Technical Manual (Troubleshooting)

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 Secondary Pilot Pressure ...................... T4-4-3
Test ..................................................... T4-1-2 Main Relief Pressure Shift Control
Pressure(SA Pressure) ........................ T4-4-4
Group 2 Engine Test Travel Mode Shift Control
Engine Speed........................................ T4-2-1 Pressure(SB Pressure) ........................ T4-4-5
Injector and Valve Clearance Swing Parking Brake Release
Adjustment .......................................... T4-2-3 Pressure(SC Pressure)........................ T4-4-6
Main Relief Pressure ............................. T4-4-8
Group 3 Excavator Test Overload Relief Pressure....................... T4-4-12
Travel Speed ......................................... T4-3-1 Main Pump Flow Rate ........................... T4-4-14
Track Revolution Speed ........................ T4-3-2 Swing Motor Drainage ........................... T4-4-17
Mistrack Check ..................................... T4-3-3 Travel Motor Drainage ........................... T4-4-19
Travel Parking Function Check .............. T4-3-4
Swing Speed ......................................... T4-3-5 Group 5 Standard
Swing Function Drift Check ................... T4-3-6 Operational Performance
Swing Motor Leakage ............................ T4-3-7 Standard Table .................................... T4-5-1
Maximum Swingable
Slant Angle .......................................... T4-3-8
Swing Bearing Play ............................... T4-3-9
Hydraulic Cylinder Cycle Time ............... T4-3-10
Dig Function Drift Check ....................... T4-3-11
Control Lever Operating Force .............. T4-3-12
Control Lever Stroke ............................. T4-3-13
Boom Raise/Swing Combined
Operation Check ................................. T4-3-14
167T-4-1
(Blank)
167T-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 Date
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 deterio-
rate as the working hours increase. However, the
3. To economically operate the machine under opti- machine performance is normally considered to re-
mal conditions. duce in proportion to the increase of the operation
hours.
Kinds of Tests Accordingly, restoring the machine performance by
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”
2. Hydraulic component unit test is to check the op- 1. Operation speed values and dimensions of the
erational performance of each component such new machine.
as hydraulic pump, motor, and various kinds of
valves. 2. Operational performance of new components ad-
justed to specification. Allowable errors will be in-
Performance Standards dicated as necessary.
“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 per-

formance tests accurately and safely.
1. THE MACHINE
Repair any defects and damage found, such as oil
or water leaks, Ioose bolts, cracks and so on, be-
fore starting to test.
2. TEST AREA
(1) Select a hard, flat surface.
(2) Secure enough space to allow the machine to
run straight more than 20 m (65 ft 7 inch), and
to make a full swing with the front attachment
extended.
(3) If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.
3. PRECAUTIONS
(1) Before starting to test, agree upon the signals
to be employed for communication among co-
workers. Once the test is started, be sure to T105-06-01-003
communicate with each other using these sig-
nals, 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 acci-
dents due to landslides or contact with high-
voltage power lines. Always confirm that there
is sufficient space for full swings.
(4) Avoid polluting the machine and the ground
with leaking oil. Use oil pans to catch escaping
oil. Pay special attention to this when removing
hydraulic pipings.
4. MAKE PRECISE MEASUREMENTS

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

the engine speed meets specification be-
fore performing all other operational per-
1 2
tormance tests. If the engine speed is not
adjusted correctly, all other performance
test data will be unreliable.
Preparation:
1. Connect Dr.EX and select the monitor function.

When using a pulse counter, disconnect the en-
gine speed sensor connector, then attach a pulse
counter to the connector.
2. Warm up the engine until the engine coolant tem- 3 T162-04-02-001

perature reaches 50 °C (122 °F) or more, and hy-
draulic oil temperature is 50±5 °C (122±9 °F).
NOTE: Prior to the measurement, confirm that

governor lever (2) comes into stopper bolts
SP Mode
(1) and (3) at the slow idle and at the fast Switch E Mode
idle, respectively. Switch
Measurement:
1. Idle Speeds
1-1 Measure the slow and fast (standard) idle Engine Control
speed. Dial
1-2 Start the engine. Select the switch positions
as specified .
1-3 Set the engine control dial to the slow idle M142-03-002
and to the fast idle positions to measure idle

engine speeds.
Engine E Mode SP Mode Auto-Idle Work

Control Switch Switch Switch Mode
Dial Switch
General
Slow
OFF ON OFF Purpose Work Mode
Idle
Mode Switch
General
Fast Idle OFF ON OFF Purpose
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.
Engine E Mode SP Mode Auto-Idle Work
Control Switch Switch Switch Mode
Dial Switch
General
Fast Idle OFF OFF ON Purpose
Mode Work Mode
Switch
2-2 Operate the bucket control lever.
2-3 Return the bucket control lever to neutral.
Measure the engine speed after it automati-
cally drops approximately 4 seconds later. Auto-Idle
Switch
Evaluation:
Refer to the performance standard table in group M162-01-004
T4-5.
When using pulse counter, calculate the engine
speed using the following formula:
-1
Engine speed (min :rpm)=
-1
Pulse Number (sec :Hz) /118
Remedy:
Engine Control
Refer to the troubleshooting B in group T5-4. Dial
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 Accessory Pulley Pointer
system.
Preparation:
or
1. Locate the top dead center (TDC) in the compres-
sion stroke.
or
Align the “B” or “2-5” mark on the accessory pulley
with the pointer on the gear case.
Piston N0.5 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 or
N0.5 is at TDC in its compression stroke. If they
do not move, rotate the accessory pulley one turn
clockwise and align the “B” or “2-5” mark with the T162-04-02-003
pointer again.
4. Tighten rocker arm shaft mounting bolts (1). 6 1 4
: 156 N⋅m (16 kgf⋅m, 35 Ibf⋅ft)

9
5. Tighten housing mounting bolts (2) to (7) in the
order of bolt number. 1 10
3
2
: 115 N⋅m (12 kgf⋅m, 26 Ibf⋅ft) 1
6. Tighten housing mounting bolts (8) and (9). 8

10
: 45 N⋅m (4.6 kgf⋅m, 10 Ibf⋅ft)
7. Tighten injector holding bolt (10).

T162-04-02-008
: 54 N⋅m (5.5 kgf⋅m, 12 Ibf⋅ft) 5 1 7
NOTE: Start the measurement from cylinder No. 5

which is at TDC.
T4-2-3
Measurement:
Injector Injector
IMPORTANT: Before measuring or adjusting valve Exhaust Intake Intake Exhaust
clearance, be sure to first adjust in-
jectors.
1. Loosen lock nut (12) on cylinder No.5 injector ad-

justing screw.
IMPORTANT: Excessive tightening of injector ad-

justing 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 specifica-
11 12
tion.
: 14 N⋅m (1.43 kgf⋅m, 3 Ibf⋅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, 14 Ibf⋅ft)
4. Insert a thickness gauge into the clearance be-

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

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/Exhaust
Accessory Injector
Order Valve
Pulley T162-04-02-006
1 B 5 5 Adjustment:
2 C 3 3 • If the measurement results are out of specification,
3 A 6 6 adjust the valve clearance in the same order of
4 B 2 2 measurement.
5 C 4 4
6 A 1 1 1. Loosen the lock nut of rocker arm adjusting screw.
Adjust the adjusting screw while inserting a
Evaluation: thickness gauge set to specified value.
Standard Valve Clearance (Cold Engine): 2. Retighten the lock nuts.
Intake Valve: 0.35 mm Recheck the valve clearance.
Exhaust Valve: 0.68 mm
: 65 N⋅m (6.6 kgf⋅m, 14 Ibf⋅ft)
T4-2-4
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary:
Measure the time required for the excavator to travel
a 10 m (32.8 ft) test track to evaluate the travel sys-
tem (from the main pump to the travel motors). Arm Rolled-In,
Bucket Rolled-In End
Preparation: 0.3 to 0.5 m
1. Adjust the track sag of both tracks to be equal.
Start
2. Prepare a firm, Ievel test track 10 m (32.8 ft) in
10 m 3 to 5 m
length, with an extra length of 3 to 5 m (9.8 to 16 Deceleration
ft) on both ends for machine acceleration and de- Zone
celeration.
0.3 to 0.5 m
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above Acceleration Zone
the ground with the arm and bucket rolled in.
4. Maintain the hydraulic oil temperature at 50±5 °C T105-06-03-001
(122±9 °F).
Measurement:
1. Measure both the slow and fast travel mode
speeds.
2. Select the following switch positions:
Engine Control Dial : Fast Idle

SP Mode Switch : ON
E Mode Switch : OFF
Work Mode Switch : General Purpose Mode
Auto-Idle Switch : OFF
3. Start traveling the machine in the acceleration

zone with the travel levers to full stroke.
4. Measure the time required to travel 10 m (32.8 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 the ground to evaluate the travel sys-
tem (from the main pump to the travel motors).
90 to 110°
Preparation:
1. Adjust the track sag of both side tracks to be
equal.
2. On the track to be measured, mark one shoe with M104-07-067
chalk.
3. Swing the upperstructure 90° and lower the
bucket to raise the track off ground. Keep the
boom-arm angle between 90 to 110° as shown.
Place blocks under the machine frame.
CAUTION: Securely support the raised track

using wooden blocks.
4. Maintain the hydraulic oil temperature at 50±5 °C

(122±9 °F).
Measurement:
Travel Mode Switch : Fast Speed Mode

SP Mode Switch : ON
E Mode Switch : OFF
2. Operate the travel control lever of the raised track

to full stroke.
3. Measure the time required for 3 revolutions in
both directions after a constant track revolution
speed is obtained.
4. Raise the other side and repeat the above proce-
dures.
5. Repeat steps (2 to 4) three times and calculate
the average values.
Evaluation:
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 10
m (32.8 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). Meas-
ure the maximum tread deviation from the tread
chord line drawn between the travel start and end
points to check the performance equilibrium be-
tween both sides of the travel device systems
(from the main pump to the travel motor).
2. If measured on a concrete surface, the tread de-
viation has a trend to decrease.
Preparation:
Maximum
1. Adjust the track sag of both tracks to be equal. Distance
2. Provide a flat, solid test yard 20 m (65.5 ft) in
length, with extra length of 3 to 5 m (9.8 to 16 ft)
on both ends for machine acceleration and decel-
eration. 3 to 5 m
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above Extra Length
for
the ground with the arm and bucket rolled in. Acceleration
(122±9 °F).
Measurement:
1. Measure the amount of mistracking in both fast,
and slow travel speeds. T105-06-03-022

SP Mode Switch : ON
E Mode Switch : OFF
3. Start traveling the machine in the acceleration

zone with the travel levers at full stroke.
4. Measure the maximum distance between a
straight 20 m (65.5 ft) tread chord line and the
tread made by the machine.
5. After measuring the tracking in forward travel, turn
the upperstructure 180° and measure in reverse
travel.
the average values.
Evaluation:
T4-5.
Remedy:
T4-3-3
TRAVEL PARKING FUNCTION CHECK
Summary:
To measure the parking brake function on a speci-
fied 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. Hold the bucket 0.2 to 0.3 m (8 to 12 in) above the
ground with the arm and bucket fully rolled in.
(122±9 °F).
Measurement:
1. Select the following switch positions: 0.2 to 0.3 m

SP Mode Switch : ON
E Mode Switch : OFF T105-06-03-004
Work Mode Switch : General Purpose Mode Position where the machine
Auto-Idle Switch : OFF comes to a stop
Position where the travel levers
2. Measure the displacement (revolution angle) of are in neutral
Displacement
the travel device cover until the parking brake is (Revolution Angle)
applied . Marks
2-1 Climb the slope and place the travel levers in
neutral.
2-2 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.
T107-06-03-002
3. Measure the travel parking brake slip amount

while parked.
3-1 Climb the slope and place the travel levers in
neutral.
3-2 Stop the engine.
3-3 After the machine stops, put alignment
marks on a track link or shoe, and the track Alignment marks on the track
side frame and shoe when the
side frame. machine comes to a stop.
3-4 After 5 minutes, measure the distance be- Displacement measured
after 5 minutes
tween the marks on the track link or shoe
and the track side frame. T105-06-03-006
Evaluation:
T4-5.
T4-3-4
SWING SPEED
Summary:
Measure the time required to swing three complete
turns.
Preparation:
1. Check the lubrication of the swing gear and swing
bearing.
2. Place the machine on flat, solid ground with ample

space for swinging. Do not conduct this test on
slopes.
The same height
3. With the arm rolled out and bucket rolled in, hold as the boom foot
the bucket so that the height of the bucket pin is pin height.
the same as the boom foot pin. The bucket must
be empty. T105-06-03-013

(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:

SP Mode Switch : ON
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:
T4-5.
Remedy:
T4-3-5
SWING FUNCTION DRIFT CHECK
Summary:
Measure the swing drift on the bearing outer circum-
ference when stopping after a 180° full-speed swing.
Preparation:
bearing.
2. Place the machine on flat, solid ground with ample
space for swinging. Do not conduct this test on a Two Chalk Marks
slope.
T105-06-03-008
3. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
the same as the boom foot pin. The bucket must
be empty.
4. Make two chalk marks: one on the swing bearing
and one directly below it on the track frame.
5. Swing the upperstructure 180°.
(122±9 °F).

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

Measure Difference Between Marks
Measurement:

SP Mode Switch : ON
E Mode Switch : OFF
Work Mode Switch : General Purpose Mode Marking on the Track Frame
Marking on the Swing Bearing
2. Operate the swing control lever fully and return it
to the neutral position when the mark on the up- T105-06-03-010
perstructure aligns with that on the track frame af-

ter swinging 180°.
3. Measure the distance between the two marks.
4. Align the marks again, swing 180°, then test in the
opposite direction.
5. Repeat steps (3 to 5) three times each and calcu-
late the average values.
Evaluation:
T4-5.
Remedy:
T4-3-6
SWING MOTOR LEAKAGE
Summary:
Check for upperstructure drift while suspending a
load on a slope.
Preparation:
bearing.
2. Park the machine on a smooth slope with a gradi-
ent of 26.8 %,
3. Load bucket fully. In lieu of loading the bucket,
weight (W: tons) of the following specification can
be used.
W=M×1.5 T105-06-03-011
3
where: M= Bucket heaped capacity (CECE: m )
1.5=Soil specific gravity
4. With the arm rolled out, and bucket rolled in, posi-
tion the arm top pin height to be level with the
boom foot pin. Apply a rated load to the bucket.
5. Swing the upperstructure to position it 90° to the
slope. Make aligning marks on the swing bearing
periphery and track frame using tape, as illus-
trated.
(122±9 °F).
Measurement:
1. Select the following switch position:
SP Mode Switch : ON
E Mode Switch : OFF
Measure Difference Between Marks
2. Maintain the engine at slow idle. After five minutes,
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 di-
rection and calculate the average values. Marking on the Track Frame
Evaluation: Marking on the Swing Bearing

T105-06-03-010
T4-5.
Remedy:
T4-3-7
MAXIMUM SWINGABLE SLANT ANGLE
Summary:
With the upperstructure swung 90° to the slope,
check the maximum slant angle on which the upper-
structure can swing to the uphill side.
Preparation:
1. Check that the swing gear and bearing are well
lubricated.
be used.
W= M×1.5
3
where: M= Bucket heaped capacity (CECE: m )
1.5= Soil specific gravity
3. With the arm cylinder fully retracted and the T105-06-03-011
bucket cylinder fully extended, hold the arm top
pin to the position flush with the boom foot pin
height.
4. Climp a slope and swing the upperstructure 90° to
the slope.
(122±9 °F).
Measurement:

SP Mode Switch : ON
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:
T4-3-8
SWING BEARING PLAY
Summary:
Measure the swing bearing play using a dial gauge
to check the wear of bearing races and balls.
Preparation:
1. Check swing bearing mounting bolts for loose-
ness.
2. Check the lubrication of the swing bearing. Con-
firm that bearing rotation is smooth and without
noise.
3. Install a dial gauge on the track frame as shown,
using a magnetic base.
T105-06-03-014
4. Position the upperstructure so that the boom
aligns with the tracks facing towards the front
idlers.
5. Position the dial gauge so that its needle point
comes into contact with the bottom face of the
bearing outer race.
6. Bucket should be empty.
Measurement:
1. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
the same as the boom foot pin. Record the dial
gauge reading (h1).
2. Lower the bucket to the ground and use it to raise
the front idler 0.5 m (20 in). Record the dial gauge
reading (h2)
3. Calculate bearing play (H) from this data (h1 and T105-06-03-015
h2) as follows:
H=h2 - h1
Measurement: (h2 )
Measurement: (h1 )
The same height

as the boom foot pin
height
T105-06-03-017
T105-06-03-013
Evaluation:
T4-5.
T4-3-9
HYDRAULIC CYLINDER CYCLE TIME
Summary:
Measure the cycle time of the boom, arm, and
bucket cylinders.
Preparation:
1. To measure the cycle time of the boom cylinders:
With the arm rolled out and the empty bucket
rolled in, Iower the bucket to the ground, as
shown.
2. To measure the cycle time of the arm cylinder:
With the empty bucket rolled in, position the arm
so that it is vertical to the ground. Lower the boom T105-06-03-018
until the bucket is 0.5 m (20 in) above the ground.
3. To measure the cycle time of the bucket cylinder:
The empty bucket should be positioned at mid-
stroke between roll-in and roll-out, so that the
sideplate edges are vertical to the ground.
(122±9 °F).
Measurement: 0.5 m
T105-06-03-019
E Mode Switch : OFF
SP Mode Switch : ON
2. To measure cylinder cycle times:

(Cylinder full stroke includes cylinder cushioning
zone.)
(1) Boom cylinders:
Measure the time it takes to raise the boom,
and the time it takes to lower the boom. To
do so, position the boom at one stroke end, T105-06-03-020
then move the control lever to the other
stroke end as quickly as possible.
(2) Arm cylinder:
Measure the time it takes to roll in the arm,
and the time it takes to roll out the arm. To do
so, position the arm at one stroke end, then
move the control lever to the other stroke
end as quickly as possible.
(3) Bucket cylinder:
Measure the time it takes to roll in the bucket,
and the time it takes to roll out the bucket. To
do so, position the bucket at one stroke end, Evaluation:
then move the control lever to the other Refer to the Performance Standard Table in Group
stroke end as quickly as possible. T4-5.
3. Repeat each measurement three times and calcu- Remedy

late the average values. Refer to the Troubleshooting B in Group T5-4.
T4-3-10
DIG FUNCTION DRIFT CHECK
Summary:
Measure dig function drift, which can be caused by
oil leakage in the control valve and boom, arm, and
bucket cylinders, with the loaded bucket.
NOTE: When testing the dig function drift just after

cylinder replacement, slowly operate each
cylinder to its stroke end to purge air.
Preparation:
be used. Extended
Retracted Distance
W=M×1.5 Distance
3 Retracted
where: M= Bucket heaped capacity (CECE: m ) Distance
1.5= Soil specific gravity
2. Position the arm cylinder with the rod 50 mm (2 in)
extended from the fully retracted position. Same Height
3. Position the bucket cylinder with the rod 50 mm (2
in) retracted from the fully extended position.
4. With the arm rolled out and the bucket rolled in, Bucket Bottom
hold the bucket so that the height of the bucket
pin is the same as the boom foot pin.
5. Maintain the hydraulic oil temperature at 50±5 °C T105-06-03-021
(122±9 °F).
Boom and Bucket Cylinders Retraction
Measurement:
1. Stop the engine. Mark Mark
2. Five minutes after the engine has been stopped,
measure the change in the position of the bottom
of the bucket, as well as the boom, arm and
bucket cylinders.
3. Repeat step (2) three times and calculate the av-
erage values.
Evaluation:
Refer to the Performance Standard Table in Group T110-06-03-002
T4-5. Arm Cylinder Extension
Remedy:
Mark
T110-06-03-001
T4-3-11
CONTROL LEVER OPERATING FORCE
Summary:
Use a spring scale to measure the maximum resis-
tance of each control lever at the middle of the grip.
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Start the engine.

