Ex750-5,800h-5 Tt162e-01

INTRODUCTION
TO THE READER
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form at the end of this man-
• Be sure to thoroughly read this manual for correct ual.
product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog
MANUAL COMPOSITION
• This manual consists of three portions: the Techni- • Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
• Information included in the Technical Manual • Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redeliver and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
PAGE NUMBER
• Each page has a number, located on the center

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

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

signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. • IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropri- • NOTE:
ate lifting techniques and equipment when lifting heavy Indicates supplementary technical information or
parts. know-how.
UNITS USED
2
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKS system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 Power kW PS 1.360
Volume L US qt 1.057 kW HP 1.341
3 3
m yd 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
• This is the SAFETY ALERT SYMBOL.
• When you see this symbol on your machine or in

this manual, be alert to the potential for personal
injury.
• Follow recommended precautions and safe
operating practices.
001-E01A-0688 SA-688
UNDERSTAND SIGNAL WORDS
• On machine safety signs, signal words designating

the degree or level of hazard - DANGER, WARNING,
or CAUTION - are used with the safety alert symbol.
• DANGER indicates an imminently hazardous

situation which, if not avoided, will result in death
or serious injury.
• WARNING indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury.
• CAUTION indicates a potentially hazardous

situation which, if not avoided, may result in minor
or moderate injury.
• DANGER or WARNING safety signs are located

near specific hazards. General precautions are
listed on CAUTION safety signs.
• Some safety signs don’t use any of the SA-1223

designated signal words above after the safety
alert symbol are occasionally used on this
machine.
• CAUTION also calls attention to safety messages in

this manual.
• To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT
indicates a situation which, if not avoided, could
result in damage to the machine.
• NOTE indicates an additional explanation for an

element of information.
002-E01C-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
• Carefully read and follow all safety signs on the ma-

chine and all safety messages in this manual.
• Safety signs should be installed, maintained and re-

placed when necessary.
• If a safety sign or this manual is damaged or miss-

ing, order a replacement from your authorized
dealer in the same way you order other replace-
ment parts (be sure to state machine model and
serial number when ordering).
SA-003
• Learn how to operate the machine and its controls

correctly and safely.
• Allow only trained, qualified, authorized personnel to

operate the machine.
• Keep your machine in proper working condition.
• Unauthorized modifications of the machine may

impair its function and/or safety and affect ma-
chine life.
• The safety messages in this SAFETY chapter are

intended to illustrate basic safety procedures of ma-
chines. However it is impossible for these safety
messages to cover every hazardous situation you
may encounter. If you have any questions, you
should first consult your supervisor and/or your
authorized dealer before operating or performing
maintenance work on the machine.
003-E01B-0003
PREPARE FOR EMERGENCIES
• Be prepared if a fire starts or if an accident occurs.
• Keep a first aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label at-
tached on the fire extinguisher to use it properly.
• To ensure that a fire-extinguisher can be always
used when necessary, check and service the fire-
extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
• Establish emergency procedure guidelines to
cope with fires and accidents.
• Keep emergency numbers for doctors, ambu- SA-437
lance service, hospital, and fire department

posted near your telephone.
004-E01A-0437
SA-2
SAFETY
WEAR PROTECTIVE CLOTHING
• Wear close fitting clothing and safety equipment

appropriate to the job.
You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear SA-438
Respirator or filter mask.
Be sure to wear the correct equipment and clothing
for the job. Do not take any chances.
• Avoid wearing loose clothing, jewelry, 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.
005-E01A-0438
PROTECT AGAINST NOISE
• Prolonged exposure to loud noise can cause

impairment or loss of hearing.
• Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against
objectionable or uncomfortably loud noises.
006-E01A-0434 SA-434
INSPECT MACHINE
• Inspect your machine carefully each day or shift by

walking around it before you start it to avoid personal
injury.
• In the walk-around inspection be sure to cover all

points described in the “PRE-START
INSPECTION” chapter in the operator’s manual.
S007-E01A-0435
SA-435
SA-3
SAFETY
GENERAL PRECAUTIONS FOR CAB
• Before entering the cab, thoroughly remove all dirt

and/or oil from the soles of your work boots. If any
controls such as a pedal is operated while with dirt
and/or oil on the soles of the operator’s work
boots the operator’s foot may slip off the pedal,
possibly resulting in a personal accident.
• Don’t leave parts and/or tools lying around the op-

erator’s seat. Store them in their specified loca-
tions.
• Avoid storing transparent bottles in the cab. Don’t

attach any transparent type window decorations
on the windowpanes as they may focus sunlight,
possibly starting a fire.
• Refrain from listening to the radio, or using music

headphones or mobile telephones in the cab while
operating the machine.
• Keep all flammable objects and/or explosives

away from the machine.
• After using the ashtray, always cover it to extin-

guish the match and/or tobacco.
• Don’t leave cigarette lighters in the cab. When the

temperature in the cab increases, the lighter may
explode.
524-E01A-0000
SA-4
SAFETY
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.
• When you mounting and dismounting the ma-

chine, always face the machine and maintain a
three-point contact with the steps and handrails.
• Do not use any controls as hand-holds.
• Never jump on or off the machine. Never mount or

dismount a moving machine.
SA-439
• Be careful of slippery conditions on platforms,
steps, and handrails when mounting and dis-
mounting the machine.
008-E01B-0439
ADJUST THE OPERATOR'S SEAT
• A poorly adjusted seat for either the operator or for

the work at hand may quickly fatigue the operator
leading to misoperations.
• The seat should be adjusted whenever changing

the operator for the machine.
• The operator should be able to fully depress the
pedals and to correctly operate the control levers
with his back against the seat back.
• If not, move the seat forward or backward, and
check again. SA-378
009-E01A-0378
SA-5
SAFETY
FASTEN YOUR SEAT BELT
• If the machine should overturn, the operator may

become injured and/or thrown from the cab.
Additionally the operator may be crushed by the
overturning machine, resulting in serious injury or
death.
• Prior to operating the machine, thoroughly

examine webbing, buckle and attaching hardware.
If any item is damaged or worn, replace the seat
belt or component before operating the machine.
• Be sure to remain seated with the seat belt SA-237
securely fastened at all times when the machine is
in operation to minimize the chance of injury from
an accident.
• We recommend that the seat belt be replaced
every three years regardless of its apparent
condition.
010-E01A-0237
MOVE AND OPERATE MACHINE SAFELY
• Bystanders can be run over.
• Take extra care not to run over bystanders.

Confirm the location of bystanders before moving,
swinging, or operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the SA-426
machine.
011-E01A-0426
SA-6
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
• Inappropriate engine starting procedures may cause

the machine to runaway, possibly resulting in serious
injury or death.
• Start the engine only when seated in the

operator's seat.
• NEVER start the engine while standing on the
track or on ground.
• Do not start engine by shorting across starter
terminals. SA-444
• Before starting the engine, confirm that all control
levers are in neutral.
012-E01B-0444
JUMP STARTING
• Battery gas can explode, resulting in serious injury.
• If the engine must be jump started, be sure to

follow the instructions shown in the “OPERATING
THE ENGINE” chapter in the operator’s manual.
• The operator must be in the operator’s seat so
that the machine will be under control when the
engine starts. Jump starting is a two-person
operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures SA-032
could result in a battery explosion or a runaway
machine.
S013-E01A-0032
SA-7
SAFETY
KEEP RIDERS OFF MACHINE
• Riders on machine are subject to injury such as

being struck by foreign objects and being thrown off
the machine.
• Only the operator should be on the machine.

Keep riders off.
• Riders also obstruct the operator’s view, resulting
in the machine being operated in an unsafe
manner.
SA-379
014-E01B-0379
PROVIDE SIGNALS FOR FOBS INVOLV-

ING MULTIPLE NUMBERS OF MACHINES
• For jobs involving multiple numbers of machines,

provide signals commonly known by all personnel
involved. Also, appoint a signal person to coordinate
the job site. Make sure that all personnel obey the
signal person’s directions.
018-E01A-0481
SA-481
CONFIRM DIRECTION OF MACHINE TO

BE DRIVEN
• Incorrect travel pedal/lever operation may result in

serious injury death.
• Before driving the machine, confirm the position of

the undercarriage in relation to the operator’s po-
sition. If the travel motors are located in front of
the cab, the machine will move in reverse when
travel pedals/levers are operated to the front.
SA-491
017-E01A-0491
SA-8
SAFETY
DRIVE MACHINE SAFELY
• Before driving the machine, always confirm that the

travel levers/pedals direction corresponds to the di-
rection you wish to drive.
• Be sure to detour around any obstructions.

• Avoid traveling over obstructions. Soil, fragments
of rocks, and/or metal pieces may scatter around
the machine. Don’t allow personnel to stay around
the machine while traveling.
SA-387
• Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or death.
• When driving up or down a slope, keep the bucket

facing the direction of travel, approximately 200 to
300 mm (A) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop traveling.
SA-388
SA-441
• Driving across the face of a slope or steering on a

slope may cause the machine to skid or turnover.
If the direction must be changed, move the ma-
chine to level ground, then, change the direction
to ensure sage operation.
019-E01D-0492
SA-589
SA-9
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
• Death or serious injury may result if you attempt to

mount or stop a moving machine.
To avoid rollaways:
• 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.
• Turn the auto-idle / acceleration seleclter and the SA-391
H/P mode switch off.
• Run the engine at slow idle speed without load for
5 minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK
position.
• Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
SA-392
020-E08A-0493
SA-10
SAFETY
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.
SA-383
• Keep the travel alarm in working condition (if
equipped).
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. SA-384
• 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 who has
the responsibility for signaling.
• 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 operator’s manual.
S021-E01A-0494
SA-11
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING

MACHINE---SERIOUS OR FATAL CRUSHING
INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU

CAN JUMP FREE
FASTEN YOUR SEAT BELT
• The danger of tipping is always present when

operating on a grade, possibly resulting in serious SA-012
injury or death.
To avoid tipping:
• Be extra careful before operating on a grade.
• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to
the machine.
• Reduce operating speeds to avoid tipping or
slipping.
• Avoid changing direction when traveling on
grades.
• NEVER attempt to travel across a grade steeper SA-440
than 15 degrees if crossing the grade is

unavoidable.
• 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.
S025-E01B-0495
SA-12
SAFETY
AVOID POWER 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 (10 ft) 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. SA-381
029-E01A-0381
OBJECT HANDLING
• If a lifted load should fall, any person nearby may be

struck by the falling load or may be crushed
underneath it, resulting in serious injury or death.
• When using the machine for craning operations,

be sure to comply with all local regulations.
• Do not use damaged chains or frayed cables,
sables, slings, or ropes.
• Before craning, position the upperstructure with
the travel motors at the rear.
• Move the load slowly and carefully. Never move it
suddenly.
• Keep all persons well away from the load.
• Never move a load over a person's head.
• Do not allow anyone to approach the load until it is
SA-014
safely and securely situated on supporting blocks
or on the ground.
• Never attach a sling or chain to the bucket teeth.
They may come off, causing the load to fall.
032-E01A-0014
SA-13
SAFETY
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 bystanders away from the working area
before striking any object.
SA-432
031-E01A-0432
PARK MACHINE SAFELY
To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Turn auto-idle / acceleration selector and H/P
mode switch off.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK
position. SA-390
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.
033-E09B-0390
SA-14
SAFETY
HANDLE FLUIDS SAFELYҥ
ҥAVOID 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 refueling the
machine.
• Fill the fuel tank outdoors.
• All fuels, most lubricants, and some coolants are SA-018

flammable.
• Store flammable fluids well away from fire

hazards.
• Do not incinerate or puncture pressurized
containers.
• Do not store oily rags; they can ignite and burn
spontaneously.
• Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-019
SA-15
SAFETY
SAFETY TRANSPORTING
• The danger of tipping is present when

loading/unloading the machine onto/from a truck or
trailer bed.
• Be sure to observe local regulations when

transporting the machine on public roads.
• Provide an appropriate truck or trailer for
transporting the machine.
Take the following precautions when loading /

unloading the machine: SA-395
1) Select firm level ground.
2) Be sure to use a loading dock or ramp.
3) Be sure to have a signal person when
loading/unloading the machine.
4) Always turn the auto-idle / acceleration selector
and the H/P mode switch OFF when loading or
unloading the machine, to avoid unexpected
speed increase due to unintentional operation of
a control lever.
5) Always select the slow speed mode with the
travel mode switches. In the high speed mode,
travel speed may automatically increase.
6) Avoid steering while driving up or down the ramp
as it is extremely dangerous. If steering is
unavoidable, first move back to the ground or
flatbed, modify traveling direction, and begin to
drive again.
7) Do not operate any levers besides the travel
levers when driving up or down the ramp.
8) The top end of the ramp where it meets the
flatbed is a sudden bump. Take care when
traveling over it.
9) Prevent possible injury from machine tipping
while the upperstructure is rotating.
10) Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
11) Securely fasten chain or cables to the machine
frame. Refer to "transporting" chapter in the
operator's manual for details.
S035-E08A-0395
SA-16
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
• Understand service procedures before doing

work.
• Keep work area clean and dry.
• Do not spray water or steam inside cab.
• Never lubricate or service the machine while it is
moving.
• Keep hands, feet and clothing away from power-
driven parts.
• Before servicing the machine:

1) Park the machine on a level surface.
2) Lower the bucket to the ground.
3) Turn the auto-idle / acceleration selecltor off.
4) Run the engine at slow idle speed without load
for 5 minutes. SA-028
5) Turn the key switch to OFF to stop engine.
6) Relieve the pressure in the hydraulic system by
moving the control levers several times.
7) Remove the key from the switch.
8) Attach a “Do Not Operate” tag on the control
lever.
9) Pull the pilot control shut-off lever to the LOCK
position.
10) Allow the engine to cool.
• If a maintenance procedure must be performed

with the engine running, do not leave machine
unattended.
• If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
• Never work under a machine raised by the boom.
• Inspect certain parts periodically and repair or SA-527
replace as necessary. Refer to the section

discussing that part in the “MAINTENANCE”
chapter in the operator’s manual.
• Keep all parts in good condition and properly
installed.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or
debris.
• When cleaning parts, always use nonflammable
detergent oil. Never use highly frammable oil such
as fuel oil and gasoline to clean parts or surfaces.
• Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
• Illuminate your work area adequately but safely.
S500-E02B-0497
SA-17
SAFETY
• Use a portable safety light for working inside or
under the machine.
• Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
• Sufficiently illuminate the work site. Use a
maintence work light when working under or
inside the machine.
• Always use a work light protected with a guard. In SA-037
case the light bulb is broken, spilled fuel, oil

antifreeze fluid, or window washer fluid may catch
fire.
S500-E02B-0497
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause serious

injury.
• Before performing any work on the machine,

attach a “Do Not Operate” tag on the control lever.
S501-E01A-0287
SA-287
SUPPORT MACHINE PROPERLY
• Never attempt to work on the machine without

securing the machine first.
• Always lower the attachment to the ground before

you work 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, hollow tires, or props that may crumble
under continuous load. Do not work under a
SA-527
machine that is supported solely by a jack.
519-E01A-0527
STAY CLEAR OF MOVING PARTS
• Entanglement 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 around
rotating parts.
502-E01A-0026
SA-026
SA-18
SAFETY
PREVENT PARTS FROM FLYING
• Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in
serious injury, blindness, or death.
• Do not 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.

SA-344
• As pieces may fly off, be sure to keep body and
face away from AIR RELEASE PLUG to avoid
injury. GEAR OIL is hot.
• Wait for GEAR OIL to cool, then gradually loosen
AIR RELEASE PLUG to release pressure.
503-E01B-0344
STORE ATTACHMENTS SAFELY
• Stored attachments such as buckets, hydraulic

hammers, 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.
SA-034
504-E01A-0034
USE TOOLS PROPERLY
• Use tools appropriate for the work to be done.

• Makeshift tools, parts, and procedures can create
safety hazards.
• For loosening and tightening hardware, use the
correct size tools to avoid injury caused by
slipping wrenches.
• Use only recommended replacement parts.
(See the parts catalog.)
SA-040
S522-E01A-0040
SA-19
SAFETY
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 avoid 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 SA-039
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
cap.
Hot fluids and surfaces:
• Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot
as well.
SA-225
• Wait for the oil and components to cool before

starting any maintenance or inspection work.
505-E01B-0498
REPLACE RUBBER HOSES

PERIODICALLY
• Rubber hoses that contain flammable fluids under

pressure may break due to aging, fatigue, and
abrasion. It is very difficult to gauge the extent of
deterioration due to aging, fatigue, and abrasion of
rubber hoses by inspection alone.
• Periodically replace the rubber hoses. (See the

page of “Periodic replacement of parts” in the
operator’s manual.)
SA-019
• Failure to periodically replace rubber hoses may
cause a fire, fluid injection into skin, or the front
attachment to fall on a person nearby, which may
result in severe burns, gangrene, or otherwise
serious injury or death.
S506-E01A-0019
SA-20
SAFETY
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- SA-031
pressure fluids. Wear a face shield or goggles for

eye protection.
• If 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.
SA-292
507-E03A-0499
SA-044
SA-21
SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to

fires.
• Check for oil leaks due to 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.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and oil- SA-019
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 starting work for loose, kinked,
hardened or frayed electrical cables and wires.
• Check before starting work for missing or
damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..
Clean up Flammables:
• Spilled fuel and oil, 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 Switch:
• If a fire breaks out, failure to stop the engine will

escalate the fire, hampering fire fighting.
• Always check key switch function before

operating the machine every day:
1) Start the engine and run it at slow idle.
2) Turn the key 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.
S508-E02B-0019
SA-22
SAFETY
Check Emergency Engine Stop Switch:
• If a fire breaks out, failure to release pressurized air
inside the hydraulic tank will escalate fire, hampering
fire fighting.
• Check the emergency engine stop switch function
every 250 hours:
1) Start the engine and run it at slow Idle.
2) Turn the emergency engine stop switch to the
EMERG. STOP position.
3) Confirm that both engines stop and that pres-
surized air inside the hydraulic oil tank is re-
leased (a hissing sound should be heard).
• 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.
S508-E02B-0019
EVACUATING IN CASE OF FIRE
• If a fire breaks out, evacuate the machine in the

following way:
• Stop the engine by turning the key switch to the

OFF position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.
SA-393
• In an emergency, if the cab door and/or the front
window cannot be opened, break the front or rear
window panes with the emergency evacuation
hammer to escape from the cab.
Refer to the explanation page on “EMERGENCY
EXIT” in Operator’s Manual.
518-E02B-0393
SS-1510
SA-23
SAFETY
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.
509-E01A-0016
SA-016
PRECAUTIONS FOR WELDING AND

GRINDING
• Welding may generate gas and/or small fires.

• Be sure to perform welding in a well ventilated and
prepared area. Store flammable objects in a safe
place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
• Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before start-
ing grinding.
• After finishing welding and grinding, recheck that SA-818
there are no abnormalities such as the area sur-

rounding the welded area still smoldering.
523-E01A-0818
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
SA-030
hoses or other materials before engaging in
welding, soldering, etc..
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 nonflammable solvent
before welding or flame cutting them.
510-E01B-0030
SA-24
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
• Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
• Avoid potentially toxic fumes and dust.

• Do all such work outside or in a well-ventilated
area. Dispose of paint and solvent properly.
• Remove paint before welding or heating:

1) If you sand or grind paint, avoid breathing the SA-029
dust.
Wear an approved respirator.
2) If you use solvent or paint stripper, remove
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.
511-E01A-0029
PREVENT BATTERY EXPLOSIONS
• Battery gas can explode.
• Keep sparks, lighted matches, and flame away

from the top of battery.
• Never check battery charge by placing a metal ob-
ject across the posts. Use a voltmeter or hy-
drometer.
• Do not charge a frozen battery; it may explode.
Warm the battery to 16 °C ( 60 °F ) first.
• Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion SA-032
of the battery may result.
• Loose terminals may produce sparks. Securely
tighten all terminals.
• Battery electrolyte is poisonous. If the battery should

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

electrolyte specific gravity.
512-E01C-0032
SA-25
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
• If spilled onto skin, refrigerant may cause a cold

contact burn.
• Refer to the freon container for proper use when

servicing the air conditioning system.
• Use a recovery and recycling system to avoid
venting freon into the atmosphere.
• Never let the freon stream make contact with the
skin.
SA-405
513-E01A-0405
HANDLE CHEMICAL PRODUCTS SAFELY
• Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used
with your machine include such items as lubricants,
coolants, paints, and adhesives.
• A Material Safety Data Sheet (MSDS) provides

specific details on chemical products: physical
and health hazards, safety procedures, and
emergency response techniques.
• Check the MSDS before you start any job using a SA-309
hazardous chemical. That way you will know
exactly what the risks are and how to do the job
safely. Then follow procedures and use
recommended equipment.
S515-E01A-0309
SA-26
SAFETY
DISPOSE OF WASTE PROPERLY
• Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids. Do

not use food or beverage containers that may
mislead someone into drinking from them.
• Do not pour waste onto the ground, down a drain,
or into any water source.
• Air conditioning refrigerants escaping into the air SA-226
can damage the Earth’s atmosphere.
Government regulations may require a certified air
conditioning service center to recover and recycle
used air conditioning refrigerants.
• Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center.
S516-E01A-0226
BEFORE RETURNING THE MACHINE TO

THE CUSTOMER
• After maintenance or repair work is complete,

confirm that:
• The machine is functioning properly, especially
the safety systems.
• Worn or damaged parts have been repaired or
replaced
S517-E01A-0435 SA-435
SA-27
SAFETY
(Blank)
SA-28
SECTION 4
OPERATIONAL
PERFORMANCE TEST
; CONTENTS;
;
Group 1 Introduction Group 4 Component Test
Operational Performance Tests ................T4-1-1 Primary Pilot Pressure ..............................T4-4-1
Preparation for Performance Test.............T4-1-2 Secondary Pilot pressure..........................T4-4-3
Swing Preference Circuit Shift Control
Group 2 Engine Test Pressure (MA Pressure) .........................T4-4-4
Engine Speed...........................................T4-2-1 Main Relief Pressure Shift Control
Injector and Valve Clearance Pressure (SA Pressure) ..........................T4-4-5
Adjustment .............................................T4-2-3 Travel Mode Shift Control
Pressure (SB Pressure) ..........................T4-4-6
Group 3 Excavator Test Main Relief Pressure ................................T4-4-8
Travel Speed ............................................T4-3-1 Overload Relief Valve Set Pressure ........T4-4-12
Track Revolution Speed ...........................T4-3-2 Main Pump Flow Test .............................T4-4-15
Mistrack Check ........................................T4-3-3 Swing Motor Drainage ............................T4-4-20
Travel Parking Function Check .................T4-3-4 Travel Motor Drainage ............................T4-4-22
Swing Speed ............................................T4-3-6
Swing Function Drift Check ......................T4-3-7 Group 5 Standard
Swing Motor Leakage ...............................T4-3-8 Operational Performance
Maximum Swingable Slant Angle..............T4-3-9 Standard Table .......................................T4-5-1
Swing Bearing Play ................................T4-3-10
Hydraulic Cylinder Cycle Time ................T4-3-12
Dig Function Drift Check ........................T4-3-14
Control Lever Operating Force ...............T4-3-15
Control Lever Stroke ..............................T4-3-16
Boom Raise / Swing Combined
Operation Check ..................................T4-3-17
162T-4-1
(Blank)
162T-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedures to

quantitatively check all systems and functions on the
machine.
Purpose of Performance Tests Precautions for Evaluation of Test Data

1. To comprehensively evaluate each operational 1. To evaluate not only that the test data are correct,
function by comparing the performance test data but also in what range the test data are.
with the standard values.
2. Be sure to evaluate the test data based on the
2. According to the evaluation results, repair, adjust, machine operation hours, kinds and state of work
or replace parts or components as necessary to loads, and machine maintenance conditions.
restore the machine's performance to the desired
standard. The machine performance does not always deteriorate
as the working hours increase. However, the machine
3. To economically operate the machine under performance is normally considered to reduce in
optimal conditions. proportion to the increase of the operation hours.
Accordingly, restoring the machine performance by
Kinds of Tests repair, adjustment, or replacement shall consider the
1. Base machine performance test is to check the number of the machine's working hours.
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders. Definition of “Performance Standards”
1. Operation speed values and dimensions of the
2. Hydraulic component unit test is to check the new machine.
operational performance of each component such
as hydraulic pump, motor, and various kinds of 2. Operational performance of new components
valves. adjusted to specification. Allowable errors will be
indicated as necessary.
Performance Standards
“Performance Standards” is shown in tables to
evaluate the performance test data.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out

performance tests accurately and safely.
1. THE MACHINE
Repair any defects and damage found, such as oil
or water leaks, loose bolts, cracks and so on,
before starting to test.
2. TEST AREA
(1) Select a hard, flat surface.
(2) Secure enough space to allow the machine to
run straight more than 20 m (65 ft 7 inch), and
to make a full swing with the front attachment
extended.
(3) If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.
3. PRECAUTIONS T105-06-01-003
(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.Ȁ Use oil pans to catch
escaping oil.Ȁ Pay special attention to this
when removing hydraulic pipings.
4. MAKE PRECISE MEASUREMENTS T105-06-01-004

(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 procured repeatedly.
Use mean values of measurements if
necessary.
T4-1-2
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary:
1. Use Dr. EX. If Dr. EX is not available, use a pulse
counter.
2. Measure the engine speeds in each mode.
NOTE: Measure the engine speed to check that

the engine speed meets specification
before performing all other operational
performance tests. If the engine speed is
not adjusted correctly, all other
performance test data will be unreliable.
1 2
Preparation:
1. Connect Dr. EX and select the monitor function.
When using a pulse counter, disconnect the
engine speed sensor connector, then attach a
pulse counter to the connector.
2. Warm up the engine until the engine coolant

temperature reaches 50 °C (122 °F) or more, and
hydraulic oil temperature is 50±5 °C (122±9 °F).
NOTE: Prior to the measurement, confirm that 3 T162-04-02-001
governor lever (2) comes into stopper bolts

(1) and (3) at the slow idle and at the fast
idle, respectively.
SP Mode
Measurement: Switch
E Mode Switch
1. Idle Speeds
1-1. Measure the slow and fast idle speed.
1-2. Start the engine. Select the switch positions as
specified.
1-3. Set the engine control dial to the slow idle and Engine Control
to the fast idle positions to measure idle engine Dial
speeds.
M142-03-002
SP Quick Work
Engine E Mode Auto-Idle
Mode Idle Mode
Control Dial Switch Switch
Switch Switch Switch
General
Slow Idle OFF OFF OFF OFF Purpose
Mode
General Work Mode
Fast Idle OFF OFF OFF OFF Purpose Switch
Mode
Auto-Idle Switch
M162-01-004
T4-2-1
2. Auto-idle speed
2-1. Start the engine. Select the switch positions as
specified.
SP Quick Work
Mode Idle Mode
General
Fast Idle OFF OFF ON OFF Purpose Work Mode
Mode Switch
2-2. Operate the bucket control lever.

