Excavator: Technical Manual Troubleshooting

EXCAVATOR MODELS
TECHNICAL MANUAL
TROUBLESHOOTING
All information, illustrations and specifications in this manual are based on the latest product information available
at the time of publication.
The right is reserved to make changes at any time without notice.
FIAT-HITACHI EXCAVATORS S.p.A. - ENGINEERING - FORM No. 604.06.852

Edition - VII - 1998
IN-1
INTRODUCTION
TO THE READER
• This manual is written for an experienced - If you have any questions or comments, or if you
technician to provide technical information needed found any errors regarding the contents of this
to maintain and repair this machine. manual, please contact:
- Be sure to thoroughly read this manual for correct FIAT-HITACHI EXCAVATORS S.p.A.
information concerning the service procedures. Strada Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax. ++39 011 6877357
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition

to this service manual:
- Operator’s Manual
- Spare Parts Catalog
SERVICE MANUAL COMPOSITION
• The complete service manual consists of three - The Excavator Workshop Manual includes infor-
books: mation needed for maintenance and repair of the
- Technical Manual - Operational Principle machine, tools and devices needed for mainte-
- Technical Manual - Troubleshooting nance and repair, maintenance standards, re-
- Excavator Workshop Manual moval/installation and assembly/disassembly
procedures.
- The Technical Manual-Operational Principle in-
cludes the technical information concerning the • The Service Manual for EX255 Excavator consists
operation of main devices and systems. of the following book/print numbers:
- The Technical Manual -Troubleshooting includes

the technical information needed for operational
performance tests, and troubleshooting proce-
dures.
BOOK PRINT NUMBER

- Technical Manual - Operational Principle 604.06.847
- Technical Manual - Troubleshooting 604.06.852
- Workshop Manual - Excavator 604.06.857
NOTE - For the Engine Workshop Manual, make reference to the print No. 604.06.901
IN-2
INTRODUCTION
PAGE NUMBER
• Each page has a number, located on the external upper corner of the page. Each page number contains the
following information:
Example: T 1-2-3
Consecutive page number for each group
Group number (if exist)
Section number
T : Technical Manual
W : Excavator Workshop Manual
SYMBOLS
In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for
personal injury or machine damage.
This is the safety alert symbol.

When you see this symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed along with the safety alert symbol.
The safety alert symbol is also used to draw attentio in to component/part weights.
To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy
parts.
UNITS USED
SI Units (International System of Units) are used in this manual.

MKSA system units and English units are also indicated in parentheses just behinds SI units.
Example: 24.5 Mpa (250 kgf/cm2, 3560 psi)
A table for conversion from SI units to other system units is shown below for reference purposes.
To To
Quantity convert Into Multiply by Quantity convert Into Multiply by
from (SI) (Others) from (SI) (Others)
Lenght mm in 0.039 37 Pressure MPa kgf/cm2 10.197
mm ft 0.003 281 MPa psi 145.0
L US gal 0.264 2 Power kW PS 1.360
Volume L US qt 1.057 kW HP 1.341
m yd 1.308 Temperature °C °F °C x 1.8 + 32
Weight Kg lb 2.205 Velocity Km/h mph 0.621 4
-1
Force N kgf 0.101 97 min rpm 1.0
N lbf 0.224 8 Flow rate L/min US gpm 0.264 2
Torque N.m Kgf.m 0.10197 ML/rev Cc/rev 1.0
N.m lbf.ft 0.737 5
S-1
SAFETY PRECAUTIONS
RECOGNISE SAFETY INFORMATION
• This is your SAFETY ALERT SYMBOL.
- When you see this symbol on your machine or in

this Manual, be alert of the potential for personal
injury.
- Follow recommended precautions and safe
operating practices.
S0021
UNDERSTAND SIGNAL WORDS
• In this Manual you will find the following words:

- DANGER;
- WARNING;
- CAUTION.
referring to different hazard risks. DANGER
These words are always accompanied by the safety
alert symbol.
WARNING
DANGER: indicates an imminent hazardous
situation which, if not avoided, will result in death or
serious injury. CAUTION
WARNING: indicated a potential hazardous
situation which, if not avoided, could result in death or
serious injury. IMPORTANT
CAUTION: indicates a potential hazardous situation
which, if not avoided, may result in minor or moderate NOTE
injury.
IMPORTANT: indicates a situation which, if not

avoided, may cause damage to the machine.
NOTE: indicates an additional explanation for

information purposes.
ENVIRONMENTAL PROTECTION
• This Manual also contains this symbol

accompanying instructions for correct behaviour
as regards environmental protection.
S0024
S-2
SAFETY PRECAUTIONS
FOLLOW SAFETY PRECAUTIONS
• Carefully read and observe all safety signs on the

machine and read all safety precautions in this
Manual.
• Safety signs should be installed, maintained, and
replaced when necessary.
- If a safety sign or this Manual are damaged or
missing, obtain a replacement from your FIAT-
HITACHI Dealer in the same way you order a
spare part (be sure to detail machine model and
serial number upon ordering).
• Learn how to operate the machine and its controls
correctly and safely. S0022
• Allow only trained, qualified, authorised personnel

to operate the machine.
• Keep the machine in proper working conditions.
- Unauthorised changes to the machine may
impair function and/or safety and affect machine
life.
• Safety messages in this Chapter “SAFETY
PRECAUTIONS”, are intended to illustrate basic
safety procedures of the machine. However, it is
impossible for these safety messages to cover
every hazardous situation you may encounter. If
you have any doubts, consult your direct supervisor
prior to operating or servicing the machine.
PREPARE FOR EMERGENCIES
• Be prepared if a fire starts or an accident occurs.

- Keep the first-aid kit and fire extinguisher on hand.
- Thoroughly read and understand the label
attached to the fire extinguisher to use it properly.
- Establish emergency priority procedures to cope
with fires and accidents.
- Keep emergency numbers for doctors,
ambulance service, hospitals and fire department
posted near the telephone.
S0023
S-3
SAFETY PRECAUTIONS
WEAR PROTECTIVE CLOTHING
• Wear close-fitting clothing and safety equipment

appropriate to the job.
You need:
- A hard hat;
- Safety shoes;
- Safety glasses or face shield;
- Heavy gloves;
- Ear protection;
- Reflective clothing;
- Waterproof clothing;
- Respirator or filter mask;
Be sure to correctly wear equipment and clothing S0025
for the job.

- Do not take any chances.
- Avoid wearing loose clothing, jewellery, or other
items that can catch on control levers or other
parts of the machine.
• Operating equipment safely requires the full
attention of the operator. Do not wear radio or music
headphones while operating the machine.
PROTECT AGAINST NOISE
• Prolonged exposure to loud noise can cause

impairment or loss of hearing.
- Wear a suitable hearing protection such as
earmuffs or earplugs to protect objectionable or
uncomfortably loud noise.
S0026
INSPECT THE MACHINE
• Inspect the machine carefully every day or work-

shift by an attentive visual inspection of machine
outside prior to starting it to prevent damages and
personal injuries.
- In the walk-around inspection, be sure to cover all

points detailed in the OPERATION AND
MAINTENANCE INSTRUCTION MANUAL.
S0027
S-4
SAFETY PRECAUTIONS
USE HAND HOLDS AND STEPS
• Falling is one of the major causes of personal injury.
- When you get on and off the machine, always face

the machine and maintain a three-point contact
with the steps and handrails.
- Do not use any control as a handhold.
- Never jump off the machine. Never get on and off

a moving machine,
S0028
- Be careful of slippery conditions of platforms,
steps, and handrails when leaving the machine.
ADJUST THE OPERATOR'S SEAT
• A seat poorly adjusted for operator or work

requirements may quickly fatigue the operator
leading to improper operations.
- The seat should be adjusted whenever machine

operator changes.
- The operator should be able to fully press the

pedals and correctly move the control levers with
his back resting against the seat back.
- If not, move the seat fore and aft, and check again.
S0029
S-5
SAFETY PRECAUTIONS
FASTEN SEAT BELT
• Should the machine overturn, the operator may

become injured and/or thrown from the cab. Not
only, the operator may be crushed by the
overturning machine resulting in serious injury or
even death.
- Prior to operating the machine, thoroughly

examine belt webbing, buckle, and attaching
hardware. If any item is damaged or worn, replace
the seat belt or component before operating the S0030
machine.
- Be sure to remain seated with the seat belt

securely fastened at all times when the machine
is in operation to minimise injury hazard in case of
accident.
- After a significant accident, replace the seat belts

even though they do not look damaged.
MOVE AND OPERATE MACHINE

SAFELY
• Bystanders can be run over.
- Pay the utmost attention not to run over

bystanders.
- Be sure and aware of the location of bystanders

before moving, swinging or operating the
machine.
- If fitted, keep the travel alarm and horn sounding

to warn people that the machine is about to move.
S0031
- When operating, swinging, or moving the

machine in a congested area use a signal man.
- Co-ordinate hand signals before starting the

machine.
S-6
SAFETY PRECAUTIONS
OPERATE ONLY FROM THE DRIVER'S

SEAT
• Inappropriate engine starting procedures may

cause the machine unexpected movement,
possibly resulting in serious injury and even death.
- Start the engine only from the operator’s seat.
- NEVER start the engine while standing on the
track or on the ground.
- Do not start the engine by shorting across starter
motor terminals.
- Before starting the engine, ensure that all control
levers are in the neutral position. S0032
STARTING THE ENGINE WITH

BOOSTER BATTERIES
• Battery gas may explode causing serious damages

and injuries.
- If the engine is to be started using booster
batteries, ensure to comply with all procedures
detailed in the OPERATION AND MAINTE-
NANCE INSTRUCTION MANUAL.
- The operator should be sitting in the driver’s seat
to keep the machine under control when the
engine starts. Starting the engine with booster
batteries is a two man operation.
- Do not use batteries that have been stored in the S0001
cold for a long time.
- Mistakes in following procedures detailed for
starting the engine with slave batteries may cause
the batteries to explode or machine to move
unexpectedly.
KEEP RIDERS OFF THE MACHINE
• Riders on the machine are subject to injuries such

as being struck by foreign objects and being thrown
off the machine.
- Only machine operator is allowed on the

machine. Keep riders off.
- Riders also obstruct the operator’s visibility,

resulting in the machine being operated unsafely.
S0033
S-7
SAFETY PRECAUTIONS
PROVIDE SIGNALS FOR JOBS

INVOLVING A NUMBER OF MACHINES
• For jobs involving several machines, provide

signals commonly known by all personnel involved.
Also, appoint a signal person to co-ordinate the job
site. Make sure that all personnel obey the signal
person’s directions.
S0036
CONFIRM DIRECTION WHERE THE

MACHINE IS TO BE DRIVEN
• Incorrect travel controls operation may result in

serious injury and even death.
- Before driving the machine, be aware of the

undercarriage position relative to the operator’s
position. If travel motors are located at the front of
the cab, the machine will move reverse when
travel controls are moved towards cab front.
S0037
S-8
SAFETY PRECAUTIONS
DRIVE MACHINE SAFELY
• Before moving the machine, confirm which way to

move travel pedals/levers for the corresponding
direction you wish to go.
- Pushing down on the front of the travel pedals or

pushing the levers forward moves the machine
towards the idlers. (Refer to the OPERATION
AND MAINTENANCE INSTRUCTION
MANUAL). S0038
• Traveling on a grade may cause the machine to slip

or to overturn, possibly resulting in serious injury or
death.
- When traveling up or down a grade, keep the

bucket in the direction of travel, approximately 20
to 30 cm (A) above the ground.
- If machine starts to skid or becomes unstable,

lower the bucket immediately.
S0039
- Traveling across the face of a slope may cause

the machine to skid or to overturn. When
travelling (ascending/descending) on a slope, be
sure to point the tracks uphill/downhill.
S0004
- Turning on an incline may cause the machine to

tip over.
If turning on an incline is absolutely unavoidable,
do so at a place where the slope is gentle and the
surface is firm.
WRONG
S0005
S-9
SAFETY PRECAUTIONS
AVOID INJURY FROM UNEXPECTED

MACHINE MOVEMENT
• Death or serious injury may result if you attempt to

get on or off a moving machine.
• To avoid roll-aways:
- Select level ground when possible to park
machine.
- Do not park the machine on a grade.
- Lower the bucket and/or other work tools to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
- Turn the auto-idle switch off.
- Run the engine at slow idle speed without load for
S0040
5 minutes to cool down the engine.
- Stop the engine and remove the key from the key
switch.
- Pull the pilot shut-off lever to LOCK position.
- Block both tracks.
- Position the machine to prevent overturning.
- Park a reasonable distance from other machines.
S0041
S-10
SAFETY PRECAUTIONS
AVOID INJURY FROM BACK-OVER AND

SWING ACCIDENTS
• If any person is present near the machine when
backing or swinging the upperstructure, the
machine may hit or run over that person, resulting
in serious injury or death.
• To avoid back-over and swing accidents:

- Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
- Keep the travel alarm in working condition (if

equipped).
S0042
- ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
- USE A SIGNAL PERSON WHEN BACKING UP

IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
- Use hand signals, which conform to your local

regulations, when work conditions require a
signal person.
S0043
- No machine motions shall be made unless

signals are clearly understood by both signalman
and operator.
- Learn the meanings of all flags, signs, and

markings used on the job and confirm with the
person in charge of signalling.
- Keep windows, mirrors, and lights clean and in

good condition.
- Dust, heavy rain, fog, etc., can reduce visibility.

As visibility decreases, reduce speed and use
proper lighting.
- Read and understand all operating instructions in

the OPERATION AND MAINTENANCE
INSTRUCTION MANUAL.
S-11
SAFETY PRECAUTIONS
AVOID OVERTURNING
• The danger of tipping is always present when

operating on a grade, possibly resulting in serious
injury or death.
• To avoid tipping:
- Be extra careful before operating on a grade.
- Prepare machine operating area flat by grading.
- Keep the bucket low to the ground and close to the
machine.
- Reduce machine operating speed to avoid tipping
or slipping.
- Avoid changing direction when travelling on
grades. S0002
- NEVER attempt to travel across a grade steeper
than 15 degrees.
- Reduce swing speed as necessary when
swinging loads.
• Be careful when working on frozen ground.

- Temperature increases will cause the ground to
become soft and make ground travel unstable.
S0047
AVOID ELECTRIC LINES
• Serious injury or death can result if the machine or

front attachments are not kept a safe distance from
electric lines.
- When operating near an electric line, NEVER
move any part of the machine or load closer than
3 m plus twice the line insulator length.
- Check and comply with any local regulations that
may apply.
- Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
- Keep all bystanders or co-workers away from the
site.
S0010
S-12
SAFETY PRECAUTIONS
PROTECT AGAINST FLYING DEBRIS
• If flying debris hit eyes or any other part of the body,

serious injury may result.
- Guard against injury from flying pieces of metal or

debris; wear goggles or safety glasses.
- Keep bystanderds away from the working area
before striking any object.
S0046
PARK MACHINE SAFELY
• To avoid accidents:
- Park machine on a level surface.
- Lower bucket to the ground.
- Turn auto-idle (A/I) switch off.
- Run engine at slow idle speed without load for 5
minutes.
- Turn key-start switch to OFF to stop engine.
- Remove the ignition key from the key switch.
- Pull the safety lever (pilot-control shut-off lever) to
the LOCK position.
- Close windows, roof window, and cab door.
S0049
- Lock all access doors and compartments.
S-13
SAFETY PRECAUTIONS
HANDLE FLUIDS SAFELY - AVOID FIRES
• Handle fuel with care: it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur,
possibly resulting in serious injury or death.
- Do not refuel the machine while smoking or when

near open flame or sparks.
- Always stop the engine before refuelling the
machine.
- Fill the tank outdoors.
S0050
• All fuels, most lubrificants, and some antifreeze
fluids are flammable.
- Store flammable fluids well away from fire

hazards.
- Do not burn or puncture pressurized containers.
- Do not store oily rags; they can ignite and burn
spontaneously.
S0051
S-14
SAFETY PRECAUTIONS
SAFE MAINTENANCE
• To avoid accidents:
- Understand maintenance procedure before
starting the work.
- Kepp the working area clean and dry.
- Do not spray water or steam inside the cab.
- Do not lubricate or service the machine when it is
in motion.
- Kepp hands, feet and clothes far from moving
parts.
Prior to service in the machine:
1. Park the machine on the level ground.
2. Lower the bucket to the ground.
3. Switch off the Auto-Idle (A/I).
4. Let the engine idle with no load for at least five
minutes until it has cooled down.
5. Move the key-start switch to the OFF position
to stop the engine.
6. Remove the ignition key from the start switch.
S0053
7. Apply the "Maintenance in progress" tag . This
tag can be applied o the left-hand control lever,
safety lever or cab door.
8. Move the safety lever (pilot-control shut-off
lever) to the LOCK position.
9. Let the engine cool down.
- Do not leave the machine unattended if servicing
requires the engine running .
- If the machine is to be raised, place boom and arm
at an angle 90 to 110°. Lock machine components
which should be raised for maintenance or repair
using suitable supporting means.
- Never work under a machine kept raised by the
boom.
- Inspect certain component regularly, repair or
replace as necessary.
Refer to the the OPERATION AND
MAINTENANCE INSTRUCTION MANUAL. S0054
- Keep all components in good condition and properly
install. Immediately repair any fault.
- Immediately repair any damage.Replace worn or
failed components. Remove grease, oil, debris
build-ups.
- Disconnect the negative cable (−) from the battery
before carry out any work on the electrical system
or arc-welding on the machine.
S-15
SAFETY PRECAUTIONS
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause

serious injury.
- Before performing any work on the machine,

attach a maintenance in progress tag. This tag
can be applied o the left-hand control lever, safety
lever or cab door.
S0055
SUPPORT MACHINE PROPERLY
• Never attempt to work on the machine without

securing the machine first.
- Always lower the attachment or tool to the ground

before working on the machine.
- If you must work on a lifted machine or
attachment, securely support the machine or
attachment.
- Do not support the machine on cinder blocks,
bollow tires, or props that may crumble under
continuous load. S0054
- Do not work under a machine that is supported

solely by a jack.
STAY CLEAR OF MOVING PARTS
• Entanglements in moving parts can cause serious

injury.
• To prevent accidents, care should be taken to

ensure that hands, feet, clothing, jewelry and hair
do not become entangled when working near
rotating parts.
S0056
S-16
SAFETY PRECAUTIONS
PREVENT PARTS FROM FLYING OFF
• Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in
serious injury, blindness, or death.
- NEVER attempt to remove GREASE FITTING or

VALVE ASSEMBLY.
- As pieces may fly off, be sure to keep body and
face away from valve.
• Travel reduction gears are under pressure.

S0057
- As pieces may fly off, be sure to keep body and

face away from AIR RELEASE PLUG to avoid
injury. REDUCTION GEAR OIL is hot. Wait for
gear oil to cool down, then gradually loosen the air
release plug to release pressure.
STORE ATTACHMENTS SAFELY
• Stored attachments such as buckets, hydraulic

breakers, and blades can fall and cause serious
injury or death.
- Securely store attachments and implements to

prevent falling. Keep children and bystanders
away from storage areas.
S0058
S-17
SAFETY PRECAUTIONS
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under

pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
- To prevent possible injury from hot spraying

water DO NOT remove the radiator cap until the
engine is cool. When opening, turn the cap slowly
to the stop. Allow all pressure to be released
before removing the cap.
- The hydraulic oil tank is pressurized. Again, be
sure to release all pressure before removing the S0019
cap.
Hot fluids and surfaces:
• Engine oil, reduction gear oil and hydraulic oil also

become hot during operation.
The engine, hoses, lines and other parts become
hot as well.
- Wait for the oil and components to cool down

before starting any maintenance or inspection
work.
S0059
S-18
SAFETY PRECAUTIONS
AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under

pressure can penetrate the skin or eyes causing
serious injury, blindness or death.
- Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
Tighten all connections before applying pressure.
- Search for leaks with a piece of cardboard; take
care to protect hands and body from high-
pressure fluids. Wear a face shield or goggles for SA0016
eye protection.
- In an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.
• In case of accident, immediately seek appropriate

medical attention.
• Any fluid penetrated under the skin should be

removed within a few hours to prevent serious
infections.
SA0017
SA0018
S-19
SAFETY PRECAUTIONS
PREVENT FIRES
• Check for Oil Leaks:

- Fuel, hydraulic oil and lubricant leaks can lead to
fires.
- Check for missing or loose clamps, kinked hoses,
lines or hoses that rub against each other,
damage to the oil-cooler, and loose oil-cooler
flange bolts which may cause oil leaks.
- Tighten, repair or replace any missing, loose or
S0051
damaged clamps, lines, hoses, oil-cooler and oil-
cooler flange bolts.
- Do not bend or strike high-pressure lines.
- Never install bent or damaged lines, pipes, or
hoses.
• Check for Shorts:
- Short circuits can cause fires.
- Clean and tighten all electrical connections.
- Check before each shift or after about ten (10)
hour operation for loose, kinked, hardened or
frayed electrical cables and wires.
- Check before each shift or after about ten (10)
hour operation for missing or damaged terminal
caps.
- DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..
• Clean up Flammables:
- Spilled fuel and lubricans, and trash, grease,
debris, accumulated coal dust, and other
flammables may cause fires.
- Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.
• Check Key-start Switch:
- If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
- Always check key-start switch function before
operating the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key-start switch to the OFF position to
confirm that the engine stops.
- If any abnormalities are found, be sure to repair
them before operating the machine.
• Check Heat Shields:
- Damaged or missing heat shields may lead to
fires.
- Damaged or missing heat shields must be
repaired or replaced before operating the
machine.
S-20
SAFETY PRECAUTIONS
EVACUATING IN CASE OF FIRE
• If a fire breaks out, evacuate the machine in the

following way:
- Stop the engine by turning the key-start switch to

the OFF position if there is time.
- Use a fire extinguisher if there is time.
- Exit the machine.
S0060
BEWARE OF EXHAUST FUMES
• Prevent asphyxiation. Engine exhaust fumes can

cause sickness or death.
- If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.
S0061
S-21
SAFETY PRECAUTIONS
AVOID HEATING NEAR PRESSURIZED

FLUID LINES
Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
Do not heat by welding, soldering, or using a torch

near pressurized fluid lines or other flammable
materials.
Pressurized lines can be accidentally cut when heat

goes beyond the immediate flame area. Install
temporary fire resistant guards to protect hoses or
other materials when welding, soldering, etc.
S0062
AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS
- Do not weld or flame cut pipes or tubes that contain

flammable fluids.
- Clean them thoroughly with non-flammable solvent
before welding or flame cutting them.
REMOVE PAINT BEFORE WELDING OR

HEATING
• Hazardous fumes can be generated when paints is

heated by weiding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
- Avoid breathing potentially toxic fumes and dust.
- Do all such work outside or in a well-ventilated
area.
- Dispose of paint and solvents properly.
- Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing the
dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove
S0063
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.
S-22
SAFETY PRECAUTIONS
PREVENT BATTERY EXPLOSIONS
• Battery gas can explode.
- Keep sparks, lighted matches, and flames away

from the top of battery.
- Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.
- Do not charge a frozen battery; it may explode.
Warm battery to 16°C.
• Battery electrolyte is poisonous. If the battery

should explode, battery electrolyte may be
S0001
splashed into eyes, possibly resulting in blindness.
- Be sure to wear eye protection when checking

electrolyte specific gravity.
DISPOSE OF WASTE IN THE

APPROPRIATE MANNER
• Waste improperly disposed of represents a danger

for the envinronment. Potentially dangerous waste
used on the FIAT - HITACHI excavators includes
lubricants, fuel, coolant, brake fluid, filters and
batteries.
- Used sealed containers when discharging fluids.