T107-06-03-003
SP Mode Switch : ON
E Mode Switch : OFF

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

to at full stroke and measure the maximum oper-
ating force for each. T107-06-03-004
4. Lower the bucket to the ground to raise one track

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

the average values.
Evaluation:
T4-5.
T4-3-12
CONTROL LEVER STROKE
Summary:
Measure each lever stroke at the lever top using a
ruler.
NOTE: When the lever has play, take a half of this

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

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

erage values.
Evaluation:
T4-5.
T4-3-13
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
T107-06-03-009
boom raise function and check to be sure that the
cylinder movement is smooth, with out sticking.
2. With the arm fully rolled out and bucket fully rolled
in, Iower the bucket to the ground. The bucket
must be empty.
(122±9 °F).
Measurement:
General Purpose Mode:
Engine Control Dial : Fast Idle T107-06-03-010

SP Mode Switch : ON
E Mode Switch : OFF
Trenching Mode:

SP Mode Switch : ON H
E Mode Switch : OFF
Work Mode Switch : Trenching Mode
2. Raise the boom and swing simultaneously, both at T107-06-03-011

full stroke.
3. When the upperstructure rotates 90°, release the
control levers to stop both functions. Measure the
time required to swing 90° and the height (H) of
the bucket teeth.
the average values.
Evaluation:
T4-5.
Remedy:
T4-3-14
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Properly shut down the engine.
CAUTION: The hydraulic oil tank cap may off

if turned quickly. Slowly turn it to release in-
ternal pressure before removing it.
2. Move all control levers to release pressure re-

maining in the system. Slowly turn the hydraulic oil
tank cap approximately 30 degrees counterclock-
wise to release internal pressure from the hydrau-
lic oil tank.
T111-06-04-001
: 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, 27 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

SP Mode Switch : ON
E Mode Switch : OFF
2. Measure the pilot pressure in each specified set-

ting above.
3. Repeat the measurement three times and calcu-
Evaluation:
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
T167-01-02-006
1 2
1. Remove plug (1).
2. Install the estimated necessary numbers of shims

(2).
3. Tighten plug (1).
: 29.5 N⋅m (3 kgf⋅m, 42 Ibf⋅ft)
T111-06-04-004
4. Check the relief pressure of the relief valve.
Reference: Change in Relief 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:


lic oil tank.
T111-06-04-005
: 4 mm
3. Install adapter (ST6450), fitting (ST6069), pres-

sure gauge (ST6315) and coupling (ST6332) onto
the pilot hose end of the measuring circuit.
: 19 mm, 22 mm

(122±9 °F).
Measurement:
Engine Control Dial : Fast Idle and Slow Idle

SP Mode Switch : ON
E Mode Switch : OFF
2. Measure the pilot pressure in each specified set-

ting above with the corresponding control lever
operated full stroke.

Evaluation:
T4-5.
Remedy:
T4-4-3
MAIN RELIEF PRESSURE SHIFT CON-
TROL PRESSURE (SA Pressure)
Preparation:
1. Properly shut down the engine. SA


lic oil tank.
: 4 mm
T167-01-02-006
3. Disconnect the hose end from the solenoid valve
SA output port. Install adapter (ST6451), fitting
(ST6069), pressure gauge (ST6315) and coupling
(ST6332).
: 19 mm, 22 mm
4. Start the engine. Confirm that no oil leakage is Evaluation:

observed at the pressure gauge connection. Refer to the performance standard table in group
T4-5.
(122±9 °F). Remedy:
Refer to the troubleshooting B in group T5-4.
Measurement:
1. Select the following switch and lever positions:
Engine Control SP mode E mode Auto-Idle Work Mode

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

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

SB
lic oil tank.
: 4 mm

T167-01-02-006
SB output port. Install adapter (ST6451), fitting
(ST6332).
: 19 mm, 22 mm

observed at the pressure gauge connection. Evaluation:
5. Maintain the hydraulic oil temperature at 50±5 °C T4-5.
(122±9 °F).
Remedy:
Measurement: Refer to the troubleshooting B in group T5-4.
Engine Travel Mode SP mode E mode Auto-Idle Work Mode

Control Dial Switch Switch Switch Switch Switch
General
Fast Idle Fast Speed ON OFF OFF Purpose
Mode
General
Fast Idle Slow Speed ON OFF OFF Purpose
Mode
2. Read the pressure gauge in each setting above.

T4-4-5
SWING PARKING BRAKE RELEASE
PRESSURE (SC Pressure)
Preparation:

SC

tank cap 30 degrees counterclockwise to release
internal pressure from the hydraulic oil tank. Re-
move the filler cap.
: 4 mm
T167-01-02-006
SC output port. Install adapter (ST6451), fitting
(ST6332).
: 19 mm, 22 mm

5. Maintain the hydraulic oil temperature at 50±5

°C(1 22±9 °F).
Measurement:
Engine SP mode E mode Auto-Idle Work Mode

Control Dial Switch Switch Switch Switch
General
Fast Idle ON OFF OFF Purpose
Mode
2. Read the pressure gauge while operating a front

attachment (boom, arm, or bucket) or swing lever.
Also, read the pressure gauge with all control lev-
ers in neutral.

Evaluation:

T4-5.
Remedy:
Refer to the troubleshooting B in group T5-4.
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:

Pressure Gauge
Mounting Port
lic oil tank.
: 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 T116-06-04-003
: 6 mm
Or, connect Dr. EX. Select the monitor function to

monitor main pump delivery pressure.
4. Start the engine. Confirm that no oil leakage is 3. As for the swing function, secure the upperstruc-
observed at the pressure gauge connection. ture immovable. Slowly operate the swing lever to
relieve the swing function.
(122±9 °F). 4. As for the travel function, secure the tracks
against an immovable object. Slowly operate the
Measurement: travel levers to relieve the travel function.
Evaluation:
Engine Control Dial : Fast Idle Refer to the performance standard table in group
SP Mode Switch : ON T4-5.
E Mode Switch : OFF
Work Mode Switch : General Purpose Mode Reference:
Auto-Idle Switch : OFF If the pressures for all functions measured are Iower
than the specified range, the probable cause is a
2. Relieve each actuator to measure main relief decrease in the main relief valve setting pressure.
pressure.
First, slowly operate bucket, arm, and boom con- If the relief pressure of a particular function is low,
trol levers to the stroke end to relieve each func- the probable cause is something other than the main
tion one at a time. relief valve.
T4-4-8
Main Relief Pressure Setting Adjustment Proce-
dure
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 nut (4).
• High-Side Main Relief Pressure Setting Ad-

justment Procedure
1. Loosen lock nut (4). Tighten plug (3) until the bot-
tom 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, 13 Ibf⋅ft) Main Relief Valve
T111-02-05-002
2. Loosen lock nut (2). Turn sleeve (1) to adjust the 3

relief pressure setting, referring to the table below.
4 1
: 22 mm, 41 mm
: Lock nut (2): 98 N⋅m (10 kgf⋅m, 22 Ibf⋅ft) 2
• Low-Side Main Relief Pressure Setting Ad-

justment Procedure 5
3. Loosen lock nut (4). Turn plug (3) counterclock-

wise until the specified value is obtained.
Retighten lock nut (4).
: 22 mm, 30 mm
: Lock nut (4): 59 N⋅m (6 kgf⋅m, 13 Ibf⋅ft)
4. Recheck the set pressures.
Reference: Standard Change in Pressure

Sleeve (1) and plug
1/4 1/2 3/4 1 T162-04-04-010
(3) turns
MPa 4.4 8.8 13.2 17.7
2
kgf/cm 45 90 135 180
psi 640 1280 1920 2560 Sleeve Plug 1, 3
Pressure In- 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
using adjusting screw (1) after loosening lock nut Swing Relief
Valve
(2).
1. Loosen lock nut (2).
2. Turn adjusting screw (1) adjust the pressure set-

ting referring to the table below.
3. Retighten lock nut (2).
4. Recheck the set pressure. T167-01-02-005

2 1
: 27 mm, 36 mm
: 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)
T107-06-04-019
Screw turns 1/4 1/2 3/4 1
MPa 2.50 5.00 7.50 10.00
2
kgf/cm 25.5 51 76.5 102
psi 360 730 1090 1450
Adjusting Screw
W107-02-05-127
T4-4-10
Travel Relief Pressure Setting Adjustment Proce-
dure
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.
2. Turn the adjusting screw to adjust the pressure

setting, referring to the table below. T142-01-02-012
Lock Nut
3. Retighten the lock nut.
4. Recheck the set pressure
: 6 mm
: 19 mm
: 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
Adjusting Screw
T142-05-04-007

Screw turns 1/4 1/2 3/4 1 Adjusting Screw
MPa 1.96 3.92 5.88 7.85
2
kgf/cm 20 40 60 80
psi 280 570 850 1140
W107-02-05-129
T4-4-11
OVERLOAD RELIEF VALVE SET PRES- Pressure Gauge
SURE (PRESSURE IN POWER BOOST Mounting Port
MODE)
Summary:
1. The circuit pressure must be increased by apply-
ing an external force while blocking the return cir-
cuit 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. T116-06-04-003
Accordingly, even if the main relief valve set pres-

sure can be reset higher than the overload relief 4. Start the engine. Check that no oil leaks from the
valve set pressure, the main pump supplies too pressure gauge joint.
much oil to correctly measure the setting pressure
of the overload relief valve. 5. Maintain the hydraulic oil temperature at 50±5 °C
For this reason, in order to correctly measure the (122±9 °F).
set pressure of the overload relief valve, the over-
load relief valve unit must be removed from the Measurement:
machine and tested on a test stand. 1. Select the following switch positions:
3. If the overload relief valve performance must be
checked on the machine, however, measure the Engine Control Dial : Fast Idle
main relief pressure while releasing each front SP Mode Switch : ON
function respective to the measuring overload re- E Mode Switch : OFF
lief valve. And, assume that the overload relief Work Mode Switch : General Purpose Mode
valve is functioning correctly if the obtained main Auto-Idle Switch : OFF
relief pressure is within the specified value range.
Measure the main relief pressure of the front func- 2. Gradually operate the control levers for the bucket,
tions as follows: arm, or boom until each cylinder is fully extended
The main relief pressure can also be measured or retracted to relive the circuit pressure.
with Dr.EX. 3. Press the power boost switch while relieving each
cylinder to measure the main relief pressure.
Preparation: 4. Measure in the order, the bucket, arm, and boom
1. Properly shut down the engine. cylinders.
5. Repeat the measurement of each function three
CAUTION: The hydraulic oil tank cap may off times and calculate the average.
ternal pressure before removing it. Evaluation:
1. When each measured circuit pressure for the
2. Move all control levers to release pressure re- bucket, arm, or boom is equal to the main relief
maining in the system. Slowly turn the hydraulic oil pressure specification, the overload relief valve
tank cap approximately 30 degrees counterclock- function is normal.
lic oil tank. Refer to the Performance Standard Table In
Group T4-5.
: 4 mm
3. Remove the pressure check port plug at the main

pump delivery port. Install adapter (ST6069) and
pressure gauge (ST6934), or Dr. EX. Select the
monitor function when Dr. EX is installed.
: 19 mm
: 6 mm
T4-4-12
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).
: 36 mm
2. Turn adjusting screw (2) to adjust the pressure Overload Relief Valve
setting referring to the table below.
3. Retighten lock nut (1). T111-02-05-002
2 1
: 19 mm, 36 mm
: 6 mm
: 31 N⋅m (3.2 kgf⋅m, 23 Ibf⋅ft)
: 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)
4. Recheck the set pressures.
T162-04-04-004

Screw turns 1/4 1/2 3/4 1
MPa 4.9 9.8 14.7 19.6 Adjusting Screw
2
kgf/cm 50 100 150 200
psi 710 1420 2130 2840
W107-02-05-129
T4-4-13
MAIN PUMP FLOW TEST
2
3
Summary:
To check the main performance, measure the pump
flow rate by connecting a portable tester at the main 1
pump delivery port. Dr.EX or a pressure gauge is
also used.
Preparation:

T167-01-02-003
2. Move all control levers to release pressure re- Pressure Gauge

Mounting Port
lic oil tank. Connect a vacuum pump to the filter.
: 4 mm
NOTE: Be sure to keep the vacuum pump oper-

ated while connecting the portable tester to
the main pump.
T116-06-04-003
3. Disconnect high-pressure hose (1) or (2), depend-
ing on which main pump is to be measured. Con-
nect flange F87 (ST6187) to the disconnected 8. Connect Dr.EX. Or, remove the plug from the
hose end using split flange (Parts Number main pump test port. Install adapter (ST6069) and
4089703) and socket bolt (Parts Number M341 pressure gauge (ST6934) on the test port.
445). : 19 mm
: 12 mm
9. Disconnect the DP sensor and N (engine speed)
4. Connect test hose (ST6145) to flange F87 (ST61 sensor connectors. (The pump displacement an-
87). gle will be the maximum.)
: 41 mm
10. Remove the P (delivery pressure) sensor from the
5. Install adapter (ST6146) on portable tester other main pump.
(ST6299). Connect the other end of test hose to
adapter (ST6146). 11. Remove the vacuum pump. Loosen drain plug (3).
: 41 mm, 71 mm Bleed air from the casing until oil comes out.
6. Install pipe (ST6188) to the main pump delivery 12. Connect an engine tachometer to the injection
port using the split flanges and the socket bolts pipe. Fully open the loading valve located on the
removed in step 3. portable tester.
: 12 mm
13. Start the engine. Check line connections for any
7. Connect test hose (ST6145) between pipe (ST61 oil leaks.
88) and the inlet of portable tester (ST6299).
: 41 mm
T4-4-14
Measurement:

(122±9 °F).

SP Mode Switch : ON
E Mode Switch : OFF
-1
3. Adjust the engine speed to 1800 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
Convert the measured pump flow rate into the one
for the rated pump speed using the following for- (Reference: Bench Test Results)
mula. Point on 2
Q (L/min) P (kgf/cm )
PQ curve
Converted Pump Flow Rate (Qc) = (NP×Q)/(i×Ne) A 372±12 100
B 280±24 220
Where:
Q (Flow Rate)
Qc : Converted Pump Flow Rate L/min
Q : Measured Pump Flow Rate 400
i : Pump Reduction Ratio (= 1) 382 A
-1
Np : Rated Pump Speed (1800 min )
Ne : Measured Engine Speed
300
B
2
NOTE: 1 kgf/cm = 0. 03937 Mpa
2 200
1 kgf/cm = 14.22 psi
1 L/min = 0.2642 US gal/ min
100
0
100 200 290 300 350
P (Pressure)
kgf/cm 2
T116-06-05-002
T4-4-15
Adjustment of Flow Rate
Flow Rate is controlled by proportional solenoid valve

command current value which is adjusted by changing
the set force of spring (3). After loosening nut (2), ad-
just screw (1).
1 2 3
T167-04-04-003
Spring Adjustment Minimum Flow Rate Adjustment

Screw Turning Number 1/2
Change in Flow Rate 20 L/min Q
NOTE: “ I ” stands for Proportional Solenoid Valve

Command Current Value.
T4-4-16
SWING MOTOR DRAINAGE
Summary:
To check swing motor performance, measure the
amount of oil draining from the swing motor while 2
swinging the upperstructure.
A
NOTE: The amount of drain oil from the swing mo-
tor will change depending on the hydraulic
B
oil temperature. Be sure to maintain hydrau- 1
lic oil temperature at 50±5 °C (1229 °F).
Preparation:
1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F). Rotate the swing motor to warm the
inside of the motor.


lic oil tank.
T167-04-04-001
: 4 mm
3. Disconnect left swing motor drain hose (1) at part

(A). Install plug (ST6214) to the tee port.
: 22 mm
: 29.5 N⋅m(3 kgf⋅m, 22 Ibf⋅ft)
4. When measuring the right swing motor, discon-

nect drain hose (2) at part B. Connect test drain
hose (3/4-16UN) to the tee port. Install plug
(ST6637) to drain hose(2).
: 27 mm
: 93 N⋅m(9.5 kgf⋅m, 70 Ibf⋅ft)

Preconditions for Measurement:
starting machine operation.
Also, take care not to fall off the machine
SP Mode Switch : ON
while the measurement.
E Mode Switch : OFF
T4-4-17
Measurement:
1. Amount of Oil Drained While Swinging the Upper-
structure
(1) Fully retract the arm cylinder. Fully extend the
bucket cylinder. Raise the boom so that the
arm tip pin height is the same as the boom
foot pin height. Be sure that the bucket is The same height as
empty. boom foot pin height
(2) Start the engine. Operate and hold the swing
lever full stroke. Start draining oil measure- T105-06-03-013
ment after the swing speed reaches a con-

stant maximum speed. The measuring time
should be more than 20 seconds.
(3) Repeat the measurement at least three times
in both clockwise and counterclockwise di-
rections, and calculate the average values.
T107-06-06-005
2. Amount of Oil Drained While Relieving Swing Mo-
tor Circuit
(1) Thrust the bucket teeth into the ground as il-
lustrated so that the upperstructure does not
rotate when the swing lever is operated full
stroke.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start drain oil measurement
when drain oil starts coming out of the drain
hose end. The measuring time should be
more than 20 seconds.
(3) Repeat the measurement at least three times
in both clockwise and counterclockwise di-
rections, and calculate the average values.
T107-06-05-008
NOTE: Because the left swing motor drain hose is

connected to the right swing motor drain * Conversion of the amount of drain oil measured into
port, the total of the left and right swing mo- the per-minute value
tor drainage will be measured when meas-
uring the right swing motor drainage ac- First measure the amount of drain oil using a cali-
cording to step 4 in Preparation. For this brated container. Then, convert the measured drain
reason, be sure to deduct the amount of left oil into the per-minute value using the formula below:
swing motor oil drainage (step 3 in Prepara-
tion) from that total amount.
∆Q = (60×q)/t
Evaluation:
T4-5. Where:
∆Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-4-18
TRAVEL MOTOR DRAINAGE
Summary:
To check travel motor performance, measure the
amount of oil draining from the travel motor, while ro-
tating the travel motor with the measuring side track
jacked up.
NOTE: The amount of drain oil from the travel mo-

tor 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
the motor.

if turned quickly. Slowly turn it to release in- 2

lic oil tank.
3. Disconnect travel motor drain hose (1) from the

top of the center joint. Install plug (ST6637) to the 1
port of removed drain hose (1). Connect test drain
hose (2) (3/4-16UN) to the center joint.
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 70 Ibf⋅ft) T167-04-04-002
Preconditions for Measurement:


SP Mode Switch : ON
E Mode Switch : OFF
Travel Mode Switch : Fast Mode
T4-4-19
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 op-
erated full stroke. Start drain oil measurement
after the track rotation speed reaches a con-
stant 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 calcu-
late the average values. 90 to 110°
Evaluation:
T4-5.
M104-07-067
* Conversion of the amount of drain oil measured into
the paramount value
First measure the amount of drain oil using a cali-

brated container. Then, convert the measured drain 2
oil into the paramount value using the formula below:
∆Q = (60×q)/t
Where:
∆Q : Amount of drain oil per minute (L/min) 1
t : Time measured (seconds)
q : Total amount of drain oil (L)
T167-04-04-002
T4-4-20
OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE
STANDARD TABLE
The standard performance values are listed in the • The preconditions for measurement are as follows
table below. unless otherwise mentioned in each performance
Refer to the groups 2 to 4 for performance test test section:
procedures. Values indicated in parentheses are Engine Control Dial : Fast Idle
reference values. SP Mode Switch : ON
E Mode Switch : OFF
Work Mode : General Purpose
Mode
Hydraulic Oil Temperature : 50±5 °C
(122±9 °F)
Performance
Performance Test Remarks
Standard
-1
ENGINE SPEED (min )
Fast Idle (SP Mode Switch: ON) 2050±50 Dr.EX Value
Fast Idle (SP Mode Switch: OFF) 1920±50 Dr.EX Value
Slow Idle 850±100 Dr.EX Value
Auto-Idle 1200±100 Dr.EX Value
VALVE CLEARANCE (IN, EX) (mm) 0.35, 0.68 With cold engine.
TRAVEL SPEED (sec/10 m)
Fast Speed Mode 7.7±1.0
Slow Speed Mode 11.6±1.5
TRACK REVOLUTION SPEED (sec/3 rev.)
Fast Speed Mode: EX550-5 25.7±1.5
EX550LC-5 27.3±1.5
MISTRACK (Both Fast and Slow Speed 200 or less
Modes) (mm/20 m)
TRAVEL PARKING FUNCTION CHECK(rev.) 1/6 or less
TRAVEL MOTOR LEAKAGE (mm/5 min) 0
SWING SPEED (sec/3 rev.) 22.5±2.0
SWING FUNCTION DRIFT CHECK 1100 or less
(mm/180°)
SWING MOTOR LEAKAGE (mm/5 min) 0
MAXIMUM SWINGABLE SLANT ANGLE 13° or more 3.5 m Arm,
3
(deg.) 2.5 m (PCSA heaped) bucket
SWING BEARING PLAY (mm) 1.5 or less Limit of Use: 5.0
2
NOTE: 1 kgf/cm =98.07 kPa
T4-5-1
Performance
Standard
3.5 m Arm,
HYDRAULIC CYLINDER CYCLE TIME (sec) 3
2.5 m (PCSA heaped) bucket
Boom Raise 4.3±0.3
Boom Lower 3.1±0.3
Arm Roll-In 4.7±0.3
Arm Roll-Out 3.5±0.3
Bucket Roll-In 4.2±0.3
Bucket Roll-Out 3.0±0.3
3.5 m Arm,
DIG FUNCTION DRIFT CHECK (mm/5 min) 3
2.5 m (PCSA heaped) bucket
Boom Cylinder 10 or less
Arm Cylinder 10 or less
Bucket Cylinder 10 or less
Bucket Bottom 100 or less
CONTROL LEVER OPERATING FORCE
(kgf)
Boom Lever 2.0 or less
Arm Lever 1.7 or less
Bucket Lever 1.7 or less
Swing Lever 2.0 or less
Travel Lever 2.5 or less
CONTROL LEVER STROKE (mm)
Boom Lever 105±10
Arm Lever 83±10
Bucket Lever 83±10
Swing Lever 105±10
Travel Lever 100±10
5.0±0.5
BOOM RAISE/SWING (sec) ∗ With loaded bucket
∗ 5.4±0.5
Bucket Teeth Height: H (mm)
With empty bucket 7500 or more
With loaded bucket 6200 or more
NOTE: 1 kgf = 9.807 N
T4-5-2
Performance
Standard
2
COMPONENT TEST (kgf/cm )
PRIMARY PILOT PRESSURE +5
40 0
Fast Idle (SP Mode: ON)
+5
Slow Idle (SP Mode: ON) 40 0
SECONDARY PILOT PRESSURE more than 37
MAIN RELIEF PRESSURE SHIFT CONTROL
PRESSURE (SA Pressure)
more than 35
(Travel/boom raise operations in precision mode
2
and with power boost switch ON) (kgf/cm )
(Operations other than the above) 0
TRAVEL MODE SHIFT CONTROL
PRESSURE (SB Pressure) more than 35
2
(Fast Speed Mode) (kgf/cm )
(Slow Speed Mode) 0
SWING PARKING BRAKE RELEASE
PRESSURE (SC Pressure)
more than 35
(When a front or swing function control lever is
2
operated.) (kgf/cm )
MAIN RELIEF PRESSURE (Power Boost Off) +10
2 305 -5
(Boom. Arm, Bucket) (kgf/cm )
OVERLOAD RELIEF PRESSURE (Power
+15
Boost ON) 320 -10
2
(Boom Raise, Arm Roll-In/Out) (kgf/cm )
TRAVEL/SWING RELIEF PRESSURE +10
2 305 -5
(Swing Relief Pressure) (kgf/cm )
(Travel Relief Pressure) 355
+20
-5

2.0 or less
(With constant maximum speed) (L/min)
20 or less
(Having the upperstructure immovable)(L/min)
TRAVEL MOTOR DRAINAGE
5 or less
(With track jacked up) (L/min)
2
MAIN PUMP FLOW RATE (at 100 kgf/cm )
372±12 Bench Test Result
(L/min)
2
MAIN PUMP FLOW RATE (at 220 kgf/cm )
280±24 Bench Test Result
(L/min)
2
NOTE: 1 kgf/cm = 0.09807 MPa
T4-5-3
(Blank)
T4-5-4
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SECTION 5
TROUBLESHOOTING
—CONTENTS—
Group 1 Diagnosing Procedure Fault Codes 11, 12 (Short Circuit and
Introduction .......................................... T5-1-1 Discontinuity of Eng. Governor Dial/Lever
Diagnosing Procedure ........................... T5-1-2 Angle Sensor)...................................... T5-3-7
Dr. EX ................................................... T5-1-4 Fault Code 13 (N Sensor Malfunction) ... T5-3-8
Dr. EX Start-Up Procedure .................... T5-1-4 Fault Code 14
Clearing the Self-Diagnosing ................. T5-1-5 (Discontinuty of overheat Switch L and/or
Retrial “A”.............................................. T5-1-5 Hydraulic oil Temperature Sensor) ....... T5-3-9
Retrial “B”.............................................. T5-1-6 Fault Codes 17, 18, 19, 21, 22
EC Related Fault Codes ........................ T5-1-7 [Failure (type 17, 18, 19, 21, 22)
PVC Related Fault Codes...................... T5-1-8 of PVC]................................................ T5-3-10
Monitoring Function ............................... T5-1-9 Fault Code 20 (Signal from EC is not
Transmitted to PVC) ............................ T5-3-11
Group 2 Component Layout Fault Codes 23, 24
Main Components ................................. T5-2-1 (Pump Control Malfunction) ................. T5-3-12
Electrical System (1) ............................. T5-2-2 Fault Codes 26, 34
Electrical System (2) ............................. T5-2-3 (Discontinuity of DP Sensor) ................ T5-3-14
Electrical System (3) ............................. T5-2-4 Fault Codes 27, 28, 35, 36
Control Valve......................................... T5-2-6 (Short Circuit and Discontinuty of
Others ................................................... T5-2-10 P Sensor) ............................................ T5-3-15
Fault Codes 29, 30, 37, 38
Group 3 Troubleshooting A (Short Circuit and Discontinuity of
Troubleshooting A Procedure ................ T5-3-1 A Sensor) ............................................ T5-3-16
EC Related Fault Codes ........................ T5-3-2 Sensor Operating Range List................. T5-3-17
PVC Related Fault Codes...................... T5-3-3
Fault Codes 01, 02, 03, 04, 06
[Failure (type 1, 2, 3, 4, 6) of EC]......... T5-3-4
Fault Code 05 (Signal from PVC is not
Transmitted to EC) .............................. T5-3-5
Fault Codes 09, 10 (Short Circuit and
Discontinuity of EC Sensor) ................. T5-3-6
167T-5-1
Group 4 Troubleshooting B Malfunction of Fuel Level
Troubleshooting B Procedure ................ T5-4-1 Indicator .............................................. T5-5-17
Correlation between Part Failure and Malfunction of Air Filter
Abnormalities that Machine may Show. T5-4-2 Restriction Indicator ............................. T5-5-18
Correlation between Troubles and Malfunction of Hour Meter ..................... T5-5-19
Part Failures ........................................ T5-4-6 Malfunction of Buzzer ............................ T5-5-20
Engine System Troubleshooting ............ T5-4-10 Malfunction of Work Light
Total Actuator System Indicator .............................................. T5-5-22
Troubleshooting................................... T5-4-19
Front Attachment System Group 6 Electrical System Inspection
Troubleshooting................................... T5-4-24 Precautions for Inspection and
Swing System Troubleshooting.............. T5-4-30 Maintenance ........................................ T5-6-1
Travel System Troubleshooting ............. T5-4-33 Instructions for Disconnecting
Troubleshooting for Other Connectors .......................................... T5-6-3
Functions............................................. T5-4-36 Fuse Continuity Test .............................. T5-6-4
EC Sensor Installation and Fusible Link Inspection and
Voltage Adjustment.............................. T5-4-40 Replacement ....................................... T5-6-5
Installation and Adjustment Battery Voltage Check ........................... T5-6-5
of the A Sensor.................................... T5-4-41 How to Troubleshoot Alternator
Malfunctions ........................................ T5-6-6
Group 5 Troubleshooting C Continuity Check ................................... T5-6-7
Troubleshooting C Procedure ................ T5-5-1 Voltage and Current Check.................... T5-6-8
Malfunction of Coolant Check Using False Signal...................... T5-6-11
Temperature Gauge............................. T5-5-2 Relay Replacing Procedure ................... T5-6-12
Malfunction of Fuel Gauge .................... T5-5-4
Malfunction of Indicator Bulb Group 7 Harness Check
Check System ..................................... T5-5-6 Circuit Check......................................... T5-7-1
Malfunction of Level Check
Switch ................................................. T5-5-6
Malfunction of Engine Oil Level
Indicator .............................................. T5-5-8
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
T167-5-2
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 6 groups: 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
• Troubleshooting A (using fault codes)

Use these charts when the self-diagnosing
function of Dr.EX shows any fault codes.
(The controller automatically diagnoses and
memorizes malfunctions that have occurred in the
signal sending system.)
Example: Fault Code 01: EC Failure (1)
• Troubleshooting B (starting with symptoms)

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

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

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

Refer to this group for precautions and inspection
procedures of the electrical system when or
before performing inspections on the electrical
system.
Example: Fuse Inspection
• Harness Check
Refer to this group for information about the test
harnesses.
Example: ST 7129
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.
T107-07-01-001
2. Ask the operator
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 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
inspection.
T107-07-01-003
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 har-

nesses 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.
If any fault codes are displayed on the monitor, check T107-07-01-005
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
the accumulated fault codes from the controller T107-07-01-006
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, malfunc- real-time while the machine is operated. (Real-Time
tions recorded in the controller memory are indicated Monitoring Function)
as fault codes on the Dr.EX display.
(Self-Diagnosing Function) 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

Dr.EX for connecting the Dr.EX to the Screen (Select
machine. Once Dr.EX is connected “40t~kg2”)
properly and switched on, the self-
diagnosing function will automatically start
up. Initial Pattern Communica-
(Dr. EX) tion Failure
2. Turn the key switch to the ON position, or start the ·Check the
engine. harness.
3. Turn the Dr.EX power switch on. The model ·Check the
Model Code
selecting screen will appear on the Dr.EX display. fuse.
Confirmation
On each step (screen), select an appropriate item Screen
and/or follow the instructions at the bottom of the Install the new-
NOT OK
screen to proceed to the next step. The other version soft-
screens shown below will appear, in the order OK ware.
shown. Function
1. Model Selection Screen (Select “40t∼kg2.”) Selection
2. Initial Pattern (Dr.EX) Screen
3. Model Code Confirmation Screen
Real-Time Special Function
Example: Controller Model :EX550-5 Monitoring (A sensor
PVC Version :1.01 Self-Diagnosing Function Function adjustment)
4. Function Selection Screen

F1: Self-Diagnosing Function Accumulated Monitor Item Fixing Pump
Fault Codes Selection Displacement
F2: Real-Time Monitoring Function Display Angle at
Screen
F3: Special Function Maximum
4. When the Function Selection Screen appears, Retrial A or B Data Display

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

controller (PVC and EC) )
1. Turn the Dr.EX OFF, with its harness still

connected to the diagnosing connector of the
PVC.
T105-07-01-001
2. Turn the key switch OFF .
3. After 10 seconds or more have passed, turn the

key switch to the ON position or start the engine.
T107-07-06-005
4. Disconnect the harness from the diagnosing

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.
T105-07-01-002
6. Check the fault code again, following the normal
method. If the fault code is displayed again, the
problem exists.
T105-07-01-001
T5-1-5
RETRIAL “B” (For problems with the
sensors)
ON
1. Leave the key switch in the ON position. (The
engine may be stopped or may be running.)
T105-07-01-004
2. Disconnect the harness from the diagnosing

connector.
More than
1 sec.
3. After one second or more has passed, reconnect T105-07-01-002
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
EC-RELATED FAULT CODES
Fault Code Trouble Corrective Action

01 Failure (type-1) of EC 1) Retry diagnostic procedure A.
2) Replace EC if engine governor is
uncontrollable
uncontrollable
uncontrollable
uncontrollable with eight or more number
of errors indicated in self-diagnosis.
05 Signal from PVC is not transmitted 1) Retry diagnostic procedure B.
to EC 2) Check harness
3) If auto-idle is abnormal replace PVC or
EC.
06 Failure (type-6) of EC 1) Retry diagnostic procedure B.
uncontrollable
07 ∗ Short-circuit of auxiliary sensor 2 1) Retry diagnostic procedure B.
2) Check harness
3) Replace auxiliary sensor 2.
08 ∗ Discontinuity of auxiliary sensor 2. 1) Retry diagnostic procedure B.
2) Check harness
09 Short circuit of EC sensor 1) Retry diagnostic procedure B.
2) Check harness
3) Replace EC sensor
10 Discontinuity of EC sensor. 1) Retry diagnostic procedure B.
2) Check harness
11 Short-circuit of Eng. Governor 1) Retry diagnostic procedure B.
Dial/Lever angle sensor. 2) Check harness
12 Discontinuity of Eng. Governor 3) Replace Eng. Governor Dial/Lever angle
Dial/Lever angle sensor. sensor.
13 N sensor malfunction. 1) Retry diagnostic procedure B.
2) Check harness
3) Replace N sensor
14 Discontinuity of overheat switch 1) Retry diagnostic procedure B.
L and/or T sensor. 2) Check harness
3) Replace overheat switch and/ or T sensor.
∗ No aux. sensors are used on this machine.
T5-1-7
PVC-RELATED FAULT CODES

17 Failure (type-17) of PVC 1) Retry diagnostic procedure A.
18 Failure (type-18) of PVC 2) If engine stalls or working speed is
19 Failure (type-19) of PVC abnormal replace PVC.
20 Signal from EC is not transmitted 1) Retry diagnostic procedure B.
to PVC 2) Check harness
3) If speed sensing control is abnormal
replace PVC and/or EC.
21 Failure (type-21) of PVC 1) Retry diagnostic procedure B.
22 Failure (type-22) of PVC 2) Replace PVC
23 Pump control malfunction (4-spool 1) Retry diagnostic procedure B.
side) 2) If engine stalls or working speed is
24 Pump control malfunction (5-spool abnormal refer to service manual.
side)
25 Short circuit of DP sensor (4-spool 1) Retry diagnostic procedure B.
side) 2) Check harness
26 Discontinuty of DP sensor (4- 3) Replace DP sensor (4-spool side)
spool side).
27 Short-Circuit of P sensor (4-spool 1) Retry diagnostic procedure B.
side). 2) Check harness
28 Discontinuity of P sensor (4-spool 3) Replace P sensor (4-spool side)
side)
29 Short circuit of A sensor (4-spool 1) Retry diagnostic procedure B.
30 Discontinuity of A sensor (4-spool 3) Replace A sensor (4-spool side)
side)
34 Discontinuity of DP sensor (5- 3) Replace DP sensor (5-spool side)
spool side)
35 Short circuit of P sensor (5-spool 1) Retry diagnostic procedure B.
side)
37 Short circuit of A sensor (5-spool 1) Retry diagnostic procedure B.
38 Discontinuty of A sensor (5-spool 3) Replace A sensor (5-spool side)
side)
40 ∗ Short-circuit of auxiliary sensor 3. 1) Retry diagnostic procedure B.
2) Check harness
T5-1-8
MONITORING FUNCTION
Dr.EX functions to monitor command signals from the

controllers (PVC, EC) and input signals to these (4) 4-Spool Control Valve Side
controllers from various switches and sensors. (5) 5-Spool Control Valve Side
Pattern Key
Display Description Unit
No. No.
2
1 F6 Differential Pressure (dP4) DP sensor output signal. (4P) kgf/cm
2
F7 Pump Delivery Pressure (Pd4) P sensor output signal. (4P) kgf/cm
F8 Approx. Pump Displacement (D4) Calculated pump displacement. (4P) cc/rev
2 F6 Desired Pump Displacement (Dr4) Pump displacement control signal. (4P) cc/rev
F7 Approx. Pump Displacement Calculated torque. (4P) kgfxm
Torque (T4)
F8 Potential Pump Displacement Pump driving torque control signal. (4P) kgfxm
Torque (Tr4)
2
3 F6 Differential Pressure (dP5) DP sensor output signal. (5P) kgf/cm
2
F7 Pump Delivery Pressure (Pd5) P sensor output signal. (5P) kgf/cm
F8 Approx. Pump Displacement (D5) Calculated pump displacement. (5P) cc/rev
4 F6 Desired Pump Displacement (Dr5) Pump displacement control signal. (5P) cc/rev
F7 Approx. Pump Displacement Calculated torque. (5P) kgfxm
Torque (T5)
F8 Potential Pump Displacement Pump driving torque control signal. (5P) kgfxm
Torque (Tr5)
5 F6 Pump Disp. Angle Control signal Control signal to pump displacement A
(I4) control solenoid valve. (4P)
F7 Pump Disp. Angle Control signal Control signal to pump displacement A
(I5) control solenoid valve . (5P)
F8 Relief Pressure Raise Signal (Sf) Control signal to solenoid valve (SA) On
6 F6 Travel High/Low Shift Signal (Sh) Control signal to solenoid valve (SB) On
F7 Swing Parking Brake Release Control signal to solenoid valve (SC) On
Signal (Sbs)
F8 Swing/Boom Operation Signal (Ssb) Control signal to swing/boom circuit On
solenoid valve.
7 F6 Power Boost Switch On
F7 Travel Mode Switch Lo,Hi
F8 Work Mode Selector G, T, P, A
8 F6 Pressure Switch Bm,
Am,Ot,
Sw,Tr
F7 Econ. Mode sig. On
F8 Sup. Pow. Mode Sig. On
T5-1-9
Pattern Key
Display Description Unit
No. No.
9 F6 Engine Control Angle (Aec) EC sensor output signal. V
F7 Engine Control Motor Position EC motor position control signal. Pulse
(Ecmp)
F8 Actual Engine Speed (Ea) Actual engine speed. rpm
10 F6 Selected Engine Speed (Es) Engine speed control signal. %
F7 Deviation engine speed (dE) rpm
11 F6 Auto-Idle Switch On
F7 Additional Pressure Switch On
12 F6 Engine Control motor Signal (Ecms) Control signal to EC motor. Dn, St,
Up
F7 Engine Control Motor Relay Signal

On
(Ecmr)
13 F6∗ Swing Dampener Valve (sdv) On

F7 Hydraulic Oil Temperature (To) °C
F8 Overheat Switch (L) (Ovh) On
14 F6 Counterweight Switch (Cw) On
F7 Cool. Lev. Sig On