2-3. Return the bucket control lever to neutral.
Measure the engine speed after it Auto-Idle Switch
automatically drops approximately 4 seconds
later. M162-01-004
3. Quick Idle Speed

3-1. Start the engine. Select the switch positions as Quick Idle Switch
specified.
SP Quick Work
Mode Idle Mode
General
Fast Idle OFF OFF OFF ON Purpose
Mode
3-2. Push the quick idle switch. Engine speed will

drop. Measure that engine speed.
M157-05-004
When using pulse counter, calculate the
engine speed using the following formula:
-1 -1
Engine speed (min :rpm) = Pulse Number (sec :Hz)/1.967
Evaluation:
Refer to the performance standard table in group
T4-5.
Engine Control
Dial
Remedy:
Refer to the troubleshooting B in group T5-4.
M142-03-002
T4-2-2
INJECTOR AND VALVE CLEARANCE AD-
JUSTMENT
Summary:
1. Perform the measurement when the engine is
cold.
2. Be sure to disconnect the negative (-) cable from
the battery before working on the engine.
3. Also, clean the head cover mounting area to avoid
any foreign matter from getting into the engine
system. Accessory Pulley Pointer
Preparation:
1. Locate the top dead center (TDC) in the
or
compression stroke.
Align the “B” or “2-5” mark on the accessory pulley
with the pointer on the gear case. or
Piston No.5 is now at TDC in its compression
stroke.
2. Remove the head cover.
3. Joggle the intake and exhaust side rocker arms of
cylinder No. 5 by hand. If they move a little, piston
No.5 is at TDC in its compression stroke. If they or
do not move, rotate the accessory pulley one turn
clockwise and align the “B” or “2-5” mark with the
pointer again. T162-04-02-003
4. Tighten rocker arm shaft mounting bolts (1).
: 157 N⋅m (16 kgf⋅m, 116 lbf⋅ft ) 6 1 4
5. Tighten housing mounting bolts (2) to (7) in the

order of bolt number. 9
: 118 N⋅m (12 kgf⋅m, 87 lbf⋅ft) 10

1
6. Tighten housing mounting bolts (8) and (9). 3 2
: 45 N⋅m (4.6 kgf⋅m, 33.5 lbf⋅ft) 1 8
7. Tighten injector holding bolt (10). 10
: 54 N⋅m (5.5 kgf⋅m, 40 lbf⋅ft)

T162-04-02-008
NOTE: Start the measurement from cylinder No. 5 5 1 7
which is at TDC.
T4-2-3
Measurement:
Injector Injector
Exhaust Intake Intake Exhaust
IMPORTANT: Before measuring or adjusting valve
clearance, be sure to first adjust
injectors.
1. Loosen lock nut (12) on cylinder No.5 injector

adjusting screw.
IMPORTANT: Excessive tightening of injector

adjusting screw may result in engine
damage. Therefore, be sure to use a
dial-type torque wrench.
T162-04-02-002
2. Tighten injector adjusting screw (11) to 11 12

specification.
: 14 N⋅m (1.43 kgf⋅m, 10.5 lbf⋅ft)
3. Apply a wrench on injector adjusting screw (11) to

keep it immovable, and tighten lock nut (12).
: 65 N⋅m (6.6 kgf⋅m, 48 lbf⋅ft)
4. Insert a thickness gauge into the clearance

between the intake and exhaust valve rocker arm
of cylinder No.5 and the cross head to measure
valve clearance. Adjusting Screw Thickness Gauge T162-04-02-004
NOTE: The cylinders are positioned No.1 to No.6 Lock

Nut
in that order as view from the fan side.
5. After valve clearance measurement for cylinder

No.5 is complete, rotate the accessory pulley
clockwise and perform the same measurement in
the order shown in the table.
Applicable Cylinder Number

Meas-
Mark on
urement Intake/Exh
Accessory Injector
Order aust Valve
Pulley T162-04-02-006
Rocker Arm Cross Head
1 B 5 5
2 C 3 3 Adjustment:
3 A 6 6 • If the measurement results are out of specification,
4 B 2 2 adjust the valve clearance in the same order of
5 C 4 4 measurement.
6 A 1 1
1. Loosen the lock nut of rocker arm adjusting screw.
Evaluation: Adjust the adjusting screw while inserting a
Standard Valve Clearance (Cold Engine): thickness gauge set to specified value.
Intake Valve: 0.35 mm (0.01 in) 2. Retighten the lock nuts.
Exhaust Valve: 0.68 mm (0.03 in) Recheck the valve clearance.
: 65 N⋅m (6.6 kgf⋅m, 48 lbf⋅ft)
T4-2-4
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary:
Measure the time required for the excavator to travel
a 20 m (65.5 ft) test track.
Preparation:
1. Adjust the track sag (460 to 510 mm (18 to 20 in))
of both tracks to be equal.
2. Prepare a flat and solid test track 20 m (65.5 ft) in
length, with extra length of 3 to 5 m (9.8 to 16 ft)
on both ends for machine acceleration and
deceleration. Track Sag:
460 to 510 mm
3. Empty the bucket and set the front attachment in (18.1 to 20.0 in)
the driving position as illustrated.
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F). T145-05-03-001
Deceleration Zone Travel Test Distance Deceleration Zone

3 to 5 m Finish 20 m Start 3 to 5 m T142-05-03-001
Measurement:
1. Measure both the slow and fast speeds of the
machine.
2. Select the following switch positions:
Engine Control Dial : Fast Idle
E Mode Switch : OFF
SP Mode Switch : OFF
Work Mode Switch : General Purpose Mode
Auto-Idle Switch : OFF
Quick Idle Switch : OFF
3. Start traveling the machine in the acceleration T145-05-03-006
zone with the travel levers to full stroke.
4. Measure the time required to travel 20 m (65.5
ft).
5. After measuring the forward travel speed, turn the
upperstructure 180° and measure the reverse
travel speed.
6. Repeat steps (4 to 5) three times in each direction
and calculate the average values.
Evaluation:
Refer to the Performance Standard Table in
Group T4-5.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-3-1
TRACK REVOLUTION SPEED
Summary:
Measure the track revolution cycle time with the track
raised off ground.
Preparation:
1. Adjust the track sag (460 to 510 mm (18 to 20.0 90ϡ110°
in)) of both side tracks to be equal.
2. On the track to be measured, mark one shoe with
chalk or a piece of cloth. T142-05-03-011
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.
CAUTION: Securely support the raised track

using wooden blocks. 90ϡ110°

(122±9 °F).
T142-05-03-012
Measurement:

E Mode Switch : OFF
SP Mode Switch : OFF Forward
Reverse
2. Operate the travel control lever of the raised track Travel Device T145-05-03-001
to full stroke. Side
3. Measure the time required for 3 revolutions in
both directions after a constant track revolution
speed is obtained.
4. Raise the other side and repeat the above
procedures.
5. Repeat steps (2 to 4) three times and calculate
the average values.
Evaluation:
Refer to the performance standard table in group T4-
5.
NOTE: The measurement data obtained through

the raised track revolution test may have
wide variations. Therefore, the evaluation
based on the results obtained from the 20
m (65.5 ft) travel speed check described
before is more recommendable.
Remedy:
T4-3-2
MISTRACK CHECK
Summary:
1. Allow the machine to travel 20 m (65.5 ft).
Measure the maximum tread deviation from the
tread chord line drawn between the travel start
and end points to check the performance
equilibrium between both sides of the travel
device systems (from the main pump to the travel
motor).
2. If measured on a concrete surface, the tread
deviation has a trend to decrease.
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) T145-05-03-005
on both ends for machine acceleration and

deceleration.
3. Empty the bucket and set the front attachment in
the driving position as illustrated.
(122±9 °F).
Measurement:
1. Measure the amount of mistracking in both fast,
and slow travel speeds.
T145-05-03-006

E Mode Switch : OFF
Deceleration Zone
SP Mode Switch : OFF 3 to 5 m (9.8 to 16 ft)
Maximum
Quick Idle Switch : OFF Distance (A)
3. Start traveling the machine in the acceleration 20 m (65.5 ft)

zone with the travel levers at full stroke.
4. Measure maximum distance (A) between a
straight 20 m (65.5 ft) tread chord line and the
Deceleration Zone
tread made by the machine. 3 to 5 m (9.8 to 16 ft)
5. After measuring the tracking in forward travel, turn T115-07-03-005
the upperstructure 180° and measure in reverse
travel.
the average values.
Evaluation:
Group T4-5.
Remedy:
T4-3-3
TRAVEL PARKING FUNCTION CHECK
Summary:
To measure the parking brake function on a specified
slope.
Preparation:
1. The surface of the test slope shall be even with a
gradient of 20 % (11.31°).
2. Mark a white line on the travel device cover.
3. With the bucket empty, position the front
attachment as follows:
0.3 to 0.5 m
Backhoe: Hold the bucket 0.3 to 0.5 m (12 to 20 (12 to 20 in)
in) above the ground with the arm and bucket fully
rolled in.
Loading Shovel: With the arm and bucket
cylinders fully extended, hold the bucket 0.3 to 0.5
m (12 to 20 in) adobe the ground. T105-06-03-004
(122±9 °F).
0.3 to 0.5 m
Measurement: (12 to 20 in)
1. Measure in the fast travel mode.

E Mode Switch : OFF
T118-04-03-001
Auto-Idle Switch : OFF Position where the machine
Quick Idle Switch : OFF comes to a stop.
Position when the travel levers
3. Measure the displacement (revolution angle) of are in neutral.
Displacement
the travel device cover until the parking brake is (Revolution Angle)
applied.
Mark
3-1. Climb the slope and place the travel levers in
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 T107-06-03-002
while parked.
4-1. Climb the slope and place the travel levers in
neutral.
4-2. Stop the engine.
4-3. After the machine stops, put alignment marks
on a track link or shoe, and the track side
frame.
4-4. After 5 minutes, measure the distance between Alignment marks on the track
the marks on the track link or shoe and the side frame and shoe when the
machine comes to a stop.
track side frame. Displacement measured
after 5 minutes.
Evaluation: T105-06-03-006
Refer to the Operational Performance Standard

Table in Group T4-5.
T4-3-4
(NOTE)
The drive tumbler rotation angle until the parking
brake is applied can also measured as follows.
The 1/6 turns of the drive tumbler corresponds to the
1/6 circumference of the drive tumbler, which is ap-
proximately equal to the drive tumbler radius (R).
Because,
Drive Tumbler
L = 1/6 × 2 × 3.14 R = Approx. R Position when
Where: Machine Stops Drive Tumbler
L: Shoe displacement along the outer circumference Position when
of the drive tumbler Travel Lever is in
R: Drive tumbler radius including the shoe height Neutral.
Mark the contact point between the shoe and drive

tumbler with the travel lever in neutral, check if dis-
placement (L) satisfies the following range after the R
machine sops to evaluate the parking brake per-
formance.
Mark on Shoe
L
Mark Displacement (L) ≤ Drive Tumbler Radius ( R )
T118-04-03-002
T4-3-5
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 T145-05-03-007
space for swinging. Do not conduct this test on

slopes.
Backhoe:
With the arm cylinder fully retracted, and the
bucket cylinder fully extended, raise the boom so
that the arm tip pin height is flush with the boom
foot pin height.
Loading Shovel:
With the arm cylinder and the bucket cylinder fully
extended, raise the boom so that the arm tip pin
height is flush with the boom foot pin height. T145-05-03-008
(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:
E Mode Switch : OFF
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.
the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-5.
Remedy:
T4-3-6
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 Two Chalk Marks
space for swinging. Do not conduct this test on a
T105-06-03-008
slope.
Backhoe:
With the arm cylilnder fully retracted, and the
bucket cylinder fully extended, raise the boom so
that the arm tip pin height is flush with the boom
foot pin height.
Loading Shovel:
With the arm cylinder and the bucket cylinder fully
extended, raise the boom so that the arm tip pin
height is flush with the boom foot pin height. T105-06-03-009
4. Make two chalk marks: one on the swing bearing
and one directly below it on the track frame.
5. Swing the upperstructure 180°.
6. Maintain the hydraulic oil temperature at 50±5 °C Measure Difference Between Marks
(122±9 °F).

starting the measurement. Marking on the Track Frame
Measurement: Marking on the Swing Bearing

Engine Control Dial : Fast Idle T105-06-03-010
E Mode Switch : OFF

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
calculate the average values.
Evaluation:
T4-5.
Remedy:
T4-3-7
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) of the following specification can be
used.
Backhoe: W=4350 kg (9590 lb)
Loading Shovel: W=6000 kg (13230 lb) T105-06-03-011
4. Backhoe:
With the arm rolled out, and bucket rolled in,
position the arm top pin flush with the boom foot
pin height. Apply a rated load to the bucket.
Loading shovel:
With the arm cylinder and bucket cylinders fully
extended, position the arm top pin flush with the
boom foot pin height.
5. Swing the upperstructure to position it 90° to the
slope. Make aligning marks on the swing bearing
periphery and track frame using tape, as
illustrated.
(122±9 °F).
Measurement: Measure Difference Between Marks

1. Select the following switch position:
Engine Control Dial : Slow Idle

E Mode Switch : OFF
Marking on the Track Frame
Marking on the Swing Bearing
2. Maintain the engine at slow idle. After five minutes, T105-06-03-010
measure the difference between the marks along
the swing bearing periphery and the track frame.
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:
Group T4-5.
Remedy:
T4-3-8
MAXIMUM SWINGABLE SLANT ANGLE
Summary:
With the upperstructure swung 90° to the slope,
check the maximum slant angle on which the
upperstructure can swing to the uphill side.
Preparation:
1. Check that the swing gear and bearing are well
lubricated.
used.
Backhoe: W=4350 kg (9590 lb) T105-06-03-011
Loading Shovel: W=6000 kg (13230 lb)
3. Positon the front attachment as described in the
following.
Backhoe:
With the arm cylinders fully retracted and the
bucket cylinders fully extended, position the arm
top pin flush with the boom foot pin height.
Loading shovel:
With the arm cylinder fully extended and the
top pin height flush with the boom foot pin height.
4. Climp a slope and swing the upperstructure 90°
to the slope.
(122±9 °F).
Measurement:

E Mode Switch : OFF
2. Operate the swing lever to full stroke to swing the

upperstructure to the uphill side.
3. If the machine can swing, measure the cab floor
slant angle.
4. Increase the slope angle and repeat steps (2 and
3). Check both clockwise and counterclockwise.
5. Perform the measurement three times.
Evaluation:
T4-5.
Remedy:
T4-3-9
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
looseness.
2. Check the lubrication of the swing bearing.
Confirm that bearing rotation is smooth and
T105-06-03-014
without noise.
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.
T105-06-03-015
T4-3-10
Measurement:
1. Position the front attachment as described in the
following.
Backhoe:
With the arm cylinders fully retracted and the
top pin height is flush with the boom foot pin
height.
Loading shovel:
With the arm cylinder fully extended and the
top pin height is flush with the boom foot pin
height.
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 ҥ h1
Evaluation:
T4-5.
Backhoe Front
Measurement : (h1 ) Measurement : (h2 )
Figure 1 Figure 2
T142-05-03-006
Loading Shovel Front

Measurement : (h1 ) Measurement : (h2 )
Figure 1 Figure 2
T142-05-03-005
T4-3-11
HYDRAULIC CYLINDER CYCLE TIME
Summary:
1. Check the overall operational performance of the
front attachment hydraulic system (between the
hydraulic pumps and each cylinder) by measuring
the cycle time of the boom, arm, bucket, and
bucket dump (open/close) cylinders with the
bucket emptied.
Preparation:
(122±9 °F).
Measurement:
E Mode Switch : OFF
SP Mode Switch : ON Backhoe
Quick Idle Switch : OFF Boom Cylinder
2. Position the front attachment as described in the
following. Then, measure the operating time until
the cylinder reaches the stroke end by fully
moving the control lever.
• Backhoe T145-05-03-012
Boom Cylinder:
With the bucket cylinder fully extended and the
arm cylinder fully retracted, lower the bucket to
the ground.
Arm Cylinder:
Adjust the boom cylinder stroke so that the bucket
bottom height is 0.5 m (20 in) above the ground Arm Cylinder
with the bucket cylinder fully extended while
positioning the center line between the arm and
bucket connection pin centers vertical with the T145-05-03-013
arm cylinder extended half stroke.

Bucket Cylinder:
Adjust the boom and arm cylinder so that the
center of full stroke movement of the bucket is
positioned vertically.
Bucket Cylinder
T145-05-03-014
T4-3-12
• Loading Shovel
Boom Cylinder: Loading Shovel
With the bucket cylinder and the arm cylinder fully
extended, lower the bucket to the ground.
Arm Cylinder:
Boom Cylinder
With the arm fully retracted, position the bucket so
that the rear bucket does not come in contact with
the arm stopper. Then, adjust the boom cylinder
stroke to position the bucket bottom 1 m (39 in)
above the ground. T145-05-03-015
Bucket Cylinder:
With the bucket closed and held in a load dump
position, adjust the boom cylinder stroke so that
bucket bottom height is approx. 1 m (39 in) above
the ground. Arm Cylinder
Bucket Dump (Open-Close) Cylinder:
T145-05-03-016
With the bucket cylinder and arm cylinder fully
extended, adjust the boom cylinder stroke so that
the bucket bottom height approx. 1 m (39 in)
above the ground.
3. Repeat the measurement three times and Bucket Cylinder
T145-05-03-017
Evaluation:
Refer to T4-5 Operational Performance Standard.
Dump Cylinder
Remedy:
Refer to the T5-4 Troubleshooting B.
T145-05-03-018
T4-3-13
DIG FUNCTION DRIFT CHECK
Summary:
Measure dig function drift, which can be caused by oil
leakage in the control valve and boom, arm, and
bucket cylinders, with the loaded bucket.
NOTE: When testing the dig function drift just after

cylinder replacement, slowly operate each
cylinder to its stroke end to purge air.
Preparation: T145-05-03-020

used.
Backhoe: W=4350 kg (9590 lb)
Loading Shovel: W=6000 kg (13230 lb)
2. Positon the front attachment as described in the
following.
Backhoe:
With the arm cylinder with rod 20 to 30 mm (0.8 to
1.2 in) extended from the fully retracted position,
T145-05-03-021
and bucket cylinder with the rod 20 to 30 mm (0.8
to 1.2 in) retracted from the fully extended
position. BH: Boom and Bucket Cylinders Retraction
Loading shovel: LD: Boom, Arm and Bucket Cylinders Retraction
With the arm cylinder with the rod 20 to 30 mm Mark
Mark
(0.8 to 1.2 in) retracted from the fully extended
position, and bucket cylinder with the rod 20 to 30
mm (0.8 to 1.2 in) retracted from the fully
extended position.
3. 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.
(122±9 °F). T110-06-03-002
Measurement:
BH: Arm Cylinder Extension
1. Stop the engine.
2. Five minutes after the engine has been stopped,
measure the change in the position of the bottom
of the bucket, as well as the boom, arm and
bucket cylinders.
3. Repeat step (2) three times and calculate the Mark
average values.
Evaluation:
T4-5.
Remedy:
T110-06-03-001
T4-3-14
CONTROL LEVER OPERATING FORCE
Summary:
1. Measure each control lever stroke and operating
force, and check if it can be moved smoothly.
2. Measure the maximum operating force for the
front attachment control levers.
3. Measure operating force at each lever grip center.
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
T107-06-03-003
1. Start the engine.

E Mode Switch : OFF

workers are out of the swing area before T107-06-03-004
3. Operate each boom, arm, bucket and swing lever

to at full stroke and measure the maximum
operating force for each.
4. Lower the bucket to the ground to raise one track

off the ground. Operate the travel lever to full
stroke and measure the maximum operating force
required. When finished, lower the track and then
jack-up the other track.

the average values.
Evaluation:
Group T4-5.
T4-3-15
CONTROL LEVER STROKE
Summary:
1. Measure each control lever stroke and stroke play,
and check if it can be moved smoothly.
2. Measure each lever stroke at the lever grip center.
3. If a stroke play is present in the neutral position,
add half the value of the play to the one side
stroke.
Preparation:
1. Maintain the hydraulic oil temperature at 50 ± 5 °C
(122 ± 9 °F).
Measurement:
1. Stop the engine.
2. Measure the boom, arm, bucket, swing travel lev- T107-06-03-005
ers full stroke from the neutral position at the lever

grip top center.
3. Measure the stroke straight from the neutral posi-
tion to the stroke end.
4. Repeat each measurement three times and calcu-
late the average values.
Evaluation:
Refer to T4-5 Operational Performance Standard.
T4-3-16
BOOM RAISE/SWING COMBINED OPERA-
TION CHECK
Summary:
Check boom raise and swing movement and speeds
while operating both functions simultaneously.
Preparation:
1. Start the engine and run it at fast idle. Operate the T142-05-03-007
boom raise function and check to be sure that the

cylinder movement is smooth, with out sticking.
2. Position the machine with front attachment
positioned as illustrated.
(122±9 °F).
CAUTION: Prevent personal injury. Always T142-05-03-008

Measurement:
General Purpose Mode:

SP Mode Switch : ON
E Mode Switch : OFF
Quick Idle Switch : OFF T107-06-03-010
Trenching Mode:
SP Mode Switch : ON
E Mode Switch : OFF
Work Mode Switch : Trenching Mode
H
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 T107-06-03-011
the bucket teeth.
the average values.
Evaluation:
T4-5.
Remedy:
T4-3-17
(Blank)
T4-3-18
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation: Test Port
1. Properly shut down the engine.
CAUTION: The hydraulic oil tank cap may

pop off if turned quickly. Slowly turn it to
release internal pressure before removing it.
2. Move all control levers to release pressure

remaining in the system. Slowly turn the hydraulic
oil tank cap approximately 30 degrees
counterclockwise to release internal pressure
from the hydraulic oil tank.
T162-04-04-008
: 4 mm
3. Disconnect the hose end from the pilot filter outlet

port. Install adapter (ST6477), fitting (ST6069),
pressure gauge (ST6315) and coupling (ST6332).
: 24 mm, 22 mm
4. Start the engine. Confirm that no oil leakage is

observed at the pressure gauge connection.
(122±9 °F).
Measurement:
Engine Control Dial : Fast Idle and Slow Idle

E Mode Switch : OFF
2. Measure the pilot pressure in each specified

setting above.
3. Repeat the measurement three times and
Evaluation:
Group T4-5.
T4-4-1
Primary Pilot Pressure Adjustment Procedure
Adjustment:
Adjust the setting pressure of the pilot relief valve (the
primary pilot pressure).
: 22 mm
Pilot Relief Valve
T162-04-04-005
1
1. Remove plug (1). 2
2. Install the estimated necessary numbers of shims

(2).
3. Tighten plug (1).
: 29.5 N⋅m (3 kgf⋅m, 21.5 lbf⋅ft)
T111-06-04-004
4. Check the relief pressure of the relief valve.
Reference:Standard Change in Pressure

Shim
2
Thickness kPa kgf/cm psi
(mm)
0.25 78 0.8 11
0.5 147 1.5 21
1.0 294 3.0 42
T4-4-2
SECONDARY PILOT PRESSURE
Connecting Port
Preparation:
: 4 mm
3. Install adapter (ST6450), fitting (ST6069),
pressure gauge (ST6315) and coupling (ST6332)
onto the pilot hose end of the measuring circuit. T111-06-04-006
: 19 mm, 22 mm
(122±9 °F).
Measurement:
CAUTION: Before starting measurement,
check that there are no bystanders and/or
obstructions within the swing radius.
When measuring the boom lower secondary
pilot pressure operate the machine carefully
as the base machine front will be raised off
the ground. This will cause the base machine
to become imbalanced and possibly allow the
rear of the machine to come in contact with
the ground.
E Mode Switch : OFF
2. Measure the pilot pressure in each specified
setting above with the corresponding control lever
operated full stroke.
Evaluation:
Group T4-5.
Remedy:
T4-4-3
SWING PREFERENCE CIRCUIT SHIFT
CONTROL PRESSURE (MA Pressure)
Preparation:
Swing Preference
Circuit Shift Solenoid
CAUTION: The hydraulic oil tank cap may Valve
release internal pressure before removing it. Preference Valve

Hose MA
: 4 mm T162-04-04-001
3. Disconnect the end of hose MA from the

preference valve. Install adapter (ST6451), fitting
(ST6069), pressure gauge (ST6315) and coupling
(ST6332).
: 19 mm

(122±9 °F).
Measurement:

E Mode Switch : OFF
2. Read the pressure gauge with all control levers in

neutral.
Read the pressure gauge with the boom raise and
swing control levers operated full stroke.
Evaluation:
T4-5.
Remedy:
Refer to the troubleshooting B in group T5-4.
T4-4-4
MAIN RELIEF PRESSURE SHIFT CON-
TROL PRESSURE (SA Pressure)
Preparation:


: 4 mm
SA
3. Disconnect the hose end from the solenoid valve Main Relief
SA output port. Install adapter (ST6451), fitting Pressure Shift
(ST6069), pressure gauge (ST6315) and coupling Solenoid Valve
(ST6332).
T162-04-04-005
: 19 mm, 22 mm
Evaluation:
4. Start the engine. Confirm that no oil leakage is Refer to the performance standard table in group
observed at the pressure gauge connection. T4-5.
5. Maintain the hydraulic oil temperature at 50±5 °C Remedy:
(122±9 °F). Refer to the troubleshooting B in group T5-4.
Measurement:
1. Select the following switch and lever positions:
Engine Control E mode SP mode Work Mode Auto-Idle Quick Idle

Control Dial Levers Switch Switch Switch Switch Switch
Travel lever General Purpose
OFF OFF OFF OFF
operation Mode
All in
Fast Idle OFF OFF Precision Mode OFF OFF
neutral
All in General Purpose
OFF OFF OFF OFF
neutral Mode
2. Read the pressure gauge in each setting above.

T4-4-5
TRAVEL MODE SHIFT CONTROL PRES-
SURE (SB Pressure)
Preparation:

pop off if turned quickly. Slowly turn it to Travel Mode
Shift Solenoid
release internal pressure before removing it. Valve SB

: 4 mm
3. Disconnect the hose end from the solenoid valve

SB output port. Install adapter (ST6451), fitting
(ST6069), pressure gauge (ST6315) and coupling
(ST6332).
T162-04-04-005
: 19 mm, 22 mm
Evaluation:
4. Start the engine. Confirm that no oil leakage is Refer to the performance standard table in group
observed at the pressure gauge connection. T4-5.
5. Maintain the hydraulic oil temperature at 50±5 °C Remedy:
(122±9 °F). Refer to the troubleshooting B in group T5-4.
Measurement:
E mode
Engine Travel Mode Switch Work Mode Auto-Idle Quick Idle
Control Dial Switch SP mode Switch Switch Switch
Switch
General
Fast Idle Fast Speed OFF Purpose OFF OFF
Mode
General
Fast Idle Slow Speed OFF Purpose OFF OFF
Mode
2. Read the pressure gauge in each setting above.

T4-4-6
(Blank)
T4-4-7
MAIN RELIEF 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:

pop off if turned quickly. Slowly turn it to Test Port

from the hydraulic oil tank. T162-03-01-001
: 4 mm 3. As for the swing function, secure the
upperstructure immovable. Slowly operate the
3. Remove the plug from the test port located on the swing lever to relieve the swing function.
main pump delivery port. Install fitting (ST6069)
and pressure gauge (ST6934). 4. As for the travel function, secure the tracks
: 19 mm against an immovable object. Slowly operate the
travel levers to relieve the travel function.
Or, connect Dr. EX. Select the monitor function to
monitor main pump delivery pressure. Evaluation:
4. Start the engine. Confirm that no oil leakage is T4-5.
Reference:
5. Maintain the hydraulic oil temperature at 50±5 °C If the pressures for all functions measured are lower
(122±9 °F). than the specified range, the probable cause is a
decrease in the main relief valve setting pressure.
If the relief pressure of a particular function is low,

the probable cause is something other than the main
relief valve.
Measurement:
Engine SP Mode E Mode Work Mode Auto-Idle Quick Idle
Control Dial Switch Switch Switch Switch Switch
Boom, Arm, General
Fast Idle ON OFF OFF OFF
Bucket Purpose Mode
General
Swing Fast Idle ON OFF OFF OFF
Purpose Mode
Precision
Travel Fast Idle ON OFF OFF OFF
Mode
2. Relieve each actuator to measure main relief
pressure.
First, slowly operate bucket, arm, and boom
control levers to the stroke end to relieve each
function one at a time.
T4-4-8
Main Relief Pressure Setting Adjustment
Procedure
Adjustment:
Adjust the main relief valve pressure settings using
plug (3) (for the low-side main relief pressure) and
sleeve (1) (for high-side main relief pressure) after
loosening lock nuts (2 and 4).
• High-Side Main Relief Pressure Setting

Adjustment Procedure
1. Loosen lock nut (4). Tighten plug (3) until the

bottom of piston (5) comes into contact with
sleeve (1). Retighten lock nut (4).
: 22 mm, 30 mm
: Lock nut (4): 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft)
Front
2. Loosen lock nut (2). Turn sleeve (1) to adjust the Main Relief Valve
relief pressure setting, referring to the table below.
3 T162-05-02-012
: 27 mm, 41 mm
: Lock nut (2): 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft) 4 1
• Low-Side Main Relief Pressure Setting

Adjustment Procedure 2
3. Loosen lock nut (4). Turn plug (3)

counterclockwise until the specified value is
obtained. Retighten lock nut (4).
: 22 mm, 30 mm 5
: Lock nut (4): 59 N⋅m (6 kgf⋅m, 43 lbf⋅ft)
4. Recheck the set pressures.

