EX75UR-5 Technica Manuall+All Diagram

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
SECTION 1
GENERAL
CONTENTS
Group 1 Specifications
Specifications ...........................................T1-1-1
Working Ranges and Machine
Transportation Dimensions .....................T1-1-3
Component Specification..........................T1-1-5
Group 2 Component Layout

Main Components ....................................T1-2-1
Electrical System (Overall System)...........T1-2-2
Electrical System
(Monitor and Switches) ...........................T1-2-4
Others ......................................................T1-2-6
197T-1-1
(Blank)
197T-1-2
GENERAL / Specifications
SPECIFICATIONS
ȥȸȗȕȵȲ ȍȕ
A C
E
D
J J I
H G
M197-12-002
Model EX75UR-5
Front-End Attachment Type − Offset Type
3 3 3
Bucket Capacity (Heaped) − PCSA: 0.28 m (0.37 yd ), CECE: 0.25 m
Operating Weight kg (lb) 8000 (17600)
Basic Machine Weight kg (lb) 6150 (13600)
-1
Engine ISUZU A-4JG1 40.5 kW / 1900 min
−
(55 PS / 1900 rpm)
A: Overall Width mm (ft in) 2300 (7’ 7”)
B: Cab Height mm (ft in) 2720 (8’ 11”)
C: Rear End Swing Radius mm (ft in) 1150 (3’ 9”)
D: Minimum Ground Clearance mm (ft in) 405 (1’ 4”)
E: Counterweight Clearance mm (ft in) 805 (2’ 7”)
F: Engine Cover Height mm (ft in) 1760 (5’ 9”)
G: Undercarriage Length mm (ft in) 2960 (9’ 9”)
H: Undercarriage Width mm (ft in) 2320 (7’ 7”)
I: Sprocket Center to Idler Center mm (ft in) 2290 (7’ 6”)
J: Track Shoe Width mm (ft in) 450 (1’ 6”) (Pad Crawler)
2
Ground Pressure kPa (kgf/cm , psi) 34.5 (0.35, 5.0)
-1
Swing Speed min (rpm) 10
Travel Speed (Fast/Slow) km/h (mph) 4.5/2.9 (2.8/1.8)
Gradeability Degree (%) 35 (70)
T1-1-1
ȥȸȗȕȵȳ ȍȕ
A C
D I
J J
G
H
M197-12-005
Model EX75US-5
Front-End Attachment Type − 1.6 m Arm
3 3 3
Bucket Capacity (Heaped) − PCSA: 0.28 m (0.37 yd ), CECE: 0.25 m
Operating Weight kg (lb) 7000 (15400)
Basic Machine Weight kg (lb) 5650 (12500)
-1
Engine ISUZU A-4JG1 40.5 kW / 1900 min
−
(55 PS / 1900 rpm)
A: Overall Width mm (ft in) 2300 (7’ 7”)
B: Cab Height mm (ft in) 2720 (8’ 11”)
C: Rear End Swing Radius mm (ft in) 1150 (3’ 9”)
∗
D: Minimum Ground Clearance mm (ft in) 355 (1’ 2”)
∗
E: Counterweight Clearance mm (ft in) 805 (2’ 6”)
∗
F: Engine Cover Height mm (ft in) 1730 (5’ 8”)
G: Undercarriage Length mm (ft in) 2920 (9’ 7”)
H: Undercarriage Width mm (ft in) 2320 (7’ 7”)
I: Sprocket Center to Idler Center mm (ft in) 2290 (7’ 6”)
J: Track Shoe Width mm (ft in) 450 (1’ 6”) (Grouser Shoe)
2
Ground Pressure kPa (kgf/cm , psi) 30.4 (0.31, 4.4)
-1
Swing Speed min (rpm) 10
Travel Speed (Fast/Slow) km/h (mph) 4.5/2.9 (2.8/1.8)
Gradeability Degree (%) 35 (70)
NOTE: Dimensions marked Ȋ don’t include the

shoe lug height.
T1-1-2
WORKING RANGES AND MACHINE
TRANSPORTATION DIMENSIONS
ȥȸȗȕȵȲ ȍȕ
G
J J
C D
E
H
K
F
I
M197-12-003 M197-12-004
Item Category 1.75 m Arm

A: Maximum Digging Reach mm (ft in) 6430 (21’ 1”)
B: Maximum Digging Depth mm (ft in) 4230 (13’ 11”)
C: Maximum Cutting Height mm (ft in) 7420 (24’ 4”)
D: Maximum Dumping Height mm (ft in) 5320 (17’ 5”)
E: Overall Transport Height mm (ft in) 2720 (8’ 11”)
F: Overall Transport Length mm (ft in) 6040 (19’ 10”)
G: Minimum Swing Radius of Front-End Attachment
1160 (3’ 10”)
mm (ft in)
H: Blade Bottom Highest Position mm (ft in) 450 (1’ 6”)
I: Blade Bottom Lowest Position mm (ft in) 230 (9”)
J: Maximum Offset mm (ft in) Left (Cab Side): 1100 (3’7”)
(From the front-end attachment center) Right: 1050 (3’ 5”)
K: Maximum Approach Angle Degree 31°
T1-1-3
ȥȸȗȕȵȳ ȍȕ
G
M197-12-006
Item Category 1.62 m Arm

A: Maximum Digging Reach mm (ft in) 6540 (21’ 5”)
∗
B: Maximum Digging Depth mm (ft in) 4600 (15’ 1”)
∗
C: Maximum Cutting Height mm (ft in) 7250 (23’ 9”)
∗
D: Maximum Dumping Height mm (ft in) 5170 (17’ 0”)
E: Overall Transport Height mm (ft in) 2730 (8’ 11”)
F: Overall Transport Length mm (ft in) 6020 (19’ 9”)
G: Minimum Swing Radius of Front-End Attachment mm (ft in) 1670 (5’ 6”)
NOTE: Dimensions marked ∗ don’t include the

shoe lug height.
T1-1-4
COMPONENT SPECIFICATION
Engine
MAIN SPECIFICATION
Manufacturer ....................................................ISUZU
Model No. .........................................................4JG1
Type .................................................................Diesel, 4 cycle, water-cooled, in-line direct injection type
Cyl. No. – bore × stroke ....................................4-95.4 mm×107 mm (3.76 in×4.21 in)
3 3
Piston displacement .........................................3059 cm (187 in )
-1
Rated output .....................................................39 kW/1900 min (53 PS/1900 rpm)
Compression ratio ............................................18.6
Dry weight ........................................................248 kg (546 lb)
Firing order .......................................................1-3-4-2
Rotation direction..............................................Clockwise (viewed from fan side)
COOLING SYSTEM
Cooling fan .......................................................Dia. 430 mm (17 in) E type, 10 blades, draw-in type
Fan pulley speed ratio ......................................Engine rpm×1.07
Thermostat .......................................................Cracking temp. at atmospheric pressure: 82 °C (180 F°)
Full open tem: 95 °C (203 F°)
Water pump......................................................Centrifugal type, belt driven
LUBRICATION SYSTEM
Lubrication pump type ......................................Trochoid pump
Oil filter.............................................................Full-flow paper element type
STARTING SYSTEM
Motor ................................................................Reduction type
Voltage ⋅ Output ................................................24 V ⋅ 3.2 kW
PREHEAT SYSTEM
Type .................................................................Glow plug (24V-25sec)
ENGINE STOP SYSTEM

Type .................................................................Fuel shut-off
ALTERNATOR
Type .................................................................AC (with IC regulator)
Voltage ⋅ Current...............................................24 V ⋅ 30 A
FUEL SYSTEM
Type .................................................................BOSCH A-type
Governor ..........................................................Centrifugal all speed control type
Injection nozzle.................................................Multi-hole nozzle
PERFORMANCE
Lubrication oil consumption ..............................Less than 20 mL/hr (New engine, at rated output)
Fuel consumption ratio .....................................Less than 238 g/kW/h (175 g/PS/h)
(New engine, at rated output)
Injection timing .................................................13 ° before T.D.C
-1
Max. output torque............................................201 N⋅m (20.5 kgf⋅m, 148 lbf⋅ft) or more at 1600 min
2
Injection pressure .............................................18.1 MPa(150 kgf/cm , 2133 psi)
2 -1
Compression pressure......................................2.94 MPa(30 kgf/cm , 427 psi) @ 250 min
Valve clearance (inlet/outlet) .............................0.4/0.4 mm (when cool)
+50 -1 -1
No load speed .................................................Min: 1000 –0 min , Max.: 2090±25 min
T1-1-5
Engine (BD3004) Performance Curve
Test Conditions
1. Conforms with JIS D 1005 (Performance Test Method for Diesel Engines Used for Construction Machinery)
under standard atmospheric pressure.
2. With fan and alternator.
201 Nѕm (20.5 kgfѕm) or more Output

Output Torque
220
22
kW PS
50
39 kW/1900 min-1 200 20
(53 PS/1900 ㉁㈿㈼)
60
180
40 18
50
30 40 0 0
NĊm kgfĊm
Fuel
30 Less than 238 g/kWѕh Consumption
(175 g/PSѕh) Ratio
20
180
240
20
220
160
10
10 200
140
g/PSĊh g/kWĊh
0
1000 1200 1400 1600 1800 2000
T197-01-03-002
Engine Speed min-1 (rpm)
T1-1-6
Engine Accessories
RADIATOR ASSEMBLY
Type .................................................................Radiator/oil cooler tandem type assembly
Radiator Oil Cooler

Capacity ...........................................................3.1 L (0.8 US gal) 1.7 L (0.45 US gal)
Air-tight testing pressure...................................118 kPa 981 kPa
2
(1.2 kgf/cm 2, 17 psi) (10 kgf/cm , 142 psi)
Cap opening pressure ......................................88 kPa(0.9 kgf/cm 2, 13 psi) ҥ
BATTERY
Capacity ...........................................................52 Ah (5 hour rate), 65 Ah (20 hour rate)
Voltage .............................................................12 V
Hydraulic Components
MAIN PUMP 1, 2
Model ...............................................................AP2D36LV1RS6
Type .................................................................Variable displacement swash plate type
.........................................................................axial plunger pump
Theoretical maximum flow rate .........................68.4 L/min (18 US gpm)
MAIN PUMP 3 (SWING, BLADE, AND ARM 3)

Type .................................................................Fixed displacement gear pump
Theoretical maximum flow rate .........................40.7 L/min (10.7 US gpm)
PILOT PUMP
Type .................................................................Fixed displacement gear pump
Theoretical displacement .................................20.3 L/min (5.4 US gpm)
CONTROL VALVE 1
Model ...............................................................KVMM-80-HD
Type .................................................................Pilot pressure operated type (5-spool + 4-spool sections)
Main relief pressure
(Front Attachment)............................................31.4 MPa(320 kgf/cm 2, 4550 psi) @ 33 L/min
(Travel).............................................................26.0 MPa(265 kgf/cm 2, 3770 psi) @ 43 L/min
Overload relief pressure ...................................27.9 MPa(285 kgf/cm 2, 4050 psi) @ 10 L/min
Boom, Arm, Bucket, and Offset
CONTROL VALVE 2
Model ...............................................................MVX 14
Type .................................................................Pilot pressure operated type
(EX75UR-5 / 3-spool section, EX75US-5 / 2-spool section)
Main relief pressure ..........................................22.6 MPa(230 kgf/cm 2, 3270 psi) @ 43 L/min
Overload relief pressure (Blade) .......................26 MPa(265 kgf/cm 2, 3770 psi) @ 20 L/min
T1-1-7
SWING DEVICE
Type .................................................................Two-stage reduction planetary gear
SWING MOTOR
Model ...............................................................MFB-50-007
Type .................................................................Fixed displacement swash plate type axial plunger motor
SWING MOTOR VALVE UNIT

Type .................................................................Non-counterbalance valve type
Relief pressure .................................................25 MPa (255 kgf/cm 2, 3630 psi) @ 63 L/min
SWING PARKING BRAKE

Type .................................................................Wet multi-disc negative type
Cracking pressure for release (Full stroke) .......1.18±0.15 MPa (12±1.5 kgf/cm 2, 171±21 psi)
TRAVEL DEVICE
Type .................................................................Two-stage reduction planetary gear
TRAVEL MOTOR
Model ...............................................................HMK059BF-2FA
Type .................................................................Radial Piston Motor
TRAVEL BRAKE VALVE

Type .................................................................Counterbalance type
Relief pressure .................................................31.9 MPa (325 kgf/cm 2, 4620 psi)
TRAVEL PARKING BRAKE

Type .................................................................Wet multi-disc negative type
Cracking pressure for release (Slow / Fast) ......0.88/1.57 MPa (9.0/16 kgf/cm 2, 128/228 psi)
CYLINDER (EX75UR-5) Boom Arm Bucket

Rod dia............................................................ 75 mm(2.95 in) 65 mm(2.56 in) 55 mm(2.17 in)
Cylinder bore ................................................... 125 mm(4.92 in) 105 mm(4.13 in) 85 mm(3.35 in)
Stroke.............................................................. 945 mm(37.2 in) 777 mm(30.6 in) 730 mm(28.7 in)
Fully retracted length ....................................... 1439 mm(56.7 in) 1240 mm(48.8 in) 1120 mm(44.1 in)
Plating thickness ............................................. 30 µm 30 µm 30 µm
Offset Blade
Rod dia.............................................................60 mm(2.36 in) 70 mm(2.76 in)
Cylinder bore ....................................................105 mm(4.13 in) 130 mm(5.12 in)
Stroke...............................................................424 mm(16.7 in) 145 mm(5.71 in)
Fully retracted length ........................................942 mm(37.1 in) 568 mm(22.4 in)
Plating thickness ..............................................30 µm 30 µm
CYLINDER (EX75US-5) Boom Arm Bucket

Rod dia.............................................................70 mm(2.76 in) 60 mm(2.36 in) 55 mm(2.17 in)
Cylinder bore ....................................................115 mm(4.53 in) 95 mm(3.74 in) 85 mm(3.35 in)
Stroke...............................................................945 mm(37.2 in) 900 mm(35.4 in) 730 mm(28.7 in)
Fully retracted length ........................................1370 mm(53.9 in) 1300 mm(51.2 in) 1120 mm(44.1 in)
Plating thickness ..............................................30 µm 30 µm 30 µm
T1-1-8
FRONT ATTACHMENT PILOT VALVE
Model ...............................................................HVP04D-040-101
TRAVEL PILOT VALVE

Model ...............................................................HVP05D-040-101
OFFSET PILOT VALVE (EX75UR-5)

Model ...............................................................RCV8C1021
BLADE PILOT VALVE

Model ...............................................................RCV8C1031
SOLENOID VALVE UNIT (3-UNIT SOLENOID VALVE WITH PILOT RELIEF VALVE) (EX75UR-5)
Model ...............................................................EPV220RU
Set-relief pressure ............................................3.7+0.2-0.1 MPa (38+2-1 kgf/cm 2, 540+28-14 psi)
Solenoid valve ..................................................SA: Travel mode solenoid valve
SB: Arm oil flow combining solenoid valve
: Emergency stop solenoid valve
SOLENOID VALVE UNIT (SOLENOID VALVE WITH PILOT RELIEF VALVE) (EX75US-5)
Model ...............................................................EPV220RU
Set-relief pressure ............................................3.7+0.2-0.1 MPa (38+2-1 kgf/cm 2, 540+28-14 psi)
Solenoid valve ..................................................SA: Travel mode solenoid valve
9-UNIT SOLENOID VALVE (EX75UR-5)

Model ...............................................................307414-0160 (2DN Specification)
Rated pressure .................................................3.7 MPa (38 kgf/cm 2, 540 psi)
SHOCKLESS VALVE
Model ...............................................................VU-477/0-8W4F14S
Type .................................................................Flow control
PILOT SHUT-OFF VALVE

Type .................................................................Rotary type
OIL COOLER BYPASS CHECK VALVE

2
Cracking pressure ............................................294 kPa (3.0 kgf/cm , 43 psi) @ 5 L/min
T1-1-9
Electrical Equipment
GENERAL PURPOSE RELAY

Application........................................................Horn, Work light, Wiper, Auto-air bleed solenoid valve,
Washer, Load damp
Voltage / Current ...............................................24 V ⋅ 10 A
BATTERY RELAY
Voltage ⋅ Current ...............................................24 V ⋅ 100 A
HORN
Specification .....................................................24 V ⋅ 1.5 A, 113 dB(A)
LIGHT
Output ..............................................................Work light: Halogen H3 24 V ⋅ 70W
Cab light: 24 V ⋅ 10 W
HEATER
Model ...............................................................WH20-R (DENSO / 116600-2140)
Output ..............................................................DC 24 V ⋅ 35 W
Heating capacity ...............................................8372 J/min (2000 kcal/min)
Air flow .............................................................150 m 3/h
T1-1-10
GENERAL / Component Layout
MAIN COMPONENTS 2
NOTE: Components marked * are used only on the

EX75UR-5. 1
EX75UR-5 2
M197-01-023
EX75US-5
29 4
5
6
7
8
9
10
11
28 12
13
27
26
25
24
23
22
21
20
19 14
18
15, 16
17
T197-01-01-001
1- Bucket Cylinder 9- Fuel Tank 16 - Oil Cooler 23 - Pilot Shut-Off Valve
2- Arm Cylinder 10 - Hydraulic Oil Tank 17 - Swing Device 24 - Blade Pilot Valve*
3- Boom Cylinder 11 - Engine 18 - Center Joint 25 - Travel Pilot Valve
4- Pilot Filter 12 - Pump Device 19 - Swing Bearing 26 - Offset Pilot Valve*
5- Control Valve 1 13 - Auto Air Bleed Solenoid 20 - Shockless Valve 27 - Offset Pilot Valve
Valve
6 - Solenoid Valve Unit 14 - Blade Cylinder 21 - 9-Unit Solenoid Valve* 28 - Offset Anti-Drift Valve*
7 - Shuttle Valve 15 - Radiator 22 - Travel Device 29 - Offset Cylinder*
8 - Control Valve 2
T1-2-1
ELECTRICAL SYSTEM (Overall System)

EX75UR-5.
EX75UR-5
M197-01-023
1 EX75US-5
4
5
6 View A
7
8
9
10
11
30
12
13
29 14
28
27
26
25
24
23 15, 16
22 17
21
18
20 19
T197-01-01-002
1 - Arm Angle Sensor* 9 - Horn 17 - Alternator 24 - Battery Relay
2 - Offset Angle Sensor* 10 - EC Motor and EC Sensor 18 - Air Cleaner Restriction 25 - 9-Unit Solenoid Valve*
Switch
3 - Work Light 11 - Pump Delivery Pressure 19 - Diode D2, D3, D4, D5, and 26 - Travel Mode Switch
Sensor D20
4 - Diode D6, D7, D8, D9, 12 - Pump Control Solenoid Valve 20 - Diode D12, D13, D14, D15, 27 - Auto-MARCCINO Control
and D10* and D16* Unit*
5 - Diode D21 13 - Starter 21 - Battery 28 - Fuse Box
6 - Boom Angle Sensor* 14 - Auto Air Bleed Solenoid 22 - Glow Plug Relay 29 - MC (Main Controller)
Valve
7 - Solenoid Valve Unit 15 - Coolant Temperature Sensor 23 - Starter Relay 30 - System Monitor*
8 - Fuel Sensor 16 - Overheat Switch
T1-2-2

EX75UR-5.
• View A • 9-Unit Solenoid Valve*
27 Front
34
5 33
28
49 35
29
48
30 36
47
31 46 Outside
Inside Base Base
Machine Machine
45 37
32 44
38
43
T197-01-02-003
39
• Relays 42
41
Rear 40 T197-01-02-007
• View B
50
51
52 56
53
View B
22 54
55
T197-01-02-005
50 51 52 53 54 55
T197-01-02-004
27 - Pressure Switch (Travel) 35 - Arm Roll-In Deceleration 43 - Boom Raise Acceleration 50 - Buzzer*
Solenoid Valve* Solenoid Valve*
28 - Emergency Stop Solenoid 36 - Arm Roll-Out Deceleration 44 - Right Offset Acceleration Pilot 51 - Horn Relay
Valve* Solenoid Valve* Pressure Sensor*
29 - Arm Oil Flow Combining 37 - Left Offset Deceleration 45 - Right Offset Acceleration 52 - Wiper Relay
Solenoid Valve* Solenoid Valve* Solenoid Valve*
30 - Travel Mode Solenoid Valve 38 - Boom Lower Deceleration 46 - Left Offset Acceleration 53 - Washer Relay
Solenoid Valve Solenoid Valve*
31 - Pilot Relief Valve 39 - Boom Raise Deceleration 47 - Left Offset Acceleration Pilot 54 - Load Damp Relay
Solenoid Valve Pressure Sensor*
32 - Pressure Switch 40 - Boom Raise Pilot Pressure 48 - Arm Roll-Out Acceleration 55 - Work Light Relay
(Front Attachment/Swing) Sensor* Solenoid Valve*
33 - Arm Roll-In Pilot Pressure 41 - Boom Lower Pilot Pressure 49 - Arm Roll-Out Acceleration 56 - Fuel Pump Relay
Sensor* Sensor* Pilot Pressure Sensor*
34 - Oil Temperature Sensor* 42 - Boom Raise Acceleration
Pilot Pressure Sensor*
T1-2-3
ELECTRICAL SYSTEM
(Monitor and Switches)

EX75UR-5.
××××
1 2 3 4 5 6
M197-01-015
7 8 9 10 11 12
M197-01-006
15 14 13
M197-01-017
System Monitor
16 17
19
×××× ××××
20
21
×× ××
×××
22
18 M197-03-003
M197-05-029
T1-2-4
Seat Rear Side Seat Left-Rear Side
24
M197-01-001
T191-02-02-001
23
1 - Auto-Idle Switch 7 - Alternator Indicator 13 - Hour Meter 19 - LCD Monitor*

2 - E Mode Switch 8 - Engine Oil Pressure 14 - Fuel Gauge 20 - System Malfunction
Indicator Indicator*
3 - Work Light Switch 9 - Preheat Indicator 15 - Coolant Temperature Gauge 21 - Depth Restriction
Switch*
4 - Buzzer Deactivation Switch 10 - Overheat Indicator 16 - Left Offset Switch* 22 - Depth-Set Dial*
5 - Wiper Switch 11 - Air Filter Restriction 17 - Right Offset Switch* 23 - Fuse Box
Indicator
6 - Auto-MARCCINO Mode 12 - Fuel Level Indicator 18 - Depth Restriction 24 - Emergency Evacuation
Switch* Deactivation Switch* Switch*
T1-2-5
OTHERS
Pump Device 3 Swing Device
6
2
8
1 7
4
T197-01-02-006
T152-01-02-003
Travel Device
10 T192-01-02-003
1 - Main Pump (1 and 2) 4 - Pump Control Solenoid Valve 7 - Parking Brake Switch 9 - Counter Balance Valve
Valve
2 - Main Pump 3 5 - Delivery Pressure Sensor 8 - Swing Relief Valve 10 - Travel Relief Valve
3 - Pilot Pump 6 - Make-Up Valve
T1-2-6
MEMO
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SECTION 2
SYSTEM
CONTENTS
Group 1 Control System
Outline .....................................................T2-1-1
Engine Control .........................................T2-1-2
Pump Control ...........................................T2-1-8
Other Controls........................................T2-1-12
Group 2 Front Control System

Outline .....................................................T2-2-1
Front Function Control..............................T2-2-2
Group 3 Hydraulic System

Outline .....................................................T2-3-1
Main Circuit ..............................................T2-3-2
Pilot Circuit.............................................T2-3-10
Group 4 Electrical System