F8 Cool. Lev. Ing. Sig. On
15 F6 Dial Angle Sig. Signal from dial angle sig. V

F7∗ Auxiliary Sensor 2 (Aux2) Signal from auxiliary sensor 2 V
F8∗ Auxiliary Sensor 3 (Aux3) Signal from auxiliary sensor 3 V
Aux. Sensor 3 is used to monitor bucket roll-in
pressure switch operation.
• 3V or higher: No bucket operation (Neutral)

• 2V or lower: During bucket roll-in operation.
∗ This item not used on this machine.
NOTE: UNIT ABBREVIATIONS

Lo : Slow Speed Bm : Boom
Hi : Fast Speed Am : Arm
G : General Purpose Mode Ot : Other
T : Trenching Mode Sw : Swing
P : Precision Mode Tr : Travel
A : Atttachment Mode
T5-1-10
TROUBLESHOOTING / Component Layout
MAIN COMPONENTS
2
3
1
4
5
6
36 7
8
9
10
11
12
13
14
15,16
17
35
34
33
32 18
31 19
30 20
29 21
28 22
27 23
26 24 T166701-02-001
25
1 - Bucket Cylinder 10 - Battery 19 - Engine Oil Filter 28 - Swing Shuttle Valve

2 - Arm 11 - Swing Device 20 - Air Filter 29 - Upper Roller
3 - Arm Cylinder 12 - Fuel Tank 21 - Solenoid Valve Unit 30 - Shockless Valve (Front)
(3 Solenoid Valve Used)
4- Boom 13 - Control Valve 22 - Pump Device 31 - Travel Shuttle Valve
5- Boom Cylinder 14 - Engine 23 - Pilot Filter 32 - Pilot Shut-Off Valve
6- Front/Swing Pilot Valve 15 - Radiator 24 - Hydraulic Oil Tank 33 - Track Adjuster
7- Swing Bearing 16 - Oil Cooler 25 - Travel Device 34 - Front Idler
8- Lubricator 17 - Counterweight 26 - Shockless Valve (Travel) 35 - Travel Pilot Valve
9- Center Joint 18 - Muffler 27 - Lower Roller 36 - Bucket
T5-2-1
ELECTRICAL SYSTEM
1 2
3
4
5
6
7
8
9
10
11
12
13
14
33
15
32
31 16
30 17
29 18
28
27 19
26 20
25 21
22
23 T167-01-02-012
24
1 - Work Light (On Boom) 10 - Fuel Level Switch 18 - Engine Oil Level Switch 26 - DP Sensor
(5-Spool Side)
2 - Monitor 11 - DP Sensor (4-Spool Side) 19 - Fuel Solenoid Valve 27 - Hydraulic Oil
Temperature Sensor
3 - Pressure Switch (Travel) 12 - Overheat Switch L 20 - Starter 28 - Hydraulic Oil Level Switch
4 - Pressure Switch 13 - Overheat Switch H 21 - Air Filter Restriction Switch 29 - Windshield Washer Motor
(Bucket Roll-In)
5 - Horn 14 - Coolant Temperature 22 - Engine Oil Pressure Switch 30 - Pressure Switch (Other)
Sensor (For Monitor)
6 - Work Light 15 - Coolant Level Switch 23 - N (Engine Speed) Sensor 31 - Pressure Switch (Arm Roll-
(On Right Side Frame) In)
7 - Battery 16 - Alternator 24 - Solenoid Valve Unit 32 - Pressure Switch (Boom
(3 Solenoid Valve Used) Raise)
8 - Fuel Sensor 17 - Thermoguard Switch 25 - EC Motor 33 - Pressure Switch (Swing)
9 - Coolant Level Switch
T5-2-2
ELECTRICAL SYSTEM (2)
Relays 1 Battery Area
24 26
27
2 25
3
28
4
5
6 23 29
7
8
9
10
11 30
12
13
22
21
T167-01-02-013
14, 15
20 19 18 17 16 T167-01-02-007
1 - Power Boost Switch 9 - Lubricator Relay (Optional) 17 - Blower Medium 24 - Battery Relay
Position Relay 2
2 - Load Dump Relay 10 - Work Light Relay 1 18 - Blower Medium 25 - Breaker
Position Relay 1
3- Wiper Relay B1 11 - Work Light Relay 2 19 - Compressor Clutch Relay 26 - Ether Relay
4- Washer Relay 12 - Horn Relay 20 - Blower Main Relay 27 - Starter Relay 1
5- Wiper Relay B2 13 - Wiper Relay A 21 - Dr. EX Connector 28 - Starter Relay 2
6- Preheat Relay 1 14 - EC (Top Side) 22 - Fuse Box 29 - Fusible Link 45 A
7- Wiper Relay BM 15 - PVC (Bottom Side) 23 - Battery 30 - Fusible Link 75 A
8- EC Motor Relay 16 - Blower Fast Position Relay
T5-2-3
ELECTRICAL SYSTEM (3)
Monitor and Switch Panels Monitor Panel
10 11 12
13
1 14
15
36 16
2 17
35
18
19
34
33
32
3 20
31
30 21
9
22
8 23
7
6 29
24
28
25
4 27 26
5
M167-01-006
T167-01-02-014
1 - Monitor Panel 10 - Warm Up Complete 19 - Fuel Level Indicator 28 - Wiper Switch

Indicator
2 - Switch Panel 11 - Coolant Temperature 20 - Attachment Mode Indicator 29 - Washer Switch
Gauge
3 - Cigar Lighter 12 - Fuel Gauge 21 - Precision Mode Indicator 30 - Work Light Switch
4 - Option Switch 13 - SP Mode Indicator 22 - Trenching Mode Indicator 31 - Level Check Switch
5 - Air Conditioner Control 14 - E Mode Indicator 23 - General Purpose Mode 32 - Overheat Indicator
Panel Indicator
6 - Engine Control Dial 15 - Auto-Idle Indicator 24 - Work Mode Switch 33 - Engine Oil Pressure
Indicator
7 - E Mode Switch 16 - Hydraulic Oil Level Indica- 25 - Buzzer Stop Switch 34 - Alternator Indicator
tor
8 - SP Mode Switch 17 - Preheat Indicator 26 - Travel Mode Switch 35 - Engine Oil Level Indicator
9 - Key Switch 18 - Air Filter Restriction Indi- 27 - Auto-Idle Switch 36 - Coolant Level Indicator
cator
T5-2-4
(Blank)
T5-2-5
CONTROL VALVE
Left Travel Motor 1 2 3 4 5 6 7 8 9 Right Travel Motor
Travel (L)
41 10
40 11
Travel (R)
39 12
13
38
Bucket
37
Aux. 14
36
Bucket Cylinder
35 Boom 1 15
Boom 2
16
34
Arm 2 17
Arm Cylinder
Arm 1
Boom Cylinder
18
Swing
Swing Motor
19
33 32 31 30 29 28 27 26 25 24 23 22 21 20
T167-01-02-008
1 - Pump Control Valve 12 - Check Valve (Aux. Parallel 22 - Pump Control Valve 32 - Holding Valve Shift Valve
(5-Spool Side) Circuit) (4-Spool Side) (Arm)
2 - Load Check Valve (Left 13 - Load Check Valve 23 - Load Check Valve 33 - Overload Relief Valve
Travel Parallel Circuit) (Boom 1 Parallel Circuit) (Arm 2 Parallel Circuit) (Arm)
3 - Load Check Valve (Aux. 14 - Overload Relief Valve 24 - Check Valve (Arm Flow 34 - Holding Check Valve (Arm)
Parallel Circuit) (Bucket) Combining Circuit)
4 - Check Valve (Bucket Flow 15 - Check Valve (Boom Flow 25 - Check Valve (Aux. Flow 35 - Make-Up Valve (Boom 2)
Combining Circuit) Combining Circuit) Combining Circuit)
5 - Check Valve (Main Relief 16 - Overload Relief Valve 26 - Arm Regenerative Flow 36 - Load Check Valve
Pressure Combining Cir- (Boom) Control Valve (Boom 2 Tandem Circuit)
cuit)
6 - Flow Combiner Valve 17 - Holding Check Valve 27 - Check Valve (Arm 1 Paral- 37 - Load Check Valve
(Boom) lel Circuit) (Boom 2 Parallel Circuit)
7 - Check Valve (Travel Flow 18 - Make-Up Valve (Arm 2) 28 - Load Check Valve 38 - Load Check Valve (Aux.
Combining Circuit) (Arm 1 Parallel Circuit) Tandem Circuit)
8 - Check Valve 19 - DP Sensor (4-Spool Side) 29 - Load Check Valve 39 - Overload Relief Valve
(Swing Tandem Circuit) (Aux.)
9 - Shuttle Valve 20 - Holding Valve Shift Valve 30 - Arm Regenerative Valve 40 - Load Check Valve (Left
(Boom) Travel Tandem Circuit)
10 - Main Relief Valve 21 - Load Check Valve (Arm 2 31 - Load Check Valve 41 - DP Sensor (5 Spool Side)
Tandem Circuit) (Arm 1 Tandem Circuit)
11 - Load Check Valve
(Bucket Tandem Circuit)
T5-2-6
Swing 9 10 1 41
Arm 1
Boom 2
Aux.
Left Travel
Arm 2
Boom 1
Bucket
8
Right Travel Front Side
7 6 T162-05-02-009
T162-05-02-012
42 28 43 14 46 12 47 39
Right Travel Left Travel Bucket Aux.
40
38
3
2
39
T162-05-02-004 T166-01-02-004
45 44
14 49 25 4 48
42 - Right Travel Forward Port 44 - Left Travel Reverse Port 46 - Bucket (Roll Out) Port 48 - Aux. Port
43 - Left Travel Forward Port 45 - Right Travel Reverse Port 47 - Aux. Port 49 - Bucket (Roll-In) Port
T5-2-7
Left Travel Motor 1 2 3 4 5 6 7 8 9 Right Travel Motor

Travel (L)
41 10
40 11
Travel (R)
39 12
13
38
Bucket
37
Aux. 14
36
Bucket Cylinder
35 Boom 1 15
Boom 2
16
34
Arm 2 17
Arm Cylinder
Arm 1
Boom Cylinder
18
Swing
Swing Motor
19
33 32 31 30 29 28 27 26 25 24 23 22 21 20
T167-01-02-008
1 - Pump Control Valve 12 - Check Valve (Aux. Parallel 22 - Pump Control Valve 32 - Holding Valve Shift Valve
(5-Spool Side) Circuit) (4-Spool Side) (Arm)
2 - Load Check Valve (Left 13 - Load Check Valve 23 - Load Check Valve 33 - Overload Relief Valve
Travel Parallel Circuit) (Boom 1 Parallel Circuit) (Arm 2 Parallel Circuit) (Arm)
3 - Load Check Valve (Aux. 14 - Overload Relief Valve 24 - Check Valve (Arm Flow 34 - Holding Check Valve (Arm)
Parallel Circuit) (Bucket) Combining Circuit)
4 - Check Valve (Bucket Flow 15 - Check Valve (Boom Flow 25 - Check Valve (Aux. Flow 35 - Make-Up Valve (Boom 2)
Combining Circuit) Combining Circuit) Combining Circuit)
5 - Check Valve (Main Relief 16 - Overload Relief Valve 26 - Arm Regenerative Flow 36 - Load Check Valve
Pressure Combining Cir- (Boom) Control Valve (Boom 2 Tandem Circuit)
cuit)
6 - Flow Combiner Valve 17 - Holding Check Valve 27 - Check Valve (Arm 1 Paral- 37 - Load Check Valve
(Boom) lel Circuit) (Boom 2 Parallel Circuit)
7 - Check Valve (Travel Flow 18 - Make-Up Valve (Arm 2) 28 - Load Check Valve 38 - Load Check Valve (Aux.
Combining Circuit) (Arm 1 Parallel Circuit) Tandem Circuit)
8 - Check Valve 19 - DP Sensor (4-Spool Side) 29 - Load Check Valve 39 - Overload Relief Valve
(Swing Tandem Circuit) (Aux.)
9 - Shuttle Valve 20 - Holding Valve Shift Valve 30 - Arm Regenerative Valve 40 - Load Check Valve (Left
(Boom) Travel Tandem Circuit)
10 - Main Relief Valve 21 - Load Check Valve (Arm 2 31 - Load Check Valve 41 - DP Sensor (5 Spool Side)
Tandem Circuit) (Arm 1 Tandem Circuit)
11 - Load Check Valve
(Bucket Tandem Circuit)
T5-2-8
43 43 46 24 47
Arm 2 Arm 1
Boom 1 Boom 2
26
35 32
39 34
18
27
36 21 31
36
20
37 28
23
33
T166-01-02-002
17 45 15 44 16 50 49 T167-01-02-009
19 22 50
Swing
33
52 29
T167-01-02-011
18 51 T167-01-02-010
42 - Boom 1 (Lower) Port 45 - Boom 1 (Raise) Port 48 - Arm 1 (Roll-In) Port 51 - Swing (Right) Port
43 - Boom 2 (Lower) Port 46 - Arm 2 (Roll-Out) Port 49 - Arm 2 (Roll-In) Port 52 - Center Bypass Valve
44 - Boom 2 (Lower) Port 47 - Arm 1 (Roll-Out) Port 50 - Swing (Left) port
T5-2-9
OTHERS
2
Pump Device
1
9 8 7 6 5 T167-01-02-003
Solenoid Valve Unit (3 Solenoid Valves Used)
10
11
12
13
T167-01-02-006
1 - Main Pump 1 5 - A (Displacement Angle) 8 - A (Displacement Angle ) 11 - Main Relief Pressure Shift
Sensor (Main Pump 2) Sensor (Main Pump 1) Solenoid Valve
2 - Pilot Pump 6 - Pump Control Proportional 9 - P (Pump Delivery Pres- 12 - Travel Mode Shift Solenoid
Solenoid Valve (Main Pump sure) Sensor Valve
2) (Main Pump 1)
3 - P (Pump Delivery Pres- 7 - Pump Control Proportional 10 - Pilot Relief Valve 13 - Swing Parking Brake Re-
sure) Sensor Solenoid Valve lease Solenoid Valve
(Main Pump 2) (Main Pump 1)
4 - Main Pump 2
T5-2-10
Swing Device 1 Travel Device
T142-01-02-012
T167-01-02-005
1 - Swing Relief Valve 2 - Counterbalance Valve 3 - Travel Relief 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
(1)
• (OK) or No (NOT OK) and proceed to item (2) or (3), as
appropriate.
(3)
NO (NOT OK)
• Special instructions or reference item are indicated in the spaces under the box.
•
Incorrect measuring or checking methods will render troubleshooting impossible,
and may damage components as well.
·Key switch: ON
• Explanation of how to use lamp harness kit required. Refer to “Harness Check”
•
Group (Group 7) in this section.
• Use Dr. EX function.

•
• Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
•
causes can be seen without going through the flow chart.
T5-3-1
EC-RELATED FAULT CODES

uncontrollable
02 Failure (type-2) of EC Retry diagnostic procedure A.
Replace EC if engine governor is
uncontrollable
uncontrollable
uncontrollable with eight or more number of
errors indicated in self-deagnosis.
05 Signal from PVC is not transmitted 1) Retry diagnostic procedure B.
to EC 2) Check harness
3) If auto-idle is abnormal replace PVC or EC.
06 Failure (type-6) of EC 1) Retry diagnostic procedure B.
uncontrollable
07 ∗ Short-circuit of auxiliary sensor 2 1) Retry diagnostic procedure B.
2) Check harness
08 ∗ Discontinuity of auxiliary sensor 2. 1) Retry diagnostic procedure B.
2) Check harness
09 Short circuit of EC sensor 1) Retry diagnostic procedure B.
2) Check harness
10 Discontinuity of EC sensor. 1) Retry diagnostic procedure B.
2) Check harness
11 Short-circuit of Eng. Governor 1) Retry diagnostic procedure B.
Dial/Lever angle sensor. 2) Check harness
12 Discontinuity of Eng. Governor 3) Replace Eng. Governor Dial/Lever angle
Dial/Lever angle sensor. sensor.
13 N sensor malfunction. 1) Retry diagnostic procedure B.
2) Check harness
3) Replace N sensor
14 Discontinuity of overheat switch L 1) Retry diagnostic procedure B.
and/or T sensor. 2) Check harness
3) Replace overheat switch and/ or T sensor.
T5-3-2
PVC-RELATED FAULT CODES

17 Failure (type-17) of PVC 1) Retry diagnostic procedure A.
18 Failure (type-18) of PVC 2) If engine stalls or working speed is
19 Failure (type-19) of PVC abnormal replace PVC.
20 Signal from EC is not transmitted 1) Retry diagnostic procedure B.
to PVC 2) Check harness
3) If speed sensing control is abnormal
replace PVC and/or EC.
21 Failure (type-21) of PVC 1) Retry diagnostic procedure B.
22 Failure (type-22) of PVC 2) Replace PVC
23 Pump control malfunction (4-spool 1) Retry diagnostic procedure B.
side) 2) If engine stalls or working speed is
24 Pump control malfunction (5-spool abnormal refer to service manual.
side)
26 Discontinuty of DP sensor (4-spool 3) Replace DP sensor (4-spool side)
side).
27 Short-Circuit of P sensor (4-spool 1) Retry diagnostic procedure B.
side). 2) Check harness
side)
29 Short circuit of A sensor (4-Spool 1) Retry diagnostic procedure B.
30 Discontinuity of A sensor (4-spool 3) Replace A sensor (4-spool side)
side)
34 Discontinuity of DP sensor (5- 3) Replace DP sensor (5-spool side)
spool side)
35 Short circuit of P sensor (5-Spool 1) Retry diagnostic procedure B.
36 Discontinuity of P sensor (5-Spool 3) Replace P sensor (5-Spool side)
side)
37 Short circuit of A sensor (5-Spool 1) Retry diagnostic procedure B.
38 Discontinuty of A sensor (5-Spool 3) Replace A sensor (5-Spool side)
side)
40 ∗ Short-circuit of auxiliary sensor 3. 1) Retry diagnostic procedure B.
2) Check harness
∗ Aux. sensor 3 is used to monitor bucket roll-in

pressure switch operation.
T5-3-3
FAULT CODES 01, 02, 03, 04, 06
[Failure (type-1, 2, 3, 4, 6) of EC]
Replace the EC if the machine shows any abnormali- ∗ However, the machine can be used without
ties and if fault code(s) are still indicated after perform- replacing the EC if the machine functions normally
ing applicable “Retrial”. despite the fact that the fault code(s) are indicated
after performing applicable “Retrial”.
Fault Codes 01, 02, and 03
YES Normal
Check if fault codes

