350 to 370 kgf/cm
2 the cause of the
trouble by
checking other
Monitor pump 1 symptoms.
and 2 delivery
pressures.
Adjust main relief
!"
Monitor item: !"
E mode switch: OFF 2 valve.
!"
Pump 1 and 2 delivery pressure !"
HP mode switch: OFF Less than 350 kgf/cm
Relieve boom, arm, or bucket. !"
Work mode: General
purpose mode.
T5-4-38
F-2 Some Cylinders Do Not Move or Speeds are
Slow.
• Discriminate whether the cause of the trouble is in

the pilot system or in the main circuit system.
• If other functions (travel, swing) are normal, the
pilot pump is considered to be normal.
• If bucket single operation speed is slow, refer to
F-5 as well.
• If arm roll-in single operation speed is slow, refer to
F-6 as well.
• If boom lower single operation speed is slow, refer YES Faulty cylinder
to F-7 as well. (Seal kits are
Check if overload faulty.)
Monitor pump YES
control pressure by relief pressure is
slowly operating normal.
YES the control lever. !"
Refer to Operational Faulty overload
Check if the pilot
Check if the control Performance Test NO relief valve
valve delivery
pressure changes section.
pressure is normal
smoothly. Control valve spool
by monitoring or NO is sticking.
measuring.
!"
Monitor item:
!"
Pilot valve delivery Pump 1 and 2
pressure: Refer to control pressure
Operational Performance
Test section.
!"
Monitor Item: NO Faulty pilot valve
!"
Arm roll-in pilot pressure Check if the pilot
When measuring the pilot valve delivery
valve delivery pressure NO pressure is correct
for boom raise or lower, at the inlet port of
bucket roll-in or roll-out, or Shockless valve
the shockless spool sticking
arm roll-out, install a valve. YES
pressure gauge to the
control valve pilot oil port. !"
Only when
operating arm
roll-out or boom
raise.
Shockless Valve
2 1
3
4 1- From swing left pilot valve
5
2- From swing right pilot valve
6
3- From bucket roll-out pilot valve
7
4- From bucket roll-in pilot valve
5- From boom raise pilot valve
6- From boom lower pilot valve
8 7- From arm roll-out pilot valve
8- From arm roll-in pilot valve
T157-07-03-018
T5-4-39
F-3 Boom Lower Single Operation Speed is Fast.
• When the speed is too fast, travel/boom lower

selector valve may be sticking.
NO Trace the cause of the trouble

by checking other types of
Check if travel/boom lower trouble.
selector valve is scored or
stuck.
Faulty travel/boom lower
YES selector valve.
T5-4-40
(Blank)
T5-4-41
F-4 Arm Speed is Slow in a Combined Operation.
Arm Speed is Slow in leveling Operation.
Related Fault Codes: 03 or 06
• Refer to the Control System Group titled “Arm

Regenerative Control” in the SYSTEM section in
• When arm speed is slow in only a combined
operation with boom lowering, travel/boom lower
selector valve may be faulty.
• Refer to the Control Valve group in the
COMPONENT OPERATION section in the
NOTE: When the grading mode is selected, arm

regenerative control does not function so
that arm speed becomes slow.
Disconnect
harness from YES Faulty solenoid
Monitor the output solenoid valve unit
signal from valve unit (SC)
(SC). Connect test
solenoid valve unit NO harness (ST7123)
(SC). Install a between solenoid
pressure gauge to valve unit (SC) and
NO port SC and Broken harness
the disconnected
compare the NO between solenoid
harness. Check if
monitored valve and MC.
Check if any fault the harness lamp
codes are pressures by Dr. comes ON.
displayed. EX with the gauge
readings. Check if
!"
Fault codes: both pressures
Pump delivery pressure vary identically. !"
Perform the combined
sensor (Pump 2): 03 operation of boom raise
Pilot pressure sensor !"
Monitor Item:
and arm roll-in.
(Arm roll-in): 06 "Arm regenerative
"proportional solenoid
"valve output
!"
Perform a combined YES
NOTE: If other fault operation of boom raise
codes are displayed, and arm roll-in.
check the suspected !"
Measurement: Refer to
parts referring to the Operational Performance
Test section. Faulty sensor or
displayed fault code.
broken harness
YES between MC and
sensors.
T5-4-42
YES Faulty arm regen-

erative valve
Check if arm
regenerative valve
on 5-spool control Faulty check valve
valve is seized or YES or restriction (in 4-
Check if check spool control
stuck. valve or restriction valve).
in the parallel
passage in the 4-
spool control valve
NO is seized, bound, or YES Faulty restriction
Check if the
clogged. restriction in arm 1 (in 5-spool control
parallel passage in valve)
NO 5-spool control
valve is clogged.
Trace the cause of
NO the trouble by
checking other
types of trouble.
T5-4-43
F-5 Bucket Digging Single Operation is Slightly
Slow.
Bucket Digging Single Operation is Jerky.
• Refer to A-3.
• Refer to Control Valve group in the COMPONENT
OPERATION section in the Operational Principle
book (Technical Manual).