Do not use containers for food or beverages
which may induce drinking.
- Do not spill waste over the ground, into drains, or
water beds.
- Obtain information about the correct methods to
recycle or dispose of waste from local Authorities,
collection centres or your Dealer. S0064
S-23
SAFETY PRECAUTIONS
BEFORE RETURNING THE MACHINE

TO THE CUSTOMER
• After maintenance or repair work is complete,

confirm that:
- The machine is functioning, especially the safety

system.
- Worn or damaged parts have been repaired or
replaced.
S0027
S-24
SAFETY PRECAUTIONS
NOTES
TECHNICAL MANUAL EX255
TROUBLESHOOTING
SECTION AND GROUP CONTENTS
Section 4 - OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Hydraulic Component Test
Section 5 - TROUBLESHOOTING
Group 1 Diagnosing Procedure

Group 2 Component Layout
Group 3 Troubleshooting A
Group 4 Troubleshooting B
Group 5 Troubleshooting C
Group 6 Electrical System Inspection
Group 7 Harness Check
SECTION 4 EX255
OPERATIONAL PERFORMANCE
CONTENTS
Group 1 - Introduction Group 5 - Component test

Operational performance test .............. T4-1-1 Primary pilot pressure ......................... T4-5-1
Preparation for performance tests ....... T4-1-2 Secondary pilot pressure ..................... T4-5-3
Solenoid valve set pressure ................ T4-5-4
Main pump delivery pressure .............. T4-5-6
Main relief valve set pressure .............. T4-5-7
Group 2 - Standard Overload relief valve set
pressure .............................................. T4-5-11
Operational Performance Main pump flow test ............................ T4-5-14
standard tables .................................... T4-2-1
Swing motor drainage ......................... T4-5-18
Main pump P-Q diagram ..................... T4-2-5
Travel motor drainage ......................... T4-5-20
Group 3 - Engine test
Engine speed ...................................... T4-3-1
Group 4 - Excavator test

Travel speed ........................................ T4-4-1
Track revolution speed ........................ T4-4-2
Mistrack check .................................... T4-4-3
Travel parking function
check ................................................... T4-4-4
Swing speed ........................................ T4-4-5
Swing function drift check .................... T4-4-6
Swing motor leakage ........................... T4-4-7
Swing bearing play .............................. T4-4-8
Maximum swingable slant
angle ................................................... T4-4-9
Hydraulic cylinder cycle time ............... T4-4-10
Dig function drift check ........................ T4-4-12
Control lever operating force ............... T4-4-13
Control lever stroke ............................. T4-4-14
Combined boom raise/swing
function check ..................................... T4-4-15
T4-1-1
INTRODUCTION
OPERATIONAL PERFORMANCE TEST
Use operational performance test procedure to

quantitatively check all system and functions on the
machine.
Purpose of Performance Tests

1. To comprehensively evaluate each operational
function by comparing the performance test data
with the standard values.
2. According to the evaluation results, repair, adjust,
or replace parts or components as necessary to
restore the machine’s performance to the desired
standard.
3. To economically operate the machine under opti-
mal conditions.
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the
operational performance of each component
such as hydraulic pump, motor, and various kinds
of valves.
Performance Standards
“Performance Standard” is shown in tables to evalu-
ate the performance test data.
Precautions for Evaluation of Test Data

1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.
The machine performance does not always deterio-

rate as the working hours increase. However, the
machine performance is normally considered to re-
duce in proportion to the increase of the operation
hours. Accordingly, restoring the machine perform-
ance by repair, adjustment, or replacement shall
consider the number of the machine’s working hours.
Definition of “Performance Standard”

1. Operation speed values and dimensions of the
new machine.
2. Operational performance of new components
adjusted to specifications. Allowable errors will be
indicated as necessary.
T4-1-2
INTRODUCTION
PREPARATION FOR PERFORMANCE

TESTS
Observe the following rules in order to carry out

performance tests accurately and safely.
THE MACHINE
1. Repair any defects and damage found, such as oil
or water leaks, loose bolts, cracks and so on,
before starting to test.
TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run
straight more than 20 m (65 ft 7 in), and to make
a full swing with the front attachment extended.
3. If required, rope off the test area and provide
SM0131
signboards to keep unauthorized personnel
away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among
coworkers. Once the test is started, be sure to
communicate with each other using these signals,
and to follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid accidents
due to landslides or contact with high-voltage
power lines. Always confirm that there is sufficient
space for full swings.
4. Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil. Pay
special attention to this when removing hydraulic
pipings.
MAKE PRECISE MEASUREMENT

SM3026
1. Accurately calibrate test instruments in advance
to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.
T4-2-1
STANDARD
OPERATIONAL PERFORMANCE STANDARD

TABLES
The standard Performance values related to excava- indicated below as the preconditions of performance
tor test are listed in the table 1 shown below. In table tests unless otherwise instructed in each perform-
2 are listed the standard performance related to ance test procedure:
component test. Engine Control Dial : Fast Idle
Refer to the Group T4-3 to T4-5 for performance test E Mode Switch : OFF
procedures. HP Mode Switch : OFF
Values indicated in parentheses are reference val- Work Mode Switch : General Purpose Mode
ues. Hydraulic Oil Temperature : 50 ± 5°C (122 ± 9°F)
The following switch positions shall be selected and
the hydraulic oil temperature shall be maintained as NOTE - 1 kgf = 9.807 N
Table 1 - Excavator performance
Performance test designation Performance standard Remarks

EX255
ENGINE SPEED rpm
Fast idle speed with E and HP modes

OFF 2180 ± 100
Fast idle speed with E mode ON 1980 ± 50
Fast idle speed with HP mode ON 50 or more higher Extend the arm cylinder to relieve the
than fast idle speed arm roll-in circuit
measured with E
and HP modes OFF
and arm roll-in cir-
cuit relieved
Slow idle speed 850 ± 100
Auto-idle speed (A/I) 1200 ± 100
TRAVEL SPEED sec/20 m
Fast speed 13.2 ± 1
Slow speed 20 ± 2
TRACK REVOLUTION
SPEED sec/3 rev
EX255 26.5 ± 2 Travel slow speed only

EX255 LC 28.8 ± 2
MISTRACK mm/20 m
(With fast and slow travel speed modes) 200 or less
TRAVEL PARKING FUNCTION

CHECK rev 1/6 or less
Travel motor
leak mm/5 min 0
T4-2-2
STANDARD

EX255
SWING SPEED sec/3 rev 13.3 ± 1
SWING FUNCTION DRIFT

CHECK mm/180° 1500 or less 2950 arm (Mono) or 2158 arm (Triple
articulation) and 1.1 m3 bucket (SAE
heaped)
SWING MOTOR
LEAKAGE mm/5 min 0 2950 arm (Mono) or 2158 arm (Triple
heaped)
SWING BEARING PLAY mm 1.3 or less Allowable limit: 4.3 mm
MAXIMUM SWINGABLE SLANT

ANGLE (deg.) 19.2° or more 2950 arm (Mono) and 1.1 m3 bucket
(SAE heaped)
HYDRAULIC CYLINDER sec. 2950 arm (Mono) or 2158 arm (Triple

CYCLE TIME articulation) and 1.1 m3 bucket (SAE
heaped)
Boom Raise 3.1 ± 0.3

(Mono version) Lower 2.5 ± 0.3
Boom (Triple Raise 4.1 ± 0.3

articulation version) Lower 3.6 ± 0.3
Arm Roll-in 3.9 ± 0.3

Roll-out 2.6 ± 0.3
Bucket Roll-in 4.1 ± 0.3

Roll-out 2.5 ± 0.3
Positioning (Triple Roll-in 6.0 ± 0.3

ariticulation version) Roll-out 3.9 ± 0.3
DIG FUNCTION DRIFT

CHECK mm/5 min 2950 arm (Mono) or 2158 arm (Triple
heaped)
Boom cylinder 20 or less
Positioning cylinder
(Triple articulation version) 20 or less
Arm cylinder 20 or less
Bucket cylinder 20 or less
Total drop Mono 150 or less

Triple articulation 150 or less
T4-2-3
STANDARD

EX255
CONTROL LEVER OPERATING

FORCE kgf
Boom lever 2.0 or less
Arm lever 2.0 or less
Bucket lever 1.7 or less
Swing lever 1.7 or less
Travel lever 2.5 or less
CONTROL LEVER STROKE mm
Boom lever 105 ± 10
Arm lever 105 ± 10
Bucket lever 83 ± 10
Swing lever 83 ± 10
Travel lever 115 ± 10
BOOM RAISE/SWING sec 3.7 ± 0.3 2950 arm (mono) and 1.1 m3 bucket
(Bucket empty) (SAE heaped)
Bucket teeth height: H mm

Mono 6700 or more
NOTE - 1 kgf = 9.807 N.

T4-2-4
STANDARD
Table 2 - Component performance standard

EX255
PRIMARY PILOT
PRESSURE kgf/cm2 40 +10
–5 (Engine: Fast idle)
SECONDARY PILOT
PRESSURE kgf/cm2 (34 to 40) (Engine: Fast idle and slow idle)
Value indicated on Dr. EX (Lever: Full
stroke)
SOLENOID VALVE SET kgf/cm2 Value indicated on

PRESSURE Dr. EX ± 2
MAIN PUMP DELIVERY

PRESSURE kgf/cm2 25 +15
–7 Value indicated on Dr. EX
MAIN RELIEF VALVE SET

PRESSURE kgf/cm2
Boom, Arm and Bucket 350 +20

Swing 330 +20

Travel 350 +20

Power Boost 370 +20

OVERLOAD RELIEF VALVE

SET PRESSURE kgf/cm2 Reference values
at 50 L/min
Boom (raise/lower), arm roll-in and

bucket roll-in 380 +10
–0
Arm roll-out and

bucket roll-out 400 +10
–0
MAIN PUMP FLOW

TEST (L/min) –– Refer to page T4-2-5
SWING MOTOR DRAINAGE
With constant maximum speed (L/min) 0.2 to 1.0 Allowable limit: 2.0
With the motor

relieved (L/min) 8 Allowable limit: 16
TRAVEL MOTOR DRAINAGE
With the track jacked up (L/min) 1.5 to 2.0 Allowable limit: 3.4
With the motor

relieved (L/min) (1.5 to 4.8) Allowable limit: (5.2)
NOTE - 1 kgf/cm2 = 0.09807 MPa.

T4-2-5
STANDARD
MAIN PUMP P-Q DIAGRAM Points on P-Q Line

(Reference: Measured at Test Stand)
Delivery Pressure Flow Rate
• Rated Engine Speed : 2000 min–1 (rpm) kgf/cm2 L/min
• Hydraulic Oil Temperature : 50 ± 5°C A 144 196+3
–6
B 202 (154)
C 354 84 ± 10
NOTE - Refer to T4-5-14. D 370
The value indicated in parentheses is only a

reference value.
NOTE - 1 kgf/cm2 = 0.09807 MPa.
L/min
A
•
▲
Flow
Rate
(Q1 + Q2)/2
B
•
C
•
D
•
Delivery Pressure (P1 + P2)/2 kgf/cm2

▲
SM3027
T4-2-6
STANDARD
NOTES
T4-3-1
ENGINE TEST
ENGINE SPEED
Summary:
1. Use Dr.EX. if Dr.EX is not available, use an engine
tachometer.
2. Measure the engine speeds in each mode.
NOTE - Measure the engine speed before perform-

ing all other tests to check that the engine speed
meets specification. Because, if the engine speed is
2
not adjusted correctly, all other performance data will
be unreliable.
3
Preparation:
1. Connect Dr.EX to the diagnosing connector be-
side the fuse box located behind the operator’s
seat, and select the monitor function. When using
an engine tachometer, install speed pickup (2) to
injection pipe (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).
1
IMPORTANT - Never attempt to the readjust stopper (1). SM3028

T4-3-2
ENGINE TEST
Measurement: E Mode
Switch
1. No Load Engine Speed HP Mode
Switch
1-1. Measure the engine slow idle speed, fast
idle speed (in normal mode), and fast idle
speeds (in both E and HP modes).
1-2. Select the switch positions as shown be-
low.
1-3. Start measurement from the slow idle
speed.
1-4. Measure while changing the engine control
dial, E mode switch, and HP mode switch.
Engine E Mode HP Mode Auto- Work

Control Switch Switch Idle Mode
Dial Switch Switch
Slow Idle OFF OFF OFF General
Purpose
Mode
Fast Idle OFF OFF OFF General
(Normal Purpose
Mode) Mode
Fast Idle ON OFF OFF General
(E Mode) Purpose
Mode
Fast Idle OFF ON OFF General
(HP Mode) Purpose Engine
Control Dial SM0631
Mode
2. No Load Auto-Idle Speed

2-1. Select the switch positions as shown be-
low.
Engine E Mode HP Mode Auto- Work

Control Switch Switch Idle Mode
Dial Switch Switch
Fast OFF OFF ON General
Idle Purpose
Mode
2-2. Start the engine and operate the bucket

lever.
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
T4-2.
Auto-Idle
Switch Work Mode
Switch
SM0612
T4-4-1
EXCAVATOR TEST
TRAVEL SPEED
Summary:
Measure the time required for the excavator to travel
a 20 m (65.6 ft) test track.
Preparation:
1. Adjust the track sag on both side tracks equally.
2. Prepare a flat and solid test track 20 m (65.6 ft) in Arm Rolled-In, Bucket Rolled-In
End
length with extra length of 3 to 5 m (9.8 to 16 ft) on Bucket Height: 0.3 to 0.5 m
both ends for machine acceleration and decelera-
tion. Start
20 m Deceleration
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above the
Zone
ground with the arm and bucket rolled-in. 3 to 5 m
4. Maintain hydraulic oil temperature at 50 ± 5°C Acceleration
(122 ± 9°F). Zone
3 to 5 m
SM0138
Measurement:
1. Measure both the slow and fast speeds of the
machine.
2. Select the following switch positions:
Travel Engine E Mode HP Mode Work Auto-Idle

Mode Control Switch Switch Mode Switch
Switch Dial Switch
Slow Fast OFF OFF General OFF
Mode Idle Purpose
Mode
Fast Fast OFF OFF General OFF
Mode Idle Purpose
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 (65.6 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:
T4-2.
T4-4-2
EXCAVATOR TEST
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 90 to 110°
chalk.
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. Mark
SM0139
CAUTION
Securely support the raised track using wooden
blocks.
4. Maintain the hydraulic oil temperature at 50 ± 5°C

(122 ± 9°F).
Measurement:

Switch Dial Switch
Mode Idle Purpose
Mode
Mode Idle Purpose
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 proce-
dures.
5. Repeat steps 2. to 4. three times and calculate the
average values.
Evaluation:
T4-2.
NOTE - The measurement data obtained through the

raised track revolution test may have wide variations.
Therefore, the evaluation based on the results ob-
tained from the 20 m travel speed check described
before is more recommendable.
T4-4-3
EXCAVATOR TEST
MISTRACK CHECK
Summary:
1. Allow the machine to travel 20 m (65.5 ft). Meas-
ure the maximum tread deviation from the tread
chord line drawn between the travel start and end Maximum Distance
points to check the performance equilibrium be-
tween 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 decelera- SM0140
tion.
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.

Switch Dial Switch
Mode Idle Purpose
Mode
Mode Idle Purpose
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:
T4-2.
T4-4-4
EXCAVATOR TEST
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).
SM0141
Measurement:
1. Measure in the fast travel mode.
Position where the machine
Travel Engine E Mode HP Mode Work Auto-Idle comes to a stop
Mode Control Switch Switch Mode Switch Position when the travel
levers are in neutral
Switch Dial Switch
Displacement
Fast Fast OFF OFF General OFF (Revolution Angle)
Mode Idle Purpose
Mode
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
SM0142
neutral.
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.
Alignment marks on the track
4-3. After the machine stops, put alignment side frame and shoe when the
marks on a track link or shoe, and the track machine comes to a stop
side frame. Displacement measured
after 5 minutes
4-4. After 5 minutes, measure the distance be-
tween the marks on the track link or shoe and
the track side frame. SM0143
Evaluation:
T4-2.
T4-4-5
EXCAVATOR TEST
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 same height as the
the bucket so that the height of the bucket pin is boom foot pin height
the same as the boom foot pin. The bucket must
be empty.
SM0144
(122 ± 9°F).
CAUTION
Prevent personal injury. Always make sure that
the area is clear and that co-workers are out of the
swing area before starting the measurement.
Measurement:
Engine E Mode HP Mode Work Auto-

Control Switch Switch Mode Idle
Dial Switch Switch
Fast OFF OFF General OFF
Idle Purpose
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:
T4-2.
T4-4-6
EXCAVATOR TEST
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 chalk marks
slope. SM0145
the bucket so that the height of the bucket pin is
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).
CAUTION
SM0146
the area is clear and that coworkers are out of the
Measurement: Measure difference between marks


Dial Switch Switch
Fast OFF OFF General OFF Marking on the Track Frame
Idle Purpose
Mode Marking on the Swing Bearing
SM0147
2. Operate the swing control lever fully and return it
to the neutral position when the mark on the
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 calcu-
late the average values.
Evaluation:
T4-2.
T4-4-7
EXCAVATOR TEST
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 x 1.5
where: M = Bucket heaped capacity (m3) SM0148
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 illus-
trated.
(122 ± 9°F).
Measurement:
1. Select the following switch position:
E Mode HP Mode Work Auto-

Measure difference between marks
Switch Switch Mode Idle
Switch Switch
OFF OFF General OFF
Purpose
Mode
2. Maintain the engine at slow idle. After five min- Marking on the Track Frame
utes, measure the difference between the marks
along the swing bearing periphery and the track Marking on the Swing Bearing
frame. SM0147
3. Perform the measurement in both right and left

swing directions.
4. Perform the measurement three times in each
direction and calculate the average values.
Evaluation:
T4-2.
T4-4-8
EXCAVATOR TEST
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.
SM0149
3. Install a dial gauge on the track frame as shown,
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 bucket so that the height of the bucket pin is
the same as the boom foot pin. Record the dial
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
SM0150
Measurement: (h1) Measurement: (h2)
The same height as the

boom foot pin height
SM0144 SM0152
Evaluation:
T4-2.
T4-4-9
EXCAVATOR TEST
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 x 1.5
SM0148
where: M = Bucket heaped capacity (m3)
3. With the arm cylinder fully retracted and the
bucket 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:

Dial Switch Switch
Idle Purpose
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:
T4-2.
T4-4-10
EXCAVATOR TEST
HYDRAULIC CYLINDER CYCLE TIME
Measure the cycle time of the boom, positioning, 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 positioning
cylinder (triple articulation)
With the empty bucket rolled in and arm rolled out,
raise the boom to the maximum height.
3. To measure the cycle time of the arm cylinder:
With the empty bucket rolled in, position the arm so
SM0153
that it is vertical to the ground. Lower the boom until
the bucket is 0.5 m (20 in) above the ground.
4. 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: SM0154

Dial Switch Switch
Idle Purpose
Mode
SM0155
T4-4-11
EXCAVATOR TEST
2. To measure cylinder cycle times:

(Cylinder full stroke includes cylinder cushioning
zone)
– Boom cylinders:
Measure the time it takes to raise the boom, and
the time it takes to lower the boom. To do so,
position the boom at one stroke end, then move
the control lever to the other stroke end as
quickly as possible.
– Positioning cylinder (triple articulation):
Measure the time it takes to extend and retract
the positioning cylinder. To do so, position the
cylinder at one stroke end, then move the control
pedal to the other stroke end as quickly as
possible.
– Arm cylinder:
Measure the time it takes to roll in the arm, and
the time it takes to roll out the arm. To do so,
position the arm at one stroke end, then move the
control lever to the other stroke end as quickly as
possible.
– Bucket cylinder:
Measure the time it takes to roll in the bucket, and
the time it takes to roll out the bucket. To do so,
position the bucket at one stroke end, then move
the control lever to the other stroke end as
quickly as possible.
3. Repeat each measurement three times and calcu-

Evaluation:
Refer to the Performance Standard Table in Group T4-
2.
T4-4-12
EXCAVATOR TEST
DIG FUNCTION DRIFT CHECK

Extended
Summary: Retracted Distance
Distance
Measure dig function drift, which can be caused by oil Retracted
leakage in the control valve and boom, arm, and Distance
bucket cylinders, with the loaded bucket.
Same Height
NOTE - When testing the dig function drift just after

cylinder replacement, slowly operate each cylinder to Bucket Bottom
its stroke end to purge air.
SM0156
Preparation:
1. Load bucket fully. In lieu of loading the bucket, Arm Cylinder Extension (and positioning cylinder for
weight (W: tons) of the following specification can triple articulation)
be used.
W = M x 1.5
where: M = Bucket heaped capacity (m3)
2. Position the arm cylinder with the rod 50 mm (2 in)
extended from the fully retracted position. Mark
3. Position the positioning cylinder (triple articula-
tion) with the rod 50 mm (2 in) extended from the
fully retracted position.
4. Position the bucket cylinder with the rod 50 mm
(2 in) retracted from the fully extended position.
5. With the arm rolled out and the bucket rolled in,
hold the bucket so that the height of the bucket pin
is the same as the boom foot pin.
6. Maintain the hydraulic oil temperature at 50 ± 5°C SM0157
(122 ± 9°F).
Boom and Bucket Cylinder Retraction

Measurement:
1. Stop the engine. Mark Mark
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, positioning
(triple articulation), arm and bucket cylinders.
3. Repeat step 2. three times and calculate the
average values.
Evalution:
SM0158
T4-2.
T4-4-13
EXCAVATOR TEST
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.
SM0159
Dial Switch Switch
Idle Purpose
Mode
CAUTION
3. Operate each boom, arm, bucket and swing lever

to at full stroke and measure the maximum oper-
ating 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 SM0160
required. When finished, lower the track and then

jack-up the other track.
average values.
Evaluation:
T4-2.
T4-4-14
EXCAVATOR TEST
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).
SM0161
Measurement:
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.
Evaluation:
T4-2.
T4-4-15
EXCAVATOR TEST
COMBINED BOOM RAISE/SWING

FUNCTION 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. SM0162
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).
CAUTION
Measurement:

Dial Switch Switch SM0163

Idle Purpose
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
time required to swing 90° and the height (H) of the
bucket teeth.
average values.
Evaluation:
T4-2.
SM0164
T4-4-16
EXCAVATOR TEST
NOTES
T4-5-1
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. Remove the plug from the pilot pump delivery
port. Install adapter (75301519) and pressure
gauge (75301518) on the port.
: 6 mm
Plug
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
(122 ± 9°F).
SM0165
Measurement:

Dial Switch Switch
Idle Purpose
Mode
Slow OFF OFF General OFF
Idle Purpose
Mode
2. Measure the pilot pressure in each specified set-

ting above.
3. Repeat the measurement three times and calcu-
Evaluation:
T4-2.
T4-5-2
COMPONENT TEST
Primary Pilot Pressure Adjustment
Adjustment:
Adjust the setting pressure of relief valve (1) (the
primary pilot pressure) as necessary.
: 36 mm 1
SM0166
1. Remove plug (3).