Sleeve (1) and plug
1/4 1/2 3/4 1
(3) turns
MPa 4.4 8.8 13.2 17.7
kgf/cm 2
45 90 135 180
psi 640 1280 1920 2560
T162-04-04-011
Sleeve (1),
Plug (3)
Pressure Increase Pressure Decrease
W107-02-05-127
T4-4-9
Swing Relief Pressure Setting Adjustment Proce-
dure
Adjustment:
Adjust the pressure setting of the swing relief valve
Swing Relief Valve
using adjusting screw (1) after loosening lock nut (2).
1. Loosen lock nut (2).

: 19 mm
2. Turn adjusting screw (1) adjust the pressure

setting referring to the table below.
: 6 mm
3. Retighten lock nut (2).

: 19 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
4. Recheck the set pressure.
T162-04-04-002
2 1

Screw Turns 1/4 1/2 3/4 1
MPa 3.3 6.7 10.0 13.3
T162-04-04-003
kgf/cm 2
34 68 102 136
psi 480 970 1450 1930
Lock Nut (2) Adjusting Screw (1)
Pressure
Pressure Decrease
Increase
W107-02-05-129
T4-4-10
Travel Relief Pressure Setting Adjustment
Procedure
Travel Relief Valve

Adjustment:
Adjust the pressure setting of the travel relief valve
using the adjusting screw after loosening the lock nut.
1. Loosen the lock nut.

: 17 mm
2. Turn the adjusting screw to adjust the pressure

setting, referring to the table below.
: 6 mm
T142-01-02-012
3. Retighten the lock nut.
Lock Nut
: 17 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
4. Recheck the set pressure.
Adjusting Screw
T142-05-04-007
MPa 1.96 3.92 5.88 7.85
kgf/cm 2
20 40 60 80
Lock Nut Adjusting Screw
psi 280 570 850 1140
W107-02-05-129
T4-4-11
OVERLOAD RELIEF VALVE SET PRES-
SURE
Summary:
1. The circuit pressure must be increased by
applying 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 Test Port
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
T162-03-01-001
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
(122±9 °F).
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 relief pressure of the front
functions as follows:
The main relief pressure can also be measured
with Dr. EX.
Preparation:


: 4 mm
3. Remove the plug from the test port located on the

main pump delivery port. Install fitting(ST6069)
and pressure gauge(ST6934).
: 19 mm
Or, connect Dr. EX. Select the monitor function to

monitor main pump delivery pressure.
T4-4-12
Measurement:
Engine SP Mode E Mode Work Mode Auto-Idle Quick Idle
Control Dial Switch Switch Switch Switch Switch
Boom, Arm, General
Bucket Purpose Mode
Swing General
Purpose Mode
Travel Precision
Mode
2. Relieve each actuator to measure main relief

pressure.
First, slowly operate bucket, arm, and boom
control levers to the stroke end to relieve each
function one at a time.
4. Perform the measurement for the bucket, arm,
and boom, in that order.
calculate the average value for each front
function.
Evaluation:
1. Performance of each overload relief valve is
normal if the measured main relief pressure of the
concerned function is within the specified value
range.

Group T4-5.
T4-4-13
Overload Relief Valve Set Pressure Adjusting
Procedure
NOTE: In principle, adjust the overload relief valve

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

: 19 mm
2. Turn adjusting screw (2) to adjust the pressure

setting referring to the table below.
: 6 mm
Overload Relief Valve
3. Retighten lock nut (1).
: 19 mm T111-02-05-002
: 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft) 2 1
4. Recheck the set pressures.

MPa 4.9 9.8 14.7 19.6
kgf/cm2 50 100 150 200
psi 710 1420 2130 2840
T162-04-04-004
Lock Nut (1) Adjusting Screw (2)
W107-02-05-129
T4-4-14
MAIN PUMP FLOW TEST
IMPORTANT: Using Dr. EX, check differences
between target pump displacement 4
and target pump displacement 5, 3 4
and between pump displacement 4
and pump displacement 5. When
both differences are within 3% of the
maximum pump displacement, the
main pump delivery flow rate is
normal. When normal, do not adjust
the maximum and minimum pump
flow rate and flow rate control
setting.
Test Port
Summary:
To check the main pump performance, measure the
pump flow rate by connecting a portable tester at the
main pump delivery port. Dr. EX and a pressure
gauge are also used. 2
1
Preparation: T162-03-01-001
CAUTION: The hydraulic oil tank cap may 5. Install pipe (ST6144) on the main pump delivery
pop off if turned quickly. Slowly turn it to re- port using the split flanges and socket bolts
lease internal pressure before removing it. removed in step 2.
1. Properly shut down the engine. Turn the filler cap 6. Connect test hose (ST6145) between pipe
on the hydraulic oil tank to the stop to release (ST6144) and portable tester (ST6299).
remaining pressure. Remove the filler cap.
Connect a vacuum pump to the filler. 7. Remove the plug from the main pump test port.
Install adapter (ST6069) and pressure gauge
NOTE: Be sure to keep the vacuum pump (ST6934) on the test port.
operated while connecting the portable : 19 mm
tester to the main pump.
8. Disconnect the DP sensor and engine speed (N)
2. Disconnect high-pressure hose (1) or (2), sensor connectors. (The pump displacement
depending on which main pump is to be angle will be the maximum.)
measured.
Connect flange F18 (ST6118) to the disconnected 9. Remove the P (delivery pressure) sensor from the
hose end using split flange and socket bolt (Part other main pump.
No. M341245).
: 10 mm 10. Disconnect the vacuum pump. Loosen drain hose
(3) or (4) connection on the top of the main pump
3. Connect test hose (ST6145) to flange F18 to bleed air from the casing (until oil comes out).
(ST6118).
: 41 mm 11. Connect the pulse counter to the N sensor. Fully
open the loading valve of the portable tester.
4. Install adapter (ST6146) on portable tester
(ST6299). Connect the other end of test hose to 12. Start the engine. Check line connections for any
adapter (ST6146). oil leak. Connect Dr. EX and monitor pump
: 41 mm, 71 mm delivery pressure.
: 10 mm
T4-4-15
Measurement:
1. The maximum flow rate will be measured. (This
can be done as the following parts have been
removed in the preparation stage: the DP sensor
and N sensor from the main pump to be
measured and the P sensor from the other main
pump.)
Travel Mode Switch : Fast Speed Mode
SP Mode Switch : ON
-1
3. Adjust the engine speed to 2000 min with the
engine control dial.
4. Gradually close the loading valve on the portable
tester and measure (record) pump flow rate and
engine speed at each specified delivery pressure.
Evaluation:
1. Conversion (Reference: Bench test result)
Convert the measured pump flow rate into the one Point on 2
Q ( L/min ) P ( kgf/cm )
for the rated pump speed using the following PQ curve
formula. A 485±20 100
Ne = Pulse Number (Hz)/1.967 B 285±35 250
Converted Pump Flow Rate (Qc) = (Np×Q) / (i×Ne)×Q
Where: Q (Flow Rate)

Qc : Converted Pump Flow Rate L/min
A
Q : Measured Pump Flow Rate 500
i : Pump Reduction Ratio (= 1)
-1
Np : Rated Pump Speed (2000 min )
400
Ne : Measured Engine Speed
B
2
NOTE: 1 kgf/cm = 98.07 kPa 300
2
1 kgf/cm = 14.22 psi
1 L/min = 0.2642 US gal
200
100
0 100 200 300 400

P (Pressure)
kgf/cm 2
T162-04-04-009
T4-4-16
Adjustment:
IMPORTANT: Using Dr.EX, check differences To adjust the minimum flow rate, loosen nut (3) and
between target pump displacement 4 turn screw (4) on the small chamber side end of the
and target pump displacement 5, servo piston.
and between pump displacement 4
and pump displacement 5. When NOTE: Turn screw (1) clockwise to decrease the
both differences are within 3% of the maximum flow rate and counterclockwise to
maximum pump displacement, the increase. Turning screw (1) one forth a turn
main pump delivery flow rate is changes approximately 9.2 L/min of flow
normal. When normal, do not adjust rate.
the maximum and minimum pump Turn screw (4) clockwise to decrease the
flow rate and flow rate control minimum flow rate and counterclockwise to
setting. increase. Turning screw (4) one forth a turn
changes approximately 9.2 L/min of flow
Adjustment of Minimum and Maximum Flow Rate rate.
Pump flow rate can be adjusted by changing the 1 L/min = 0.2642 US gal
maximum stroke of the servo piston.
To adjust the maximum flow rate, loosen nut (2) and
turn screw (1) on the large chamber side end of the
servo piston.
1 2 3 4
T162-04-04-007
Maximum Flow Rate Adjustment Minimum Flow Rate Adjustment
(Pump Flow (Pump Flow

Q Rate) Q
Rate)
I I
NOTE: “ I ” Means Proportional Solenoid Valve

Command Electrical Current Value
T4-4-17
Flow Rate Control Setting Adjustment
The flow rate is controlled by signal current (A) to the

proportional solenoid valve.
If the pump flow rate control is abnormal, or the regu-

lator flow rate control adjusting screw is mistakenly
rotated, readjust the flow rate control by resetting
spring (1) force while measuring the correlation be-
tween signal current value (A) to the pump control
proportional solenoid valve and the pump displace-
ment (cc/rev) using Dr. EX.
IMPORTANT: Before adjusting the flow rate, check

that the pump control proportional
solenoid valves are normal by
switching them between pumps 1
and 2.
1. Disconnect the travel control pilot pressure switch.

Short-circuit harness end connector terminal #1 to
#2 using a clip.(The relief flow rate reducing con-
trol in the pump control is deactivated.)
2. Connect Dr. EX.
3. Loosen nut (2). Adjust the pump flow rate by turn-

ing screw (3).
4. While slowly operating the control lever, Dr. EX

monitor signal current (A) (proportional solenoid
valve command electrical current value) and the
pump displacement (cc/rev). When signal current
value (A) to the pump flow rate control propor-
tional solenoid valve is 580±50 mA, hold the con-
trol lever in that position for approx. 3 seconds.
Then, monitor the pump displacement (cc/rev).
5. Adjust the spring (1) set force while referring to

the diagram on the next page.
6. Adjust the pump one by one.

• Signal Current 4: Pump Displacement 4 (Main
Pump 2)
• Signal Current 5: Pump Displacement 5 (Main
Pump 1)
T4-4-18
1 2 3
T162-04-04-007
(Reference Diagram)
Spring Setting Adjustment
Screw Turns 1/4 Pump
Displacement
Flow Rate Control
Flow Rate 40.5 L/min (cc/rev.)
1 L/min = 0.2642 US gal

278
55
300±50 580±50 (mA) Proportional

Solenoid Valve
Command
Electrical
Current Value
T4-4-19
SWING MOTOR DRAINAGE
Summary:
To check swing motor performance, measure the
amount of oil draining from the swing motor while
swinging the upperstructure.
NOTE: The amount of drain oil from the swing

motor will change depending on the
hydraulic oil temperature. Be sure to
maintain hydraulic oil temperature at 50±5
°C (122±9 °F).
1

starting machine operation.
A
Preparation:
1. Maintain hydraulic oil temperature at 50±5 °C B
(122±9 °F). Rotate the swing motor to warm the
inside of the motor.

2. Move all control levers to release pressure 2

oil tank cap approximately 30 degrees counter- Rear
T162-04-04-006
clockwise to release internal pressure from the
Right Left
hydraulic oil tank.
Front
: 4 mm
3. To measure the right swing motor drainage, Preconditions for Measurement:

disconnect right swing motor drain hose (1) at part 1. Select the following switch positions:
A. Install plug (ST6491) on the tee side.
: 27 mm E Mode Switch : OFF
: 93 N⋅m (9.5 kgf⋅m, 70 lbf⋅ft) SP Mode Switch : OFF
4. To measure the left swing motor drainage, Auto-Idle Switch : OFF
disconnect drain hose (2) at part B. Connect the Quick Idle Switch : OFF
test drain hose (3/4-UN) to the motor side and
plug (ST6637) to drain hose (2).
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 70 lbf⋅ft)
T4-4-20
Measurement:
1. Amount of Oil Drained While Swinging the
Upperstructure
(1) With the bucket empty, position the front
Backhoe:
With the arm cylinder fully retracted, and the
bucket cylinder fully extended, raise the
boom so that the arm tip pin heigh is flush
with the boom foot pin height. T145-05-03-007
Loading Shovel:
With the arm cylinder and the bucket cylinder
fully extended, raise the boom so that the
arm tip pin height is flush with the boom foot
pin height.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start draining oil
measurement after the swing speed reaches
a constant maximum speed. The measuring
time should be more than 20 seconds.
(3) Repeat the measurement three times in both T145-05-03-008
clockwise and counterclockwise directions,
2. Amount of Oil Drained While Relieving Swing
Motor Circuit
(1) Thrust the bucket teeth into the ground as
illustrated so that the upperstructure does not
rotate when the swing lever is operated full
T107-06-06-005
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 20 seconds.
(3) Repeat the measurement three times in both
clockwise and counterclockwise directions,
NOTE: Because the right swing motor drain hose is
connected to the left swing motor drain port,
the total of the right and left swing motor
drainage will be measured when measuring
the left swing motor drainage according to
step 4 in Preparation. For this reason, be
sure to deduct the amount of right swing
motor oil drainage (step 3 in Preparation) T107-06-05-008
from that total amount.
Evaluation:
T4-5.
∗ Conversion of the amount of drain oil measured into ∆Q = 60 × q / t

the per-minute value Where:
First measure the amount of drain oil using a ∆Q : Amount of drain oil per minute (L/min)
calibrated container. Then, convert the measured t : Time measured (seconds)
drain oil into the per-minute value using the formula q : Total amount of drain oil (L)
below:
T4-4-21
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 2

motor and the drain oil pressure will change
depending on hydraulic oil temperature.
Maintain hydraulic oil temperature within
50±5 °C (122±9 °F).
Preparation:
1. Main hydraulic oil temperature at 50±5 °C (122±9
°F). Rotate the travel motor to warm the inside of 1
the motor.


oil tank cap approximately 30 degrees T142-05-04-018

3. Disconnect the travel motor drain hose (2) at the

travel motor end. Install plug (ST 6637) to the
disconnected end. Connect the drain hose (3/4-
16UN) to the travel motor.
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 70 lbf⋅ft)
Preconditions for Measurement:


E Mode Switch : OFF
T4-4-22
Measurement:
(1) Start the engine. Jack up the measuring side
track using the front attachment, as illustrated.
CAUTION: Securely support the raised track

using wooden blocks.
(2) Rotate the raised track with the travel lever

operated full stroke.Ȁ Start drain oil
measurement after the track rotation speed T142-05-03-011
reaches a constant maximum speed. The
measuring time should be more than 20
seconds.
(3) Repeat the measurement at least three times

in both forward and reverse directions and
Evaluation:
Refer to the Performance Standard Table in T142-05-03-012
Group T4-5.
* Conversion of the amount of drain oil measured into

the paramount value
First measure the amount of drain oil using a

calibrated container. Then, convert the measured
drain oil into the paramount value using the formula
below:
∆Q=60×q/t
Where:
˿ Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T142-05-04-018
T4-4-23
(Blank)
T4-4-24
OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE
STANDARD TABLE
The standard performance values are listed in the

table below.
Refer to the groups 2 to 4 for performance test
procedures. Values indicated in parentheses are
reference values.
* The values listed below are on the premise that the

hydraulic oil temperature is maintained at 50±5 °C
(122±9 °F).
Performance
Performance Test Remarks
Standard
ENGINE SPEED (min-1)
Fast Idle 2070±50 Dr. EX Value

Slow Idle 850±50 Dr. EX Value
Auto-Idle Speed 1650±100 Dr. EX Value
Quick Idle 850±50 Dr. EX Value
VALVE CLEARANCE (IN) (mm) 0.35 With cold engine.
(EX) (mm) 0.68 With cold engine.
TRAVEL SPEED (sec/20 m)
Fast Speed Mode 15.5±1.0

Slow Speed Mode 22.0±2.0
TRACK REVOLUTION SPEED (Fast Speed Mode) 29.5±1.0
(sec/3 rev)
MISTRACK (Fast/Slow Speed Mode) (mm/20 m) 200 or less

TRAVEL PARKING FUNCTION CHECK (rev) 1/6 or less
TRAVEL MOTOR LEAKAGE (mm/5 min) 0
SWING SPEED (sec/3 rev) 21.0±2.5
SWING FUNCTION DRIFT CHECK (mm/180°) Less than 1600
SWING PARKING FUNCTION CHECK (mm/5 min) 0
3
MAXIMUM SWINGABLE SLANT ANGLE (deg.) 3.6 Arm, 3.3 m (PCSA heaped)
15° or possible more
Bucket
SWING BEARING PLAY (mm) 2.0 or less Limit of Use: 5.0
NOTE: 1 mm=0.03937 in
T4-5-1
Performance
Standard
3.6 Arm,
HYDRAULIC CYLINDER CYCLE TIME (sec) 3
3.3 m (PCSA heaped) Bucket
Boom Raise 4.0±0.4 (EX800H-5: 4.5±0.4)
Boom Lower 3.1±0.4
Arm Roll-In 4.3±0.4
Arm Roll-Out 3.2±0.4 (EX800H-5: 3.6±0.4)
Bucket Roll-In 2.7±0.4
Bucket Roll-Out 3.0±0.4 (EX800H-5: 3.1±0.4)
3.6 Arm,
DIG FUNCTION DRIFT CHECK (mm/ 5 min) 3
3.3 m (PCSA heaped) Bucket
Boom Cylinder Less than 21
Arm Cylinder Less than 16
Bucket Cylinder Less than 15
Bucket Bottom -
CONTROL LEVER OPERATING FORCE (kgf) HITACHI Lever Pattern
Boom Lever 2.0 or less
Arm Lever (ISO Lever Pattern: Swing Lever) 1.7 or less
Bucket Lever 1.7 or less
Swing Lever (ISO Lever Pattern: Arm Lever) 2.0 or less
Travel Lever 2.4 or less
CONTROL LEVER STROKE (mm) HITACHI Lever Pattern
Boom Lever 100±10
Arm Lever (ISO Lever Pattern: Swing Lever) 78±10
Bucket Lever 78±10
Swing Lever (ISO Lever Pattern: Arm Lever) 100±10
Travel Lever 100±10
NOTE: 1 kgf=9.807 N
1 mm=0.03937 in
T4-5-2
Performance
Standard
BOOM RAISE/SWING in General Purpose Mode 3.6 Arm,
Less than 5.3 3
with Empty Bucket ( sec ) 3.3 m (PCSA heaped) Bucket
Bucket Teeth Height: H ( mm ) more than 6200
BOOM RAISE/SWING in Trenching Mode
Less than 4.6
with Empty Bucket ( sec )
Bucket Teeth Height: H ( mm ) more than 4200
COMPONENT TEST
PRIMARY PILOT PRESSURE ( kgf/cm ) 2
+7
(Engine Slow Idle) 40 -2
+10
(Engine Fast Idle) 40 -2
SECONDARY PILOT PRESSURE
(34 to 40) Dr. EX Value (Lever: Full Stroke)
(Engine Fast Idle and Slow Idle) ( kgf/cm ) 2
SWING PREFERENCE CIRCUIT SHIFT CONTROL

PRESSURE (MA Pressure)
0
(Swing/boom raise combined operation in trenching
mode) ( kgf/cm ) 2
in neutral more than 35

MAIN RELIEF PRESSURE SHIFT CONTROL
PRESSURE (SA Pressure)
more than 35
(Travel operation and
operation in precision mode) ( kgf/cm ) 2
in neutral 0
TRAVEL MODE SHIFT CONTROL PRESSURE (SB
Pressure) more than 35
(Fast Speed Mode) ( kgf/cm ) 2
(Slow Speed Mode) more than 18

MAIN RELIEF PRESSURE ( kgf/cm ) 2
+15
Boom, Arm, Bucket 315 -0 Dr. EX Value
+15
Swing 295 -5 Dr. EX Value
Travel 350±10 Dr. EX Value
OVERLOAD RELIEF PRESSURE ( kgf/cm ) 2
(Reference value at
110 L/min)
1
Boom Raise/Lower, * Arm Roll-In, +10
330 -0 Test Stand Value
Bucket Roll-In/Roll-Out
2 +10
* Arm Roll Out 350 -0 Test Stand Value
MAIN PUMP FLOW RATE ( L/min ) − Refer to T4-4-16.
2 or less Limit of Use:
(With constant maximum speed) ( L/min )
31 or less Limit of Use:
(With the motor relieved) ( L/min )
5 Limit of Use: 10
(With track jacked up/ slow speed mode) ( L/min )
(15) Limit of Use: (30)
(With the motor relieved/ fast speed mode) ( L/min )
2
NOTE: 1 kgf/cm =0.09807 MPa
*1 In the case of loading shovel specifica-
tion, the operation is arm extend.
*2 In the case of loading shovel specifica-
tion, the operation is arm retract.
T4-5-3
(Blank)
T4-5-4
MEMO
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SECTION 5
TROUBLESHOOTING
; CONTENTS;
;
Group 1 Diagnosing Procedure Fault Code 14, 15 (Overheat Switch L
Introduction ..............................................T5-1-1 Failure, Hydraulic Oil Temperature
Diagnosing Procedure ..............................T5-1-2 Sensor Failure) .......................................T5-3-9
Dr. EX ......................................................T5-1-4 Fault Codes 17, 18, 19, 21, 22
Dr. EX Start Up Procedure .......................T5-1-4 (PVC Failure)........................................T5-3-10
Clearing the Self-Diagnosing Fault Code 20 (Communication Failure
Function .................................................T5-1-5 between EC and PVC) .......................... T5-3-11
Retrial “A” ................................................T5-1-5 Fault Code 23, 24 (Pump Control
Retrial “B” ................................................T5-1-6 Failure) .................................................T5-3-12
Fault code List..........................................T5-1-7 Fault Code 25, 26, 33, 34
Monitoring Function ..................................T5-1-9 (DP Sensor Failure) ..............................T5-3-14
Fault Code 27, 28, 35, 36
Group 2 Component Layout (P Sensor Failure) ................................T5-3-15
Main Components ....................................T5-2-1 Fault Code 29, 30, 37, 38
Electrical System Component (1) .............T5-2-2 (A Sensor Failure) ................................T5-3-16
Electrical System Component (2) .............T5-2-3 Sensor Operating Range List..................T5-3-17
Electrical System Component (3) .............T5-2-4
Control Valve............................................T5-2-6 Group 4 Troubleshooting B
Others ....................................................T5-2-10 Troubleshooting B Procedure ...................T5-4-1
Correlation between Part Failure and
Group 3 Troubleshooting A Abnormalities that Machine may
Troubleshooting A Procedure ...................T5-3-1 Show ......................................................T5-4-2
Fault Code List .........................................T5-3-2 Correlation between Troubles and
Fault Codes 01, 02, 03, 04, 06 Part Failures ...........................................T5-4-6
(EC Failure) ............................................T5-3-4 Engine System Troubleshooting .............T5-4-10
Fault Code 05 (Communication Total Actuator System
Failure between PVC and EC) ................T5-3-5 Troubleshooting ....................................T5-4-19
Fault Code 09, 10 Front Attachment System
(EC Sensor Failure) ................................T5-3-6 Troubleshooting ....................................T5-4-25
Fault Code 11, 12 (Engine Control Swing System Troubleshooting...............T5-4-28
Dial Failure) ............................................T5-3-7 Travel System Troubleshooting...............T5-4-31
Fault Code 13 (N Sensor Failure) .............T5-3-8
162T-5-1
Troubleshooting for Other Group 6 Electrical System Inspection
Functions..............................................T5-4-34 Precautions for Inspection and
Engine Speed Adjustment ......................T5-4-38 Maintenance ...........................................T5-6-1
EC Sensor Installation and Voltage Instructions for Disconnecting
Adjustment ...........................................T5-4-39 Connectors .............................................T5-6-3
Fuse Continuity Test .................................T5-6-4
Group 5 Troubleshooting C Fusible Link Inspection and
Troubleshooting C Procedure ...................T5-5-1 Replacement ..........................................T5-6-5
Malfunction of Coolant Battery Voltage Check ..............................T5-6-5
Temperature Gauge................................T5-5-2 How to Troubleshoot Alternator
Malfunction of Fuel Gauge .......................T5-5-4 Malfunctions .........................................T5-6-6
Malfunction of Indicator Bulb Continuity Check ......................................T5-6-7
Check System ........................................T5-5-6 Voltage and Current Check.......................T5-6-8
Malfunction of Level Relay Replacing Procedure ....................T5-6-12
Check Switch..........................................T5-5-6
Malfunction of Engine Oil Group 7 Harness Check
Level Indicator ........................................T5-5-8 Circuit Check............................................T5-7-1
Malfunction of Coolant
Level Indicator ......................................T5-5-10
Malfunction of Hydraulic Oil
Level Indicator ......................................T5-5-12
Malfunction of Alternator
Indicator ...............................................T5-5-14
Malfunction of Engine Oil Pressure
Indicator ...............................................T5-5-15
Malfunction of Overheat Indicator ...........T5-5-16
Malfunction of Fuel Level
Indicator ...............................................T5-5-17
Malfunction of Air Filter Restriction
Indicator ...............................................T5-5-18
Malfunction of Hour Meter ......................T5-5-19
Malfunction of Buzzer .............................T5-5-20
Malfunction of Work Light
Indicator ...............................................T5-5-22
Malfunction of Quick Idle Indicator..........T5-5-22
162T-5-2
TROUBLESHOOTING / 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 7 groups: the

diagnosing procedure, the component layout, the
troubleshooting A (using fault codes), troubleshooting
B (starting with symptoms), troubleshooting C (gauges
and indicators), the electrical system inspection
procedures, and harness check groups.
• Component Layout Drawing • Electrical System Inspection Procedure

Refer to this group for precautions and inspection
• Troubleshooting A (using fault codes) procedures of the electrical system when or
Use these charts when the self-diagnosing before performing inspections on the electrical
function of Dr.EX shows any fault codes. system.
(The controller automatically diagnoses and
memorizes malfunctions that have occurred in the Example: Fuse Inspection
signal sending system.)
• Harness Check
Example: Fault Code 01: EC Sensor Failure Refer to this group for information about the test
harnesses.
• Troubleshooting B (starting with symptoms)
Use these charts when the machine is exhibiting Example: ST 7129
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.
T5-1-1
DIAGNOSING PROCEDURE
These six basic steps are essential for efficient

troubleshooting:
1. Study the system
Study the machine’s technical manuals. Know the

system and how it works, and what the construction,
functions and specifications of the system components
are.
2. Ask the operator

T107-07-01-001
Before inspecting, get the full story of malfunctions
from your star witness --- the operator.
(a) How is the machine being used? (Find out if the