Check if bucket flow control trouble.
valve in control valve is seized
or bound.
Cleaning or replacement of
YES bucket flow control valve.
F-6 Arm Starting Speed is Slow during

Combined Operations. Arm Operation is
Jerky.
During Arm Roll-in Single Operation, Arm
Starting Speed is Slightly Slow which Often
Occurs at Low Temperature.


troubles.
Check if anti-drift valve is
seized or bound.
YES anti-drift valve.
T5-4-44
F-7 Boom Starting Speed is Slow during
Combined Operations.
Boom Operation is Jerky.
Boom Starting Speed is Slightly Slow during
Boom Lower Single Operation.


by checking other symptoms.
NO Check if boom regenerative

valve is seized or stuck.
boom regenerative valve.
Check if boom anti-drift valve YES
is seized or stuck.
YES boom anti-drift valve.
T5-4-45
F-8 When Operating the Control Lever to Raise
Boom or to Roll-out Arm, Boom or Arm
Starts to Move after Slightly Moving in the
Reverse Direction.
YES Faulty anti-drift valve
YES Check if anti-drift valve for arm

or boom is seized or bound.
Check if load check valve in Cylinder internal leakage

control valve operates NO
correctly.
!"
Disassemble and visually
check.
Faulty load check valve
NO
T5-4-46
NOTE: 1. During the initial stage of operation, oil

pressure and flow rate from the pump is
low. Therefore, if the load check valve is (B)
malfunctioning, the oil in the bottom side
of the boom cylinder flows back into the When the load check
circuit through the load check valve, valve is malfunctioning:
(A)
causing the boom cylinder to temporarily
retract.
2. If the clearance between the piston and
the cylinder barrel is poor, oil pressure in
the bottom side (A) leaks to rod side (B).
As oil pressure and flow rate from the
pump is low during the initial stage of
operation, and if the amount of oil leaking
through the gap between the piston and
T105-07-04-012
the barrel is large, the cylinder is
temporarily retracted. In addition,
cylinder force is reduced. In this case,
the cylinder drift is also increased.
T5-4-47
F-9 Front Attachment Cylinder Drift is Large.
YES Normal
Check if each front

attachment Correctly adjust
cylinder drift is Check if manual NO manual boom
within the specified boom lowering lowering valve and
value. NO valve in boom lock it up.
section in 4-spool
Check if the cylin- control valve is
der drift is reduced correctly adjusted. Check if the
NO when pilot shut-off symptom is deleted
valve is closed. when the overload
YES valve is temporarily
switched with one
in an other cylinder
circuit.
Faulty pilot valve

YES
!" Boom Cylinder Internal Leakage Check
1. With the bucket cylinder fully retracted and the arm

cylinder slightly extended from the fully retracted
position, lower the bucket tooth tips onto the
ground.
2. Disconnect hoses to the boom cylinder rod side.

T105-07-04-009
Then, drain oil from hoses and cylinders. (Plug the
disconnected hose ports.)
3. Retract the arm cylinder to lift the bucket above the

ground.
At this time, if oil flows out of the pipes from which

the hoses were disconnected and the boom
cylinder is retracted, internal leakage in the boom
cylinder exists.
If no oil flows out of the pipes from which the hoses
were disconnected but the boom cylinder is
retracted, internal leakage in the control valve
exists.
T5-4-48
Manual Boom Lowering Valve
Control valve spool

is scored, spring is
damaged, or spool
NO end is loose.
NO Check if internal
leakage in cylin-der
exists.
Faulty cylinder
YES (replace seal kit.)
T157-07-03-017
Adjustment Procedure:
Tighten (1). Then, tighten (2).
Faulty overload
YES relief valve Tightening Torque:
20 N#m (2.0 kgf#m, 14.5 Ibf#ft)
T5-4-49
SWING SYSTEM TROUBLESHOOTING
S-1 Swing Speed is Slow or Swing Function

Does not Operate.
• Check whether the pilot system is malfunctioning

or the main hydraulic system is malfunctioning.
• If other functions (front attachment or travel)
operate normally, the pilot pump is considered to
be normal. If the pilot system is malfunctioning, the Check if swing
cause of the trouble may exist in the pilot system YES motor oil drain
after the pilot valve. amount is normal.
• When the left travel speed is also slow, refer to A-
!"
2. Check if swing Performance Test
YES relief pressure is
Monitor the pump section.
control pressure. normal.
While slowly !"
Monitor item:
operating the "Pump 2 delivery pressure
control lever, check Faulty swing relief
YES
if the pump control
!"
Refer to Operational valve
Performance Test section. NO
pressure changes
smoothly.
Check if the pilot

secondary !"
Monitor item:
"Pump 2 control pressure Seized control
pressure is normal. valve spool
NO
!"
Performance Test
section.
Faulty pilot valve
NO
T5-4-50
NO Faulty swing
reduction device
Check if swing
YES motor parking
brake release valve
is stuck or seized. Faulty swing motor
parking brake
YES release valve
Faulty swing motor

NO
T5-4-51
S-2 Swing Speed is Slow during Swing
Combined Operation with Boom Lower.