Outline .....................................................T2-4-1
Power Source Circuit (Key Switch:OFF) ...T2-4-2
Bulb Check Circuit (Key Switch:ON) .........T2-4-3
Preheat Circuit (Key Switch:Heat) ............T2-4-4
Engine Start Circuit (Key Switch:Start) .....T2-4-6
Charging Circuit (Key Switch:ON).............T2-4-8
Surge Voltage Prevention Circuit ............T2-4-11
Accessory Circuit ...................................T2-4-12
Engine Stop Circuit.................................T2-4-13
197T-2-1
(Blank)
197T-2-2
SYSTEM / Control System
OUTLINE
A microcomputer built-in main controller (MC) monitors

and regulates all machine operations. The MC re-
ceives signals from the engine control dial and other
various sensors and switches. Then, the MC proc-
esses these signals and sends out control signals to
actuate the EC motor, and various kinds of solenoid
valve to control machine operation as described below.
NOTE: EX75UR-5 has the front function control

system besides the control systems ex-
plained herein. (Refer to the Front Function
Control System in T2-2.)
• EC Sensor → → EC Motor Ÿ Speed Control

• Engine Control Dial → (Engine Control) Ÿ E mode Control
Ÿ Auto-Idle Control
Ÿ Engine Learning
• Pressure Switch →
(Travel, Front Attachment, MC → Pump Control Ÿ Pump Swash
and Swing) Solenoid Valve Angle Control
• Auto-Idle Switch → (Pump Control) Ÿ Travel Mode Control
• Learning Plug / Receptor →
Connector
• E Mode Switch → → Travel Mode Ÿ Travel Mode Control
• Key Switch → Solenoid Valve
• Travel Mode Switch → (Valve Control)
→ Auto Air Bleed Ÿ Auto Air Bleed Control
Solenoid Valve
(Other Function
Control)
T2-1-1
ENGINE CONTROL
Speed Control
Function: The engine speed is controlled in re-
sponse to the engine control dial rotation
angle.
Operation: The engine control dial signals in re-

sponse to the dial rotation angle to the
MC. The MC drives the EC motor to move
the governor lever, controlling the engine
speed. The EC sensor checks the EC mo-
tor rotational position and feeds it back to
the MC, allowing the MC to correctly op-
erate.
EC Sensor
Engine Control Dial Stop Full
EC Motor
T197-02-01-002
Governor Lever
T2-1-2
E Mode Control
Function: The engine speed is reduced to less than
1800 min-1 to save fuel consumption.
Operation: When the E mode switch ON signal

reaches the MC, the MC drives the EC
motor to move the governor lever so that
the engine speed is reduced to less than
1800 min-1.
EC Sensor
Engine Control
Dial
E Mode Switch
EC Motor
Governor Lever T197-02-01-003
T2-1-3
Auto-Idle Control
Function: To reduce the engine speed to 1200 min-1
when all control levers are in neutral to in-
crease fuel efficiency and to decrease
noise.
Operation: The MC drives the EC motor to move the

governor lever so that the engine speed is
reduced to 1200 min–1 approx. four sec-
onds after all control levers are released
and in neutral (the travel, front attachment,
and swing pressure switches are OFF)
with the auto-idle switch ON.
Pressure Switch Pressure Switch

(Front Attachment / Swing): OFF (Travel): OFF
Control
Valve
EC Sensor
Auto-Idle Switch
T197-02-01-004
T2-1-4
Engine Learning Control
Function: The MC is calibrated to the governor lever IMPORTANT: Be sure to perform engine learning
stopper positions corresponding to the after:
fast idle operation and the engine stop, • The engine, engine control cable,
which are used as standard signals for or EC motor has been removed or
the engine speed control. replaced.
• The MC has been replaced.
Operation: When the engine learning plug is con-
nected to the plug receptacle, the MC ac- NOTE: Engine learning is not required to be per-
tuates the EC motor so that the EC motor formed after replacing the batteries.
moves the governor lever from the slow
idle position to full stroke position and
then to the engine stop position. Mean- Left Console
while, the EC sensor detects both the
governor lever full stroke and engine stop
positions and instructs the MC. The MC
stores these positions in its memory, by Learning Plug/
which the correct engine control can be Plug Receptacle
maintained.
T197-02-01-009
EC Sen-
Learning
Plug/ Plug
Receptacle Stop Full
Key Switch EC Motor
Governor Lever T197-02-01-008
T2-1-5
Noise Reduction Control
Purpose: While the auto-idle switch is OFF and NOTE: Engine speed change is slowly made:
engine speed is faster than 2000 min-1, When engine speed is decreased , it takes
when all control levers are placed in the approx. 3 seconds or 1.5 seconds to reach
neutral positions, engine speed is re- 2000 min-1 from 2100 min-1 or 2050 min-1,
duced to 2000 min-1 to reduce noise respectively.
level. When engine speed is increased, it takes
approx, 1 second or 0.5 seconds to reach
Operation: When all control levers are placed in the 2100 min-1 or 2050 min-1 from 2000 min-1,
neutral positions (pressure switches for respectively.
travel and front attachment are OFF),
the MC instructs the EC motor to reduce
engine speed to 2000 min-1.
When the control levers are operated
(pressure switches for travel and front
attachment are ON), the MC instructs
the EC motor to return to the original
engine speed.
Pressure Switch
Pressure Switch (Travel)
(Front Attachment)
Engine Control Dial
EC Motor Governor Lever
Auto-Idle Switch
T197-02-01-010
T2-1-6
(Blank)
T2-1-7
PUMP CONTROL
Pump Swash Angle Regulation

Function: Regulates the pump displacement to
meet the machine operating conditions.
Operation: When receiving signals from the travel

mode switch and pressure switches
(travel, front attachment, and/or swing),
the MC activates or deactivates the pump
control solenoid valve to regulate the
pump displacement depending on the in-
put signal status. When the pump control
solenoid valve is turned ON, the pump
displacement is increased and when
turned OFF, the pump displacement is
reduced. (See pages for the COMPO-
NENT OPERATION / Pump Device.)
Input Signal to MC Output Signal From MC Note

Travel Pressure Switch
Pump Control
Mode Front Attachment
Travel Solenoid Valve
Switch / Swing
OFF OFF
OFF Pump Control Solenoid Valve
Slow ON ON
O N: Increasing pump displacement
Mode OFF OFF
ON OFF: Reducing pump displacement
ON OFF
OFF OFF
OFF
Fast ON ON
Mode OFF ON
ON
ON ON
T2-1-8
Pressure Switch
(Front Attachment / Swing)
Travel Mode Switch
Pump Control T197-02-01-005
Solenoid Valve
T2-1-9
Travel Mode Control (Pump and Valve Control)
Function: Selects travel speed either the fast or
slow mode.
Operation: Slow Mode Operation: Fast Mode

When the travel mode switch is placed in When the travel mode switch is placed in
the SLOW position, the MC turns the the FAST position, the MC turns the travel
travel mode solenoid valve OFF. Then, mode solenoid valve ON. Then, the travel
the travel mode solenoid valve blocks the mode solenoid valve supplies the swash
travel motor swash angle control oil pres- angle control oil pressure to the travel mo-
sure. Thus, travel motor swash angle is tor. Thus, travel motor swash angle is re-
increased, reducing the travel motor duced, increasing the travel motor speed.
speed. At the same time, The MC turns At the same time, The MC turns the pump
the pump control solenoid valve OFF so control solenoid valve ON so that the
that the pump swash angle is reduced. pump swash angle is increased. Thereby,
Thereby, the pump delivery oil flow rate is the pump delivery oil flow rate is in-
reduced. creased. (Refer to the PUMP CONTROL
in this section and the pages for the
COMPONENT OPERATION / Pump De-
vice and the COMPONENT OPERATION
/ Travel Device groups.)
Input Signal to MC Output Signal from MC

Travel Mode
Pump Control Solenoid Valve Travel Mode Solenoid Valve
Switch
OFF OFF
Slow Mode (Reduced pump swash angle (Increased motor swash angle
and flow rate) and reduced rotation speed)
ON ON
Fast Mode (Increased pump swash angle (Reduced motor swash angle
and flow rate.) and increased rotation speed)
T2-1-10
Pressure Switch Pressure Switch

(Front Attachment / Swing) (Travel)
Travel Mode
Switch
Pump Control Solenoid Valve
Travel Mode Solenoid Valve
T197-02-01-006
T2-1-11
OTHER CONTROLS
Auto-Air Bleed Control

Function: Activates the auto-air bleed solenoid
valve to release any remaining air pres-
sure from the engine fuel system.
Operation: When the key switch is ON or START, the

key switch sends signals to the MC. Then,
MC magnetizes the auto-air bleed sole-
noid valve relay for 40 seconds. When the
auto-air bleed solenoid valve relay is
magnetized, the auto-air bleed solenoid
valve relay activates to release any re-
maining air pressure from the engine fuel
system.
Key Switch
From Fuse #7
Auto-Air Bleed
Solenoid Valve
Relay
Key ON Signal
Auto-Air Bleed
Solenoid Valve
T197-02-01-007
T2-1-12
SYSTEM / Front Control System
OUTLINE
Only the EX75UR-5 is equipped with the front Control

system. The microcomputer built-in auto-MARCCINO
control unit achieves total front function control. The
auto-MARCCINO control unit processes input signals
from various sensors and switches, and drives the 9-
unit solenoid valve and emergency stop solenoid valve
to perform the following controls.
Auto-MARCCINO Control Unit
• Pilot Oil Pressure Sensors (Boom Raise, → 9-Unit Solenoid ŸDepth Limit Control
Boom Raise Acceleration, Boom Lower, Valve ŸCab Collision
Arm Roll-In, Arm Roll-Out Acceleration, (Front Control) Prevention Control
Right Offset Acceleration, and Left Offset → ŸAuto-MARCCINO
Acceleration) Control
• Angle Sensor (Boom, Arm, and Offset) → → Emergency Stop ŸFront Motion
• Depth Set Dial → Solenoid Valve Restriction Control
• Pump Delivery Pressure Sensor → → Arm Oil Flow ŸArm Oil Flow
• Right Offset Switch → Combining Solenoid Control
• Left Offset Switch → Valve
• Auto-MARCCINO Mode Switch → → LCD Monitor ⋅ ŸSystem Malfunction
• Emergency Evacuation Switch → System Malfunction Display Control
Indicator
T2-2-1
FRONT FUNCTION CONTROL
The front function control falls into the following control

systems:
• Depth Limit Control
• Cab Collision Prevention Control
• Auto-MARCCINO Control
• Front Motion Restriction Control
• System Malfunction Display Control
• Arm Oil Flow Combining Control
Left Offset
Arm Roll- Boom Raise Acceleration
Out Accel- Pilot Pres- Pilot Pres- Right Offset
eration Pilot sure Sensor sure Sensor Acceleration
Pressure Pilot Pres-
Sensor sure Sensor
Boom Raise
Pump Acceleration Arm Roll-In
Pilot Pres- Pilot Pres- Boom Lower
Delivery Pilot
Pressure sure Sensor sure Sensor
Pressure
Sensor Sensor
Boom Angle Sensor

9-Unit Solenoid Valve Unit
Boom Raise Deceleration
Arm Angle Sensor Solenoid Valve
Boom Raise Acceleration
Offset Angle Sensor Solenoid Valve
Boom Lower Decelera-
tion Solenoid Valve
Left Offset Switch (7) Arm Roll-Out Decelera-
tion Solenoid Valve
Arm Roll-In Deceleration
Right Offset Switch (5) Auto-MARCCINO Solenoid Valve
Control Unit Arm Roll-Out Acceleration
Solenoid Valve
Right Offset Acceleration
Depth Limit Override Solenoid Valve
Switch (6) Left Offset Deceleration
Solenoid Valve
Auto-MARCCINO Left Offset Acceleration
Mode Switch (8) Solenoid Valve
Emergency Stop Solenoid Valve
Depth Set Dial (4) LCD Monitor System Malfunc-

tion Indicator
Arm Oil Flow Combining
Solenoid Valve
Emergency Evacuation
Switch (9)
T197-02-02-001
T2-2-2
Inside Cab System Monitor
×××× ××××
2
3
×× ××
×××
M197-01-006 4
M197-03-003
System Monitor 7 5
9
6
M197-03-005
T191-02-02-001
×××
M197-01-015
1 - LCD Monitor 4 - Depth Set Dial 6 - Depth Restriction Deactiva- 8 - Auto-MARCCINO Mode
tion Switch Switch
2 - System Malfunction 5 - Right Offset Switch 7 - Left Offset Switch 9 - Emergency Evacuation Switch
Indicator
3 - Depth Limit Switch
T2-2-3
Depth Limit Control
Function: Automatically controls the front attachment
motion so that the bucket won’t be lowered
more than the depth limited by the depth
set dial.
Operation: The auto-MARCCINO control unit monitors

the location (depth) of the bucket by the When the depth restriction deactivation switch is de-
signals sent from the boom angle sensor pressed while operating this system, the depth limit
(height/depth) and arm angle sensor. When control system is deactivated.
the bucket comes near the set position dur-
ing operation, the auto-MARCCINO control
unit activates the 9-unit solenoid valve
(boom raise acceleration / deceleration,
boom lower deceleration, arm roll-in / roll-
out deceleration, and arm roll-out accelera-
tion) to block pilot pressure oil or accelerate
the front attachment so that the bucket
won’t be lowered more than the depth lim-
ited by the depth set dial.
9-Unit Solenoid Valve

Solenoid Valve
Boom Angle Sensor Boom Raise Acceleration
Solenoid Valve
Boom Lower Deceleration
Solenoid Valve
Arm Angle Sensor Arm Roll-Out Deceleration
Auto-MARCCINO Solenoid Valve
Control Unit Arm Roll-In Deceleration
Solenoid Valve
Depth Restriction
Deactivation Switch Arm Roll-Out Acceleration
Solenoid Valve
Solenoid Valve
Depth Set Dial Left Offset Deceleration
Solenoid Valve
Left Offset Acceleration
Solenoid Valve
T197-02-02-002
T2-2-4
Depth Limit:
When the arm is rolled-in,

the boom is automatically
raised by the amount the
bucket is lowered. Then,
the bucket isn’t lowered
more than the set-depth.
M197-05-023
T2-2-5
Cab Collision Prevention Control
Function: Automatically decelerates and/or stops the
front attachment when the bucket enters
the pre-set range (deceleration, intermedi-
ate deceleration, and stop) to prevent the
bucket from colliding with the cab.
Operation: The auto-MARCCINO control unit monitors

the position of the front attachment by the
signals sent from the boom angle sensor,
arm angle sensor, and offset angle sensor.
If the bucket enters the pre-set range, the
auto-MARCCINO control unit activates the
9-unit solenoid valve (boom raise decelera-
tion, arm roll-in deceleration, and left offset
deceleration) to block pilot pressure oil, de-
celerating or stopping the front attachment.

Solenoid Valve
Solenoid Valve
Boom Angle Sensor Solenoid Valve
Arm Roll-Out Deceleration
Solenoid Valve
Arm Angle Sensor Control Unit Arm Roll-Out Acceleration
Solenoid Valve
Solenoid Valve
Offset Angle Sensor Left Offset Deceleration
Solenoid Valve
Solenoid Valve
Emergency Stop Sole-
noid Valve
T197-02-02-003
T2-2-6
Control Range:
NOTE: Unit: mm Arm Deceleration
Boom Deceleration
Arm Intermediate Deceleration
Boom Intermediate Deceleration

Boom/Arm Stop Line
T197-02-02-004
Offset Deceleration
Offset Intermediate
Deceleration
Offset Stop Line
Allowed Boom /
Arm Approaching Range from
the front
T192-02-02-002
T2-2-7
Auto-MARCCINO Control
• Cab Collision Prevention Control
Function: When the machine is operated in the cab Operation: The auto-MARCCINO control unit monitors
collision prevention mode, if the bucket en- the position of the front attachment by sig-
ters the cab collision prevention range while nals from the boom angle sensor, arm an-
raising the boom such as in a truck loading gle sensor, and offset angle sensor and the
operation, all front attachment functions are front attachment movement by the signals
stopped. In the auto-MARCCINO control from the boom raise pilot pressure sensor
mode, even if the bucket enters the cab col- and arm roll-in pilot pressure sensor. If the
lision prevention range, the bucket can be boom is raised when the bucket enters the
moved along the cab collision prevention cab collision prevention range, the auto-
control line without stopping the front at- MARCCINO control unit activates the 9-
tachment function, allowing the truck loading unit solenoid valve (arm roll-in deceleration,
work to continue. and arm roll-out acceleration). Then, the 9-
unit solenoid valve (arm roll-in deceleration,
and arm roll-out acceleration) supplies pilot
pressure oil to the control valve arm spool
so that the arm is rolled out. Thus, the
bucket is moved along the cab collision
prevention control line.
NOTE: How much the arm should be moved (arm

roll-out acceleration command) depends
upon how much the boom is raised (boom
raise pilot pressure sensor) and how far the
bucket has entered the cab collision pre-
vention range.
Arm Deceleration
Boom Deceleration
Cab Collision Prevention Control line

Stop Line
T197-02-02-005
T2-2-8
Boom Raise Arm Roll-in

Pilot Pres- Pilot Pres-
sure Sensor sure Sensor

Solenoid Valve
Boom Angle Sensor Boom Raise Acceleration
Solenoid Valve
Solenoid Valve
Arm Angle Sensor Arm Roll-Out Deceleration
Control Unit Arm Roll-In Deceleration
Arm Roll-Out Acceleration
Solenoid Valve
Mode Switch (1) Left Offset Deceleration
Solenoid Valve
Solenoid Valve
T197-02-02-006
T2-2-9
• Offset Control by Offset Switch
Function: Achieves the offset control by operating
the offset switch.
Operation: When the auto-MARCCINO mode

switch is ON and signals from the offset
switch are input to the auto-MARCCINO
control unit, the auto-MARCCINO con-
trol unit activates the 9-unit solenoid
valve (left / right offset acceleration).
Then, the 9-unit solenoid valve (left /
right offset acceleration) supplies a con-
stant pilot pressure to the control valve
offset spool, achieving the offset opera-
tion.
Left Offset Accel- Right Offset Ac-

eration Pilot celeration Pilot
Pressure Sensor Pressure Sensor

Solenoid Valve
Left Offset Solenoid Valve
Switch Boom Lower Deceleration
Solenoid Valve
Right Offset Auto-MARCCINO Solenoid Valve
Switch Control Unit Arm Roll-In Deceleration
Solenoid Valve
Arm Roll-Out Accelera-
Auto- tion
MARCCINO Solenoid Valve
Mode Switch Left Offset Deceleration
Solenoid Valve
Solenoid Valve
T197-02-02-007
T2-2-10
(Blank)
T2-2-11
Front Motion Restriction Control
Function: Restricts the front attachment motion de- Operation: Signals from various sensors and switches
pending on the fault after any failure has are input into the auto-MARCCINO control
occurred in the front attachment control unit. If any abnormal signals are input from
system. the various sensors and/or switches, the
auto-MARCCINO control unit activates ei-
ther the 9-unit solenoid valve or emergency
NOTE: When any failure has occurred in the front
stop solenoid valve depending on the ab-
attachment control system, the system mal-
normal status. In case the auto-
function indicator comes ON and the LCD
MARCCINO control unit restricts a limited
monitor displays the fault code relating to
number of front attachment actuators, the
the fault.
auto-MARCCINO control unit activates the
9-unit solenoid valve and restricts the re-
lated actuator motion. When restricting all
actuator motion, the auto-MARCCINO con-
trol unit activates the emergency stop sole-
noid valve, blocking the pilot pressure oil
flow. Thus, the control valve spools be-
come inoperable so that all actuators can’t
be operated. (Refer to the COMPONENT
OPERATION / Others (Upperstructure)
group.)
T2-2-12
Left Offset
Arm Roll-Out Boom Raise Acceleration
Acceleration Pilot Pres- Pilot Pres- Right Offset
Pilot Pressure sure Sensor sure Sensor Acceleration
Sensor Pilot Pressure
Sensor
Boom Raise
Pump Acceleration Arm Roll-In
Delivery Oil Pilot Pres- Pilot Pres- Boom Lower
Pressure sure Sensor sure Sensor Pilot Pressure
Sensor Sensor
Boom Angle Sensor


Solenoid Valve
Left Offset Switch Solenoid Valve
Right Offset Switch Control Unit Arm Roll-Out Acceleration
Solenoid Valve
Depth Restriction Solenoid Valve
Deactivation Switch Left Offset Deceleration
Solenoid Valve
Mode Switch Solenoid Valve
Solenoid Valve
Depth Set Dial LCD Monitor System Malfunction
Indicator
Solenoid Valve
Emergency
Evacuation Switch
T197-02-02-008
T2-2-13
System Malfunction Display Control
Function: Turns the system malfunction indicator
ON and displays the fault code associ-
ated with the failure on the LCD monitor
after any failure has occurred in the front
attachment control system.
LCD Monitor
Operation: Signals from various sensors and

switches related to the front attachment
control are input into the auto-
MARCCINO control unit. If any abnormal ×××× ××××
signals are input from various sensors
and/or switches, the auto-MARCCINO System
×× ×× Malfunction
control unit sends signals to the system ×××
Indicator
malfunction indicator and LCD monitor.
Thereby, the system malfunction indicator
comes ON and the LCD monitor displays
the fault code associated with the failure. M197-03-003
T2-2-14
Arm Roll- Left Offset

Out Accel- Boom Raise Acceleration
Pilot Pres- Right Offset
eration Pilot Pilot Pres- Acceleration
Pressure sure Sensor sure Sensor Pilot Pres-
Sensor sure Sensor
Boom Raise
Acceleration Arm Roll-In
Pump
Pilot Pres- Pilot Pres- Boom Lower
Delivery Oil
sure Sensor sure Sensor Pilot
Pressure
Sensor Pressure
Sensor
Boom Angle Sensor


Solenoid Valve
Left Offset Switch Solenoid Valve
Right Offset Switch Control Unit Arm Roll-Out Acceleration
Solenoid Valve
Depth Restriction
Solenoid Valve
Deactivation Switch Left Offset Deceleration
Solenoid Valve
Mode Switch Solenoid Valve
Solenoid Valve
Depth Set Dial LCD Monitor System Malfunction
Indicator
Solenoid Valve
Emergency
Evacuation Switch
T197-02-02-008
T2-2-15
Arm Oil Flow Combining Control
Function: Increases the arm roll-in operating pres-
sure when the bucket comes in contact
with any obstacles or if the arm is rolled in
with a heavy load.
Operation: Signals from the pump delivery pressure The set pressure of the relief valve for
sensor and the arm roll-in pilot pressure control valve 1 is higher than that of the
sensor are input into the auto- relief valve for control valve 2, increasing
MARCCINO control unit. In case the the arm roll-in operating hydraulic oil
bucket comes in contact with any obsta- pressure. The delivery oil pressure is act-
cles and if the arm roll-in oil pressure in- ing on the shift piston of main pumps (1
creases, the signals from the pump deliv- and 2). When pressure oil from control
ery pressure sensor and the arm roll-in pi- valve 2 is combined with pressure oil from
lot pressure sensor informs the auto- control valve 1 and supplied to the arm
MARCCINO control unit that the arm roll- cylinder, the shift piston is pushed with
in pressure is high. Then, the auto- high pressure oil, reducing the swash an-
MARCCINO control unit activates the arm gle of main pumps (1 and 2) so that the
oil flow combining solenoid valve so that flow rate of main pumps (1 and 2) is re-
the arm roll-in pilot pressure is also routed duced. When the arm 3 spool is returned
to side A of the arm 3 spool in control to neutral, the oil pressure delivered from
valve 2. main pump 3 is reduced so that the
Therefore, the arm 3 spool in control swash angle of main pumps (1 and 2) is
valve 2 receives the equal pilot pressure increased. Accordingly, the flow rate of
on the both spool ends, returning the main pumps (1 and 2) is increased. (Refer
spool to neutral. to pages for the SYSTEM / Hydraulic Sys-
Since the arm 3 spool is in neutral, only tem and the COMPONENT OPERATION
pressure oil from control valve 1 is sup- / Control Valve.)
plied to the arm cylinder.
T2-2-16
When the oil flow from main pump 3 is combined:
From Pilot Pump
Arm Oil Flow Combin-

ing Solenoid Valve
A
Arm 3
22.6 MPa Control Valve 2 Arm Cylinder

(230 kgf/cm 2, 3270 psi)
P/V
Arm Roll-In Pilot

Pressure Sensor
Pump Delivery Pressure

Sensor
Control
Arm 1 Valve 1 Arm 2
26 MPa
Main Pump 3 (265 kgf/cm 2, 3770 psi)
Main Pump 2
Main Pump 1
T197-02-02-009
When the oil flow from main pump 3 is not combined:

From Pilot Pump Arm Oil Flow Combin-
ing Solenoid Valve
From Auto-MARCCINO
Control Valve
A
22.6 MPa Control Valve 2
Arm Cylinder
(230 kgf/cm 2, 3270 psi)
P/V
Arm 3
Arm Roll-In Pilot
Pressure Sensor
Pump Delivery Pressure

Sensor
Control
Arm 1 Valve 1 Arm 2
26 MPa
Main Pump 3 (265 kgf/cm 2, 3770 psi)
Main Pump 2
Main Pump 1
T197-02-02-010
T2-2-17
Distance Indication Control (Option)
Purpose: To display the bucket height, depth, and Operation: Sensing signals from the boom angle
offset amount in both absolute and sensor, arm angle sensor, and offset
relative distance values. angle sensor are input into the auto-
The absolute distance value means the MARCCINO control unit. The auto-
movement distance measured from a MARCCINO control unit calculates the
preset-specified standard point. The bucket tip position using the input
relative distance means the movement signals, allowing the system monitor to
distance measured from a position se- display the calculation results in
lected by the zero position set switch. response to instructions given from the
switches.
Boom Angle Sensor
Arm Angle Sensor
Offset Angle Sensor
Auto-MARCCINO
Absolute/Relative Distance Selector Control Unit
Display Sensor
Zero Position Set Switch

System Monitor
T191-02-02-008
T2-2-18
Distance Display:
• Absolute Distance Display
(A) Standard
Center Line
Standard
Level
(C) Standard Point
(B)
M190-05-024 M190-05-025
• Relative Distance Display
(A)
Zero
Position
(B)
Zero Position
M190-05-026 T191-02-02-002
Zero
Position
T191-02-02-003
A - Height C - Reach D - Right Offset E - Left Offset

B - Depth C’ - Reach
T2-2-19
Front Movement Restriction Control (Option)
Purpose: To limit and stop the movement of the Operation: The boom angle sensor (height/depth
boom top height and depth, and left offset limit) or offset angle sensor (offset limit)
at the positons specified using the height checks the front movement limit set
limit switch, depth limit switch, and offset positions and the auto-MARCCINO
limit switch, respectively. control unit stores the data. During
operation, when the front attachment
approaches the movement limit set
position, the auto-MARCCINO control
unit magnetizes the 9-spool solenoid
valve unit (boom raise deceleration
/boom lower dceleration/left offset
deceleration) to block pilot pressure,
causing the front movement to stop.
Boom Angle Sensor

Solenoid Valve
Offset Angle Sensor Boom Raise Acceleration

Solenoid Valve

Depth limit Switch Solenoid Valve

Control Unit
Offset Limit Switch Arm Roll-In Deceleration
Solenoid Valve
Arm Roll-Out Acceleration

Solenoid Valve
Height Limit Switch
Solenoid Valve
Left Offset Deceleration

Solenoid Valve

Solenoid Valve
T197-02-02-011
T2-2-20
Front Movement Restriction
• Height Limit
M190-05-031
• Depth Limit
M190-05-032
• Offset Limit
M190-05-034
T2-2-21
(Blank)
T2-2-22
SYSTEM / Hydraulic System
OUTLINE
The hydraulic system consists of the main circuit and

pilot circuit.
• Main Circuit
Controls pressure oil from the main pump with the
control valves to actuate the cylinders and motors.
• Pilot Circuit
Supplies pressure oil from the pilot pump to the
control valve spool operation circuit, pump control
circuit, front control circuit, travel mode control circuit,
valve control circuit, swing parking brake release
circuit, and hydraulic oil heating circuit.
T2-3-1
MAIN CIRCUIT
The main pumps (1, 2, and 3) draw hydraulic oil from Return oil from the motors and/or cylinders is routed
the hydraulic oil tank and discharge pressure oil to the again to the control valve spool and merges in the
control valves. Pressure oil from main pump 2 enters control valve. Then, return oil from the control valve
the 4-spool section of control valve 1 and is routed to flows back to the hydraulic oil tank after being cooled in
the right travel, bucket, boom 1 and arm 2 spools. the hydraulic oil cooler.
Pressure oil from main pump 1 enters the 5-spool When the hydraulic oil temperature is low (high
section of control valve 1 and is routed to the auxiliary, viscosity), oil flow resistance in the hydraulic oil cooler
arm 1, boom 2, offset, and left travel spools. Pressure increases so that return oil pressure increases. To
oil from main pump 3 enters control valve 2 and is prevent the pressure increase of return oil, the bypass
routed to the blade, swing, and arm 3 spools. check valve opens, allowing the hydraulic oil to flow
Pressure oil routed in each spool flows further to the back to the hydraulic oil tank without passing through
corresponding motors and/or cylinders to operate them the oil cooler.
in response to the spool operation.
When the boom raise and swing operations are
NOTE: Only the EX75UR-5 has the oil flow
performed simultaneously, or when the arm is rolled in,
combining circuits for pressure oil from
pressure oil from main pumps (1, 2, and 3) merges in
main pump 3 when the arm 3 and/or arm
the boom raise and arm roll-in circuits via the oil flow
roll-in spool is operated.
combining circuits.
T2-3-2
NOTE: The diagram shown below is for the EX75UR-5.

Blade Cylinder
Control Valve 2
Blade Swing Arm 3

Swing
(4-Spool Section)
Left Travel
Motor
Right
Left Travel Right Travel
Travel Motor
Offset
Bucket Bucket
Cylinder
Offset
Cylinder Boom 2 Boom 1
Boom
Cylinder
Oil Flow Arm Arm 1 Arm 2
Combining Cylinder
Check
Valve
Auxi-
Oil Flow
liary
Combining
Passage Oil Flow
Combining
Passage
(5-Spool Section) Control Valve 1
Bypass Check
Pilot Main Main Main Valve
T197-02-03-001
Pump Pump 3 Pump 1 Pump 2
T2-3-3
Bypass Check Valve
• Travel and front attachment function combined The bucket, boom 1, and arm 2 spools are located
operation. (EX75UR-5) in the hydraulic circuit after the right travel spool,
When the front attachment is operated while so pressure oil from main pump 2 is not supplied
traveling, the front attachment spool blocks all to these spools when the right travel spool is
signal pilot circuits except for the travel, operated. Then, main pump 1 supplies pressure
increasing the pilot oil pressure. Consequently, oil to the bucket, arm roll-out, and boom spools in
the flow combiner valve is shifted. Then, pressure this case. When the arm is rolled in, pressure oil
oil from main pump 2 flows into the right travel from main pumps (1 and 3) is supplied to the arm
motor via the right travel spool. In addition, it flows cylinder by shifting the arm 3 spool.
to the left travel motor via the flow combiner valve
and the left travel spool. Therefore, the same
amount of pressure oil is supplied from main
pump 2 to both right and left travel motors so that
the machine can travel straight.
T2-3-4
Blade Cylinder
Control Valve 2
Blade
Swing
Arm 3
Swing
Left Travel Flow

Motor Combiner
Valve
Right
Left Travel Right Travel
Travel Motor
Offset Bucket Bucket

Cylinder
Boom 2 Boom 1
Arm Arm 1 Arm 2

Cylinder
Auxiliary
Control Valve 1
Pilot Main Main Main T197-02-03-002

T2-3-5
Bypass Check Valve
• Travel and front attachment function combined The bucket, boom 1, and arm 2 spools are located
operation. (EX75US-5) in the hydraulic circuit after the right travel spool,
When the front attachment is operated while so pressure oil from main pump 2 is not supplied
traveling, the front attachment spool blocks all to these spools when the right travel spool is
signal pilot circuits except for the travel, operated. Then, main pump 1 supplies pressure
increasing the pilot oil pressure. Consequently, oil to the bucket, arm , and boom spools in this
the flow combiner valve is shifted. Then, pressure case.
oil from main pump 2 flows into the right travel
motor via the right travel spool. In addition, it flows
to the left travel motor via the flow combiner valve
and the left travel spool. Therefore, the same
amount of pressure oil is supplied from main
pump 2 to both right and left travel motors so that
the machine can travel straight.
T2-3-6
Control Valve 2
Aux. Swing
Swing
Left Travel Flow

Motor Combiner
Right Valve
Travel Right Travel
Motor
Auxiliary
Bucket Bucket
Cylinder
Boom 2 Boom 1
Arm 1 Arm 2
Arm
Cylinder
Left
Travel
Control Valve 1

T2-3-7
• Swing and Boom Raise Combined Operation
An oil flow combining passage to the boom 2 At the beginning of the combined operation, the oil
circuit is provided in the hydraulic circuit between pressure in the hydraulic circuit between the
main pump 3 and control valve 2. A check valve is swing motor and main pump 3 becomes high due
located in the oil flow combining passage to to increased load to the swing motor. As the oil
regulate the pressure oil flow when the swing and pressure between the swing motor and main
boom raise combined operation is performed. pump 3 is high, the check valve in the oil flow
When the swing and boom raise combined combining passage opens, allowing pressure oil
operation is performed, the pilot oil pressure shifts from main pump 3 to flow to the boom cylinders in
the swing and boom 1 and 2 spools in the control which the oil pressure is still low. Thus, the boom
valve. Pressure oil from main pump 2 flows into and bucket can be raised quickly. Once the swing
the boom cylinder bottom via the parallel passage motor starts to rotate, the load to the swing motor
and the boom 1 spool in control valve 1. Pressure is reduced, decreasing the oil pressure in the
oil from main pump 1 flows through the parallel hydraulic circuit between the swing motor and
passage and boom 2 spool in control valve 1 and main pump 3. Thereby, the check valve in the oil
merges in the pressure oil flow from main pump 2. flow combining passage is closed, by which major
Then, it flows into the boom cylinder bottom to pressure oil from main pump 3 flows to the swing
raise the boom. Pressure oil from main pump 3 motor, increasing the swing speed. Accordingly,
flows into the swing motor via the parallel passage truck loading operation can be performed more
and swing spool in control valve 2. efficiently.
T2-3-8
NOTE: The diagram shown below is for the EX75UR-5.
Control Valve 2
Blade Arm 3
Swing Motor
Swing
Parallel Passage
Parallel
Passage
Oil Flow
Combining
Passage Boom 2 Boom 1
Boom
Cylinder
Oil Flow
Combining
Check Valve
Parallel Passage
Control Valve 1

T2-3-9
PILOT CIRCUIT
Pressure oil from the pilot pump is supplied to the

following circuits.
• Control Valve Spool Operation Circuit • Valve Control Circuit (Refer to the COMPONENT
Pressure oil from the pilot pump is regulated at the OPERATION / Control Valve group.)
pilot valve to operate the control valve spools. The Depending on opening/closing of the signal pilot
shockless valves are provided to prevent the circuit, pilot pressure oil shifts the flow combiner
control valve spools from moving too quickly. valve spool and main relief valve set-pressure.
• Pump Control Circuit (Refer to the COMPONENT • Swing Parking Brake Release Circuit (Refer to the
OPERATION / Pump Device group.) COMPONENT OPERATION / Swing Device
In response to the pump control solenoid valve, group.)
pilot pressure oil regulates the pump swash plate When the signal pilot circuit (front attachment
angle to control the maximum pump flow rate. /swing) is closed, the swing parking brake is
released.
• Front Control Circuit (Refer to the SYSTEM /
Front Control System group.) • Hydraulic Oil Heating Circuit (Refer to the
Pilot pressure oil from each pilot valve is regulated COMPONENT OPERATION / Others
by the 9-unit solenoid valve, emergency stop (Upperstructure) group.)
solenoid valve, and/or arm oil flow combining When the pilot shut-off valve is closed, pilot
solenoid valve to control the movement of the pressure oil is routed to the shockless valve.
front attachment. Hydraulic oil is heated as it flows through the
orifice in the shockless valve.
NOTE: The front control circuit is provided only to
the EX75UR-5.
• Travel Mode Control Circuit (Refer to the

COMPONENT OPERATION / Travel Device
group.)
In response to the travel mode solenoid valve,
pilot pressure oil regulates the motor swash plate
angle to control the travel speed.
T2-3-10
NOTE: Components marked ∗ are used only on the EX75UR-5.
Offset
Left Pilot Valve Right Pilot Blade Pilot Valve∗
Pilot Valve∗ Valve
Pilot Shut-off Valve Shockless Valve
9-Unit Solenoid Valve∗
Emergency Stop
Travel Pilot Valve
Solenoid Valve
Swing Parking
Brake Release
Control Valve-1
Control Valve-2
Pump Control Solenoid

Valve

Solenoid Valve∗
Travel Mode Solenoid

Valve
Relief Valve Pilot Filter Pilot Pump
T2-3-11
(Blank)
T2-3-12
SYSTEM / Electrical System
OUTLINE
The electrical circuit is roughly classified into the main • Accessory Circuit: The circuit to activate the
circuit, the control circuit, and the monitor circuit. accessories only when the key switch is in the ACC
position.
• Main Circuit
Engine and engine accessory circuit • Engine Stop Circuit: The circuit to stop the engine
with the EC motor, consisting of the MC and EC
• Control Circuit motor.
Engine, pump, valve control circuits consisting of
actuators such as solenoid valves, MC (main
controller), switch box, sensors, and pressure
switches.
• Monitor Circuit
Circuit that indicates machine operating conditions,
consisting of monitor, sensors, and switches.
In this section, major functions and construction of the

main circuit are described.
• Power Source Circuit: The power source of all

electrical system on this machine, consisting of the
key switch, batteries, fuses (fuse box and fusible
links), and battery relay.
• Bulb Check Circuit: The circuit to check if the

monitor warning light and indicator bulbs have
blown.
• Preheat Circuit: The circuit to help the engine start in

cold weather, consisting of the key switch, glow plug
relay, and glow plugs.
• Engine Start Circuit: The circuit to start the engine,

consisting of the key switch, starter, starter relay.
• Charging Circuit: The circuit to supply electricity to

the battery to replenish discharged electricity,
consisting of the alternator and regulator.
• Surge Voltage Prevention Circuit: The circuit to

prevent surge voltage from being generated when
the engine is stopped, consisting of the load damp
relay.
T2-4-1
POWER SOURCE CIRCUIT
(Key Switch: OFF)
The battery negative terminal is grounded to the
vehicle frame. With the key switch OFF, the electrical
current from the battery positive terminal flows as
follows:
Battery Ÿ Glow Plug Relay

(Power Source)
Fusible Link Ÿ Key Switch Terminal B
Terminal #1 → Optional
Ÿ Load Damp Relay
Terminal #2 → MC (Power Source)
Ÿ Fuse Box
Terminal #3 → MC (EC Motor)
Terminal #4 → Radio (Backup Power Source)
Monitor (Backup Power Source)
Key Switch
Fusible
Link
Battery
Load Damp
Relay
Battery
Relay
Fuse
Box
To MC Radio (Backup Power Source)

Monitor (Backup Power Source)
Fuse Box
Glow Plug
Relay
MC (EC Motor)
MC
Optional
T197-02-04-001
T2-4-2
BULB CHECK CIRCUIT (Key Switch: ON)
When the key switch is turned ON, key switch In addition, the battery current routed to the work lights,
terminals M and ACC are connected to terminal B in wipers, heater, system monitor, emergency evacuation
the key switch. switch, auto air bleeding solenoid valve, and optional
The electrical current from terminal M magnetizes the as power source via the fuse box.
battery relay. The battery current is routed to the
monitor via the battery relay and the fuse box as
power source and checks the alarm light and indicator
bulbs.
Key Switch
Battery
Battery
Relay
Fuse
Box
Emergency
Wiper Evacuation Switch
Work
Light
Heater
Monitor
System
Monitor
Fuse
Box
Auto Air Bleeding Solenoid Valve
Optional
Optional
T197-02-04-002
T2-4-3
PREHEAT CIRCUIT (Key Switch: HEAT)
When the key switch is turned to the HEAT position,
key switch terminal B is connected to terminal G1 in
the key switch. The current from terminal G1
magnetizes the glow plug relay via the fuse box and
also flows to the monitor and MC, turning the preheat
indicator ON.
The battery current is routed to the glow plugs through
the glow plug relay. The MC timer operates approx. 20
seconds after preheating starts, turning the preheat
indicator OFF and informing that preheating is
complete.
Key Switch
Battery
Battery
Relay
Fuse
Box
Glow
Plug
Relay
Glow
Plug Monitor
MC
T197-02-04-003
T2-4-4
(Blank)
T2-4-5
ENGINE START CIRCUIT (Key Switch: Starter Relay Operation
START)
When the key switch is turned to the START position, • When the key switch is turned to the START position,
key switch terminals G2, M and ST are connected to key switch terminal B connects to key switch
terminal B in the key switch. The current from key terminal ST. As a result, electrical current flows to
switch terminal M energizes the battery relay. Then, the base of transistor Q2 via resistance R4 in the
the current from the batteries is routed to starter starter relay, turning transistor Q2 ON. Then,
terminal B and starter relay terminal B via the battery electrical current flows through relay coil L.
relay. Key switch terminal ST is connected to starter Consequently, starter terminal B is connected to
relay terminal S so that the battery current energizes terminal C, rotating the starter.
the starter relay coil, turning the starter relay ON. • After the engine starts, the alternator starts
Consequently, electrical current flows to starter generating electrical current, increasing the voltage
terminal C, turning the relay inside starter ON so that at starter relay terminal R.
the starter rotates. When this voltage reaches between 21 to 22 volts,
Terminal G2 is connected to terminal G1 by the zener diode (Z) is turned ON. Consequently,
harness so that the heating circuit is activated with the transistor Q1 is turned ON, disconnecting electrical
key switch in the START position. current to the base of transistor Q2 so that transistor
Therefore, the battery current flows to the glow plugs. Q2 is turned OFF.
The current from key switch terminal M also flows to Then, starter terminal C is disconnected from
the MC instructing the MC that the key switch is ON or terminal B, stopping the starter.
in the START position. When the MC receives this
signal, the MC actuates the EC motor to move the Capacitor C1 shown in the diagram is used to
governor lever. stabilize the operating voltage. Diode D4 is provided
to protect the circuit in case the battery terminals are
connected in reverse.
Starter Relay
S B
R4 D3
(1) L
C
R3 (2)
(1)
C
R2 Z D2
To Alternator R Q2 M B
Terminal L Q1
(2)
C1 C
E Starter
D4
B 12V
ST Battery
Key Switch 12V
T107-04-04-003
T2-4-6
Key Switch
Battery
Battery Relay Key Switch ON Signal

to MC
Starter
Starter Relay
T157-04-02-003
T2-4-7
CHARGING CIRCUIT (KEY SWITCH: ON)
The key switch automatically returns to the ON position At the same time, electrical current flows to the work
upon releasing it after the engine starts. With key lights, wipers, and heater via the fuse box. Electrical
switch ON, terminal B is connected to terminals ACC current from alternator terminal L flows to the MC,
and M in the key switch. turning the alternator indicator OFF.
Then, the battery relay remains ON. As the engine
runs, the alternator rotates, starting to generate
electrical current. Electrical current from alternator
terminal B flows to the batteries via the battery relay,
recharging the batteries.
Key Switch
Battery
To Fuse Box
To Fuse Box
Battery
Relay
Alternator
MC
T197-02-04-004
T2-4-8
Power Generation
The alternator consists of field coil FC, stator coil SC, When battery relay BS is ON, the battery voltage is
and diode D. The regulator consists of transistors T1 routed to base B of regulator transistor T1, connecting
and T2, zener diode ZD, and resistances R1 and R2. collector C and emitter E. Therefore, the ground side of
Stator coil SC connects as follows: field coil FC is grounded via transistor T1.
Before field coil FC is grounded, no current flows

B→R→RF→(R)→R 1→Base B of Transistor T1 through field coil FC. However, when the rotor starts
SC rotating, alternating voltage is generated in stator coil
SC by remanent excitation field in the rotor.
FC→(F)→Collector C of Transistor T1
Then, when electrical current flows through field coil
FC, the rotor is further magnetized, causing generating
voltage to increase, and letting more electrical current
to flow through field coil FC. Thereby, generating
voltage increases further, starting to charge the
batteries.
Alternator
B R L Regulator
RF (R) R5
BS R3 R4
R6
D
ZD
R2
Battery SC B
E
R1 C
T2
FC B
D1 C E
T1
(F)
(E)
E
T157-04-02-008
T2-4-9
Regulator Operation
When generating voltage exceeds the set voltage of When the voltage applied to zener diode ZD decreases
zener diode ZD, electrical current flows to base B of lower than the set voltage of zener diode ZD, transistor
transistor T2, connecting collector C and emitter E. T2 is turned OFF so that transistor T1 is turned ON,
Consequently, electrical current flowing to base B of allowing electrical current to flow through field coil FC
transistor T1 is cut, turning transistor T1 OFF. Then, and increasing generating voltage in stator coil SC. By
electrical current flowing through field coil FC is cut, repeating the above operations, alternator generating
decreasing the generating voltage in stator coil SC. voltage is kept constant.
BS RF
R3 R4 R5
R6
ZD
R2
Battery SC B
A
E
C
T2
FC B
R1 E
C
T1
(F) D1
E (E)
T157-04-02-009
T2-4-10
SURGE VOLTAGE PREVENTION CIRCUIT
The surge voltage prevention circuit is provided to Accordingly, the load damp relay coil is magnetized so
protect the electronic components and parts such as that the load damp relay is turned ON. Therefore, even
the controller from being damaged by the surge if the key switch is turned OFF, electrical current from
voltage to be developed by turning the key switch OFF. the batteries continues to excite the battery relay via
When the alternator is generating electricity, the load damp relay so the battery relay is kept ON
generating current from alternator terminal L flows to until the alternator stops generating.
MC terminal #B1, turning the output transistor at MC
terminal #A16 ON.
Key Switch
Battery
Battery
Relay
Load Damp Relay
Alternator
MC
Regulator
T197-02-04-005
T2-4-11
ACCESSORY CIRCUIT
When the key switch is turned to the ACC position,
terminal B is connected to terminal ACC in the key
switch. Then, electrical current from terminal ACC
flows to the horn, radio, cab light, and auxiliary circuits
via the fuse box to activate them.
Key Switch
Battery
Battery
Relay
Cab Light
Auxiliary
Radio
Horn
T197-02-04-006
T2-4-12
ENGINE STOP CIRCUIT
When the key switch is turned OFF from the ON
position, the key switch ON signal from terminal M to
the MC is cut. Then, the MC moves the EC motor to
stop the engine.
Key Switch
Battery
Battery
Relay
MC
EC Motor
T197-02-04-007
T2-4-13
(Blank)
T2-4-14
MEMO
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SECTION 3
COMPONENT OPERATION
CONTENTS
Group 1 Pump Device Group 5 Travel Device
Outline .....................................................T3-1-1 Outline .....................................................T3-5-1
Main Pumps (1 and 2) ..............................T3-1-3 Travel Motor .............................................T3-5-2
Main Pump 3 and Pilot Pump....................T3-1-6 Parking Brake...........................................T3-5-8
Travel Brake Valve ...................................T3-5-9
Group 2 Swing Device Travel Reduction Gear ...........................T3-5-11
Outline .....................................................T3-2-1
Swing Motor .............................................T3-2-2 Group 6 Others (Upperstructure)
Valve Unit.................................................T3-2-4 Pilot Shut-Off Valve ..................................T3-6-1
Swing Reduction Gear..............................T3-2-6 Shockless Valve .......................................T3-6-2
9-Unit Solenoid Valve (EX75UR-5)............T3-6-8
Group 3 Control Valve Solenoid Valve Unit ................................T3-6-10
Outline .....................................................T3-3-1 Offset Anti-Drift Valve (EX75UR-5) .........T3-6-13
Hydraulic Circuit .......................................T3-3-8 EC Motor ................................................T3-6-16
Flow Combiner Valve .............................T3-3-12
Main Relief Set Pressure Change...........T3-3-13 Group 7 Others (Undercarriage)
Boom Anti-Drift Valve .............................T3-3-14 Swing Bearing ..........................................T3-7-1
Main Relief Valve ...................................T3-3-16 Center Joint..............................................T3-7-2
Overload Relief Valve.............................T3-3-17 Track Adjuster ..........................................T3-7-3
Group 4 Pilot Valve