2. Install the estimated necessary number of shims
(2).
3. Tighten plug (3).
: 49 Nm (5 kgf•m, 36 lbf•ft)
3
4. Check the relief pressure of relief valve (1).
2
Change in Relief Pressure
Shim Thickness (mm)
kPa kgf/cm2 psi
SM2201
0.25 78 0.8 11
0.5 157 1.6 23
1.0 304 3.1 44

T4-5-3
COMPONENT TEST
SECONDARY PILOT PRESSURE
Preparation:
1
3. Install pressure gauge (75301518) and tee
(75301520) to the end of pilot line (1) at the
respective control valve spool end, as illustrated.
: 14 mm, 17 mm

(122 ± 9°F).
Measurement:

Control Switch Switch Mode Idle SM0168
Dial Switch Switch
Idle Purpose
Mode
Slow OFF OFF General OFF
Idle Purpose
Mode
2. Measure the pilot pressure in each specified set-

ting above with the corresponding control lever
operated full stroke.
Evaluation:
Refer to the Performance Standard Table in Group SM0169
T4-2.
T4-5-4
COMPONENT TEST
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 (75301482), tee
(75301521), adapter (75301522), and pressure
gauge (75301518) to the disconnected end at the
solenoid valve side, as illustrated.
: 17 mm, 19 mm, 22 mm 1
Connect Dr.EX to the machine for solenoid valve

set pressure monitoring. SM0629
(122 ± 9°F).
Solenoid Valve
Pressure Gauge
Measurement:
1
Engine E Mode HP Mode Work Travel
Control Switch Switch Mode Mode
Dial Switch Switch
Fast OFF OFF General Fast
Hose Tee Adapter
Idle Purpose Speed
Mode Mode
SM0171
2. Operate as instructed below for each measuring

solenoid valve:
Solenoid Valve SG: Repeat pressing and releas-
ing of the power boost switch.
Solenoid Valve SD: Perform a combined opera-
tion. Relieve both actuators.
Solenoid Valve SC: Perform a combined opera-
tion 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.
T4-5-5
COMPONENT TEST
Solenoid Valve Set Pressure Adjustment Proce-

dure
IMPORTANT - Do not loosen the adjusting screw

excessively.
The O-ring on the threads may come off the sealing
surface, causing oil leakage.
1. Mark the end of the adjusting screw with a white

The distance between the
marker for the record of the original position. lock nut end and screw end
(Take care not to touch any part of the screw should be 4.0 mm (0.157 in)
threads with the white marker). or less.
2. Loosen lock nut (7). Turn adjusting screw (8) to
adjust the set pressure of the solenoid valve. SM0172
3. Retighten lock nut (7).
: 13 mm
: 4 mm
: 8.8 N•m (0.9 kgf•m, 6.5 lbf•ft)
Reference: Standard Change in Pressure

8 7
Turns 1/4 1/2 3/4 1
kPa 98 196 294 392 SM0173
kgf/cm2 1 2 3 4
psi 14 28 43 57
Adjusting Screw
4. Check the set pressure of the solenoid valve.
Pressure Pressure
Increase Decrease
SM0174
T4-5-6
COMPONENT TEST
MAIN PUMP DELIVERY PRESSURE
The main pump delivery pressure can also be meas-

ured with Dr.EX.
Preparation:
3. Remove the plug from the main pump delivery
port. Install adapter (75301519), hose
(75301523) and pressure gauge (75301524) on
the port.
: 6 mm
Or connect Dr.EX to the machine for main pump

delivery pressure monitoring.
(122 ± 9°F).
SM0175
Measurement:

Dial Switch Switch
Idle Purpose
Mode
2. Measure the pressure with the control levers in

neutral.
Evaluation:
T4-2.
T4-5-7
COMPONENT TEST
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:
the port.
: 6 mm
Or connect Dr.EX to monitor the main pump

delivery pressure.
5. Maintain the hydraulic oil temperature at 50 ± 5°C SM0175
(122 ± 9°F).
Measurement:
Engine E Mode HP Mode Work

Control Switch Switch Mode
Dial Switch
Fast OFF OFF General
Idle Purpose
Mode
2. Relieve each actuator to measure main relief

pressures.
First, slowly operate bucket, arm, and boom con-
trol levers to the stroke end to relieve each func-
tion one at a time.
3. As for the swing function, secure the upperstruc-
ture 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:
T4-2.
Reference:
If the measure pressures for all functions are lower
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.
T4-5-8
COMPONENT TEST
Main Relief Pressure Setting Adjustment Proce-

dure
Main Relief
Valve
Adjustment:
Adjust the pressure setting of the main relief valve
using plug (3) (for the low-side relief pressure setting)
and plug (5) (for the high-side relief pressure setting)
after loosening lock nut (1).
• High-Side Relief Pressure Setting Adjustment

Procedure
1. Loosen lock nut (1). Lightly tighten plug (3) until
the end of plug (3) comes into contact with
piston (2). Retighten lock nut (1).
: 27 mm
: Plug (3): 19.5 N•m (2 kgf•m, 14.5 lbf•ft)
: Lock Nut (1):
68 to 78 N•m
(7 to 8 kgf•m, 51 to 58 lbf•ft)
SM0168
2. Loosen lock nut (4). Turn plug (5) to adjust the

relief pressure setting referring to the table
3
below.
: 27 mm, 32 mm
: Lock Nut (4): 1
78 to 88 N•m
(8 to 9 kgf•m, 58 to 65 lbf•ft) 5
• Low-Side Relief Pressure Setting Adjustment

Procedure 4
3. Loosen lock nut (1). Turn plug (3) counter
clockwisely until the specified value is obtained 2
referring to the table below. Retighten lock nut
(1).
: 27 mm
: Lock Nut (1):
59 to 68 N•m
(6 to 7 kgf•m, 43 to 51 lbf•ft)
4. Recheck the set pressures.
Change in Relief Pressure: Plug (5)

(High-Side Relief Pressure)
SM0177
Turns 1/4 1/2 3/4 1
MPa 7.1 14.2 21.3 28.4
kgf/cm2 72.5 145 217.5 290 5-3
psi 1031 2062 3093 4120 Plug
Change in Relief Pressure: Plug (3)

(Low-Side Relief Pressure)
Pressure
Pressure Decrease
Turns 1/4 1/2 3/4 1 Increase
MPa 5.3 10.7 16.0 21.3
kgf/cm2 54 109 163 217
psi 770 1550 2320 3090
SM0178
T4-5-9
COMPONENT TEST
Swing Relief Pressure Setting Adjustment Proce- Swing Relief

Valve
dure
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 set-

ting referring to the table below.
4. Recheck the set pressure.
: 24 mm, 32 mm
: 177 N•m (18 kgf•m, 130 lbf•ft)
SM0179
1
2
SM0180

1
Turns 1/4 1/2 3/4 1
MPa 2.9 5.8 8.7 11.7
kgf/cm2 30 59.5 89 119
psi 430 850 1270 1690 Pressure Pressure
Increase Decrease
SM0181
T4-5-10
COMPONENT TEST
Travel Relief Pressure Setting Adjustment Proce-

dure
Adjustment:
Adjust the pressure setting of the travel relief valve
using adjusting screw (1) after loosening lock nut (2).
: 19 mm
: 6 mm
2. Turn adjusting screw (1) to adjust the pressure

setting referring to the table below.
Travel Relief Valve
SM0182
: 49 N•m (5 kgf•m, 36 lbf•ft)

1
2
SM0183

Adjusting
Turns 1/4 1/2 3/4 1 Screw
MPa 2.9 5.9 8.8 11.8
kgf/cm2 30 60 90 120
Pressure Pressure
psi 430 850 1280 1710 Increase Decrease
SM0174
T4-5-11
COMPONENT TEST
OVERLOAD RELIEF VALVE SET PRESSURE
Summary:
Measuring the set pressure of the overload relief
valves on the machine is not recommended for the
following reasons:
1. The circuit pressure must be increased by apply-

ing an external force while blocking the return
circuit from the control valve. This measuring
method is hazardous and the results obtained
with this method are unreliable.
2. Pressure setting of the overload relief valve must
be made at a specified oil flow rate normally far
smaller than the main pump delivery flow rate.
Accordingly, even if the main relief valve set
pressure can be reset higher than the overload
relief valve set pressure, the main pump supplies
too much oil to correctly measure the setting
pressure of the overload relief valve.
For this reason, in order to correctly measure the
set pressure of the overload relief valve, the
overload relief valve unit must be removed from
the machine and tested on a test stand.
3. If the overload relief valve performance must be
checked on the machine, however, measure the
main relief pressure while releasing each front
function respective to the measuring overload
relief valve. And, assume that the overload relief
valve is functioning correctly if the obtained main
relief pressure is within the specified value range.
Measure the main pressure of the front functions
as follows:
Preparation:
the port.
: 6 mm
Or connect Dr.EX to the machine for main pump

delivery pressure monitoring.
(122 ± 9°F). SM0175
T4-5-12
COMPONENT TEST
Measurement:
Engine E Mode HP Mode Work

Control Switch Switch Mode
Dial Switch
Fast OFF OFF General
Idle Purpose
Mode
2. Slowly operate bucket, arm, and boom control

levers to the stroke ends to relieve each function
one at a time.
3. Read the pressures on the pressure gauge while
releasing the front functions.
4. Perform the measurement for the bucket, arm,
and boom, in that order.
late the average value for each front function.
Evaluation:
1. Performance of the overload relief valves are
normal if the measured main relief pressures are
within the specified value range.
Refer to the Performance Standard Table in

Group T4-2.
T4-5-13
COMPONENT TEST
Overload Relief Valve Set Pressure Adjusting

Procedure
NOTE - In principle, adjust the overload relief valve

set pressure on a test stand. 1
Adjustment:
Adjust the pressure setting of the overload relief
valve using adjusting screw (2) after loosening lock
nut (1).

2
2. Turn adjusting screw (2) to adjust the pressure
setting referring to the table below.
SM0185
: 17 mm
: 6 mm
: 29.5 N•m (3.0 kgf•m, 22 lbf•ft)
4. Recheck the set pressures.
Turns 1/4 1/2 3/4 1 Adjusting

MPa 5.2 10.6 15.9 21.1 Screw
kgf/cm2 54 108 162 216
psi 770 1540 2300 3070 Pressure Pressure
Increase Decrease
SM0174
T4-5-14
COMPONENT TEST
MAIN PUMP FLOW TEST
Summary:
To check the main pump performance, measure the Measurement:
pumps flow rate by connecting a portable tester at the 1. Maintain the hydraulic oil temperature at 50 ± 5°C
delivery port of the main pumps. (122 ± 9°F).
Preparation: Travel Engine E Mode HP Mode Work Auto-Idle

1. Properly shut down the engine. Press the air Mode Control Switch Switch Mode Switch
release valve on top of the hydraulic oil tank to Switch Dial Switch
release any remaining pressure. Connect a Fast Fast OFF OFF General OFF
vacuum pump to the oil filler on the hydraulic oil Mode Idle Purpose
tank. Mode
NOTE - Operate the vacuum pump while connecting 3. Lower the pilot shut-off valve. Gradually close the
the portable tester to the main pumps. loading valve of the portable tester to obtain the
specified pressure on the P-Q curve, and meas-
ure the flow rate and engine speed. Repeat step
2. Disconnect hoses A and B from the main pumps. 3. for all specified pressure points on the P-Q
Install flanges (8), split flanges C, and bolts D on curve.
the disconnected hoses. Remove plug E from
hydraulic oil tank connection and install adapter 4. Repeat the measurement three times and calcu-
(10). late the average values.
: 41 mm
: 10 mm
3. Install test pipes (4) and (5), split flanges C, bolts

D, to the pumps, and connect them together
throught “T” fitting (11). Connect the hose (9)
between “T” fitting (11) and the loading valve (2).
Connect the test hose (6) to the adapter (10), then
connect the portable test (75298406) as shown.
Straighten hoses (4) and (5), as much as possi-
ble, and secure to restrict any movement of
hoses.
: 41 mm, 17 mm
: 6 mm, 10 mm
4. Disconnect the vacuum pump. Loosen plug K on

the pump housing to bleed air from the pump until
oil comes out of plug K clearance.
5. Connect a tachometer to the injection pipe. Fully

open the loading valve of the portable tester.
6. Start the engine. Check the portable tester con-

nection for any oil leakage.
T4-5-15
COMPONENT TEST
Evaluation:
1. Convert the measured pump flow rate into the one 2. Specified Pump Flow Rate
for the rated pump speed using the following Refer to the Pump P-Q Diagram in Group T4-2.
formula.
Converted Pump Flow Rate:

Qc = Ns x Q / Ne
Where:
Qc : Converted Pump Flow Rate
Q : Measured Pump Flow Rate
Ns : Rated Engine Speed
(2000 rpm)
Ne : Measured Engine Speed
A
8
4 5
C, D
C, D
11 C, D
B
C, D
9 6
10
2
E
SM0186
T4-5-16
COMPONENT TEST
Regulator Adjustment
4
6
5
9
3
10
7
8
SM0187
1 - Lock Nut (For Minimum Flow Adjustment) 6 - Adjusting Screw

2 - Adjusting Screw (For Minimum Flow Adjustment) (For Pilot Pressure Characteristic Adjustment)
3 - Lock Nut (For Maximum Flow Adjustment) 7 - Lock Nut (For P-Q Line Adjustment)
4 - Adjusting Screw(For Maximum Flow Adjustment) 8 - Adjusting Screw (For P-Q Line Adjustment)
5 - Lock Nut 9 - Lock Nut (For P-Q Line Adjustment)
(For Pilot Pressure Characteristic Adjustment) 10 - Adjusting Screw (For P-Q Line Adjustment)
T4-5-17
COMPONENT TEST
Adjustment Item Adjustment Procedure Remarks
1. Minimum Flow Rate Loosen lock nut (1) and turn ad- 1) Do not turn the adjusting screw
justing screw (2). more than two turns.
Q
Rotating adjusting screw (2) 1/4 2) Securely retighten lock nut (1)
a turn clockwise increases the after the adjustment.
minimum pump flow rate by 6.47
cm3/rev. (0.39 in3/rev).
Pi
2. Maximum Flow Rate Loosen lock nut (3) and turn ad- 1) Do not turn the adjusting screw
justing screw (4). more than two turns.
Rotating adjusting screw (4) 1/4 2) Do not increase the maximum
Q a turn clockwise decreases the flow rate.
maximum pump flow rate by 5.39 In other words, do not turn the
cm3/rev. (0.33 in3/rev). adjusting screw counterclock-
wise. Increasing the maximum
flow rate (turning the adjusting
screw counterclockwise), how-
ever, will be required after ad-
justing the pilot pressure char-
acteristics.
Pd 3) Securely retighten lock nut (3)
after the adjustment.
3. Pilot Pressure Characteris- Loosen lock nut (5) and turn ad- 1) Do not turn the adjusting screw
tics (Pi-Q Line) justing screw (6). more than one turn.
Rotating adjusting screw (6) 1/4 2) When adjusting screw (6) is
a turn clockwise decreases the turned clockwise, the maxi-
Q flow rate by 10.77 cm3/rev. mum flow rate will also be de-
(0.66 in3/rev). creased.
To maintain the maximum flow
rate unchanged, turn adjusting
screw (4) counterclockwise
twice as much as adjusting
screw (6) is turned.
This ratio of 2 (adjusting screw
(4) counter clockwise turn) to 1
Pi (adjusting screw (6) clockwise
turn) is to counterbalance.
3) Securely retighten lock nut (5)
after the adjustment.
4. P-Q Line A: Loosen lock nut (7) and turn 1) Do not turn the adjusting
(Torque Adjustment) adjusting screw (8). Rotating screws more than one turn.
adjusting screw (8) 1/4 a turn 2) Rotate the adjusting screws
Q
clockwise increases the watching the engine perform-
maximum pump flow rate by ance.
10.77 cm3/rev. (0.66 in3/rev.). 3) Securely retighten lock nut (7)
B: Loosen lock nut (9) and turn or (9) after the adjustment.
A
adjusting screw (10). Rotat-
ing adjusting screw (10) 1/4 a
turn clockwise increases the
B
maximum pump flow rate by
Pd 2.60 cm3/rev. (0.16 in3/rev).
T4-5-18
COMPONENT TEST
SWING MOTOR DRAINAGE
Summary:
To check swing motor performance, measure the
amount of oil draining from the swing motor while
swinging the upperstructure.
1
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).
CAUTION
Also, take care not to fall off the machine while the
measurement.
Preparation:
1. Maintain hydraulic oil temperature at 50 ± 5°C
OM0400
(122 ± 9°F). Rotate the swing motor to warm the
inside of the motor.
2. Properly shut down the engine. Press the air

release valve (1) on top of the hydraulic oil tank to 2
release any remaining pressure.
3. Disconnect the swing motor drain hose (2) at the

hydraulic oil tank end. Install plug (75301529) to
the disconnected end on the hydraulic oil tank.
: 22 mm
: 39 N•m (4 kgf•m, 29 lbf•ft)
Preconditions for Measurement:


Dial Switch Switch
Idle Purpose
Mode
SM0189
T4-5-19
COMPONENT TEST
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 The same height as
boom foot pin height
lever full stroke. Start draining oil measure-
ment after the swing speed reaches a con-
stant maximum speed. The measuring time SM0144
should be more than 45 seconds.
(3) Repeat the measurement at least three times
in both clockwise and counterclockwise direc-
tions, and calculate the average values.
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
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.
SM0190
in both clockwise and counterclockwise direc-
tions, and calculate the average values.
Evaluation:
T4-2.
* Conversion of the amount of drain oil measured

into the per-minute value
First measure the amount of drain oil using a cali-

brated container. Then, convert the measured drain
oil into the per-minute value using the formula below:
∆Q = 60 x q / t
Where:
∆Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
SM0191
T4-5-20
COMPONENT TEST
TRAVEL MOTOR DRAINAGE
Summary:
To check travel motor performance, measure the
amount of oil draining from the travel motor while
rotating the travel motor with the measuring side track
jacked up.
NOTE - The amount of drain oil from the travel motor

1
will change depending on hydraulic oil temperature.
Maintain hydraulic oil temperature at 50 ± 5°C (122 ±
9°F).
Preparation:
1. Maintain 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 valve (1) on top of the hydraulic oil tank to
release any remaining pressure.
3. Disconnect the travel motor drain hose (2) at the

travel motor end. Install plug (75301525) to the
disconnected end. Connect the drain hose (3/4-
OM0400
16UN) to the travel motor.
2
: 22 mm, 27 mm
: 93 N•m (9.5 kgf•m, 69 lbf•ft)
Preconditions for Measurement:


Dial Switch Switch
Idle Purpose
Mode
SM0182
T4-5-21
COMPONENT TEST
Measurement:
1. Amount of oil drained while travel motor is rotating
(1) Start the engine. Jack up the measuring side
track using the front attachment, as illus-
trated. 90° to 110°
CAUTION
Securely support the raised track using wooden
blocks. SM0139
(2) Rotate the raised track with the travel lever

operated full stroke. Start drain oil measure-
ment after the track rotation speed reaches a
constant maximum speed. The measuring
time should be more than 45 seconds.

in both forward and reverse directions, and
calculate the average values.
Evaluation:
T4-2.
* Conversion of the amount of drain oil measured

into the per-minute value
SM0193
First measure the amount of drain oil using a cali-

brated container. Then, convert the measured drain
oil into the per-minute value using the formula below:
∆Q = 60 x q / t
Where:
∆Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-5-22
COMPONENT TEST
NOTE
SECTION 5 EX255
TROUBLESHOOTING
INDEX
Group 1 - Diagnosing Procedure Group 4 - Troubleshooting B

Introduction ........................................... T5-1-1 Troubleshooting B Procedure ............... T5-4-1
Diagnosing Procedure ......................... T5-1-2 Relationship between Machine Trouble
Dr.EX .................................................... T5-1-4 Symptoms and Parts in Trouble ........ T5-4-2
Dr.EX Start-Up Procedure ................... T5-1-4 Correlation between Trouble
Dr.EX Fault Code ................................. T5-1-5 Symptoms and Part Failures .......... T5-4-12
Dr.EX Monitoring Function ................... T5-1-6 Engine Troubleshooting ...................... T5-4-18
Dr.EX Special Function Actuator Control System
(Service Mode) ................................. T5-1-7 Troubleshooting ............................... T5-4-32
Adjustable Data List ........................... T5-1-14 Front Attachment Control System
Troubleshooting ............................... T5-4-38
Swing System Troubleshooting ........... T5-4-50
Group 2 - Component Layout Travel System Troubleshooting ........... T5-4-53
Main Components ................................ T5-2-1 Troubleshooting for Other Functions .. T5-4-58
Electrical System (Overall System) ..... T5-2-2 Engine Speed Adjustment and
Electrical System (Relays, Diodes, etc) ... T5-2-3 Engine Learning ............................. T5-4-60
Electrical System Exchange Inspection Method ............. T5-4-61
(Monitor and Switch Panels) ............ T5-2-4
Pump and Related Parts ...................... T5-2-5 Group 5 - Troubleshooting C
Control Valve ........................................ T5-2-6 Troubleshooting C Procedure ............... T5-5-1
Other Components ............................. T5-2-10 Malfunction of Coolant

Temperature Gauge .......................... T5-5-2
Malfunction of Fuel Gauge ................... T5-5-4
Group 3 - Troubleshooting A Malfunction of Fuel Level
Troubleshooting A Procedure .............. T5-3-1 Indicator ............................................ T5-5-6
Fault Codes .......................................... T5-3-2 Malfunction of Indicator Light
Fault Code 01 ....................................... T5-3-4 Check System ................................... T5-5-8
Fault Code 02, 03 ................................. T5-3-5 Malfunction of Level Check Switch ....... T5-5-8
Fault Code 04, 05 ................................. T5-3-6 Malfunction of Engine Oil Level
Fault Code 06 ....................................... T5-3-7 Indicator .......................................... T5-5-10
Fault Code 07 ....................................... T5-3-8 Malfunction of Coolant Level
Sensor Operating Range List .............. T5-3-9 Indicator .......................................... T5-5-12
INDEX
Malfunction of Hydraulic Oil Level Group 7 - Harness Check

Indicator .......................................... T5-5-14 Circuit Check......................................... T5-7-1
Malfunction of Alternator Indicator .... T5-5-16
Malfunction of Engine Oil Pressure
Indicator .......................................... T5-5-18
Malfunction of Overheat
Indicator .......................................... T5-5-20
Malfunction of Air Filter Restriction
Indicator .......................................... T5-5-22
Malfunction of Buzzer ........................ T5-5-24
Malfunction of Hour Meter ................. T5-5-26
Group 6 - Electrical System Inspection

Precautions for Inspection and
Maintenance ..................................... T5-6-1
Instructions for Disconnecting
Connectors ....................................... T5-6-3
Fuse Continuity Test ............................. T5-6-4
Inspection and Replacement of Maxi
Fusible Links .................................... T5-6-5
Inspection and Replacement
of Mega fusibible ................................ T5-6-6
Battery Voltage Check .......................... T5-6-7
How to Troubleshoot Alternator
Malfunctions ..................................... T5-6-8
Continuity Check .................................. T5-6-9
Voltage and Current Check ................ T5-6-10
Replacement of Relay ........................ T5-6-14
Replacement of Diode .......................... T5-6-16
Replacement of Power Oulet ................ T5-6-18
T5-1-1
DIAGNOSING PROCEDURE
INTRODUCTION
Each troubleshooting section group is presented in

an orderly fashion so as to make the inspecting and
troubleshooting procedures easy to follow. Use the
troubleshooting section to guide you in locating the
source of any problems that may arise.
The troubleshooting section consists of 6 groups: the

component layout, the troubleshooting A (using fault
codes), troubleshooting B (starting with symptoms),
troubleshooting C (gauges and indicators), the elec-
trical system inspection procedures, and harness
check groups.
• Component Layout Diagrams
• Troubleshooting A (using fault codes)

Use these charts when the self-diagnosing func-
tion of Dr.EX shows any fault codes.
(The controller automatically diagnoses and
memorizes malfunctions that have occurred in the
signal sending system.)
Example: Fault Code 01 EC Sensor Failure
• Troubleshooting B (starting with symptoms)

Use these charts when the machine is exhibiting
trouble and when Dr.EX does not indicate any fault
codes.
Example: Even if engine control dial is operated,

engine speed does not change.
• Troubleshooting C (Gauges and indicators)

Use these charts when any gauges or indicators
malfunction.
Example: The fuel gauge does not operate.
• Electrical System Inspection Procedure

Refer to this group for precautions and inspection
procedures of the electrical system when or before
performing inspections on the electrical system.
Example: Fuse Inspection
• Harness Check
Refer to this group for information about the test
harnesses.
Example: 75301517
T5-1-2
These six basic steps are essential for efficient

troubleshooting:
1. Study the System

Study the machine’s technical manuals. Know the
system and how it works, and what the construc-
tion, functions and specifications of the system
components are.
2. Ask the operator

Before inspecting, get the full story of malfunc- SM0600
tions from your star witness ···· the operator.
(a) How is the machine being used? (Find out if

the machine is being operated correctly)
(b) When was the trouble noticed, and what types

of work the machine doing at that time?
(c) What are the details of the trouble? Is the

trouble getting worse, or did it appear sud-
denly for the first time?
(d) Did the machine have any other troubles

previously? If so, which parts were repaired
before?
SM0601
3. Inspect the machine

Before starting the troubleshooting procedure,
check the machine’s daily maintenance points, as
shown in the operator’s manual.
Also, check the electrical system, including the

batteries, as troubles in the electrical system such
as low battery voltage, loose connections and
blown fuses will result in malfunction of the con-
trollers, causing total operational failure of the
machine.
Fuse failure is often caused by a fine crack in the
fuse, and such fine cracks are very hard to detect
by visual inspection.
SM0602
T5-1-3
4. Operate the machine yourself.