YES Clean or replace travel/boom

lower selector valve.
Check if travel/boom lower

selector valve is stuck.
Trace the cause of the trouble
by checking other symptoms.
NO
T5-4-52
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Both Right and Left Travel Side Tracks Do

Not Move or Move Slowly.
• Pilot valves, travel motors, control valve spools in

both right and left travel systems are unlikely to be
faulty at the same time.
• If both travel systems do not operate, the pilot
system, which is applied to both side travel motors,
may be faulty. If the pilot pump delivery pressure is
lower than specification, the front attachment does
not operate as well. Refer to A-1.
T-2 When a Single Travel Operation is Shifted to

a Combined Operation with Front Functions,
a Shock Load is Felt.
• Travel flow control valve might be seized.

T5-4-53
T-3 One Side Track does not Move or Move
Slowly, or the Machine cannot Travel Straight
(Mistracks).

!"
Checking Instructions Performance Test
section.
• If one side system only does not operate, pilot Check if travel
valve, control valve, travel motor, or center joint YES motor oil drain
might be faulty. amount is normal.
• If a symptom such as bucket or swing function NO Check if travel relief
speed is slow, or arm roll-in or boom raise speed is pressure in slow
slow during a leveling operation is recognized at speed side system Switch rear and
is normal. front or right and
the same time, refer to A-2 and A-3.
left travel relief
NO
Check if the !"
Relieve travel system. valves with each
YES symptom is !"
Monitor Item: other. Check if
reversed when "Pump 1 and 2 delivery symptom is
right and left travel "pressure reversed.
line hoses !"
connected to top of Performance Test section.
Check if travel pilot center joint are
secondary switched with each
pressure is normal. other.
!"
Refer Operational Seized control
Performance Test valve spool
YES
section.
Faulty pilot valve

NO
!" Relation between Faulty Seal Position and Mistrack

Derection
Seal No. Traveling Pivot Turn
Seal Position
1 External oil leakage $
2
1
3
2
Left Travel 3
(Reverse)
4 Right Travel
(Reverse)
Left Travel 4
(Forward) 5
Right Travel
5 (Forward)
6
7
6 T105-07-04-015
7 External oil leakage $
T5-4-54
NO Faulty travel motor
Disassemble and YES Faulty travel

clean travel motor reduction device
YES swash angle
End
Disassemble and control valve and
(Faulty travel motor
clean travel motor piston. Check if
NO swash angle control
counterbalance same symptom
valve or piston)
YES valve. Then, arises.
recheck if same End
symptom arises. (Faulty counterbal-
NO ance valve)
NO
Faulty center joint
Faulty travel relief

valve
YES
Piping Location
1 2 Front
5 4
W157-03-03-003
1- Left Travel (Forward)

2- Right Travel (Forward)
3- Pilot
4- Right Travel (Reverse)
5- Left Travel (Reverse)
6- Drain
T5-4-55
T-4 During a Combined Operation of Travel and YES Faulty load check valve
Front Function, the Machine Mistracks.
Related Fault Code: None NO Check if load check valve is

normal. Trace the cause of the trouble
NO by checking other symptoms.
Check if flow combiner valve is
normal.
Faulty flow combiner valve

YES
T-5 Steering Power and Gradeability are

Insufficient in the Fast Travel Mode. (Normal
in the Slow Travel Mode)
Related Fault Codes: None

Trace the cause of the trouble
YES by checking other symptoms
Monitor travel motor swash
angle. After installing a
pressure gauge to solenoid
valve unit (SI) port, repeat !"
Monitor item:
traveling and travel pressure "Travel motor displacement Seized solenoid valve unit (SI)
relief operation. Check if the angle change pressure NO
pres-sure value displayed on !"
Travel mode: Fast
Dr.EX equals is to the pressure !"
Measurement: Refer to
gauge reading and vary Operational Performance
identically. Test section.
T-6 Travel Mode Does Not Change to the Fast

Speed Range.
Related Fault Codes: 02, 03, 04, and 05
• Refer to the Control group titled “Travel Motor

Faulty travel mode
Swash Angle Control” in the SYSTEM section in switch or broken
the Operational Principle book (Technical Manual). NO
har-ness between
travel mode switch
Monitor travel Monitor travel and MC.
NO mode switch. pressure switch.
Check if “Lo” or Check if the display
“Hi”, displayed on “Tr” is indicated or
Dr.EX, changes deleted on Dr.Ex
alternately each screen each time
Check if any fault
time the travel travel lever is
codes are
switch is operated. operated or
displayed.
YES released.
!"
Monitor item:
Selected travel mode !"
Monitor item: Pressure switch
swigch
Faulty sensor or
!"
Fault code:
broken harness
!"
Pump delivery pressure sensor (Pump 1): 02
Pump delivery pressure sensor (Pump 2): 03
YES between sensors Pump control pressure sensor (4-Spool Side): 04
and MC.
Pump control pressure sensor (5-Spool Side): 05
NOTE: If any other fault codes are displayed,
check suspected parts referring to the
displayed fault codes.
T5-4-56
Faulty travel
pressure switch,
broken harness
NO between travel
pressure switch
and MC, or clogg-
ed filter in travel
Disconnect pilot signal circuit.
Monitor travel motor harness from
swash angle. After solenoid valve unit
installing a pressure (SI). Connect test YES
Faulty solenoid
gauge to solenoid valve harness (ST7123) valve unit (SI).
unit (SI) port, repeat between solenoid
NO valve unit (SI) and
traveling and stopping.
Check if the pressure the disconnected
value displayed on Dr. EX harness. Check if Broken harness
equals to the pressure the harness lamp between solenoid
YES gauge reading and vary comes ON. NO
valve and MC.
identically.
!"
Travel mode: Fast
!"
Monitor item: Travel motor Faulty travel motor
displacement angle change pressure YES or travel reduction
!"
Travel mode: Fast device.
!"
Refer to Operational Performance Test
section.
T5-4-57
TROUBLESHOOTING FOR OTHER FUNC-
TIONS
O-1 Wiper Does Not Operate, or will not Retract.
• When the wiper does not operate, first check if the