Outline .....................................................T3-4-1
Operation .................................................T3-4-3
197T-3-1
(Blank)
197T-3-2
COMPONENT OPERATION / Pump Device
OUTLINE
The pump device is directly driven by the engine and The main pump 3 is a gear pump, supplying high
consists of main pumps (1 and 2), main pump 3, and pressure oil to the actuators via control valve 2. The
pilot pump. Main pumps (1 and 2) are equipped with pilot pump is a gear pump, supplying pressure oil to
the pump control solenoid valve to regulate the pump the pilot circuit.
flow rate. The main pumps (1 and 2) are variable
displacement swash-plate type axial plunger pumps,
having dual type delivery ports and supplying high
pressure oil to the actuators via control valve 1.
Main Pumps (1 and 2) Main Pump 3 Pilot Pump
Pump Control
Solenoid Valve
T195-03-01-001
T3-1-1
(Blank)
T3-1-2
MAIN PUMPS (1 and 2)
The shaft is splined to the cylinder block in which the The cylinder block has the oil inlet and outlet ports
plungers are located. The engine rotation is directly arranged alternately along dual circle diameters. The
transferred to the shaft so that the cylinder block and valve plate has a set of dual outlet ports (one of each is
plungers are rotated together. While sliding along the located inside and outside respectively) and one inlet
shoe plate, the plungers reciprocate inside the cylinder port. The dual outlet port design allows one pump to
block. The plunger stroke varies depending on the function like two pumps having equal oil displacement.
swash plate tilt angle.
Swash
Plate Shoe Plunger Valve Plate
Shaft
Shoe Plate Cylinder Block

T196-03-01-001
Valve Plate
Outlet Port (Inside)
Inlet Port
Outlet Port (Outside)
Inlet/Outlet Port
(Outside)
Inlet/Outlet Port
(Inside)
T5632-02-02-003
Cylinder Block
T3-1-3
Flow Rate Increase / Decrease Operation
Pump flow rate is controlled by changing the swash
plate angle, causing the plunger stroke to change.
The flow rate varies depending on the machine
working conditions.
• Flow Rate Control in Response to Pump Delivery • Flow Rate Decrease by Pilot Pressure
Pressure When the pump control solenoid valve is deactivated
The delivery oil pressure from pumps (1 and 2) is (OFF), the pilot oil pressure is routed to control
routed into the oil chambers in each control piston 2 piston 1. Then, control piston 1 reduces the swash
(two control pistons-2 used). When the pump plate angle until control piston 1 force balances with
delivery oil pressure increases, control pistons 2 the spring force, decreasing the pump flow rate.
move control pistons-3 to the left, decreasing the (Refer to the SYSTEM / Control System group.)
swash plate angle and reducing the pump flow rate.
When the pump delivery oil pressure decreases, • Flow Rate Increase by Pilot Pressure
control pistons-3 move to the right, allowing the When the pump control solenoid valve is activated
swash plate angle to increase so that the pump flow (ON), the pilot oil pressure acting on the control
rate increases. piston 1 is returned to the hydraulic oil tank. Then,
control piston 1 is moved to the right by the spring
• Flow Rate Control When the Swing Function is force, increasing the swash plate angle so that the
Operated. pump flow rate increases. (Refer to the SYSTEM /
The delivery oil pressure from main pump 3 is routed Control System group.)
into the oil chamber in control piston 4 in main
pumps (1 and 2). When the swing function is
operated and the delivery oil pressure from main
pump 3 increases, control piston 4 moves to the left,
pushing the swash plate together with control
pistons 3. Therefore, the swash plate angle is
reduced further, decreasing the flow rate of pumps Q
(1 and 2) further. Consequently, even if main pump 3 Flow
is loaded, the load to main pumps (1 and 2) is Rate
reduced, preventing the engine from stalling.
0 Pressure P
T3-1-4
Spring
Swash Plate
Oil Pressure from

Main Pumps
(1 and 2)
Pump Control
Solenoid Valve
Oil Chamber Control Control T196-03-01-002
Control
Piston-3 Piston 2 Piston 1
Control Oil Chamber (Oil Pressure from Main Pumps 1 and 2)

Cross Section Y-Y Piston 4
Control
Piston 1
Control
Piston 3
T196-03-01-003
Oil Chamber Control
(Oil Pressure from Main Pump 3) Piston 2
Control Piston 2
Main Pump 3
Control Piston 1 Pilot Pump
Control Piston 4 Main

Pump 1, 2
Pump Control
Solenoid Valve Control Piston 3
T196-03-01-004
T3-1-5
MAIN PUMP 3 AND PILOT PUMP
Main pump 3 and the pilot pump are connected to the When the drive gear rotates, the driven gear is rotated.
main pump shaft by a coupling. Therefore, when the The hydraulic oil, routed from the inlet port, fills the
engine rotates, main pump 3 and the pilot pump are spaces between the gear teeth and the housing, is
rotated together with main pumps (1 and 2). transferred along the inside surface of the housing,
and is discharged from the outlet port.
Main Pumps (1 and 2)
Main Pump 3 Pilot Pump
T195-03-01-001
Inlet Port
Driven Gear
Drive Gear
Outlet Port Housing
T137-02-03-005
T3-1-6
COMPONENT OPERATION / Swing Device
OUTLINE
The swing device consists of the valve unit, parking The swing motor, driven by pressure oil from the pump,
brake switch valve, swing motor, and swing reduction transmits the torque to the swing reduction gear. The
gear. The valve unit prevents the occurrence of swing reduction gear converts the swing motor rotation
cavitation and overload in the swing circuit. The power to a slow but large torque which rotates the
parking brake switch valve controls the brake release upperstructure.
oil pressure to apply or release the brake. The swing
motor is a swash-plate type axial plunger motor
incorporating a parking brake.
Valve Unit
Swing Motor
Parking Brake
Switch Valve
Swing Reduction Gear
T152-03-02-001
T3-2-1
SWING MOTOR
The plungers are inserted into the rotor. The swash
plate is installed with an angle toward the rotor. When
the pump supplies pressure oil to the swing motor, the
plungers are moved downward, pushing the swash
plate while sliding along the swash plate. Then, the
rotor starts turning. The shaft and the rotor constitute a
mono-block. The shaft is splined to the first stage sun
gear in the swing reduction gear so that rotor turning
force is transmitted to the swing reduction gear.
Shoe
Rotor
Swash Plate
Plunger
T152-03-02-002
Shaft
T3-2-2
Parking Brake
The parking brake is a wet-negative-type multiple
disc brake. When the brake release pressure oil is
routed into the brake piston chamber, the brake is
released. When the swing and/or the front attachment
function is operated, the parking brake is released.
While traveling and when the engine is stopped, the
parking brake is automatically applied by spring force.
• When releasing the brake: • When applying the brake:

When the swing and/or the front attachment When the swing and/or the front attachment
control lever is operated, the brake release signal control lever is returned to neutral, the brake
pressure oil from the control valve is guided to release signal pressure oil is not guided to port SH
port SH of the parking brake switch valve. Then, so that the spool is moved upward. At this time,
the brake release signal pressure oil moves the the brake release signal pressure oil is returned
spool downward via the orifice. On the other hand, via the orifice, the spool gradually closes port PG
the pilot oil pressure is always fed to port PG while and the brake release port passage. Therefore,
the engine is running. Therefore, when the spool the brake piston gradually pushes the plates and
is moved downward, the pilot pressure oil is the friction plates downward, allowing the swing
routed into the brake piston chamber via the brake movement to stop smoothly.
release port. Accordingly, the brake piston is
pushed upward against the spring force, allowing
the plate and the friction plate contact to free and
releasing the brake.
Port SH
Spring (Brake
Orifice
Release
Signal
Pressure)
Spool
Brake Piston Port PG

Chamber (Brake
To Brake Piston
Chamber Release
Brake Piston Pressure)
Plate
Brake
Release
Friction Plate Port
T152-03-02-007
Parking Brake Parking Brake Switch Valve T152-03-02-003
T3-2-3
VALVE UNIT
The valve unit consists of the make-up valves and
relief valves. The make-up and the relief valves
prevent the occurrence of cavitation, surge pressure
and overload in the circuits respectively.
Make-Up Valve
When the upperstructure is swung downward on a
slope, the upperstructure is accelerated by its own
weight so that the swing motor is rotated quicker than
driven by the pressure oil delivered from the pump,
causing cavitation to develop in the circuit.
To prevent cavitation, the make-up valve poppet
opens to draw hydraulic oil into the circuit when the oil
pressure in the circuit is lower than the pressure at
port M (hydraulic oil tank), compensating the lack of
pressure oil from the pump.
Control Valve
Poppet Port M
Make-Up
Valve
T152-03-02-004
Relief Valve
T3-2-4
Relief Valve
The relief valve reduces shocks developed when
swing movement starts or stops (shockless function)
and protects the circuit from overloading (relief
function).
• Shockless Operation: • Relief Operation:

When the circuit pressure increases, pressure oil During swing operation, if the circuit pressure
is routed into the piston chamber via the poppet exceeds the relief set-pressure, the poppet is
and the oil passage in the piston, moving the opened to relieve hydraulic oil.
piston to the left. As long as the piston is moving,
the spring force is weak, allowing the poppet to
open. Then, hydraulic oil is relieved to the
hydraulic oil tank. When the piston comes in
contact with the end face of the sleeve, the spring
force increases up to the normal relief set-
pressure, closing the poppet.
Operation at Low Pressure
Port M
(Hydraulic Oil Sleeve
Swing Circuit
Piston
Chamber
T196-03-02-003
Poppet Spring Piston
Normal Operation
Port M
(Hydraulic Oil Tank) Sleeve
Swing Circuit
Piston
Chamber
T196-03-02-002
Poppet Spring Piston
T3-2-5
SWING REDUCTION GEAR
The swing reduction gear is a two-stage planetary gear
reduction type. The swing motor drives the first stage
sun gear via the motor shaft. The first stage sun gear
rotary speed is reduced by the first stage planetary
gear and the first stage carrier and transmitted to the
second stage sun gear. The second stage sun gear
rotary speed is again reduced by the second stage
planetary gear and the second stage carrier and
transmitted to the reduction gear shaft.
First Stage
Sun Gear
First Stage
Planetary Gear First Stage
Carrier
Second Stage
Planetary Gear Second Stage
Sun Gear
Second Stage
Carrier
Shaft
T152-03-02-006
T3-2-6
COMPONENT OPERATION / Control Valve
OUTLINE
The control valve controls the oil pressure, flow rate, The spools are all operated by pilot pressure oil. The
and flow direction in the hydraulic circuit. The major spool arrangement in the control valve 1 is as follows
components in the control valve are the main relief from the right side:
valve, the overload relief valves, the flow combiner
valve, the boom anti-drift valve, and the spools.
5-Spool Section: Left Travel, Offset (Auxiliary on
EX75US-5), Boom 2, Arm 1, Auxiliary
4-Spool Section: Right Travel, Bucket, Boom 1, Arm 2
The spools arrangement in the control valve 2 are arm
3 (only EX75UR-5), swing, and blade (auxiliary on
EX75US-5) from the front side.
Right Travel
Control Valve 1 Bucket
Boom 1
Arm 2
Left Travel
Offset
Boom 2
Arm 1
Machine Front Auxiliary
T197-03-03-001
Blade Swing Arm 3
Control Valve 2
Machine Front
T197-03-03-005
T3-3-1
Control Valve Layout
Control Valve 1 1 2 3 4 5 6
23
22 7
21
9
10
20
19 11
18
17 12
13
16 15 14
T197-03-03-010
1 - Main Relief Valve 7 - Load Check Valve 13 - Load Check Valve 19 - Overload Relief Valve
(Bucket Circuit) (Arm 1 Circuit) (Arm Circuit)
2 - Check Valve 8 - Overload Relief Valve 14 - Check Valve (Arm Roll-In 20 - Check Valve (Offset
(Bucket) Flow Combining Circuit) Parallel Circuit)
3 - Check Valve 9 - Load Check Valve 15 - Check Valve (Arm Roll- 21 - Overload Relief Valve
(Boom 2 Circuit) Out Flow Combining (Offset Circuit)
Circuit)
4 - Check Valve (Bucket 10 - Boom Anti-Drift Valve 16 - Check Valve 22 - Check Valve (Left Travel
Flow Combining Circuit) (Check Valve) (Auxiliary Parallel Circuit) Parallel Circuit)
5 - Flow Combiner Valve 11 - Boom Anti-Drift Valve 17 - Load Check Valve 23 - Load Check Valve
(Switch Valve) (Arm 2 Tandem Circuit) (Left Travel Circuit)
6 - Check Valve 12 - Overload Relief Valve 18 - Check Valve
(Boom Circuit) (Arm 2 Parallel Circuit)
T3-3-2
1 10
Cross Section A
12
21
19 1
21
19
T197-03-03-001
Cross Section G
T152-03-03-003
Cross Section F
Cross Section E
Cross Section C
Cross Section D
Cross Section C
Cross Section B
Cross Section A
T197-03-03-002
2 View 3
Cross Section B
22, 23
6 5
T197-03-03-004
T152-03-03-004
T3-3-3
• Control Valve 1
1 2 3 4 5 6
23
22 7
21
9
10
20
19 11
18
17 12
13
16 15 14
T197-03-03-010
Circuit)
4 - Check Valve (Bucket 10 - Boom Anti-Drift Valve 16 - Check Valve (Auxiliary 22 - Check Valve (Left
Flow Combining Circuit) (Check Valve) Parallel Circuit) Travel Parallel Circuit)
T3-3-4
Cross Section D Cross Section E
10
21
8
11
7 20
8 21 12
T197-03-03-003 T152-03-03-006
Cross Section F Cross Section G
19
12
14
16
17
13 18
15
19 T152-03-03-009
T152-03-03-008
T3-3-5
• Control Valve 2
Only EX75UR-5
24 25
26 27 28
Pilot Pump
Main Pump 3 T197-03-03-011
24 - Main Relief Valve 26 - Load Check Valve 27 - Load Check Valve 28 - Load Check Valve
(Control Valve 2) (Blade) (Swing Parallel Circuit) (Only EX75UR-5)
(Arm 3 Tandem Circuit)
25 - Overload Relief Valve
(Blade)
Cross Section A
Cross
Cross 24
Section D
Cross Section B (Only EX75UR-5)
Cross
Section A
Section C
T197-03-03-005
T196-03-03-008
T3-3-6
Cross Section B 25 Cross Section C
26
27
25
T197-03-03-007
T196-03-03-009
Cross Section D (Only EX75UR-5) Cross Section E
Cross Section E
T197-03-03-008
T197-03-03-006
T3-3-7
HYDRAULIC CIRCUIT
The control valve hydraulic circuit falls into 3 main

groups: main circuit, pilot pressure circuit, and signal
pilot pressure circuit.
Main Circuit
The pressure oil from main pump 2, main pump 1,
and main pump 3 is routed to the 4-spool section of
control valve 1, the 5-spool section of control valve 1,
and control valve 2, respectively. When all spools are
in neutral (all control levers are in neutral), the
pressure oil from main pump 2 flows back to the
hydraulic oil tank through the neutral passages.
When a spool (a control lever) is operated, the
pressure oil from main pump 2 flows to the
actuator(s) through the spool. There are parallel
circuits and the flow combining circuits provided in the
main circuits, allowing more than one actuators to be
operated simultaneously.
The main circuit pressure (between the pumps and

the actuators) is regulated by the main relief valve so
that the main circuit pressure is maintained within the
relief set-pressure when a spool (a control lever) is
operated. The set-pressure of the main relief valve in
control valve 1 can be selected in 2 stages: one is for
the travel function and the other is for the front
attachment/swing function. The main relief valve in
control valve 2 operates when the blade, swing,
and/or arm roll-in function is operated. The actuator
circuit pressure (between the control valve and
actuators) is regulated by the overload relief valves,
protecting the circuits from surge pressure applied by
external loads when the spool (the control lever) is in
neutral.
T3-3-8
NOTE: The diagram shown below is applied only to
the EX75UR-5.
Blade Cylinder Neutral Passage
Overload Relief
Valve
Blade Swing Arm 3

Main Relief Swing Motor
Valve
Control Valve 2
Parallel
Passage
4-Spool Section
Main Relief
Valve
Left Travel Left

Motor Travel
Right Right Travel
Travel Motor
Overload
Relief Valve
Offset Bucket
Bucket
Cylinder
Flow Overload
Com- Boom 2 Boom 1 Relief Valve
bining
Circuit
Offset Cylinder
Arm Arm 1
Cylinder Arm 2
Boom
Cylinder
Overload
Relief Valve
Neutral
Auxiliary
Flow Passage
Neutral
Passage Combining
Circuit
（5-Spool Section） Control Valve 1
Parallel Passage

T3-3-9
Pilot Pressure Circuit
The control valve spools are operated by pressure oil
from the pilot valve. The air bleed circuit is provided in
this circuit, to automatically bleed any air trapped in
the circuit.
Signal Pilot Pressure Circuit

The signal pilot pressure circuit is made up by 2
circuits: travel, and front attachment/swing circuits.
When the travel function is operated, the travel spool
blocks the signal pilot pressure oil flow in the travel
signal pilot pressure circuit, increasing the circuit
pressure. Thereby, the travel pressure switch is
turned ON so that the main relief valve set-pressure
is increased. When either the front attachment or the
swing function is operated, the front attachment or
swing spool blocks the signal pilot pressure oil flow in
the front attachment/swing signal pilot pressure
circuit, increasing the circuit Thereby, the front
attachment pressure switch is turned ON, and the
flow combiner valve and the swing parking brake
switch valve are opened.
T3-3-10
NOTE: The diagram shown below is applied only to
the EX75UR-5.
Control Valve 2
13 15 12
14 16 17
Swing Signal Pilot

Pressure Circuit Swing Parking Brake
Pressure Switch Switch Valve
(Front Attachment
Pressure Switch
/ Swing)
(Travel)
Main Relief Valve
Travel
Flow Combiner Signal Pilot
Valve Pressure
Circuit
Front
1 2 3 4 Attachment
Signal Pilot
Pressure
Circuit
5 6 7 8
9
10
11
12 12
Air Bleeding
Circuit
Control Valve 1
Pilot Pump T197-03-03-015
1 - Left Travel Forward 6 - Offset Left 10 - Boom Lower 14 - Blade Lower

2 - Left Travel Reverse 7 - Bucket Roll-Out 11 - Arm Roll-Out 15 - Right Swing
3 - Right Travel Reverse 8 - Bucket Roll-In 12 - Arm Roll-In 16 - Left Swing
4 - Right Travel Forward 9 - Boom Raise 13 - Blade Raise 17 - From Arm Oil Flow Combining Solenoid
Valve
5 - Offset Right
T3-3-11
FLOW COMBINER VALVE
When the front attachment and travel functions are Therefore, even if the front attachment and travel
operated, the operated front attachment spool restricts functions are operated at the same time, the both the
the signal pilot pressure oil flow in the front attachment right and left travel motors are supplied with an equal
system, increasing the signal pilot pressure. Thereby, amount of pressure oil from main pump 2, ensuring
the flow combiner valve spool is shifted, opening the straight traveling.
valve. When the travel function is operated at this time,
pressure oil from main pump 2 is routed to the right
travel spool as well as to the left travel spool via the
flow combiner valve. Pressure oil from main pump 1 is
fed to the front attachment function.
Front Signal Pilot

Pressure Circuit
Left Travel Motor Flow

Left
Combiner
Travel
Valve Right Right Travel
Travel Motor
Offset
Bucket Bucket
Cylinder
Boom 2 Boom 1
Offset Cylinder
Arm 1 Arm 2
Arm Cylinder
Boom
Cylinder
Aux-
iliary
Pilot Main Pump 1 Main Pump 2 T197-03-03-013

Pump
T3-3-12
MAIN RELIEF SET PRESSURE CHANGE
When the travel function is operated, the signal pilot

pressure in the travel circuit is restricted by the travel
spool, increasing the signal pilot pressure. Therefore,
the increased pilot pressure is guided to the spring
side of the main relief valve, causing the relief set
pressure to be increased.
Signal Pilot
Pressure Circuit in
Travel System
Main Relief
Valve
Left Travel Motor
Right Travel
Motor
T197-03-03-014
T3-3-13
BOOM ANTI-DRIFT VALVE
The boom ant-drift valve is provided in the boom
cylinder bottom side circuit to reduce the boom cylinder
drift.
When the boom spool is in neutral: When the boom is lowered:

When the engine is stopped with the boom raised, oil When the boom lower operation is made, the
pressure in the boom cylinder bottom increases due pressure oil from the boom spool is fed into the boom
to the weight of the front attachment. This oil pressure cylinder rod side. At this time, the boom lower pilot
is guided to the check valve spring side via the oil pressure moves the piston. Then the spool in the
passage in the anti-drift valve spool, closing the check boom anti-drift valve is moved to the right, allowing
valve. Therefore, the pressure oil flow is blocked by the pressure oil in the spring side chamber of the
the check valve, reducing the cylinder drift. check valve to return to the hydraulic oil tank via the
oil passage in the spool. At the same time, the return
When the boom is raised: oil from the boom cylinder bottom side is applied to
When the boom raise operation is made, the pressure the stepped shoulder on the check valve so that the
oil from the boom spool opens the check valve and check valve is opened. As a result, the pressure oil in
flows into the boom cylinder bottom side. the boom cylinder bottom side returns to the boom
spool via the check valve.
T3-3-14
When the boom spool is in neutral:

Piston Spool
Spring
Boom Cylinder
Check Valve
T196-03-03-013
Hydraulic Oil Tank

When the boom is lowered:
Boom Lower
Pilot Pressure
Spring
Boom Cylinder
Check Valve
To Boom Spool
T196-03-03-012
T3-3-15
MAIN RELIEF VALVE
The main relief valve prevents the oil pressure in the

main circuit from rising higher than the set-pressure.
The relief valve is a two-stage set-pressure type,
increasing the relief set-pressure when the travel
function is operated.
Relief Valves (Low Set-Pressure) for Front Relief Valve (High Set-Pressure) for Front
Attachment and Travel, and Relief Valve for Blade, Attachment and Travel
Swing, and Arm 3 When the travel function is operated, the pilot
The oil pressure at port HP acts on pilot poppet (5) pressure is guided to port SG, pushing piston (9) to
through orifice (2) in main poppet (1) and orifice (4). the left and increasing spring (7) set-force. Therefore,
When the oil pressure at port HP increases to the set- the oil pressure required to open the pilot poppet (5)
pressure, pilot poppet (5) opens, allowing a small is increased. Accordingly, the main relief valve set-
quantity of the pressure oil flows to port LP via oil pressure is increased higher than that in front
passage (6). Then, a pressure difference is present attachment operation.
between port HP and spring chamber (8) due to
orifice (2). When this differential pressure increases
more than spring (3) force, main poppet (1) opens
allowing the pressure oil at port HP to relieve from
port LP.
8 6 9
Relief Valve for Front