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

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

disappears after Re-
NO ∗ EC failure
trial B.
·Perform Retrial B a Check if engine

few times if fault speed changes with
NO engine control dial.
code does not dis-
appear after one Replace EC.
trial. YES
T5-3-4
FAULT CODE 05
(Signal from PVC is not Transmitted to
EC)
The PVC, EC, or the harness between the PVC and ∗ However, the machine can be used without
EC may have failed if the auto-idle does not function replacing the EC or PVC if the machine functions
normally and if fault code 05 is still indicated after normally despite the fact that the fault code is still
Retrial B. indicated after Retrial B.
YES Normal
Check if fault code

disappears after Re-
trial B. YES ∗ PVC or EC failure
·Perform Retrial B a Check if auto-idle

few times if fault Disconnect harness end connec-
NO functions normally. tors from PVC and EC.
code does not dis-
appear after one Check if continuity exists between YES Replace PVC and
trial. terminals stated below: EC.
• PVC harness end connector
terminal No. 4 and EC harness
NO end connector terminal No. 9
• PVC harness end connector Failure of harness
terminal No. 5 and EC harness between PVC and
NO
end connector terminal No. 3 EC.
end connector terminal No. 2
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
(Short Circuit and Discontinuity of EC
Sensor)
Fault code 09 indicates the input voltage from the EC

sensor is 4.75 V or more.
Fault code 10 indicates the input voltage from the EC
sensor is 0.25 V or less.
YES Normal
Check if breakage
or short circuit ex- NO EC failure
Check if fault code ists in the line be-
disappears after Re- Disconnect EC tween EC connec-
Disconnect EC sen-
trial B. sensor connector. YES tor terminal No. 34
sor connector. Check
if resistance between Check if voltage be- and EC sensor
·Perform Retrial B EC side connector YES tween harness end connector terminal
Harness failure be-
a few times if fault terminals No. 1 and connector terminals No.2.
code does not No. 1 and No. 3 is YES tween EC and EC
No. 3 is 1.7±0.4 kΩ. sensor.
disappear after Connect test harness 5±0.5 V. ·Fault code 09:
one trial. (ST7129) to EC sen- Check for short
NO ·Key switch: ON circuit.
sor. Check if voltage
varies as specified Fault code 10:
when engine control Check for break-
dial is operated. age.
·Specified voltage:
Refer to T5-3-17.
Harness failure be-

NO tween EC and EC
sensor.
EC sensor failure
NO
EC Harness End Connector (Open End Side)
34
EC Sensor Side Connector (Open End Side)
Harness End Connector

(Red) (Open End Side)
3 2 1 EC Sensor
(Black)
Ω V
ST7129
1 2 3
EC 21 34 35
T107-07-03-009 T162-05-03-005
T107-07-03-008
T5-3-6
FAULT CODES 11, 12
(Short Circuit and Discontinuty of Eng.
Governor Dial/Lever Angle Sensor)
YES Normal
Disconnect engine
control dial connec-
tor. Check if resis- Check if breakage
Check if fault code YES Harness failure be-
tance between en- or short circuit ex- tween EC and en-
disappears after Re- gine dial side connec- ists in the line be- gine control dial.
trial B. Disconnect engine YES tween EC connec-
tor terminals No. 5 control dial connec-
and No. 7 is 5.0±0.5 tor terminal No. 23
·Perform Retrial B tor. Check if voltage and engine control
kΩ. YES between harness
a few times if fault Reconnect engine dial connector ter- EC failure
code does not end connector terminal No.6. NO
control dial connec- minals No. 5 and
disappear after tor. Insert test probes
one trial. No. 7 is 5±0.5 V.
from the back of en-
NO gine control dial con- ·Key switch: ON
nector: (-) probe on
terminal No. 7 and
(+) probe on terminal
No. 5. Check if volt-
age varies as speci-
fied when engine
control dial is oper-
ated. Harness failure be-
tween EC and en-
·Specified voltage: NO gine control dial.
0.3 to 1.0 V with en-
gine control dial at
slow idle
Engine control dial
4.0 to 4.7 V with en-
NO failure
gine control dial at
fast idle
EC Harness Side Connector (Open End Side)
23
Engine Control Dial Side Connector Engine Control Engine Control Dial
(Open End Side) Dial Side (Harness Side) Harness End Connector
(Open End Side)
7 6 5
5 6 7 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 Malfunction)
Check the engine speed using the Dr. EX monitoring

function. If breakage exists in the harness between the
N sensor and EC, EC judges that the engine speed is
-1
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 connec-
tors from the N sen-
Check if fault code sor and EC. Connect
disappears after Re- N sensor harness YES EC failure
trial B. end connector termi-
nals No. 1 and No. 2
YES using a clip. Check if
·Perform Retrial B a
few times if fault Disconnect N sensor continuity exists be-
code does not dis- connector. Check if tween EC harness Harness failure be-
appear after one resistance between N end connector termi- tween EC and N
sensor side connec- nals No. 4 and No. NO
trial. NO sensor
tor terminals No. 1 11.
and No. 2 is 810±240
Ω.
N sensor failure.
NO
N Sensor Side Connector N Sensor

(Open End Side) Harness End Connector
(Open End Side)
1 2
1 2
– + 4
11
EC Ω
Harness End
Connector
(Open End Side)
T162-05-03-009
T5-3-8
FAULT CODE 14
(Discontinuity of Overheat Switch L and/or
Hydraulic Oil Temperature Sensor)
Fault code 14 indicates that the input voltage from the However, if the coolant temperature exceeds 95 °C
sensor is 4.75 V or more. In this case, harness (203 °F) causing overheat switch L to turn on, Dr. EX
breakage between the EC and the overheat switch L / also indicates 120 °C (248 °F).
the hydraulic oil temperature sensor may be the cause.
In addition, Dr.EX indicates -45 °C (-49 °F) in this case.
If the harness between the EC and the overheat switch
L / hydraulic oil temperature sensor short-circuits, Dr.
EX indicates 120 °C (248 °F).
Connect hydraulic oil YES EC failure

temperature sensor har-
ness end connector ter-
minals No. 1 and No. 2
using a clip. Harness breakage
YES Ground 48P harness
Disconnect 48P connec- between EC and
end connector terminals YES
tor from the EC. Check if hydraulic oil tem-
continuity exists between No. 33 to vehicle frame. perature sensor
Disconnect hydraulic 48P harness end con- Check if continuity ex- terminal No. 2.
oil temperature sen- nector terminals No. 33 ists between hydraulic
sor connector. Check and No. 35. NO oil temperature sensor
if resistance at hy- harness end connector
terminal No. 1 and ve- Harness breakage
draulic oil tempera- between EC and hy-
ture sensor side con- hicle frame.
draulic oil tempera-
nector is within stan- NO ture sensor terminal
dard value range. No. 1.
·Standard value:
Refer to the table
Hydraulic oil tem-
below.
NO perature sensor
failure
Hydraulic Oil Temperature Sensor Overheat Switch L
Hydraulic Oil Resistance Coolant Temperature Switch Operation

Temperature °C kΩ °C (°F)
(°F) 93 to 97 (199 to 207) ON
-20 (-4) 16.2±1.6 88 to 97 (190 to 207) OFF
0 (32) (5.88)
20 (68) 2.45±0.24
40 (104) (1.14)
60 (140) (0.534)
80 (176) 0.322
EC (48P) Hydraulic Oil Temperature Sensor
1 2
35 33
T5-3-9
FAULT CODES 17, 18, 19, 21, 22
[Failure (type-17, 18, 19, 21, 22) of PVC
Replace the PVC if the machine shows any

abnormalities and if fault code(s) are still indicated
∗ 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
Fault Codes 17, 18, 19
YES Normal
Check if fault codes disappear

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

after Retrial B.
·Perform Retrial B a few times

if fault codes do not disappear Replace PVC.
after one trial. NO
T5-3-10
FAULT CODE 20
(Signal from EC is not Transmitted to
PVC)
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 Retrial B. OK ∗ Failure of PVC/EC
·Perform Retrial B a few times
if fault code does not disap- Check the harness between
pear after one trial. NO PVC and EC.
·Refer to page T5-3-5. Harness failure between PVC

NOT OK and EC
T5-3-11
FAULT CODES 23, 24
(Pump Control Malfunction)
Fault codes 23 and 24 are indicated when the target One of the following may be the cause:
pump displacement does not match with the actual 1. Pump control solenoid valve failure.
pump displacement. 2. A sensor failure
3. PVC failure
If any other codes are also indicated, troubleshoot
those codes first.
PVC
37 3 106
10 114
OK
1
Pump Control Solenoid Valve Check harness
NOT OK between fuse No.
8 and PVC termi-
nal No. 37.
Troubleshoot us-
1 2 2
ing indicated fault YES Check fuse No. 8. ·Be sure to re-
YES codes (other than NOT OK
place failed fuse
Check if any fault 23 and 24). (No. 8) after the
NO codes other than cause is found. OK
23 and 24 are in- 3
dicated. Check if fault
code 23 is indi- OK 4
NO cated. NOT OK
OK
5
Check if fault YES Check fuse No. 8.
codes disappear
after Retrial B. Check if fault 6
code 24 is indi- NOT OK
NO cated.
·Perform Retrial Normal
B a few times if YES Normal
NO
fault codes do
not disappear
Disconnect one A
after one trial.
Check if machine sensor. Check if A sensor failure
and engine oper- machine and en- or loose or incor-
YES ate normally. gine operate nor- YES rect connection of
mally. Reconnect A sensor.
A sensor and
check if machine
NO and engine oper-
ate normally. Re- Failure of PVC or
peat the same pump.
NO
procedure for the
other A sensor.
·If machine and

engine operate
normally when
one of A sensors
is disconnected,
the disconnected
A sensor has
failed.
·Refer to T5-4-39.
T5-3-12
NOTE: (4) : 4-Spool Control Valve Side OK Failure of PVC or

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

4 No. 8 and PVC terminal No. between pump con- pump (5).
37.
OK trol solenoid valve
(5) connector termi-
Check if continuity exists be- nals No. 1 and No.
tween pump control solenoid 2.
valve (5) harness end con- Pump control valve
nector terminals No. 1 and · Standard value: NOT OK solenoid valve (5)
No. 2. ·14±3 Ω at 20 °C failure.
OK Connect PVC side harness
end connector terminal No. (68 °F)
114 (No. 106) to vehicle
frame using a clip. Check if Harness failure be-
continuity exists between
pump control solenoid valve tween pump control
5 (5) harness end connector solenoid valve (5)
terminal No. 1 (No. 2) and ve- NOT OK and PVC.
hicle frame.
Check if continuity exists be- Check resistance

Harness failure between fuse
tween pump control solenoid OK Failure of PVC or
No. 8 and PVC terminal No. between pump con- pump (5).
NOT valve (5) harness end connector trol solenoid valve
37.
OK terminals No. 1 and No. 2. OK (5) connector termi-
Connect PVC side harness end nals No. 1 and No.
connector terminal No. 114 (No.
106) to vehicle frame using a 2. Pump control valve
OK clip. Check if continuity exists solenoid valve (5)
between pump control solenoid ·Standard value: NOT OK failure.
Check harness
valve (5) harness end connector 14±3 Ω at 20 °C
terminal No. 1 (No. 2) and vehi- (68 °F)
between fuse cle frame.
6 No. 8 and PVC
terminal No. 37. Harness failure be-
NOT OK tween pump control
Harness failure between fuse No. solenoid valve (5)
NOT OK 8 and PVC terminal No.37. and PVC.
T5-3-13
FAULT CODES 26, 34
(Discontinuty of DP Sensor)
Fault codes 26 and 34 indicate input from the DP

sensor is 0.25 V or less. Harness breakage between
DP sensor and PVC may be the cause.
Check harness NO PVC failure

lines between
PVC connector
YES terminal No. 44
(No. 32) and DP Harness break-
sensor terminal age between
No. 2 for harness PVC and DP
breakage. YES sensor terminal
Disconnect DP ·Fault codes 26 No.2.
sensor connector. and 34:
Check if voltage Check for harness
YES between harness breakage.
end connector
terminals No. 1
and No. 3 is
5±0.5 V. Harness break-
Attach test har- NO age between
ness (ST 7129) ·Key switch: ON Check if voltage PVC and DP
between DP sen- between the har- sensor terminal
NO sor and harness ness end connec- No.1.
end. Check if indi- tor terminal No.1
cated voltage is NO and vehicle frame Harness break-
+0.15
0.4 – 0.1 or less. is 5±0.5 V. age between
PVC and DP
·Key switch: ON ·Key switch: ON YES sensor terminal
Check if fault code ·Fault code 26: 4- No.3.
disappears after spool side DP
Retrial B. sensor
Fault code 34: 5- DP sensor failure.
·Perform Retrial B a spool side DP
sensor NO
few times if fault
codes does not
disappear after one Normal
trial.
YES
PVC
(5-Spool Side)
32
44
Black
Red (4-Spool Side)
ST 7129
DP Sensor
ȑ Ȓ ȓ
T162-05-03-004
T5-3-14
FAULT CODES 27, 28, 35, 36
(Short Circuit and Discontinuity of
P Sensor)
Fault codes 27 and 35 indicate the input from the P

sensor is 4.75 V or more. Short circuit between the P
sensor and PVC may be the cause.
Fault codes 28 and 36 indicate the input from the P
the P sensor and PVC may be the cause.
Check harness
lines between the NO PVC failure
PVC connector
terminal No. 42
YES (No. 31) and P
Disconnect P sensor terminal Harness failure
sensor connector. No. 2 for harness between PVC
Check if voltage breakage (short and P sensor.
circuit). YES
NO between harness
end connector
Switch pump 1 terminals No. 1
side P sensor and No. 3 is
with pump 2 side 5±0.5 V.
NO P sensor. Check Harness failure
if indicated fault ·Key switch: ON between PVC
code changes to NO and P sensor.
the one for the
other P sensor.
P sensor failure
·Fault codes 27
Check if fault code YES
and 28: Fault
disappears after codes for pump
Retrial B. 2 side P sensor
·Fault codes 35
·Perform Retrial B and 36: Fault
a few times if fault codes for pump
codes does not 1 side P sensor
disappear after Normal
one trial. YES
PVC P Sensor
(5-Spool Side)
31
42 1 2 3
(4-Spool Side)
T5-3-15
FAULT CODES 29, 30, 37, 38
(Short Circuit and Discontinuity of A
Sensor)
Fault codes 29 and 37 indicate the input from the A

sensor is 4.75 V or more. Short circuit between the A
sensor and PVC may be the cause.
Fault codes 30 and 38 indicate the input from the A
the A sensor and PVC may be the cause.
Check the harness

lines between PVC NO Failure of PVC or
connector terminal A sensor
YES No. 30 (No. 22) and A
sensor terminal No. 2
Disconnect the A sen- for harness breakage Harness failure be-
sor connector. Check if (short circuit). tween PVC and A
NO voltage between the YES sensor.
harness end connector
terminals No. 1 and No.
3 is 5±0.5 V.
·Key switch: ON Harness failure be-
·Fault codes 29 and 30: tween PVC and A
Check if fault code NO
Fault codes for pump 2 sensor.
disappears after
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 does not
disappear after one Normal
trial.
YES
PVC A Sensor
(Pump 1)
22
30 1 2 3
(Pump 2)
T5-3-16
SENSOR OPERATING RANGE LIST
1. Measurement Preconditions SP Mode E

Switch Mode
• Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
• Unless otherwise instructed, set the switches as
follows:
Engine Work
SP Mode HP Mode Auto-Idle Slow Fast
Control Mode
Switch Switch Switch
Dial Switch
General
Fast Idle
ON OFF Purpose OFF
(Max.)
Mode
• Monitor using the Dr.EX. Engine Control

M142-01-047
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
P (Pump Control Levers: Neutral 25
+15
kgf/cm2
-7
Delivery
Pressure) +15
Sensor Boom Raise: Full Stroke, Relieved 300 -5 kgf/cm2
Control Levers: Neutral 66 cc/rev.
A Sensor One Track Jacked-Up,
Travel Lever (Raised Track Side): 249 cc/rev.
Full Stroke
Control Levers: Neutral 26 kgf/cm2
Pump Control
Pressure Sensor One Track Jacked-Up,
Travel Lever (Raise Track Side): Full 0 kgf/cm2
Stroke
NOTE: 1 kgf/cm2=0.09807 Mpa

3
1 cc/rev=1 cm /rev
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 machine may show.
• How to Read the Troubleshooting Flow Charts

YES (OK)
(2)
• After checking or measuring item (1), select either YES

• (1)
(OK) or NO (NOT OK) and proceed to item (2) or (3), as
appropriate.
(3)
NO (NOT OK)
• Special instructions or reference item are indicated in the spaces under the
• box. Incorrect measuring or checking methods will render troubleshooting
impossible, and may damage components as well.
ѕʝKey switch: ON
• Explanation of how to use lamp harness kit required. Refer to “Harness

• Check” Group (Group 7) in this section.
• Use Dr. EX function.

•
• Causes are stated in a thick-line box. Scanning through thick-line boxes,

• possible causes can be seen without going through the flow chart.
NOTE: For all connector drawings illustrated in this

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

T158-05-03-001
One End Side
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.
PVC EC DP Sensor
(Pump and Valve Controller) (Engine Controller) (Differential Pressure Sensor)
Designated Function • Controls main hydraulic • Controls engine • Senses differential pressure
pump and main control speed. for pump displacement angle
valve. control.
Effects in Control • Loss of pump and/or valve • Loss of engine speed • Loss of main pump
System control. (Loss of pump control. displacement angle control.
control has resulted more
often than loss of valve
control.)
Abnormalities that the • Slow actuator speed. (Pump • Loss of engine speed • Correct metering may not be
machine may show. fixed to the minimum control. obtained.
displacement angle.) • Abnormal sound is heard from
• Engine may stall. (Pump the control valve with control
fixed to the maximum levers in neutral.
displacement angle.) • Excessively high oil and
• Actuator speed may vary coolant temperature.
unstably. (Displacement • Slow actuator speed.
angle varies unstably.) • Machine mistracks.
Dr.EX Self- • Dr.EX may display “Can not • Dr.EX displays fault • Dr.EX displays fault code 26 or
Diagnosing communicate with PVC” or code 01, 02, 03, 04, 34.
Function one or more of the following 05, or 06.
fault codes may be
displayed: 17, 18, 19, 20, 21,
and 22.
Dr.EX • Check the DP sensor pressure

Monitor with 3-F6.
− −
Function
Trouble-
Test Harness
shooting
Check − − −
Pro-
cedures Other − − −
Note • Check fuse No. 8 (for PVC) • Check fuse No. 2
output side for wire (for EC) output side
breakage. for wire breakage.
• Be sure that the bolt on the • Be sure that the bolt
PVC connector is tight. on the PVC
connector is tight. −
T5-4-2
N Sensor A Sensor (Pump (P Sensor) EC Sensor

(Engine Speed Sensor) Displacement Angle Sensor) Pressure Sensor (Engine Control Sensor)
• Senses engine (pump) • Senses main hydraulic • Senses main hydraulic • Senses governor lever
speed. pump displacement pump delivery pressure. position.
angle.
• Loss of speed sensing • Loss of pump control. • Loss of horsepower • Loss of learning control for
control. (This happens control. governor lever maximum
when engine speed speed position.
signal is not sent to the
EC due to harness
breakage, etc.)
• Engine stalls when • Machine mistracks. (It • Actuator maximum speed • Engine speed cannot be
operating under severe may be noticed when will decrease. controlled from slow idle to
conditions, such as traveling straight.) • Engine may stall. fast idle with engine speed
when operating at high • Engine overload or control dial. (Engine can be
altitude. decrease in speed may started.)
result. • EC motor moves beyond the
control range.
• Dr. EX displays fault • Dr. EX displays fault code • Dr. EX displays fault code • Dr. EX displays fault code 09
code 13 when engine 23, 24 ,29, 30, 37, or 38. 27, 28, 35 or 36. or 10.
speed is not within
specification. No fault
code is displayed if
circuit between N
sensor and EC is open.
• Monitor engine speed. • Monitor and compare the • Monitor pump delivery
pump displacement target pressure. If P sensor
angle and the pump harness is open, 0 kgf/cm
2 −
displacement angle. will be indicated.
− − − −
− − − −
If EC sensor fails, the fast idle
speed is set using the
previous learning value or the
backup value. For this reason,
the machine can still operate
− − − almost normally. However,
after the EC is replaced, the
machine may show
abnormalities described as no
fast idle values are stored in a
new EC.
T5-4-3
Overheat Switch L,
Pump Control Solenoid Swing Preference Circuit Shift
Hydraulic Oil Temperature
Valve Solenoid Valve
Sensor
Designated Function • Senses hydraulic oil and • Shifts the pump • Turns on/off the pilot
coolant temperatures. displacement angle. pressure to shift (turn
on/off) the swing
preference circuit.
Effects in Control System • Loss of overheat • Loss of pump control. • Loss of swing preference
prevention control. circuit shifting (turning
• Loss of auto warm-up on/off) control.
function.
Abnormalities that the • Slow actuator speed may • Pump flow rate becomes • Priority is given to swing
machine may show. result if sensor signal line minimum if the harness in swing/boom raise
is short-circuited. has an open. combined operation.
• Auto warm-up function is • In the trenching mode,
not operating. priority is not given to
swing in swing/boom raise
combined operation.
Dr.EX Self- • Dr.EX displays fault code • Dr.EX displays fault code
Diagnosing 14. 23 or 24. −
Function
Dr.EX • Check signals from the
Monitor swing and boom raise
Function − − pressure switches and from
the work mode switch for
any abnormalities.
Trouble- Test Harness
shooting Check − − −
Proce-
dure Other
− − −
Note
− − −
T5-4-4
Travel Mode Shift Main Relief Pressure Shift