relay system or wiper motor operate correctly. In
addition, check if the wiper link is normal.
Remove the test
harness and
reconnect the
disconnected
YES Faulty wiper relay
harness to the
As illustrated to the original position.
right, connect test YES Check wiper relays YES End
harness (P/N one by one to see if
wiper operates. Replace the
3073259) between monitor assembly.
auxiliary power Check if wiper
NO
source (#19 on the !"
Key switch: ON operates.
fuse box) and wiper Faulty cab harness
motor. Check if NO
wiper operates.
Faulty wiper motor
NO, or lamp or link
!"
Key switch: ON does not light
normally.
NOTE: When the wiper motor
is normal, lamp S
comes ON while the
wiper is moving within
the operating range.
Then, only when the
wiper reaches the
intermittent stop posi-
tion, both lamps B and
S light for a moment at
the same time.
T5-4-58
!" Electrical Circuit When Test Harness is Connected
Fuse Box #19
Lamp S
Lamp B Wiper Monitor
Ground
T157-07-04-002
!" Wiper’s Operating Range Intermittent Stop Position
Retracted Position
Wiping Range
T157-07-04-003
!" Test Harness Connection
Wiper Monitor
Lamp B
Lamp S
Test Harness Fuse Box
T157-07-04-004
T5-4-59
ENGINE SPEED ADJUSTMENT AND
ENGINE LEARNING
When the following repair or inspection is made, or

when engine speeds deviate from the specifications,
perform the engine speed adjustment and engine
learning.
• When the engine, engine control cable, or EC

motor is removed.
• When MC is replaced.
Engine Speed Adjustment:
1. Turn the key switch to START and run the engine.

(Note: Turn the air-conditioner switch OFF.)
2. Turn the engine control dial to the minimum speed
position. (EC sensor voltage is set to 2.5 V.)
3. Loosen the bolt tightening the control lever to the
EC motor output axis.
4. While checking the engine actual speed with
Dr.EX or a tachometer, adjust the control lever to
conform the slow idle speed specification.
Specification: Refer to Operational Performance Bolt
Test section. Control Lever
5. Tighten the bolt to secure the control lever to the T157-07-04-015
EC motor output axis.
: 13 N#m (1.3 kgf m)
NOTE: Take care not to allow oil or grease to stick

to the motor output axis. Rear Console
6. Perform engine learning.

Fuse Box
Engine Learning :
1. Turn the key switch OFF.
NOTE: If the engine does not stop with the key

switch OFF, pull the fuel cut-off handle
under the operator's seat to stop the engine.
2. Remove Dr.EX. Wait for 5 seconds.

3. Turn the engine learning switch ON.
Engine Learning
4. Turn the key switch ON. Wait for 5 seconds.
5. Turn the key switch OFF. Wait for 5 seconds.
6. Turn the engine learning switch OFF.
7. Check the engine speed. Neutral Position
T157-07-04-001
(OFF)
T5-4-60
EXCHANGE INSPECTION METHOD
Exchange inspection method is used to check if a part

and/or a component is normal by replacing or switching
the part/component with one being identical in
performance characteristics.
Pump 2 Pump 1
(5-Spool (4-Spool
Some of sensors and solenoid valves used on this Side) Side)
machine are identical in performance characteristics.
Accordingly, the exchange inspection method is
effective to find out if a part/component or harness is PP2 PP1
normal.
Example: Abnormal Pump 1 Delivery Pressure Sensor

Failure (Fault Code: 02)
Fig. 1
Check:
1. Switch two delivery sensor connectors from the T157-07-04-006
position shown in Fig.1 to Fig.2.
2. Retry troubleshooting.
Result:
If pump 2 delivery pressure is shown as abnormal
(Fault Code: 03), the pump 1 delivery pressure
sensor is faulty. Pump 2 Pump 1
(5-Spool (4-Spool
Side) Side)
If pump 1 delivery pressure is shown as abnormal
(Fault Code: 02), the harness which was
connected to the pump 1 delivery pressure sensor
PP2 PP1
is faulty.
Fig. 2
T5-4-61
Exchange Inspection Method Application
Fault Code Trouble Application

01 EC Sensor Failure Not Applicable
02 Pump 1 Delivery Pressure Sensor Failure Applicable

03 Pump 2 Delivery Pressure Sensor Failure Applicable
04 Pump 1 Control Pressure Sensor Failure Applicable

05 Pump 2 Control Pressure Sensor Failure Applicable
06 Arm Roll-In Pilot Pressure Sensor Failure Applicable (Pump Control Pressure
Sensor)
07 Engine Control Dial Failure Not Applicable
T5-4-62
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TRUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source.