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

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

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

previously? If so, which parts were repaired
before?
T107-07-01-002
3. Inspect the machine
Before starting the troubleshooting procedure, check

the machine’s daily maintenance points, as shown in
the operator's manual.
Also, check the electrical system, including the

batteries, as troubles in the electrical system such as
low battery voltage, loose connections and blown fuses
will result in malfunction of the controllers, causing total
operational failure of the machine.
Fuse failure is often caused by a fine crack in the fuse,
and such fine cracks are very hard to detect by visual
T107-07-01-003
inspection.
T5-1-2
4. Operate the machine yourself
Try to identify the trouble by operating the machine

yourself.
If the trouble cannot be confirmed, stop the engine and
obtain further details of the malfunction from the
operator.
Also, check for any incomplete connections of the wire
harnesses.
T107-07-01-004
5. Perform troubleshooting
CAUTION: Never attempt to disconnect

harnesses or hydraulic lines while the engine
is running. The machine may malfunction or
pressurized oil may spout, possibly resulting
in personal injury. Be sure to stop the engine
before disconnecting harnesses or hydraulic
lines.
Connect the diagnostic analyzer, Dr.EX, to the PVC

(Controller) to obtain malfunction records.
T107-07-01-005
If any fault codes are displayed on the monitor, check

sensing signal circuits, referring to Troubleshooting 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
troubleshooting B procedures for monitoring real time
component performance.
∗ Note that the fault codes displayed do not necessarily

indicate machine trouble. The controller stores even
temporary electrical malfunctions, such as a drop in
battery output voltage or disconnections of the
switches, sensors, etc., for inspections.
For this reason, the “RETRIAL” is required to erase
T107-07-01-006
the accumulated fault codes from the controller
memory and to confirm if any fault codes are
indicated after the “RETRIAL”.
6. Trace possible causes
Before reaching a conclusion, check the most likely

causes again. Try to identify the actual cause of the
trouble.
Based on your conclusion, make a plan for appropriate

repairs to avoid consequent malfunctions. T107-07-01-007
T5-1-3
Dr.EX
The Dr.EX is a handy microcomputer used for Input signals from the sensors and switches that are
diagnosing malfunctions of the machine electronic connected to the controller, and output signals from the
control system, including the controllers. controller to the solenoid valves can be monitored in
When Dr.EX is connected to the controller, real-time while the machine is operated. (Real-Time
malfunctions recorded in the controller memory are Monitoring Function)
indicated as fault codes on the Dr.EX display.
(Self-Diagnosing Function) The Dr.EX can also function to increase the pump
displacement angle to the maximum angle.
(Special Function)
Dr.EX START-UP PROCEDURE
1. Connect the Dr.EX harness end to the diagnosing Start

connector in the cab.
NOTE: Be sure to use the harness supplied with Model Selection Screen
Dr.EX for connecting the Dr.EX to the (Select “40tϡkg1.”)
machine. Once Dr.EX is connected
properly and switched on, the self-
diagnosing function will automatically start Initial Pattern Communication
up. (Dr. EX) Failure
ѕʝCheck the
2. Turn the key switch to the ON position, or start the harness.
engine. ѕʝCheck the fuse.
Model Code
3. Turn the Dr.EX power switch on. The model Confirmation
selecting screen will appear on the Dr.EX display. Screen
On each step (screen), select an appropriate item NOT OK
and/or follow the instructions at the bottom of the Install the new-
OK version
screen to proceed to the next step. The other
screens shown below will appear, in the order Function Selection Screen
shown.
(1) Model Selection Screen (Select “40tϡkg1.”)
(2) Initial Pattern (Dr.EX) Real-Time Special Function
Monitoring (A sensor
(3) Model Code Confirmation Screen Self-Diagnosing Function Function adjustment)
Example: Controller Model: EX750-5
PVC :
EC: Monitor Item Fixing Pump
Accumulated Fault Displacement
(4) Function Selection Screen Codes Display Selection
Screen Angle at
F1: Self-Diagnosing Function Maximum
F2: Real-Time Monitoring Function • Refer to the
F3: Special Function page T5-4-41.
Retrial A or B Data Display
4. When the Function Selection Screen appears,

select the desired function, then proceed by
following the instructions at the bottom of the
display. Fault Code Display
NOTE: For Dr.EX operating procedures, refer to

the Dr.EX Operator's Manual. Failure Description
T5-1-4
CLEARING THE SELF-DIAGNOSING
FUNCTION
The PVC self-diagnosing function temporarily stores

information on any abnormality that occurs in the
electrical system. These include such things as a drop
in battery voltage or a sensor connector being
disconnected for inspection.
Therefore, when a fault code is displayed, it does not
necessarily mean that the machine has a problem.
To check the cause of a fault code, first erase the fault
code and check whether it is displayed again or not.
There are two ways to erase fault codes, depending on
the problem area.
1. Problems with controllers (PVC and EC)

(Retrial “A”)
2. Problems with sensors (Retrial “B”)
OFF
RETRIAL “A” (For problems with the con-
troller (PVC and EC) )
1. Turn the Dr.EX OFF, with its harness still

connected to the diagnosing connector of the
PVC.
2. Turn the key switch OFF.

T105-07-01-001
3. After 10 seconds or more have passed, turn the OFF More than 10 sec.
key switch to the ON position or start the engine.
4. Disconnect the harness from the diagnosing ON

T107-07-06-005
connector.
T105-07-01-004
5. After one second or more has passed, reconnect
the harness to the diagnosing connector.
NOTE: If the harness of the Dr.EX is connected to

the diagnosing connector without an More than
interruption of at least one second, fault 1 sec.
codes may not be erased.
6. Check the fault code again, following the normal T105-07-01-002
method. If the fault code is displayed again, the

problem exists.
T105-07-01-001
T5-1-5
RETRIAL “B” (For problems with the sen-
sors)
1. Leave the key switch in the ON position. (The ON

engine may be stopped or may be running.)
T105-07-01-004
2. Disconnect the harness from the diagnosing

connector.
More than
1 sec.
T105-07-01-002
3. After one second or more has passed, reconnect
the harness to the diagnosing connector.
NOTE: If the harness of the Dr.EX is connected to

the diagnosing connector without an
interruption of at least one second, fault
codes may not be erased.
4. Then, check the fault code again, following the

normal method. If the fault code is displayed again, T105-07-01-001
the problem exists.
The fault code will be displayed with NO actual

problems existing in the following cases:
1. When a sensor connector was previously

disconnected with the key switch ON or the
engine running. (This may happen when replacing
a part.)
2. When the PVC or EC connector was previously

replaced or disconnected.
3. When the battery was removed, or when fuse No.

2 or No. 7 was previously replaced.
Be sure to perform Retrial “A” in order to erase the

fault codes in the above cases.
T5-1-6
FAULT CODE LIST
Applicable
Fault Code Description Cause
Retrial
01 EC Failure (1) A • EC Failure

02 EC Failure (2)
03 EC Failure (3)
05 Communication Failure between PVC B • EC/PVC Failure

and EC (Auto-Idle Control) • Harness Failure
06 EC Failure (6) B • EC Failure
07 ∗ Aux. Sensor 2 Failure: Short Circuit B • Harness Failure

08 ∗ Aux. Sensor 2 Failure: Harness Breakage • Aux. Sensor 2 Failure
09 EC Sensor Failure: Short Circuit B • Harness Failure

10 EC Sensor Failure: Harness Breakage • EC Sensor Failure
• EC Failure
11 Engine Control Dial Failure: Short Circuit B • Harness Failure
Engine Control Dial Failure: Harness • Engine Control Dial Failure
12 Breakage • EC Failure
13 N Sensor Failure B • EC Failure

• Harness Failure
• N Sensor Failure
14 Overheat Switch L, Oil Temperature B • EC Failure
Sensor Failure: Harness Breakage • Harness Failure
15 Overheat Switch L, Oil Temperature • Overheat Switch L Failure
Sensor Failure: Short Circuit • Oil Temperature Sensor Failure
17 PVC Failure (17) A • PVC Failure

18 PVC Failure (18)
PVC Failure (19)
19
20 Communication Failure between EC and B • PVC Failure

PVC (Speed Sensing Control) • EC Failure
• Harness Failure
∗ȀNo aux. sensors are used on the EX750-5.
T5-1-7
Applicable
Retrial
21 PVC Failure (21) B • PVC Failure

22 PVC Failure (22)
23 4-Spool Side Pump Control Failure B • PVC Failure

24 5-Spool Side Pump Control Failure • Harness Failure
• Failure of Pump 1 or 2
• Failure of 4 or 5-Spool Side Pump
Control Solenoid Valve
• A (Pump Displacement Angle) Sensor
Failure
25 4-Spool Side DP (Differential Pressure) B • PVC Failure
Sensor Failure: Short Circuit • Harness Failure
26 4-Spool Side DP (Differential Pressure) • DP Sensor Failure
Sensor Failure: Harness Breakage
27 4-Spool Side P (Pump Delivery Pressure) B • PVC Failure

28 4-Spool Side P (Pump Delivery Pressure) • P Sensor Failure
29 4-Spool Side A (Pump Displacement B • PVC Failure

Angle) Sensor Failure: Short Circuit • Harness Failure
30 4-Spool Side A (Pump Displacement • A Sensor Failure
Angle) Sensor Failure: Harness Breakage




∗ No aux. sensors are used on the EX750-5.
T5-1-8
MONITORING FUNCTION
Dr.EX functions to monitor command signals from the

controllers (PVC, EC) and input signals to these
controllers from various switches and sensors. (4) : 4-Spool Control Valve Side
(5) : 5-Spool Control Valve Side
Screen Designated Display

Data (Source and Type) Description
No. Key Unit and Form
F6 Pump Displacement (4) Input from 4-spool side A sensor cc/rev

2
F7 Pump Delivery Pressure (4) Input from 4-spool side P sensor kgf/cm
2
F8 Pump Control Pressure (4) Input from 4-spool side DP sensor kgf/cm
1
F9 Target Pump Torque (4) Command to control 4-spool side pump (kgf⋅m)
F10 Pump Torque (4) (Calculated) Calculated value kgf⋅m

(Pump displacement × Delivery pressure)
F6 Pump Displacement (5) Input from 5-spool side A sensor cc/rev
2
F7 Pump Delivery Pressure (5) Input from 5-spool side P sensor kgf/cm
2
F8 Pump Control Pressure (5) Input from 5-spool side DP sensor kgf/cm
2
F9 Target Pump Torque (5) Command to control 5-spool side pump (kgf⋅m)
F10 Pump Torque (5) (Calculated) Calculated value kgf⋅m

(Pump displacement × Delivery pressure)
F6 Output to shift the relief valve Command to solenoid valve (SA) (On)
F7 Output to shift the travel motor Command to solenoid valve (SB) (On)
displacement angle
3
F8 ∗ Swing brake output Command to solenoid valve (SC) (On)
F9 Swing/boom raise output Command to solenoid valve (On)
F10
F6 Signal current to control pump Command value to 4-spool side pump (A)
(4) control solenoid valve
F7 Target pump displacement (4) 4-spool side pump control command (cc/rev)
4
F8
F9
F10
F6 Signal current to control pump Command value to 5-spool side pump (A)
(5) control solenoid valve
F7 Target pump displacement (5) 5-spool side pump control command (cc/rev)
5
F8
F9
F10
∗ No solenoid valve (SC) is used on the EX750-5.
T5-1-9
Screen Designated Display

Data (Source and Type) Description
No. Key Unit and Form
F6 Travel Mode Switch Switch Position Lo, Hi
F7 Work Mode Selector Switch Switch Position G, T, L, P
F8 Work Mode Pressure Switch Switch Position Bm, Am, Ot, Sw,
6
Tr
F9 E Switch Switch Position (ON/OFF) On
F10 SP Switch Switch Position (ON/OFF) On
F6 EC angle Input from EC sensor V
F7 EC motor position Command value to control EC Motor ( digit )
F8 Engine speed Input from N sensor rpm

7
F9 Target engine speed Command value to control EC (%)
F10 Engine speed deviation Calculated value (Target engine speed - ( rpm )
Actual engine speed)
F6 Output to EC motor relay Command to control EC motor relay ( On )
F7 EC motor control command Command to control EC motor (Dn, St, Up)

output
8
F8
F9
F10
F6 Overheat switch L Switch position (ON/OFF) On
F7 Auto-idle switch Switch position(ON/OFF) On
9 F8 Output to Q/i indicator Q/i switch position (ON/OFF) On
F9 Q/i switch Switch position (ON/OFF) On
F10
F6 C/W Removal/Installation Switch position (ON/OFF) On

Device Switch
F7 Hydraulic oil temperature Input from T sensor °C

10
F8 Engine control dial angle Input from engine control dial V
F9∗ Aux. sensor 2 Input from aux. sensor 2. V
F10∗ Aux. sensor 3 Input from aux. sensor 3. V
∗ No aux. sensores are used on the EX750-5.
T5-1-10
TROUBLESHOOTING / Component Layout
MAIN COMPONENTS
3
2
4
5
6
7
8
35
9
10
11
12
13
14
15
16
34
33
32
31
30 17
29
28 18
27 19
26 20
25 21
24 23 22
M162-01-013
1- Bucket Cylinder 10 - Fuel Tank 19 - Pump Device 28 - Swing Bearing

2- Arm 11 - Control Valve 20 - Pilot Filter 29 - Hydraulic Oil Tank
3- Arm Cylinder 12 - Engine 21 - Reducing Valve 30 - Upper Roller
4- Boom 13 - Radiator 22 - Travel Device 31 - Pilot Shut-Off Valve
5- Boom Cylinder 14 - Oil Cooler 23 - Check Valve (Pilot) 32 - Track Adjuster
6- Front/Swing Pilot Valve 15 - Accumulator 24 - Solenoid Valve Unit 33 - Front Idler
(2 Solenoid Valves Used)
7 - Center Joint 16 - Counterweight 25 - Solenoid Valve (For Swing 34 - Travel Pilot Valve
Preference Circuit)
8 - Swing Device 17 - Muffler 26 - Preference Valve 35 - Bucket
9 - Battery 18 - Air Filter 27 - Lower Roller
T5-2-1
ELECTRICAL SYSTEM (1)
(Overall System)
3
4
5
6
7
8
9
36 10
11
12
13
14
37
15
16
35
34 17
33 18
32
31 19
30
29 20
28 21
22
27
26 24 23
25
T162-01-02-004
1 - Work Light 11 - Fuel Sensor 20 - Thermoguard Switch 29 - Hydraulic Oil Temperature

Sensor
2 - Monitor 12 - Fuel Level Switch 21 - Engine Oil Level Switch 30 - Solenoid Valve Unit
(2 Solenoid Valve Used)
3 - Horn 13 - Ether Solenoid Valve 22 - Engine Oil Pressure Switch 31 - Hydraulic Oil Level Switch
4 - Starter Relay 2 14 - DP Sensor (4-Spool Side) 23 - Starter 32 - Pressure Switch
(On Swing Shuttle Valve)
5 - Work Light 15 - Coolant Level Switch 24 - Air Filter Restriction Switch 33 - Pressure Switch
(on Right Side Frame) (On Shockless Valve For
Front Attachment)
6 - Starter Relay 1 16 - Coolant Sensor 25 - N (Engine Speed) 34 - Windshield Washer Motor
(For Monitor) Sensor
7 - Ether Relay 17 - Overheat Switch H 26 - EC Motor 35 - Pressure Switch
(On Travel Shuttle Valve)
8 - Battery Relay 18 - Overheat Switch L 27 - DP Sensor (5-Spool Side) 36 - Work Light (On Cab)
9 - Breaker 19 - Alternator 28 - Swing Preference Circuit 37 - ∗ Outside Temperature
Shift Solenoid Valve Sensor
10 - Battery
NOTE: Outside temperature sensor marked with ∗ EX750-5: Serial No. 005244 and above
is installed on the following machines: EX800H-5: Serial No. 005244 and above
T5-2-2
Relays 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
24
23
16 17
22 21 33 20 19 18 T162-01-02-002
Battery Area
25
26
27
28
32
29
30
31
T162-05-02-001
1 - Quick Idle Switch 10 - EC Motor Relay 18 - Blower Fast Position Relay 26 - Ether Relay
2 - Horn Relay 1 11 - Wiper Motor BM 19 - Blower Medium 27 - Starter Relay 1
Position Relay 2
3 - Load Dump Relay 12 - Work Light Relay 1 20 - Blower Medium 28 - Starter Relay 2
Position Relay 1
4- Horn Relay 2 13 - Work Light Relay 2 21 - Compressor Clutch Relay 29 - Fusible Link (45A)
5- Washer Relay 14 - Work Light Relay 3 22 - Blower Main Relay 30 - Fusible Link (75A)
6- Wiper Relay A 15 - Lubrication Relay 23 - Dr. EX Connector 31 - Breaker
7- Charge Relay 16 - EC 24 - Fuse Box 32 - Battery
8- Wiper Relay B1 17 - PVC 25 - Battery Relay 33 - ∗ Cab Interior Temperature
Sensor
9 - Wiper Relay B2
NOTE: Cab interior temperature sensor marked EX750-5: Serial No. 005244 and above
with ∗ is installed on the following ma- EX800H-5: Serial No. 005244 and above
chines:
T5-2-3
Monitor and Switch Panels Monitor Panel
10 11 12
1
40 13
14
2 15
39
38 16
37 17
18
36 19
35 20
34
21
3 33
22
32 23
9
31 24
8
30 25
7
6 26
27
29 28
4 M162-01-003
T166-01-02-017
1 - Monitor Panel 11 - Coolant Temperature 21 - Quick Idle Indicator 31 - Washer Switch
Gauge
2 - Switch Panel 12 - Fuel Gauge 22 - Trenching Mode Indicator 32 - Work Light Switch
3 - Cigar Lighter 13 - SP Mode Indicator 23 - Precision Mode Indicator 33 - Level Check Switch
4 - Option Switch 14 - E Mode Indicator 24 - Grading Mode Indicator 34 - Automatic Lubrication
Indicator (Optional)
5 - Automatic Air Conditioner 15 - Auto-Idle Indicator 25 - General Purpose Mode 35 - Overheat Switch
Control Panel Indicator
6 - Engine Control Dial 16 - Hydraulic Oil Level 26 - Work Mode Switch 36 - Engine Oil Pressure
Indicator Indicator
7 - E Mode Switch 17 - Coolant Level Indicator 27 - Buzzer Stop Switch 37 - Alternator Indicator
8 - SP Mode Switch 18 - Air Filter Restriction 28 - Travel Mode Switch 38 - Coolant Level Indicator
Indicator
9 - Key Switch 19 - Fuel Level Indicator 29 - Auto-Idle Switch 39 - Engine Oil Level Indicator
10 - Warm Up Complete 20 - Work Light Indicator 30 - Wiper Switch 40 - ∗ Solar Radiation Sensor
Indicator
NOTE: Solar radiation sensor marked with ∗ is in- EX750-5: Serial No. 005244 and above
stalled on the following machines: EX800H-5: Serial No. 005244 and above
T5-2-4
(Blank)
T5-2-5
CONTROL VALVE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
41
42
Swing Motor
40
Boom Cylinder
Arm Cylinder
39
38
16
Bucket Cylinder
17
18
19
20
37 21
36
22
35
34 23
33
Left Travel Motor
Right Travel Motor 32 31 30 29 28 27 26 25 24 T162-01-02-003
1 - Holding Valve Shift 12 - Load Check Valve 23 - DP Sensor (5-Spool Side) 33 - Main Relief Valve
Valve (Boom) (Arm 1 Tandem Circuit)
2 - Load Check Valve 13 - Holding Valve Shift Valve 24 - Pump Control Valve 34 - Load Check Valve (BH:
(Arm 2 Tandem Circuit) (Arm) (5-Spool Side) Bucket 1 Tandem Circuit,
LD: Bucket Open/Close
Tandem Circuit)
3 - Pump Control Valve 14 - Overload Relief Valve (Swing) 25 - Load Check Valve 35 - Check Valve (BH: Bucket 2
(4-Spool Side) (Left Travel Parallel Circuit) Parallel Circuit, LD: Bucket
Parallel Circuit)
4 - Load Check Valve 15 - Overload Relief Valve (Arm) 26 - Load Check Valve 36 - Load Check Valve
(Arm 2 Parallel Circuit) (BH: Bucket 2 Parallel Circuit, (Boom 1 Parallel Circuit)
LD: Bucket Parallel Circuit)
5 - Check Valve (Arm Flow 16 - Holding Check Valve (Arm) 27 - Check Valve (Bucket Flow 37 - Overload Relief Valve
Combining Circuit) Combining Circuit) (BH: Bucket, LD: Bucket
Open/Close)
6 - Check Valve (Bucket 17 - Make-Up Valve (Boom 2) 28 - Check Valve 38 - Overload Relief Valve
Flow Combining Circuit) (Main Relief Pressure Com- (Boom)
bining Circuit)
7 - Arm Regenerative Flow 18 - Load Check Valve 29 - Flow Combiner Valve 39 - Holding Check Valve
Control Valve (Boom 2 Tandem Circuit) (Boom)
8 - Check Valve 19 - Load Check Valve 30 - Check Valve (Travel Flow 40 - Make-Up Valve (Arm 2)
(Arm 1 Parallel Circuit) (Boom 2 Parallel Circuit) Combining Circuit)
9 - Load Check Valve 20 - Load Check Valve 31 - Check Valve 41 - DP Sensor (4-Spool side)
(Arm 1 Parallel Circuit) (BH: Bucket 2 Tandem Circuit (Main Relief Pressure Com-
LD: Bucket Tandem Circuit) bining Circuit)
10 - Load Check Valve 21 - Overload Relief Valve 32 - Shuttle Valve 42 - Center Bypass Valve
(Swing Tandem Circuit) (Bucket)
11 - Arm Regenerative 22 - Load Check Valve
Valve (Left Travel Tandem Circuit) (continued on next page)
T5-2-6
Swing
Arm 1
BH: Bucket 2 32 33 24 23
Boom 2
LD: Bucket
Arm 2
Left Travel
Boom 1
BH: Bucket 1
LD: Bucket
Open/Close
31
Right Travel
Front Side
30 29 T162-05-02-009
T162-05-02-012
43 28 44 37 47 35 48 21
Right Travel Left Travel BH: Bucket 1 BH: Bucket 2
LD: Bucket LD: Bucket
Open/Close
22
20
25 26
34
21
46 45 T162-05-02-004
37 50 6 27 49 T162-05-02-005
43 - Right Travel Forward Port 45 - Left Travel Reverse Port 47 - BH: Bucket 1 (Roll-Out) Port 49 - BH: Bucket 2 (Roll-In) Port
LD: Bucket Open/ LD: Bucket (Tilt-In) Port
Close(Open) Port
44 - Left Travel Forward Port 46 - Right Travel Reverse Port 48 - BH: Bucket 2 (Tank) Port 50 - BH: Bucket 1 (Roll-In) Port
LD: Bucket (Tilt-Out) Port LD: Bucket Open/
Close(Close) Port
NOTE: BH: Backhoe

LD: Loading Shovel
T5-2-7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
41
42
Swing Motor
40
Boom Cylinder
Arm Cylinder
39
38
16
Bucket Cylinder
17
18
19
20
37 21
36
22
35
34 23
33
Left Travel Motor
Right Travel Motor 32 31 30 29 28 27 26 25 24 T162-01-02-003
1 - Holding Valve Shift Valve 12 - Load Check Valve 23 - DP Sensor (5-Spool Side) 33 - Main Relief Valve
(Boom) (Arm 1 Tandem Circuit)
2 - Load Check Valve 13 - Holding Valve Shift 24 - Pump Control Valve 34 - Load Check Valve (BH:
(Arm 2 Tandem Circuit) Valve(Arm) (5-Spool Side) Bucket 1 Tandem Circuit,
LD: Bucket Open/Close
Tandem Circuit)
3 - Pump Control Valve 14 - Overload Relief Valve 25 - Load Check Valve 35 - Check Valve (BH: Bucket 2
(4-Spool Side) (Swing) (Left Travel Parallel Circuit) Parallel Circuit, LD: Bucket
Parallel Circuit)
4 - Load Check Valve 15 - Overload Relief Valve (Arm) 26 - Load Check Valve 36 - Load Check Valve
(Arm 2 Parallel Circuit) (BH: Bucket 2 Parallel Circuit (Boom 1 Parallel Circuit)
LD: Bucket Parallel Circuit)
5 - Check Valve (Arm Flow 16 - Holding Check Valve (Arm) 27 - Check Valve(Bucket Flow 37 - Overload Relief Valve
Combining Circuit) Combining Circuit) (BH: Bucket, LD: Bucket
Open/Close)
6 - Check Valve (Bucket 17 - Make-Up Valve (Boom 2) 28 - Check Valve 38 - Overload Relief Valve
Flow Combining Circuit) (Main Relief Pressure Com- (Boom)
bining Circuit)
7 - Arm Regenerative Flow 18 - Load Check Valve 29 - Flow Combiner Valve 39 - Holding Check Valve
Control Valve (Boom 2 Tandem Circuit) (Boom)
8 - Check Valve 19 - Load Check Valve 30 - Check Valve (Travel Flow 40 - Make-Up Valve (Arm 2)
(Arm 1 Parallel Circuit) (Boom 2 Parallel Circuit) Combining Circuit)
9 - Load Check Valve 20 - Load Check Valve 31 - Check Valve 41 - DP Sensor (4-Spool side)
(Arm 1 Parallel Circuit) (BH: Bucket 2 Tandem Circuit (Main Relief Pressure Com-
LD: Bucket Tandem Circuit) bining Circuit)
10 - Load Check Valve 21 - Overload Relief Valve 32 - Shuttle Valve 42 - Center Bypass Valve
(Swing Tandem Circuit) (Bucket)
11 - Arm Regenerative Valve 22 - Load Check Valve
(Left Travel Tandem Circuit) (continued on next page)
T5-2-8
55 5 56
51 52
Boom 1 Boom 2 Arm 2 Arm 1

7
16 13
17
38 40
8
36 18
12
2
1
19 9
4
15
39 54 53 T162-05-02-006
38 58 57 T162-05-02-007
41 3 59
Swing
14
15
42 10
14
40 60 T162-05-02-008 T162-05-02-010
51 - Boom 1 (Lower) Port 54 - Boom 1 (Raise) Port 57 - BH: Arm 1 (Roll-In) Port 59 - Swing (Left) Port
LD: Arm 1 (Extend) Port
52 - Boom 2 (Lower) Port 55 - BH: Arm 2 (Roll-Out) Port 58 - BH: Arm 2 (Roll-In) Port 60 - Swing (Right) Port
LD: Arm 2 (Retract) Port LD: Arm 2 (Extend) Port
53 - Boom 2 (Raise) Port 56 - BH: Arm 1 (Roll-Out) Port
LD: Arm 1 (Retract) Port
NOTE: BH: Backhoe

LD: Loading Shovel
T5-2-9
OTHERS
Pump Device
4
5
3
2
9 7
8
T162-03-01-001
Valve Front Solenoid Valve Unit (2 Solenoid Valve Used)

10 11
Left Right
Rear
12 13 14 15 18
19
16 17
20
21
T162-05-02-002
T162-04-04-005
1 - Main Pump 2 7 - P (Pressure) Sensor 12 - Pressure Switch 17 - Pressure Switch

(Main Pump 1) (Boom Raise) (Others)
2 - Pump Control Proportional 8 - P (Pressure) Sensor 13 - Shockless Valve 18 - Shockless Valve
Solenoid Valve (Main Pump 2) (Main Pump 2) (Front Attachment) (Travel)
3 - Main Pump 1 9 - A (Pump Displacement Angle) 14 - Pressure Switch 19 - Travel Mode Shift
Sensor (Main Pump 2) (Arm Roll-In) Solenoid Valve
4 - Pilot Pump 10 - Travel Shuttle Valve 15 - Pressure Switch 20 - Main Relief Pressure
(Swing) Shift Solenoid Valve
5 - A (Pump Displacement Angle) 11 - Pressure Switch (Travel) 16 - Swing Shuttle Valve 21 - Pilot Relief Valve
Sensor (Main Pump 1)
6 - Pump Control Proportional
Solenoid Valve (Main Pump 1)
T5-2-10
Swing Device Travel Device
1 1
4
2
1
3
T142-01-02-012
T162-04-04-006
1 - Swing Relief Valve 2 - Swing Parking Brake Re- 3 - Counterbalance Valve 4 - Travel Relief Valve
lease Valve
T5-2-11
(Blank)
T5-2-12
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Use troubleshooting A procedure when fault codes are

shown on Dr.EX.
• How to Read the Troubleshooting Flow Charts
YES (OK)
(2) • After checking or measuring item (1), select either
YES (OK) or NO (NOT OK) and proceed to item
О (1) (2) or (3), as appropriate.
(3)
NO (NOT OK)
О • 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.
О • Explanation of how to use lamp harness kit required. Refer to “Harness Check”
Group (Group 7) in this section.
О • Use Dr. EX function.
• Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
О
causes can be seen without going through the flow chart.
NOTE: For all connector drawings illustrated in this