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

− − − 11 or 12.
• Operate and return the • Monitor the input signal

travel lever, and confirm that for engine control dial
− the travel code on Dr. EX − angle. (If it is 1.0 to 4.0 V,
goes to the reverse video engine control dial is
and returns to the normal normal.)
− - − −
• The solenoid valve function • EC motor is
is considered normal if the considered normal if
main relief pressure rises governor lever moves
− temporarily when a front when key switch is −
function, i.e. boom, arm, or turned to ON position.
bucket, is relieved in the
precision mode.
− − − −
T5-4-5
CORRELATION BETWEEN TROUBLES
AND PART FAILURES
Pump
Engine Control Controll Electrical Parts
Eng. EC EC EC N Pres. Pres. Pres. Arm Others
Cont. Motor Sensor Motor Sensor Sw. Sw. Sw. Roll-
Dial Relay (Travel) (Swing) (Boom In
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 Auto-Idle does not function.
{ { { { { { { {
E-5 Engine stalls with engine
control dial turned to fast idle
position.
With engine control dial
turned to fast idle position
{ {
and auto-idle switched turned
ON, engine sometimes stalls
while operating.
Slow idle speed is
excessively slow or fast.
E-6 Engine speed does not
change with engine control { { {
dial.
Pump Control Valve Cont. Electrical Parts

Pump P DP A Swing Swing Hyd. Work SP E
Cont. Sensor Sensor Sensor Pref. Park. Temp. Mode Mode Mode
Prop. Sol. Brake Sensor Sw. Sw. Sw.
Sol. Valve Sol. /Over-
Valve Valve hert
Sw. L
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
levers 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
{ {
responsiveness is slow.
NOTE: The above table shows the correlation supposing that each trouble occurs
between machine operation trouble and independently. If any other trouble occur at
related parts which may cause trouble. the same time, find out the faulty parts
However, the correlations in this table are causing the trouble by checking all
described based on the condition suspected parts in each symptom.
T5-4-6
Electrical Parts Engine

Bucket Key Fuel Bat- Starter Starter Moni- EC Eng. Gover Fuel Gauze EC
Roll-In Sw. Sol. tery Relay tor Unit nor Filter Filter Motor
Valve Relay /Auto- Link
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
Pres.
Pump Control Valve Control Sw. Electrical Parts Pump
P DP A Swing Travel Travel Power Moni- PVC Pump
Sensor Sensor Sensor Pref. Mode Boost tor Unit
Sol. Shift Sw. /Auto-
Valve Sol. Idle
Valve Sw.
F-1 Front attachment cylinder(s)

{
move slowly or do not move.
F-2 Bucket drops excessively.
F-3 In the beginning of front

attachment operation, bucket
drops slightly.
F-4 Power does not increase with
power boost switch turned on. {
S-1 Upperstructure does not

rotate, rotates slowly, or { {
swing power is weak.
S-2 Upperstructure coasts
excessively 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 Swing Boom Arm Work Monitor
Sensor Sensor Sensor Pref. Relief Raise Roll- Mode /Auto-
Sol. Pres. In Sw. Idle
Valve Sol. Sw.
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 Main Over- Load Hold- Swing Travel Center Shut- Shock Pilot Pilot Cylin-
Spool Relief load Check ing Device Device Joint tle -less Shut- Valve der
Valve Relief Valve Valve Valve Valve Off
Valve Valve
{ { { { { { {
{ { { {
{ { { {
{ { { { { {
{ { {
{ {
{ { { { {
Electrical Parts Pump

Wiper PVC Pump
Sw. Unit
T5-4-9
ENGINE SYSTEM TROUBLESHOOTING

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

relay 1 terminal No. 1, at
terminals B and at terminal
S are not 24 V with key
switch in START position.
ʝ 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. Turn the key switch to the ON or START position. S
2 B
2. Connect the negative probe of a circuit tester to
1
the vehicle frame (unpainted surface such as a
bolt head). Connect the positive probe to starter
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

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

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

Terminal No. 6: 24 V 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. ST G1 ACC

V
3. With the key switch connected to the harness,
measure voltage at terminals No. 1 and No. 6. View A
(Insert the probe from the back of the connector.)
B G2 M
T105-07-04-002
T5-4-11
E-2 Starter rotates but engine does not start.
Checking Instruction:
• 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.
ѕʝRefer to the engine shop

manual.
Check if fuel solenoid valve
operates (If operating sound
is heard from fuel solenoid NO Harness breakage between
valve). fuel solenlid valve and fuse
No. 5.
Key switch: OFF↔ON
Disconnect the harness end

from fuel solenoid valve.
NO Check if harness end valtage
is 24 V.
ѕʝKey switch: ON
Fuel solenoid valve failure.

YES
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.
YES Thermoguard switch

Disconnect failure
white/black wire
connector from
YES
thermoguaud switch. Harness failure between
Ground harness end YES thermoguard switch and
connector terminal Re-connect the con-
starting aide solenoid
and check if the start- nector.Discon-nect
valve.
ing aid system oper- white/black wire plug
Check if ether bot- ates. NO from starting aid so-
lenoid valve. Ground Re-connect the plug.
tle is securely in- ·Key switch: START solenoid valve side Disconnect
stalled.
plug and check if the brown/white wire end
·Confirm that ether starting aid system from starting aid sole-
NO noid valve. Measure
bottle is not empty. operates.
voltage at the discon-
·Key switch: START nected harness end.
Insecure ether bottle

NO installation.
T5-4-14
24 V Starting aid solenoid

valve failure.
Starting aid switch fail-

YES
ure.
Re-connect the dis-
connected wire. Dis- Harness breakage be-
connect the starting Re-connect the dis- tween fuse box and
0V
aid switch connector. connected wire. Dis- starting aid relay, or
0V connect starting aid
Connect the connec- blown starting aid fuse.
tor termimals with a relay connector.
clip and check if start- Check voltage at
ing aid system oper- NO white wire connector Re-connect the dis-
connected wire. Dis- 0V Harness breakage be-
ates. terminal.
connect yellow/blue tween starting aid relay
·Key switch: START ·Key switch: START connector from start- and starting aid switch
24 V ing aid relay. Check
voltage at harness
end connector termi- Starting aid relay failure
nal. or harness breakage
24 V between starting aid
solenoid valve and
starting aid relay.
NOTE: Be sure to
also check ground
line.
T5-4-15
E-4 Auto-idle does not function.
Required Preconditions:
• EC motor and EC sensor are functioning normally.
• 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
been replaced, increase the engine speed to the
maximum (fast idle) speed.
Pressure switch (travel, swing,
boom raise, arm roll-in, bucket
roll-in and/or others) failure.
NO Harness failure between PVC
and pressure switches.
Restriction of filter in pilot sig-
Monitor pressure switches nal circuit.
(travel, swing, boom raise,
arm roll-in, bucket roll-in and Note: Pressure switch location:
others). Pressure switch (travel): Travel shuttle valve
ȹȥȳ Check if letters “Tr”, “Sw”,
Pressure switch (swing): Swing shuttle valve
“Bm”, “Am”, Bucket and “Ot” Pressure switch (boom raise): Shockless valve
turn reverse video when re- Pressure switch (arm roll-in): Shockless valve
spective control lever is oper- Pressure switch (bucket roll-in): Swing shuttle valve
Monitor auto-idle switch. ated. Pressure switch (others): Swing shuttle valve
Check if letters “On” turn re- ·Monitor items: No 8-F6
verse video. EC failure.
No 15-F8
YES
·Monitor item No 11-F6
Auto-idle switch failure, or

harness breakage between
NO auto-idle switch and EC.
T5-4-16
E-5 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
• If the EC sensor has failed, the governor lever fast Moreover, because the fast idle position may vary
idle position learning will not be performed when depending on the governor lever position when
the key switch is turned to the ON position. (The the key switch is turned to the ON position, the
slow idle position learning will be performed.) For trouble may not appear constantly.
this reason, the fast idle is set referring to the N sensor failure may be the cause if the engine
previously performed fast idle position learning or stalls under severe operating conditions such as
the preset fast idle. operation at high altitude.
YES EC sensor failure.
·Refer to page T5-4-40.
YES End
Check if fault code
09 or 10 is indi-
cated.
YES
Check if governor Failure of engine
lever comes into unit and fuel sys-
Restart engine. contact with stop- tem.
Check if the trouble per when the key
NO disappears. YES switch is turned to
the ON position Control cable fail-
(when the slow idle ure. Incorrect en-
position learning is gine governor
Turn engine control performed). lever adjustment.
dial and monitor EC NO
Torque limiter fail-
angle. Check if EC ure.
angle changes as
NO engine speed ·Refer to T5-4-40.
changes.
EC failure, harness
·Monitor items No 9-F6
failure between EC
No 10-F6
motor and EC, or
NO blown fuse No. 2
or No. 3.
T5-4-17
E-6 Engine speed does not change with engine
control dial.
• If the above phenomenon occurs after the EC is
replaced, EX sensor failure may be the cause.
Related Fault Codes: 11, 12
Engine control dial failure, or

YES 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. Turn
·Refer to page T5-4-40.
engine control dial and check
NO if test harness lamp comes on.
EC failure, or harness break-
NO age between EC and EC mo-
tor.
T5-4-18
TOTAL ACTUATOR SYSTEM TROUBLE-
SHOOTING
A-1 All cylinders and motors move slowly or do
not move.
• Pilot system (pilot pump, pilot relief valve, pilot
shut-off valve), relief valve circuit, work mode
select switch circuit, or overheat switch
L/hydraulic oil temperature sensor circuit may Move pilot control
have failed. NO shut-off lever to
UNLOCK position.
Check if pilot con-

trol shut-off lever is NO Work mode selec-
in UNLOCK posi- tor failure.
tion.
Remove, disas- NO End

Check if work semble, clean,
mode can be NO and reassemble
YES shifted. pilot relief valve.
Check if trouble
still exists. Pilot pump failure.
·Key switch: ON
·Monitor Item No 7-F8 YES
Check if primary
pilot pressure is
YES normal. NO Main relief valve
failure.
·Engine speed: SP
mode Check if main
·Refer to OPERA- YES relief pressure is Check if let-
TIONAL PER- normal.
ters “ON” for
FORMANCE ·Monitor items No 1-F7 overheat
TEST section for A
No 3-F7 YES switch L turn
pressure meas- ·Refer to OPERA- reverse video.
urement proce- TIONAL PERFORM-
dure. ANCE TEST section for ·Key switch: ON
pressure measurement ·Monitor item No 13-F8
procedure.
YES Overheat of coolant

Check if coolant and/or hydraulic oil.
temperature ex-
ceeds 95 °C (203
A
°F) or if hydraulic oil
temperature ex-
Check overheat
ceeds 120 °C (248
switch L / hydraulic oil
°F).
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.
• Switching part(s) in 4-spool control valve side with
those in 5-spool side, it can be judged that
switched part(s) have failed if the trouble appears
on the other side.
• Pump control sensors (DP sensor, A sensor),
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
pressure again
NO with engine
stopped. Is it 4
kgf/cm2 or less?
Operate one con-
trol lever and moni- ·Key switch: ON DP sensor circuit har-
tor the correspond- ·Monitor items No 1-F6 YES ness failure.
ing DP sensor Ȁ No 3-F6
pressure. Is it 4
2 DP sensor failure.
kgf/cm or less? YES
·Engine: Running Switch DP sensors

·Monitor items No 1-F6 with each other.
No 3-F6 Check if slower
YES side becomes YES Insecure or incorrect A
normal. sensor installation, or A
Remove A sensor.
Check if slower sensor failure
NO side becomes ·Refer to T5-4-41.
normal.
A
NO
Check if target pump

flow rate is the minimum Insecure A sensor
value with control levers YES installation or the cor-
in neutral. responding main
Also, check if target pump failure.
pump flow rate is the
A maximum when one ·Refer to T5-4-41.
travel lever is operated
full stroke while the cor- Pump control sole-
responding track is noid valve circuit fail-
NO ure
jacked up.
·Control levers in neutral:

3
Minimum value 66 cm /rev.
Travel lever full stroke:
3
Maximum value 249 cm /rev.
·Monitor Items No 2-F6
No 4-F6
T5-4-20
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

Pull up pilot control shut-off falsely routed to the control
lever and check if cylinders valve.
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.
• 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 (Sticking
or seizure).
Check if boom speed changes Check if the swing preference
in swing/boom raise combined circuit shift solenoid valve indi-
operation when general pur- cation “On” turns reverse video
pose mode and trenching when swing/ boom raise func-
mode are selected. tions are operated simultane-
ously.
Harness breakage between
·Monitor item; No 6-F8 the PVC and swing prefer-
YES ence circuit shift solenoid
valve.
T5-4-21
A-5 SP mode cannot be activated with SP mode
switch.
(Other controls are normal.)
• If only SP mode is the one does not function,
related switches or controller may have failed.
• Refer to “SP Mode Control” in the Control System
Principle book.
NO SP mode switch failure, or

harness breakage between
SP mode switch and PVC.
Monitor SP mode switch. Op-
erate SP mode switch and
check if the letters “On” turn
reverse video.
PVC failure.
YES
A-6 E mode cannot be activated with E mode

switch.
• Refer to “E Mode Control” in the Control System
Principle book.
NO E mode switch failure, or har-

ness breakage between E
mode switch and PVC.
Monitor E mode switch. Oper-
ate E mode switch and check
if the letters “On” turn reverse
video.
PVC failure.
YES
T5-4-22
A-7 Cylinder or motor responsiveness is slow.
More than 1 second. Pump servo piston mecha-

nism failure.
While monitoring pump dis-
placement angle value, oper-
ate corresponding control More than 1 Pilot system failure (Excessive
lever and measure time lag second. drop in pilot pressure, pilot
between lever operation and valve failure, etc.)
change in displacement angle Operate the slow responding
value. lever and measure time lag
between lever operation and
·Monitor items No 1-F8 the moment the correspond-
No 3-F8 Less than 1 ing pressure switch letters
second. turn into reverse video.
Control valve failure.
Less than 1
·Monitor items No 8-F6 second.
T5-4-23
FRONT ATTACHMENT SYSTEM
TROUBLESHOOTING
F-1 Front attachment cylinder(s) move slowly or
do not move.
• 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 pressure
switch circuit failure.
Check if pilot pres-

sure switch letters
turn reverse video
when corresponding NO Pilot valve failure.
control lever is oper-
ated.
Check if corre-
·Engine: Running sponding secon-
·Control lever: Full dary pilot pressure
is normal. NO Corresponding over-
stroke YES
load relief valve failure.
·Monitor item #8-F6
Boom raise ·Refer to OPERA- Check if corre-
Arm roll-in TIONAL PERFORM- sponding overload
Swing ANCE TEST section relief pressure is
Travel YES normal.
for pressure meas-
Bucket roll-in urement procedure.
Others Control valve failure
·Refer to OPERA- (sticking, etc.)
TIONAL PER- YES
FORMANCE TEST
section for pressure
measurement pro-
cedure.
T5-4-24
(Blank)
T5-4-25
F-2 Bucket drops excessively.
YES Normal.
Damaged control
NO valve spool, bro-
Remove holding ken spring, or
check valve and Check if excessive loose spool end.
Check if cylinders holding check YES cylinder internal
for drift quantity. valve shift valve leakage exists.
Are drift values from control valve. Cylinder sealing
within the specifica- YES Disassemble, YES failure.
tions? clean, reassemble,
·Refer to OPERA- and reinstall them.
Replace the over- Check if bucket still END (Failure of
TIONAL PER- load relief valve(s)
FORMANCE drops excessively. holding check
for cylinder(s) valve or holding
TEST section for NO
which shown ex- valve shift valve).
cylinder drift cessive drift, with
measurement one(s) from other ·If holding valve shift valve is sticking:
procedure. NO function(s). Check Arm cylinder: Roll-out: Operable
if excessive cylin- Roll-in: Inoperable
der drift is still ob- Boom cylinder: Raise: Operable
served. Lower: Inoperable
·If holding check valve has failed, responsiveness of
both the arm and boom becomes slow.
END (Overload
NO relief valve failure.)
F-3 In the beginning of front attachment operation

(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.
Cylinder sealing failure.
Check if load check valve lo- YES
cated in control valve is nor-
mal.
·Disassemble and visually

check. Load check valve failure.
NO
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
disconnected hose ports.) T105-07-04-009
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

(B)
pressure and flow rate from the pump is
low. Therefore, if the load check valve is
malfunctioning, the oil in the bottom side When the load check
of the boom cylinder flows back into the valve is malfunctioning:
(A)
circuit through the load check valve,
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 leak- T105-07-04-012
ing through the gap between the piston

and the barrel is large, the cylinder is
temporarily retracted. In addition, cylin-
der force is reduced. In this case, the
cylinder drift is also increased
T5-4-27
F-4 Power does not increase with power boost
switch turned on.
• Refer to the heading “Power Boost” in the Control
System group, the SYSTEM section, the
Technical Manual (Operating Principle).
2
NOTE: 1 kgf/cm = 0.09807 Mpa
Pressure increases
2
from 305 kgf/cm or
2
less to 320 kgf/cm .
Normal
Power boost
switch failure or
NO harness breakage
Monitor delivery
between power
pressure for
boost switch and
pumps 1 and 2.
PVC.
No 3-F7 Monitor power
·Push the power boost Disconnect the
boost switch.
switch to monitor harness end from YES Solenoid valve SA
Check if the let-
change in pressure. Pressure solenoid valve SA. failure.
ters “ON” turn
does not Connect test har-
reverse video
Pressure when the power change. ness (ST7123)
does not boost switch is between solenoid
increase. pressed. valve SA and the
harness end. Harness failure
Measure the pilot Check if the test between solenoid
·Monitor items
pressure at sole- harness lamps NO valve SA and PVC.
No 7-F6
noid valve SA port come on.
in the solenoid
YES valve unit (3 sole- ·Power boost switch: ON
noid valves used).
·Push the power

boost switch to ob- Main relief valve
serve pressure Pressure changes from 0 failure.
2
change. to max. 40 kgf/cm .
·Refer to OPERA-
TIONAL PER-
FORMANCE TEST
section for the
measurement pro-
cedure.
T5-4-28
(Blank)
T5-4-29
SWING SYSTEM TROUBLESHOOTING
S-1 Upperstructure does not rotate, rotates
slowly, or swing power is weak.
• 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 OPERA-
Check if oil quantity TIONAL PERFORM-
draining from ANCE TEST section
YES swing motor is for swing relief pres-
normal. sure measurement
procedure.
Monitor DP sensor ·Refer to OPERA-
pressure. Operate TIONAL PER-
control lever slowly FORMANCE TEST
YES section for swing Swing motor failure.
to the stroke end NO
and check if DP motor draining oil
sensor pressure quantity measure-
changes smoothly. ment procedure.
Check if secondary Control valve spool

pilot pressure is NO sticking.
normal.
NO END (Pilot valve fail-

·Refer to OPERA- ure.)
TIONAL PER-
FORMANCE TEST
Disassemble, clean,
section for secon-
and reassemble the
dary pilot pressure
NO pilot valve. Check if
measurement pro-
the trouble still exists.
cedure.
Check if sticking or sei-
zure exists in swing
YES shuttle valve.
T5-4-30
2
YES Swing reduction gear

failure.
Corresponding swing
NO relief valve failure.
YES Swing shuttle valve

failure.
Swing preference circuit

Check if the swing NO shift solenoid valve fail-
preference circuit shift ure (sticking or seizure).
solenoid valve indica-
tion (On) turns reverse
video when
NO swing/boom raise
functions are operated Harness breakage be-
simultaneously. tween the PVC and
swing preference circuit
YES shift solenoid valve.
·Monitor item: No 6-F8
T5-4-31
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 failure.