If the trouble cannot be confirmed, stop the engine
and obtain further details of the malfunction from
the operator.
Also, check for any incomplete connections of the
wire harnesses.
5. Perform troubleshooting
CAUTION: SM0603
Never attempt to disconnect harnesses or hy-
draulic lines while the engine is running. The
machine may malfunction or pressurized oil may
spout, possibly resulting in personal injury. Be
sure to stop the engine before disconnecting
harnesses or hydraulic lines.
Connect the diagnostic analyzer, Dr.EX, to the MC

(Main Controller) to obtain malfunction records.
If any fault codes are displayed on the monitor,

check sensing signal circuits, referring to Trouble- SM0604
shooting A.
If no fault code is indicated on the monitor, go to the

troubleshooting B group.
Note that Dr.EX will be necessary in the trouble-
shooting B procedures for monitoring real time
component performance.
∗Note that the fault codes displayed do not neces-

sarily indicate machine trouble. The controller
stores even temporary electrical malfunctions,
such as a drop in battery output voltage or
disconnections of the switches, sensors, etc., for
inspections.
For this reason, the “RETRIAL” is required to erase
the accumulated fault codes from the controller
SM0605
memory and to confirm if any fault codes are
indicated after the “RETRIAL”.
6. Trace possible causes

Before reaching a conclusion, check the most
likely causes again. Try to identify the actual cause
of the trouble.
Based on your conclusion, make a plan for appro-

priate repairs to avoid consequent malfunctions.
SM0606
T5-1-4
Dr.EX
Dr.EX (75301336) is a handy micro computer used

for diagnosing malfunctions of the machine control
system, including the MC (Main Controller).
When the Dr.EX is connected to the MC, malfunc-

tions recorded in the MC memory are indicated as
fault codes on the Dr.EX display.
(Self-Diagnosing Function)
Input signals from the sensors or switches that are

connected to the MC, or output signals from the MC
to solenoid valves can be monitored on a real-time
basis while the machine is being operated.
(Real-Time Monitoring Function)
Dr.EX START-UP PROCEDURE
1. Connect the harness of the Dr.EX to the diagnos-

ing connector of the MC, located near fuse box
behind the operator’s seat.
Start
NOTE - Only this connecting harness can be used to
connect the Dr.EX to the controller. Do not use any
other harness to connect Dr.EX to the controller.
Initial Screen
2. Turn the key switch to the ON position or start the

engine.
Model Code
Can not
Confirmation
3. Turn the Dr.EX ON. After a few seconds, following communicate
with MC
patterns will appear on the Dr.EX display:
Check MC
power source Not OK
3-1. Initial Pattern and/or OK?
communication
3-2. Model Code Pattern harness
Dr. EX Other
Example : OK
Software
Model : EX200-5
Ver : XXXX
Self- Monitor Special
3-3. Function Selection Pattern Diagnosing Function Data Functions
F-1 : “Self-diagnosing Results” Selection
F-2 : “Monitor Data”
F-3 : “Special Functions”
Self-Diagnosing Record Data Selecting
Results Pattern
4. Select key F1 (Proceed according to the in- (Fault Code)
structions that appear on the display.)
Monitor
Retrial B Data Display
NOTE - For the operation procedure of the Dr.EX,
refer to the Dr.EX OPERATOR’S MANUAL.
Self-Diagnosing
Results
(Fault Code)
T5-1-5
Dr.EX 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.
T5-1-6
Dr.EX MONITORING FUNCTION
Dr.EX has a function to monitor the command signals

from the MC and the input signals to the MC from
various switches and sensors.
Monitor Item Description Display Unit and Form

Pump 1 Control Pressure Input from the PC pressure sensor (4-spool side) kgf/cm2
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
EC Angle Input Signal from EC Sensor V

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Pump 1 Delivery Pressure Input from the pump 1 delivery pressure sensor kgf/cm2
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Pump 2 Delivery Pressure Input from the pump 2 delivery pressure sensor kgf/cm2
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Arm Roll-In Pilot Pressure Input from the arm roll-in pilot pressure sensor kgf/cm2
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Pump 2 Control Pressure Input from the PC pressure sensor (5-spool side) kgf/cm2
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Accelerator Angle
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Dial Angle Input from the engine control dial V

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Arm Regenerative Proportional The value of the command signal to the solenoid kgf/cm2
Solenoid Valve Output valve unit SC
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Travel Motor Displacement The value of the command signal to the solenoid kgf/cm2
Angle Change Pressure valve unit SI
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Pump Proportional Solenoid The value of the command signal to the solenoid kgf/cm2
Valve Output valve unit SD
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Power Boost Pressure The value of the command signal to the solenoid kgf/cm2
valve unit SG
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Target Engine Speed Target engine speed under loaded condition. rpm
(Approx. 150 min-1 difference from engine speed
under no load.)
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Actual Engine Speed Input from the N sensor rpm

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
EC Motor Position step

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Pressure Switch On/off state of the pressure switches BmH, Fr, Tr

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Selected Work Mode Switch Selected work mode S, G, P, A

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
E Mode Switch On/off state of the E mode switch EP

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Auto-Idle Switch On/off state of the auto-idle switch AI

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
HP Mode Switch On/off state of the HP mode switch HP

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Power Boost Switch ON/off state of the power boost switch Pd

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Selected Travel Mode Switch Selected travel mode Lo. Hi

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Key Switch On/off state of the key switch Ky

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Engine Learning Control Done, Undone, Aborted

T5-1-7
Dr.EX SPECIAL FUNCTION (SERVICE

MODE)
1. Purpose
Some data in the MC (Main Controller), such as the
flow rate in the attachment mode, engine speed in
the E mode, can be changed as required.
2. Parts pertaining to the special function.
Dr.EX
Learning Switch MC
Key Switch
3. Operation
• How to Turn Dr.EX in the Service Mode
1) Turn the key switch OFF. Wait 10 seconds or
more.
2) Connect the Dr.EX.
3) Turn the learning switch to the Engine Learning
position.
4) Turn the key switch to the ON position. (Do not
start the engine.)
5) Turn on the switch on the Dr.EX.
• On the following pages, the service mode panels

on the Dr.EX and the service mode operating
procedure are shown.
T5-1-8
HITACHI Service mode related to Dr.EX screen panels, be-

ginning with the start screen, are shown along with
Dr.EX VER **** the corresponding Dr.EX key operations.
However, Dr.EX screen panels which are not related
to the Dr.EX key operation are excluded.
(C) Hitachi Construction
Machinery Co.,Ltd 1996
F1 : Start F10 : Model Menu
F1 Press
Model : XXXX-X
Ver : XXXX
Is model correct ?
F1 : Correct F5 : ESC
F1 Press
Service mode selected
In service mode, self diagnosis

operation and / or monitor display
will not be conducted.
F1 : Rechecked F5 : ESC
F1 Press
▼
1
T5-1-9
Select Functions
F3 : Special Functions
F5 : ESC
F3 Press
A
▼
Select Functions Select learning data to be dis-

F6 : F7 Press played.
F7 : Learning Data Display F6 : EC Motor Stop Position
▼
F8 : Parameter Change F7 : EC Motor Maximum Speed

▼
Position
F8 Press
F5 : ESC F5 : ESC
F8 Press F6 Press F5 Press
▼
Select Item
F6 : Li Speed
F7 : E Speed EC Motor Stop Position Learning
F8 : P Speed data is
F3 : Next -XXXX digit displayed.
F5 : ESC F5 : ESC
F3 Press
▼
2
T5-1-10
Select Item
F6 : AI Speed Control
F8 : Crusher (L) Engine Speed
Control An example of “F7: Breaker Engine
F5 Press Speed Control” operation is shown
on the next page.
F4 : Prev. ↑ F5 : ESC
▼
3
F5 Press
(Press F4 to return to the previous screen.)

▼
End
(Returns to panel (A) on the previous page.)
T5-1-11
Breaker Engine Speed Control Breaker Engine Speed Control

adjustable range in HELP F7 Press HELP
Adjustable Range : -500 to+100 rpm
▼
Input the adjusting deviation you Initial : 0 rpm
▼
want. Minimum Adjusting Deviation :
10 rpm
F3 : Next F5 : ESC F7 : HELP F5 Press
F5 : ESC
▼ Values
Adjusted
F3 Press
In Tens
▼
Breaker Engine Speed Control
123
F7 Press
Current : 0 rpm
123
123
Adjustment : 123 rpm
▼
F1 : Execute F2 : Corr F5 Press

F4 : Prev. F5 : ESC F7 : HELP
“-100” is entered as an example here.
SFT
SFT
Press (“123” on the upper right corner of the screen will change to “ABC”.)
-
Press (“-” will be displayed in the Adjustment field.)
3
SFT
Press (“ABC” on the upper right corner of the screen will change to “123”.)
SFT
* Press (“-1” will be displayed in the Adjustment field.)

1
. Press (“-10” will be displayed in the Adjustment field.)

0
. Press (“-100” will be displayed in the Adjustment field.)

0
▼
Breaker Engine Speed Control NOTE - Confirm that “123” is displayed on the upper
123 right corner of the screen before pressing key
Current : 0 rpm
Adjustment : -100 rpm
F1 : Execute F2 : Corr
F4 : Prev. F5 : ESC F7 : HELP
F1 Press
▼
4
T5-1-12
∗Adjusting Deviation∗
∗Data Confirmation∗
Adjusting Deviation Data Name :
F3 : Next F5 : ESC
F3 Press The value input on the previous page will be displayed again in
the Adjustment field.
▼
Current : 0 rpm
F1 : Execute F4 : Prev. F5 : ESC
F1 Press
▼
Adjustment was made as follows :
Adjusting Deviation Data Name :
F3 : Next
F3 Press The last screen for the Breaker Engine Speed Control will be
displayed.
▼
Current : 0 rpm
F4 : Prev F5 : ESC
Turn off Dr.EX.

▼
End
T5-1-13
• Check the engine performance (Check if the en-

gine speed has been changed), as follows:
IMPORTANT - Be sure to turn the learning switch to

the OFF (Neutral) position before checking the en-
gine performance. Because the MC does not perform
the engine, pump, and valve controls if the learning
switch is in the Engine Learning position, engine
speed change cannot be confirmed properly.
1) Turn the key switch OFF.

2) Wait 10 or more seconds.
3) Turn the learning switch to the OFF (Neutral)
position.
4) Disconnect Dr.EX. (This step can be omitted if you
wish to monitor the engine speed on Dr.EX.)
5) Turn the key switch to the ON position.
6) Start the engine.
7) Operate the machine to check the engine perform-
ance.
T5-1-14
ADJUSTABLE DATA LIST
Adjustable Data Values Adjusted In Adjustable Range Set Adjustment Value Before
Factory Shipment
Li Mode Speed 10’s min-1 (rpm) 0 to 120 min-1 (rpm) 0 min-1 (rpm)
E Mode Speed 10’s min-1 (rpm) -120 to 120 min-1 (rpm) 0 min-1 (rpm)
-1 -1
P Mode Speed 10’s min (rpm) -120 to 120 min (rpm) 0 min-1 (rpm)
AI Mode Speed 10’s min-1 (rpm) -120 to 100 min-1 (rpm) 0 min-1 (rpm)
-1 -1
Breaker Engine Speed 10’s min (rpm) -500 to 100 min (rpm) 0 min-1 (rpm)
Crusher Engine Speed 10’s min-1 (rpm) -500 to 100 min-1 (rpm) 100 min-1 (rpm)
T5-2-1
COMPONENT LAYOUT
MAIN COMPONENTS
1
3
4
5
6
7
8
9
19
18 10
17 11
16 12
13
14
15
SM3001
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
T5-2-2
COMPONENT LAYOUT
ELECTRICAL SYSTEM
(Overall System)
1 2
4
3
5 6
29
28 8
9
27
26
10 -11
25
12
13
24
23
14 -15
22
21
20
19
on the side
of engine
18 17 pan 16
SM3002
1 - Wiper Motor 16 - Engine Oil Pressure Switch

2 - Monitor Panel 17 - Engine Oil Level Switch
3 - Relays 18 - Overheat Switch (Lower)
4 - Pressure Switch (Front) 19 - Coolant Temperature Sensor
5 - Pressure Switch (Travel) 20 - Alternator
6 - Work Light 21 - Battery Relay
7 - Fuel Sensor with Fuel Low Level Switch 22 - Glow Relay
8 - Solenoid Valve Unit 23 - Coolant Level Switch
9 - Hydraulic Oil Level Switch 24 - Battery
10 - PC Pressure Sensor (Upper: 5-Spool Side) 25 - Starter Relay
11 - PC Pressure Sensor (Lower: 4-Spool Side) 26 - Pressure Switch and Sensor
12 - N Sensor 27 - Windshield Washer Tank
13 - Pump Delivery Pressure Sensors 28 - MC (Main Controller)
14 - EC Sensor 29 - Fuse Box
15 - EC Motor
T5-2-3
COMPONENT LAYOUT
ELECTRICAL SYSTEM (Relays, Diodes, etc)

Cab compartment
29
1
2
3
4
5
6
7
8
9
28
27
22 17
23 18 11
24 19 12
25 20 13 10
26 21 14
15
16
Battery compartment
30
31
34
32
SM3003
33
1 - Cigar lighter 18 - Engine stop relay (R-19)

2 - Wiper relay BM (R11) 19 - Provision for Load momentum alarm relay (TBG) (R-17)
3 - Wiper relay B-2 (R10) 20 - Provision for rotary bucket relay (R-16)
4 - Diode 5 21 - Provision for Nordic kit relay (R-15)
5 - Wiper relay B-1 (R9) 22 - Timer
6 - Wiper relay A (R8) 23 - Diodes 10-11
7 - Diodes 6-7 24 - Diodes 8-9
8 - Washer relay (R4) 25 - Diode 2
9 - Connectors for option switches 26 - Provision for Load momentum alarm buzzer (TBG)
10 - Air condition relays 27 - Dr. EX connector
11 - Horn relay (R7) 28 - Engine Learning switch
12 - Light relay 1 (R6) 29 - Fuse box
13 - Light relay 2 (R5) 30 - Solenoid relay
14 - Anti Load Dump relay (R3) 31 - Starter relay
15 - Safety relay (R2) 32 - Battery relay
16 - Alternator relay (R1) 33 - Diodes A - B - C
17 - Provision for hammer relay (R19) 34 - Glow relay
T5-2-4
COMPONENT LAYOUT
ELECTRICAL SYSTEM
(Monitor and Switch Panels)
SM0610
SM0611 SM0612
1 - Monitor Panel 9 - Air Conditioner Panel 17 - Fuel Level Indicator 25 - Work Light Switch
2 - Switch Panel 10 - Warm Up Complete Indicator 18 - Overheat Indicator 26 - Wiper Switch
3 - Power Boost Switch 11 - Fuel Gauge 19 - Alternator Indicator 27 - Travel Mode Switch
4 - Key Switch 12 - E Mode Indicator 20 - Engine Oil Pressure Indicator 28 - Work Mode Switch
5 - Cigar Lighter 13 - Auto-Idle Indicator 21 - Engine Oil Level Indicator 29 - Buzzer Stop Switch
6 - HP Mode Switch 14 - Hydraulic Oil Level Indicator 22 - Coolant Level Indicator 30 - Auto-Idle Switch
7 - E Mode Switch 15 - Preheat Indicator 23 - HP Mode Indicator 31 - Washer Switch
8 - Engine Control Dial 16 - Air Filter Restriction Indicator 24 - Coolant Temperature Gauge 32 - Level Check Switch
T5-2-5
COMPONENT LAYOUT
PUMP AND RELATED PARTS
5 6 7
3-4
8
SM3004
1 12 11 10 9
1 - Pilot Filter 7 - N Sensor

2 - Pilot Relief Valve 8 - Regulator (Pump 1)
3 - EC Motor 9 - Pump Delivery Pressure Sensor (Pump 1)
4 - EC Sensor 10 - Pump 1
5 - Pilot Pump 11 - Pump Delivery Pressure Sensor (Pump 2)
6 - Regulator (Pump 2) 12 - Pump 2
T5-2-6
COMPONENT LAYOUT
CONTROL VALVE
Left travel motor Right travel motor

3 4 5 6 7 8 9 10
2
1
11
41
12
13
14
40
15
16
39
Bucket cylinder
38
37
36
Boom cylinder
35
34
Arm cylinder
17
18
33
32 19
31 20
30 21
29 22
23
26
27
24
28 25
Swing motor
SM0037
1 - Hydraulic Timer 15 - Overload Relief Valve (Bucket) 29 - Load Check Valve (Arm Tandem
2 - Travel Flow Control Valve 16 - Overload Relief Valve (Bucket) Circuit)
3 - Load Check Valve (Travel 17 - Overload Relief Valve (Boom) 30 - Check Valve
Parallel Circuit) 18 - Overload Relief Valve (Boom) 31 - Arm Regenerative Valve
4 - Check Valve 19 - Boom Anti-Drift Valve (Check 32 - Check Valve
5 - Main Relief Valve Valve) 33 - Overload Relief Valve (Arm)
6 - Check Valve 20 - Boom Anti-Drift Valve (Switch 34 - Overload Relief Valve (Arm)
7 - Check Valve Valve) 35 - Arm Anti-Drift Valve (Check Val-
8 - Flow Combiner Valve 21 - Boom Regenerative Valve ve)
9 - Load Check Valve (Bucket) 22 - Check Valve 36 - Arm Anti-Drift Valve (Switch Val-
10 - Bucket Flow Control Valve 23 - Pump Control Valve (4-Spool ve)
(Switch Valve A) Side) 37 - Load Check Valve (Boom 2
11 - Bucket Flow Control Valve 24 - Check Valve Parallel Circuit)
(Switch Valve B) 25 - Restriction (4-Spool Side 38 - Travel/Boom Lower Selector Val-
12 - Bucket Flow Control Valve Parallel Circuit) ve
(Poppet Valve) 26 - Load Check Valve (Arm Parallel 39 - Check Valve
13 - Load Check Valve (Boom 1 Circuit) 40 - Load Check Valve (Travel
Parallel Circuit) 27 - Restriction (Arm 1 Parallel Tandem Circuit)
14 - Load Check Valve (Boom 1 Circuit) 41 - Pump Control Valve (5-Spool
Tandem Circuit) 28 - Load Check Valve (Swing) Side)
T5-2-7
COMPONENT LAYOUT
Section A
H A
B 5
G C
D
E
F
41 8
SM0036 SM0038
Section C Auxiliary Bucket
15
12
39 11
Section D
9
Boom 2
16
Boom 1
Section B
SM0040
L. Travel R. Travel
38 20
17 21
19
37
3
2 13
14
10
40
18
SM0039 SM0041
T5-2-9
COMPONENT LAYOUT
Section E (2) Arm 1

Arm 2
31
32
Section E (1)
Section F
Arm 1 Arm 2
Swing
SM0042
36
34
35 28
24
26 25
27 23
29 22
33 SM0043 SM0045
30
Section H
Section G
6 7
SM0044 SM0046
T5-2-8
COMPONENT LAYOUT
Control valve layout
Left travel motor Right travel motor

3 4 5 6 7 8 9 10
2
1
11
41
12
13
14
40
15
16
39
Bucket cylinder
38
37
36
Boom cylinder
35
34
Arm cylinder
17
18
33
32 19
31 20
30 21
29 22
23
26
27
24
28 25
Swing motor
SM0037
1 - Hydraulic Timer 15 - Overload Relief Valve (Bucket) 29 - Load Check Valve (Arm Tandem
2 - Travel Flow Control Valve 16 - Overload Relief Valve (Bucket) Circuit)
3 - Load Check Valve (Travel 17 - Overload Relief Valve (Boom) 30 - Check Valve
Parallel Circuit) 18 - Overload Relief Valve (Boom) 31 - Arm Regenerative Valve
4 - Check Valve 19 - Boom Anti-Drift Valve (Check 32 - Check Valve
5 - Main Relief Valve Valve) 33 - Overload Relief Valve (Arm)
6 - Check Valve 20 - Boom Anti-Drift Valve (Switch 34 - Overload Relief Valve (Arm)
7 - Check Valve Valve) 35 - Arm Anti-Drift Valve (Check Val-
8 - Flow Combiner Valve 21 - Boom Regenerative Valve ve)
9 - Load Check Valve (Bucket) 22 - Check Valve 36 - Arm Anti-Drift Valve (Switch Val-
10 - Bucket Flow Control Valve 23 - Pump Control Valve (4-Spool ve)
(Switch Valve A) Side) 37 - Load Check Valve (Boom 2
11 - Bucket Flow Control Valve 24 - Check Valve Parallel Circuit)
(Switch Valve B) 25 - Restriction (4-Spool Side 38 - Travel/Boom Lower Selector Val-
12 - Bucket Flow Control Valve Parallel Circuit) ve
(Poppet Valve) 26 - Load Check Valve (Arm Parallel 39 - Check Valve
13 - Load Check Valve (Boom 1 Circuit) 40 - Load Check Valve (Travel
Parallel Circuit) 27 - Restriction (Arm 1 Parallel Tandem Circuit)
14 - Load Check Valve (Boom 1 Circuit) 41 - Pump Control Valve (5-Spool
Tandem Circuit) 28 - Load Check Valve (Swing) Side)
T5-2-9
COMPONENT LAYOUT
Section E (2) Arm 1

Arm 2
31
32
Section E (1)
Section F
Arm 1 Arm 2
Swing
SM0042
36
17
35 28
24
26 25
27 23
29 22
33 SM0043 SM0045
30
Section H
Section G
6 7
SM0044 SM0046
T5-2-10
COMPONENT LAYOUT
OTHER COMPONENTS
Swing Device Shockless Valve

4
1
5
8
6
T157-01-01-011 T157-07-03-018
SM0626 SM0627
Travel Device Solenoid Valve Unit
FRONT
10
11
12
2
13
3
SM0628 SM0629
T157-01-01-012 W157-02-11-020
1 - Swing Relief Valve 8 - Check Valve