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

Harness End Connector
T158-05-03-001
T5-3-1
FAULT CODE LIST
Applicable
Retrial

02 EC Failure (2)
03 EC Failure (3)
05 Communication Failure between PVC B • EC/PVC Failure

and EC (Auto-Idle Control) • Harness Failure
06 EC Failure (6) B • EC Failure

09 EC Sensor Failure: Short Circuit B • Harness Failure

10 EC Sensor Failure: Harness Breakage • EC Sensor Failure
• EC Failure
11 Engine Control Dial Failure: Short Circuit B • Harness Failure

12 Engine Control Dial Failure: Harness • Engine Control Dial Failure
Breakage • EC Failure
13 N Sensor Failure B • EC Failure

• Harness Failure
• N Sensor Failure
14 Overheat Switch L, Oil Temperature B • EC Failure

Sensor Failure: Harness Breakage • Harness Failure
Overheat Switch L, Oil Temperature • Overheat Switch L Failure
15
Sensor Failure: Short Circuit • Oil Temperature Sensor Failure
17 PVC Failure (17) A • PVC Failure

18 PVC Failure (18)
19 PVC Failure (19)
20 Communication Failure between EC and B • PVC Failure

PVC (Speed Sensing Control) • EC Failure
• Harness Failure
T5-3-2
Applicable
Retrial
21 PVC Failure (21) B • PVC Failure

22 PVC Failure (22)
23 4-Spool Side Pump Control Failure B • PVC Failure

24 5-Spool Side Pump Control Failure • Harness Failure
• Failure of Pump 1 or 2
• Failure of 4 or 5-Spool Side Pump
Control Solenoid Valve
• A (Pump Displacement Angle)
Sensor Failure

Sensor Failure: Short Circuit
• Harness Failure
26 4-Spool Side DP (Differential Pressure)
Sensor Failure: Harness Breakage • DP Sensor Failure






T5-3-3
FAULT CODES 01, 02, 03, 04, 06
(EC Failure)
• Be sure to inspect wiring connections prior to ∗ However, the machine can be used without replacing
troubleshooting. the EC if the machine functions normally despite the
• Replace the EC if the machine shows any abnor- fact that the fault code(s) are indicated after
malities and if fault code(s) are still indicated after performing applicable “Retrial.”
performing applicable “Retrial.”
Fault Codes 01, 02, and 03
YES
Normal
Check if fault codes dis-

appear after Retrial A. YES
∗ EC failure
Turn auto-idle switch
·Perform Retrial A a few ON and OFF. Check if
times if fault codes do not engine speed changes
disappear after one trial. NO when auto-idle switch is
operated. Replace EC.
NO
Fault Code 04
YES
Normal
Check if fault codes dis-

appear after Retrial A. NO
∗ EC failure
·Perform Retrial A a few Check if the number of
times if fault code does not fault codes indicated is
disappear after one trial. NO 8 or more.
Replace EC.
YES
Fault Code 06
YES
Normal
Check if fault code dis-

appears after Retrial B. YES
∗ EC failure
·Perform Retrial B a few Check if engine speed
times if fault code does changes with engine
not disappear after one NO control dial.
trial. Replace EC.
NO
T5-3-4
FAULT CODE 05
(Communication Failure between PVC and
EC)
• Be sure to inspect wiring connections prior to ∗ However, the machine can be used without replacing
troubleshooting. the EC or PVC if the machine functions normally
• The PVC, EC, or the harness between the PVC despite the fact that the fault code is still indicated
and EC may have failed if the auto-idle does not after Retrial B.
function normally and if fault code 05 is still
indicated after Retrial B.
YES
Normal
Check if fault YES

∗ PVC or EC fail-
code disappears
after Retrial B.
·Perform Retrial B a
few times if fault
code does not dis-
appear after one
trial. Check if auto-idle Disconnect harness end connectors
NO functions normally. from PVC and EC.
Check if continuity exists between YES Replace PVC and
terminals stated below: EC.
PVC harness end connector termi-
nal No. 4 and EC harness end con-
nector terminal No. 9
NO nal No. 5 and EC harness end con-
nector terminal No. 3
PVC harness end connector termi- Failure of harness
nal No. 11 and EC harness end between PVC
connector terminal No. 2 NO and EC.
nal No. 12 and EC harness end
connector terminal No. 10
·Key Switch: OFF
Harness End Connector (Open End Side)
PVC EC
5 4 3 2
12 11 10 9
T5-3-5
FAULT CODES 09, 10
(EC Sensor Failure)
• Be sure to inspect wiring connections prior to

troubleshooting.
• Fault code 09 indicates the input voltage from the
EC sensor is 4.75 V or more.
Ȁ Fault code 10 indicates the input voltage from the
EC sensor is 0.25 V or less.
YES
Normal
NO
Check if breakage or EC failure
short circuit exists in
YES the line between EC
connector terminal
Check if fault code
No. 34 and EC sen-
disappears after Harness failure
Disconnect EC sensor connector termi-
Retrial B. between EC and
sor connector. nal No.2.
YES EC sensor.
·Perform Retrial B a Check if voltage be-
few times if fault Disconnect EC sensor YES tween harness end ·Fault code 09:
code does not dis- connector. Check if re- connector terminals Check for short circuit.
appear after one sistance between EC No. 1 and No. 3 is Fault code 10:
trial. side connector terminals 5±0.5 V. Check for breakage.
No. 1 and No. 3 is Harness failure
1.7±0.4 kΩ. ·Key Switch: ON between EC and
NO
NO Connect test harness EC sensor.
(ST7129) to EC sensor.
Check if voltage varies
as specified when en-
gine control dial is oper- EC sensor failure
ated. NO
·Specified voltage:
Refer to T5-3-17. EC Harness End Connector (Open End Side)
21
35 34
EC Sensor Side Connector (Open End Side) Harness End Connector

(Open End Side)
EC Sensor
3 2 1
(Red)
Ω
(Black)
1 2 3
ST 7129
V
EC 21 34 35
T162-05-03-005
T107-07-03-009
T107-07-03-008
T5-3-6
FAULT CODES 11, 12
(Engine Control Dial Failure)

troubleshooting.
YES
Normal
NO
Harness failure
Check if breakage or between EC and
short circuit exists in engine control dial.
the line between EC
YES
connector terminal
Check if fault code No. 23 and engine
disappears after Disconnect engine con- Disconnect engine control dial connec-
Retrial B. trol dial connector. control dial connector terminal No.2. EC failure
Check if resistance be- tor. Check if voltage YES
·Perform Retrial B a tween engine dial side YES between harness
few times if fault connector terminals No. end connector ter-
code does not dis- 5 and No. 7 is 5.0±0.5 minals No. 5 and No.
appear after one kΩ. 7 is 5±0.5V.
trial. Reconnect engine con-
trol dial connector. Insert ·Key Switch: ON Harness failure
test probes from the between EC and
NO back of engine control NO engine control dial.
dial connector: (-) probe
on terminal No. 7 and
(+) probe on terminal Engine control dial
No. 5. Check if voltage failure
varies as specified when NO
engine control dial is
operated.
·Specified voltage: 0.3 to
0.85 V with engine control
dial at slow idle EC Harness Side Connector (Open End Side)
4.15 to 4.7 V with engine con-
trol dial at fast idle
23 21
35
Engine Control Dial Side Connector

Engine Control Engine Control Dial
(Open End Side)
Dial Side (Harness Side) Harness End Connector
(Open End Side)
Ω
5 6 7 V
7 6 5
7 6 5 EC 35 23 21
T162-05-03-007 T162-05-03-008
T162-05-03-006
T5-3-7
FAULT CODE 13 (N Sensor Failure)
• Be sure to inspect wiring connections prior to • Check the engine speed using the Dr. EX
troubleshooting. monitoring function. If breakage exists in the
• Be sure to inspect N sensor installation condition. harness between the N sensor and EC, EC
-1
judges that the engine speed is 0 min (rpm), in
other words, that the engine is not running. For
this reason, no fault code will be displayed in the
case of a wire breakage between the N sensor
and EC.
YES
Normal
Disconnect connectors
from the N sensor and YES
Check if fault code EC. Connect N sensor EC failure
disappears after Re- harness end connector
trial B. YES terminals No. 1 and No.
2 using a clip. Check if
·Perform Retrial B a few continuity exists be-
times if fault code does Disconnect N sensor
tween EC harness end
not disappear after one connector. Check if Harness failure between
connector terminals No.
trial. resistance between N
4 and No. 11. NO EC and N sensor
NO sensor side connector
terminals No. 1 and
No. 2 is 810±240 Ω.
N sensor failure
NO
N Sensor Installation:
1) While looking at the ring gear teeth through the
sensor installation hole, center a tooth in the hole. N Sensor
2) Screw the sensor in until the sensor comes in Harness End Connector
(Open End Side)
contact with the ring gear tooth.
Don’t use any tools tighten the sensor at this time. 1 2
3) Turn the sensor back 2 full turns plus approxi-
mately a quarter turn from contacting the ring gear
teeth. (The gap between the sensor and ring gear
should be 3.1 mm (0.12 in). The thread pitch is
1.5 mm. (0.06 in))
4) While holding the sensor, tighten the lock nut.
(Tightening torque: 24.5 to 34 N⋅m (2.5 to 3.5
kgf⋅m, 18 to 25.5 lbf⋅ft)) 4
11
EC
Harness End Connector Ω
(Open End Side)
N Sensor
Lock Nut
T162-05-03-009
3.1 mm (0.12 in)
Ring Gear T166-05-03-001
T5-3-8
FAULT CODES 14, 15
(Overheat Switch L Failure, Hydraulic Oil
Temperature Sensor Failure)
• Be sure to inspect wiring connections prior to However, fault code 15 will also be indicated when
troubleshooting. the coolant temperature exceeds 98 °C (208 °F)
• Fault code 14 indicates that the input voltage from or when the hydraulic oil temperature exceeds
the sensor is 4.75 V or more. In this case, harness 120 °C (248 °F). In this case, no electrical
breakage between the EC and the overheat components have failed.
switch L / the hydraulic oil temperature sensor
may be the cause. In addition, Dr.EX indicates -45
°C (-49 °F).
Ȁ Fault code 15 indicates that the input voltage from
the sensor is 0.25 V or less. In this case, short
circuit between the EC and the overheat switch L /
the hydraulic oil temperature sensor may be the
cause. In addition, Dr.EX indicates 120 °C (248
°F).
Connect hydraulic oil tem- YES
perature sensor harness EC failure
end connector terminals
No. 1 and No. 2 using a
YES clip. Harness breakage be-
Disconnect 48P connector Ground 48P harness end
connector terminals No. YES tween EC and hydraulic
from the EC. Check if con- oil temperature sensor
Disconnect hydrau- tinuity exists between 48P 33 to vehicle frame. terminal No. 2.
lic oil temperature harness end connector Check if continuity exists
sensor connector. terminals No. 33 and No. between hydraulic oil
Check if resistance 35. NO temperature sensor har-
at hydraulic oil tem- Harness breakage be-
ness end connector ter-
perature sensor side tween EC and hydraulic
minal No. 1 and vehicle
connector is within frame. NO oil temperature sensor
standard value terminal No. 1.
range.
·Standard Value: Hydraulic oil temperature
Refer to the table NO sensor failure
below.
Hydraulic Oil Temperature Sensor Overheat Switch L

Hydraulic Oil Resistance Coolant Temperature
Switch Operation
Temperature °C (°F) kΩ °C (°F)
-20 (-4) 16.2±1.6 96 to 100 (205 to 212) ON
0 (32) (5.88) 89 to 100 (192 to 212) OFF
20 (68) 2.45±0.24
40 (104) (1.14)
60 (140) (0.534)
80 (176) 0.322

Hydraulic Oil Temperature
EC (48P) Sensor
1 2
35 33
T5-3-9
FAULT CODES 17, 18, 19, 21, 22
(PVC Failure)

troubleshooting.
• Replace the PVC if the machine shows any
abnormalities and if fault code(s) are still indicated
after performing applicable “Retrial.”
∗ However, the machine can be used without replacing

the PVC if the machine functions normally despite
the fact that the fault code(s) are indicated after
performing applicable “Retrial.”
Fault Codes 17, 18, 19

YES
Normal
Check if fault codes

disappear after Retrial NO
A. ∗ PVC failure
·Perform Retrial A a few Check if engine
times if fault codes do stalls or if operating
not disappear after one NO speed is abnormal.
trial. Replace PVC.
YES
Fault Codes 21, 22
YES
Normal
Check if fault codes

disappear after Retrial
B.
·Perform Retrial B a few
times if fault codes do Replace PVC.
NO
not disappear after one
trial.
T5-3-10
FAULT CODE 20
(Communication Failure between PVC and
EC)

troubleshooting.
• If the fault code still appears after Retrial B, check
the harness between the PVC and EC.
∗ Since it is practically impossible to determine whether

the PVC or EC has failed, replace both if a failure
occurs in the PVC/EC.
YES
Normal
Check if fault code

disappears after Re- OK
trial B. ∗ Failure of PVC/EC
·Perform Retrial B a few Check the harness
times if fault code does between PVC and
not disappear after one NO EC.
trial. ·Refer to page T5-3-5. Harness failure be-
NOT OK tween PVC and EC
T5-3-11
FAULT CODES 23, 24
(Pump Control Failure)
• Be sure to inspect wiring connections prior to One of the following may be the cause:
troubleshooting. 1. Pump control solenoid valve failure.
• Fault codes 23 and 24 are indicated when the 2. “A” sensor failure
target pump displacement does not match with 3. PVC failure
the actual pump displacement. If any other codes are also indicated, troubleshoot
those codes first.

PVC
37 3 106
10 114
Pump Control Solenoid Valve OK

Check har- 1
ness between
1 2 NOT OK fuse No. 8
and PVC ter-
minal No. 37.
Troubleshoot
using indi- YES Check fuse ·Be sure to re- 2
YES cated fault NOT OK
No. 8. place failed fuse
codes (other (No. 8) after the
Check if any than 23 and OK
cause is found. 3
NO fault codes 24).
other than 23
and 24 are OK
4
indicated. Check if fault NOT OK
code 23 is OK
NO indicated. 5
YES Check fuse

Check if fault No. 8.
codes disap- Check if fault
pear after Re- code 24 is 6
trial B. NO indicated. NOT OK
·Perform Retrial Normal

NO
B a few times if YES
fault codes do Normal.
not disappear
after one trial. Check if ma- A sensor fail-
Disconnect one A
chine and en- YES ure or loose
sensor. Check if ma-
or incorrect
YES gine operate chine and engine op-
normally. connection of
erate normally. Re-
A sensor.
connect A sensor and
check if machine and
NO
engine operate nor-
Failure of
mally. Repeat the
PVC or
same procedure for
NO pump.
the other A sensor.
·If machine and engine
operate normally when
one of A sensors is dis-
connected, the discon-
nected A sensor has
failed.
T5-3-12
NOTE: (4) : 4-Spool Control Valve Side OK Failure of PVC or

(5) : 5-Spool Control Valve Side pump (4).
Check swing/
OK boom circuit
Check resistance be- shift solenoid Failure of the line
Check if continuity exists between tween pump control between PVC
YES valve line.
pump control solenoid valve (4) har- solenoid valve (4) con- terminal No. 112
ness end connector terminals No. 1 nector terminals No. 1 NOT OK and swing/boom
and No. 2. and No. 2. Pump control circuit shift sole-
Connect PVC side harness end NOT OK valve solenoid noid valve.
1 connector terminal No. 3 (No. 10) to ·Standard Value: valve (4) failure.
vehicle frame using a clip. Check if 14±3 Ω at 20 °C (68 °F)
continuity exists between pump con-
trol solenoid valve (4) harness end Harness failure be-
connector terminal No. 1 (No. 2) and tween pump control
vehicle frame. NO
solenoid valve (4) and
PVC.
Harness failure between fuse No. 8
2
and PVC terminal No. 37. OK
Check resistance be- Failure of PVC or
Check if continuity exists between tween pump control pump (4).
YES
pump control solenoid valve (4) har- solenoid valve (4) con-
ness end connector terminals No. 1 nector terminals No. 1 Pump control
and No. 2. and No. 2. valve solenoid
Connect PVC side harness end NOT OK valve (4) failure.
·Standard Value:
connector terminal No. 3 (No. 10) to 14±3 Ω at 20 °C (68 °F)
3 vehicle frame using a clip. Check if
continuity exists between pump con- Harness failure be-
trol solenoid valve (4) harness end tween pump control
connector terminal No. 1 (No. 2) and solenoid valve (4)
NO
vehicle frame. and PVC.
4 Harness failure between fuse No. 8

OK Failure of PVC or
and PVC terminal No. 37. Check resistance pump (5).
between pump con-
Check if continuity exists between YES trol solenoid valve (5)
pump control solenoid valve (5) har- connector terminals
ness end connector terminals No. 1 No. 1 and No. 2.
and No. 2. Pump control
Connect PVC side harness end valve solenoid
OK NOT OK
connector terminal No. 114 (No. valve (5) failure.
·Standard Value:
106) to vehicle frame using a clip. 14±3 Ω at 20 °C (68 °F)
Check if continuity exists between
pump control solenoid valve (5) har- Harness failure be-
5 ness end connector terminal No. 1 tween pump control
(No. 2) and vehicle frame. solenoid valve (5)
NO
and PVC.
NOT OK and PVC terminal No. 37.
Check resistance OK Failure of PVC or
between pump con- pump (5).
trol solenoid valve (5)
Check if continuity exists between YES
connector terminals
pump control solenoid valve (5)
No. 1 and No. 2.
harness end connector terminals
Pump control
No. 1 and No. 2.
valve solenoid
OK Connect PVC side harness end ·Standard Value: NOT OK
valve (5) failure.
connector terminal No. 114 (No. 14±3 Ω at 20 °C (68 °F)
106) to vehicle frame using a clip.
Check har-
Check if continuity exists between Harness failure be-
ness between
pump control solenoid valve (5) tween pump control
fuse No. 8 and
6 harness end connector terminal No. solenoid valve (5)
PVC terminal NO
1 (No. 2) and vehicle frame. and PVC.
No. 37.

NOT OK and PVC terminal No. 37.
T5-3-13
FAULT CODES 25, 26, 33, 34
(DP Sensor Failure)

troubleshooting.
• Fault codes 25 and 33 indicate the input from the
DP sensor is 4.75 V or more. Short circuit
between the DP sensor and PVC may be the
Check harness lines NO
cause. PVC failure
Ȁ Fault codes 26 and 34 indicate the input from the between PVC con-
DP sensor is 0.25 V or less. Harness breakage YES nector terminal No.
44 (No. 32) and DP
between the DP sensor and PVC may be the sensor terminal No. Harness failure be-
cause. 2 for harness break- tween PVC and DP
age (short circuit). sensor terminal
YES No.1.
Disconnect DP sen-
sor connector. Check ·Fault Codes 25 and 33:
YES if voltage between Check for short circuit.
harness end connec- Fault Codes 26 and 34:
tor terminals No. 1 Check for harness Harness failure be-
and No. 3 is 5±0.5 V. breakage. tween PVC and DP
NO
sensor terminal
·Key Switch: ON Check if voltage
No.1.
Attach test harness between the DP
(ST 7129) between sensor harness end
DP sensor and har- NO connector terminal Harness failure be-
NO No.1 and vehicle
ness end. Check if tween PVC and DP
indicated voltage is frame is 5±0.5 V.
0.4 +0.15 YES sensor terminal
-0.1 No.3.
·Key Switch: ON
Check if fault ·Fault Codes 25 and
code disap- 26: 4-spool side DP DP sensor failure, or
pears after Re- sensor harness breakage
trial B. Fault Codes 33 and between PVC and
NO
34: 5-spool side DP DP.
·Perform Retrial sensor
B a few times if
fault codes do Normal
not disappear YES
after one trial.
PVC
(5-Spool Side)
32
Black 44
Red
(4-Spool Side)
ST 7129
DP Sensor
V 1 2 3
T162-05-03-004
T5-3-14
FAULT CODES 27, 28, 35, 36
(P Sensor Failure)

troubleshooting.
P sensor is 4.75 V or more. Short circuit between
the P sensor and PVC may be the cause.
Ȁ Fault codes 28 and 36 indicate the input from the
P sensor is 0.25 V or less. Harness breakage
between the P sensor and PVC may be the
cause.
Check harness lines NO

between the PVC PVC failure
connector terminal
YES No. 42 (No. 31) and
P sensor terminal
No. 2 for harness
breakage (short cir- Harness failure be-
Disconnect P sensor tween PVC and P
connector. Check if cuit). YES sensor.
NO voltage between har-
ness end connector
Switch pump 1 side terminals No. 1 and
P sensor with pump No. 3 is 5±0.5 V.
NO 2 side P sensor. Harness failure be-
·Key Switch: ON
Check if indicated tween PVC and P
fault code changes NO
sensor.
to the one for the
other P sensor.
·Fault Codes 27 and P sensor failure
Check if fault YES
code disap- 28: Fault codes for
pears after Re- pump 2 side P sensor
trial B. Fault Codes 35 and
36: Fault codes for
·Perform Retrial pump 1 side P sensor
B a few times if
fault codes do
not disappear Normal
after one trial. YES
PVC P Sensor
(5-Spool Side)
31
1 2 3
42
(4-Spool Side)
T5-3-15
FAULT CODES 29, 30, 37, 38
(A Sensor Failure)

troubleshooting.
A sensor is 4.75 V or more. Short circuit between
the A sensor and PVC may be the cause.
Ȁ Fault codes 30 and 38 indicate the input from the
A sensor is 0.25 V or less. Harness breakage
between the A sensor and PVC may be the
cause.
Check the harness NO Failure of PVC or A

lines between PVC sensor
connector terminal
YES No. 30 (No. 22) and ·Refer to T5-4-41
Disconnect the A A sensor terminal
sensor connector. No. 2 for harness
Check if voltage be- Harness failure be-
breakage (short
NO tween the harness tween PVC and A
circuit). YES
end connector ter- sensor.
minals No. 1 and No.
3 is 5±0.5 V. Harness failure be-
tween PVC and A
·Key Switch: ON NO sensor.
Check if fault code ·Fault Codes 29 and 30:
disappears after Fault codes for pump 2
Retrial B. side A sensor
Fault Codes 37 and 38:
·Perform Retrial B a Fault codes for pump 1
few times if fault side A sensor
codes do not disap-
pear after one trial.
Normal
YES
PVC A Sensor
(5-Spool Side)
22
1 2 3
30
(4-Spool Side)
T5-3-16
SENSOR OPERATING RANGE LIST
SP Mode
1. Measurement Preconditions Switch E Mode
Switch
• Hydraulic Oil Temperature: 50±5 °C (122±9 °F)

• Unless otherwise instructed, set the switches as
follows: Fast
Slow
E Mode
Engine Switch/ Work Mode Auto-Idle
Control Dial SP Mode Switch Switch
Switch
General
Fast Idle
ON Purpose OFF
(Max.)
Mode Engine Control M142-01-047
• Monitor using the Dr.EX. Dial
2. Sensor Operating Range
Item Required Control/Switch Operation Specified Range
Engine Control Slow Idle (Minimum Speed) 0.3 to 1.0 V

Dial Fast Idle (Maximum Speed) 4.0 to 4.7 V
Engine Control Dial at Slow Idle 2.5 to 2.7 V
EC Sensor
Engine Control Dial at Fast Idle 3.9 to 4.3 V
Pump Delivery Control Levers: Neutral 25 kgf/cm2

+15
ҥ7
Pressure Sensor Boom Raise: Full Stroke, Relieved 350 +5

ҥ0 kgf/cm2
Control Levers: Neutral 58 to 68 cc/rev.
A Sensor One Track Jacked-Up,
278 cc/rev.
Travel Lever(Raise Track Side): Full Stroke
Control Levers: Neutral 27 kgf/cm2
Pump Control
Pressure Sensor One Track Jacked-Up, 0 kgf/cm2
Travel Lever(Raise Track Side): Full Stroke
NOTE: 1 kgf/cm2=0.09807 MPa
T5-3-17
(Blank)
T5-3-18
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault code Start the troubleshooting with more probable causes
is displayed on the Dr.EX although the machine’s selected by referring to these tables.
operation is abnormal.
On the front section pages of this group T5-4, are
tables indicating the correlation between part failure
and abnormalities that the machine may show.
• How to Read the Troubleshoting Flow Charts
YES (OK)
(2) • After checking or measuring item (1), select either YES (OK) or
NO (NOT OK) and proceed to item (2) or (3), as appropriate.
О (1)
(3)
NO (NOT OK)
ѕʝKey Switch: ON may damage components as well.
О • Explanation of how to use lamp harness kit required. Refer to “Harness Check”
Group (Group 7) in this section.
О
• Use Dr. EX function.
О • Causes are stated in a thick-line box. Scanning through thick-line boxes, possible

Wire Harness Side
Open End Side

T158-05-03-001
T5-4-1
CORRELATION BETWEEN PART FAILURE
AND ABNORMALITIES THAT MACHINE
MAY SHOW
The table below shows abnormalities that the machine

may show and the effects in the control system if the
listed parts have failed. Also, troubleshooting
procedures are shown to find out if the listed parts
have failed in case the indicated abnormalities are
found.
Part Pump and Valve Controller Engine Controller Differential Pressure Sensor
(PVC) (EC) (DP Sensor)
Designated Function x Controls main hydraulic x Controls engine speed. x Senses differential
pump and main control pressure for pump
valve. displacement angle control.
Effects in Control System x Loss of pump and/or valve x Loss of engine speed x Loss of main pump
control. (Loss of pump control. displacement angle control.
control has resulted more
often than loss of valve
control.)
Abnormalities that the x Slow actuator speed. x Loss of engine speed x Correct metering may not
machine may show. (Pump fixed to the control. be obtained.
minimum displacement x Abnormal sound is heard
angle.) from the control valve with
x Engine may stall. (Pump control levers in neutral.
fixed to the maximum x Excessively high oil and
displacement angle.) coolant temperature.
x Actuator speed may vary
unstably. (Displacement
angle varies unstably.)
Dr.EX Self- x Dr.EX may display ”Can not x Dr.EX displays fault code x Dr.EX displays fault code
Diagnosing communicate with PVC” or 01, 02, 03, 04, 05, or 06. 25, 26, 33 or 34
Function one or more of the following
fault codes may be
displayed: 17, 18, 19, 20,
21, and 22.
Dr.EX Monitor
Function
− − −
Trouble-
shooting
Procedures Test Harness
− − −
Check
Other
− − −
Note x Check fuse No. 8 (for PVC) x Check fuse No. 2 (for EC)
output side for wire output side for wire
breakage. breakage. −
x Be sure that the bolt on the x Be sure that the bolt on the
PVC connector is tight. PVC connector is tight.
T5-4-2
Engine Speed Sensor Pump Displacement Pressure Sensor Engine Control Sensor
(N Sensor) Angle Sensor (P Sensor) (EC Sensor)
x Senses engine (pump) x Senses main hydraulic x Senses main hydraulic x Senses governor lever
speed. pump displacement angle. pump delivery pressure. position.
x Loss of speed sensing and x Loss of pump control. x Loss of horsepower control. x Loss of governor lever
pump control. (This maximum speed position
happens when engine learning control.
speed signal is not sent to
the EC due to harness
breakage, etc.)
x Slow actuator speed. x Machine mistracks. (It may x Actuator maximum speed x Engine speed cannot be
be noticed when traveling will decrease. controlled from slow idle to
straight.) x Engine may stall. fast idle with engine speed
x Engine overload or control dial. (Engine can be
decrease in speed may started.)
result. x EC motor moves beyond
the control range.
x Dr. EX displays fault code x Dr. EX displays fault code x Dr. EX displays fault code x Dr. EX displays fault code
13 when engine speed is 23, 24 ,29, 30, 37, or 38. 27, 28, 35 or 36. 09 or 10.
not within specification. No
fault code is displayed if
circuit between N sensor
and EC is open.
x Monitor engine speed. x Monitor and compare the x Monitor pump delivery
pump displacement target pressure. If P sensor
2 −
angle and the pump harness is open, 0 kgf/cm
displacement angle. will be indicated.)
− − − −
− − − −
− − − −
T5-4-3
Part Overheat Switch L,