Be sure to remove the negative terminals from the
batteries first when taking wire harnesses and
connectors off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses, and fusible links and, in some
cases, cause fire due to short circuiting.
2. Color coding of wire harnesses. Code Color Code Color
The color codes of the wire harnesses in the R Red W White
electrical system are shown below. L Blue G Green
In cases on the design sheet where two colors are Or Orange Lg Light green
indicated for one wire, the left initial stands for the Y Yellow B Black
base color, while the right initial stands for the Br Brown P Pink
marking color.
Gr Gray V Violet
NOTE: 1) Code BW indicates a black base wire

with white fine-line marking.
2) Initials “O” and “Or” both stand for the
Right Wrong
color orange.
3) Wires with longitudinal stripes printed on
them are not color coded. Be sure not to
confuse them with color coded wires.
T107-07-06-001
3. Precautions for connecting and disconnecting
terminal connectors.
1) When disconnecting harnesses, grasp them by
their connectors. Do not pull on the wire itself. Be
sure to release the lock first before attempting to
separate connectors, if a lock is provided. (Refer
to “Instructions for Disconnecting Connector” on Right
page T5-6-3.) Rust
2) Water-resistant connectors keep water out so that Wrong
if water enters them, water will not easily drain (deformation)
from them. When checking water-resistant
Wrong
connectors, take extra care not to allow water to (Separation)
enter the connectors. In case water should enter
T107-07-06-002
the connectors, reconnect only after the
connectors are thoroughly dried.
3) Before connecting terminal connectors, check that
no terminals are bent or coming off. In addition, as
most connectors are made of brass, check that no
terminals are rusting.
4) When connecting terminal connectors provided
with a lock, be sure to insert them together until the
lock “clicks.”
T5-6-1
4. Precaution for using a circuit tester.
1) Before using a circuit tester, refer to the
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object to be Wind a Piece of Wire Tester Probe
measured, voltage range and current polarity.
2) Before starting the connector test, always check
the connector terminal numbers, referring to the
circuit diagram.
Sharpen the end of the Wire
When the connector size is very small, and the T107-07-06-003
standard probe size is too large to be used for
testing, wind a fine piece of sharpened wire or a
pin around the probe to make the test easier.
T5-6-2
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
!" Push the lock to disconnect.
NOTE: 1) Connectors may not be separated if the

lock is pushed while the connectors are
pulled. Be sure to push the lock first
before pulling the connectors.
2) The lock is provide on the female
connector (harness side).
T107-04-05-002
Locations of This Type Connector
Fuel Gauge Washer Engine Oil Level Switch Radio

Hydraulic Oil Level Switch Pilot Pressure Switch Coolant Level Switch Speaker
Horn EC Motor Diode Learning Switch
Cab Harness EC Sensor Key Switch Wiper
Pressure Switch(Travel) Pump Delivery Pressure Sensor Engine Control Dial Monitor
Starter Relay N Sensor Relay
!" Pull up the lock to disconnect.
Pressure Switch (Front)

Pilot Pressure Sensor
Pump Control Pressure Sensor
T107-04-05-003
!" Pull to disconnect.
Solenoid Valve Unit

Dr.EX
T107-04-05-004
T5-6-3
FUSE CONTINUITY TEST
Fuse failure is often caused by a fine crack in the fuse, NOTE: (a) All the inside terminals of the fuses in the
and such fine cracks are very hard to detect by visual fuse box are connected to the power
inspection. source, while the outside terminals are
Checking fuse continuity with a tester is far superior to connected to the accessories.
sight inspection. Test all fuses using the same method,
except the fuse for the glow plug relay
(1) Turn the key switch ON circuit.
In doing so, the battery relay is activated by the
(b) To check the fuse for the glow plug relay
current from terminal M of the key switch, and
circuit, turn the key switch to the HEAT
electric power is supplied to all circuits except the
position and perform the test as
glow plug relay circuit.
described in (3).
(2) Remove the fuse box cover and set the correct
voltage measurement range of the tester.
(Measurement range: 0 to 30 V)
(3) (3) Connect the negative probe to the vehicle

ground, and touch the outside terminal of each
fuse with the positive probe of the tester.
When normal continuity of a fuse is intact, the
tester will indicate 20 to 25 volts.
For Glow Relay Accessory (Outside)
T157-07-06-001
Power Sauce (inside)
Accessory (Outside)
T5-6-4
INSPECTION AND REPLACEMENT OF
FUSIBLE LINKS
Battery Relay
Inspection
1. Remove the negative cable from the battery.
2. Loosen bolt M8 connecting the cable from the

fusible link box to the starter and manually turn the
cable to the horizontal position, out of the way of
the front cover, as shown. Fusible Link
Box
3. Open the front cover of the fusible link box and M8 Bolt Cable
visually inspect the fusible link inside.
Replacement
T107-04-02-006
1. Make sure that the negative cable is removed from

the battery.
2. Remove bolt M8 connecting the cable to the

fusible link box and take the fusible link box off the
battery relay. Cover
3. Open the right and left side covers of the fusible

link box and remove both screws (M6).
4. Take out the fusible link and replace it.