2 - Counterbalance Valve 9 - Pilot Pressure Sensor (Arm Roll-In)
3 - Travel Relief Valve 10 - Solenoid Valve Unit (SC)
4 - Shockless Valve 11 - Solenoid Valve Unit (SD)
5 - Pilot Pressure Switch (Boom Raise) 12 - Solenoid Valve Unit (SI)
6 - Check Valve 13 - Solenoid Valve Unit (SG)
7 - Shockless Valve
T5-3-1
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
(1) OK) and proceed to item (2) or (3), as appropriate.
(3)
NO(NG)
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.
SM0630
T5-3-2
TROUBLESHOOTING A
FAULT CODES
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.
T5-3-3
TROUBLESHOOTING A
T5-3-4
TROUBLESHOOTING A
FAULT CODE 01 (EC SENSOR FAILURE)
NO
Faulty MC
Check if breakage or
short circuit exists • After replacement,
YES between MC 22P refer to page T5-4-60.
connector terminal
No.D15 and EC
sensor terminal No.2. Harness failure
Disconnect EC between MC and EC
sensor connector. YES sensor.
YES Check if voltage
between harness end
connector terminals Harness breakage
Disconnect EC sensor No.1 and No.3 is YES between MC and EC
connector. Check if 5±0.5 V. sensor terminal
resistance between EC No.3.
• Key switch: ON Check if voltage
sensor side connector
between harness end
terminals No.1 and No.3
is 1.7±0.4 kΩ. connector terminals
NO No.1 and vehicle
Connect test harness
frame is 5±0.5 V. Harness breakage
between EC sensor
between MC and EC
connector halves. Turn • Key switch: ON
engine control dial and NO sensor terminal
• 5±0.5 V for the voltage No.1.
check if voltage changes change standard
as specified. values.
Faulty EC sensor
• Test harness: 75301517 NO
• Refer to page T5-3-9 for • After replacement,
the voltage change refer 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 2 3 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
EC Sensor
1 2 3
T5-3-5
TROUBLESHOOTING A
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 sen-
sors (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
Check if breakage or YES between MC and
short circuit exists pump delivery
between MC 22P pressure sensor.
YES connector terminal
No. D16 (pump 1)/
No. D17 (pump 2)
Disconnect the pump and pump delivery Faulty EC sensor
delivery pressure pressure sensor ter- NO
sensor connector. minal No.2. • After replacement,
NO Check if voltage refer to page T5-4-60.
between harness end
connector terminals Harness failure
No.1 and No.3 is between MC and
Switch pump delivery YES
5±0.5 V. pump delivery
pressure sensors
(for pumps 1 and 2) pressure sensor
• Key switch: ON Check if voltage terminal No.3.
with each other. between harness end
Perform “RETRIAL.” connector terminals
Check if indicated NO No.1 and vehicle
fault code changes Harness failure
frame is 5±0.5 V. between MC and
to the one for the
other pump delivery • Key switch: ON pump delivery
NO pressure sensor
pressure sensor. • 5±0.5 V for the voltage
change standard terminal No.1.
values.
Faulty pump delivery
YES pressure sensor.
1 2 2 3 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
T5-3-6
TROUBLESHOOTING A
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 sen-
sors (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.
Harness failure
YES between MC and
Check if breakage or pump control
short circuit exists pressure sensor.
between MC 22P
YES connector terminal No.
D14 (4-spool side)/No.
D19 (5-spool side) and
Disconnect pump pump control pressure Faulty MC
control pressure sensor terminal No.2. NO
sensor connector. • After replacement,
NO Check if voltage refer to page T5-4-60.
between harness end
No.1 and No.3 is YES between MC and
Switch pump control 5±0.5 V. pump control
pressure sensors (ones pressure sensor
in 4-spool side and in • Key switch: ON Check if voltage terminal No.3.
5-spool side control between harness end
valves) with each other. connector terminals
Perform “RETRIAL.” NO No.1 and vehicle
Harness breakage
Check if the indicated frame is 5±0.5 V. between MC and
fault code changes to
• Key switch: ON pump delivery
the one for the other NO pressure sensor
pump control pressure • 5±0.5 V for the voltage
change standard terminal.
sensor.
values.
Faulty pump control
YES pressure sensor.
1 2 2 3 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
T5-3-7
TROUBLESHOOTING A
FAULT CODE 06
(ARM ROLL-IN PILOT PRESSURE SENSOR
FAILURE)
Harness failure
YES
between MC and
Check if breakage or pilot pressure sensor.
short circuit exists
YES between MC 22P
connector terminal
No.D18 and pilot
pressure sensor Faulty MC
Disconnect pilot terminal No.2. NO
pressure sensor
connector. Check if • After replacement,
NO voltage between refer to page T5-4-60.
harness end
No.1 and No.3 is YES between MC and
5±0.5 V. pilot pressure sensor
Replace pilot pressure terminal No.3.
sensor with pump
between harness end
control pressure
connector terminals
sensor. NO No.1 and vehicle
Perform “RETRIAL.”
frame is 5±0.5 V. Harness breakage
Check if fault code
disappears. between MC and
• Key switch: ON NO pilot pressure sensor
• 5±0.5 V for the voltage terminal No.1.
change standard
values.
Faulty pilot pressure
YES sensor (arm roll-in).
1 2 2 3 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
Pilot Pressure Sensor
1 3
2
T5-3-8
TROUBLESHOOTING A
FAULT CODE 07
(ENGINE CONTROL DIAL FAILURE)
Harness failure
YES
between MC and
Check if breakage or engine control dial.
short circuit exists
YES between MC 22P
connector terminal
No.D21 and engine
control dial terminal Faulty MC
Disconnect engine No.6. NO
control dial
connector. Check if • After replacement,
NO voltage between refer to page T5-4-60.
harness end
Disconnect engine connector terminals Harness breakage
control dial connector. No.5 and No.7 is YES between MC and
Check if resistance 5±0.5 V. engine control dial
between engine control terminal No.7.
dial side terminals No.5
between harness end
and No.7 is 5±0.5 kΩ.
connector terminals
With the engine control NO No.5 and vehicle
dial connected, insert
test probe from back of frame is 5±0.5 V. Harness breakage
engine control dial. Turn between MC and
• Key switch: ON NO engine control dial
engine control dial and • 5±0.5 V for the voltage
check if voltage changes terminal No.5.
change standard
as specified. values.
• Refer to page T5-3-9 for Faulty engine control
the voltage change YES dial.
standard values.
1 2 2 3 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
T5-3-9
TROUBLESHOOTING A
SENSOR OPERATING RANGE LIST
1. Preconditions for measurement
• Hydraulic Oil Temperature: 50±5 °C (122±9 °F)

• Unless otherwise instructed, set the switches as
follows:
Engine E Mode Work Auto-Idle

Control Dial Switch/HP Mode Switch
Mode Switch Switch
Max. OFF General OFF
Position Purpose
Mode
• Monitor using the Dr.EX.
SM0631
2. Sensor Operating Range
Item Required Control/Switch Operation

At minimum speed position 0.3 to 1.0 V
Engine Control Dial
At maximum speed position 4.0 to 4.7 V
Engine control dial at Min. position 2.5 to 2.7 V
Engine control dial at Max. position with HP mode 3.3 to 3.7 V
switch turned OFF
EC Sensor
Engine control dial at Max. position with HP mode 0.2 V or more larger than the voltage
switch turned ON obtained above (with the engine con-
trol dial at Max. position with HP
mode switch turned OFF)
Control Levers: Neutral 25+15-7 kgf/cm2
Pump Delivery Pressure
Sensor
Boom Raised and Cylinder Relieved 350+20-5 kgf/cm2
Control Levers: Neutral 0 to 1.0 kgf/cm2
Pilot Control Shut-Off Lever:
Locked Position
Control Lever: Full Stroke 34 to 40 kgf/cm2
Pilot Control Shut-Off Lever:
Unlocked Position
Control Levers: Neutral 10 to 16 kgf/cm2
Pump Control Pressure
Sensor One Track Jacked-Up Travel Lever (Raised track 30 to 40 kgf/cm2
side): Full Stroke
NOTE - 1 kgf/cm2=0.09807 MPa=14.22 psi

T5-3-10
TROUBLESHOOTING A
T5-4-1
TROUBLESHOOTING B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault Start the troubleshooting with more probable causes
code is displayed on the Dr.EX although the ma- selected by referring to these tables.
chine’s 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 Troubleshooting Flow Charts
YES(OK)
(2)
• After checking or measuring item (1), select either Yes (OK) or No
(1) (NOT OK) and proceed to item (2) or (3), as appropriate.
(3)
NO(NG)
• Special instructions or reference item are indicated in the spaces under the box.
Incorrect measuring or checking methods will render troubleshooting impossible, and
Key switch: ON 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.
T5-4-2
TROUBLESHOOTING B
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.
Part Name EC Motor EC Sensor Engine Control Dial
Part function • To operate governor lever. • To detect the slow-idle speed • To instruct the engine
governor lever position (2.5 V). target speed governor lever
position.
Control System • Governor lever does not • Whenever key switch is ON, • Even if engine control dial
Trouble move. governor lever position is learned as is operated, engine speed
in the slow idle speed position is unchanged.
differing from the correct position. • If harness to engine control
Accordingly, engine speed is dial is broken, target speed
controlled afterward with the 1600 min-1 is used as the
discrepancy which occurred at this backup value
time.
Machine Symptoms • Even if engine control dial is • If the discrepancy occurred to the • Engine speed is constantly
operated, engine speed does slower side, engine speed is held at 1600 min-1.
not increase from slow changed by engine control dial. (Auto-idle function
speed range. However, engine speed control operates, and engine can
• Starter rotates but engine range stays slower than normal. be stopped by turning key
(Note: If the discrepancy occurred switch.)
fails to start occasionally.
to the faster side, when engine
• While engine is running at a control dial is turned to the fastest
faster than specific speed, if position, EC motor continues
harness to EC motor is bro- moving. However, EC motor is a
ken, engine stalls. worm gear type so that governor
• While engine is running at a lever is kept holding at the full
slower than specific speed, if stroke position. If engine control dial
harness to EC motor is bro- is turned to the slowest position,
ken, engine becomes uncon- governor lever returns to the slow
trollable. idle position.)
• When engine is started, engine
speed fluctuates.
• Engine start may become difficult
Trouble By Dr.EX Self- - Fault code 01 is displayed. Fault code 07 is displayed.

shooting Diagnosing
Proce- Function
dures
By Dr.EX Monitor - Monitor Item: EC Angle Monitor item:
Function Target Engine Speed
By Lamp Harness • Install lamp harness - -

Check (75301515). Then, check
output signal from EC and
check if harness is normal
By Other Check/ - - -
Measurements
Note • Engine is stopped by de- • If EC sensor is failed, engine -

energizing of fuel cut learning operation becomes
solenoid (Synchro-start). impossible.
Descriptions in T2-1 T2-1 T2-1

(Operational
Principle)Technical
Manual
T5-4-3
TROUBLESHOOTING B
Pump Control Pump Delivery N Sensor Solenoid Valve Unit

Pressure Sensor Pressure Sensor (SG)
• To detect pump control valve • To detect both right and left • To detect engine speed to • To increase relief setting
pressure in control valve to pump delivery pressures to control speed sensing system. pressure temporarily.
control the travel motor swash control speed sensing system,
angle. HP mode circuit, arm regen-
erative circuit, and travel motor
swash angle.
• Sensor output is reduced to • When pump delivery pressure • Speed sensing system does • If solenoid valve unit (SG)
zero and travel motor swash sensor output is 0 V or 5 V, the not function. is not energized, pilot pres-
angle is held to the maximum following symptoms appear. sure at port SG is 0 MPa (0
angle. kgf/cm2).
• Even if travel mode switch is • Travel speed is changed to the • Engine stalls when the • Main relief pressure set is
turned to the fast mode slow speed range. However, machine is operated at a high unchanged from the
position, travel speed does not automatic up shifting to the fast altitude or under heavy operating standard setting pressure
change to the fast range. speed range from slow speed conditions. of 34 MPa (350 kgf/cm2).
range is impossible. Even if the power boost
• HP mode does not work. switch is depressed, main
• When combined operation is relief pressure does not
made, arm speed is slow increase. Digging force
(when delivery pressure does not increase.
sensor for pump 2 has failed).
Fault codes 04 and 05 are Fault codes 02 and 03 are - -

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

Pump 1 Control Pressure Actual Engine Speed Power boost pressure
Pump 2 Control Pressure
- - - • Install lamp harness

(75301514). Then, check
output signal from MC and
check if harness is normal.
- - - -
• Evaluation by Dr.EX - - • Proportional solenoid

0.25 V or Less: Discontinuity valve is used for the ON-
4.75 V or More: Short Circuit OFF valve so that whether
the power boost switch is
depressed or not, as long
as indicator comes ON,
solenoid valve unit is
normal. If the indicator
does not light, a broken
wire harness may be a cause.
T2-1 T2-1 T2-1

T2-1
T5-4-4
TROUBLESHOOTING B
Part Name Solenoid Valve Unit (SD) Solenoid Valve Unit (SC) Solenoid Valve Unit (SI)
Part function • To reduce pump swash angle • When arm is rolled in, arm • To increase travel speed by
by guiding pilot pressure to speed is increased by guiding decreasing travel motor
regulator to operate the speed return oil from arm cylinder rod swash angle when fast travel
sensing control system. side to bottom side. mode is selected and pump
delivery pressure is low.
Control System • Pilot pressure is not fed to • If solenoid valve unit (SC) is not • Travel speed is held in slow
regulator. energized, pilot pressure at port speed range.
Trouble SC is 0 MPa (0 kgf/cm2).
Thereby, arm regenerative
function does not work.
Machine Symptoms • Engine may stall under • When leveling, arm speed • Travel speed does not
heavy conditions such as becomes very slow. increase even if travel mode
operation at a high altitude. switch is turned to the fast
travel speed position.
By Dr.EX Self- - - -
Diagnosing
Function
Trouble By Dr.EX Monitor Monitor item: Monitor item: Monitor item:

shooting Function Pump proportional Arm regenerative proportional Travel motor displacement
Proce- Solenoid valve output solenoid valve output angle change pressure
dures
By Lamp Harness • Install lamp harness • Install lamp harness • Install lamp harness
Check (75301514). Then, check (75301514). Then, check output (75301514). Then, check
output signal from MC and signal from MC and check if output signal from MC and
check if harness is normal. harness is normal. check if harness is normal.
Measurements
Note - - -

(Operational
Principle)Technical
Manual
T5-4-5
TROUBLESHOOTING B
Pressure Switch (Travel) Pressure Switch (Front) Pressure Switch Pilot Pressure Sensor
(Boom Raise) (Arm Roll-In)
• To detect that travel spool • To detect that front and/or • To detect boom raise pilot • To detect arm roll-in pilot
is operated (for auto-idle swing spool is operated (for pressure (for arm pressure (for HP mode
operation and travel motor auto-idle operation). regenerative control). control and arm regenerative
swash angle control). control).
• No signal is sent to MC. • No signal is sent to MC. • No signal is sent to MC. • No signal is sent to MC.
• Even if machine is traveled • Even if either front or swing • As arm regenerative function • When the combined operation
with auto-idle switch ON, control lever is operated with does not work, when boom is of swing and arm roll-in is
engine speed does not auto-idle switch ON, engine raised and arm is rolled in, made, arm regenerative
increase. speed does not increase. arm speed is slower than function does not work so that
• When traveling on a flat normal (difficult to discern). arm speed is slow when
area in the fast travel mode, • When beginning to level a starting to roll in (difficult to
travel speed is slow. ground surface, bucket is discern).
slightly lowered into the • Arm speed is slow when
ground. leveling.
• HP mode does not function
when arm is rolled in.
- - - Fault code 06 is displayed.
Monitor item: Pressure Switch Monitor item: Pressure Switch Monitor item: Monitor item:
While traveling, monitor to While operating front or swing Pressure Switch Arm Roll-In Pilot Pressure
check if pressure switch is ON function, monitor to check if
or OFF. pressure switch is ON or OFF.
- - - -
- - - -
• It is possible to check if • It is possible to check if - -

pressure switch has failed or pressure switch has failed or
if a port is clogged by if a port is clogged by
switching the pressure switch switching the pressure switch
with an adjacent one (for with an adjacent one (for
front). travel).
T2-1 T2-1 T2-1 T2-1

T5-4-6
TROUBLESHOOTING B
Part Name Learning Switch Power Boost Switch HP Mode Switch
Part function • To start learning engine control • To operate power boost function • To control HP mode
operation
ON: 0 V → Learning ON: 0 V → Boost function works.
OFF: 5 V → Normal Control OFF: 5 V → Boost function does ON: 0 V → HP Mode.
not work. OFF: 5 V → Standard Mode.
Control System • Engine learning does not • Breaking of Wire: Boost function -
function. does not work.
Trouble Short Circuit: Boost function works
for 8 seconds after key switch is
turned ON, but becomes
inoperative afterwards.
Machine Symptoms • If trouble is caused by cir- • Power boost function does not • Broken Wire: Even if HP
cuit discontinuity, engine work if whether a wire is broken or mode switch is
control system operates short circuit occurs. depressed, HP mode does
normally. (Only engine not operate.
learning function fails.) • Short Circuit: Even if HP
• If trouble is caused by a short mode switch is turned
circuit, the learning mode OFF, HP mode is not
operates when key switch is deactivated.
turned ON. Therefore, engine
may stall 5 seconds after
engine starts.
Diagnosing
Function
Trouble By Dr.EX Monitor Monitor item: Monitor item: Power Boost Switch Monitor item: HP Mode
shooting Function Engine Learning Control Switch
Proce-
dures
By Lamp Har- - - -
ness Check
Measurements
Note - - -

(Operational
Principle)Technical
Manual
T5-4-7
TROUBLESHOOTING B
E Mode Switch Travel Mode Switch MC Pump Control

Valve
• To select E mode. • To change travel speed at two • To control engine, pump, and valve • To develop pump control
stages. operations. pressure in response to the
ON: 0 V → E Mode oil flow rate passing through
OFF: 5 V → Standard Mode Fast Travel Mode: the center bypass passage
0 V → Traveling at fast in the control valve.
speed
Slow Travel Mode: 5 V
- • Discontinuity in Switch: • Problems may differ depending • If the pump control valve
Travel speed is kept in slow on the trouble. (Machine spool is seized, or the spring
range (5 V). troubles shown below signify is broken, pump control
that the logic circuit in MC has pressure does not change.
some faults.)
• Broken Wire: Even if E • Even if travel mode switch is • Even if key switch is turned to • When the 5-spool side pump
mode switch is depressed, turned to the fast travel mode the ON position, EC motor control valve is faulty:
engine runs at full speed. position, travel speed is un- does not rotate to the start 1.Left track travel speed only
• Short Circuit: Engine speed changed. position so that engine cannot is slow.
is not increased up to full start. Or, even if engine is 2.Swing function is also slow.
speed. started, engine speed does not 3.Arm speed is slow when
leveling.
increase.
4.Single operation of bucket,
• Pump swash angle is held to a
boom, or arm is almost
minimum, all function speeds normally performed.
are slow. • When 4-spool side pump
control valve is faulty:
1.Bucket single operation
speed is very slow.
2.Boom is not raised when
leveling.
3.Right track travel speed
only is slow.
4.Single operation of boom,
arm, or swing is almost
normally performed.
- - Procedures may differ depending -

on the locations of failures.
Monitor item: Monitor item: - Monitor items:

E Mode Switch Selected Travel Mode Switch Pump 1 Control Pressure
- - - -
- - - -
- - • Before suspecting a failure in MC, -

check the fuse in this control cir-
cuit.
T2-1 T2-1 - T3-3

T5-4-8
TROUBLESHOOTING B
Part Name Flow Combiner Valve Restriction in Arm 1 Check Valve and Restriction in
Parallel Passage 4-Spool Side Parallel Circuit
Part function • To supply hydraulic oil to both • To ensure lateral thrust force of • To supply hydraulic oil from
right and left travel spools from the front by swing function. pump 1 to arm 1 spool in
pump 1 when the combined pump 2 side.
operation of travel and
front/swing is made.
Control System • When the combined opera- • If the restriction is clogged, • If the check valve is seized
tion of travel and front/swing hydraulic oil does not flow and kept closed, or the
Trouble is made, hydraulic oil is not through the arm 1 parallel restriction is clogged,
supplied to the left travel circuit. hydraulic oil does not flow
spool, or oil flow to the left from pump 1 to arm 1 spool.
travel spool is insufficient. • If the check valve is seized
and kept opened, hydraulic
oil from pump 2 flows to the
pump 1 side.
Machine Symptoms • While traveling straight, the • Arm speed is slow when • When check valve is kept
machine mistrack when the leveling. closed, or restriction is
swing lever is operated. clogged:
Arm speed is slow when
leveling.
• When check valve is kept
opened:
Left travel speed is slow.
Diagnosing
Function
Trouble By Dr.EX Moni- - - -

shooting tor Function
Proce-
dures
By Lamp Harness - - -
Check
Measurements
Note - - -

(Operational Principle)
Technical Manual
T5-4-9
TROUBLESHOOTING B
Arm Regenerative Travel Flow Control Valve Travel and Boom Lower Arm Anti-Drift Valve
Control Valve Selector Valve
• To increase arm speed by • To reduce the shock load • To ensure the boom lower • To prevent the arm drift
allowing the return oil from the developed when single travel force when the combined caused by inner leakage
arm cylinder rod side to flow operation is switched to the operation of travel and boom of hydraulic oil in control
into the arm cylinder bottom combined operation of travel lower is made. valve. Only when arm roll-
side when the valve is and front by gradually in operation is made, anti-
switched by pilot pressure oil restricting oil flow in the travel drift valve (check valve) in
led from solenoid valve unit parallel circuit. the arm cylinder return
(SC) circuit is forcibly opened
so that the arm is rolled in.
• Arm regenerative function • Oil flow is not restricted • Boom 2 spool does not move • Check valve does not
does not operate. properly. when the combined operation open if the changeover
of travel and boom lower is valve is seized.
made.
• Boom 2 spool is moved even if
the single operation of boom
lower is made.
• Arm speed is very slow • When fully closed: • When fully opened: • If check valve does not
when leveling. Great shock is felt when Boom lower speed is very fast. open fully, arm roll-in
changed from travel single With swing lever fully stroked, speed is slow.
operation to travel combined swing speed is slow when the • If check valve is kept
operation. combined operation of swing opened, arm drift
• When fully opened: and boom lower is made. increases due to the
The boom is not raised when • When fully closed: control valve inner leakage.
the combined operation of With the front lowered while • According to the degree of
travel down a slope and boom traveling, the track of the base seizure in check valve,
raise with the bucket loaded is machine is not raised off the arm roll-in operation
made. (Boom is raised when ground. becomes jerky, or slower.
boom single operation is
performed.)
- - - -
- - - -
- - - -
- - - -
- - - -
T3-3 T3-3 T3-3 T3-3

T5-4-10
TROUBLESHOOTING B
Part Name Boom Anti-Drift Valve Boom Regenerative Valve Bucket Flow Control
Valve
Part function • To prevent the boom drift • To prevent boom hesitation when • To restrict the bucket
caused by inner leakage of lowering boom by allowing the circuit to assist boom to
hydraulic oil in control valve. return oil from the boom cylinder raise when the combined
Only when boom lower bottom side to flow into the boom operation of bucket, arm
operation is made, anti-drift cylinder rod side. roll-in, and boom raise is
valve (check valve) in the made.
boom cylinder return circuit
is forcibly opened so that
boom is lowered.
Control System • Check valve does not open • With check valve kept closed, • Bucket circuit is always
Trouble if the switch valve is seized. boom lower speed becomes slow. restricted if the switch
• With check valve kept opened, the valve is seized.
track of the base machine is not
raised off the ground by lowering
the boom.
Machine Symptoms • If check valve does not • Same as described in the above • Bucket speed is slow if
open, boom is not lowered. column. poppet valve is seized and
• If check valve is kept kept closed, or switch valve
opened, boom drift is seized so that the poppet
increases due to the control valve is closed.
valve inner leakage. • Boom is not raised when
• According to the degree of the combined operation of
seizure in check valve, bucket, arm roll-in, and
boom lower operation boom raise is made with
becomes jerky, or slower. poppet valve fully opened,
or if the switch valve is
seized so that the poppet
valve is fully opened.
Diagnosing
Function
Trouble By Dr.EX Monitor - - -

shooting Function
Proce-
dures
By Lamp Harness - - -
Check
Measurements
Note - - -

(Operational
Principle)Technical
Manual
T5-4-11
TROUBLESHOOTING B
T5-4-12
TROUBLESHOOTING B
CORRELATION BETWEEN TROUBLE

SYMPTOMS AND PART FAILURES
Engine Control Pump / Valve Control Switch Panel

EC EC Eng. Sol. Pump Pump N Arm Press. Press. Auto- Learn- HP
Motor Sen- Cont. Valve Deliv. Deliv. Sen- Roll Sw. Sw. Idle ing Mode
Trouble Symptom sor Dial Unit Press. Press. sor In Travel Front Sw. Sw. Sw.
SD Sensor Sensor Sen-
Pump Pump sor
2 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 is
depressed.
E-9 Engine stalls several sec-
onds after engine starts.
E-10 Engine stalls when ma-
chine is operated at high
altitude or under adverse
conditions.
E-11 Engine is hard to start at
low ambient temperature.
A-1. All actuators speeds are

slow
A-2. When single travel opera-
tion is made, left side track
slow but right side track is
normal. Single swing op-
eration is slow. Bucket op-
eration is normal. Arm
speed is slow when level-
ing. (All above symptoms
occurred at the same time).
A-3. When single travel opera-
tion is made, right side
track is slow but left side
track is normal. 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.
NOTE - The above table shows the correlation be- If any other trouble occur at the same time, find out
tween machine operation trouble and related parts the faulty parts causing the trouble by checking all
which may cause trouble. However, the correlations suspected parts in each symptom.
in this table are described based on the condition
supposing that each occurs independently.
T5-4-13
TROUBLESHOOTING B
Switch Panel Engine Pump Control Valve Other

E Key MC Eng. Eng. Gover- Main Pilot Spool Pump Pump Main Pilot Pilot Remarks
Mode Sw. Elec. Unit nor Pump Pump Cont. Cont. Relief Valve Relief
Sw. Parts Unit Valve Valve Valve Valve
5- 4-
Spool Spool
Side Side
Check battery
Check fuel system.
Check engine control

cable.
Be sure to operate
engine learning
whenever engine is
replaced.
Check if fuel system

is clogged
: being linked closely. Checking the part is required.