Pump Control Solenoid Swing Preference Circuit Shift
Hydraulic Oil Temperature
Valve Solenoid Valve
Sensor (T Sensor)
Designated Function x Senses hydraulic oil and x Shifts the pump x Turns on/off the pilot
coolant temperatures. displacement angle. pressure to shift (turn
on/off) the swing preference
circuit.
x Loss of overheat prevention x Loss of pump control. x Loss of swing preference
Effects in Control System
control. circuit shifting (turning
x Loss of auto warm-up on/off) control.
function.
Abnormalities that the x Slow actuator speed may x Pump flow rate becomes x Priority is given to swing in
machine may show. result if sensor signal line is minimum if the harness has swing/boom raise
short-circuited. an open circuit. combined operation.
x Auto warm-up function is x In the trenching mode,
not operating. priority is not given to swing
in swing/boom raise
combined operation.
Dr.EX Self- x Dr.EX displays fault code x Dr.EX displays fault code
Diagnosing 14. 23 or 24. −
Function
Dr.EX Monitor x Check signals from the
Function swing and boom raise
pressure switches and from
− −
the work mode switch for
any abnormalities.
Test Harness
− − −
Check
Trouble-
shooting Other
Procedures
− − −
Note − − −
T5-4-4
Travel Mode Shift Solenoid Main Relief Pressure Shift

EC Motor Engine Control Dial
Valve Solenoid Valve
x Shifts travel motor x Temporarily raises the main x Operates governor lever. x Controls engine speed.
displacement angle. relief pressure.
x Travel motor displacement x Main relief pressure cannot x Governor lever does not x Engine speed does not
angle is fixed to the be raised. move. change with engine control
maximum (slow speed). dial.
x Travel speed mode does x Travel steering power x When turning engine x Engine speed stays at
-1
not shift to the fast speed decreases. control dial, engine speed around 1000 min with no
mode with the travel mode x Main relief pressure cannot stays at slow idle. load applied.
switch. be raised even in the
precision work mode.
x Dr.EX displays fault code 11

− − − or 12.
x Operate and return the x Monitor the input signal for

travel lever, and confirm engine control dial angle. (If
that the travel code on Dr. it is 1.0 to 4.0 V, engine
− −
EX goes to the reverse control dial is normal.)
video and returns to the
normal display.
− − − −
x The solenoid valve function x EC motor is considered

is considered normal if the normal if governor lever
main relief pressure moves when key switch is
temporarily rises when a turned to ON position.
− front function is relieved −
while the travel levers are
slightly operated to a
degree that the machine
stays immovable.
x Note that the engine speed
does not rise when the
− − −
quick idle switch is turned
ON.
T5-4-5
CORRELATION BETWEEN TROUBLES
AND PART FAILURES
Engine Control Press. Sw.
Eng. EC EC EC Ther- Start. Start. Press. Press. Press.
Cont. Motor Sensor Motor mo. Aid Aid Sw. Sw. Sw.
Dial Relay Sw. Sol. Sw/ (Travel) (Swing) (Boom
Valve Relay Raise)
E-1 Starter does not rotate.
E-2 Starter rotates but engine

does not start.
E-3 Starting aid system does not
{ { {
operate.
E-4 Quick-Idle does not function.
{ { {
E-5 Auto-Idle does not function
{ { { { { {
E-6 Engine stalls with engine
control dial turned to fast idle
position.
With engine control dial
{
turned to fast idle position
and auto-idle switch turned
ON, engine sometimes stalls
while operating.
E-7 Engine speed does not
change with engine control { { {
dial.
Pump Cont. Valve Cont. Electrical Parts

Pump P DP A Swing Prefe- Hyd. Work SP E
Cont. Sensor Sensor Sensor Pref. rence Temp. Mode Mode Mode
Prop. Cir. Valve Sensor Sw. Sw. Sw.
Sol. Shift /Over-
Valve Sol. heat
Valve Sw.
A-1 All cylinders and motors
{ { { { { {
move slowly or do not move
A-2 Cylinders and motors, which
are hydraulically connected to
{ { { { {
one particular main pump,
move slowly or do not move.
A-3 Cylinders and motors do not
stop moving with control lev-
ers returned to neutral.
A-4 Boom is slow in swing/boom
{ {
raise combined operation.
A-5 SP mode cannot be activated
{
with SP mode switch.
A-6 E mode cannot be activated
{
with E mode switch.
A-7 Cylinder or motor respon-
{ {
siveness is slow.
NOTE: The above table shows the correlation the same time, find out the faulty parts causing the
between machine operation trouble and trouble by checking all suspected parts in each
related parts which may cause trouble. symptom.
However, the correlations in this table are
described based on the condition
supposing that each trouble occurs
independently. If any other trouble occur at
T5-4-6
Electrical Parts Engine

Press. Press. Quick Key Fuel Bat- Starter Starter Moni- EC Eng. Gov- Fuel Gauze EC
Sw. Sw. Idle Sw. Sol. tery Relay tor/ Unit ernor Filter Filter Motor
(Arm (Others) Sw. Valve Relay Auto- Link
Roll-In) Idle
Sw.
{ { { {
{ { { { { {
{ { { {
{ { { {
{ { { { { {
{ {
Pump Cont. Valve Others

PVC Pump Servo Pilot Main Main Shock- Pilot Pilot Pilot
Unit Piston Pump Spool Relief less Shut- Valve Relief
Valve Valve Off Valve
Valve
{ { { { { { {
{ { {
{ {
{ { { {
T5-4-7
Press.
Pump Control Valve Cont. Sw. Electrical Parts Pump
P DP A Swing Travel Press. Moni- PVC Pump Main
Sensor Sensor Sensor Pref. Mode Sw. tor/ Unit Spool
Cir. Shift (Travel) Auto-
Shift Sol. Idle
Sol. Valve Sw.
Valve
F-1 Front attachment cylinder(s)
{ {
move slowly or do not move.
F-2 Bucket drops excessively.
{
F-3 In the beginning of front at-
tachment operation, bucket {
drops slightly.
S-1 Upperstructure does not ro-
tate, rotates slowly, or swing { { {
power is weak.
S-2 Upperstructure coasts exces-
sively when stopping swing
{
operation or when machine is
parked on a slope.
T-1 Both tracks move slowly.
{ {
T-2 Travel mode does not shift.
{ { { {
T-3 Machine mistracks.
{ { { { { { {
Pump Control Valve Cont. Pressure Switch Electrical Parts

P DP A Swing Main Press. Press. Press. Work Monitor
Sensor Sensor Sensor Pref. Relief Sw. Sw. Sw. Mode /Auto-
Cir. Press. (Swing) (Boom (Arm Sw. Idle
Shift Shift. Raise) Roll-In) Sw.
Sol. Sol.
Valve Valve
O-1 Work mode does not shift.
{ { { { { { {
O-2 Pump emits abnormal sound
{ { { {
or vibration.
O-3 Wiper does not operate or
does 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 trouble occurs
independently. If any other trouble occur at
the same time, find out the faulty parts
causing the trouble by checking all
suspected parts in each symptom.
T5-4-8
Control Valve Others

Main Over- Load Hold- Swing Travel Center Shut- Shock Pilot Pilot Cyl-
Relief load Check ing Device Device Joint tle -less Shut- Valve inder
Valve Relief Valve Valve Valve Valve Off
Valve Valve
{ { { { { {
{ { {
{ { {
{ { { { {
{ {
{ {
{ { { {
Pump
Wiper PVC Pump
Sw. Unit
T5-4-9
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter does not rotate.

troubleshooting. YES
• Measure each voltage by referring to the table
below.
• Electronic control system, i.e. EC, etc., is not
related with the fact that the starter does not
rotate Voltage at terminal B is
0 V in both key switch
positions: ON and
Check if voltage values at START.
starter and starter relay
YES terminals shown in the ѕʝKey switch: ON↔START
table are as specified, key
switch in ON and START
positions.
Unit: V
Key Switch
ON START
Check if Terminals Voltage at starter relay
battery voltage 1 terminal No. 1 is not
and electrolyte B 24 24 24 V with key switch in
specific gravity NO
START position.
are normal. S 0 24
ѕʝKey switch: START
Voltage: Starter Relay 1 (1) 0 24
24 V or more
Specific gravity:
1.26 or larger
Voltage values at
starter relay 1 terminal
No. 1, at terminal B and
at terminal S are not 24
V with key switch in
START position.
NO (Battery also has failed if voltage at terminal B is

less than 18 V with key switch in START position.)
• Starter Terminal Voltage Check Starter Relay 1

1. Turn the key switch to the ON or START position.
2
2. Connect the negative probe of a circuit tester to S
1
the vehicle frame (unpainted surface such as a
bolt head). Connect the positive probe to starter B
terminals B and S and to starter relay 1 terminal
No. 1. Measure voltage at each terminal.
T162-05-06-004
T5-4-10
Starter Failure.
YES Harness failure between

battery relay and starter.
Check if a click sound
is heard from the
battery relay when key Check if battery relay
switch is turned OFF functions.
NO
from ON position.
ѕʝKey switch: ON↔START
NO Harness failure between

fusible link and key switch.
Terminal No. 1: 0 V Check if fusible

link (45A) has
blown.
Measure voltage
at key switch ѕʝVisual check Blown fusible link.
terminals No. 1 YES
Terminal No. 1: 24 V
and No. 6.
Terminal No. 6: 0 V
ѕʝKey switch: START Key switch failure.
Terminal No. 1: 24 V Harness failure between

Terminal No. 6: 24 V key switch terminal No. 6
and starter relay 1 terminal
No. 2.
Starter relay 1 failure.
Battery failure.
• Key Switch Voltage Check

1. Remove the key switch from the console.
2. Turn the key switch to the ON position.
3. With the key switch connected to the harness, ST G1 ACC

V
measure voltage at terminals No. 1 and No. 6.
(Insert the probe from the back of the connector.) View A
B G2 M
T105-07-04-002
T5-4-11
E-2 Starter rotates but engine does not start.

troubleshooting.
• Check the governor lever position while cranking
the engine. If the governor lever position is normal,
the engine unit or fuel system may have failed.
YES
Engine Unit Failure.
Check if fuel solenoid ѕʝRefer to the engine shop
valve operates (if manual.
operating sound is
heard from fuel Harness breakage between
NO
solenoid valve). fuel solenoid valve and fuse
ѕʝKey switch: OFF↔ON No. 5.
Disconnect the
harness end from fuel
NO solenoid valve. Check
if harness end voltage
is 24 V. Fuel solenoid valve failure.
YES
ѕʝKey Switch: ON ѕʝRefer to the engine shop
manual.
T5-4-12
(Blank)
T5-4-13
E-3 Starting aid system does not operate. (Ether
bottle is an optional item.)

troubleshooting.
YES Thermoguard switch

failure
Disconnect
white/black wire
connector from Harness failure
YES between thermoguard
YES thermoguard switch.
Ground harness end switch and starting
connector terminal Re-connect the aide solenoid valve.
and check if the connector.
starting aid system Disconnect
operates. white/black wire plug
ѕʝKey switch: START from starting aid
NO solenoid valve.
Ground solenoid
Check if ether bottle valve side plug and Re-connect the plug.
is securely installed. check if the starting Disconnect
aid system operates. brown/white wire end
ѕʝConfirm that ether from starting aid
bottle is not empty. ѕʝKey switch: START solenoid valve.
NO
Measure voltage at the
disconnected harness
end.
Insecure ether bottle

NO installation.
T5-4-14
24 V
Starting aid solenoid
valve failure.
YES Starting aid switch

failure.
Re-connect the
disconnected wire.
Disconnect the Harness breakage
starting aid switch 0V between fuse box and
connector. Connect starting aid relay, or
0V the connector blown starting aid
terminals with a clip Re-connect the fuse.
and check if starting disconnected wire.
aid system operates. Disconnect starting aid
relay connector. Check
ѕʝKey switch: START voltage at white wire
NO connector terminal. Harness breakage
Re-connect the 0V between starting aid
ѕʝKey switch: START disconnected wire. relay and starting aid
Disconnect switch.
yellow/blue
connector from
24 V starting aid relay.
Check voltage at
harness end Starting aid relay
connector terminal. failure or harness
breakage between
24 V starting aid solenoid
valve and starting aid
relay.
NOTE: Be sure to also

check ground line.
T5-4-15
E-4 Quick idle does not function.
• EC motor and EC sensor are functioning normally.

troubleshooting.
• If any of trouble E-1 to E-3 has occurred, trouble-
Connector
shoot them first.
(Harness end connector terminals seen from the
open end side)
EC (48P)
32 31
NO
Quick idle switch failure.
Monitor quick idle switch.
Check if indication of “On”
is displayed or deleted on
Dr.EX screen when NO Harness breakage between
Disconnect 48 P connector
switching Quick idle on off. from EC. Check if EC and quick idle switch.
continuity exists between
ѕʝMonitor item No.9-F9 YES the 48 P harness end
connector terminals No. 31
EC failure.
and No. 32. YES
ѕʝQuick idle switch: ON
E-5 Auto-idle does not function.
• EC motor and EC sensor are functioning normally. NOTE: ∗ In the case of loading shovel specification,
• Be sure to inspect wiring connections prior to the operation is arm extend.
troubleshooting.
• If E-1 to E-4 has occurred, troubleshoot them first.
• Refer to “Auto-Idle Control” in the Control System
Group, the SYSTEM section, the Operation
Principle book.
• If the auto-idle function has failed after EC had Pressure switch (travel,
been replaced, increase the engine speed to the swing, boom raise, ∗arm
maximum (fast idle) speed. NO roll-in, and/or others) failure.
Harness failure between
PVC and pressure switches.
Restriction of filter in pilot
Monitor pressure switches signal circuit.
(travel, swing, boom raise,
∗arm roll-in, and others). Note: Pressure switch location:
YES Check if letters “Tr”, “Sw”, Pressure switch (travel): Travel shuttle valve
“Bm”, “Am”, and ”Ot” Pressure switch (swing): Swing shuttle valve
appear on the Dr.EX Pressure switch (boom raise): Shockless valve
screen when each Pressure switch (∗arm roll-in): Shockless valve
Monitor auto-idle switch. respective control lever is Pressure switch (others): Swing shuttle valve
Check if indication of “On” operated.
is displayed or deleted on EC failure.
Dr.EX screen when ѕʝMonitor Item No.6 YES
switching Quick idle on off. ѕʝAfter replacing EC, refer to
page T5-4-39.
ѕʝMonitor item No.9-F7 Auto-idle switch failure, or
harness breakage between
NO auto-idle switch and EC.
T5-4-16
E-6 Engine stalls with engine control dial turned
to fast idle position.
With engine control dial turned to fast idle
position and auto-idle switch turned ON,
engine sometimes stalls while operating.
Engine speed is slow in general.
Slow idle speed is excessively slow or fast.
Related Fault Codes: 09, 10
• Be sure to inspect wiring connections prior to Moreover, because the fast idle position may vary
troubleshooting. depending on the governor lever position when
• If the EC sensor has failed, the governor lever fast the key switch is turned to the ON position, the
idle position learning will not be performed when trouble may not appear constantly.
the key switch is turned to the ON position. (The
slow idle position learning will be performed.) For
this reason, the fast idle is set referring to the
previously performed fast idle position learning or
the preset fast idle.
YES
EC sensor failure.
ѕʝRefer to page T5-4-39.

YES
End
Check if fault
code 09 or 10
is indicated. Check if governor
lever comes into YES Failure of engine unit
contact with and fuel system.
Restart engine. stopper when the
Check if the YES key switch is
NO trouble turned to the ON
disappears. position (when the Control cable failure.
Turn engine slow idle position Incorrect engine
learning is
control dial and
performed). NO governor lever
monitor EC adjustment.
angle. Check if T li it f il
ѕʝRefer to page T5-4-38
NO EC angle for engine speed
changes as
adjustment.
engine speed
changes.
EC failure, harness
ѕʝMonitor items No.7-F6 failure between EC
No.7-F9 NO motor and EC, or
blown fuse No. 2 or
No. 3.
T5-4-17
E-7 Engine speed does not change with engine
control dial.
Related Fault Codes: 11, 12

troubleshooting.
Engine control dial

YES failure, or harness
breakage between
engine control dial and
EC.
Check if fault code 11

or 12 is indicated. YES
EC motor failure.
Connect test harness
(ST7125) to EC motor. ѕʝAfter replacing EC motor,
Turn engine control dial refer to page T5-4-39.
NO and check if test harness
lamp comes on. EC failure, or harness
breakage between EC
NO and EC motor.
ѕʝAfter replacing EC, refer
to page T5-4-39.
T5-4-18
TOTAL ACTUATOR SYSTEM
TROUBLESHOOTING
A-1 All cylinders and motors move slowly or do
not move.

troubleshooting.
• Pilot system (pilot pump, pilot relief valve, pilot
shut-off valve), relief valve circuit, work mode
switch circuit, or overheat switch L / hydraulic oil
temperature sensor circuit may have failed.
NO Move pilot control

shut-off lever to
UNLOCK position.
Check if pilot
control shut-off NO Work mode switch
lever is in failure.
UNLOCK
position.
NO
Check if work End
mode can be Remove,
YES shifted. NO disassemble,
clean, and
ѕʝKey switch: ON reassemble pilot
relief valve. Pilot pump failure.
ѕʝMonitor Item No.6-F7 YES
Check if trouble
Check if primary
still exists.
pilot pressure is
YES normal. NO Main relief valve
failure.
ѕʝEngine speed: Fast
Check
Check ifif main
main
and slow idle
relief
relief pressure
pressure is
is
ѕʝRefer to Operational Check if
normal.
Performance Test YES normal. indication of
section for pressure “On” for
measurement ѕʝM onitor Items No.1-F7 A
No.2-F7 YES overheat switch
procedure. L is displayed or
ѕʝRefer to Operational
Performance Test deleted on
section for pressure Dr.EX screen.
measurement
procedure. ѕʝKey switch: ON
ѕʝMonitor item No.9-F6
Check if coolant YES Overheat of coolant

temperature exceeds and/or hydraulic oil.
98 °C (208 °F) or if
A hydraulic oil
temperature exceeds Check overheat switch
120 °C (248 °F). L / hydraulic oil
NO temperature sensor
circuit.
T5-4-19
A-2 Cylinders and motors, which are
hydraulically connected to one particular
main pump, move slowly or do not move.
• Be sure to inspect wiring connections prior to • Any actuator speeds feel slow when the main
troubleshooting. pump delivery flow rate is insufficient.
• Switching part(s) in 4-spool control valve side with While referring to the actuator-pump relationships
those in 5-spool side, it can be judged that table and the operational performance standard
switched part(s) have failed if the trouble appears table described on page T4-5-1 and operating
on the other side. each actuator separately, find out which pump has
• Pump control sensors (DP sensor, A sensor), failed.
pump control solenoid valve circuit, or main pump
have failed.
2
NOTE: 1 kgf/cm = 98.07 kPa
NO
DP sensor failure.
Monitor DP sensor
NO pressure again with
engine stopped. Is it
4 kgf/cm2 or less?
DP sensor circuit
ѕʝKey switch: ON YES harness failure.
Operate one control
lever and monitor the ѕʝMonitor items No.1-F8
corresponding DP No.2-F8 YES
sensor pressure. Is it DP sensor failure.
2
4 kgf/cm or less?
Switch DP sensors
ѕʝEngine: Running
with each other.
ѕʝMonitor items No.1-F8 YES Insecure or incorrect A
No.2-F8 YES Check if slower side sensor installation, or A
becomes normal. sensor failure
Remove A sensor.
Check if slower side ѕʝRefer to T5-4-41.
NO becomes normal.
NO
T5-4-20
Actuator-Pump Relationships
Main Pump 1 Main Pump 2

Arm Roll-In ∗ ӝ ӝ
Arm Roll-Out ∗∗ ӝ ӝ
Boom Raise ӝ ӝ
Boom Lower ӝ
BH: Bucket Roll-Out ӝ
BH: Bucket Roll-In ӝ ӝ
LD: Bucket Tilt-Out ӝ
LD: Bucket Tilt-In ӝ ӝ
Travel Lt. (Fwd) ӝ
Travel Lt. (Rev) ӝ
Travel Rt. (Fwd) ӝ
Travel Rt. (Rev) ӝ
Swing Right ӝ
Swing Left ӝ
Bucket Open ӝ
Bucket Close ӝ
NOTE: ∗ In the case of loading shovel

specification, the operation is arm
extend.
∗∗ In the case of loading shovel
specification, the operation is arm
retract.
BH: Backhoe
LD: Loading Shovel
Check if target pump

flow rate is the minimum Insecure A sensor
YES installation or the
value with control levers
in neutral. corresponding main
Also, check if target pump failure.
pump flow rate is the
maximum when one
travel lever is operated Pump control solenoid
full stroke while the valve circuit failure
NO
corresponding track is
jacked up.
ѕʝControl levers in neutral:

Minimum value 48±10 L/rev.
Travel lever full stroke:
Maximum value 183±10 L/rev.
ѕʝMonitor Items No.4-F7
No.5-F7
T5-4-21
A-3 Cylinders and motors do not stop moving
when control levers are returned to neutral.
• Sticking of spools in pilot valve and/or control

valve may be the cause.
YES
Pilot valve failure.
·Pilot pressure has been
falsely routed to the control
Pull up pilot control shut- valve.
off lever and check if
cylinders and motors
stop moving.
Control valve failure.

NO
·Although pilot pressure was
not routed to the control
valve, control valve spool(s)
were open due to sticking.
A-4 Boom is slow in swing/boom raise combined

operation.

troubleshooting.
• If operations other than swing/boom raise are
normal, the swing preference circuit may have
failed.
2
NO Swing preference circuit shift

solenoid valve failure
Check if boom speed
(Sticking or seizure).
changes in swing/boom Swing preference circuit
raise combined shift control pressure
operation when general (MA pressure) is more
2
purpose mode and than 35 kgf/cm .
trenching mode are
selected.
·Refer to Operational Preference valve failure
Performance Test YES (Sticking or seizure).
section for pressure
measurement
procedure.
T5-4-22
A-5 SP mode cannot be activated with SP mode
switch.
(Other controls are normal.)

troubleshooting.
• If SP mode is the only one that does not function,
related switches or controller may have failed.
• Refer to “SP Mode Control” in the Control System
Principle book.
SP mode switch failure, or

NO harness breakage between
SP mode switch and PVC.
Monitor SP mode switch.

Operate SP switch and
check if indication of “SP”
is displayed or deleted on
the Dr.EX screen.
·Monitor item No.6-F10 PVC failure.

YES
A-6 E mode cannot be activated with E mode

switch.

troubleshooting.
• Refer to “E Mode Control” in the Control System
Principle book.
E mode switch failure, or
NO harness breakage between
E mode switch and PVC.
Monitor E mode switch.

Operate E switch and
check if indication of “E” is
displayed or deleted on
the Dr.EX screen.
·Monitor item No.6-F9

PVC failure.
YES
T5-4-23
A-7 Cylinder or motor
responsiveness is slow.
More than 1 second. Pump servo piston

mechanism failure.
While monitoring pump

displacement angle value, More than 1
operate corresponding second. Pilot system failure
control lever and measure (Excessive drop in pilot
time lag between lever pressure, pilot valve
operation and change in failure, etc.)
Operate the slow
displacement angle value. responding lever and
measure time lag
·Monitor items No.1-F6
between lever operation
No.2-F6
Less than and the moment the
1 second. corresponding pressure
switch letters pop up on
the Dr.EX screen.
·Monitor Item No.6-F8 Control valve failure.
Less than 1
second.
T5-4-24
FRONT ATTACHMENT SYSTEM
TROUBLESHOOTING
F-1 Front attachment cylinder(s) move slowly or
do not move.

troubleshooting.
• The corresponding pilot valve, overload relief
valve, or pressure switches may have failed.
• If only boom raise in swing/boom raise combined
operation is slow, go to troubleshooting A-4.
NO Corresponding
Check if Dr.EX pressure switch circuit
detects signal from failure.
pilot pressure switch
by displaying “Tr”,
“Sw”, etc... when
NO
corresponding Pilot valve failure.
control lever is
operated.
Check if
corresponding
·Engine: Running YES secondary pilot NO Corresponding
·Control lever: Full pressure is normal. overload relief valve
stroke Check if
·Refer to Operational
·Monitor item No.6-F8 corresponding
Performance Test
Boom raise section for pressure YES overload relief
Arm roll-in pressure is normal.
measurement
Swing Control valve failure
procedure. ·Refer to Operational
Travel YES (sticking, etc.)
Performance Test
Others
section for pressure
measurement
procedure.
T5-4-25
F-2 Bucket drops excessively.
YES
Normal.
Damaged control
NO valve spool, broken
spring, or loose
Check if spool end.
Remove holding YES excessive
Check if cylinders check valve and cylinder internal
for drift quantity. holding check valve leakage exists.
Are drift values shift valve from Cylinder sealing
within the control valve.
YES Disassemble, clean, YES failure.
specifications?
reassemble, and
·Refer to reinstall them. Check
Operational if bucket still drops Failure of holding
Performance excessively. NO check valve or
Test section for Replace the overload holding valve shift
cylinder drift relief valve(s) for ·If holding valve shift valve is sticking: valve.
measurement cylinder(s) which Arm Cylinder: Roll-out: Operable (Backhoe)
procedure. shown excessive drift, Roll-in: Inoperable (Backhoe)
with one(s) from other Retract: Operable (Loading Shovel)
NO function(s). Check if Extend: Inoperable (Loading Shovel)
excessive cylinder Boom Cylinder: Raise: Operable
drift is still observed. Lower: Inoperable
·If holding check valve has failed, responsiveness of both
the arm and boom becomes slow.
Overload relief valve

NO failure.
F-3 In the beginning of front attachment opera-

tion (boom raise or arm roll-out), bucket
drops slightly.
NO Damaged control valve

spool, broken spring, or
loose spool end.
YES Check if excessive
cylinder internal
leakage is found.
Check if load check Cylinder sealing failure.

valve located in control YES
valve is normal.
·Disassemble and
visually check.
Load check valve
NO failure.
T5-4-26
• 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.