T107-04-05-007
5. Retighten both screws (M6).
6. Attach both the fusible link box and the front cable Battery
Relay
to the battery relay, as shown, using bolt M8.
7. Reconnect the negative cable to the battery. M8 Bolt
M6 Bolt
Cable
T107-04-05-008
T5-6-5
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between

the battery positive terminal and the vehicle.
Normal Voltage: 24 V
NOTE: If voltage is abnormal, recharge or replace

the battery.
2. Start the engine. Check voltage between the

battery positive terminal and the vehicle.
Normal Voltage: 26 to 28 V
NOTE: If voltage is abnormal, check the charging V

system.
T157-07-06-007
T5-6-6
HOW TO TROUBLESHOOT ALTERNATOR
MALFUNCTIONS
In general, the alternator indicator remains off when the

alternator is generating power.
If the alternator indicator comes on while the engine is
running, the alternator might be defective.
How to check the circuit
1. Stop the engine. Turn the key switch to the ON

position. Confirm that the alternator indicator
comes on.
2. Measure the voltage between the B and E B

terminals of the alternator. If the measured voltage
is around 24 V, the alternator circuit can be
considered normal. If the measured voltage is low,
a shortage in battery capacity or looseness of the
wire connectors of the alternator circuit might be
the cause of the malfunction. When the voltage is
0 V, the wiring between the fuse box and alternator
might be loose or disconnected. E
Also, the alternator cannot generate electricity if
the ground line is disconnected.
3. Next, start the engine and measure the voltage

generated while as the alternator rotates. T157-07-06-003
As described above, measure the voltage between
terminals B and E on the side of the alternator. If
the voltage is around 28 V, the alternator is
operating normally. If the rated voltage is not being
generated, there is some trouble with the
alternator or the regulator.
T5-6-7
CONTINUITY CHECK
Harness
Single-line continuity check A a
Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is: 0 %=Continuity
& %=Discontinuity
%
NOTE: When the one end connector is far apart

from the other, connect one end of
A a
connector (A) to the machine chassis using Connect to
a clip. Then, check continuity of the harness the vehicle.
through the vehicle as illustrated.
If the ohm-meter reading is: 0 %=Continuity %

& % = Discontinuity Connect to
the vehicle.
Single-line short-circuit check

A a
Disconnect both end connectors of the harness and
check continuity between one end connector of the ' Short-circuit
harness and the vehicle: between the
harness and
If the ohm-meter reading is: the vehicle
0 %=Short circuit is present. % frame
& %=No short circuit is present.
Multi-line continuity check

T107-07-05-003
Disconnect both end connectors of the harness, and
short-circuit two terminals, (A) and (B), at one end First short-circuit
connector, as illustrated. Then, check continuity
between terminals (a) and (b) at the other connector.
If the ohm-meter reading is & %, either line (A) - (a), A a
or (B) - (b) is in discontinuity. To find out which line is B b
C c
discontinued, conduct the single line continuity check
on both lines individually, or, after changing the
Second short-circuit
short-circuit terminals from (A) - (B) to (A) - (C),
check continuity once more between terminals (a)
and (c).
%
NOTE: By conducting the multi-line continuity

check twice, it is possible to find out which
line is discontinued. With terminals (A) and T107-07-05-004
(C) short-circuited, check continuity

Short-circuit between harnesses.
between terminals (a) and (c).
If the ohm-meter reading is:
A a
0 %= Line (B) - (b) has discontinuity. B ' b
& %= Line (A) - (a) has discontinuity. C c
Multi-line short-circuit check

Disconnect both end connectors of the harness, and
check continuity between terminals (A) and (B) or
(C).
%
If the ohm-meter reading is:
0 %=Short-circuit exists between the lines.
& %=No short-circuit exists between the lines.
T107-07-05-005
T5-6-8
(Blank)
T5-6-9
VOLTAGE AND CURRENT CHECK
Turn switch ON so that the specified voltage (current) is 24 Voltage Circuit

applied to the point to be measured. Then start Start checking in order up to the point where voltage
measuring either voltage or current. Judge if the is measured from either power source or actuator
specified voltage is applied. side. Thereby, the faulty location in the circuit will be
found.
Black Probe (Minus) of Tester : To vehicle ground.
Red Probe (Plus) of Tester : To location to be
measured.
Engine Key Check Point Standard