: being linked, but if this parts is faulty another type of
trouble will be prominent. Therefore this part may not
be the main cause of the trouble.
T5-4-14
TROUBLESHOOTING B
Pump/Valve Control Sw. Control valve

Sol. Sol. Pump Arm Press. Power Spool Main Over- Load Boom Re- Check
Valve Valve Deliv. Roll in Sw. Boost Relief load Check Re- stric- Valve
Trouble Symptom Unit SG Unit SC Press. Sensor Boom Sw. Valve Relief Valve gener- tion & Re-
Sensor Raise Valve ative Arm 1 stric.
Pump 2 Valve Parallel 4-Spool
Parallel
F-1 All front attachment
functions are weak.
F-2 Digging force is not
increased even if
power boost switch is
depressed.
F-3 Some cylinders do
not move or speeds
are slow.
F-4 Boom lower single
operation is fast.
F-5 Arm speed is slow in
a combined opera-
tion.
Arm speed is slow in
leveling operation.
F-6 Bucket digging single
operation is slightly
slow.
Bucket digging single
operation is jerky.
F-7 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.
F-8 Boom starting speed
is slow during
combined operations.
Boom operation is jerky.
Boom starting speed
is slightly slow during
boom lower single
operation.
F-9 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-10Front attachment
cylinders 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 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
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.
T5-4-15
TROUBLESHOOTING B
Control valve Others

Arm Travel Arm Boom Bucket Swing Shock- Pilot Cylinder Remarks
Re- Boom Anti Anti Flow Device less Valve
gener- Lower Drift Drift Cont. Valve
ative Select. Valve Valve Valve
Valve Valve
Check the work mode switch position
Take care not to confuse power boost

operation with HP mode
Check the work mode switch position

T5-4-16
TROUBLESHOOTING B
Pump/Valve Control Sw. Control valve Others

Sol. PC PC Pump Pump. Press Travel Spool Load Flow Travel Travel Center
Valve Press. Press. Deliv. Deliv. Sw. Mode Check Comb. Boom Device Joint
Trouble Symptom Unit Sensor Sensor Press. Press. Travel Switch Valve Valve Lower
SI 5 Spool 4 Spool Sensor Sensor Select .
Side Side Pump Pump Valve
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 in-
sufficient in the fast
travel mode.
T-6 Travel mode does
not change to the
fast speed range.
O-1 The wiper does not

operate, or will not
retract.
NOTE - The above table shows the correlation 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
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.
T5-4-17
TROUBLESHOOTING B
Others
Pilot Remarks
Valve
Refer to A1.
Refert to T-6.
Refer to the troubleshooting section.

T5-4-18
TROUBLESHOOTING B
ENGINE TROUBLESHOOTING
E-1 Starter Does Not Rotate.
Related Fault Code: None
Checking Instructions
• Measure each voltage by referring to the table YES
below.
• Electronic system such as MC has nothing to do
with the trouble obstructing the rotation of starter.
With key switch positioned Regardless of key switch

as shown in table below, position ON or START,
YES
check if each terminal voltage at terminal B is 0
voltage on starter and volts.
Check if battery voltage and
starter relay is normal.
electrolyte density are • Key switch: ON↔START
normal.
Unit: V
• Voltage: 24 volts or more
KEY SW
• Density: 1.26 or more
Terminal ON START
B 24 24 With key switch positioned
C 0 24 at START, voltage at
NO terminal C does not
increase to 24 volts.
• Key switch: START
With key switch positioned

at START, voltages at
terminal B is 24V but at
terminal C does 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.
SM3029
T5-4-19
TROUBLESHOOTING B
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↔OFF NO D2.
YES Faulty harness between

fusible 1 and key switch.
Voltage at terminal No.1: 0 V Check if fusible 1
(40 A) is normal.
Measure each voltage at
terminal No.1 and No.6 on Faulty fusible 1.
key switch. NO
Voltage at terminal No.1: 24 V
• Key switch: START Voltage at terminal No.6: 0 V Faulty key switch.
Voltage at terminal No.1: 24 V

Voltage at terminal No.6: 24 V Faulty harness between key
switch terminal No.6 and
starter relay terminal e.
Faulty starter relay.
Faulty battery.
• Key Switch Voltage Check
NOTE - Remove the key switch from the console.
SM0633
T5-4-20
TROUBLESHOOTING B
E-2 Although Starter Rotates, Engine Does Not

Start.
• Check the governor lever position and fuel cut
solenoid position while the engine is cranking. If
they are in normal position, the engine and the fuel
system may be faulty.
YES Faulty engine.
With key switch ON, check if • Refer to engine

governor lever and fuel cut Workshop manual.
solenoid move to the
starting position.
• Key switch : ON
Check EC motor activating

NO circuit.
Check fuel cut solenoid

operation for + 24V voltage
on terminal C.
T5-4-21
TROUBLESHOOTING B
YES Fuel cut solenoid (push coil)

faulty.
Engine stop relay (R18) or

Check fuse POWER ON at harness between fuse box
NO
fuse box terminal 4. and relay R18, or Diode
D11 faulty
YES Fuel cut solenoid (holding

coil) faulty.
With key switch to START
check voltage + 24V on
terminal B of fuel cut
solenoid for 1 second. Solenoid relay or fusible
N 4 (40 A) or timer or diode
NO D10 faulty.
T5-4-22
TROUBLESHOOTING B
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 posi-
tion 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.
Restore governor
NO lever or EC motor
cable to correct
Check governor operation.
lever or EC motor YES Faulty EC sensor.
cable for proper
operation.
Check if fault • After replacement, YES End.
code 01 is refer to T5-4-60.
YES displayed.
Check if the
trouble is
NO reconditioned
after engine Monitor the
learning operation engine learning
NO operation.
is conducted.
• Refer to T5-4-60. • Monitor item:

Engine Learning
Control
T5-4-23
TROUBLESHOOTING B
Check if governor YES Faulty engine or

lever comes in fuel system.
OK contact with the
stopper when
conducting Faulty control
engine learning cable. Faulty
operation. NO engine governor
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.
T5-4-24
TROUBLESHOOTING B
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 YES Faulty EC motor.
displayed. Connect Lamp Harness
(75301515) to EC motor. • After replacement, refer to
Check if the lamp comes T5-4-60.
NO ON when engine control dial
is turned. Failure in MC or broken
harness between MC and
NO
EC motor.
• After replacement, refer to
T5-4-60.
T5-4-25
TROUBLESHOOTING B
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 Opera-
tional Principle book (Technical Manual).
Faulty HP mode
NO switch, or broken
harness between
Monitor HP mode
HP mode switch
switch. Check if
and MC.
indication of “HP”
is displayed or
NO deleted on Dr. EX
screen by
operating the HP
mode switch on Check if governor
the right console YES Faulty engine or
lever comes into poor quality fuel.
ON or OFF. contact with full-
Check if fault speed side
code is displayed. • Monitor item: stopper when
YES hydraulic oil
HP Mode Switch
pressure is
relieved by arm Failure in MC.
Faulty sensors, or roll-in operation. NO
broken harness • After replacement,
YES between MC and 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
T5-4-26
TROUBLESHOOTING B
E-6 Engine Does Not Stop Even If Key Switch is

Turned OFF.
(When the engine does not stop, check the
fuel cut solenoid operation both mechani-
cally and electrically. Check Diode D2 for
correct operation. Refer also to E-1.).
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
(travel and front
circuit is clogged.
attachment).
YES Check if indication of “Tr”
and “Fr” is displayed or NOTE - Pressure switches
deleted on Dr.EX screen by (travel, and front attachment)
operating each of the travel are installed on the control
Monitor auto-idle switch. and front control levers.
Check if indication of “AI” valve.
is displayed or deleted on
Dr.EX screen by • Monitor item:
Pressure Switch Failure in MC
operating the auto-idle
switch on the right panel YES
ON or OFF. • After replacement,
refer to T5-4-60.
• Monitor item: Faulty auto-idle switch, or
Auto-Idle Switch broken harness between
NO auto-idle switch and MC.
T5-4-27
TROUBLESHOOTING B
E-8 Engine Speed Does Not Change Even If

E Mode Switch is Depressed.
• If trouble corresponding to E-1 to E-7 exist, per-
form the troubleshooting of them beforehand.
• Refer to the Control System group titled “E Mode
Control” in the SYSTEM Section in the Operational
Faulty E mode
Monitor E mode switch, or broken
switch. Check if NO
harness between E
indication of “E” or mode switch and
“P” is displayed MC.
alternately on Dr.EX
screen by operating
the E mode switch Failure in MC.
on the right console YES
ON or OFF.
• 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
• If engine learning switch is set to the engine
learning side, engine comes to a stop 5 seconds
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
between learning
NO switch and MC.
Or, check if the
fuel system is
clogged. SM0108
T5-4-28
TROUBLESHOOTING B
E-10 Engine Stalls When Machine is Operated

at High Altitude, or under Adverse
Conditions.
• If speed sensing control does not function, engine
Disconnect
may stall under adverse operating conditions. harness from
solenoid valve
Monitor output unit (SD) and
signal from connect test
solenoid valve harness
NO (75301514)
unit (SD). With
a pressure gauge between solenoid
installed to port valve unit (SD)
SD, compare the and the
pressure gauge disconnected
NO reading with the harness. Check if
monitored the lamp comes
pressure by ON.
Dr.EX. Check if
pressure values
indicated on both Disassemble and
the pressure check regulator.
YES
gauge and the
Dr.EX vary
Monitor engine identically.
NO speed. Check if
engine runs at
abnormal speed. • Monitor item:
Check if fault Pump Proportional
code is displayed. • Monitor item: Solenoid Valve Output
Actual Engine Speed • Refer to Operational
Performance Test
section.
Referring to the Faulty N sensor

displayed fault or faulty harness
code, check YES between N
YES suspectable sensor and MC.
parts.
T5-4-29
TROUBLESHOOTING B
YES Faulty solenoid

valve unit (SD).
Broken harness
between solenoid
NO valve and MC.
T5-4-30
TROUBLESHOOTING B
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 air intake heater
and the heater is normal.
0.20 Ω or less Faulty engine.
• Refer to engine shop

20 to 24 V Measure the air intake manual.
heater resistance value. • After replacement, refer to
T5-4-60.
• Key switch: OFF
Measure voltage at heater Replace air intake heater.
on air intake. ∞Ω
• Key switch: HEAT
Check if glow plug relay

functions correctly, by
0V turning the key switch from
OFF to HEAT.
• Measurement of Air Intake Heater Voltage and Resistance
Standard: 20 to 24 V
Standard: 0,20Ω or Less
SM3030 SM3031
Ground wire
Air Intake Heater

Gasket
Insulating washer
Hex flange Head Cap Screw
Threaded plug
SM3044
T5-4-31
TROUBLESHOOTING B
Check wiring
YES harness for continuity from
glow relay and air intake
heater.
Check Mega
YES fuse (150A)
for correct
operation.
Check wiring harness

from air intake heater to
battery relay for
NO chafing and/or insulation.
Replace the Mega Fuse (150A).
Check voltage
Check for +20V to 24V NO Replace key switch.
Fuse N. 8 at key switch
GLOW RELAY terminal 2
NO for correct when key
operation. switch is turned
to HEAT.
Replace glow relay
or repair wiring.
YES harness
T5-4-32
TROUBLESHOOTING B
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 normal.
YES Select general Monitor actual • Arm: Fully rolled in.
purpose mode. NO engine speed. • Monitor item:
Check if abnormal Arm Roll-In Pilot
speed is Pressure
Check if precision monitored.
work mode is Faulty N sensor
• Monitor item:
selected. or broken
Actual Engine Speed
YES harness in N
sensor circuit.
Check if fault
NO code is displayed.
Referring to the
displayed fault
YES code, check
suspected parts.
T5-4-33
TROUBLESHOOTING B
NO End
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

of trouble by
YES checking other
symptoms.
T5-4-34
TROUBLESHOOTING B
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). Ac-
cordingly, 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 opera-
tion 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).
YES Reconnect
correctly.
Check if pump
NO control pipe lines
NO Faulty pump
are correctly
control valve
connected.
(5 spool side).
Check if fault Monitor pump

code is displayed. control pressure
by operating
NO control lever.
Referring to the
displayed fault Check if pump
code, check control pressure
YES
suspected parts. increases.
Check regulator
YES for pump 2.
• Swing or travel left
• Monitor item:
T5-4-35
TROUBLESHOOTING B
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). Ac-
cordingly, 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 opera-
tion 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
Manual).
YES Reconnect
correctly.
Check if pump
NO control pipe lines
NO Faulty pump
are correctly
control valve (4
connected.
spool side).
Check if fault Monitor pump

code is displayed. control pressure
by operating
NO control lever.
Referring to the
displayed fault Check if pump
code, check control pressure
YES
suspected parts. increases.
Check regulator
for pump 1.
• Bucket or travel right. YES
• Monitor item:
T5-4-36
TROUBLESHOOTING B
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 guided to control valve
when pilot control shut-off spool.
lever is raised.
Faulty Control Valve.

NO
• Pilot pressure is not
guided to control valve
spool. However, control
valve is kept open as
spool is stuck.
T5-4-37
TROUBLESHOOTING B
T5-4-38
TROUBLESHOOTING B
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
too slow, pump control system may have malfunc-
tion (A-2, or A-3) and pilot system also may be
faulty. NOTE - 1 kgf/cm2=98.07 kPa
Main Relief Valve

2
is normal. Trace
350 to kgf/cm the cause of the
trouble by
Monitor pump 1 checking other
and 2 delivery symptoms.
pressures.
Adjust main relief
• Monitor item: • E mode switch: OFF Less than 350 kgf/cm2 valve.
Pump 1 Delivery Pressure • HP mode switch: OFF
Pump 2 Delivery Pressure • Work mode: General
• Relieve boom, arm, or purpose mode.
bucket.
F-2 Digging Force is Not Increased Even If

Power Boost Switch is Depressed.
• Refer to the Control System Group titled “Power
Boost” in the SYSTEM Section in the Operational
Normal
Pressure increases from less than (HP mode
350 kgf/cm2 to 370 kgf/cm2. operation might
have been
mistaken for
Monitor the Faulty power Power Boost
delivery Monitor power boost switch, or operation.)
pressures from boost switch. NO broken harness
pumps 1 and 2. Check if the
between power
indication of “Pd”
boost switch and
• Monitor items: is displayed or MC.
Pump 1 Delivery Pressure does deleted on Dr.EX
Pressure not increase. by operating
Pump 2 Delivery power boost Measure oil
Pressure switch. YES pressure at the
• With power port of solenoid
boost switch • Monitor items: valve unit (SG).
depressed, Power Boost Switch
• With power boost
check the pump
switch depressed,
delivery pressure.
check pressure
change.
• Refer to Operational
Performance Test
section
T5-4-39
TROUBLESHOOTING B
NOTE - 1 kgf/cm2=98.07 kPa

Disconnect harness
from solenoid valve
YES Faulty solenoid
unit (SG) and
connect test valve unit (SG).
Pressure does harness (75301514)
not change. between solenoid
valve unit (SG)
and the
disconnected Faulty harness
harness. Check if between solenoid
NO
the lamp comes valve and MC.
ON.
• Power boost switch: ON
Faulty main relief

Pressure increases valve.
from less than 5
kgf/cm2 up to 10
kgf/cm2.
T5-4-40
TROUBLESHOOTING B
F-3 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-6 as well.
• If arm roll-in single operation speed is slow, refer to
F-7 as well.
• If boom lower single operation speed is slow, refer
to F-8 as well.
Faulty cylinder
YES
(Seal kits are
faulty.)
Monitor pump Check if overload
control pressure YES relief pressure is
by slowly normal.
YES operating the
Faulty overload
control lever.
Check if the pilot NO relief valve
Check if the
valve delivery control pressure
pressure is changes Control valve
normal by smoothly. spool is sticking.
NO
monitoring or
measuring.
• Monitor item:
Pump 1 Control
• Pilot valve delivery Pressure
pressure: Refer to Pump 2 Control
Operational Pressure
Performance Test NO Faulty pilot valve
section.
• Monitor Item: Check if the pilot
Arm Roll-In Pilot valve delivery
Pressure NO pressure is
• When measuring the correct at the inlet
pilot valve delivery Shockless valve
port of the spool sticking
pressure for boom YES
shockless valve.
raise or lower, bucket
roll-in or roll-out, or • Only when
arm roll-out, install a operating arm
pressure gauge to the roll-out or boom
control valve pilot oil raise.
port.
Shockless Valve
2 1
3
4
5
6
1 - From swing left pilot valve
7 2 - From swing right pilot valve
3 - From bucket roll-out pilot valve
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
SM0634
T5-4-41
TROUBLESHOOTING B
F-4 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 trouble.
Check if travel/boom lower

selector valve is scored or
stuck.
Faulty travel/boom lower

YES selector valve.
T5-4-42
TROUBLESHOOTING B
F-5 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
Manual).
• 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 COMPO-
NENT OPERATION section in the Operational
NOTE - When the grading mode is selected, arm

regenerative control does not function so that arm
speed becomes slow. Disconnect
harness from
solenoid valve
Monitor the unit (SC). YES Faulty solenoid
output signal from Connect test
solenoid valve valve unit (SC)
harness
unit (SC). Install a NO (75301514)
pressure gauge between solenoid
to port SC and valve unit (SC)
NO Broken harness
compare the and the between solenoid
monitored disconnected NO valve and MC.
pressures by Dr. harness. Check if
Check if any EX with the
fault codes the harness lamp
gauge readings. comes ON.
are displayed. Check if both
pressures vary
• Fault codes: • Perform the combined
identically.
Pump delivery operation of boom
pressure sensor raise and arm roll-in.
(Pump 2): 03 • Monitor Item:
Pilot pressure sensor Arm Regenerative
(Arm roll-in): 06 Proportional Solenoid
• Perform a combined
operation of boom raise YES
NOTE - If other fault and arm roll-in.
codes are displayed, • Measurement: Refer to
check the suspected parts Operational Performance
referring to the displayed Test section.
fault code.
Faulty sensor or
broken harness
YES between MC and
sensors.
T5-4-43
TROUBLESHOOTING B
YES Faulty arm

regenerative
valve
Check if arm
regenerative
Faulty check
valve on 5-spool
YES valve or
control valve is
Check if check restriction
seized or stuck.
valve or (in 4-spool control
restriction in the valve).
parallel passage
NO in the 4-spool YES Faulty restriction
control valve is
(in 5-spool
seized, bound, or
control valve)
clogged. Check if the
NO restriction in
arm 1 parallel Trace the cause
passage in 5- of the trouble by
spool control NO
checking other
valve is clogged. types of trouble.
T5-4-44
TROUBLESHOOTING B
F-6 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).

types of trouble.
Check if bucket flow control
valve in control valve is
seized or bound.
Cleaning or replacement of
YES bucket flow control valve.
F-7 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 Tempera-
ture.

types of trouble.
Check if anti-drift valve is
seized or bound.
YES anti-drift valve.
T5-4-45
TROUBLESHOOTING B
F-8 Boom Starting Speed is Slow during

Combined Operations. Boom Operation is
Jerky.
Boom Starting Speed is Slightly Slow
during Boom Lower Single Operation.


symptoms.
NO Check if boom regenerative
valve is seized or stuck.
boom regenerative valve.
YES
Check if boom anti-drift
valve is seized or stuck.
YES boom anti-drift valve.
T5-4-46
TROUBLESHOOTING B
F-9 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 sized or
bound.
Cylinder internal leakage
Check if load check valve in NO
control valve operates
correctly.
• Disassemble and visually

check. Faulty load check valve
NO
T5-4-47
TROUBLESHOOTING B
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 valve
circuit through the load check valve, is malfunctioning:
causing the boom cylinder to temporarily (A)
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 SM0635
the barrel is large, the cylinder is tempo-
rarily retracted. In addition, cylinder force
is reduced. In this case, the cylinder drift
is also increased.
T5-4-48
TROUBLESHOOTING B
F-10 Front Attachment Cylinder Drift is Large.
YES Normal
Check if each Correctly adjust

NO manual boom
front attachment Check if manual
cylinder drift is lowering valve
boom lowering and lock it up.
within the NO valve in boom
specified value. section in 4-spool
control valve is Check if the
Check if the correctly symptom is
cylinder drift is adjusted. deleted when the
NO
reduced when overload valve is
pilot shut-off YES temporarily
valve is closed. 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. SM0636
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 cylin-
der 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 re-
tracted, internal leakage in the control valve exists.
T5-4-49
TROUBLESHOOTING B
Manual Boom Lowering Valve
Control valve
spool is scored,
NO spring is
damaged, or
NO spool end is
Check if internal
loose. SM0637
leakage in cylin-
der exists.
Faulty cylinder Adjustment Procedure:
(replace seal kit.)
YES Tighten (1). Then, tighten (2).
Tightening Torque:
Faulty overload (1)- 7 N⋅m (0.7 kgf⋅m)
relief valve.
(2)- 13 N⋅m (1.3 kgf⋅m)
YES
T5-4-50
TROUBLESHOOTING B
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) ope-
rate 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 motor oil drain
after the pilot valve. YES amount is
• When the left travel speed is also slow, refer to normal.
A-2. • Measurement:
YES Check if swing Refer to
relief pressure is Operational
normal. Performance Test
Monitor the pump
control pressure. section.
• Monitor item: Pump 2
While slowly Delivery Pressure
YES operating the • Specification: Refer to
control lever, Operational Faulty swing
check if the pump Performance Test NO relief valve
control pressure section.
changes
smoothly.
Check if the pilot
secondary • Monitor item: Seized control
pressure is Pump 2 Control Pressure valve spool
NO
normal.
• Specification: Refer
to Operational
Performance Test Faulty pilot valve
section.
NO
T5-4-51
TROUBLESHOOTING B
NO Faulty swing
Check if swing reduction device
YES motor parking
brake release
valve is stuck or Faulty swing
seized. motor parking
YES brake release
valve
Faulty swing
NO motor
T5-4-52
TROUBLESHOOTING B
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
NO symptoms.
T5-4-53
TROUBLESHOOTING B
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 Func-
tions, a Shock Load is Felt.
• Travel flow control valve might be seized.