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

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

the hoses were disconnected and the boom
cylinder is retracted, internal leakage in the boom
cylinder exists.
If no oil flows out of the pipes from which the
hoses were disconnected but the the boom
cylinder is retracted, internal leakage in the control
valve exists.
NOTE: 1. During the initial stage of operation, oil

pressure and flow rate from the pump is (B)
low. Therefore, if the load check valve is
malfunctioning, the oil in the bottom side When the load check
valve is malfunctioning:
of the boom cylinder flows back into the
circuit through the load check valve, (A)
causing the boom cylinder to
temporarily retract.
2. If the clearance between the piston and

the cylinder barrel is poor, oil pressure
in the bottom side (A) leaks to rod side
(B). As oil pressure and flow rate from
the pump is low during the initial stage
of operation, and if the amount of oil T105-07-04-012
leaking through the gap between the

piston and the barrel is large, the
cylinder is temporarily retracted. In
addition, cylinder force is reduced. In
this case, the cylinder drift is also
increased.
T5-4-27
SWING SYSTEM TROUBLESHOOTING
S-1 Upperstructure does not rotate, rotates
slowly, or swing power is weak.

troubleshooting.
• If other functions (front attachment and travel)
operate normally, the pilot pump is considered to
be normal. If the pilot system has failed, the
trouble exists in the pilot circuit after the pilot
pump (the pilot valve and thereafter).
YES Check if swing relief

pressure is normal.
·Refer to Operational
Performance Test
Check if oil quantity section for swing
YES draining from swing relief pressure
motor is normal. measurement
procedure.
Monitor DP sensor
pressure. Operate ·Refer to Operational
control lever slowly to Performance Test
YES section for swing
the stroke end and Swing motor failure.
check if DP sensor motor draining oil
quantity NO
pressure changes
smoothly. measurement
procedure.
·Monitor item No.2-F8 Control valve spool
Check if secondary NO sticking.
pilot pressure is
normal.
NO
·Refer to Operational Pilot valve failure.
Performance Test
Disassemble,
section for secondary
clean, and
pilot pressure
reassemble the
measurement
NO pilot valve. Check if
procedure.
the trouble still
exists. Check if sticking or
seizure exists in
YES swing shuttle valve.
T5-4-28
2
NO Swing reduction
gear failure.
Check if sticking or
YES seizure exists in
swing motor
parking brake
release valve. Swing motor parking
brake release valve
YES failure.
NO Corresponding
swing relief valve
Switch swing motor failure.
relief valve with the
other swing relief
NO valve. Check if the
trouble still exists. Failure of swing
overload relief valve
YES located in control
valve.
YES Swing shuttle valve

failure.
Swing preference
NO circuit shift solenoid
valve failure (sticking
Check if swing or seizure).
preference circuit
shift control
NO pressure (MA
pressure) is more
2
than 35 kgf/cm . Preference valve
failure (sticking or
·Refer to Operational YES seizure).
Performance Test
section for MA
pressure
measurement
procedure.
T5-4-29
S-2 Upperstructure coasts excessively when
stopping swing operation or when machine
is parked on a slope.
• If upperstructure jerks when coasting, valve

related failure is suspected. If it coasts smoothly
(but excessively), spool related failure is
suspected.
YES Swing motor parking

Check if sticking brake release valve
YES or seizure exists failure.
in swing motor
Monitor DP sensor
parking brake
pressure. Operate
release valve.
control lever slowly Swing motor failure.
YES NO
to the stroke end
and check if DP
Check if swing
sensor pressure
secondary pilot
changes smoothly.
YES pressure is 0 Swing spool failure.
2
kgf/cm with NO
swing lever in
neutral.
·Refer to Pilot valve failure.
Operational NO
Check if swing Performance Test
relief pressure section for swing
is normal. secondary pilot
·Refer to pressure
Operational measurement
Performance Test procedure. Failure of overload
section for swing relief valve in control
relief pressure NO valve, or swing relief
measurement valve failure.
procedure.
T5-4-30
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Both tracks move slowly.
• It is unlikely that both sides (left and right) of the Note, however, that the front attachment operation
pilot valves, travel motors, or travel control valve will also have difficulty if the primary pilot pressure
spools fail simultaneously. If both tracks are slow, is abnormal. (Refer to troubleshooting A-1.)
the pilot system which is commonly used for left
and right travel motors may have failed.
2
NO Restriction of filter
located at outlet of pilot
shut-off valve.
Check if pilot
valve inlet
pressure is
NO Travel pilot valve
normal.
failure.
·Engine: Running Check if
·In SP mode: more secondary travel
than 40 kgf/cm2 YES pilot pressure is
normal.
Go to Troubleshooting
·Engine: Running A-1.
·In SP mode: more YES
than 35 kgf/cm2
T-2 Travel mode does not shift.
• The switch circuit may have failed if the travel

mode indicator does not shift in accordance to the
travel mode switch operation. If the indicator shifts
but actual travel mode (speed) does not shift, the 2
travel motor displacement angle shift circuit may
have failed.
Switch failure, or
NO harness breakage
between switch and
PVC.
Check if monitor
indicates Hi and NO
Lo alternately PVC failure.
when travel
mode switch is Check if travel Travel mode shift
operated. mode shift solenoid valve failure,
solenoid valve NO or harness failure
·Key switch: On YES shifts as travel between PVC and
mode switch is travel mode shift
operated. Check if travel solenoid valve.
mode shift
YES pressure (SB) YES Travel motor
is normal. Check if sticking displacement angle
·SP Mode or seizure exists shift valve failure.
·Auto-idle: OFF in travel motor
YES Failure of travel motor
·Refer to Operational displacement
Performance Test angle shift valve. or travel reduction gear.
NO
section for SB pressure
measurement procedure.
T5-4-31
T-3 Machine mistracks.

troubleshooting.
• Mistrack is caused by the failure of pump control
system. Refer to troubleshooting A-2 if swing or
bucket function is slow in addition.
• The flow combiner valve may have failed if
machine mistracks only during front attachment
function combined operations.
Disassemble, clean, NO
Shuttle valve failure.
NO and reassemble
travel shuttle valve.
Check if the trouble
still exists. Pilot valve failure.
YES
Check if secondary
travel pilot pressure is NO
Operate left and right DP sensor failure.
normal.
travel levers the same
·SP Mode distance and check if
·Travel lever: full stroke pump target YES
·Refer to Operational Switch the P sensor P sensor failure.
YES displacement angle
Performance Test on 5-spool side is the on 5-spool side with
section for travel same as that on 4- that on 4-spool side. Switch the left and right
secondary pilot pressure spool side. YES Check if machine travel hoses with each
measurement mistracks in the other at the upper side
procedure. ·Monitor items No.4-F7 opposite direction. of center joint. Check if
No.5-F7 NO
machine mistracks to
the opposite direction.
Relation between Faulty Seal Position

and Mistrack Direction Seal Location
Seal
Traveling Pivot Turn 1
NO.
1 External oil leakage ← 2
Right Travel
(Reverse)
2
Left Travel 3
(Forward)
3
Left Travel Right Travel
(Reverse) (Forward)
4 4
5
7 6
5
T142-06-04-017
7 External oil leakage ←
T5-4-32
Disassemble, NO Control valve spool

clean, sticking.
reassemble
YES corresponding
spool in control Control valve failure
valve. Check if (internal leak), A
the trouble still sensor failure, or
exists. YES
main pump failure.
Switch the right and left YES Travel relief valve

travel relief valves with failure.
NO each other. Check if
machine mistracks in the
Check if slower- opposite direction. Center joint failure.
side travel relief NO
pressure is NO
NO normal. Check if Travel motor failure.
quantity of oil
·Refer to Operational draining from YES
travel motor is Travel brake valve
Performance Test Disassemble failure.
YES normal. travel motor
section for travel relief
pressure ·Refer to Operational brake valve and
Remove travel YES Travel motor tilt
measurement Performance Test YES check if any motor tilt pistons
procedure. section for travel abnormalities piston failure.
are found. and check if any
motor drain oil
NO abnormalities Travel reduction gear
quantity are found.
measurement NO failure.
procedure.
Travel Hose Connections
1
2
3 4
6
1 - Left Travel Reverse 4 - Right Travel Forward
2 - Left Travel Forward 5 - Pilot Hose
(Travel Mode Shift)
5 3 - Right Travel Reverse 6 - Drain Hose
M162-07-071
T5-4-33
TROUBLESHOOTING FOR OTHER
FUNCTIONS
O-1 Work mode does not shift.

troubleshooting.
• The work mode switch may have failed if the work
mode indicators do not shift with the work mode
selector. The pressure switch or solenoid valve
may have failed if the work mode indicators shift
but actual work mode does not shift.
Disconnect the harness

end from swing preference
circuit shift solenoid valve, YES
solenoid valve, and main Solenoid valve
relief pressure shift failure.
YES solenoid valve one by one.
Monitor pressure Connect test harness (ST
switches (travel, swing, 7123) between each Harness breakage
boom raise, arm roll-in, solenoid valve and harness between solenoid
and others). end, and check if harness NO valve and PVC.
Check if letters “Tr”, lamp comes on.
YES “Sw”, “Am”, and “Ot”
come up on the Dr.EX
screen. when the
respective control lever Disconnect the harness YES Pressure switch
is operated. end from each pressure failure.
Check if work mode switch one by one. Connect
letters turn into test harness (ST 7123)
reverse video when ·Monitor item No.6-F8 NO between each pressure
switch and harness end, Harness breakage
work mode select
and check if harness lamp between PVC and
switch is operated. NO
comes on. pressure switch.
Work mode switch

NO failure.
(Reference)
Work Mode Designed Application
General Purpose Mode Designed for general digging and truck loading.
Arm is slow. In arm/bucket and arm/boom combined operations, bucket and boom also
Grading Mode
become slow.
Precision Mode All front functions are slow for easy load lifting work.
Trenching Mode Swing is given priority in swing/boom raise combined operation.
T5-4-34
O-2 Pump emits abnormal sound or vibration.

troubleshooting.
YES
Main pump failure.
YES
Main pump failure
Check if
indicated pump
displacement Check if indicated
angle value YES pump differential NO DP sensor or P
stays stable. pressure and pump
Replace the sensor failure.
pressure values
stay stable. sensor which
·Monitor Items obtained
No.1-F6 ·Monitor items unstable values
No.2-F6 No.1-F7, F8 NO and check if the
Check if A sen- No.2-F7, F8 trouble still
sor is installed exists.
NO securely. Main pump failure.
·Replace DP YES
sensor and/or P
sensor.
Insecure A sensor
NO installation.
·Refer to T5-4-41.
T5-4-35
O-3 Wiper does not operate or does not retract.

troubleshooting.
• Wiper is operated by battery power via the relay
circuit. The relay circuit is closed/opened at the
monitor assembly. For this reason, if wiper does
not move, check if wiper motor and link functions
using the auxiliary power source and test harness.
Remove test YES

harness and Wiper relay failure.
reconnect the
YES harness end.
Replace relays one YES
Connect test harness by one with new End.
(Parts Number 3073259) ones. Check if
Replace monitor
between auxiliary power wiper operates
assembly. Check if
source (fuse box No.16) each time a relay is NO wiper operates.
and wiper motor as replaced. Cab harness failure.
illustrated on the next ·Key switch: ON NO
page. Check if wiper
operates.
Wiper motor or link
·Key switch: ON NO or lamps does not light failure.
NOTE: If wiper motor is normal, as indicated in the note.
lamp S comes on while
wiper operates in wiping
range. In addition, lamps
B and S come on
momentary when wiper
comes to intermittent
stop position.
T5-4-36
Electrical Circuit When Test Harness is Connected.

Fuse Box No.16
Lamp S
Lamp B Wiper Motor
Ground
T157-07-04-002
Wiper’s Operating Range

(Headguard-Integrated Cab) Retracted Position
Intermittent Stop Position
(Standard Cab)
Retracted Position
Intermittent Stop
Position
Wiping Range
T162-05-04-007
Wiping Range
T157-07-04-003
Test Harness Connection
Wiper Motor Lamp B
Lamp S
Test Harness Fuse Box
T157-07-04-004
T5-4-37
O-4 Counter Weight removal cylinder moves
slowly or does not move.
NO Pilot valve for counterweight

removal failure.
Check if secondary pilot NO

pressure is normal. Holding valve or slow return
Remove holding valve and valve failure.
·Refer to OPERATIONAL slow return valve.
PERFORMANCE TEST Disassemble, clean, reas-
section for pressure YES semble, and reinstall then.
measurement procedure. Check if failure phenome- Control valve for
non happens again. counterweight removal
YES failure.
1 - Counter Weight Removal Cylinder

2 - Holding Valve
3 3 - Slow Return Valve
T162-05-04-008
T5-4-38
ENGINE SPEED ADJUSTMENT
Be sure to readjust engine speed in the following Stopper Bolt Slow Idle Position Bracket
cases:
• When engine speed deviates from specification. Governor Lever
Spring 1 Control Cable
• When the engine, engine control cable, or EC 0.1 to 0.3 mm
motor is removed (for inspection or repair).
• When EC is replaced.
Engine Speed Adjustment Procedure:
1. Adjust the gap between the governor lever and

the stopper bolts to 0.1 to 0.3 mm (0.004 to 0.012
in). Be sure to adjust the gap for both the slow idle Stopper Bolt
and fast idle positions. When adjusting, remove 0.1 to 0.3 mm Spring 2
spring 2. Also, take care not to compress spring 1.
Fast Idle
Position
2. Connect spring 2 ends to the governor lever and
to the bracket and move the governor lever until it
comes into contact with the slow idle stopper bolt.
While the governor lever is into contact with the
slow idle stopper bolt, connect the control cable EC Motor
end to the governor lever/bracket end.
T162-05-04-001
3. Connect the other end of the control cable to the Lever

EC motor.
4. Securely install the EC motor lever secure bolt so

that the end of the secure bolt is 10 mm (0.4 in) EC Motor
EC Motor Lever
away from the lever. Securing Bolt
5. In case only the EC motor has been replaced (or

when the battery cable has been removed):
Key Switch: ON 10 mm
Engine Control Dial: Turn it from slow idle to fast
idle. Then, one second later,
return it to slow idle.
T162-05-04-002
6. Check actual engine speed using Dr.EX or a

tachometer.
Standard engine speed:
-1
Slow idle: 850±50 min
-1
Fast idle: 2070±50 min
T5-4-39
EC SENSOR INSTALLATION AND VOLT-
AGE ADJUSTMENT
1. Install M8 bolt into the T link positioning hole. Note

Control Cable
that this position will be the idle position.
2. Temporarily connect EC sensor at the middle of
the EC sensor mounting slit. Connect the
connector.
3. Connect Dr. EX to the monitor terminal. Install test
harness (ST7129) between EC sensor and
harness.
4. Turn the key switch to the ON position. Turn the
engine control dial to the slow idle position.
Measure the EC sensor output voltage using Dr.
EX or a digital type tester.
5. Adjust EC sensor position so that the output
voltage is within the specified range. Secure EC
sensor.
Specified Voltage: 2.50±0.05 V
T Link Positioning Hole
T Link
T107-04-05-013
T5-4-40
INSTALLATION AND ADJUSTMENT OF
THE A SENSOR 1, 2
Removal
1. Put matching mark on the A sensor and pump
housing. Remove the A sensor connector from its
harness.
2. Remove two A sensor mounting bolts (1) and

washers (2).
3. Remove the A sensor. Take care not to lose

internal spacer (3) and fastener spring (4). O-ring
(5) is provided on the A sensor side.
Installation and Adjustment

1. Apply a film of grease to the surface of fastener
spring (4) and install it into the cavity on the T111-04-05-001
feedback shaft end. 3
2. With the key switch turned OFF, connect the

connector of the A sensor. Then, connect the Dr. 4
EX to the diagnosing connector located in the
operator's cab.
3. Start the engine and operate it in the slow idle

speed. Maintain hydraulic oil temperature at 50±5
°C (122±9 °F).
4. Operate the Dr. EX. Select information for “A

Sensor Mounting Angle Adjustment” (Push F3
T107-04-05-010
key). Then, increase displacement angle to the
maximum by pushing F1 key on the next display.
Wait about one second. The pump displacement
angle is set to the maximum.
5. Select information for “Monitor Data”. Then, push

F8 key to indicate the approx. Pump displacement
(D4 or D5) on the next display.
5
6. Before installing the A sensor to the pump, turn 3
the punch mark on the A sensor shaft towards the
Punch Mark
opposite side of the harness so that the reading of 4
FeedbackShaft
Feedback Shaft
T107-04-05-011
the Dr.EX display indicates 278±3 mL/rev.
Front
7. Insert the A sensor shaft into the feedback shaft Harness Side
and tentatively tighten bolts (1). The bolt holes of
the A sensor are made in a ellipse form. Adjust
the A sensor position using ellipse holes so that
the reading of 1-F8 (D4) and/or 3-F8 (D5) on the Engine
Dr. EX display indicates 278±3 mL/rev.
4-Spool Side 5-Spool Side
8. Tighten bolts (1) and washers (2) to 9.8 Nxm (1.0
kgf⋅m, 7.2 lbf⋅ft).
Main Pump
T111-04-05-002
T5-4-41
(Blank)
T5-4-42
TROUBLESHOOTING / 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 (NOT OK) and proceed to item (2) or (3), as appropriate.
О (1)
(3)
NO (NOT OK)
ѕʝKey Switch: ON may damage components as well.
О • Causes are stated in a thick-line box. Scanning through thick-line boxes, possible

Harness Side
Open End Side

T158-05-03-001
T5-5-1
MALFUNCTION OF COOLANT
TEMPERATURE GAUGE

troubleshooting.
YES
Disconnect coolant
Gauge pointer does temperature sensor
not move at all. (It terminal. Ground harness
does not rise from end terminal to vehicle
zero.) frame. Does pointer swing to With sensor terminal
the (H) side? disconnected, disconnect
ѕʝKey switch: ON 20P connector from monitor.
NO Check if continuity exists
between terminal No. 47 and
sensor terminal.
YES
Disconnect coolant
Gauge pointer temperature sensor
swings over scale. terminal. Does pointer swing
back to zero? With sensor terminal
ѕʝKey switch: ON disconnected, disconnect
20P connector from monitor.
between harness end
terminal and vehicle frame.
YES
Disconnect coolant
temperature sensor
Gauge pointer terminal. Ground harness
swings unstably. end terminal to vehicle
frame. Does pointer swing to
the (H) side, and stably?
ѕʝKey switch: ON
NO
T5-5-2
Approximate temperature on
Coolant Temperature Gauge
Coolant temperature 105 °C (221 °F)

sensor failure 101 °C (214 °F)
YES 70 °C (158 °F)

Monitor failure
T162-05-05-003
Harness breakage
between monitor and
NO sensor Coolant Temperature Sensor
Coolant
Resistance
Temperature
Ω
°C (°F)
Coolant temperature
sensor failure 50 (122) 153.9
80 (176) 51.9±10
100 (212) 27.4±4
YES Short circuit between
monitor and sensor 120 (248) 16.1
Connector
(Harness end connector terminals seen from
Monitor failure
NO 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
Coolant temperature
sensor failure
Monitor failure
T5-5-3
MALFUNCTION OF FUEL GAUGE

troubleshooting.
YES
Disconnect connector from

Gauge pointer does fuel level sensor. Connect
not move at all. (It harness end connector
does not rise from terminals No. 1 and No. 2
using a clip. Does pointer With sensor connector
zero.)
swing to the (F) side? disconnected, disconnect
ѕʝKey switch: ON Check if continuity exists
NO between monitor terminal
No. 46 and sensor terminal
No. 2.
YES
Gauge pointer Disconnect the connector

swings over scale. from fuel level sensor. Does
pointer swing back to zero?
With sensor connector
ѕʝKey switch: ON disconnected, disconnect
between sensor terminal No.
2 and vehicle frame.
YES
Disconnect connector from

fuel level sensor. Connect
Gauge pointer harness end connector
swings unstably. terminals No. 1 and No. 2
using a clip. Does pointer
swing to the (F) side?
ѕʝKey switch: ON
NO
T5-5-4
NOTE: 1 mm=0.03937 in
Fuel Level Sensor

Float
Fuel level sensor FULL

failure
YES 257 mm
Monitor failure
53°
R381.9
70.5 mm
Harness breakage
1/2 51°
between monitor and
NO sensor
338 mm
Fuel level sensor EMPTY

failure
T162-05-05-001

monitor and sensor Resistance
Float Position
Ω
+0
FULL 10 -4
3/4 26
Monitor failure
NO 1/2 38±5
1/4 53
+10
EMPTY 90 -0
Fuel level sensor

failure
Connector
open end side)
Monitor (20P) Fuel Level Sensor

Monitor failure
29 30 31 32 33 34 35 36 37 38
ȑ Ȓ
39 40 41 42 43 44 45 46 47 48
T5-5-5
MALFUNCTION OF INDICATOR BULB
CHECK SYSTEM
• Be sure to inspect wiring connections prior to Check power line:

ѕʝCheck fuse.
troubleshooting.
ѕʝDisconnect 20 P
YES connector from monitor.
Check if continuity
exists between harness
Indicators do not end 20P connector
come on when key Check if all indica- terminal No. 30 and
switch is turned to tors fail to come on. fuse No. 8 terminal.
ON position.
Troubleshoot individual
indicators which failed to
NO come on.
Connector
(Harness end connector terminals seen from the open end side)
Monitor (20P)
Ȓș ȓȐ ȓȑ ȓȒ ȓȓ ȓȔ ȓȕ ȓȖ ȓȗ ȓȘ
ȓș ȔȐ Ȕȑ ȔȒ Ȕȓ ȔȔ Ȕȕ ȔȖ Ȕȗ ȔȘ
MALFUNCTION OF LEVEL CHECK

SWITCH
• This troubleshooting flow chart can be applied to a

level check switch malfunction only. If power is not
supplied at all when the key switch is turned ON,
or if any level indicators fail to light during the bulb
check, troubleshoot these failures first.
• Park the machine on a level surface.
troubleshooting.
YES Level check switch failure
or harness breakage.
YES Check if oil and

coolant levels are
normal.
Add engine oil, hydraulic

Level indicators oil, and/or coolant as
Check if all level NO necessary.
do not come on
indicators do not
when level check
come on.
switch is pressed.
Troubleshoot each failed

NO indicator(s).
T5-5-6
(Blank)
T5-5-7
MALFUNCTION OF ENGINE OIL LEVEL
INDICATOR
• Conduct indicator light check to confirm that the

indicator light is normal.
• In case all indicators do not come ON, refer to the
troubleshooting for Malfunction of Indicator Bulb
Check System.
• Be sure to inspect wiring connections prior to YES
troubleshooting.
Reconnect engine
oil level switch
connector.
Disconnect 12P
YES connector from
monitor. Check if
Disconnect engine continuity exists
oil level switch between harness
Engine oil level
connector. Check if end 12P connector
indicator does not
continuity exists terminal No. 7 and
come on when level
between engine oil vehicle frame.
check switch is NO
pressed. level switch
connector and
vehicle frame.
NO
With engine oil level

switch connector
YES disconnected,
disconnect 12P
connector from
monitor. Check if
Disconnect engine oil continuity exists
level switch between harness
YES connector. Press level end 12P connector
check switch. Check if terminal No. 7 and
engine oil level vehicle frame.
Check engine oil indicator comes on.
Although engine oil
is insufficient, level on the
engine oil level dipstick. Is oil level
indicator comes on lower than the LOW NO
when level check mark line on the
switch is pressed. dipstick?
NO
T5-5-8
Monitor failure Connector

open end side)
Monitor (12P)
1 2 3 4 5 6
7 8 9 10 11 12
Harness breakage
between engine oil
level switch and
monitor.
Engine oil level switch

failure

engine oil level switch
and monitor
Monitor failure
NO
Engine oil level switch

failure
Normal
T5-5-9
MALFUNCTION OF COOLANT LEVEL IN-
DICATOR

Check System.
troubleshooting.
Reconnect coolant
level switch 2P
connector.
YES Disconnect 12P
connector from
monitor. Check if
Disconnect coolant continuity exists
Coolant level level switch 2P between harness
indicator does not connector. Check if end 12P connector
come on when level continuity exists terminal No. 8 and
check switch is between coolant vehicle frame.
level switch 2P NO
pressed.
connector
terminals.
NO
With coolant level

switch connector
disconnected,
disconnect 12P
connector from
YES monitor. Check if
continuity exists
between harness
end 12P connector
Disconnect coolant terminal No.8 and
level switch vehicle frame.
YES connector. Press level
check switch. Check if
coolant level indicator
comes on.
Although coolant is
insufficient, coolant Check if coolant
level indicator level on reservoir is
comes on when lower than LOW NO
level check switch mark.
is pressed.
NO
T5-5-10
Coolant Level Switch

Monitor failure
Reservoir
ON
FULL
LOW
Radiator
Harness breakage OFF
T107-04-03-012
Coolant level switch

failure
Connector (harness end connector terminals

YES Short circuit between seen from the open end side)
coolant level switch Monitor (12P)
and monitor
1 2 3 4 5 6
7 8 9 10 11 12
Coolant Level Switch
Monitor failure 1 2
NO
Coolant level switch

failure
Normal
T5-5-11
MALFUNCTION OF HYDRAULIC OIL
LEVEL INDICATOR

Check System.
troubleshooting.
Reconnect hydraulic
oil level switch 2P
connector.
YES Disconnect 12P
connector from
Disconnect monitor. Check if
hydraulic oil level continuity exists
Hydraulic oil level switch 2P between harness
indicator does not connector. Check if end 12P connector
come on when level continuity exists terminal No. 9 and
check switch is between hydraulic vehicle frame.
NO
pressed. oil level switch 2P
connector
terminals.
NO
With hydraulic oil

level switch
connector
disconnected,
disconnect 12P
YES connector from
monitor. Check if
continuity exists
between harness
Disconnect hydraulic end 12P connector
oil level switch terminal No.9 and
NO connector. Press level vehicle frame.
check switch. Check if
hydraulic oil level
indicator comes on.
Although hydraulic
Check oil level on
oil is insufficient,
the level gauge.
hydraulic oil level
Check if oil can be
indicator comes on NO
seen on the level
when level check
gauge.
switch is pressed.
YES
T5-5-12
NOTE: 1 mm=0.03937 in
Monitor failure Hydraulic Oil Level Switch
Harness breakage
Hydraulic oil level T137-04-04-001

switch failure
Connector
open end side)
hydraulic oil level Monitor (12P)
switch and monitor
1 2 3 4 5 6
7 8 9 10 11 12
Hydraulic Oil Level Switch
1 2
Monitor failure
NO
Hydraulic oil level

switch failure
Normal
T5-5-13
MALFUNCTION OF ALTERNATOR INDICA-
TOR

troubleshooting.
• Also, check continuity between starter relay 2
terminal No.1 and alternator terminal R and
betwwen starter relay 2 terminal No.3 and charge
relay terminal No.2.
More than 20V

Monitor failure
Alternator Check voltage at

indicator does the monitor 20P NO
not go out after connector Charge relay failure
engine is started. terminal No. 42.
Check if charge
ѕʝEngine: Running ѕʝKey switch: ON
relay continuity
ѕʝEngine: Running YES
Less is normal. Starter relay 2 failure
than ѕʝBetween terminals Check if voltage
1V No. 3 and No. 5: at alternator
No continuity exists. YES terminal R is 13
ѕʝBetween terminals to 15V.
No. 1 and No. 2: Alternator failure
Continuity exists. ѕʝEngine: Running NO
More than 20 V
Monitor failure
Check voltage
YES at the monitor NO Charge relay
20P connector
terminal No. Check if failure
42. charge
relay
Although ѕʝKey switch: ON Less continuity YES
Check if Starter relay 2
alternator ѕʝEngine: Running than is normal. Check if
alternator failure
output is low, indicator 1V voltage at
alternator comes on when ѕʝBetween terminals YES alternator
indicator does key switch is No. 3 and No. 5: No terminal R is
Alternator
not come on. turned ON. continuity exists. 13 to 15V.
NO failure
ѕʝBetween terminals ѕʝEngine: Running
ѕʝKey switch: ON No. 1 and No. 2:
ѕʝEngine: Stopped Continuity exists. Blown
NO alternator
indicator bulb
Connector
(Harness end connector terminals seen from ȈCharge relay side connector terminals)
the open end side)
Monitor (20P) Charge Relay
1 2
29 30 31 32 33 34 35 36 37 38
3 5
39 40 41 42 43 44 45 46 47 48
4
T5-5-14
MALFUNCTION OF ENGINE OIL
PRESSURE INDICATOR

troubleshooting.
• Engine oil pressure may remain 1 to 2 minutes
after engine stops. This is normal.
YES Engine oil pressure
Disconnect engine switch failure
oil pressure switch
terminals. Ground
the harness end
YES (+) terminal (white
line with blue Harness breakage
YES between monitor
stripe) to vehicle
frame. Check if Connect the and engine oil
engine oil monitor 12P pressure switch
pressure indicator connector terminal
Although engine to vehicle frame.
Check if engine oil comes on.
oil pressure is NO Check if engine oil
pressure indicator ѕʝKey switch: ON
insufficient, engine pressure indicator
comes on when ѕʝReconnect engine
oil pressure comes on. Monitor failure
key switch is oil pressure switch
indicator does not NO
turned ON. terminals after the ѕʝKey switch: ON
come on.
ѕʝKey switch: ON checking. ѕʝInsert a clip from the back of
ѕʝEngine: Stopped 12P connector to reach the
terminal. Ground the other end
of the clip to vehicle frame.
Blown indicator
NO bulb
Engine oil pressure