Switch
Power Sourse Circuit
Stopped OFF Between (2) and (1): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (2): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (1): Two Batteries 20 to 25 V
Stopped OFF Between (4) and Ground: Power Source 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link 20 to 25 V
Stopped OFF Between (1) and Ground: Backup Current ( 6 mA
Preheat Circuit
Stopped HEAT Between (6) and Ground: Key Switch 20 to 25 V
Stopped HEAT Between (7) and Ground: Glow Plug 20 to 25 V
Starting Circuit
Started START Between (8) and Ground: Key Switch 20 to 25 V
Started START Between (9) and Ground: Battery Relay (Coil) 20 to 25 V
Started START Between (10) and Ground: Batter Relay (Switch) 20 to 25 V
Started START Between (11) and Ground: Starter (B) 20 to 25 V
Started START Between (12) and Ground: Starter (C) 20 to 25 V
Started START Between (13) and Ground: Starter Relay (S) 20 to 25 V
Charging Circuit
Fast Speed ON Between (14) and Ground: Alternator Generating Voltage (B) 26 to 30 V
Fast Speed ON Between (10) and Ground: Alternator Generating Voltage 26 to 30 V
Fast Speed ON Between (15) and Ground: Alternator Generating Voltage 26 to 30 V
Fast Speed ON Between (16) and Ground: Alternator Generating Voltage (L) 13 to 30 V
Fast Speed ON Between (17) and Ground: Monitor 13 to 30 V
Surge Voltage
Prevention Circuit
Slow Idling ON Between (14) and Ground: Alternator (B) 26 to 30 V
Slow Idling ON Between (16) and Ground: Alternator (L) 13 to 30 V
Slow Idling ON Between (18) and Ground: Load Dump Relay 26 to 30 V
Slow Idling ON Between (10) and Ground: Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (19) and Ground: Auxiliary 20 to 25 V
Stopped ON Between (20) and Ground: Cab Light 20 to 25 V
Stopped ON Between (21) and Ground: Cihar Lighter 20 to 25 V
Stopped ON Between (22) and Ground: Radio 20 to 25 V
Stopped ON Between (23) and Ground: Horn 20 to 25 V
Stopped ON Between (9) and Ground: Battery Relay 20 to 25 V
( After disconnection the minus cable to the battery,
start,easiromg.
T5-6-10
Key Switch
1 2 3 5 4 9
6
8
Battery
Battery Relay
11 10 Load
Dump
Relay
Starter
18 Fuse Box
12
23 22 21 20 19
Starter
Relay
13
16 Fuse Box
Alternator 14
Glow
Relay
Glow Plug
17
7 Monitor
T157-07-06-002
T5-6-11
5 Voltage Circuit
!" Voltage between terminal No.1 and the vehicle Power source
Signal or
ground
Two polarities
(ground) 1 2
With the key switch turned OFF, disconnect the
sensor connector.
Measure the voltage between terminal No.1 on the
machine harness side connector and the vehicle
(ground) under the following conditions.
• Key switch position: ON V

• Tester black terminal (negative):
Connected to the vehicle (ground)
• Tester red terminal (positive):
Connected to terminal No.1 T107-07-05-006
Three polarities Power source Signal Ground

Evaluation:
If the measuring voltage is within 5)0.5 volts, the 1 2 3
circuit up to terminal No.1 is normal.
!" Voltage between terminal No.1 and the ground

T107-07-05-007
terminal
With the key switch turned OFF, disconnect the Two polarities
sensor connector. 1 2
Measure the voltage between terminal No.1 on the
machine harness side connector and the ground
terminal (terminal No.2 for two polarities, or terminal
No.3 for three polarities) under the following
conditions. V
• Key switch position: ON

• Tester black terminal (negative):
Connected to the ground terminal
(terminal No.2 or 3)
• Tester red terminal (positive): T107-07-05-008
Connected to terminal No.1

Three polarities
1 2 3
Evaluation:
If the measuring voltage is within 5)0.5 volts, the
circuit up to terminal No.1 or the ground terminal is
normal.
V
T107-07-05-009
T5-6-12
!" Check Using False Signal
With the key switch turned OFF, disconnect the
sensor connector.
Two polarities
Short-circuit terminal No.1 (power source) and No.2
1 2
(signal) on the machine harness side connector and
supply the power source voltage as a false signal to
the controller. Check the controller under this
(Pressure switch)
condition, using the Dr.EX monitor function. (N sensor)
Evaluation:
Except for the pressure switch circuits, if the Short circuit
maximum value is displayed, the MC (Main
Controller) and the circuits up to the machine
harness side connector are normal. When the
pressure switch circuits are normal, the Dr.EX T107-07-05-010
monitor displays “ON”.