Attachment and
Travel Functions
ＨＰ Port SG
ＬＰ
T152-03-03-014
1 2 3 4 5 7
Relief Valve for Blade,

Swing, and Arm 3
Functions
ＨＰ
ＬＰ
8 6
T563-02-04-002
1 - Main Poppet 4 - Orifice 6 - Oil Passage 8 - Spring Chamber

2 - Orifice 5 - Pilot Poppet 7 - Spring 9 - Piston
3 - Spring
T3-3-16
OVERLOAD RELIEF VALVE
The overload relief valve has two functions:
1. Relief function to prevent the actuator circuit
pressure from increasing more than the set-
pressure.
2. Make-up function to prevent the occurrence of
cavitation in the circuit.
The construction of the overload relief valves in the
boom, arm, bucket, and offset circuits is different from
that of the overload relief valves in the blade circuit.
Relief Operation
When the actuator circuit pressure is increased by
external loads, the overload relief valve opens to
relieve the pressure oil to the hydraulic oil tank.
Overload Relief Valve in the Boom, Arm, Bucket, and
Offset Circuit
• Overload Relief Valve in the Boom, Arm, Offset
and Bucket Circuits 12 5 7 8 9
3 13
Oil pressure at port HP acts on pilot poppet (8) via
orifice (12) in piston (13). When oil pressure at
port HP increases up to the set-pressure, pilot
poppet (8) opens to allow a small quantity of
pressure oil to flow into port LP through passage
(10) in seat (7). As orifice (12) is provided, a
pressure difference is developed between port HP HP
and spring chamber (11). When this pressure
difference increases more than spring (5) set-
force, piston (13) and main poppet (3) are
unseated, allowing the pressure oil to relieve from
port HP to port LP. LP 14 11 10
T152-03-03-015
• Overload Relief Valve in the Blade Circuits Overload Relief Valve in the Blade Circuit
Oil pressure at port HP acts on pilot poppet (8) via
orifice (4) in main poppet (3) and orifice (6) in seat 1 2 3 4 5 6 7 8 9
(7). When oil pressure at port HP increases up to
the set-pressure, pilot poppet (8) opens, a small
quantity of pressure oil flows into port LP through
passage (10) in seat (7). As orifice (4) is provided,
a pressure difference is developed between port
HP and spring chamber (11). When this pressure HP
difference increases more than spring (5) set-
force, main poppet (3) is unseated, allowing the
pressure oil to relieve from port HP to port LP. LP
11 10
T563-02-04-003
1- Spring 8- Pilot Poppet
2- Sleeve 9- Spring
3- Main Poppet 10 - Passage
4- Orifice 11 - Spring Chamber
5- Spring 12 - Orifice
6- Orifice 13 - Piston
7- Seat 14 - Sleeve
T3-3-17
Make-Up Operation
When an actuator speed is increased faster than the Overload Relief Valve in the Boom, Arm, Bucket and
speed moved by the pressure oil from the pump such Offset Circuit
as when the boom is quickly lowered, the overload
relief valve supplies hydraulic oil from the hydraulic oil 12 3 13 5 7 8 9
tank into the actuator circuit. As described on the
previous page, when the overload relief valve relieves
due to external loads, the oil pressure in the opposite
side will decrease. At this time, the overload relief
valve draws hydraulic oil from the hydraulic oil tank
into the actuator circuit. HP
When oil pressure at port HP decreases lower than

that in port LP, sleeve (14) [sleeve (2) in the overload
relief valve in the blade circuit] is unseated. Then, the
hydraulic oil is supplied from port LP to port HP, 14 11 10
LP T152-03-03-015
preventing cavitation.
Overload Relief Valve in the Blade Circuit
1 2 3 4 5 6 7 8 9
HP
LP
11 10
T563-02-04-003
1- Spring 8- Pilot Poppet
2- Sleeve 9- Spring
3- Main Poppet 10 - Passage
4- Orifice 11 - Spring Chamber
5- Spring 12 - Orifice
6- Orifice 13 - Piston
7- Seat 14 - Sleeve
T3-3-18
COMPONENT OPERATION / Pilot Valve
OUTLINE
The pilot valve controls the pilot pressure to move the The travel, blade, and offset pilot valves is the same in
control valve spools. construction except for the cam which pushes the
The 4-port pilot valve is used for front attachment, pusher.
swing, and travel operation. The 2-port pilot valve is
used for blade and offset operation.
• Front Attachment / Swing Pilot Valve • Offset Pilot Valve

Port Port
Hitachi Std. ISO Std. Hitachi Std.
No. No.
1 Bucket Roll-Out ← 1 Right Offset
2 Boom Lower ← 2 Left Offset
Right
3 Bucket Roll-In ←
4 Boom Raise ← • Blade Pilot Valve
1 Arm Roll-In Right Swing Port
Hitachi Std.
2 Right Swing Arm Roll-Out No.
Left 1 Blade Lower
3 Arm Roll-Out Left Swing
4 Left Swing Arm Roll-In 2 Blade Raise
P T
P T
1 2
1 3 2 4
T105-02-07-020 T554-02-07-009
T
T
P
P
1 2
T190-02-06-005
1 2
T107-02-06-032
T3-4-1
• Travel Pilot Valve

Port
Hitachi Std.
No.
1 Right Track Reverse
2 Right Track Forward
3 Left Track Forward
4 Left Track Reverse
T
P
P T
4 1
T105-02-07-020
3 2
T154-02-04-001
T3-4-2
OPERATION
Front Attachment / Swing Pilot Valve • In Neutral (Corresponding to A to B Point on the
The head bottom face of spool (8) is suspended by the Output Diagram):
upper face of spacer (4) and they are kept in contact When control lever (1) is in neutral (pusher stroke =
each other by the set-force of balance spring (6). 0), spool (8) completely blocks pressure oil port P.
Spacer (4) is located between pusher (3) and spring The output port is open to port T so that the output
guide (5) and supported by return spring (7). Piston (9) port pressure is equal to the hydraulic oil tank
is located inside spool (8). The lower end of piston (9) pressure. When control lever (1) is tilted slightly,
makes contact with a plate so that piston (9) can’t cam (2) tilts, moving pusher (3) downward. Then,
move further downward. The chamber on piston (9) is pusher (3), spacer (4), and spring guide (5) move
connected to the outside of spool (8) via the hole downward as a unit while compressing return spring
provided in spool (8) (7). As spool (8) is supported by balance spring (6),
spool (8) is moved downward while keeping its head
bottom face in contact with the top surface of
spacer(4). This state is maintained until control lever
(1) is tilted further and clearance A at section (a)
becomes zero. This process corresponds to the A to
B point on the output diagram.
Pilot
Pressure
(Output
Port
Pressure)
Pusher Stroke
Output Diagram
Section（ａ）
Port T
Output Port
Port P
T157-03-04-001
1 - Control Lever 4 - Spacer 6 - Balance Spring 8 - Spool

2 - Cam 5 - Spring Guide 7 - Return Spring 9 - Piston
3 - Pusher
T3-4-3
• Increasing Output Port Pressure (Corresponding to
B to C Point on the Output Diagram):
When the control lever is tilted further slightly after As soon as the pressure force to raise spool (8)
clearance (A) is zero, pusher (3) is moved overcomes the set-force of balance spring (6) due to
downward so that spool (8) is also moved downward, the pressure increase in the output port, spool (8)
opening the spool notch at section (b) to port P, compresses balance spring (8) and moves upward. As
allowing pressure oil to flow from port P to the output spool (8) moves upward, the upper spool notch at
port. In addition, as pressure oil is also routed into section (a) is opened and the lower spool notch at
the chamber on piston (9) through orifice (10) so that section (b) is closed. Therefore, pressure oil in the
piston (8) is pushed upward. However, until the output port is discharged to port T, decreasing the
pressure force in this chamber increases larger than output port pressure.
the set-force of balance spring (6), balance spring When the output port pressure decreases, force
(6) is not compressed so that spool (8) can’t be raising spool (8) is reduced. Then, balance spring (6) is
moved upward. Then, the upper spool notch at extended so that spool (8) is moved downward and
section (a) is kept closed and the lower spool notch stopped at the position where both the lower spool
at section (b) is kept opened, allowing the output port notch at section (b) and the upper spool notch at
pressure to quickly increase. section (a) are closed at the same time. The output
port pressure increases until the pressure force
balances with the set-force of balance spring (6)
(corresponding C point on the output diagram). This
process corresponds to the B to C point on the output
diagram.
Pilot
Pressure
(Output
Port
Pressure)
Pusher Stroke
Output Diagram
Section (a)
Port T
Clearance (A)
becomes zero. Output Port Section (b)
Port P
T110-02-07-003
1 - Control Lever 6 - Balance Spring 9 - Piston 10 - Orifice

3 - Pusher 8 - Spool
T3-4-4
• Outputting Pressure in Proportion to Control Lever
Stroke (Corresponding to the C to D point on the
Output Diagram):
When the control lever is tilted further to lower When spool (8) is moved upward until the upper spool
pusher (3), spool (8) is moved downward, opening notch at section (a) opens, the output port is connected
the lower spool notch at section (b) and increasing to port T, decreasing the output port pressure and
the output port pressure. Then, the pressure force to stopping the movement of spool (8). Consequently,
raise spool (8) increases. When the pressure force balance spring (6) is compressed by pusher (3) until
overcomes the set-force of balance spring (6), spool balance spring (6) force balances with the pressure
(8) is moved upward while compressing balance force to raise spool (8). This pressure is equal to the
spring (6). output port pressure. This process corresponds to the
C to D point on the output diagram.
Pilot
Pressure
(Output
Port
Pressure)
Pusher Stroke
Output Diagram
Section (a)
Port T
Output Port
Section (b)
Port P
T110-02-07-004
1 - Control Lever 3 - Pusher 6- Balance Spring 8- Spool
T3-4-5
• Outputting Pressure near Control Lever Stroke End
(Corresponding to the D to E point on the Output
Diagram):
As pusher (3) is moved downward, balance spring
(6) is compressed in proportion to the movement of
pusher (3). Therefore, clearance (B) (shown by
section (c)) between the inside bore end of pusher
(3) and the top of spool (8) is gradually reduced until
it becomes zero. After this point, pusher (3) directly
comes in contact with spool (8) so that even if the
output port pressure is increased, spool (8) can’t
move upward. Then, the output port is not connected
to port T while the output port is kept connected to
port P. Therefore, the output port pressure continues
to increase until the output port pressure is equal to
the pressure in port P. This process corresponds to
the D to E point on the output diagram.
Pilot
Pressure
(Output
Port
Pressure)
Pusher Stroke
Section (c) Output Diagram
Clearance (B) becomes zero.
Port T
Output Port
Port P
T110-02-07-005
3 - Pusher 6 - Balance Spring 8 - Spool
T3-4-6
• Outputting Pressure at Control Lever Stroke End
(Corresponding to the E to F point on the Output
Diagram):
When the control lever is tilted to lower pusher (3) Pusher (3) can be moved downward until spring guide
further, spool (8) moves downward together with (5) comes in contact with the casing counter bore end
pusher (3), widening the lower spool notch at section (d). This position corresponds to the pusher
clearance at section (b) so that the output port stroke end (F point on the output diagram). This
pressure is maintained equal to the pressure in port process corresponds to the E to F point on the output
P. diagram.
Pilot
Pressure
(Output
Port
Pressure)
Pusher Stroke
Output Diagram
Section (d)
Port T
Output Port Section (b)
Port P
T110-02-07-006
3 - Pusher 5 - Spring Guide 8 - Spool
T3-4-7
Offset, Blade, and Travel Control Pilot Valve
Spool (6) is supported with return spring (5) via spring
guide (3). However, bushing (7) is held in position so
that the flange of pusher (2) or the top face of spring
guide (3) can’t move upward, obstructing return
spring (5) to move upward further.
• In Neutral (Corresponding to A to B Point on the • Outputting Pressure in proportion to Control

Output Diagram): Lever/Pedal Stroke (Corresponding to the C to D
In neutral, spool (6) completely blocks pressure oil point on the Output Diagram)
port P. The output port is open to port T so that the When cam (1) is tilted further to lower pusher (2),
output port pressure is equal to the hydraulic oil tank the spool notch (B) is connected to the passage in
pressure. spool (6), allowing the pressure oil to flow from port
When cam (1) is tilted slightly, pusher (2) and spring P to the output port. When the oil pressure at the
guide (3) move downward as a unit while output port increases, spool (6) moves upward,
compressing return spring (5) and balance spring (4). closing notch B so that the oil pressure at the output
As the pressure at the top and bottom of spool (6) is port is maintained constant. As pusher (2) is lowered,
equal to the hydraulic oil tank pressure, spool (6) is balance spring (4) is compressed further, increasing
moved downward with the head bottom face of the the spring force. Then, the oil pressure at the output
spool kept in contact with spring guide (3). This state port is increased in proportion to balance spring (4)
is maintained until clearance A becomes zero. force.
• Outputting Pressure at Control Lever/Pedal Stroke

End (Corresponding to the stroke end on the Output
Diagram)
When pusher (2) is pushed downward further, spool
(6) moves downward together with pusher (2). Then,
notch B is widened so that the output port pressure
is maintained equal to the pressure in port P. Pusher
(2) can be moved downward until spring guide (3)
comes in contact with the casing counter bore face.
This position corresponds to the lever/pedal stroke
end. Stroke dimension C of pusher (2) determines
the total lever/pedal stroke
Pilot
Pressure D
A B
Output Diagram
T522-02-05-001
T3-4-8
Between Points A and B:
1
3
4
5
Port T
A Clearance A: 0
Port P
T191-03-04-008
Output Port T191-03-04-007
Between Points C and D: Full Stroke:
2
2
4
5 C
Port T Notch B 3
Port T
Port P
Port P
6 6
T191-03-04-009
Output Port T191-03-04-010
Output Port
1 - Cam 3- Spring Guide 5- Return Spring 7- Bushing

2 - Pusher 4- Balance Spring 6- Spool
T3-4-9
(Blank)
T3-4-10
OUTLINE
The travel device consists of the brake valve, travel The travel reduction gear is a two-stage reduction
motor, and travel reduction gear. The travel motor is a planetary gear and converts the travel motor rotation
variable displacement swash plate type axial plunger power to a slow-large torque and drives the sprocket to
motor driven by the pressure oil from the pump and rotate the track. The brake valve protects the travel
outputs the rotation power to the travel reduction gear. circuit from overloads.
Brake
Valve Travel Motor Travel Reduction Gear
Sprocket
T197-03-05-001
T3-5-1
TRAVEL MOTOR
The travel motor consists of the valve plate, rotor, The swash plate is installed at an angle toward the
plunger, shoe, swash plate, and shaft. The shaft is plunger. Then, the shoes slide along the swash plate
splined to the rotor, in which the plungers are installed. surface, causing the rotor to rotate. This rotation is
When pressure oil is supplied from the pump, the transferred to the travel reduction gear via the shaft.
plunger is pushed toward the swash-plate.
Valve Plate Rotor Plunger Shoe
Shaft Swash Plate
T196-03-05-001
T3-5-2
(Blank)
T3-5-3
Travel Mode Change
The tilt angle of swash plate (7) is controlled by
moving piston (8) to change travel mode. (Refer to
the SYSTEM /Control System group.)
• Slow Travel Mode

When the travel mode switch is in the SLOW
position, the MC (main controller) doesn’t send
signals to the travel mode solenoid valve. Then, the
pilot pressure is not fed to pilot port (1). Accordingly,
spool (2) is pushed upward by spring (3). Therefore,
surface (a) on the swash-plate comes in contact with
the housing by hydraulic oil pressure applied to the
end faces of plungers (6) and the spring located in
rotor (5). Consequently, the swash-plate tilt angle is
increased, extending the plunger stroke. Then the
motor capacity is increased so that the motor rotates
at a slow speed.
T3-5-4
A Cross Section A-A
T196-03-05-006
T196-03-05-007
Surface (a)
T196-03-05-008
1 - Pilot Port 4 - Piston Control Shuttle Valve 6 - Plunger 8 - Piston

2 - Spool 5 - Rotor 7 - Swash Plate 9 - Shaft
3 - Spring
T3-5-5
• Fast Travel Mode
When the travel mode switch is turned to the FAST
position, the MC (main controller) sends signals to
the travel mode solenoid valve. Then, the pilot
pressure is fed to pilot port (1), moving spool (2)
downward. Therefore, high pressure oil from either
port AM or BM is fed to piston (8) via piston control
shuttle valve (4). Consequently, swash plate (7) is
tilted by piston (8), contacting surface (b) to the
housing, reducing the plunger stroke. Then the
motor capacity is reduced so that the motor rotates
at a fast speed.
T3-5-6
A Cross Section A-A
4
Port AM Port BM
4 P
T196-03-05-006
T196-03-05-009
P 5
10
Surface (b)
T196-03-05-008
1 - Pilot Port 4 - Piston Control Shuttle Valve 6 - Plunger 8 - Piston

2 - Spool 5 - Rotor 7 - Swash Plate 9 - Shaft
3 - Spring
T3-5-7
PARKING BRAKE
The parking brake is a wet type multi-disc brake. Only

when brake release pressure is routed to the brake
piston chamber, the brake is released (negative type).
Applying Brake Releasing Brake

When the travel function is stopped, the main When the travel function is operated, the travel main
hydraulic oil pressure in the brake piston chamber hydraulic pressure oil is routed into the brake piston
decreases. Then, the brake piston is pushed by the chamber. When this oil pressure overcomes the disc
disc spring, causing the friction plates and plates to spring force, the brake piston is moved toward the disc
contact tightly. Therefore, the brake is applied. spring, causing the contact between the friction plates
and plates to be freed. Then, the brake is released.
When the brake When the brake

is applied: is released:
Brake Piston
Chamber
Plate
Brake T152-03-05-003
Disc Spring Friction Plate
Piston
T196-03-05-001
T3-5-8
TRAVEL BRAKE VALVE
The travel brake valve consists of the counter balance

valve, check valve, and relief valve.
When Traveling: When Descending a Slope:

When the hydraulic pressure oil is supplied from the When descending a slope, the travel motor is rotated
control valve to port A, the pressure oil flows into by the machine weight so that the motor draws
motor port AM after flowing around spool (1) and hydraulic oil like a pump. The pressure oil in port A is
opening check valve (4). However, the return oil from drawn by the travel motor, decreasing the oil
motor port BM is blocked by check valve (3) and pressure. Then, spool (1) is returned to the left,
spool (1) for a moment. Then, oil pressure in port A restricting the returning oil flow from port BV at the
gradually increases and is routed to the end face of spool notch. Therefore, the travel motor is braked by
spool (1) via orifice (5), moving spool (1) to the right. hydraulic oil pressure. Once the returning oil from
Thereby, port BV is connected to port B through the port BV is restricted, oil pressure in port A increases
notch on spool (1), allowing the motor to rotate. again, moving spool (1) to the right and allowing the
travel motor to rotate.
Port A Port B 2
5
Port BV
Port AV
Port AM Port BM
3
4
T152-03-05-004
1 - Spool 3 - Check Valve 4 - Check Valve 5 - Orifice
2 - Orifice
T3-5-9
Circuit Protection
Hydraulic oil pressure in the travel circuit is routed to When the circuit oil pressure increases more than
poppet (1) via port AC or port BC. Then, pressure oil spring (5) force, poppet (1) is unseated, relieving
is further routed to the bottom side of piston (3) via hydraulic oil pressure at the relief set-pressure. As
orifices (2 and 4), moving piston (3) upward. As described above, surge oil pressure is relieved in two-
piston (3) is moved, a pressure difference arises stages, reducing shocks developed in the circuit when
between the upper and lower sides of poppet (1). starting or stopping the travel motor.
When the pressure difference overcomes spring (5)
force, poppet (1) unseats so that hydraulic oil
pressure relieves to the opposite port side. When
piston (3) reaches the stroke end, the pressure
difference between the upper and lower sides of
poppet (1) is reduced, poppet (1) is seated (normal
relief pressure is set).
Port A Port B
Port AC
Port BC
1 1
2
2
3 3
4 4
5 5
T152-03-05-004
1 - Poppet 3 - Piston 4 - Orifice 5 - Spring

2 - Orifice
T3-5-10
TRAVEL REDUCTION GEAR
The travel motor rotates shaft (5). This rotation is Second stage carrier (7) is secured to the travel motor
transferred to sun gear (8) after its speed is reduced with knock pin (1). Ring gear (4) is bolted to drum (9).
between first stage planetary gear (3) and first stage Therefore, rotation of second stage planetary gear (2)
carrier (6). Rotation speed of sun gear (8) is reduced is transferred to sprocket (10) via ring gear (4) and
again between second stage planetary gear (2) and drum (9).
second stage carrier (7).
1 2 3 4
9 8 7 6
10
T197-03-05-001
1 - Knock Pin 4 - Ring Gear 7 - Second Stage Carrier 9 - Drum

2 - Second Stage Planetary Gear 5 - Shaft 8 - Sun Gear 10 - Sprocket
3 - First Stage Planetary Gear 6 - First Stage Carrier
T3-5-11
(Blank)
T3-5-12
COMPONENT OPERATION / Others (Upperstructure)
PILOT SHUT-OFF VALVE
The pilot shut-off valve is a manually-operated switch

valve. The spool in the pilot shut-off valve is rotated by To Pilot Valve and 9-Unit
moving the pilot control shut-off lever to flow or block Solenoid Valve
the pilot oil flow to the pilot valves.
To Hydraulic Oil Tank
From Pilot
Pump
To 9-Unit Solenoid Valve

and Shockless Valve
From Pilot Valve W157-02-08-001
• When the pilot control shut-off lever is in the LOCK

position: From Pilot Valve
The pilot shut-off valve is closed so that pressure oil
from the pilot pump doesn’t flow to the pilot valve but
is routed to the shockless valve and the 9-unit
To 9-Unit Solenoid
solenoid valve. As the return oil passage is opened, Valve and Shockless
pilot oil from the pilot valve is routed to the hydraulic Valve
oil tank. The pilot valve is inoperable even if a control
lever is operated under this condition.
To Hydraulic Oil Tank From Pilot

Pump
• When the pilot control shut-off lever is in the
T157-02-07-003
To Pilot Valve and 9-
Unit Solenoid Valve
UNLOCK position:
The shut-off valve is opened, allowing pilot oil from
the pilot pump to flow to the pilot valve. The return oil
passage from the pilot valve to the hydraulic oil tank
is closed. The pilot valve becomes operable when
the control lever is operated under this condition.
From Pilot
Valve T157-02-07-004
T3-6-1
SHOCKLESS VALVE
The shockless valves are located in the boom

raise/lower, arm roll-out, and swing right/left circuits to
regulate the pilot oil flow between the pilot valve and
the control valve spool so that the spools in the control
valve are moved smoothly. The pilot oil heating circuits
are also provided in the shockless valve.
Heating Circuit
When the pilot shut-off valve is in the LOCK position,
hydraulic oil from the pilot pump passes through the
pilot shut-off valve and is routed to the shockless
valve. As hydraulic oil flow is restricted by the orifice
located at the inlet of the shockless valve so that
hydraulic oil is warmed. The warmed hydraulic oil is
routed to the shockless valve and the pilot valve to
warm the components in the pilot system.
To Pilot Valve To Pilot Valve To Pilot Valve
Pilot Shut-Off Valve