T5-4-54
TROUBLESHOOTING B
T-3 One Side Track does not Move or Move

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

Operational valve spool
YES
Performance Test
section
Faulty pilot valve

NO
• Relation between Faulty Seal Position and

Mistrack Direction
Seal No. Traveling Pivot Turn

1 External oil leakage ←
2 Seal Position
1
3
2
4
Left Travel 3
(Reverse)
Right Travel
(Reverse)
5 Left Travel 4
(Forward) 5
Right Travel
(Forward)
6
6
7
SM0638
7 External oil leakage ←

T5-4-55
TROUBLESHOOTING B
NO Faulty travel
motor
YES Faulty travel

Disassemble and reduction device
clean travel motor
YES
servo piston.
Disassemble and Check if same Faulty travel
clean travel motor symptom arises. motor servo
counterbalance piston
valve. Then, NO
YES
recheck if same
symptom arises. Faulty
counterbalance
NO
NO
Faulty center joint
Faulty travel relief

YES valve
Piping Location
1 2
Front
5 4 SM0639
1 - Left Travel (Forward)

2 - Right Travel (Forward)
3 - Pilot
4 - Right Travel (Reverse)
5 - Left Travel (Reverse)
6 - Drain
T5-4-56
TROUBLESHOOTING B
T-4 During a Combined Operation of Travel

and Front Function, the Machine Mis-
YES
tracks. Faulty load check valve
Related Fault Code: None NO Check if load check valve is

normal. NO Trace the cause of the
Check if flow combiner valve symptoms.
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
Monitor travel motor swash Trace the cause of the

YES
angle. After installing a trouble by checking other
pressure gauge to solenoid symptoms.
valve unit (SI) port, repeat
traveling and travel pressure
relief operation. Check if the
• Monitor item:
pressure value displayed
Travel Motor Displacement
on Dr.EX equals is to the Seized solenoid valve unit
Angle Change Pressure
pressure gauge reading and (SI)
• Travel mode: Fast NO
vary identically.
• Measurement: Refer to
Operational Performance
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
Swash Angle Control” in the SYSTEM section in Faulty travel
mode switch or
the Operational Principle book (Technical NO broken harness
Manual). between travel
Monitor travel Monitor travel mode switch and
NO mode switch. pressure switch. MC.
Check if “Lo” or Check if the
“Hi”, displayed on display “Tr” is
Dr.EX, changes indicated or
alternately each deleted on Dr.Ex
time the travel screen each time
switch is travel lever is
Check if any operated. operated or
fault codes are YES released.
displayed.
• Monitor item:
Selected Travel Mode • Monitor item:
Switch Pressure Switch
• Fault code:
Faulty sensor or
• Pump delivery pressure sensor (Pump 1): 02
broken harness
between sensors Pump delivery pressure sensor (Pump 2): 03
YES 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 dis-
played fault codes.
T5-4-57
TROUBLESHOOTING B
Faulty travel
pressure switch,
broken harness
between travel
pressure switch
NO and MC, or
clogged filter in
travel pilot signal
Disconnect circuit.
harness from
Monitor travel motor solenoid valve
swash angle. After unit (SI). Connect YES Faulty solenoid
installing a pressure test harness valve unit (SI).
gauge to solenoid (75301514)
valve unit (SI) port, NO between solenoid
repeat traveling and valve unit (SI)
stopping. Check if the and the
pressure value disconnected Broken harness
displayed on Dr. EX harness. Check if between solenoid
the harness lamp NO valve and MC.
equals to the pressure
YES comes ON.
gauge reading and
vary identically.
• Travel mode: Fast Faulty travel
• Monitor item: Travel Motor motor or travel
Displacement Angle Change YES reduction device.
Pressure
• Travel mode: Fast
• Measurement: Refer to Operational
Performance Test section.
T5-4-58
TROUBLESHOOTING B
TROUBLESHOOTING FOR OTHER

FUNCTIONS
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
harness to the YES Faulty wiper relay
original position.
As illustrated to YES Check wiper YES End
the right, connect relays one by one
test harness to see if wiper Replace the
(75301484) operates. monitor assembly.
between auxiliary NO Check if wiper
power source • Key switch: ON operates. Faulty cab
(#12 on the fuse NO harness
box) and wiper
motor. Check if Faulty wiper
wiper operates. NO, or lamp motor or link
does not light
• Key switch: ON 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 in-
termittent stop position, both
lamps B and S light for a moment
at the same time.
T5-4-59
TROUBLESHOOTING B
• Electrical Circuit When Test Harness is Connected.
Fuse Box #12
Lamp S
Wiper Motor
Lamp B
Ground
SM0640
• Wiper’s Operating Range
Intermittent Stop Position

Retracted Position
Wiper Range
SM0641
• Test Harness Connection
Lamp B
Lamp S
Wiper Motor
Test Harness Fuse Box
SM0642
T5-4-60
TROUBLESHOOTING B
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 Bolt
EC motor output axis. Tightening
4. While checking the engine actual speed with
Control Lever
Dr.EX or a tachometer, adjust the control lever to
conform the slow idle speed specification. SM0643
Specification: Refer to Operational Performance

Test section.
5. Tighten the bolt to secure the control lever to the
EC motor output axis.
: 13 N⋅m (1.3 kgf⋅m, 9.4 lbf⋅ft)
NOTE - Take care not to allow oil or grease to stick

to the motor output axis.
6. Perform engine learning.
Engine Learning :
Rear cover
1. Turn the key switch OFF.
2. Remove Dr.EX. Wait for 5 seconds.
3. Turn the engine learning switch ON.
4. Turn the key switch ON. Wait for 5 seconds. Fuse box
5. Turn the key switch OFF. Wait for 5 seconds.
6. Turn the engine learning switch OFF. Engine
7. Check the engine speed. Learning
switch
Engine
Learning
side
Neutral position (OFF)

SM0108
T5-4-61
TROUBLESHOOTING B
EXCHANGE INSPECTION METHOD
Exchange inspection method is used to check if a part

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

sor Failure (Fault Code: 02)
Fig. 1
Check :
1. Switch two delivery sensor connectors from the SM0644
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
Pump 2 Pump 1
sensor is faulty. (5-Spool (4-spool
Side) Side)
If pump 1 delivery pressure is shown as abnormal
(Fault Code: 02), the harness which was con-
nected to the pump 1 delivery pressure sensor is PP1 PP2
faulty.
Fig. 2
SM0645
T5-4-62
TROUBLESHOOTING B
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

T5-5-1
TROUBLESHOOTING C
TROUBLESHOOTING C
(TROUBLESHOOTING FOR MONITOR)
PROCEDURE
Use troubleshooting C when any monitors, such as

gauges or indicators malfunction.
• How to Read Troubleshooting Flow Charts
YES(OK)
(2)
• After checking or measuring item (1), select either Yes (OK) or No

(1)
(NOT OK) and proceed to item (2) or (3), as appropriate.
(3)
NO(NG)
• 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.
• 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
SM0646
T5-5-2
TROUBLESHOOTING C
MALFUNCTION OF COOLANT
TEMPERATURE GAUGE
Providing that:
• Be sure to inspect wiring connections prior to
troubleshooting.
YES
Remove coolant
temperature sensor
Gauge pointer does not
terminal, ground harness
move at all. (It does not rise
side terminal to vehicle.
from zero.) With sensor terminal
Does pointer swing to the
(H) side? disconnected, remove 20P
NO connector from monitor, and
• Key switch : ON check continuity between
terminal No.47 and sensor
terminal.
YES
When removing coolant NOT OK

Gauge pointer swings over temperature sensor, does (Continuity)
scale. pointer swing back to With sensor terminal
zero? disconnected, remove 20P
connector of monitor, and
• Key switch : ON NO check continuity between
harness side terminal and
ground.
OK
(No continuity)
Remove coolant YES

temperature sensor
Gauge pointer swings terminal, and ground
unstably. harness side terminal to
vehicle. Does the pointer
swing to [H] side, and
stably? NO
• Key switch : ON
T5-5-3
TROUBLESHOOTING C
Approximate Temperature on Coolant Temperature

Gauge
105 °C (221 °F)

95 °C (203 °F)
Faulty coolant temperature 70 °C (158 °F)

sensor.
OK
(Continuity) Failure in monitor.
Faulty harness (breakage)

NOT OK between monitor and
(No continuity) sensor.
SM0647
Coolant Temperature Sensor

Coolant Resistance
Faulty coolant temperature Temperature
sensor.
(50 °C) (153.9 Ω)
(122 °F)
Faulty harness (short circuit)
between monitor and 80 °C 51.9±10 Ω
sensor. (176 °F)
100 °C 27.4±4 Ω
Failure in monitor. (212 °F)
(120 °C) (16.1 Ω)
(248 °F)
NOTE - The value indicated in parentheses is only

a reference value.
Faulty coolant temperature
sensor.
Failure in monitor.
Connector (harness end connector terminals seen

from the open end side)
Monitor (20P)
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48
T5-5-4
TROUBLESHOOTING C
MALFUNCTION FUEL GAUGE
Providing that:
troubleshooting.
YES
Remove connector of fuel
sensor, short-circuit
Gauge pointer does not terminals C and A of
swing. (It does not rise from harness side connector by
zero.) using a jumper wire. Does With sensor connector
pointer swing to (FULL) disconnected, remove 20P
side? connector of monitor, and
NO
• Key switch : ON check continuity between
terminal No.46 of monitor
and terminal C of fuel
sensor.
YES
When fuel sensor NOT OK

Gauge pointer swings over connector is removed, (Continuity)
scale. does pointer swing back to With sensor connector dis-
zero? connected, remove the 20P
connector of monitor, and
• Key switch : ON NO check continuity between
terminal C of harness side
connector and ground.
OK
(No continuity)
Remove connector of fuel YES

sensor, and short-circuit
terminals C and A of
Gauge pointer swings
harness side connector by
unstably.
using jumper wire. Does
pointer swing to [FULL] side,
and stably? NO
• Key switch : ON
T5-5-5
TROUBLESHOOTING C
Fuel Sensor 1 mm=0.03937 in

Float
FULL
257 mm
3/4
22°
138.6 mm R370
33°
Faulty fuel sensor.
70.5 mm
OK
(Continuity) Failure in monitor. 27°
1/2
228 mm 28°
1/4 Resistance
292 mm
Faulty harness (breakage) Reserve
NOT OK between monitor and fuel 338 mm
sensor. EMPTY
(No continuity)
SM0648
Float Resistance (Ω)

Faulty fuel sensor.
FULL 10+0-4
3/4 26
Faulty harness (short- 1/2 38±5
circuit) between monitor and
fuel sensor. 1/4 53
EMPTY 90+100
Failure in monitor.

Faulty fuel sensor. Monitor (20P)

Fuel Sensor
29 30 31 32 33 34 35 36 37 38
Failure in monitor. 39 40 41 42 43 44 45 46 47 48 C B A
C
Level signal
B
Reserve signal
A
Ground
T5-5-6
TROUBLESHOOTING C
MALFUNCTION OF FUEL LEVEL

INDICATOR (RESERVE)
Providing that:
troubleshooting.
YES
With fuel sensor

connector
removed, short Reconnect fuel
YES circuit terminals B level sensor
and A of harness
Though fuel When key switch connector
side connector by
gauge pointer is returned to Remove 12P
using a jumper connector of
shows E, the HEAT position, wire. Does
indicator does does indicator monitor, and
indicator light? NO check continuity
not light. light?
• Key switch : ON between terminal
• Key switch : HEAT No.2 of connector
and vehicle
ground.
NO
YES
When fuel level

With fuel in tank,
sensor connector
the indicator Disconnect fuel
removed, does NOT OK (Continuity)
lights. level sensor
indicator go out?
connector and
• Key switch : ON 12P connector of
monitor, and
NO check continuity
between terminal
No.2 of connector
and vehicle OK (No Continuity)
ground.
T5-5-7
TROUBLESHOOTING C
Faulty fuel level

sensor.
YES Failure in
monitor.
Faulty harness
(breakage)
between monitor
and low fuel level
NO
switch.
Burned out
indicator light.
Faulty fuel level

sensor.
Faulty harness
(short circuit)
between monitor
and fuel level
sensor.
Failure in
monitor.

Monitor (12P)
1 2 3 4 5 6
7 8 9 10 11 12
T5-5-8
TROUBLESHOOTING C
MALFUNCTION OF INDICATOR LIGHT

CHECK SYSTEM
Check power line.
• Fuse
YES • Disconnect 20P monitor
connector. Then, check
continuity between harness
side terminal No.30 and
Indicator does not come ON
Check if all indicators do not fuse terminal No.6.
when indicator light check
come ON.
switch is turned ON.
Perform troubleshooting for
the individual indicator which
NO does not come ON.

Monitor (20P)
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48
MALFUNCTION OF LEVEL CHECK SWITCH
Process to be taken:
• This troubleshooting is applied when only the level
check switch malfunctions.
If power is not supplied at all when key switch is
turned ON, or indicator does not come ON when
indicator light check is conducted, perform trouble-
shooting for these failures first.
Required Condition:
• Park the machine on level surface.
YES Faulty level

switch or harness
(breakage).
YES Check if oil and
coolant levels are
Check if indicator correct.
does not come Check if all Refill engine oil,
ON when level indicators do not hydraulic oil, or
NO coolant.
check switch is come ON.
depressed.
Perform
troubleshooting
for individual
NO indicator which
does not come
ON.
T5-5-9
TROUBLESHOOTING C
T5-5-10
TROUBLESHOOTING C
MALFUNCTION OF ENGINE OIL LEVEL

INDICATOR
Reconnect the
engine oil level
Providing that: sensor
• Indicator light is not burned out. connector, then
• Other indicators work correctly. with exeternal
jumper, connect
• The machine is parked on a level surface. the terminal A of
• Be sure to inspect wiring connections prior to the sensor
troubleshooting. (harness side:
not connected
sensor side:
green wire color)
to the vehicle
YES (+24 V) ground.
Check the
With engine oil voltage between
level sensor terminal C sensor
disconnected, connector and
Indicator does not check the voltage vehicle ground.
come ON even if between Should be read
the level check connector more than 16V.
switch is harness side
depressed. terminal C • Key switch : ON
(sensor side: red
wire color) and
vehicle ground.
Check fuse No.4
• Key switch : ON NO (0 V) for integrity.
Leave the oil level

sensor connector
disconnected.
Disconnect 12 P
connector of
monitor.
Lower than LOW level Check continuity
YES between harness
Disconnect the side terminal No.7
engine oil level and vehicle
sensor connector. ground.
Indicator comes Check if indicator
ON even if oil comes ON when
level is lower than Check oil level level check switch NO
the specified level with oil level is depressed.
when level check gauge.
switch is
depressed.
Higher than LOW level

T5-5-11
TROUBLESHOOTING C
Check continuity YES Faulty in monitor

between engine
oil level sensor
connector
YES harness side
terminal D and
harness side Faulty harness
terminal 7 of (breakage)
monitor 12P NO
connector Faulty engine oil
level sensor
(Tightening
NO torque:
Max 20 Nm
(2 kgf.m, 15 lbft)
YES
Faulty harness
(breakage)
Replace
NO fuse No. 4
YES Faulty harness.

(short circuit)
Failure in
monitor.
NO
Faulty engine oil
level sensor
(Tightening
torque:
Max 20 Nm
(2 kgf.m, 15 lbft)
Normal

Monitor (12P) Engine oil level sensor

Green
Black
Blue
Red
1 2 3 4 5 6
7 8 9 10 11 12 D C B A
(A: harness side not connected)

T5-5-12
TROUBLESHOOTING C
MALFUNCTION OF COOLANT LEVEL

INDICATOR
Providing that:
• Indicator light is not burned out.
• Other indicators work correctly.
• The machine is parked on a level surface.
troubleshooting.
Reconnect
coolant level YES
switch.
YES Disconnect 12 P
connector of
With coolant level monitor. Check
switch continuity
Indicator does not disconnected, between harness NO
come ON even if check continuity side terminal No.8
level check switch between and vehicle
is depressed. terminals on level ground.
switch 2P
connector.
NO
Leave coolant
level switch
disconnected.
Disconnect 12 P
YES connector of
Disconnect monitor. Check
coolant level continuity
switch. Check if between harness
YES indicator comes side terminal No.8
ON and vehicle
Indicator comes when level check ground.
ON even if Check coolant switch is
coolant level is level at coolant depressed.
lower than reservoir. Check
specified level if coolant level is NO
when level check lower than LOW
switch is mark.
depressed.
NO
T5-5-13
TROUBLESHOOTING C
Coolant Level Switch
Coolant Reservoir
ON
FULL
LOW
Failure Radiator
in monitor. OFF
SM0649
Faulty harness.
(breakage)

Faulty coolant
level switch.
Monitor (12P) Coolant Level Switch
1 2 3 4 5 6
7 8 9 10 11 12 1 2
YES Faulty harness.

(short circuit)
Failure in
NO monitor.
Faulty coolant
level switch.
Normal
T5-5-14
TROUBLESHOOTING C
MALFUNCTION OF HYDRAULIC OIL LEVEL

INDICATOR
Providing that:
• Indicator light is not burned out.
• Other indicators work correctly.
• The machine is parked on a level surface.
troubleshooting.
Disconnect 12P YES

connector of
monitor. Check
YES continuity
between harness
With hydraulic oil side terminal No.9
level switch and vehicle
Indicator does not NO
disconnected, ground.
come ON even if
level check switch check continuity
is depressed. between level
switch 2P
connector.
NO
Leave hydraulic
oil level switch
disconnected.
Disconnect 12P
YES connector of
monitor. Check
Disconnect oil continuity
level switch. between harness
YES Check if indicator side terminal No.9
comes ON when and vehicle
Indicator comes level check switch ground.
ON even if oil Check oil level is depressed.
level is lower than with level gauge.
the specified level Check if oil can NO
when level check be seen at level
switch is gauge.
depressed.
NO
T5-5-15
TROUBLESHOOTING C
Hydraulic Oil Level Switch

1 mm=0.03937 in
ON
6.2 mm
Failure OFF
in monitor.
Faulty harness.
(breakage) SM0650

Faulty hydraulic
oil level switch.
Monitor (12P) Hydraulic Oil Level Switch
1 2 3 4 5 6
1 2
YES Faulty harness. 7 8 9 10 11 12
(short circuit)
Failure in
NO monitor.
Faulty hydraulic
oil level switch.
Normal
T5-5-16
TROUBLESHOOTING C
MALFUNCTION OF ALTERNATOR
INDICATOR
Providing that:
troubleshooting.
Check operation
of alternator
relay (R1). With
relay not
YES (24 V) energized
continuity should
Check integrity be found from
Alternator
and correct Measure voltage terminal D+ and
indicator does not
operation of at alternator terminal 42 of
go off after
alternator drive terminal D+. monitor 20P
engine is started.
belt. connector.
• Engine: Running
NO
YES (24 V).
Measure
YES voltage at
Although Check if indicator alternator
alternator output comes on when terminal D+.
is low, alternator key switch is
indicator does not turned to HEAT
come on. position.
• Key switch: HEAT NO

• Engine: Stopped
NO
T5-5-17
TROUBLESHOOTING C
YES (Continuity) Faulty monitor.
Harness breakage
between alternator
terminal D+ and
NO (No Continuity) monitor terminal No.
42, or alternator relay
(R1) failure.
Faulty regulator or
faulty alternator.
Faulty regulator and/or

alternator.
Harness breakage
NO between alternator
terminal D+ and
terminal No. 42 of
Check continuity from monitor 20P connector.
terminal D+ of alternator
and terminal 42 of monitor
connector (20P).
Faulty monitor.
YES (Continuity)
Blown indicator bulb.

Monitor (20P)
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48
T5-5-18
TROUBLESHOOTING C
MALFUNCTION OF ENGINE OIL

PRESSURE INDICATOR
Providing that:
troubleshooting.
YES
With engine oil

pressure switch
disconnected, check
YES if indicator comes
ON when terminal
Check if indicator
Indicator does not of wire number 210
comes ON when is grounded to
come ON even if
key switch is vehicle.
key switch is
turned to HEAT NO
turned ON.
position. • Key switch: ON
• Key switch: ON • Key switch: HEAT
NOTE - During one to two

minutes after the engine is
stopped, engine oil pressure
may exist. This phenome- NO
non is normal.
YES
Check if indicator
Indicator stays goes OFF when
ON after engine engine oil
is started. pressure switch is
disconnected.
• Check if oil filter is
clogged or not. • Key switch: ON
• Engine: Stopped
NO
T5-5-19
TROUBLESHOOTING C
Engine Oil Pressure Switch
Pressure Indicator
Approx. ON
98 kPa (1.0 kgf/cm2,
14.2 psi) or Less
More than Approx. OFF
98 kPa (1.0 kgf/cm2,
14.2 psi)
Faulty engine oil
pressure switch.
Reconnect engine oil Faulty harness

pressure switch. (breakage)
YES
Check if indicator between monitor
comes ON when and engine oil Connector (harness end connector terminals seen
monitor terminal pressure switch. from the open end side)
No.10 is grounded to
vehicle.
• Key switch: ON Monitor (12P)
• Without disconnecting, Failure in
ground connector to monitor.
vehicle using a clip from NO 1 2 3 4 5 6
the reverse side of the 7 8 9 10 11 12
connector.
Burned out
indicator light.
Faulty engine oil

pressure switch,
failure in engine
oil lubrication
system, or
clogged oil filter.
With engine oil Faulty harness

pressure switch (short circuit)
connected, and 12P YES
between monitor
connector of monitor and engine oil
disconnected, check pressure switch.
if continuity between
harness side
connector terminal Failure in
No.10 and vehicle NO monitor.
ground when monitor
is disconnected.
T5-5-20
TROUBLESHOOTING C
MALFUNCTION OF OVERHEAT
INDICATOR
Providing that:
troubleshooting.
YES
With overheat
switch connector
disconnected,
YES check if indicator
comes ON when
Check if indicator terminal of wire
Indicator does not comes ON when number 201 is
come ON even if key switch is grounded to
engine overheats. turned to HEAT vehicle. NO
position.
• Key switch: ON
NO
YES
Indicator comes
ON even if Check if indicator
coolant goes OFF when Disconnect
temperature is overheat switch overheat switch YES
low. connector is connector and
disconnected. 12P connector of
monitor. Check if
• Key switch: ON continuity
NO
between 12P
connector
terminal No.1 and
NO
vehicle.
T5-5-21
TROUBLESHOOTING C
Overheat Switch
Coolant Temperature Indicator
Lower than 105 °C OFF
Faulty overheat (221 °F)
switch.
105 °C (221 °F)
or more ON
Reconnect overheat
switch connector.
Check if indicator
YES Faulty harness.
comes ON when Connector (harness end connector terminals seen
monitor 12P (breakage)
connector terminal from the open end side)
No.1 is grounded to
vehicle.
Monitor (12P) Overheat switch
• Key switch: ON
• Without disconnecting, Failure in
ground connector to monitor. 1 2 3 4 5 6
vehicle using a clip from NO
7 8 9 10 11 12
1 2
the reverse side of the
connector.
Burned out
indicator light.
Faulty overheat
switch.
Faulty harness
(short circuit)
between monitor
and overheat
switch.
Failure in
monitor.
T5-5-22
TROUBLESHOOTING C
MALFUNCTION OF AIR FILTER

RESTRICTION INDICATOR
Providing that:
troubleshooting.
YES
When restriction
switch is
disconnected,
YES and harness side
terminal of wire Reconnect
When key switch number 203 is restriction switch.
When air filter is is returned to grounded to Disconnect 12P
clogged, indicator HEAT position, vehicle, does connector of
does not light. does indicator indicator light? NO monitor, and
light?
check continuity
• Key switch: ON between terminal
No.3 of connector
and vehicle
ground.
NO
YES
When air filter

Although air filter restriction switch
is not clogged, is disconnected, Disconnect air
indicator lights. does the indicator filter restriction YES
go out? switch connector
• Disassembled and and 12P
visual check • Key switch: ON connector of
• Confirm that air filter monitor, and
is not moist. NO check continuity
between terminal
No.3 of connector
and vehicle NO
ground.
T5-5-23
TROUBLESHOOTING C
Air Restriction Switch

Pressure Indicator
62 mbar (6.2 kPa) OFF
(630 mmH2O)
or Less
More than ON
Faulty air 62 mbar (6.2 kPa)
restriction switch. (630 mmH2O)

YES Failure in from the open end side)
monitor.
Monitor (12P) Air restriction switch
Faulty harness 1 2 3 4 5 6
(breakage) 7 8 9 10 11 12 B A
between monitor
NO and air restriction
switch.
Burned out
indicator light.
Faulty air
restriction switch.
Faulty harness
(short circuit)
between monitor
and air restriction
switch.
Failure in
monitor.
T5-5-24
TROUBLESHOOTING C
MALFUNCTION OF BUZZER
NOTE - Before measuring voltage, be sure of the

operation of Alternator relay R1 by checking the
continuity between terminal D+ of alternator and
terminal 42 on monitor connector.
13 V or more
Faulty regulator.
Buzzer keeps
Check voltage
sounding when
key switch is at monitor
turned ON. terminal No.42.
Failure in
• Key switch: ON monitor.
(Engine is stopped.) Less than 13 V
Failure in engine
YES
oil pressure
system.
Buzzer keeps Check if engine
sounding when oil pressure YES Overheat of
engine is started. indicator is ON. engine.
Check if overheat
NO indicator is ON.
Check if buzzer
stops when
buzzer stop
NO switch is
depressed.
NO Normal
Buzzer does not
sound even if
Check if engine is
engine oil
running at 1000
pressure indicator NO Normal
min-1 (rpm) or
or overheat
faster.
indicator comes Check if
ON. alternator
YES indicator is ON.
Check voltage at
alternator
YES terminal D+.
• Engine speed:
1000 min-1 (rpm) or
faster.
T5-5-25
TROUBLESHOOTING C

Monitor (20P)
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48
YES Normal
Failure in monitor.
NO
Less than 13 V Faulty regulator or

alternator.
Less than 13 V Faulty harness

Check voltage at (breakage) between
monitor 20P alternator terminal D+
connector terminal and monitor terminal
13 V or more No.42. No.42.
• Engine speed:
1000 min-1 (rpm) or Failure in monitor.
faster.
13 V or more
T5-5-26
TROUBLESHOOTING C
MALFUNCTION OF HOUR METER
Faulty harness
(breakage)
0V between monitor
terminal No.29
and No.6 fuse.
Check voltage at
NO monitor 20P Failure in
Hour meter connector terminal 24 V monitor.
does not count Check if No.29. Less than 13 V
operating hours alternator Faulty
when engine indicator is ON. alternator.
is running. Check voltage at
alternator terminal 13 to 14.5 V
YES or more Failure in
• Engine : Running D+.
monitor.
Check voltage at
• Engine speed: monitor 20P
1 000 min-1 (rpm) or connector
faster Faulty harness
terminal No.42.
(breakage) between
13 V or more alternator terminal
Less than D+ and monitor
13 V terminal No.42.