Monitor DP sensor
pressure. Operate
control lever slowly
YES
to the stroke end
and check if DP
sensor pressure
changes smoothly. Swing spool failure.
Check if swing sec-
ondary pilot pres- ·Monitor item No 3-F6 NO
YES sure is 0 kgf/cm
2
with swing lever in

neutral.
·Refer to OPERA-
TIONAL PER- Pilot valve failure.
Check if swing re- FORMANCE TEST NO
lief pressure is section for swing
normal. secondary pilot pres-
sure measurement
·Refer to OPERA- procedure.
TIONAL PER-
FORMANCE
TEST section for Swing relief valve fail-
swing relief pres- ure.
NO
sure measure-
ment procedure.
T5-4-32
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 pres-

sure is normal. NO Travel pilot valve failure.
·Engine: Running
·In SP mode: more than 40 Check if secondary travel pilot
2
kgf/cm pressure is normal.
YES
·Engine: Running Go to Troubleshooting A-1.
·In SP mode: more than 35 YES
2
kgf/cm
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
2
but actual travel mode (speed) does not shift, the NOTE: 1 kgf/cm = 98.07 kPa
travel motor displacement angle shift circuit may
have failed.
Switch failure, or har-

NO ness breakage be-
tween switch and
PVC.
Check if monitor
indicates Hi and Lo
NO PVC failure.
alternately when
travel mode switch
is operated. Check if travel
mode shift solenoid Travel mode shift
valve shifts as travel solenoid valve failure,
·Monitor items No 7-F7 NO
mode switch is op- or harness failure
·Key switch: On
YES erated. between PVC and
travel mode shift so-
lenoid valve.
·Monitor items No 6-F6 Check if travel mode
shift pressure (SB) is
YES normal. YES Travel motor dis-
Check if sticking or placement angle shift
·SP mode valve failure.
·Auto-idle: OFF seizure exists in
·Refer to OPERATIONAL travel motor dis-
YES placement angle Failure of travel mo-
PERFORMANCE TEST
section for SB pressure shift valve. tor or travel reduction
measurement procedure. gear.
NO
T5-4-33
T-3 Machine mistracks.
• 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.
NO Shuttle valve failure.

Disassemble, clean,
NO and reassemble travel
shuttle valve. Check if
the trouble still exists.
Pilot valve failure.
YES
Check if secondary
travel pilot pres-
sure is normal. Operate left and NO DP sensor failure.
right travel levers
·SP mode the same distance
·Travel lever: full and check if pump
stroke target displace- YES P sensor failure.
·Refer to OPERA- ment angle on 5- Switch the P sen-
TIONAL PER- YES spool side is the
sor on 5-spool side
FORMANCE TEST same as that on with that on 4- Switch the left and
section for travel 4-spool side. spool side. Check right travel hoses
secondary pilot
pressure meas- YES if machine mis- with each other at
·Monitor item No 2-F6 tracks in the oppo- the upper side of
urement procedure.
Ȁ No 4-F6 site direction. center joint. Check if
NO machine mistracks
to the opposite direc-
tion.
Seal Location
Relation between Faulty Seal Position
and Mistrack Direction 1
Seal 2
Traveling Pivot Turn
NO.
1 External oil leakage ←
2 Right Travel
(Reverse)
Left Travel
(Forward)
3
3 Right Travel
(Forward)
Left Travel
(Reverse)
4
4 5
6
7
6
7 External oil leakage ←
T142-06-04-017
T5-4-34
Disassemble, END (Control

clean, reassemble NO valve spool stick-
corresponding ing.)
spool in control
YES
valve. Check if the Control valve fail-
trouble still exists. ure (internal leak),
A sensor failure, or
YES main pump failure.
YES Travel relief valve

Switch the right and left travel
NO relief valves with each other. failure.
Check if machine mistracks in Center joint failure.
the opposite direction.
Check if slower- NO
side travel relief NO Travel motor fail-
NO pressure is normal. ure.
Check if quantity
of oil draining from
·Refer to OPERA- Disassemble YES Travel brake valve
TIONAL PER- YES travel motor is travel motor failure.
normal.
FORMANCE brake valve
TEST section for ·Refer to OPERA- and check if YES Travel motor tilt
Remove travel
travel relief pres- TIONAL PERFORM- YES any abnormali-
motor tilt pistons piston failure.
sure measure- ANCE TEST section ties are found. and check if any
ment procedure. for travel motor drain NO abnormalities are Travel reduction
oil quantity meas-
urement procedure.
found. NO gear failure.
Travel Hose Connections

2
1
3
4
1- Left Travel Reverse

2- Left Travel Forward
3- Right Travel Reverse
4- Right Travel Forward
5- Pilot Hose (Travel Mode Shift)
6 6- Drain Hose
M162-07-071
T5-4-35
TROUBLESHOOTING FOR OTHER FUNC-
TIONS
O-1 Work mode does not shift.
• The work mode switch may have failed if the work
mode indicators do not shift with the work mode
switch. 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 prefer-
ence circuit shift solenoid YES
valve, solenoid valve, Solenoid valve failure.
and main relief pressure
shift solenoid valve one
YES by one. Connect test
Monitor pressure
harness (ST 7123) be-
switches (travel,
tween each solenoid
swing, boom raise, Harness breakage be-
valve and harness end,
arm roll-in, bucket tween solenoid valve
and check if harness NO
roll-in and others). and PVC.
lamp comes on.
YES Check if letters “Bm”,
“Tr”, “Sw”, “Am”,
“Bucket roll-in” and
“Ot” turn reverse Disconnect the harness YES Pressure switch failure.
video when respec- end from each pressure
tive control lever is switch one by one. Con-
Monitor work mode nect test harness (ST
operated.
switch. Check if work 7123) between each
mode letters turn ·Monitor item No 8-F6 NO pressure switch and har-
reverse video when ness end, and check if
work mode switch is Harness breakage be-
harness lamp comes on. tween PVC and pres-
operated. NO sure switch.
Work mode switch fail-

NO ure.
(Reference)
Work Mode Designed Application
General Purpose Mode Designed for general digging and truck loading.
Attachment Mode Select this mode when using breakers.
Precision Mode All front functions are slow for easy load lifting work.
Trenching Mode Swing is given priority in swing/boom raise combined operation.
T5-4-36
O-2 Pump emits abnormal sound or vibration.
YES Main pump failure.
YES Main pump failureϔ

Check if indicated
pump displace- Check if indicated
ment angle value pump differential
stays stable. YES pressure and pump
pressure values NO DP sensor or P sen-
stay stable. Replace the sensor failure.
No 3-F8
sor obtained un-
·Monitor items stable values and
Check if A sensor No 1-F6, F7 NO check if the trouble
is installed se- No 3-F6, F7 still exists.
NO curely. Main pump failure.
·Replace DP sen- YES
sor and/or P sen-
sor.
Insecure A sensor
NO installation.
·Refer to T5-4-41
T5-4-37
O-3 Wiper does not operate or does not retract.
• 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.
YES Wiper relay failure.

Remove test harness
and reconnect the har-
ness end. Replace re-
YES lays one by one with
new ones. Check if
wiper operates each YES End.
Connect test harness time a relay is replaced.
(Parts Number Replace monitor as-
3073259) between aux- sembly. Check if wiper
·Key switch: ON NO operates.
iliary power source (fuse
box No 20) and wiper Cab harness failure.
motor as illustrated on
the next page. Check if NO
wiper operates.
·Key switch: ON Wiper motor or link fail-

No or lamps does not light as indicated in the note. ure.
NOTE: If wiper motor is normal, lamp S comes

on while wiper operates in wiping range.
In addition, lamps B and S come on
momentary when wiper comes to inter-
mittent stop position.
T5-4-38
Electrical Circuit When Test Harness is Connected.
Fuse Box #20
Lamp S
Lamp B Wiper Motor
Ground
T157-07-04-002
Wiper's Operating Range

Intermittent Stop Position
Retracted Position
Wiping Range
T157-07-04-003
Test Harness Connection
Wiper Motor Lamp B
Lamp S
Test Harness Fuse Box
T157-07-04-004
T5-4-39
EC SENSOR INSTALLATION AND
VOLTAGE 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.
Connect Dr. EX to the monitor terminal. Install test
harness (ST 7129) between EC sensor and har-
ness.
3. 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.
4. 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
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).
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 T111-04-05-001
spring (4) and install it into the cavity on the
feedback shaft end.
3
2. With the key switch turned OFF, connect the
connector of the A sensor. Then, connect the Dr.
EX to the diagnosing connector located in the 4
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. On Dr.EX. “A Sensor Mounting Angle Adjustment”

screen, select “Increase displacement angle to
the maximum”. The pump displacement angle will
be set to the maximum one second later. T107-04-05-010
5. On “Monitor Data” screen, select No 1-F8 (Pump

Displacement 4) or No 3-F8 (Pump Displacement
5).
6. Before installing the A sensor to the pump, turn

the punch mark on the A sensor shaft towards the
opposite side of the harness so that the reading of
3
the Dr.EX display indicates 245 cc/rev (cm /rev). 5
3
7. Install the A sensor on the pump. Move the A
sensor on the slit mounting hole so that the Punch Mark
4 Feedback Shaft T107-04-05-011
reading for No 1-F8 (Pump Displacement 4) or No
3-F8 (Pump Displacement 5) is within the
specified value range.
3
Specified Value: 249±4 cc/rev (cm /rev).
8. Tighten bolts (1) to 9.8 to 14.7 Nxm (1 to 1.5

kgfxm).
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
(1) appropriate.
(3)
NO (NOT OK)
• Special instructions or reference item are indicated in the spaces under the box.
•
Incorrect measuring or checking methods will render troubleshooting impossible,
and may damage components as well.
·Key switch: ON
• Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
•
causes can be seen without going through the flow chart.
NOTE: For all connector drawings illustrated in this

group, harness end connector terminals
seen from the open end side are shown.
Harness Side
Open End
Side
T158-05-03-001
T5-5-1
MALFUNCTION OF COOLANT TEMPERA-
TURE GAUGE
Precondition:
• Be sure to inspect wiring connections prior to
troubleshooting.
Disconnect coolant tempera- YES

ture sensor terminal. Ground
Gauge pointer does not move harness end terminal to vehi-
at all. (It does not rise from cle frame. Does pointer swing With coolant temperature sen-
zero.) to the (H) side? sor terminal disconnected,
disconnect 20P connector
from monitor. Check if continu-
·Key switch: ON NO ity exists between terminal No.
47 and sensor terminal.
YES
Disconnect coolant tempera-
Gauge pointer swings over ture sensor terminal. Does With coolant temperature
scale. pointer swing back to zero? sensor terminal disconnected,
disconnect 20P connector
from monitor. Check if continu-
·Key switch: ON NO ity exists between harness
end terminal and vehicle
frame.
Disconnect coolant tempera- YES

ture sensor terminal. Ground
harness end terminal to vehi-
Gauge pointer swings unstably. cle frame. Does pointer swing
to the (H) side?
·Key switch: ON NO
T5-5-2
Approximate temperature on
Coolant temperature sensor Coolant Temperature Gauge
failure
105 °C (221 °F)
YES Monitor failure 101 °C (214 °F)
70 °C (158 °F)
NO monitor and sensor
T162-05-05-003
Coolant Temperature Sensor
Coolant temperature sensor Coolant Resistance

failure
Temperature Ω
YES Short circuit between monitor °C (°F)
and sensor 50 (122) 153.9
80 (176) 51.9±10
Monitor failure 100 (212) 27.4±4
NO 120 (248) 16.1
Connector
(Harness end connector terminals seen from the open
Coolant temperature sensor end side)
failure
Monitor (20P)
29 30 31 32 33 34 35 36 37 38
Monitor failure 39 40 41 42 43 44 45 46 47 48
T5-5-3
MALFUNCTION OF FUEL GAUGE
Precondition:
troubleshooting.
Disconnect connector from YES

fuel sensor. Connect harness
Gauge pointer does not move end connector terminals No. 1
at all. (It does not rise from and No. 2 using a clip. Does With fuel sensor connector
zero.) pointer swing to the (F) side? disconnected, disconnect 20P
connector from monitor.
NO Check if continuity exists be-
·Key switch: ON tween monitor terminal No. 46
and sensor terminal No. 2.
YES
Disconnect the connector from

Gauge pointer swings over fuel level sensor. Does pointer With fuel sensor connector
scale. swing back to zero? disconnected, disconnect 20P
connector from monitor.
·Key switch: ON Check if continuity exists be-
NO
tween sensor terminal No. 2
and vehicle frame.
Disconnect connector from YES

fuel sensor. Connect harness
Gauge pointer swings unstably. end connector terminals No. 1
and No. 2 using a clip. Does
pointer swing to the (F) side?
NO
·Key switch: ON
T5-5-4
Fuel Sensor
Float
FULL
Fuel level sensor failure
257 mm
YES Monitor failure
53°
R381.9
70.5 mm
NO monitor and sensor
1/2 51°
338 mm
EMPTY
Fuel sensor failure

T162-05-05-001
YES Short circuit between monitor

and sensor
Resistance
Float Position
Monitor failure Ω
NO FULL
+0
10 –4
3/4 26
1/2 38±5
1/4 53
+10
EMPTY 90 –0
Fuel sensor failure
Connector
Monitor failure (Harness end connector terminals seen from the open
end side)
Monitor (20P) Fuel Level Sensor
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48 1 2
T5-5-5
MALFUNCTION OF INDICATOR BULB
CHECK SYSTEM
Check power line:

·Check fuse.
·Disconnect 20 P connector
YES from monitor. Check if conti-
nuity exists between harness
end 20P connector terminal
Indicators do not come on No. 30 and fuse No. 8 termi-
when key switch is turn to ON Check if all indicators fail to nal.
position. come on.
Troubleshoot individual indica-

tors which failed to come on.
NO
Connector
end side)
Monitor (20P)
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48
MALFUNCTION OF LEVEL CHECK

SWITCH
• 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.
Preconditions:
• Park the machine on a level surface.
troubleshooting.
Level check switch
failure or harness
YES breakage.
YES Check if oil and

coolant levels are
normal. Add engine oil,
Level indicators do hydraulic oil,
not come on when Check if all level and/or coolant as
NO
level check switch indicators do not necessary.
is pressed. come on.
Troubleshoot each
NO failed indicator(s).
T5-5-6
(Blank)
T5-5-7
MALFUNCTION OF ENGINE OIL LEVEL
INDICATOR
Preconditions:
• The engine oil level indicator bulb has not blown.
• Other indicators are functioning normally.
troubleshooting.
Reconnect engine
oil level switch YES
connector. Discon-
nect 12P connector
from monitor.
YES Check if continuity
Disconnect engine exists between
oil level switch harness end 12P
Engine oil level
connector. Check if connector terminal
indicator does not
continuity exists No. 7 and vehicle
come on when
between engine oil frame. NO
level check switch
level switch con-
is pressed.
nector and vehicle
frame.
NO
With engine oil

level switch con-
nector discon-
nected, disconnect
12P connector
Disconnect engine YES from monitor.
oil level switch Check if continuity
connector. Press exists between
8 mm or more level check switch. harness end 12P
Check engine oil Check if engine oil
Although engine oil connector terminal
level on the dip- level indicator
is insufficient, en- No. 7 and vehicle
stick. How many comes on.
gine oil level indica- frame.
millimeters is the
tor comes on when oil level lowor than
level check switch the LOW mark line
is pressed. on the dipstick? NO
Less than 8 mm
T5-5-8
Engine Oil Level Switch
Monitor failure
H (Indicator ON)
L
Harness breakage 8 mm (Indicator OFF)
Engine oil level switch failure T166-05-05-001
Connector
YES end side)
Short circuit between engine
oil level switch and monitor
Monitor (12P)
1 2 3 4 5 6
7 8 9 10 11 12
Monitor failure
NO
Engine oil level switch failure
Normal
T5-5-9
MALFUNCTION OF COOLANT LEVEL
INDICATOR
Preconditions:
• The bulb of the coolant level indicator has not
blown.
troubleshooting.
Re-connect coolant
level switch 3P con- YES
nector. Disconnect
12P connector from
monitor. Check if
YES continuity exists
between harness
end 12P connector
terminal No. 8 and
Disconnect coolant vehicle frame.
level switch 3P
Coolant level indi- connector. Check if NO
cator does not continuity exists
come on when between coolant
level check switch level switch 2P
is pressed. connector termi-
nals.
NO
With coolant level

switch connector
disconnected, dis-
connect 12P con-
nector from monitor.
Disconnect coolant YES Check if continuity
level switch connec- exists between har-
tor. Press level ness end 12P con-
YES check switch. nector terminal No.8
Check if coolant and vehicle frame.
Although coolant level indicator
is insufficient, cool- Check if coolant comes on.
ant level indicator level on reservoir is
comes on when lower than LOW
level check switch mark.
is pressed. NO
NO
T5-5-10
Coolant Level Switch
Reservoir
Monitor failure
ON
FULL
LOW
Radiator
OFF
Harness breakage
T107-04-03-012
Coolant level switch failure
Connector (harness end connector terminals seen

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

3
1 2
Normal
T5-5-11
MALFUNCTION OF HYDRAULIC OIL
LEVEL INDICATOR
Preconditions:
• The bulb of the hydraulic oil level indicator has not
blown.
troubleshooting.
Reconnect hydraulic YES

oil level switch 2P
connector. Discon-
nect 12P connector
YES from monitor. Check
Disconnect hydrau- if continuity exists
lic oil level switch between harness
Hydraulic oil level
2P connector. end 12P connector
indicator does not
Check if continuity terminal No. 9 and
come on when
exists between vehicle frame. NO
level check switch
hydraulic oil level
is pressed.
switch 2P connec-
tor terminals.
NO
With hydraulic oil

level switch connec-
tor disconnected,
disconnect 12P
connector from
Disconnect hydrau- YES monitor. Check if
lic oil level switch continuity exists
connector. Press between harness
NO level check switch. end 12P connector
Check if hydraulic terminal No.9 and
Although hydraulic oil level indicator vehicle frame.
oil is insufficient, Check oil level on comes on.
hydraulic oil level the level gauge.
indicator comes on Check if oil can be
when level check seen on the level
switch is pressed. gauge. NO
YES
T5-5-12
Hydraulic Oil Level Switch
Monitor failure
ON
6.2 mm
Harness breakage
OFF
Hydraulic oil level switch fail-

ure
T137-04-04-001
YES Short circuit between hydrau-

lic oil level switch and monitor
Connector
end side)
Monitor failure Monitor (12P)