YES switch failure,
engine oil system
failure, or oil filter
clogging.
Engine oil pressure Disconnect engine

indicator does not oil pressure switch.
go off after engine Check if engine oil Short circuit
is started. pressure indicator Reconnect engine oil YES between monitor
goes off. pressure switch. and engine oil
ѕʝCheck oil filter for
clogging. ѕʝKey switch: ON Disconnect 12P connector pressure switch.
ѕʝEngine: Stopped from monitor. Check if
NO continuity exists between
harness end 12P connector
terminal No. 10 and vehicle Monitor failure
frame. NO
Connector Engine Pressure Switch

the open end side) Approximate ON/OFF
Indicator
Threshold Pressure
Monitor (12P)
Less than 49 kPa (0.5 kgf/cm 2 ) ON
1 2 3 4 5 6
7 8 9 10 11 12
More than 49 kPa (0.5 kgf/cm 2 ) OFF
T5-5-15
MALFUNCTION OF OVERHEAT INDICA-
TOR

troubleshooting.
YES Overheat switch H

failure.
Disconnect
overheat switch H
terminal. Ground
YES the harness end
Harness breakage
terminal to vehicle YES between monitor
frame. Check if Reconnect overheat
and overheat
overheat indicator switch H terminal.
switch H
comes on. Connect the monitor
12P connector
ѕʝKey switch: ON
Check if overheat ѕʝEngine: Stopped NO terminal No. 1 to
Although engine vehicle frame.
indicator comes Check if overheat
overheats, on when key indicator comes on. Monitor failure.
overheat indicator switch is turned NO
does not come on. ON. ѕʝKey switch: ON
ѕʝKey switch: ON ѕʝEngine: Stopped
ѕʝEngine: Stopped ѕʝInsert a clip from the back of
12P connector to reach the
terminal. Ground the other end
of the clip to vehicle frame.
Blown indicator
NO bulb.
YES Overheat switch H

failure
Overheat indicator Disconnect

comes on even overheat switch H.
when coolant Check if overheat Short circuit
temperature is low. indicator goes off. YES between monitor
With overheat switch H
ѕʝKey switch: ON disconnected, disconnect and overheat
ѕʝEngine: Stopped 12P connector from switch H.
monitor. Check if continuity
NO exists between 12P
and vehicle frame. Monitor failure
NO
Connector Overheat Switch H

the open end side) ON/OFF Threshold Coolant
Indicator
Temperature
Monitor (12P)
Lower than 101 °C (214 °F) OFF
1 2 3 4 5 6
7 8 9 10 11 12 101 °C (214 °F) or higher ON
T5-5-16
MALFUNCTION OF FUEL LEVEL INDICA-
TOR

troubleshooting.
YES Fuel level switch

failure
Disconnect fuel
level switch
Reconnect fuel
YES terminal. Ground
the harness end level switch YES
terminal to vehicle terminal. Monitor failure
frame. Check if Disconnect 12P
fuel level indicator connector from
Although fuel Check if fuel level comes on. monitor. Check if
NO continuity exists Harness breakage
gauge indicates indicator comes
ѕʝKey switch: ON between 12P between monitor
“E”, fuel level on when key
ѕʝEngine: Stopped connector terminal NO and fuel level
indicator does not switch is turned
No. 2 and vehicle switch
come on. ON.
frame.
ѕʝKey switch: ON
ѕʝEngine: Stopped
Blown indicator
NO bulb
YES Fuel level switch

failure
Fuel level indicator Disconnect fuel

comes on even level switch. Check
when fuel is if fuel level indicator YES Short circuit
sufficient. goes off. With fuel level switch between monitor
disconnected, disconnect and fuel level
ѕʝKey switch: ON switch.
12P connector from
ѕʝEngine: Stopped
monitor. Check if continuity
NO exists between 12P
and vehicle frame. Monitor failure
NO
Connector
(Harness end connector terminals seen from the Fuel Level Switch
open end side)
OFF
Fuel Level
Monitor (12P)
1 2 3 4 5 6 35 mm ON
7 8 9 10 11 12
T162-05-05-005
NOTE: 1 mm=0.03937 in
T5-5-17
MALFUNCTION OF AIR FILTER
RESTRICTION INDICATOR

troubleshooting.
YES Air filter restriction

Disconnect air filter
restriction switch switch failure
terminals. Ground
the harness end (+) Reconnect air
YES terminal (Blue line filter restriction
switch terminals YES
with green stripe) to Monitor failure
vehicle frame. after checking.
Check if air filter Disconnect 12P
Check if air filter restriction indicator connector from
Although air filter NO monitor. Check if
restriction comes on. Harness breakage
is clogged, air filter continuity exists
indicator comes between monitor
restriction ѕʝKey switch: ON between 12P
on when key NO and air filter
indicator does not ѕʝEngine: Stopped connector terminal
switch is turned restriction switch
come on. No. 3 and vehicle
ON.
frame.
ѕʝKey switch: ON
ѕʝEngine: Stopped
Blown indicator
NO bulb
YES Air filter restriction

switch failure
Disconnect air filter

Although air filter is restriction switch.
not clogged, air Check if air filter Short circuit
filter restriction YES between monitor
restriction indicator
indicator comes on. With air filter restriction switch and air filter
goes off.
disconnected, disconnect 12P restriction switch.
ѕʝRemove and visually ѕʝKey switch: ON connector from monitor. Check
check the air filter. ѕʝEngine: Stopped if continuity exists between
ѕʝConfirm that the air NO harness end 12P connector
filter is not damp. terminal No. 3 and vehicle
frame. Monitor failure
NO
Connector Air Filter Restriction Switch

open end side)
Indicator ON/OFF Pressure Indicator
Monitor (12P)
5.1 kPa (520 mm H2 O) OFF
1 2 3 4 5 6
7 8 9 10 11 12 6.2 kPa (630 mm H2 O) ON
T5-5-18
MALFUNCTION OF HOUR METER

troubleshooting.
terminal No. 1 and alternator terminal R and
between starter relay 2 terminal No. 3 and charge
relay terminal No. 2.
Harness
breakage
0V between
monitor
Check voltage terminal No.
NO at the monitor 29 and fuse
20P connector No. 8.
terminal No.
29.
Monitor failure
Hour meter 24 V
does not count
Check if
operating
alternator
hours with
indicator is on.
engine More than 20V
running. Monitor failure
ѕʝEngine: Running Check voltage
at the monitor NO Charge relay
20P connector
YES terminal No. failure
42. Check if
ѕʝKey switch: charge relay
Less continuity is YES Starter relay 2
ON Check if
ѕʝEngine: than normal. voltage at failure
Running 1 V ѕʝBetween alternator
terminals No. YES terminal R is
3 and No. 5: 13 to 15V. Alternator
No continuity NO failure
ѕʝEngine: Running
exists.
ѕʝBetween
terminals No.
1 and No. 2:
Continuity
exists.
Connector
(Harness end connector terminals seen from the open end side) (Charge relay side connector terminals)
Monitor (20P) Charge Relay

1 2
29 30 31 32 33 34 35 36 37 38
3 5
39 40 41 42 43 44 45 46 47 48
4
T5-5-19
MALFUNCTION OF BUZZER

troubleshooting.
terminal No. 1 and alternator terminal R and
between starter relay 2 terminal No. 3 and charge
relay terminal No. 2.
More than 20 V
Monitor failure
Buzzer starts Check voltage at Less than

sounding when key monitor 20P 1V Failure of starter
switch is turned to connector terminal relay 2 or
ON position. No. 42. alternator.
Check voltage at
ѕʝKey switch: ON starter relay 2
ѕʝEngine: Running Less than terminal No. 3.
1V
Charge relay
More than failure
20 V
YES Engine oil

pressure system
failure
Buzzer starts Check if engine oil

sounding when pressure indicator is YES
Engine overheat
engine starts. on.
Check if overheat
NO indicator is on.
Check if buzzer
stops when buzzer
NO stop switch is
pressed.
NO
Normal
Although engine oil
pressure indicator or Check if engine is
overheat indicator running at 800 min-1 NO
has turned on, (rpm) or higher. Normal
buzzer does not
sound.
Check if alternator
YES indicator is on.
Check voltage at
monitor 20P
YES connector
terminal No.42.
ѕʝKey switch: ON
ѕʝEngine: Running
T5-5-20
Connector
(Harness end connector terminals seen from the open end side) (Charge relay side connector terminals)
Monitor (20P) Charge Relay Connector
1 2
29 30 31 32 33 34 35 36 37 38
3 5
39 40 41 42 43 44 45 46 47 48
4
YES
Normal
Monitor failure
NO
20V or more
Monitor failure
NO Failure of starter relay 2

Check if continuity or alternator.
exists between
charge relay side
Less than 20V connector
terminals No. 3 Charge relay failure
and No. 5. YES
ѕʝEngine: Running
T5-5-21
MALFUNCTION OF WORK LIGHT INDICA-
TOR

troubleshooting.
YES Harness breakage

between work light
switch and monitor.
YES Check if work lights turn

on when work light
switch is turned on.
Check if work light Work light switch

Work light indicator NO failure
indicator comes on
does not come on
when key switch is
when work light
turned to ON
switch is turned on.
position.
Blown indicator bulb

NO or monitor failure.
MALFUNCTION OF QUICK IDLE INDICA-

TOR

troubleshooting.
Connector
(Harness end connector terminals seen from the open end side)
EC (48P) Monitor (20P)
32 31 14 45
NO Harness breakage
Disconnect 48P between quick idle
connector from switch and EC
EC. Check if
Disconnect 20P
YES continuity exists connector from
between harness NO Harness breakage
end connector monitor. Check if between monitor
terminals No. 31 / continuity exists and EC
Disconnect quick No.32 and quick between harness
Quick idle indicator idle switch plugs (2 idle switch plug. YES end connector
does not come on used). Check if terminal No. 14
Blown indicator
when quick idle continuity exists and 20P
connector YES bulb or EC failure
switch is turned on. between switch
side plug terminals. terminal No. 45.
ѕʝKey switch: ON
Quick idle switch
NO failure
T5-5-22
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source. 3. Precautions for connecting and disconnecting

Be sure to remove the negative terminals from the terminal connectors.
batteries first when taking wire harnesses and 1) When disconnecting harnesses, grasp them by
connectors off for repair or replacement work. their connectors. Do not pull on the wire itself.
Failure to do so can result in damage to the wire Be sure to release the lock first before
harnesses, fuses, and fusible links and, in some attempting to separate connectors, if a lock is
cases, cause fire due to short circuiting. provided. (Refer to “Instructions for
2. Color coding of wire harnesses. Disconnecting Connector” on page T5-6-3.)
The color codes of the wire harnesses in the 2) Water-resistant connectors keep water out so
electrical system are shown below. that if water enters them, water will not easily
In cases on the design sheet where two colors are drain from them. When checking water-resistant
indicated for one wire, the left initial stands for the connectors, take extra care not to allow water to
base color, while the right initial stands for the enter the connectors. In case water should enter
marking color. the connectors, reconnect only after the
connectors are thoroughly dried.
codes color codes color 3) Before connecting terminal connectors, check
R Red W White that no terminals are bent or coming off. In
addition, check that no terminals are rusting.
L Blue G Green 4) When connecting terminal connectors provided
Or Orange Lg Light green with a lock, be sure to insert them together until
Y Yellow B Black the lock “clicks.”
Br Brown P Pink
Gr Gray V Violet
NOTE: 1) Code BW indicates a black base wire Right Wrong

with white fine-line marking.
2) Initials “O” and “Or” both stand for the
color orange.
3) Wires with longitudinal stripes printed
on them are not color coded. Be sure T107-07-06-001
not to confuse them with color coded
wires.
Right
Rust
Wrong
(Bent)
Wrong
(Coming off, Separation)
T107-07-06-002
T5-6-1
4. Precaution for using a circuit tester.
1) Before using a circuit tester, refer to the Wind a piece of wire Tester probe
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object to
be measured, voltage range and current polarity.
2) Before starting the connector test, always check

Sharpen the end of the wire
the connector terminal numbers, referring to the
T107-07-06-003
circuit diagram.
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.
T5-6-2
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
• Push the lock to disconnect
NOTE: 1) Connector may not separate if the lock

is pushed while the connector is being
pulled. Be sure to push the lock first
before pulling the connector.
2) The lock is provided on the female
connector side (the harness end).
T107-04-05-002
Locations of This Type Connector
Fuel Sensor Swing Preference Solenoid Valve Harness Connections in Cab Thermoguard Switch
A Sensor General Purpose Relay Pressure Switch Diode Box
(Displacement Angle Sensor)
EC Sensor Diode P Sensor Wiper
EC Motor Monitor Speaker Lubricator
Coolant Level Switch Starter Relay 2 Radio Motion Alarm
Pump Control Pressure Sensor Air Conditioner Blower Motor Starter Relay 1 Power Line between Engine/Cab
Engine Oil level Switch Air Conditioner Controller Key Switch Fusible Link
Hydraulic Oil Level Switch Engine Control Dial Buzzer
N Sensor
• Pull to disconnect
Hydraulic Oil Temperature Sensor

Dr.EX
T107-04-05-004
• Remove screw to disconnect

Use a 10 mm wrench and a ratchet wrench. Projection
When connecting, tighten until the torque mark (a
projection) is seen.
EC
PVC
Connections between Cab/Engine
T107-04-05-005
T5-6-3
FUSE CONTINUITY TEST
Fuse failure is often caused by a fine crack in the fuse, (3) Connect the negative probe to the vehicle
and such fine cracks are very hard to detect by visual ground, and touch the outside terminal of each
inspection. fuse with the positive probe of the tester.
Checking fuse continuity with a tester is far superior to When normal continuity of a fuse is intact, the
sight inspection. tester will indicate 20 to 25 volts.
(1) Turn the key switch ON NOTE: (a) All the inside terminals of the fuses in
In doing so, the battery relay is activated by the the fuse box are connected to the
current from key switch terminal M and power is power source, while the outside
supplied to all circuits except the ether relay and terminals are connected to the
starter relay 1 circuits. (Refer to the electrical accessories.
circuit diagram.) Test all fuses using the above
mentioned method, except the ether
(2) Remove the fuse box cover and set the correct relay 1 and starter relay 1 circuits.
voltage measurement range of the tester. (b) To check the fuses for the ether relay
(Measurement range: 0 to 30 V) and starter relay 1 circuits, perform step
(3) while turning the key switch to the
START position.
Power Source (Inside) For Starter Relay 1
Accessories (Outside) For Ether Relay
T162-05-06-002
T5-6-4
FUSIBLE LINK INSPECTION AND
REPLACEMENT
Inspection
1. Visually check if fusible links have blown.
Replacement
1. Remove the negative cable from the battery.
2. Push (to unlock) and pull to disconnect fusible link

connector. Replace the fusible link. Fusible Link
3. Reconnect the negative cable to the battery.
T111-04-05-015
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between

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

the battery.
1. Start the engine. Check voltage between the V

battery positive terminal and the vehicle frame.
Normal Voltage: 26 to 28 V
NOTE: If voltage is abnormal, check the charging T162-05-06-005

system.
T5-6-5
HOW TO TROUBLESHOOT ALTERNATOR
MALFUNCTIONS
The alternator indicator remains off if the alternator is

generating power. If the alternator indicator comes on
while the engine is running, the alternator may have
failed.
How to check the alternator circuit

1. Turn the key switch to the ON position. Confirm
that the alternator indicator comes on.
2. Measure voltage between alternator terminals B If it is 0V, disconnection or wire breakage between
and E. If the measured voltage is approximately the battery relay and the alternator or in alternator
24 V, the alternator circuit can be considered ground line may be the cause.
normal. If it is low, insufficient battery capacity or
loose connection between the battery and the
alternator may be the cause.
T162-05-06-003
3. Next, start the engine. Measure alternator

generating voltage (voltage between alternator
terminals B and E). If the measured voltage is
approximately 28V, the alternator is normal. If it is
the same as the one measured in step 2 (around
24 V), the alternator or the regulator may have
failed.
T5-6-6
CONTINUITY CHECK Harness
A a
Single Line Breakage Check
Disconnect both harness end connectors and check
continuity (resistance) between both ends.
0 Ω : Continuity (Normal)
∞Ω : Discontinuity (Breakage) Ω
NOTE: When harness end connectors are far apart Connect to

Vehicle Frame A a
from each other, connect harness end terminal A to
the vehicle frame. Then, check continuity through the
vehicle frame as illustrated.
0 Ω : Continuity (Normal)
Connect to
∞Ω : Discontinuity (Breakage) Vehicle Frame Ω
Single Line Short Circuit Check

(Short Circuit to Vehicle Frame)
A a
continuity between one harness end and the vehicle
× Short Circuit to
frame. Vehicle Frame
0 Ω : Short Circuit
∞Ω : Normal Ω
Multi-Line Breakage Check

Disconnect both harness end connectors and T107-07-05-003
Connect with a Clip (First Check)
connect one harness end connector terminals (A)
and (B) using a clip. Then, check continuity between
the other harness end terminals (a) and (b). If the A a
ohm meter reading is ∞Ω, either line (A) - (a) or (B) - B b
C c
(b) has an open (wire breakage).
To find out which line is open, perform the single line
Connect with a Clip
breakage check on both lines, or perform the multi- (Second Check)
line breakage check lines (A) - (a) and (C) - (c). Be
sure to connect terminals (A) and (C) using a clip
before checking continuity between the other harness Ω
end terminals (a) and (c).
0Ω : an open in line (B) - (b) (wire breakage)
∞Ω : an open in line (A) - (a) (wire breakage) T107-07-05-004
Multi-Line Short Circuit Check Short Circuit between Lines

(Short Circuit between Lines)
continuity between terminal (A) and (B) or (C). A a
B × b
0Ω : Short Circuit C c
∞Ω : Normal
T107-07-05-005
T5-6-7
VOLTAGE AND CURRENT CHECK
Turn the key switch and engine control dial as 24 Voltage Circuit
specified, so as to apply specified voltage (current) to Start checking in order from either the power source
the point to be measured before starting or actuator side. Thereby, the faulty part in the circuit
measurements. Check if specified voltages (current) can be located, if any.
are obtained.
Black (Negative) Tester Probe: To Vehicle Frame
Red (Positive) Tester Probe: To the Point to be
Measured
Engine Key Switch Check Points Specified Voltage

(Current)
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 7 mA
Starting Circuit
Cranking START Between (6) and Ground: Key Switch 20 to 25 V
Cranking START Between (7) and Ground: Fuse 20 to 25 V
Cranking START Between (8) and Ground: Battery Relay (Coil) 20 to 25 V
Cranking START Between (9) and Ground: Battery Relay (Switch) 20 to 25 V
Cranking START Between (11) and Ground: Starter (B) 20 to 25 V
Cranking START Between (12) and Ground: Starter (S) 20 to 25 V
Between (10) and Ground: Starter Relay 1 (Coil) 20 to 25 V
Between (13) and Ground: Starter Relay 2 (Switch) 20 to 25 V
Between (14) and Ground: Fuel Solenoid Valve 20 to 25 V
Charging Circuit
Fast Idle ON Between (15) and Ground: 26 to 30 V
Alternator Generating Voltage (B)
Fast Idle ON Between (9) and Ground: 26 to 30 V
Alternator Generating Voltage
Fast Idle ON Between (16)(17) and Ground: 13 to 15 V
Alternator Generating Voltage (R)
Fast Idle ON Between (18) and Ground: Charge Relay (Switch) 26 to 30 V
Fast Idle ON Between (19) and Ground: Monitor 26 to 30 V
Accessory Circuit
Stopped ON Between (22) and Ground: Cab Light, Radio 20 to 25 V
Stopped ON Between (21) and Ground: Cigar Lighter 20 to 25 V
Stopped ON Between (20) and Ground: Horn 20 to 25 V
Surge Voltage Prevention

Circuit
Slow Idle ON Between (19) and Ground: Load Dump Relay 26 to 30 V
∗ Be sure to disconnect the negative cable from the

battery before starting the measurements.
T5-6-8
1 2 3 4 5 8
Key Switch
Battery
Battery Relay
9
6
Starter Relay 1
19
18
10
Charge Relay
7
Load Fuse Box
Dump
Relay
Starter
11
12
14 15
Breaker 20 21 22
16
Alternator 37 46
Starter Relay 2
Fuel Solenoid Valve 19 PVC
13 17
30 40 42
Monitor
EC
24
37
T162-05-06-001
T5-6-9
5 Voltage Circuit
Power Source Signal or Ground
• Voltage between terminal No. 1 and the vehicle 1 2
Two-Wire System Connector
frame (ground).
With the key switch turned OFF, disconnect the sensor

connector. Measure voltage between machine side
connector terminal No. 1 and vehicle frame under the
following conditions:
V
• Key switch: ON
• Black (negative) tester probe: Touching the vehicle
frame (ground)
• Red (positive) tester probe: Touching terminal T107-07-05-006
No.1
Power Source Signal Ground
Evaluation: 1 2 3
Three-Wire System Connector
If the measured voltage is 5 ± 0.5 volts, the circuit up to
terminal No. 1 is normal.
T107-07-05-007
• Voltage between terminal No. 1 and the ground

terminal. 1 2
Two-Wire System Connector
With the key switch turned OFF, disconnect the sensor

connector. Measure voltage between machine side
connector terminal No. 1 (5 V power source) and the V
ground terminal (terminal No. 2 for two-wire system
connector, or terminal No. 3 for three-wire system
connector) under the following conditions:
• Key switch: ON
• Black (negative) tester probe: Touching the ground
T107-07-05-008
terminal (terminal No.
2 or 3)
• Red (positive) tester probe: Touching terminal 1 2 3
No.1 Three-Wire System Connector
Evaluation:
If the measured voltage is 5 ± 0.5 volts, the lines up to
terminal No. 1 and to the ground terminal (terminal No. V
2 or 3) are normal.
T107-07-05-009
T5-6-10
Check Using False Signal
With the key switch turned OFF, disconnect the
sensor connector. Connect machine side connector
terminal No.1 (power source) and terminal No.2. (The Two-Wire System Connector 1 2
power source voltage is supplied to the controller as a
false signal. Monitor this false signal with Dr.EX. If the (Pressure Switch)
maximum value is indicated, the EC, PVC, and the (Hydraulic Oil Temperature Sensor)
(N Sensor)
circuit up to the machine side connector are normal.
When checking on a pressure switch circuit, Dr.EX
displays ON if it is normal. Connect
IMPORTANT: On three-wire system connectors,

never connect terminals No. 1 and/or
No. 2 to terminal No. 3 or to vehicle T107-07-05-010
frame.
Three-Wire System Connector

1 2 3
(A Sensor)
(Pump Delivery Pressure
Sensor)
(EC Sensor)
(DP Sensor)
Connect
T107-07-05-011
T5-6-11
RELAY REPLACEMENT PROCEDURE
1. Remove screw (1) under the right console to

detach cover (2).
2. Remove bolt (3) and turn the console up side

down around pin (4). Then, remove lock pin (5).
Push pin (4) to remove spacer (6).
: 17 mm
3. Move the console to the seat side. 5 2 3 1

View a 4 6
T157-07-06-004
4. Using a sharp-pointed tool, remove cap (9) from
cover (7) and duct cover (8) located under the
monitor. 7 10 11
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).

9 8 12 T157-07-06-005
8. Replace the relay.
1 - Screw 4 - Pin 7 - Cover 10 - Ashtray

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

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

Use when checking the conditions (discontinuity) of To check point.
a single wire. To ground.

During Operation: Lamp comes ON.
T107-07-05-012

Use when checking EC motor circuit. 5
(Refer to T5-4-18) 6
50
• EC Motor Circuit 1 2 150 50
2 1
When the engine control dial is rotated, 50
When both lamps come ON: Normal 3 4 4 3
If only one lamp comes ON: Check continuity of 7 50
the circuit connecting to the lamp going OFF. 8
If both lamps go OFF: Check the harness
together with the relay.

T107-07-06-024

Use when measuring the signal cable voltage
(between terminal No.2 and 3) in the EC sensor or A
(Red)
sensor (Pump displacement angle) circuit.
(Black)
Parts Number 3073259
Use when checking the wiper circuit.
V
(Refer to T5-4-36)

T107-07-03-009
2
5 4
1 2
1
Parts Number 3073259 T157-07-07-001
T5-7-1
TROUBLESHOOTING / Harness Check
Tool Number ST 7123
Use when checking the circuit between pilot pres-
sure switch and PVC.
(Refer to T5-4-34) 4
3 50
150 50 50
1 2 2 1
T162-05-07-001
Tool Number ST 7123
T5-7-2
MEMO
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162
SERVICE MANUAL REVISION REQUEST FORM
NAME OF COMPANY: MODEL:

PUBLECATION NO.:
YOUR NAME: (Located at the left bottom corner in the cover page)
PAGE NO.:
DATE: (Located at the bottom center in the page. If two or more
revisions are requested, use the comment column)
FAX:
YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch is required.
If your need more space, please use another sheet.
REPLY:
(Copy this form for usage)

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INTRODUCTION

• Each page has a number, located on the center

Consecutive Page Number for Each Group

In this manual, the following safety alert symbol and • CAUTION:

• This is the SAFETY ALERT SYMBOL.

• When you see this symbol on your machine or in

UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating

• DANGER indicates an imminently hazardous

• WARNING indicates a potentially hazardous

• CAUTION indicates a potentially hazardous

• DANGER or WARNING safety signs are located

• Some safety signs don’t use any of the SA-1223

• CAUTION also calls attention to safety messages in

• To avoid confusing machine protection with personal

• NOTE indicates an additional explanation for an

• Carefully read and follow all safety signs on the ma-

• Safety signs should be installed, maintained and re-

• If a safety sign or this manual is damaged or miss-

• Learn how to operate the machine and its controls

• Allow only trained, qualified, authorized personnel to

• Keep your machine in proper working condition.

• Unauthorized modifications of the machine may

• The safety messages in this SAFETY chapter are

PREPARE FOR EMERGENCIES

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

• Keep a first aid kit and fire extinguisher on hand.

lance service, hospital, and fire department

• Wear close fitting clothing and safety equipment

You may need:

• Avoid wearing loose clothing, jewelry, or other

• Operating equipment safely requires the full

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause

• Wear a suitable hearing protective device such as

• Inspect your machine carefully each day or shift by

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

• Before entering the cab, thoroughly remove all dirt

• Don’t leave parts and/or tools lying around the op-

• Avoid storing transparent bottles in the cab. Don’t

• Refrain from listening to the radio, or using music

• Keep all flammable objects and/or explosives

• After using the ashtray, always cover it to extin-

• Don’t leave cigarette lighters in the cab. When the

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

• When you mounting and dismounting the ma-

• Do not use any controls as hand-holds.

• Never jump on or off the machine. Never mount or

ADJUST THE OPERATOR'S SEAT

• A poorly adjusted seat for either the operator or for

• The seat should be adjusted whenever changing

• If the machine should overturn, the operator may

• Prior to operating the machine, thoroughly

MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.

• Take extra care not to run over bystanders.

• Inappropriate engine starting procedures may cause

• Start the engine only when seated in the

• Battery gas can explode, resulting in serious injury.

• If the engine must be jump started, be sure to

• Riders on machine are subject to injury such as

• Only the operator should be on the machine.