Monitor (20P)
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48
T5-6-1
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. Wire harnesses identification.
A
The wire harnesses used on electrical system of
the machine are of three colours: red, white and
0511 0511 0511
brown.
– The wire harnesses red coloured are used for 20 ÷ 30 mm
the main power supply distribution and for the
utility not controlled by key switch.
– The wire harnesses white coloured are used B
for the control of all other functions.
– The wire harnesses brown coloured are used
511
511
for ground function.
Each wire is identified by a numerical coding
printed on the whole lenght every 20 to 30 mm (A).
This coding is also shown on the wiring diagram of
electrical system (B).
3. Precautions for connecting and disconnecting ter-
minal connectors.
1) When disconnecting harnesses, grasp them Right Wrong
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 Discon-
necting Connector” on page T5-6-3.)
SM0651
2) Water-resistant connectors keep water out so
that if water enters them, water will not easily
drain from them. When checking water-resi-
stant connectors, take extra care not to allow
water to enter the connectors. In case water
should enter the connectors, reconnect only
after the connectors are thoroughly dried.
3) Before connecting terminal connectors, check Right
that no terminals are bent or coming off. In Rust
addition, as most connectors are made of
Wrong
brass, check that no terminals are rusting. (deformation)
4) When connecting terminal connectors pro-
vided with a lock, be sure to insert them to- Wrong
(Separation)
gether until the lock “clicks.”
SM0652
T5-6-2
4. Precaution for using a circuit tester.

1) Before using a circuit tester, refer to the in- Wind a Piece of Wire Tester Probe
structions in the circuit tester manual.
Then, set the circuit tester to meet the object to
be measured, voltage range and current pola-
rity.
2) Before starting the connector test, always Sharpen the end of the Wire
check the connector terminal numbers, refer-
ring to the circuit diagram. SM0653
When the connector size is very small, and the

standard probe size is too large to be used for
testing, wind a fine piece of sharpened wire or
a pin around the probe to make the test easier.
T5-6-3
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 connec- SM0654
tor (harness side).
Locations of This Type Connector
Fuel Gauge Washer N Sensor Radio

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

Pump Control Pressure Sensor
• Pull to disconnect.
Solenoid Valve Unit

Dr.EX
SM0656
T5-6-4
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
and such fine cracks are very hard to detect by visual the fuse box are connected to the power
inspection. source, while the outside terminals are
Checking fuse continuity with a tester is far superior connected to the accessories.
to 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 circuit, except the
position and perform the test as de-
glow relay circuit.
scribed 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) 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.
Accessory (Outside)
SM0657
Power Source (Inside)

Glow relay Accessory (Outside)
T5-6-5
INSPECTION AND REPLACEMENT OF

MAXI FUSIBLE LINKS
Inspection
1. Remove the negative cable from the battery.
2. Loose the bolt fixing the protection panel and open

it by rotating forward to gain the access.
3. Withdraw the front cover of the maxi fusible link box

and visually inspect the maxi fusible link inside.
Replacement
1. Make sure that the negative cable is removed from

the battery.

OM0406
3. Withdraw the front cover of the maxi fusible link box.
4. Take out the maxi fusible link and replace it. Front cover
5. Reinstall the front cover to maxi fusible link box.
6. Reconnect the negative cable to the battery.

Maxi fusible
Body
Bottom cover
SM3032
T5-6-6
INSPECTION AND REPLACEMENT

OF MEGA FUSIBLE
Inspection
1. Remove the negative cable from the battery.

3. Lift the cover up at the end of fuse box as indicated

on the cover.
NOTE - Do not cut the tie wrap that secure the cover.
4. Using a multimeter, check the continuity between

the two screws fixing the mega fusible.
OM0406
Replacement
Cover
1. Make sure that the negative cable is removed from
the battery. Lift up

it by rotating forward to gain the access. MEGA
3. Lift the cover up at the end of fuse box as indicated

on the cover. Cover locks
NOTE - Do not cut the tie wrap that secure the cover.
GA
M E1 0 0 A
4. Unscrew the two nuts fixing the mega fusible

: 13 mm.
Mega fusible
5. Withdraw the spring washers and remove the
mega fusibile.
6. Replace the mega fusibile. SM3033
7. Reinstall the spring washers and tighten the nuts.

: 13 mm.
: 0.49 daNm (0,5 kgf m)
8. Reinstall the cover of fuse box by inserting the

cover locks on their seats and pushing down.
9. Reconnect the negative cable to the battery.

T5-6-7
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between

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

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

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

system. SM3034
T5-6-8
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 B-
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 B+
comes on.
2. Measure the voltage between the B+ and B–

terminals of the alternator. If the measured voltage
is around 24 V, the alternator circuit can be consi-
dered 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 SM3035
might be loose or disconnected.
3. Next, start the engine and measure the voltage

generated while as the alternator rotates.
As described above, measure the voltage be-
tween terminals B+ and B– on the side of the
alternator. If the voltage is around 28 V, the alter-
nator is operating normally.
If the rated voltage is not being generated, there is
some trouble with the alternator or the regulator.
T5-6-9
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 Ω = Continuity
∞ Ω = Discontinuity Ω
NOTE - When the one end connector is far apart from

the other, connect one end of connector (A) to the Connect to the A a
machine chassis using a clip. Then, check continuity machine
of the harness through the vehicle frame as illus- chassis.
trated.
Connect to the
Ω
If the ohm-meter reading is: 0 Ω = Continuity machine
chassis.
∞ Ω = Discontinuity
Single-line short-circuit check A a

Disconnect both end connectors of the harness and Short-circuit
check continuity between one end connector of the between the
harness and the vehicle frame: harness and
the vehicle
If the ohm-meter reading is: Ω frame
0 Ω = Short circuit is present.
∞ Ω = No short circuit is present.
SM0660
Multi-line continuity check

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

SM0661
twice, it is possible to find out which line is disconti-
nued. With terminals (A) and (C) short-circuited,
check continuity between terminals (a) and (c). Short-circuit between harnesses.
If the ohm-meter reading is:

a
0 Ω = Line (B) - (b) has discontinuity.
A
B b
∞ Ω = 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: Ω
0 Ω = Short-circuit exists between the lines.
∞ Ω = No short-circuit exists between the lines.
SM0662
T5-6-10
VOLTAGE AND CURRENT CHECK
Turn switch ON so that the specified voltage (current) 24 Voltage Circuit

is 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 ground (vehicle
frame).
Red Probe (Plus) of Tester : To location to be
measured.
Key
Engine Check Point Standard
Switch
Power Source 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: Air intake heater 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: Battery 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 (G) 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 (D+) 26 to 30 V
Fast Speed ON Between (17) and Ground: Monitor 26 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 (D+) 26 to 30 V
Slow Idling ON Between (18) and Ground: Anti 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 (20) and Ground: Power outlet 20 to 25 V
Stopped ON Between (21) and Ground: 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 measuring.
T5-6-11
Key Switch
B G1 G2 ACC M ST
HEAT
OFF
ACC
ON
START
1 2 3 4 5 6
15
Air intake heater
SM3036
T5-6-12
5 Voltage Circuit
Signal or
• Voltage between terminal No.1 and the vehicle Two polarities Power source ground
frame (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.
V
• Key switch position: ON
• Tester black terminal (negative):
• Connected to the vehicle (ground)
• Tester red terminal (positive):
• Connected to terminal No.1 SM0664
Three polarities Power source Signal Ground

Evaluation: 1 2 3
If the measuring voltage is within 5±0.5 volts, the
circuit up to terminal No.1 is normal.
• Voltage between terminal No.1 and the ground SM0665
terminal Two polarities

1 2
sensor connector.
Measure the voltage between terminal No.1 on the
machine harness side connector and the ground
terminal (terminal No.2 for two polarities, or termi-
nal No.3 for three polarities) under the following V
conditions.
• Key switch position: ON

• Tester black terminal (negative):
Connected to the ground terminal
(terminal No.2 or 3)
SM0666
• Tester red terminal (positive):
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
SM0667
T5-6-13
• Check Using False Signal
Two polarities
IMPORTANT - On three-polarity connectors, do not
short-circuit terminals No.1 and No.2 to No.3 or the 1 2
vehicle frame (ground), causing harnesses, control-
lers and fuses to burn due to current overload.
(Pressure switch)
(N sensor)
sensor connector.
Short-circuit terminal No.1 (power source) and No.2
Short circuit
(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 condi- SM0668
tion, using the Dr.EX monitor function.
Evaluation: Three polarities

Except for the pressure switch circuits, if the maxi- 1 2 3
mum value is displayed, the MC (Main Controller)
and the circuits up to the machine harness side (EC sensor)
(Pilot pressure sensor)
connector are normal. When the pressure switch (Pump control pressure sensor)
circuits are normal, the Dr.EX monitor displays “ON”. (Pump delivery pressure sensor)
Short circuit
SM0669
T5-6-14
REPLACEMENT OF RELAY
a) Relays located in the right side of cab

(R4, R8, R9, R10, R11) R9
R8
R11 R10
1. Remove screw (1) under the right console to
detach cover (2). R4
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.

SM3037
4. Using a sharp-pointed tool, remove cap (9) from

cover (7) and duct cover (8) located under the
monitor.
5. Remove cover (7) and duct cover (8).
6. Remove ashtray (10) and the ashtray screw.

Remove aux. switch panel (11).
7. Remove relay cover (12).

a
8. Replace the relay.
5 2 3 1
View a
SM0670
4 6
7 10 11
SM0671
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
T5-6-15
b) Relays located in the rear of the seat

(R1, R2, R3, R5, R6, R7, R15, R16, R17, R18, R19
and timer)
1. Remove the rear cover (1) by loosen the 3 bolts (3)

and the four bolts (2).
: 13 mm
2. Remove the bolt (4 and 5) fixing the support (6)

: 13 mm
Timer
R15-R16-R17 R1-R2-R3
-R18-R19 -R5-R6-R7
SM3038
3. Lift the support (6).
1 2
4. Lift the protection sheet (7).
SM1126
5. Replace the relay.
5 4
SM3039
T5-6-16
REPLACEMENT OF DIODE
a) Diodes located in the right side of cab

(D5, D6, D7)
1. Carry out the same procedure as for replacement

of relay on the same location.
D5 D6-D7
SM3037
b) Diodes located in the rear of the seat

(D2, D8, D9, D10, D11)
1. Carry out the same procedure as for replacement

of relay on the same location.
D10-D11 SM3038
D8-D9
D2
T5-6-17
c) Diodes located in the battery bay.

(Diode A, B, C)

it by rotating forward to gain the acces for the
diodes.
Diodes A, B and C
OM0406
2. Replace the diode by withdrawing the diode holder

from the socket.
Diode
Diode holder
SM3040
T5-6-18
REPLACEMENT OF POWER OUTLET
1. Gain the access to the rear of panel and disconnect

the connector from power outlet.
2. Open the guard.
Power outlet
OM0376
3. Using the special plier (Fiat Auto code No.

1876044000) unlock the sleeve from the lock ring.
Panel
Power outlet
4. Withdraw the sleeve from the rear of the panel.
Guard
SM3041
5. Install the new power outlet inserting the sleeve

from the rear of the panel and pushing the lock ring
on the front of the panel.
SM3042
Special plier Fiat Auto Code No. 1876044000

6. Reconnect the connector to the power outlet.
T5-7-1
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 75301516

Use when checking the conditions (discontinuity) of
a single wire.
To check point.
To ground.
During Operation: Lamp comes ON. SM0672

Use when checking the solenoid valve unit circuit.
4
When corresponding control lever or switch is ope- 3 50
rated: Lamp comes ON.
(T5-4-39, 42, and 57) 150 50
1 2 2 1
SM0673

Use when checking EC motor circuit.
(Refer to page T5-4-24)
• EC Motor Circuit 5
When the engine control dial is rotated, 6
50
When both lamps come ON: Normal
If only one lamp come ON: Check continuity of the 1 2 150 2 1
50
circuit connecting to the lamp going OFF. 50
3 4 4 3
If both lamps go OFF: Check the harness together
with the relay.
50
SM0674
Parts Number 75301517 Parts Number 75301515
Use when measuring the signal cable voltage (be-
tween terminal No.2 and 3) in the EC sensor circuit.
(Refer to page T5-3-4) (Red)
(Black)
SM0675

T5-7-2
HARNESS CHECK

Use when checking the wiper circuit.
(Refer to page T5-4-58)
2
5 4
1 2
1
SM0676
HYDRAULIC SYSTEM CIRCUIT DIAGRAM
READING KEY
1 Left travel motor

2 Right travel motor
3 Center joint
4 Control valve
5 Bucket cylinder
6 Boom cylinders
7 Hydraulic oil tank
8 Pilot filter
9 Pilot pump
10 Main pump 1
11 Main pump 2
12 Engine
13 Solenoid valve unit
14 Arm cylinder
15 Positioning pilot valve (*)
16 Positioning cylinder (*)
17 Pilot shut-off valve
18 Travel pilot valve
19 Left pilot valve
20 Right pilot valve
21 Shockless valve
22 Swing motor
(*) Triple articulation version
ELECTRICAL SYSTEM CIRCUIT DIAGRAM
READING KEY
74 Overheat indicator light
1 Batteries 75 Buzzer
2 Battery relay 76 Rotary bucket selector (opt)
3 Starter motor 77 Air filter restriction indicator light
4 Starter relay 78 Low fuel level indicator light
5 Fuse 4 (BOX B) 40 Amp 79 Windscreen wiper safety switch
6 Key switch 80 EC sensor
7 Diode A 81 Auto-idle engaged light (led)
8 Diode 10 82 E mode engaged light (led)
9 Diode 2 83 H/P mode engaged light (led)
10 Engine stop solenoid 84 Engine learning switch connector
11 Horn button 85 Level check button (CHECK)
12 Horn relay (R7) 86 Buzzer stop button
13 Washer relay (R4) 87 Windscreen washer control button
14 Horn 88 Windscreen wiper control button
15 Fuse 1 (BOX A) 40 Amp 89 Lights control button
16 EC motor 90 WORK MODE selector button
17 Power outlet 24V 91 GENERAL PURPOSE work mode light (led)
18 Alternator relay (R1) 92 GRADING work mode light (led)
20 Windscreen wiper motor 93 PRECISION work mode light (led)
21 Windscreen washer electrical pump 94 ATTACHMENT work mode light (led)
22 Cab light 95 SI solenoid valve (travel motor swash angle control)
23 Fuse box 96 SG solenoid valve (Power boost control)
24 Nordic kit relay (R15) (opt) 97 SD solenoid valve (Speed sensing control)
25 Radio 98 SC solenoid valve (Arm regenerative control)
26 Cigar lighter 99 Air conditioner control panel (opt)
27 Diode 5 100 Air conditioning system (opt)
28 Upperstructure light 101 Auto - idle control button
29 Boom light 102 Engine speed sensor (N)
30 Light relay (R6) 103 Pump 2 delivery pressure sensor
31 Light relay (R5) 104 Pump 1 delivery pressure sensor
32 Alternator 105 Pilot control pressure sensor (arm roll-in)
33 Diode 6 106 Pump 2 control pressure sensor
34 Fuse 3 (BOX B) 80 Amp 107 Pump 1 control pressure sensor
35 Electrical fan and control 108 Pressure switch (boom raise)
36 Engine stop relay (R 18) 109 Pressure switch (front attachment)
37 Diode 11 110 Pressure switch (travel)
38 Diode 7 111 Unused indicator light
39 Air filter restriction switch 112 Unused indicator light
40 Engine coolant overheat switch 114 Compressor engage control (opt)
41 Hydraulic oil level switch 115 Breaker relay (R19) (opt)
42 Engine coolant level switch 116 Breaker/positioning selector switch (opt)
43 Engine oil level sensor 117 Breaker/positioning selector solenoid valve (opt)
44 Fuel level sensor 118 Diode 8
45 Engine coolant temperature sensor 119 Solenoid relay
46 Low engine oil pressure switch 121 Diode C
47 Rotary bucket relay (R16) (opt) 123 Unused indicator light
48 Diode 9 124 POWER BOOST control button
49 Rotary bucket solenoid valve provision (opt) 125 Mega fuse (150A) glow plug
50 Rotary bucket switch (opt) 126 Load momentum alarm (TBG) relay (R17) (opt)
51 Diagnostic tester connector (Dr. EX) 127 Load momentum alarm (TBG) buzzer (opt)
52 Engine control dial 128 Load momentum alarm (TBG) switch (opt)
53 Main controller (MC) 129 Load momentum alarm (TBG) pressure switch (opt)
54 E button (Economy mode) 130 Cab lights, Northern Country option (opt)
55 H/P button (High-Power mode) 131 Cab lights switch, Northern Country option (opt)
56 Engine speed control panel 132 Engine stop solenoid timer
57 Anti Load Dump relay (R3) 134 Pre-heat indicator light
58 Safety relay (R2) 136 Glow relay
59 Seat heating resistors and control (opt) 137 Air intake heater
60 Electrical fuel lift pump (opt) 138 Diode B
61 Engine speed control panel light 143 Loud-speakers
62 Optional equipment connector 144 Aerial
63 Engine speed pedal provision connector 145 Windscreen wiper A relay (R8)
65 Hour-counter 146 Windscreen wiper B-1 relay (R9)
66 Engine coolant temperature gauge 147 Windscreen wiper B-2 relay (R10)
67 Fuel level gauge 148 Windscreen wiper B-M relay (R11)
68 Instrument panel lighting 149 Monitor
69 Engine oil level indicator light 150 Travel speed switch
70 Engine coolant level indicator light 151 Automatic windscreen wiper connector
71 Hydraulic oil level indicator light 152 Connector (normally open)
72 Alternator (Battery charge) indicator light 155 Breaker pressure switch (opt)
73 Engine oil low pressure indicator light 156 Engine learning switch
NOTE - Pressure switches, sensors and control switches in the electrical wiring diagram are shown in the position
related to engine stop condition, without failure and with key switch (6) in OFF position.

Excavator: Technical Manual Troubleshooting

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EXCAVATOR MODELS

FIAT-HITACHI EXCAVATORS S.p.A. - ENGINEERING - FORM No. 604.06.852

• Please refer to the materials listed below in addition

SERVICE MANUAL COMPOSITION

- The Technical Manual -Troubleshooting includes

BOOK PRINT NUMBER

Consecutive page number for each group

Group number (if exist)

This is the safety alert symbol.

SI Units (International System of Units) are used in this manual.

Example: 24.5 Mpa (250 kgf/cm2, 3560 psi)

RECOGNISE SAFETY INFORMATION

• This is your SAFETY ALERT SYMBOL.

- When you see this symbol on your machine or in

UNDERSTAND SIGNAL WORDS

• In this Manual you will find the following words:

IMPORTANT: indicates a situation which, if not

NOTE: indicates an additional explanation for

• This Manual also contains this symbol

FOLLOW SAFETY PRECAUTIONS

• Carefully read and observe all safety signs on the

• Allow only trained, qualified, authorised personnel

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or an accident occurs.

WEAR PROTECTIVE CLOTHING

• Wear close-fitting clothing and safety equipment

for the job.

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause

INSPECT THE MACHINE

• Inspect the machine carefully every day or work-

- In the walk-around inspection, be sure to cover all

USE HAND HOLDS AND STEPS

• Falling is one of the major causes of personal injury.

- When you get on and off the machine, always face

- Do not use any control as a handhold.

- Never jump off the machine. Never get on and off

ADJUST THE OPERATOR'S SEAT

• A seat poorly adjusted for operator or work

- The seat should be adjusted whenever machine

- The operator should be able to fully press the

FASTEN SEAT BELT

• Should the machine overturn, the operator may

- Prior to operating the machine, thoroughly

- Be sure to remain seated with the seat belt

- After a significant accident, replace the seat belts

MOVE AND OPERATE MACHINE

• Bystanders can be run over.

- Pay the utmost attention not to run over

- Be sure and aware of the location of bystanders

- If fitted, keep the travel alarm and horn sounding

- When operating, swinging, or moving the

- Co-ordinate hand signals before starting the

OPERATE ONLY FROM THE DRIVER'S

• Inappropriate engine starting procedures may

STARTING THE ENGINE WITH

• Battery gas may explode causing serious damages

KEEP RIDERS OFF THE MACHINE

• Riders on the machine are subject to injuries such

- Only machine operator is allowed on the

- Riders also obstruct the operator’s visibility,

PROVIDE SIGNALS FOR JOBS