NO
1 2 3 4 5 6
Hydraulic oil level switch fail- 7 8 9 10 11 12
ure
Normal
Hydraulic Oil Level Switch
1 2
T5-5-13
MALFUNCTION OF ALTERNATOR INDI-
CATOR
Precondition:
troubleshooting.
NOTE: Also check continuity between starter relay

2 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
Alternator indicator Check voltage at the

does not go out after monitor 20 P connec-
engine is started. tor terminal No.42. NO Charge relay fail-
·Engine: Running ·Key switch: ON ure
·Engine: Running
Check if charge
relay continuity is
normal. YES Starter relay 2 fail-
Less than
1V ure
·Between terminals
No.3 and No.5: Check if voltage at
No continuity exists. alternator terminal R
·Between terminals YES is 13 to 15 V.
No.1 and No.2: Alternator failure
Continuity exists. ·Engine: Running
NO
More than 20 V Monitor fail-

ure
Check voltage at
YES the monitor 20 P NO Charge relay
connector termi- failure
nal No.42.
Check if YES
charge relay Starter relay
Check if alternator ·Key switch: ON 2 failure
Although alterna- ·Engine: Running Less continuity is
tor output is low, indicator comes than Check if
on when key normal.
alternator indica- 1V voltage at
switch is turned
tor does not
ON. ·Between terminals YES alternator
come on. No.3 and No.5: terminal R is
13 to 15 V. Alternator
·Key switch: ON No continuity exists. failure
·Engine: Stopped ·Between terminals NO
·Engine:
No.1 and No.2:
Running
Continuity exists. Blown alter-
nator indica-
NO tor bulb
Connector
(Harness end connector terminals seen from the open (Charge relay side connector terminals)
end side)
Monitor (20P) Charge Relay

1 2
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48 3 5
4
T5-5-14
MALFUNCTION OF ENGINE OIL PRES-
SURE INDICATOR
Precondition:
troubleshooting.
YES Engine oil pres-

Disconnect engine sure switch failure
oil pressure switch
terminals. Ground
the harness end (+) Harness breakage
YES terminal (white line YES between monitor
with blue stripe) to Connect the monitor and engine oil
vehicle frame. 12P connector ter- pressure switchϔ
Check if engine oil minal to vehicle
pressure indicator frame. Check if en-
comes on. NO gine oil pressure
indicator comes on. Monitor failure
Although engine oil ·Key switch: ON
pressure is insuffi- Check if engine oil ·Reconnect engine ·Key switch: ON NO
cient, engine oil pressure indicator oil pressure switch ·Insert a clip from the
pressure indicator comes on when key terminals after the back of 12P connec-
does not come on. switch is turned ON. checking. tor to reach the ter-
minal. Ground the
·Key switch: ON other end of the clip
·Engine: Stopped to vehicle frame.
NOTE:Engine oil pressure

may remain 1 to 2 Blown indicator
minutes after engine NO bulb
stops. This is normal.
Engine oil pres-

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

pressure switch. Check if Short circuit be-
indicator does not
engine oil pressure indica- YES tween monitor and
go off after engine is
tor goes off. engine oil pressure
started. Reconnect engine oil
switch.
pressure switch. Discon-
·Check oil filter for ·Key switch: ON nect 12P connector from
clogging. ·Engine: Stopped monitor. Check if continu-
ity exists between har-
NO ness end 12P connector
terminal No. 10 and vehi-
cle frame. Monitor failure
NO
Connector
(Harness end connector terminals seen from the open Engine Pressure Switch
end side)
Approximate ON/OFF
Monitor (12P) Indicator
Threshold Pressure
2
1 2 3 4 5 6 Less than 49Pa (0.5kgf/cm ) ON
7 8 9 10 11 12
2
More than 49Pa (0.5kgf/cm ) OFF
T5-5-15
MALFUNCTION OF OVERHEAT INDICA-
TOR
Precondition:
troubleshooting.
YES Overheat switch H

Disconnect over- failure.
heat switch H termi-
nal. Ground the Harness breakage
YES between monitor
YES harness end termi- Reconnect overheat
nal to vehicle frame. and overheat
switch H terminal. switch H.
Check if overheat Connect the monitor
indicator comes on. 12P connector ter-
minal No. 1 to vehi-
·Key switch: ON NO cle frame. Check if
·Engine: Stopped
overheat indicator Monitor failure.
comes on.
Although engine Check if overheat NO
overheats, overheat indicator comes on ·Key switch: ON
indicator does not when key switch is ·Engine: Stopped
come on. turned ON. ·Insert a clip from the
·Key switch: ON back of 12P connector
·Engine: Stopped 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 overheat Short circuit be-

comes on even switch H. Check if over- YES tween monitor and
when coolant tem- heat indicator goes off. overheat switch H.
perature is low.
·Key switch: ON With overheat switch H
·Engine: Stopped disconnected, disconnect
12P connector from moni-
tor. Check if continuity
NO exists between 12P con-
nector terminal No. 1 and
vehicle frame. Monitor failure
NO
Connector
(Harness end connector terminals seen from the open Overheat Switch
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
Precondition:
troubleshooting.
YES Low fuel level

Disconnect the har- switch failure.
ness end connector
from the low fuel level
Re-connect the har- YES Monitor failure
YES switch harness. ness end connector.
Ground the harness
end terminal to vehi- Disconnect 12P
cle frame. Check if connector from
fuel level indicator monitor. Check if
comes on. NO continuity exists be-
tween 12P connec- Harness breakage
Although fuel gauge Check if fuel level ·Key switch: ON tor terminal No. 2 between monitor
indicates “E”, fuel indicator comes on ·Engine: Stopped and vehicle frame. NO and fuel level
level indicator does when key switch is
not come on. switch.
turned ON.
·Key switch: ON
·Engine: Stopped
Blown indicator
NO bulb.
YES
Low fuel level
switch failure.

Fuel level indicator end connector from the Short circuit be-
comes on even low fuel level switch har- YES tween monitor and
when fuel is suffi- ness. Check if fuel level low fuel level
cient. indicator goes off. With low fuel level switch switch.
(harness end connector)
·Key switch: ON disconnected, disconnect
·Engine: Stopped 12P connector from moni-
tor. Check if continuity
NO exists between 12P con-
nector terminal No. 2 and
Monitor failure
vehicle frame.
NO
Connector Fuel Level Switch

end side)
OFF
Fuel Level
Monitor (12P)
ON
1 2 3 4 5 6
7 8 9 10 11 12 35 mm
T167-05-05-002
T5-5-17
MALFUNCTION OF AIR FILTER RESTRIC-
TION INDICATOR
Precondition:
troubleshooting.
Disconnect the har-

ness end plug from YES Air filter restriction
the air filter restric- switch failure.
tion switch. Ground
the harness end (+)
YES Monitor failure
YES terminal (Blue line Re-connect the har-
with green stripe) to ness end plug.
vehicle frame. Disconnect 12P
Check if air filter connector from
restriction indicator monitor. Check if
comes on. NO continuity exists
between 12 connec- Harness breakage
Although air filter is Check if air filter re- ·Key switch: ON tor terminal No. 3 between monitor
clogged, air filter striction indicator ·Engine: Stopped and vehicle frame. NO and air filter restric-
restriction indicator comes on when key
tion switch.
does not come on. switch is turned ON.
·Key switch: ON
·Engine: Stopped
Blown indicator
NO bulb.
YES Air filter restriction

switch failure.

Although air filter is end plug from the air filter
restriction switch. Check if Short circuit be-
not clogged, air filter
air filter restriction indica- YES tween monitor and
restriction indicator
tor goes off. air filter restriction
comes on. With air filter restriction switch.
·Key switch: ON switch disconnected, dis-
·Remove and visu-
·Engine: Stopped connect 12P connector
ally check the air fil-
from monitor. Check if con-
ter.
tinuity exists between har-
·Confirm that the air NO ness end 12P connector
filter is not damp.
terminal No. 3 and vehicle
Monitor failure
frame.
NO
Connector
(Harness end connector terminals seen from the open Air Filter Restriction Switch
end side)
Indicator ON/OFF Pressure Indicator
Monitor (12P)
5.1 kPa (520 mm H2O) OFF
1 2 3 4 5 6 6.2 kPa (630 mm H2O) ON
7 8 9 10 11 12
T5-5-18
MALFUNCTION OF HOUR METER
Precondition:
troubleshooting.
Harness breakage
between monitor
0V terminal No. 29
and fuse No. 8.
Check voltage at
NO the monitor 20P
connector terminal
No. 29.
Monitor failure
24V
Hour meter does not
count operating Check if alternator
hours with engine indicator is on.
running. More than 20V
Monitor failure
·Engine: Running
Check voltage at
the monitor 20P Harness failure
connector terminal between alternator
YES No. 42. YES
terminal L and
·Key switch: ON monitor terminal
·Engine: Stopped Check if voltage at No. 42.
alternator terminal L
is more than 20 V.
Less
than
1V ·Engine: Running Alternator failure
NO
Connector
(Harness end connector terminals seen from the open end side)
Monitor (20P)
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48
T5-5-19
MALFUNCTION OF BUZZER
Precondition:
troubleshooting.
NOTE: Also check continuity between starter relay

2 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 sound- Check voltage at
ing when key switch monitor 20P con- Less than
is turned to ON posi- nector terminal No. Failure of starter
1V relay 2 or alterna-
tion. 42.
Check voltage at tor.
·Key switch: ON Less than starter relay 2 ter-
·Engine: Running 1V minal No. 3. Charge relay fail-
More than 20 V ure
Engine oil pres-

YES sure system failure
Buzzer starts sound- Check if engine oil

ing when engine pressure indicator
starts. is on. YES Engine overheat
Check if overheat
NO indicator is on. Check if buzzer
stops when buzzer
stop switch is
NO pressed.
NO Normal
Although engine oil

pressure indicator or Check if engine is
-
overheat indicator running at 800 min
1
has turned on, (rpm) or higher. NO Normal
buzzer does not
sound.
Check if alternator
YES indicator is on. Check voltage at
monitor 20P con-
nector terminal
YES No.42.
·Key switch: ON
·Engine: Running
T5-5-20
Connector
(Harness end connector terminals seen from the open (Charge relay side connector terminals)
end side)
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
More than 20 V
Monitor failure
Check if continuity NO Failure of starter

exists between relay 2 or alterna-
charge relay side tor.
connector termi-
Less than 20 V nals No. 3 and No.
5. Charge relay fail-
YES ure
·Engine: Running
T5-5-21
MALFUNCTION OF WORK LIGHT INDICA-
TOR
Precondition:
troubleshooting.
Harness breakage
YES between work light
switch and moni-
Check if work lights
tor.
YES turn on when work
light switch is
turned on.
Work light indicator Check if work light Work light switch
does not come on indicator comes on NO failure.
when work light when key switch is
switch is turned on. turned to ON posi-
tion. Blown indicator
bulb or monitor
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
connectors off for repair or replacement work. by their connectors. Do not pull on the wire
Failure to do so can result in damage to the wire itself. 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-
indicated for one wire, the left initial stands for the resistant connectors, take extra care not to
base color, while the right initial stands for the allow water to enter the connectors. In case
marking color. water should enter 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
L Blue G Green addition, as most connectors are made of
Or Orange Lg Light green brass, check that no terminals are rusting.
Y Yellow B Black 4) When connecting terminal connectors
Br Brown P Pink provided with a lock, be sure to insert them
Gr Gray V Violet together until the lock “clicks."
NOTE: 1) Code BW indicates a black base wire

with white fine-line marking.
Right Wrong
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
not to confuse them with color coded T107-07-06-001
wires.
Right
Rust
Wrong
(Bent)
Wrong
(Coming of, Separation)
T107-07-06-002
T5-6-1
4. Precaution for using a circuit tester.
1) Before using a circuit tester, refer to the

instructions in the circuit tester manual. Wind a piece of wire Tester Probe
Then, set the circuit tester to meet the object
to be measured, voltage range and current
polarity.
2) Before starting the connector test, always Sharpen the end of the wire
T107-07-06-003
check the connector terminal numbers,
referring to the 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 Harness Connections in Cab Thermoguard Switch
Valve
A Sensor General Purpose Relay Pressure Switch Diode Box
(Displacement Angle Sensor)
EC Sensor Diode P Sensor Wiper
EC Motor Monitor Speaker Diode
Coolant Level Switch Starter Relay 2 Radio Lubricator
Pump Control Pressure Air Conditioner Blower Motor Starter Relay 1 Motion Alarm
Sensor
Engine Oil level Switch Air Conditioner Controller Key Switch Power Line between
Engine/Cab
Hydraulic Oil Level Switch Engine Control Dial Buzzer Fusible Link
N Sensor
• Pull to disconnect
Locations of This Type Connector
Hydraulic Oil Temperature Sensor

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

Use a 10 mm wrench and a ratchet wrench.
When connecting, tighten until the torque mark (a
projection) is seen.
Locations of This Type Connector
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
Accessories (Outside) For Ether Relay
T162-05-06-002
T5-6-4
FUSIBLE LINK INSPECTION AND RE-
PLACEMENT
Inspection
1. Visually check if fusible links have blown.
Replacement
Fusible Link
1. Remove the negative cable from the battery.
2. Push (to unlock) and pull to disconnect fusible link

connector. Replace the fusible link.
T111-04-05-015
3. Reconnect the negative cable to the battery.
BATTERY VOLTAGE CHECK

To Battery Relay
1. Turn the key switch OFF. Check voltage between
the battery positive terminal and the vehicle.
Normal Voltage: 24 V
NOTE: If voltage is abnormal, recharge or replace

the battery.
V
2. Start the engine. Check voltage between the
battery positive terminal and the vehicle frame.
Normal Voltage: 26 to 28 V
T162-05-06-005
NOTE: If voltage is abnormal, check the charging
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 terminal 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
Single Line Breakage Check a
A
Disconnect both harness end connectors and check

continuity (resitance) between both ends.
0 Ω : Continuity (Normal)
∞ Ω : Discontinuity (Breakage) Ω
NOTE: When harness end connectors are far apart Connect to Vehicle
from each other, connect harness end A a
terminal A to the vehicle frame. Then,
check continuity through the vehicle as
illustrated.
0 Ω : Continuity (Normal) Connect to Vehicle Ω
∞ Ω : Discontinuity (Breakage)
Single Line Short Circuit Check A a

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

∞ Ω : an open in line (A) - (a) (Wire breakage)
Short Circuit between Lines
Multi-Line Short Circuit Check a

(Short Circuit between Lines)
A
B × b
C c
Disconnect both harness end connectors and check
continuity between terminal (A) and (B) or (C).
0 Ω : Short Circuit
∞ Ω : Normal
Ω
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 the specified voltages can be located, if any.
(current) are obtained.
Black (Negative) Tester Probe : To Vehicle
Red (Positive) Tester Probe : To the Point to be
Measured
Specified
Engine Key Switch Check Points 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 ∗ 5 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: Battery (B) 20 to 25 V
Cranking START Between (12) and Ground: Starter (S) 20 to 25 V
Cranking START Between (10) and Ground: Starter Relay 1 (Coil) 20 to 25 V
Cranking START Between (13) and Ground: Starter Relay 2 20 to 25 V
(Switch)
Cranking START 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 30 V
Alternator Generating Voltage (R)
Fast Idle ON Between (18) and Ground: Charge Relay 26 to 30 V
(Switch)
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 Key Switch
8
Battery
Battery Relay
9
6
Starter Relay 1
18 19
10
Charge Relay
7
Load
Dump Fuse Box
Relay
Starter
11
12
14 15
20 21 22
16
Alternator 37 46
13 Starter Relay 2 19
Fuel Solenoid 17
PVC
Valve
30 40 42
Monitor
24 EC
37
T167-05-06-004
T5-6-9
5 Voltage Circuit
Power Source Signal or Ground
• Voltage between terminal No. 1 and the vehicle
1 2
frame (ground).
Two-Wire System Connector
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 (ground)
• Red (positive) tester probe: Touching terminal T107-07-05-006
No. 1 Power Source Signal Ground

1 2 3
Evaluation:
If the measured voltage is 5±0.5 volts, the circuit up to Three-Wire System Connector
terminal No. 1 is normal.
T107-07-05-007
• Voltage between terminal No. 1 and the ground

terminal.
1 2
With the key switch turned OFF, disconnect the sensor Two-Wire System Connector
connector. Measure voltage between machine side
connector terminal No. 1 (5 V power source) and the
ground terminal (terminal No. 2 for two-wire system V
connector, or terminal No. 3 for three-wire system
connector) under the following conditions:
• Key switch: ON
• Black (negative) tester probe:
Ȁ Touching the ground terminal (terminal No. 2 or 3)
• Red (positive) tester probe: T107-07-05-008
Ȁ Touching terminal No. 1

1 2 3
Evaluation: Three-Wire System Connector
If the measured voltage is 5±0.5 volts, the lines up to
terminal No. 1 and to the ground terminal (terminal No.
2 or 3) are normal.
V
T107-07-05-009
T5-6-10
CHECK USING FALSE SIGNAL
With the key switch turned OFF, disconnect the sensor Two-Wire System Connector 1 2
connector. Connect machine side connector terminal
No.1 (power source) and terminal No.2. The 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)
circuit up to the machine side connector are normal. (N Sensor)
When checking on a pressure switch circuit, Dr.EX Connect
displays ON if it is normal.
IMPORTANT: On three-wire system connectors,

never connect terminals No. 1 and/or T107-07-05-010
No. 2 to terminal No. 3 or to vehicle.
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
5 2 3 1
3. Move the console to the seat side.
View a
4. Using a sharp-pointed tool, remove cap (9) from 4 6 T157-07-06-004
cover (7) and duct cover (8) located under the

monitor.
5. Remove cover (7) and duct cover (8). 7 10 11
6. Remove ashtray (10) and the ashtray screw.

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

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 - Duct 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
depending on whether the lamp comes ON or goes
OFF during operation.
Parts Number 4283594 (ST 7126)

Use when checking the conditions (discontinuity) of
a single wire.
To check point. To ground.
During Operation: Lamp comes ON. Parts Number 4283594 (ST 7126)
T107-07-05-012

Use when checking EC motor circuit.
(Refer to page T5-4-18)
5
6
• EC Motor Circuit 50
When the engine control dial is rotated,
When both lamps come ON: Normal 1 2 150 50 2 1
If only one lamp come ON: Check continuity of the 50
3 4 4 3
circuit connecting to the lamp going OFF.
If both lamps go OFF: Check the harness together 7 50
with the relay. 8
(Refer to page T5-4-18)
Parts Number 4274589 ( ST 7125) T107-07-06-024

(Red)
Use when measuring the signal cable voltage
(between terminal No.2 and 3) in the EC sensor or A
sensor (Pump displacement angle) circuit.
(Refer to page T5-3-6, T5-4-40)
(Black)
V
Parts Number 4284347 (ST 7129) T107-07-03-009
Parts Number 3073259

2
Use when checking the wiper circuit.
(Refer to page T5-4-38) 5 4
1 2
1
Parts Number 3073259 T157-07-07-001
T5-7-1
TROUBLESHOOTING / Harness Check
Use when checking the solenoid valve unit (3
solenoid valves used).
The lamp comes on when the applicable control 4

lever or switch is operated. 3
50
(Refer to page T5-4-28.)
150 50 50
1 2 2 1
Parts Number 4274587 ( ST7123)

T107-07-06-015
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:
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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.