(LOCK Position)
Orifice Boom Shockless Swing Shockless
Valve Valve
Pilot Pump
Arm
Roll-Out
Shockless
Valve
Schockless Valve
To Control Valve To Control Valve To Control Valve
T197-03-06-009
T3-6-2
Shockless Circuit
• When Arm is Rolled Out:
When the pilot valve is operated, pressure oil from
the pilot valve enters port A, flows through passage
A, opens the check valve, and is routed into Port A Passage A Check Valve
chamber A. As chamber A is connected to port B via
the inner passage, pressure oil from chamber A
flows to port B. Then, pilot pressure oil from port B From Arm
acts on the control valve spool end to shift the spool. Roll-Out
Pilot Valve
Chamber A
T197-03-06-020
Port B
To
Control
Valve
Inner
Passage
• In Neutral:
T197-03-06-021
When the pilot valve is returned to neutral, the spool

in the control valve is moved to the neutral position
by spring force so that the oil pressure at port B in
the shockless valve increases. This increased
pressure is routed into chamber A via the inner
passage, closing the check valve. Then, the pilot Port B
return oil from the control valve flows through
passage B via the orifice, As passage B is
From
connected to passage A via the inner passage, the Control
pilot return oil is routed to the pilot valve through Valve
passage A. Thereby, the control valve spool is
returned slowly, damping shock loads developed
when stopping operation.
Passage B Orifice
T197-03-06-021
Port A Passage A Check Valve
To Arm
Roll-Out
Pilot Valve
Passage B
Chamber A
T197-03-06-020
T3-6-3
• When Swing Function is Operated (Right and Left):
When the pilot valve is operated, pressure oil from Check Valve 1 Spool 2
the pilot valve flows through spool 1, check valve 1, Passage 2
and oil passage 2 to spool 2. Then, pressure oil is
routed to the control valve through the center
passage in spool 2.
Spool 1
To
Control
From Pilot Valve
Valve
Flow Control T197-03-06-022

Valve
When pressure oil reaches the control valve, the oil

pressure flowing through the shockless valve
increases. As the oil pressure on the control valve Spool 1 Passage 2
side increases, spool 1 is moved to the right due to a
difference in the pressure receiving area by the inner
passage diameter, closing the oil port to passage 2.
Thereby, pressure oil from the pilot valve is
To
restricted by the orifice in spool 1, damping Orifice Control
movement of the control spool at the beginning of From Pilot Valve
Valve
operation.
T197-03-06-025
Spool 2
As the oil pressure on the control valve side

increases further, spool 2 is moved to the left.
Thereby, pressure oil from the pilot valve flows into
chamber A via around spool 2 and acts on the spool
in the flow control valve. There is an orifice in the
Chamber
spool so that the pressure in chamber A becomes A
higher than chamber B. Then, the spool is moved
downward.
Orifice
Spool Chamber B
T197-03-06-024
Flow Control
Valve
T3-6-4
However, pressure in chamber B gradually becomes
equal to chamber A as chamber B is connected to Check Valve 1 Spool 2
chamber A through the orifice. Therefore, the spool
is returned by spring force, allowing pressure oil in
chamber B to flow to the control valve via passage C
in the spool. This operation is repeated so that
pressure oil from the pilot valve gradually flows to
the control valve, preventing the control valve spool
from moving rapidly.
Cham-
ber A
To
From Pilot Orifice control
Valve Valve
Pas-
sage C
Spool Spring Chamber B
T197-03-06-023
• In Neutral:
When the pilot valve is returned to neutral, the pilot Check
Valve 2
oil pressure at the control valve spool end is
returned back to the shockless valve by spool spring Passage 2
Spool 1
force. Then, spool 1 is moved to the left by spring
force so that the return oil from the control valve
flows back to the pilot valve via check valve 2 and
spool 1.
From
Control
To Pilot Valve
Valve
T197-03-06-022
T3-6-5
• When Boom is Operated (Raise/Lower):
When the pilot valve is operated, pressure oil from Check Valve 1 Spool 2 Check Valve 2
the pilot valve is routed to spool 2 via check valve 1.
Then, pressure oil flows further to the control valve
through the center passage in the spool 2.
Spool 1
To
control
From Pilot
Valve
Valve
Spool Flow Control T197-03-06-001
Valve
Spool 2
When pressure oil reaches the spool ends in the
control valve, the oil pressure flowing through the
shockless valve increases. As the oil pressure on the
control valve side increases, spool 2 is moved to the
left. Therefore, pressure oil from the pilot valve flows
around spool 2 to chamber A. Pressure oil routed in
chamber A acts on the spool in the flow control Chamber
valve. A
There is an orifice in the spool so that the pressure in To
chamber A becomes higher than chamber B. Then, From Pilot control
Valve Orifice Valve
the spool is moved downward.
Chamber
B
Spool Flow Control T197-03-06-017
Valve
Spool 2
However, pressure in chamber B gradually becomes

equal to chamber A as chamber B is connected to
chamber A through the orifice. Therefore, the spool
is returned by spring force, allowing pressure oil in
chamber B to flow to the control valve via passage C Chamber
in the spool. This operation is repeated so that A
pressure oil from the pilot valve gradually flows to the To
control valve, preventing the control valve spool from From Pilot control
Orifice Valve
moving rapidly. Valve
Passage
C
Spool Flow Chamber B
Control T197-03-06-016
Valve
T3-6-6
• In Neutral:
When the pilot valve is returned to neutral, the spool
in the control valve is moved to the neutral position
by spring force so that pressure oil acting on the Check
control valve spool end is returned to the shockless Valve 2
valve. The return oil from the control valve flows
through check valve 2 to spool 1. Spool 1 has orifice Spool 1
2 so that the return oil flows back to the pilot valve
after being restricted by orifice 2. Thereby, the
control valve spool is returned slowly, damping
shock loads developed when stopping operation. From
Control
To Pilot Valve
Valve
Orifice 2 T197-03-06-001
• When Pilot Valve is Operated in Reverse:

When the pilot valve is operated to the opposite side
quickly, the pilot pressure in the opposite side is Spool 1
routed in chamber D via the inner passage. Then,
spool 1 is moved to the right so that the return oil
Chamber
from the control valve flows back to the pilot valve D
without being restricted by orifice 2. Accordingly,
even if the pilot valve is operated to the opposite From
Control
side, the lever control responsiveness is To Pilot Valve
maintained. Valve
Orifice 2 T197-03-06-018
T3-6-7
9-UNIT SOLENOID VALVE (EX75UR-5)
The 9-unit solenoid valve consists of proportional
solenoid valves, oil temperature sensor, and pressure
sensors. Front
1
Proportional Solenoid Valve
The proportional solenoid valve delivers pilot
16
pressure oil in proportion to the current routed from
the auto-MARCCINO control unit. There are two
15 2
types of the proportional solenoid valves,
deceleration proportional solenoid valve and 14
acceleration proportional solenoid valve. The 3
deceleration proportional solenoid valve is fully
13
opened when the key switch is ON to reduce or block
the secondary pilot pressure oil from the pilot valve in 12
response to the current from the auto-MARCCINO
control unit. (Refer to the SYSTEM / Front
Attachment Control System group.) 4
The acceleration proportional solenoid valve controls 11
the primary pilot pressure oil from the pilot shut-off
valve in response to the current from the auto-
10
MARCCINO control unit, supplying the pilot pressure
oil directly to the spool ends in the control valve 5
9
without routing the pilot valve. (Refer to the SYSTEM
/ Front Attachment Control System group.) 6
8
7
Rear T197-01-02-007
1 - Hydraulic Oil Temperature 5 - Boom Lower Deceleration 9 - Boom Raise Acceleration 13 - Left Offset Acceleration
Sensor Solenoid Valve Solenoid Valve Pilot Pressure Sensor
2 - Arm Roll-In Deceleration 6 - Boom Raise Deceleration 10 - Right Offset Acceleration 14 - Arm Roll-Out Acceleration
Solenoid Valve Solenoid Valve Pilot Pressure Sensor Solenoid Valve
3 - Arm Roll-Out Deceleration 7 - Boom Lower Pilot Pressure 11 - Right Offset Acceleration 15 - Arm Roll-Out Acceleration
Solenoid Valve Sensor Solenoid Valve Pilot Pressure
4 - Left Offset Deceleration 8 - Boom Raise Acceleration 12 - Left Offset Acceleration 16 - Arm Roll-In Pilot Pressure
Pilot Pressure Solenoid Valve Sensor
T3-6-8
Heating Circuit
When the pilot shut-off valve is in the LOCK position,
pressure oil (primary pilot pressure) from the pilot
pump flows to the 9-unit solenoid valve from the pilot
shut-off valve. Then, pressure oil is restricted by the
orifice located at the inlet port of the 9-unit solenoid
valve so that oil temperature increases. This warmed
oil flows through the 9-unit solenoid valve, shockless
valves, and pilot valves, warming these components.
Shockless Valve Pilot Valve
Pilot Shut-Off Valve
Pilot
Pump
T197-03-06-005
Orifice
T3-6-9
SOLENOID VALVE UNIT
Pilot Relief Valve
NOTE: Valves marked* are used only on the Travel Mode Solenoid Valve
EX75UR-5.
Solenoid Valve*
The solenoid valve unit consists of the travel mode Emergency Stop
solenoid valve, arm oil flow combining solenoid valve*, Solenoid Valve*
emergency stop solenoid valve*, and pilot relief valve.
The arm oil flow combining solenoid valve* and the
emergency stop solenoid valve* regulates the pilot
pressure in response to signals from the auto-
MARCCINO control unit. The travel mode solenoid
valve regulates the travel motor speed control
pressure in response to signals from the MC (main
controller).
The travel mode solenoid valve and the arm oil flow
combining solenoid valve* are proportional solenoid
valves. The emergency stop solenoid valve* is an ON-
T197-03-06-007
OFF solenoid valve.
Pilot Relief Valve

The pilot relief valve maintains the pilot oil pressure
routed to port P from the pilot pump at the set-
pressure.
Pilot Relief Valve

Port P
T157-05-04-007
T3-6-10
Emergency Stop Solenoid Valve (EX75UR-5)
The emergency stop solenoid valve consists of the
switch valve (solenoid valve) and unload valve. The
emergency stop solenoid valve is regulated by
signals from the auto-MARCCINO control unit. In
Switch
case any abnormality occurs in the front attachment Valve Spool
control system, the emergency stop valve is activated
to block the pilot oil flow to the pilot shut-off valve.
In Neutral: Port P1
Pressure oil from the pilot relief valve flows to port P1 Port S
of the switch valve and port P2 of the unload valve.
Port P2 is connected to port A in the unload valve.
Then, pressure oil flows to the pilot shut-off valve
from port A. When neutral, port S in the switch valve
is connected to port Dr. Port Dr is connected to the Port P2
hydraulic oil tank.
Port A
Port Dr
Unload Valve
T197-03-06-006
When Operating:
When the switch valve spool is shifted, port P1 is
connected to port S so that the pilot pressure from port
P1 is routed to the pilot chamber via port S. The oil
pressure routed in the pilot chamber acts on the sleeve
Spool
in the unload valve. When the pilot pressure
overcomes the spring force, the sleeve is moved
downward. When the sleeve is moved downward, the
pilot pressure oil flowing from port P2 to the pilot shut- Port P1 Port S
off valve via port A is blocked by the sleeve.
Pilot
Chamber
Sleeve
Port P2
Port A
T197-03-06-026
Spring
T3-6-11
Proportional Solenoid Valve
The proportional solenoid valve is controlled by
current signals from the MC and auto-MARCCINO
control unit (only EX75UR-5), delivering the pilot oil
pressure in proportion to the current signals.
• When in neutral: Spool (1) is pushed to the right by

spring (2) and output port (S) is connected to
hydraulic oil tank port (T).
• When magnetized: Solenoid (3) pushes spool (1) to
the left by force in proportion to the current flowing
through solenoid (3). Then, the pilot pressure oil
flows from port P to output port S so that pressure at
port S increases. Pressure in port S acts on the
stepped flange faces on spool (1) in section (a).
There is a difference in diameter between the two
flanges in section (a) so that spool (1) is moved to
the right by the pressure. When the force pushing
spool (1) to the right overcomes solenoid (3) force to
push spool (1) to the left, spool (1) is moved back to
the right, closing output port (S) and port (P) so that
output pressure from port (S) stops increasing.
S P 1 2 3
T
T107-02-07-005
1 - Spool 2 - Spring 3 - Solenoid
T3-6-12
OFFSET ANTI-DRIFT VALVE (EX75UR-5)
In Neutral:
Depending on the stop position of the front attachment, Port A Poppet
(Control
the front attachment will be swung to the right by its Port B (Offset Valve)
own weight. The anti-drift valve is provided in the offset Cylinder
cylinder rod side circuit to prevent the front attachment Rod Side)
from being swung by its own weight. In addition, the
relief valve is provided in the offset cylinder rod side
circuit to protect the circuit from excessive high
pressure developed by external loads.
Passage
• When Offset Spool is in Neutral: c
When the front attachment weight is applied so that
the offset cylinder is extended, the oil pressure in
the offset cylinder rod side circuit increases. This
increased oil pressure is routed from port B to the
reverse side of the poppet via passage c. Then. the
poppet is seated upward, blocking pressure oil flow
from the offset cylinder rod side circuit to port A.
Thereby, the offset cylinder drift is prevented.
T197-03-06-010
• When Offset to the Left:

When left offset operation is made, pressure oil from When Offset to the Left:
the control valve flows to port A, pushing the poppet Port A
(Control
downward. Then, pressure oil is routed to port B and Valve)
Port B (Offset
flows further to the offset cylinder rod side, allowing Cylinder
the front attachment to offset to the left. Rod Side)
T197-03-06-011
T3-6-13
• When Offset to the Right:
When right offset operation is made, the right swing When Offset to the Right:
pilot pressure is routed into port PL, moving the
piston downward. As the bottom end of the piston Port A Poppet
keeps in contact with the spool so that the spool is (Control
Port B Valve)
moved downward at the same time. When the spool (Offset
Cylinder Port PL
is moved downward, oil in the poppet spring
Rod Side) Piston
chamber flows to port DR via the orifice, allowing the
return oil from the offset cylinder rod side to passes
port B, pushing the poppet downward, and flows to Spool
port A.
Orifice
Port DR
T197-03-06-013
T3-6-14
• Offset Cylinder Rod Side Circuit Protection
When the offset cylinder rod side circuit pressure is When Anti-Drift Valve is Relieving:
increased due to external loads, pressure oil from Poppet
port B is routed into chamber D through around the Port A
sleeve. Then, when the oil pressure in chamber D (Control
Port B Valve) Z
overcomes the relief valve spring force, pressure oil (Offset
Piston
flows into the piston chamber through the inside of Cylinder
Rod Side) Piston
the relief valve. Thereby, the spool is moved
Chamber
downward, allowing oil in the poppet spring chamber
to flow to port DR via the orifice. Therefore, pressure
oil in port B opens the poppet and flows to port A. Spool
Sleeve
Orifice
Z
Port DR T197-03-06-015
Cross Section Z-Z
Piston
Relief Valve Chamber
Spool
Sleeve
Spring
Chamber D
T197-03-06-014
T3-6-15
EC MOTOR
The EC motor is used to control the engine. A worm

gear is installed in the EC motor, preventing the EC
motor from exceeding the specified range. The EC
sensor is installed to check the governor lever position
by detecting the EC motor rotation position. (Refer to
the SYSTEM / Control System group.)
Output Gear Output Shaft Worm Gear
Motor
Sensor Gear T157-02-05-018

EC Sensor Worm Wheel
T3-6-16
COMPONENT OPERATION / Others (Undercarriage)
SWING BEARING
The swing bearing supports the upperstructure and The outer race is bolted to the upperstructure and the
allows the upperstructure to rotate smoothly. This inner race to the undercarriage, respectively. The
bearing is a single-row shear ball-type bearing internal gear on the inner race meshes with the output
comprised of the outer race, inner race, balls, supports, shaft of the swing reduction gear.
and seals.
Outer Race
Seal
Inner Race
Support
Seal
Ball
T102-03-02-001
T3-7-1
CENTER JOINT
The center joint is a 360° rotary joint, allowing hydraulic

oil to flow to and from the travel motor and/or the blade
cylinder without twisting hydraulic hoses when the
upperstructure is rotated. Spindle (1) is connected to
the upperstructure, and body (2) is bolted to the swing
center of the under carriage. Pressure oil flows to the
right and left travel motors and/or to the blade cylinder
through the spindle (1) and oil ports on body (2). Seals
(3) prevent oil leaks between spindle (1) and body (2).
Right Travel
Left Travel Forward Reverse
Right Travel
Left Travel Reverse Forward
Right Travel
Left Travel Forward Reverse Blade Drain
Forward / Blade Raise Lower
Reverse / Blade Lower Right Travel 1
Left Travel Reverse Forward Blade
Raise 2
3
Drain
Blade
Blade Lower
Blade Raise
Blade
Lower Raise
Drain
T196-03-07-001
1 - Spindle 2 - Body 3 - Seal
T3-7-2
TRACK ADJUSTER
CAUTION: The adjuster cylinder contains
The track adjuster consists of spring (5), adjuster
high-pressure grease. If valve (1) is loosened
cylinder (6), and so forth. The track adjuster is installed
excessively or quickly, grease may spout out,
on the side frame. Spring (5) absorbs the loads applied
possibly causing serious personal injury. Be
to the front idler. Track sag is adjusted by adjuster
sure to slowly loosen valve (1) while keeping
cylinder (6).
body parts and face away from valve (1).
Never loosen the grease fitting.
• When grease is supplied through the grease fitting,
grease fills chamber (a) in adjuster cylinder (6) so
1
that piston rod (8) is extended to reduce track sag.
• When increasing track sag, rotate valve (1) 1 to 1.5 Grease Fitting
turns counterclockwise to discharge grease.
Grease Discharge Port
M104-07-119
1 2 3 4 a 5 6 7 8
T191-03-07-002
1 - Valve 3 - Washer 5 - Spring 7 - Flange

2 - Nut 4 - Spacer 6 - Adjuster Cylinder 8 - Piston Rod
T3-7-3
(Blank)
T3-7-4
MEMO
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162
SERVICE MANUAL REVISION REQUEST FORM
NAME OF COMPANY: MODEL:

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

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

EX75UR / EX75US-5
Manual No. : KM-197E
Vol. No. : TT197E-00
Technical Manual
(Troubleshooting)
Excavator
EX75UR
Technical Manual
EX75US -5
Excavator
(Troubleshooting)
Service Manual (Manual No. KM-197E) consists of the following three separate volumes;
Technical Manual (Operational Principle) : Vol. No. TO197E
Technical Manual (Troubleshooting) : Vol. No. TT197E
Workshop Manual : Vol. No. W197E
PRINTED IN SINGAPORE (PS)
EX75UR/75US-5 TM/Tsh 1 2/8/02, 12:10 PM

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

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

replaced when necessary.
• If a safety sign or operator's manual is damaged

or missing, replace it with new one.
• Learn how to operate the machine and its controls

correctly and safely. SA-003
• 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
machine life.
• The safety messages in this SAFETY chapter are

intended to illustrate basic safety procedures of
machines. 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.
S003-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
attached on the fire extinguisher to use it properly.
• Establish emergency procedure guidelines to
cope with fires and accidents.
• Keep emergency numbers for doctors,
ambulance service, hospital, and fire department
posted near your telephone.
SA-437
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
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.
• When you get on and off the machine, always

face the machine and maintain a three-point
contact with the steps and handrails.
• Do not use any 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 leaving the machine.
008-E01A-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-4
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
machine. SA-689
011-E01A-0689
SA-5
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-6
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.
014-E01B-0690
SA-690
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.
017-E01A-0692
SA-692
SA-7
SAFETY
DRIVE MACHINE SAFELY
• Before driving the machine, always confirm that the

travel levers/pedals direction corresponds to the
direction you wish to drive.
• Be sure to detour around any obstructions.
• 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 (approximately 8 to 12 in) (A) above the
ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop.
SA-693
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
machine to level ground, then, change the
direction to ensure sage operation.
S019-E02A-0693
SA-589
SA-8
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 switch off.
• Run the engine at slow idle speed without load for SA-694
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.
020-E02A-0694
SA-695
SA-9
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-10
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
injury or death. SA-321
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
than 15 degrees if crossing the grade is
unavoidable. SA-440
• 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-0634
SA-11
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
SA-582
site.
029-E01A-0584
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-12
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 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-700
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.
033-E02B-0700
SA-13
SAFETY
ҥAVOID FIRES
HANDLE FLUIDS SAFELYҥ
• 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.
034-E01A-0496 SA-019
SA-14
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:
1) Select firm level ground.
2) Be sure to use a loading dock or ramp.
3) Be sure to have a signal person when SA-701
loading/unloading the machine.
4) Always turn the auto-idle switch OFF when
loading or unloading the machine, to avoid
unexpected speed increase due to unintentional
operation of a control lever.
5) Be sure to load/unload the machine at slow
speed.
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.
035-E07A-0701
SA-15
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 switch off.
4) Run the engine at slow idle speed without load SA-028
for 5 minutes.
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 window is missing or broken replace
immediately.
• If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
SA-527
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
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.
• Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
• Illuminate your work area adequately but safely.
• Use a portable safety light for working inside or
under the machine.
S500-E09A-0497
SA-16
SAFETY
• 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.
SA-037
S500-E09A-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
machine that is supported solely by a jack. SA-527
519-E01A-0527
SA-17
SAFETY
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
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
SA-18
SAFETY
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
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
SA-19
SAFETY
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
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.
• Relieve the pressure by moving the control levers
several times. Tighten all connections before
SA-031
applying pressure.
• Search for leaks with a piece of cardboard; take
care to protect hands and body from high-
pressure fluids. Wear a face shield or goggles for
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-E01A-0499 SA-044
SA-20
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-21
SAFETY
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.
• In an emergency, if the cab door or front window can

not be opened, break the front or rear window panes
with the emergency evacuation hammer to escape SA-393
from the cab. Refer the explanation pages on the
Emergency Evacuation Method.
518-E02A-0393
SS-1510
SA-22
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
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-23
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.
• 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-E01B-0032
SA-24
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
AVOID HARMFUL ASBESTOS DUST
• Inhaled asbestos fibers may cause lung cancer.
• Avoid breathing dust that may be generated when