Three polarities
IMPORTANT: On three-polarity connectors, do not 1 2 3
short-circuit terminals No.1 and No.2
to No.3 or the vehicle body (ground),
(EC sensor)
causing harnesses, cont-rollers and (Pilot pressure sensor)
fuses to burn due to current (Pump control pressure sensor)
overload. (Pump delivery pressure sensor)
Short circuit
T107-07-05-011
T5-6-13
REPLACEMENT OF RELAY
1. Remove screw (1) under the right console to

detach cover (2).
2. Remove bolt (3) and turn the console around pin

(4). Then, take out lock pin (5). Push pin (4) to the
seat side, then remove spacer (6).
: 17 mm
3. Move the console to the seat side.
5 2 3 1
4. Using a sharp-pointed tool, remove cap (9) from
cover (7) and duct cover (8) located under the View a
T157-07-06-004
monitor. 4 6
5. Remove cover (7) and duct cover (8).
7 10 11
6. Remove ashtray (10) and the ashtray screw.
Remove aux. switch panel (11).
7. Remove relay cover (12).
8. Replace the relay.
T157-07-06-005
9 8 12
1 - Screw 4 - Pin 7 - Cover 10 - Ashtray

2 - Cover 5 - Lock Pin 8 - Duct Cover 11 - Aux. Switch Panel
3 - Bolt 6 - Spacer 9 - Cap 12 - Relay Cover
T5-6-14
TROUBLESHOOTING / Harness Check
CIRCUIT CHECK
Connect the lamp harness kit between connectors.

Then, check if the circuit is normal or abnormal
depending on whether the lamp comes ON or goes
OFF during operation.
Parts Number 4283594 (ST 7126)

Use when checking the conditions (discontinuity) of a
single wire.
To check point.
To ground.
During Operation: Lamp comes ON. T107-07-05-012

Use when checking the solenoid valve unit circuit.
4
When corresponding control lever or switch is 3 50
operated: Lamp comes ON.
(T5-4-28, 42, and 57) 150 50
1 2 2 1
T107-07-06-015

Use when checking EC motor circuit.
5
(Refer to page T5-4-24)
6
50
• EC Motor Circuit
When the engine control dial is rotated, 1 2 150 50 2 1
When both lamps come ON: Normal 50
3 4 4 3
If only one lamp come ON: Check continuity of the
circuit connecting to the lamp going OFF. 50
If both lamps go OFF: Check the harness together
with the relay.

T107-07-06-024

Use when measuring the signal cable voltage (Red)
(between terminal No.2 and 3) in the EC sensor
circuit.
(Black)
Parts Number 4284347 (ST 7129) T107-07-03-009
T5-7-1
TROUBLESHOOTING / Harness Check
Parts Number 3073259
Use when checking the wiper circuit.
2
5 4
1 2
1
Parts Number 3073259 T157-07-07-001
T5-7-2
TECHNICAL MANUAL
Acrobat®Reader Copyright 1987-1997 Adobe Systems
Incorporated. All rights reserved.
INTRODUCTION
TO THE READER
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using ″Service Manual
Revision Request Form″ at the end of this man-
• Be sure to thoroughly read this manual for correct ual.
product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog
MANUAL COMPOSITION
• This manual consists of three portions: the Techni- • Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
• Information included in the Technical Manual • Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redeliver and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
PAGE NUMBER
• Each page has a number, located on the center

lower part of the page, and each number contains
the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and • CAUTION:

signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. • IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropri- • NOTE:
ate lifting techniques and equipment when lifting heavy Indicates supplementary technical information or
parts. know-how.
UNITS USED
• SI Units (International System of Units) are used in 2

Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKS system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
Quantity To Convert Into Multiply By Quantity To Convert Into Multiply By

From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
°C °F °C×1.8+32
3 3
m yd 1.308 Temperature
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
IN-02
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Hitachi Ex-150lc-5, Ex160lc-6 PDF

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Hitachi Ex-150lc-5, Ex160lc-6 PDF

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SECTION 1

Group 2 Component Layout

Model EX150LC-5 Hydraulic Excavator

A: Overall Width (Excluding Back Mirrors) mm (ft"in) 2500 (8’2”)

NOTE: ! H/P mode

2.58 m (8’6”) Arm 3.10 m (10’2”) Arm

NOTE: ! The dimensions do include the height of

ENGINE STOP SYSTEM

Test Conditions: 1. In conformity with JIS D1005

Radiator Oil cooler

SWING PARKING BRAKE

TRAVEL BRAKE VALVE

TRAVEL PARKING BRAKE

FRONT ATTACHMENT PILOT VALVE

TRAVEL PILOT VALVE

SOLENOID VALVE UNIT

OIL COOLER BYPASS CHECK VALVE

1- Bucket Cylinder 6- Swing Device 11 - Engine 16 - Shockless Valve

1 - Monitor Panel 9 - Warm Up Complete 17 - Overheat Indicator 25 - Wiper Switch

1 - Pump Delivery Pressure 5 - Pump Delivery Pressure 8 - EC Motor 11 - Pump 1

Swing Device 1 Shockless Valve

Travel Device Solenoid Valve Unit

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The electrical system is classified into the main circuit,

!" Main circuit operates the engine and accessories.

!" Control circuit functions to control operations of the

!" Monitor circuit operates the monitor devices

In this group, the functions and construction of the main

!" Electric Power Circuit:

!" Bulb Check Circuit:

!" Starting Circuit:

!" Charging Circuit:

!" Surge Voltage Prevention Circuit:

!" Accessory Circuit:

!" Engine Stop Circuit:

The battery negative terminal is grounded to the vehicle.

# Glow Plug Relay (Power Source)

Glow Plug Relay Fuse Box

Glow Plug Relay