han-dling components containing asbestos fibers.
• Components that may contain asbestos fibers are
some gaskets. The asbestos used in these
components is usually found in a resin or sealed
in some way. Normal handling is not hazardous as
long as airborne dust containing asbestos is not
generated.
• Avoid creating dust. Never use compressed air for
cleaning. Avoid brushing or grinding asbestos-
SA-029
containing materials. When servicing, wear an
approved respirator. A special vacuum cleaner is
recommended to clean asbestos. If not available,
wet the asbestos containing materials with a mist
of oil or water.
• Be sure to comply with all applicable rules and
regulations for the work place.
Follow all local environmental rules and
regulations for the disposal of asbestos.
• Keep bystanders away from the areas where
asbestos particles may be in the air.
514-E01A-0029
SA-25
SAFETY
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
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
SA-26
SAFETY
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 AND GROUP SECTION 4 OPERATIONAL PER-
CONTENTS FORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
TECHNICAL MANUAL
Group 6 Adjustment
(Troubleshooting) SECTION 5 TROUBLESHOOTING
Group 1 General
Group 2 Component Layout
Group 3 Troubleshooting A
Group 4 Troubleshooting B
Group 5 Troubleshooting C
Group 6 Troubleshooting D
Group 7 Electrical System Inspection
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specification Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
SECTION 2 SYSTEM Group 3 Control Valve
Group 1 Control System Group 4 Pilot Valve
Group 2 Front Control System Group 5 Travel Device
Group 3 Hydraulic System Group 6 Others (Upperstructure)
Group 4 Electrical System Group 7 Others (Undercarriage)
All information, illustrations and speci-
fications in this manual are based on WORKSHOP MANUAL
the latest product information available SECTION 1 GENERAL INFORMA- SECTION 3 UNDERCARRIAGE
at the time of publication. The right is TION Group 1 Swing Bearing
reserved to make changes at any time
Group 1 Precautions for Disassem- Group 2 Travel Device
without notice.
bling and Assembling Group 3 Center Joint
Group 2 Tightening Torque Group 4 Track Adjuster
SECTION 2 UPPERSTRUCTURE Group 5 Front Idler
Group 1 Cab Group 6 Upper and Lower Roller
Group 2 Counterweight Group 7 Track
Group 3 Main Frame SECTION 4 FRONT ATTACHMENT
Group 4 Pump Device Group 1 Front Attachment
COPYRIGHT(C)2002
Group 5 Control Valve Group 2 Cylinder
Hitachi Construction Machinery Co., Ltd.
Group 6 Swing Device SECTION 5 ENGINE
Tokyo, Japan
Group 7 Pilot Valve
All rights reserved
Group 8 Pilot Shut-Off Valve
Group 9 Shockless Valve
Group 10 Solenoid Valve
Group 11 Holding Valve
SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction Control Lever Operating Force .............. T4-4-14
Operational Performance Tests ............. T4-1-1 Control Lever Stroke ............................. T4-4-15
Preparation for Performance Boom Raise/Swing Combined
Test ..................................................... T4-1-2 Operation Check.................................. T4-4-16
Group 2 Standard
Operational Performance Group 5 Component Test
Standard Table .................................... T4-2-1 Primary Pilot Pressure........................... T4-5-1
Main Pump P-Q Diagram....................... T4-2-4 Secondary Pilot Pressure ...................... T4-5-3
Sensor Activating Range ....................... T4-2-5 Main Relief Valve Set Pressure ............. T4-5-4
Overload Relief Valve Set Pressure....... T4-5-10
Group 3 Engine Test Main Pump Flow Rate Measurement ..... T4-5-14
Engine Speed........................................ T4-3-1 Swing Motor Drainage ........................... T4-5-18
Engine Compression Pressure .............. T4-3-2 Travel Motor Drainage ........................... T4-5-20
Valve Clearance .................................... T4-3-4
Nozzle Check ........................................ T4-3-6 Group 6 Adjustment
Injection Timing ..................................... T4-3-8 Engine Speed Adjustment and
Engine Learning .................................. T4-6-1
Group 4 Excavator Test Boom Lowering Method
Travel Speed......................................... T4-4-1 when Engine Stalling ........................... T4-6-2
Track Revolution Speed ........................ T4-4-2 Check of Governor Lever and
Mistrack Check...................................... T4-4-3 Fuel Cut Lever Position ....................... T4-6-4
Travel Motor Leakage............................ T4-4-4 Assembly and Adjustment of Link for
Swing Speed ......................................... T4-4-5 Arm Angle Sensor (EX75UR-5) ............ T4-6-6
Swing Function Drift Check ................... T4-4-6 Initial Setting of the Angle Sensor .......... T4-6-7
Swing Motor Leakage ............................ T4-4-7 Initializing the Depth Limit Control
Maximum Swingable System (EX75UR-5) ............................. T4-6-8
Slant Angle .......................................... T4-4-8
Swing Bearing Play ............................... T4-4-9
Hydraulic Cylinder Cycle Time............... T4-4-10
Dig Function Drift Check........................ T4-4-12
197T-4-1
(Blank)
197T-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedures to quan-
titatively check all systems and functions on the ma-
chine.
Purpose of Performance Tests Precautions for Evaluation of Test Data

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

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

ate 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, loose 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 at-
tachment extended.
(3) If required, rope off the test area and provide
signboards to keep unauthorized personnel
away. T105-06-01-003
3. PRECAUTIONS
(1) Before starting to test, agree upon the signals
to be employed for communication among
coworkers. Once the test is started, be sure
to communicate with each other using these
signals, and to follow them without fail.
(2) Operate the machine carefully and always
give first priority to safety.
(3) While testing, always take care to avoid 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 escap-
ing oil. Pay special attention to this when re-
moving hydraulic pipings.
T105-06-01-004
4. MAKE PRECISE MEASUREMENTS

(1) Accurately calibrate test instruments in ad-
vance to obtain correct data.
(2) Carry out tests under the exact test condi-
tions prescribed for each test item.
(3) Repeat the same test and confirm that the
test data obtained can be procured repeat-
edly.
Use mean values of measurements if neces-
sary.
T4-1-2
OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE
STANDARD TABLE
The standard Performance values are listed in the
table below. Refer to the Group T4-3 to T4-5 for
performance test procedures. Values indicated in
parentheses are reference values.
* The following switch positions shall be selected:
Engine Control Dial: Fast Idle
E Mode Switch: OFF
Oil Temperature: 50±5 °C(122±9°F)
EX75UR-5 EX75US-5
Reference
PERFORMANCE TEST DESIGNATION (Performance (Performance Remarks
Page
Standard) Standard)
ENGINE SPEED min-1 T4-3-1
Fast Idle(Normal) 1920±100 ←
E mode switch:
Fast Idle(When relieving) 1950±100 ←
Off
E mode switch:
Fast Idle(E Mode) 1800±50 ←
Off
Slow Idle +100
1050 -50 ←
Auto-Idle 1200±100 ←
ENGINE COMPRESSION PRESSURE 3.0 or more
← T-4-3-3
(After warming up) MPa (kgf/cm2) (30 or more)
With the engine
VALVE CLEARANCE(IN, EX) mm 0.4 ← T4-3-4
cold
NOZZULE INJECTION PRESSUREMPa (kgf/cm2) 18.1(185) ← T4-3-6
INJECTION TIMING(Degrees before TDC) deg. 13° ← T4-3-8
TRAVEL SPEED sec/20 m T4-4-1
Fast Speed 22.6±2.0 ←
Slow Speed 24.8±2.5 ←
TRACK REVOLUTION SPEED sec/3 rev ← T4-4-2
Fast Speed 14.6±1.0 ←
Slow Speed 22.6±2.0 ←
MISTRACK(in fast and slow speed mode)
200 or less ← T4-4-3
mm/20 m
TRAVEL MOTOR LEAKAGE mm/5 min 0 ← T4-4-4
SWING SPEED sec/3 rev 19.0±1.5 ← T4-4-5
SWING FUNCTION DRIFT CHECK mm /180° 250 or less ← T4-4-6
SWING MOTOR LEAKAGE mm/5 min 0 ← T4-4-7
18.5 or possibly
MAXIMUM SWINGABLE SLANT ANGLE deg. ← T4-4-8
more
Allowable Limit:
SWING BEARING PLAY mm (0.8 to 1.0) ← T4-4-9
(2.0)
T4-2-1
EX75UR-3 EX75US-3
PERFORMANCE TEST Reference
(Performance (Performance Remarks
DESIGNATION Page
Standard) Standard)
HYDRAULIC CYLINDER CYCLE 1.81 m Arm 1.62 m Arm 0.28 m3 (PCSA heaped) T4-4-10
TIME sec Bucket
Boom Raise 3.8±0.4 3.4±0.4
Boom Lower 2.9±0.4 2.5±0.4
Arm Roll-In 3.5±0.4 3.0±0.4
Arm Roll-Out 3.1±0.4 2.7±0.4
Bucket Roll-In 3.5±0.4 ←
Bucket Roll-Out 2.2±0.4 ←
Offset Left 3.9±0.5
(Switch Control) (4.5±0.5)
Offset Right 3.9±0.5
(Switch Control) (4.5±1.1)
Blade Raise 2.1±0.4 ←
Blade Lower 2.5±0.4 ←
DIG FUNCTION DRIFT CHECK 1.81 m Arm 1.62 m Arm 0.28 m3 (PCSA heaped) T4-4-12
mm/5 min Bucket
Boom Cylinder 10 or less ←
Arm Cylinder 20 or less ←
Bucket Cylinder 10 or less ←
Bucket Bottom 100 or less ←
Offset Cylinder 10 or less ←
Blade Cylinder 5 or less ←
CONTROL LEVER OPERATING ← HITACHI Lever Pattern T4-4-14
FORCE N (kgf)
Boom Lever 19.6 (2.0) ←
or less
Arm Lever 16.7 (1.7) ←
or less
Bucket Lever 16.7 (1.7) ←
or less
Swing Lever 19.6(2.0) ←
20.or less
Travel Lever 24.5 (2.5) ←
24.6 or less
Blade Lever 33.3 (3.4) ←
or less
Offset Pedal (Right/Left) 147.1 (15.0) ←
or less
CONTROL LEVER STROKE mm HITACHI Lever Pattern T4-4-15
Boom Lever 105±10 ←
Arm Lever 83±10 ←
Bucket Lever 83±10 ←
Swing Lever 105±10 ←
Travel Lever 115±10 ←
Blade Lever 60±10 ←
Offset Pedal (Right/Left) 14±10 ←
NOTE: 1 kgf = 9.8 N

1 kgf/cm2 = 0.09807 MPa
T4-2-2
EX75UR-5 EX75US-5
Reference
PERFORMANCE TEST DESIGNATION (Performance (Performance Remarks
Page
Standard) Standard)
COMBINED BOOM RAISE/SWING FUNCTION
T4-4-16
CHECK; With Bucket Empty sec
(Both Normal and Precise Swing) 0±0.3
Bucket Tooth Height (H) mm
(Both Normal and Precise Swing) 3600 or more
Bucket/Cab Collision Prevention System
Cab Front mm 200+100-30
Cab Side mm 220+50-40
HYDRAULIC COMPONENT PERFORMANCE
PRIMARY PILOT PRESSURE MPa (kgf/cm2) T4-5-1
+1.0 +1.0
3.73 -0.5 (38 -
Fast Idle
5 )
Slow Idle 3.43+1.0-0.5 (35+10-5)
SECONDARY PILOT PRESSURE MPa (kgf/cm ) 2
3.33 to 3.92
T4-5-3
(at both fast idle(normal)and slow idle speed) (34 to 40)
MAIN RELIEF VALVE SET PRESSURE
T4-5-4
MPa (kgf/cm2)
25.5±1.0
Front Attachment
(260±10)
31.4±1.0
Travel
(320±10)
22.6±1.0
Swing
(230±10)
22.6±1.0
Blade
(230±10)
MAIN PUMP FLOW RATE L/min - T4-5-14
SWING MOTOR DRAINAGE - Allowable
T4-5-18
(at constant speed) L/min 0.3 or less Limit: 1.0
Allowable
(at relief pressure) L/min 1.0 or less
Limit: 2.0
TRAVEL MOTOR DRAINAGE Allowable
T4-5-20
(while being raised off ground) L/min 0.5 to 1.5 Limit: 2.0
Allowable
(at relief pressure) L/min (2.0 to 4.0)
Limit: (5.0)
NOTE: 1 kgf = 9.8 N

1 kgf/cm2 = 0.09807 MPa
T4-2-3
MAIN PUMP P-Q DIAGRAM
• Pump Model : AP2D36 P-Q Point

• Rated Pump Speed : 1900 min-1(rpm) MPa (kgf/cm2) L/min
• Hydraulic Oil Temperature : 50±5 °C (122±9°F) 9.8 (100) 64
31.4 (320) 7.5
*1 : Digging
*2 : Travel
NOTE: 1 kgf = 9.8 N
1 kgf/cm2 = 0.09807 MPa
80
70
2
60
50
L/min
40
30
20
10
0
50 100 150 200 250 300 350
T197-04-05-01
(P1+P2) / 2 kgf/cm2
T4-2-4
SENSOR ACTIVATING RANGE
1. Checking Method
• Hydraulic Oil Temperature:

50±5 °C (122±9 °F)
• Unless specified:
Engine Control Dial: Fast Idle Position
E Mode Switch: OFF
Auto-Idle Switch: OFF
• Monitor using Dr. EX.
2. Sensor Activating Range
Item Engine Speed Specification

Slow Idle 0.3 to 1.0 V
Engine Control Dial (Sensor)
Fast Idle 4.0 to 4.7 V
Slow Idle 2.5 to 2.7 V
EC Sensor Fast Idle (Lever in neutral) 3.2 to 3.4 V
Fast Idle (Lever in the operating position) 3.3 to 3.5 V
T4-2-5
(Blank)
T4-2-6
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary:
1. Use an engine tachometer.
2. Measure the engine speeds in each mode.
NOTE: Measure the engine speed before

performing all other tests to check that the
engine speed meets specification. Because,
if the engine speed is not adjusted correctly,
all other performance data will be
unreliable.
Preparation:
1. Install the speed pickup to the injection pipe.
2. Warm up the machine until the engine coolant

temperature reaches 50 °C (122 °F) or more, and
hydraulic oil is 50±5 °C (122±9 °F).
IMPORTANT: Never attempt to the readjust

stopper.
Measurement:
1. No Load Engine Speed
1-1. Measure the slow idle speed, fast idle speed
(in normal mode), and fast idle speeds (in E
mode).
1-2. Select the switch positions as shown below.
Engine Control Auto-Idle
E Mode Switch
Dial Switch
Slow Idle OFF OFF
Fast Idle
OFF OFF
(Normal Mode)
Fast Idle
ON OFF
(E Mode)
2. No Load Auto-Idle Speed

2-1. Select the switch positions as shown below.
Engine Control Auto-Idle
E Mode Switch
Dial Switch
Fast Idle OFF ON
2-1. Start the engine and operate the bucket lever.

2-2. Return the lever to the neutral position. Wait
approx. 4 seconds until the engine speed is
automatically reduced. Then, measure the
reduced engine speed.
Evaluation:
Refer to Performance Standard Table in Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-3-1
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in the cylinders to
check for a decline in engine power.
2. Check exhaust gas color. Keep track of engine oil

consumption.
3. Check for abnormalities in the intake system,

including the air filter.
Preparation:
1. Confirm that valve clearances are correct.
2. Confirm that the batteries are charged properly.

T105-06-02-001
3. Run the engine until the coolant temperature
gauge reaches the operating range.
4. Stop the engine. Remove glow plugs (4 used)

from each cylinder.
5. Install an adaptor (Isuzu: 5-8531-7001-0) and

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

cylinder and calculate the mean values.
Evaluation:
Remedy:
Refer to engine shop manual.
T4-3-2
(Blank)
T4-3-3
VALVE CLEARANCE
Summary:
1. Perform the measurement when the engine is
cool.
2. Before starting work, clean the head cover

mounting area to avoid contamination in the
engine. TDC Mark Pointer
Preparation:
1. Locate the top dead center (TDC) in the
compression stroke.
Align the TDC mark on the crank pulley with the
pointer located on the timing gear case as
illustrated. Piston No.1(or piston No.4) is now
positioned at the TDC in its compression stroke.
2. Remove the head cover.

Crank Pulley T197-04-02-001
3. Move push rods for the intake and exhaust valves

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

between the rocker arm and the valve stem end to
measure the valve clearance.
T107-02-12-005
NOTE: The cylinders are aligned from No.1 to No.4

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

Valve locations I E I E I E I E
When the measurement is
! ! ! !
started from No.1 cylinder
When the measurement is
× × × ×
started from No.4 cylinder
3. Rotate the crankshaft 360°. Align the TDC mark

with the pointer. Then, continue measurement of
other valves in the same way.
Evaluation:
Adjustment:
If the measurement results are out of specification,
adjust the valve clearance in the same order of
measurement.
1. Loosen the adjusting screw lock nuts for the

rocker arms. Insert the thickness gauge set at
0.35 mm (0.014 in), adjust the adjusting screws.
2. After adjusting, retighten the lock nuts to the

specification.
Recheck the valve clearance after the lock nuts
are tightened.
: 25.5±4.9 N·m
(2.6±0.5 kgf·m, 18.8±3.6 lbf·ft)
T4-3-5
NOZZLE CHECK
Summary:
1. Check the injection pressure and the spray
pattern with a nozzle tester.
2. Before starting work, clean the nozzle holder

mounting area to avoid contamination in the
engine.
Preparation:
1. Remove the nozzle holders.
Remove all nozzle holders and fuel injection
pipings from the engine.
2. Attach a nozzle holder to the nozzle tester.
Measurement:
CAUTION: Never touch spray directly. The

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

If adjustment is required, loosen the lock nuts and
adjust the adjusting screws. Turn clockwise to
increase the pressure, and counterclockwise to
decrease the pressure.
2. Spray pattern
For this test, turn the pressure tester knob to
bypass the pressure gauge. Attach the nozzle
holder to the nozzle tester. Strongly make several
strokes of the tester and check the fuel spray
pattern.
NOTE: Use clean diesel oil.
T4-3-6
Evaluation:
1. Refer to Performance Standard Table in Group
Normal
T4-2.
2. Spray Pattern
• Large-size spray should not be visible to the
naked eye.
• No stray sideways sprays should be seen.
• During initial injection stage, spray size should be
fine and injected intermittently.
• There should be no drips found.
• Injection spray angle must be normal.
T102-02-11-005
3. Oil Tight Condition
No fuel leaks.
Abnormal
T102-02-11-006
Adjustment: Shim
• Use the adfusting shims to adjust the pressure.
Increasing the number of shims increases the
pressure.
Decreasing the number of shims decreases the
pressure.
T152-04-02-001
T4-3-7
INJECTION TIMING
Inspection:
1. Position No.1 piston to the top dead center. Turn
the crank pulley in the direction of rotation TDC Mark Pointer
(clockwise as seen from the front of the engine) to
set “TDC” mark on the crank pulley under the
“pointer”, located on the timing gear case.
2. Turn the crank pulley at approx. 30 degrees

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

Crank Pulley T197-04-02-001
cylinder from the injection pump to pull the
delivery valve and the spring out. Reinstall the
delivery valve holder.
: 29 N⋅m Delivery Valve Spring
(3 kgf⋅m, 21.7 lbf⋅ft) Holder
5. While supplying fuel with the feed pump, turn the

Delivery Valve
crank pulley slowly clockwise just until fuel cannot
be seen from the top of the delivery valve hole.
This is the position where the injection starts.
Adjustment:
1. Turn the crank pulley so that the pointer comes
just above the correct timing position (13 degrees T105-02-12-006
before the TDC) on the crank pulley.
Injection Pump
2. Loosen the mounting nuts of the injection pump.
3. When advancing timing, tilt the injection pump

outward against the cylinder body.
When delaying timing, tilt the injection pump
inward against the cylinder body. Nut
NOTE: The angle changes 2 degrees when the

alignment mark separaters for 1 mm.
Alignment Mark T197-04-02-002
T4-3-8
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary:
To totally check the travel driving system perform-
ance (between the main pump and the travel motor)
by measuring the time required to travel a 10 m (32.8
ft) test track.
Preparation:
1. Adjust the track sag on both side tracks equally.
2. Prepare a flat and solid test track 10 m (32.8 ft) in
length with extra length of 3 to 5 m (9.8 to 16 ft) on
both ends for machine acceleration and decelera-
tion. Arm Rolled-In, Bucket Rolled-In
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above End
Bucket Height: 0.3 to 0.5 m
the ground with the arm and bucket rolled in.
4. Maintain hydraulic oil temperature at 50±5 °C
Start
(122±9 °F). Deceleration Zone
20 m
3 to 5 m
Measurement:
Acceleration
1. Measure in both slow and fast travel modes. Zone 3 to 5 m
2. Select the following switch positions:
Travel Mode Engine Control E Mode Auto-Idle
Switch Dial Switch Switch T105-06-03-001
Slow Mode Fast Idle OFF OFF

Fast Mode Fast Idle OFF OFF
3. Start traveling the machine in the acceleration

zone with the travel levers fully stroked.
4. Measure the time required to travel 20 m (65.6 ft).
5. After measuring the forward travel speed, turn the
upperstructure 180° and measure the reverse
travel speed in the same way.
6. Repeat steps 4. to 5. three times in each direction
and calculate the average values.
Evaluation:
Remedy:
Refer to Troubleshooting B in Group T5-4.
T4-4-1
TRACK REVOLUTION SPEED
Summary:
To totally check the travel driving system perform-
ance (between the main pump and the travel motor)
by measuring the track revolution cycle time with the
track raised off ground.
Preparation:
1. Adjust the track sag of both side tracks equally.
2. Mark one shoe with a piece of cloth or chalk on
the track to be measured.
CAUTION: Securely support the raised track
using wooden blocks.
3. Swing the upperstructure 90° and lower the
bucket to raise the track off the ground. Keep the
boom-arm angle between 90 to 110° as shown.
4. Maintain the hydraulic oil temperature at 50±5°C
(122±9°F).
Measurement:
1. Measure in both slow and fast travel modes.
90 to 110°
Switch Dial Switch Switch
3. Operate the travel control lever of the raised track

to full stroke.
M104-07-067
4. After a constant track revolution speed is obtained,
measure the time required for 3 revolutions in
both directions.
5. Raise the other side and repeat the above proce-
dures.
6. Repeat steps 3. to 5. three times and calculate the
average values.
Evalution:
NOTE: The measurement data obtained through

the raised track revolution test may vary.
Therefore, the evaluation based on the
results obtained from the 20 m (65.6 ft)
travel speed check described before is
recommended.
Remedy:
T4-4-2
MISTRACK CHECK
Summary
1. To check the performance equilibrium between
both sides of the travel device systems (between
the main pump and the travel motors) by measur-
ing the maximum tread deviation from the tread
chord line drawn between the travel start and end
points after traveling the machine 20 m (65.5 ft).
2. If measured on a concrete surface, the tread de-
viation has a tend to decrease.
Preparation: Maximum Distance

1. Adjust the track sag of both tracks equally.
2. Prepare a flat and solid test track 20 m (65.5 ft) in
length with an extra length of 3 to 5 m (9.8 to 16 ft)
Acceleration
on both ends for machine acceleration and decel- Zone:
eration. 20 m
3 to 5 m
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above
the ground with the arm and bucket rolled in.
(122±9 °F).
Measurement: T105-06-03-002
3. Start traveling the machine in the acceleration

zone with the travel levers fully stroked.
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 in forward travel, turn the upper-
structure 180° and measure in reverse travel in
the same method.
Evaluation:
Remedy:
T4-4-3
TRAVEL MOTOR LEAKAGE
Summary:
To measure the parking brake function on a specified
slope.
Preparation:
1. The surface of the test slope shall be even with a
gradient of 20 % (11.31°).
2. Mark a white line on the travel device cover.
3. Hold the bucket 0.2 to 0.3 m (8 to 12 in) above the
ground with the arm and bucket rolled in.
(122±9 °F).
Measurement:
0.2 to 0.3 m
T105-06-03-004
3. Measure the displacement (revolution angle) of

the travel device cover until the parking brake is Position where the machine
comes to a stop.
applied.
3-1. Climb the slope and place the travel levers in Position when the travel
levers are in neutral.
neutral.
Displacement
3-2. Measure the displacement from the mark posi- (Revolution Angle)
tion on the travel device cover when the levers Mark
are placed in neutral to that position when the
machine stops moving.
4. Measure the travel parking brake slip amount
while parked.
4-1. Climb the slope and place the travel levers in
neutral. T107-06-03-002
4-2. Stop the engine.

4-3. After the machine stops, put alignment marks
on a track link or shoe, and the track side
frame.
4-4. After 5 minutes, measure the distance between
the marks on the track link or shoe and the
track side frame.
Alignment marks on the track
Evaluation: side frame and shoe when the
machine comes to a stop.
Refer to Performance Standard Table in Group T4-2. Displacement
measured after T105-06-03-006
5 minutes.
T4-4-4
SWING SPEED
Summary:
To totally check the swing drive system (between the
main pump and the swing motor) by measuring the
time required to make three turns.
Preparation:
1. Check the lubrication of the swing gear and swing
bearing.
2. Secure enough space to allow the machine to
swing on a solid and flat surface. Avoid measuring
on a slope.
3. With the arm rolled out and bucket rolled in, hold
the bucket so that the bucket hinge pin height is
flush with the boom foot pin (with the bucket
empty). Hold the same level as
4. Maintain hydraulic oil temperature at 50±5 °C the boom foot pin height.
(122±9 °F).
T105-06-03-013
CAUTION: Always make sure that the area is

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

3. After a constant swing speed is obtained, meas-
ure the time required to swing 3 turns.
4. Measure in both right and left swing directions.
Evaluation:
Remedy:
T4-4-5
SWING FUNCTION DRIFT CHECK
Summary:
To check the swing brake valve performance by
measuring the swing drift appeared on the bearing
outer circumference when stopping after a 180° full-
speed swing.
NOTE: The swing mechanical parking brake is

located in the swing motor.
Preparation:
bearing.
2. Secure enough space to allow the machine to
swing on a solid and flat surface. Avoid measuring
on a slope.
the bucket hinge pin flush with the boom foot pin Put alignment marks on the swing
bearing outer circumference and on
(with the bucket empty). the track frame T105-06-03-008
4. Put alignment marks on the swing bearing outer
circumference (on the upperstructure side) and on
the track frame with tape.
5. Swing the upperstructure 180°.
(122±9 °F).

area before starting the measurement. Start measurement after swinging
the upperstructure 180° T105-06-03-009
Measurement:
Fast Idle OFF OFF Measure difference along the swing
bearing outer circumference.
2. Operate the swing control lever fully and return it

to the neutral position when the mark on the swing
bearing aligns with that on the track frame after
swinging 180°.
3. After the upperstructure completely stops, meas-
Marking on the Track Frame
ure the distance between the two marks along the
swing bearing outer circumference.
Marking on the Swing Bearing
4. Measure in both right and left directions.
5. Repeat steps 2. to 3. three times in each direction T105-06-03-010
Evaluation:
Remedy:
T4-4-6
SWING MOTOR LEAKAGE
Summary:
To check the swing brake valve performance by
measuring the swing drift appeared on the bearing
outer circumference due to the upperstructure weight
while parking the machine on a specified slope with
the upperstructure swung 90° to the slope. (The
swing mechanical parking brake is located in the
swing motor.)
Preparation:
bearing.
2. Load the bucket with either soil or the weight of
the following specification:
W = 375 kg (825 lb)
the arm top pin flush with the boom foot pin
4. The test slope surface shall be even with a gradi-
ent of 15±1°.
5. After climbing the slope, swing the upperstructure
to position it 90° to the slope. Make aligning marks
on the swing bearing periphery and track frame
using tape, as illustrated.
T105-06-03-011
(122±9 °F).
Measurement:
E Mode Switch Auto-Idle Switch
OFF OFF
Measure difference between marks.
2. Start the engine and maintain engine speed at
slow idle. After 5 minutes, measure the difference
between the marks along the swing bearing pe-
riphery and the track frame.
3. Measure in both right and left swing directions.
4. Measure three times in each direction and calcu- Marking on the Track Frame
late the average values.
Marking on the Swing Bearing
Evaluation:
Refer to Performance Standard Table in Group T4-2. T105-06-03-010
Remedy:
T4-4-7
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:
bearing.
2. Load the bucket with either soil or the weight of
W = 375 kg (825 lb)
the arn top pin flush with the boom foot pin.
4. The test slope surface shall be even with a gradi-
ent of 15±1°.
5. After climbing the slope, swing the upperstructure
to position it 90° to the slope.
(122±9 °F).
T105-06-03-011
Measurement:
Fast Idle OFF 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. to 3.
Check both clockwise and counterclockwise.
5. Perform the measurement three times.
Evaluation:
Remedy:
T4-4-8
SWING BEARING PLAY
Summary:
To check the wear on the swing bearing races and
balls by measuring the swing bearing play between
the outer race and the inner race.
Preparation:
1. Check swing bearing mounting bolts for loose-
ness.
2. Check the lubrication of the swing bearing. Con- Dial Gauge
Magnetic
firm that bearing rotation is smooth and without Base T105-06-03-014
noise.
3. Install a dial gauge with a magnetic base on the
track frame as shown.
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 Round Frame Trunk
comes into contact with the bottom face of the
bearing outer race.
6. Bucket should be empty.
NOTE: The measured value may differ depending T105-06-03-015
on where the dial gauge magnetic base is Measurement of (h1)

located. Mount the magnetic base directly
onto the round frame trunk or ase close to
the round frame trunk as possible.
Measurement:
the bucket bottom flush with the boom fool pin.
Record the dial gauge reading (h1).
2. Lower the bucket to the ground and raise the front
side of the machine approx. 0.5 m (20 in) above
the ground. Record the dial gauge reading (h2). T105-06-03-007
3. Calculate bearing play (H) from this data (h1 and
Measurement of (h2)
h2) as follows:
(H) = (h2) — (h1)
Evaluation:
T105-06-03-017
T4-4-9
HYDRAULIC CYLINDER CYCLE TIME
Boom Cylinder
Summary:
1. To totally check the front function performance by
measuring each cylinder cycle time.
2. Bucket should be empty.
Preparation:
1. Take the following machine position:
T191-04-03-010
1-1. When measuring the boom cylinder:

With the arm cylinder fully retracted and the Arm Cylinder
bucket cylinder fully extended, lower the
bucket to the ground.
1-2. When measuring the arm cylinder:

With the bucket cylinder fully extended, adjust
the boom and arm cylinder strokes so that
when the arm is moved half the full stroke, the
arm longitudinal center line perpendicularly 0.5 m
points to the ground and the bucket bottom
clearance above the ground is approx. 0.5 m T191-04-03-011
(20 in).
Bucket Cylinder
1-3. When measuring the bucket cylinder:
Adjust the boom and arm cylinder strokes so
that when the bucket is moved half the full
stroke, the bucket edge points to the ground
perpendicularly.
1-4. When measuring the offset cylinder (EX75UR-

5):
Set the offset cylinder in either the right or left
offset stroke end position. T105-06-03-020
Offset Cylinder
1-5. When measuring the blade cylinder:
Lower the bucket to the ground to raise the
machine front off the ground and secure the
space to allow the blade to move up-and-down
full stroke.

(122±9 °F).
M190-05-034
Blade Cylinder
T191-04-03-009
T4-4-10
Measurement:
Engine Con- E Mode Auto-Idle
trol Dial Switch Switch
All Cylinders Fast Idle OFF OFF
2. Operate each cylinder as follows:

(The cylinder stroke includes the cushion range.)
2-1. Measuring the boom cylinder.

Measure the time required to raise or lower the
boom while operating the boom control lever
full stroke.
2-2. Measuring the arm cylinder.

Measure the time required to roll in or out the
arm while operating the arm control lever full
stroke.
2-3. Measuring the bucket cylinder.

Measure the time required to roll in or out the
bucket while operating the bucket control lever
full stroke.
2-4. Measuring the offset cylinder (EX75UR-5)

Measure the time required to offset the front at-
tachment from right to left or vice versa while
operating the offset control pedal full stroke.
2-5. Measuring the blade cylinder

Measure the time required to raise or lower the
blade while operating the blade control lever
full stroke.
3. Repeat each measurement three times and calcu-

late the average values.
Evalution:
Remedy:
T4-4-11
DIG FUNCTION DRIFT CHECK
Summary:
To check for internal oil leaks in the cylinders or con-
trol valve by measuring the cylinder drift (extension or
retraction) with the standard load in the bucket.
NOTE: When conducting the check soon after

cylinders were replaced, bleed any air
trapped in the cylinders by fully stroking the
cylinders before testing.
Extension
Retraction
Preparation:
1. Load the bucket with either soil or the weight of Retraction
W = 375 kg (825 lb)
the arm top pin flush with the boom foot pin Arm top pin height
3. Retract both the arm and bucket cylinders approx. should be flush with
boom foot pin.
50 mm (20 in) from the stroke end to avoid the
Bucket Bottom Height Drift
cushion range.
4. Maintain hydraulic oil temperature at 50±5 °C T105-06-03-021
(122±9 °F). Retraction of Boom or Bucket Cylinder

Mark Mark
Measurement:
1. Stop the engine.
2. Five minutes after the engine has been stopped,
measure the change in the height of the bucket
bottom, as well as the retraction or extension of
each cylinder.
3. Repeat step 2. three times and calculate the av-
erage values. T110-06-03-002
Evalution:
Refer to Performance Standard Table in Group T4-2. Extension of Arm or Blade
Cylinder
Remedy:
Mark
T110-06-03-001
T4-4-12
Drift Check for Offset Cylinder (EX75UR-5)
Preparation:
1. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
W=375 kg (825 lb)
2. With the arm rolled in and the bucket rolled in, po-
sition the offset cylinder with the rod 100 mm (4 in)
retracted from the fully extended position.
3. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Stop the engine.
2. 1 hour after the engine has been stopped, meas-
ure the change in position of the offset cylinder.
erage value.
Drift Check for Blade Cylinder
Preparation:
1. Position the blade cylinder with fully retracted.
2. Measure the distance from the tip of the blade T197-04-03-001
edge to the ground.
3. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Offset Cylinder Extension
Measurement:
1. Stop the engine.
2. After 5 minutes, measure the distance from the tip
Mark
of the blade edge to the ground. Calculate the dif-
ference between the value measured during the
preparation.
erage value.
Evaluation:
Refer to Performance Standard Table in Group T4-2. T110-06-03-001
Blade Drift
Remedy:
A B
T197-04-03-002
T4-4-13
CONTROL LEVER OPERATING FORCE
Summary:
1. To measure each control lever operating force as
well as the lever stroke end play and operation
smoothness.
2. Attach the spring scale to the lever grip center.
Preparation:
(122±9 °F).
Measurement:
1. Measure each control lever.
Fast Idle OFF OFF
T107-06-03-003
3. When measuring the boom, arm, bucket, and

swing lever, operate each lever full stroke to
measure the maximum operating force.
4. When measuring the travel levers, raise the track
to be measured using the front function and
measure the maximum operating force.
average values.
Evalution:
T107-06-03-004
T4-4-14
CONTROL LEVER STROKE
Summary:
1. To measure each control lever stroke as well as
the lever stroke end play and operation smooth-
ness.
2. Measure the stroke at the lever grip center.
3. When the lever play is provided in the neutral po-
sition, divide the play equally to measure the
stroke.
Preparation:
(122±9 °F).
Measurement:
1. Stop the engine. T107-06-03-005
2. Measure the operation strokes of the boom, arm,

bucket, swing, and travel levers at the lever grip
top from neutral to the stroke end using a ruler.
3. Measure the chord length from neutral to the
stroke end.
erage values.
Evalution:
T4-4-15
BOOM RAISE/SWING COMBINED
OPERATION CHECK
Summary:
1. To check boom raise and swing movement and
speed while operating both functions simultane-
ously.
2. To check that no cylinder hesitation occurs during
operation with the engine running at full speed.
Preparastion:
1. With the arm rolled out and the bucket rolled in,
lower the bucket to the ground.(Bucket should be T107-06-03-009
empty.)
(122±9 °F).

Measurement:
Fast Idle OFF OFF
T107-06-03-010
2. Raise the boom and swing simultaneously with

both control levers fully stroked. When the upper-
structure 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
with the bucket empty.
average values.
H
Evalution:
Remedy:
Refer to Troubleshooting B in Group T5-4. T107-06-03-011
T4-4-16
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Stop the engine.
2. Press the air release valve on the filler cap to
release any remaining pressure.
3. Disconnect the hose from the solenoid valve unit
and install tee (ST 6477) and pressure gauge (ST
6942) between the solenoid valve unit and the
hose.
: 27 mm
4. Start the engine. Check the pressure gauge
connection for oil leaks.
(122±9 °F).
Measurement:
Engine Control Auto-Idle Switch
Dial
Fast Idle OFF
Slow Idle OFF
2. Measure the pilot pressure at both fast and slow

idle engine speed.
3. Repeat the measurement three times and T1CC-04-04-001
calculate the average values.
Install tee and pressure
gauge between adapter
Evaluation: and hose.
Refer to Performane Standard Table in Group T4-2.
T4-5-1
Primary Pilot Pressure Adjustment Procedure
Solenoid Valve Unit
Adjust the set pressure of the pilot relief valve as
necessary. Plug
1. Remove the plug.

: 22 mm
2. Install the estimated necessary number of shims.

3. Tighten the plug.
: 25+5 N⋅m (2.5+0.5 kgf⋅m, 18+3.6 lbf⋅ft)
4. Check the set pressure of the relief valve.
NOTE: Standard Change in Pressure (Reference)

Pressure Change
Shim Thickness (mm)
kPa (kgf/cm2) (psi) T1CC-03-06-002
0.25 78 (0.8) (11)

Shim Plug
0.5 157 (1.6) (23)
1.0 304 (3.1) (44)
T157-05-04-007
T4-5-2
SECONDARY PILOT PRESSURE
Control Valve 1
Preparation: Pilot Port
1. Stop the engine.
3. Install tee (ST 6451) and pressure gauge (ST
6942) to the control valve spool pilot port located
in the pilot circuit to be measured.
: 14 mm, 19 mm
4. Start the engine and check the pressure gauge
connection for oil leaks.
(122±9 °F).
Measurement:
CAUTION: Before measuring, check that
there are no obstacles or personnel within
the swing radius. When measuring the boom
lower pilot pressure, raise the machine off
the ground while paying attention not to al-
low the base machine (counterweight) to
contact with the ground. Be careful not to
tip-over due to a loss of balance. T1CC-03-03-001
Control Valve 2
Pilot Port Pilot Port
Engine Control Auto-Idle Switch (EX75UR-5)
Dial
Fast Idle OFF
Slow Idle OFF
2. Measure the pilot pressure with the

corresponding control lever operated full stroke.
3. Repeat the measurement three times and

calculate the average values.
Evaluation:
Remedy: T197-03-03-005
Refer to Troubleshooting B in Groupe T5-4.

Tee
Pressure
Gauge
T157-05-04-011
T4-5-3
MAIN RELIEF VALVE SET PRESSURE
Summary:
To check the main relief valve set pressure at the
main pump delvery port.
Preparation: ST 6941
1. Stop the engine.
3. Remove the plug from the pressure check port at
the main pump delivery port. Then, install adapter
(ST 6069), hose (ST 6943) and pressure gauge ST 6943
(ST 6941) to the port.
For measuring the main relief pressure of the
blade and swing circuit, install adapter (ST 6477),
adapter (ST 6069) and pressure gauge (ST 6941) ST 6069
at the hose.
: 6 mm
: 19 mm, 27 mm, 36 mm
4. Start the engine and check the pressure gauge

connection for oil leak. Hose
(122±9 °F).
Measurement:
T190-06-04-002
Dial
Fast Idle OFF
2. Relieve each cylinder circuit by gradually

operating the bucket, arm, and boom control lever
to extend or retract each cylinder full stroke.
3. When checking the swing circuit, secure the
upperstructure so it is immovable. Then, slowly
operate the swing lever to relieve the swing
function.
When checking the travel circuit, secure the
tracks against an immovable object. Then, slowly
operate the travel levers to relieve the travel
function.
In case of offset, grab the ground using the
bucket to relieve.
When lowering the blade, it becomes the jacked-
up position. Be careful that the machine does not
roll over.
4. Measure the relief oil pressure with the pressure
gauge.
5. Repeat the measurement three times and
caluculate the average values.
T4-5-4
Evaluation:
Main Relief
NOTE: If the measured pressures for all functions Valve
are lower, a decrease in the main relief
valve set pressure may be the probable
cause.
If the relief pressure of a particular function
is lower, the probable cause may be other
than the main relief valve.
Adjusting Main Relief Valve Set Pressure:

• Control Valve 1
Ȁ After loosening lock nut (1), turn plug (3)(low pres-
sure), or plug (5)(high pressure) to adjust the relief
valve set pressure as necessary.
Adjusting High Pressure Main Relief Set Pressure:

1. Loosen lock nut (1). Lightly tighten plug (3) until it
comes in contact with piston (2). Tighten lock nut T1CC-03-03-001
(1).
: 27 mm 3
: Plug (3): 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
Lock Nut (1): 68 to 78 N⋅m 1
(7 to 8 kgf⋅m, 50 to 58 lbf⋅ft)
2. Loosen lock nut (4). While holding the condition 5
set in step 1. , turn plug (5) until the desired pres-
sure is obtained. 4
: 27 mm, 32 mm
: Lock Nut (4): 78 to 88 N⋅m
(8 to 9 kgf⋅m, 58 to 65 lbf⋅ft)
2
Adjusting Low Pressure Main Relief Set Pressure:

3. Loosen lock nut (1). Turn plug (3) counter-
clockwise until the specified pressure is obtained.
Tighten lock nut (1).
: 27 mm
: Lock Nut (1): 59 to 69 N⋅m
(6 to 7 kgf⋅m, 43 to 50 lbf⋅ft) T157-05-04-009
4. Recheck the set pressure.
NOTE: Standard Change in Pressure (Reference) Plug 5 3

Plug Turns 1/4 1/2 3/4 1
Plug (5) MPa 7.1 14.2 21.3 28.4
2
(High (kgf/cm ) (72.5) (145) (217.5) (290) Pressure
Pressure) (psi) (1031) (2062) (3093) (4124) Pressure Decrease
Increase
Plug (3) MPa 5.3 10.7 16.0 21.3
2
(Low (kgf/cm ) (54) (109) (163) (217)
Pressure) (psi) (768) (1550) (2318) (3086)
W107-02-05-127
T4-5-5
• Control Valve 2
Main Relief Valve
1. Loosen the lock nut.
2. Turn the adjusting screw until the desired pres-
sure is obtained.
3. Tighten the lock nut.
: 14 mm
: 20+0.40 N⋅m (2+0.40 kgf⋅m, 28+40 psi)

Screw Turns 1/4 1/2 3/4 1
MPa 2.9 5.9 8.8 11.8
Change in
(kgf/cm2) (30) (60) (90) (120)
Pressure
(psi) (430) (850) (1280) (1710) T197-03-03-005
Adjusting Screw
Lock Nut Adjusting Screw
Pressure Pressure
Increase Decrease
Lock Nut
T505-06-04-006
T563-02-04-002
T4-5-6
Adjusting Swing Relief Valve Set Pressure: Swing Relief
Valve
Loosen the lock nut to adjust the set pressure.
2. Turn the adjusting screw to adjust the set

pressure.
IMPORTANT: Turn the adjusting screw so that the

adjusting screw end face extends 2
to 5 mm (0.08 to 0.20 in) from the
lock nut end face.

: 24 mm (Lock Nut)
T152-04-04-004
: 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
Lock Nut
: 6 mm (Adjusting Screw)
Adjusting
Screw
Plug Turns 1/4 1/2 3/4 1 T152-03-02-005
Change in MPa 1.7 3.4 5.1 6.9

Relief (kgf/cm2) (17.5) (35) (52.5) (70)
Pressure (psi) (249) (498) (747) (995)
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-7
Adjusting Travel Relief Valve Set Pressure:
1. Remove the travel relief valve assembly.

: 30 mm
2. Remove sleeve (1) and plug (4).
3. Provide shims (2) between spring (3) and spring
guide (5) to adjust the pressure setting.
4. Install the relief valve assembly. Travel Relief
Valve
: 314 N⋅m (32 kgf⋅m, 230 lbf⋅ft)
T155-01-01-006
Shim Change in Relief Pressure 1 3 4
2
Thickness Part No. 2
kPa (kgf/cm ) (psi)
(mm)
0.5 4305162 785 to (8 to 10) (114 to
980 142)
5
T135-06-04-001
T4-5-8
(Blank)
T4-5-9
OVERLOAD RELIEF VALVE SET PRES-
SURE
Checking the pressure setting of the overload relief
valves on the machine is not recommended for the
following reasons:
1. With the return circuit from the control valve

blocked, the circuit pressure must be increased
by applying an external load. This checking
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 delivery flow rate of the main
pump. Accordingly, even if the engine speed is
reduced and the main relief valve pressure set-
ting can be reset higher than the setting pressure
of the overload relief valve, the main pump sup-
plies too much oil to correctly measure the setting
pressure of the overload valve.
The main relief valve has pre-leaking function.
Accordingly, the main relief valve pressure setting
may not be reset higher than the set pressure of
the overload relief valve plus the pressure at pre-
leaking.
Therefore, when the setting pressure of the over-
load relief valve must be checked correctly, re-
move the overload relief valve from the machine
and check the overload relief valve unit perform-
ance using the test stand and test block prepared
for this purpose.
If the poppet of overload relief valve seats to the
body of control valve, the test block requires pre-
cise machining.
Use other control valve unit for the measurement
instead of the test block.
3. As an easier method, however, measure the relief
pressure of each cylinders in the same method as
of main relief pressure setting in previous section.
Then, when each relief pressure meets its re-
spective specifications, judge that the setting
pressure of the overload relief valve is correct.
Measurement:
Repeat the measurement three times and calculate
the average values.
Evaluation:
Refer to T4-2 Standard.
T4-5-10
Adjusting Overload Relief Valve Set Pressure:
Control Valve 1
NOTE: In principle, adjust the overload relief valve For Arm
set pressure on a specified test stand. For Boom
• Control Valve 1
2. Turn the adjusting screw to adjust the set
pressure.
: 17 mm (Lock nut)
: 27 to 31 N⋅m
For Bucket
(2.8 to 3.2 kgf⋅m, 20 to 23 lbf⋅ft)
: 6 mm (Adjusting screw)

T1CC-03-03-004
Lock Nut

Change in MPa 7.1 14.2 21.3 28.4
Relief (kgf/cm2) (72.5) (145) (217.5) (290)
Pressure (psi) (1031) (2062) (3093) (4124)
Adjusting Screw
T152-03-03-015
Lock Nut
Adjusting Screw
Pressure
Pressure Decrease
Increase
W107-02-05-129
T4-5-11
• Control Valve 2
Control Valve 2
2. Turn the adjusting screw to adjust the set pres-
sure.
: 14 mm (Lock Nut)
: 20+40 N⋅m (2+0.40 kgf⋅m, 28+40 psi)
4. Recheck the set pressure. For Blade

MPa 2.9 5.9 8.8 11.8
Change in
(kgf/cm2) (30) (60) (90) (120)
Pressure
(psi) (430) (850) (1280) (1710)
T197-03-03-005
Adjusting Screw
Pressure Pressure
Increase Decrease Lock Nut
T563-02-04-003
T505-06-04-006
T4-5-12
(Blank)
T4-5-13
MAIN PUMP FLOW RATE MEASURE-
MENT
6. Disconnect the pressure sensor (Travel), connect
Summary: terminal #1 to #2 and select the travel mode
To check the main pump performance by measuring switch to the fast travel position to hold the pump
the pump flow rate with a hydraulic portable tester in- swash angle to the maximum.
stalled at the pump delivery port. Oil pressure should 7. Install the engine speed meter to the injection
also be measured using a pressure gauge at the pipe. Fully open the hydraulic tester loading
same time. valve.
8. Disconnect the vacuum pump. Loosed the plug
Preparation: on top of the pump casing. Start the engine and
1. Stop the engine and push the air release valve on bleed air until oil flows out of the clearance
top of the hydraulic oil tank to release any remain- around the plug. Check pipe connections for oil
ing pressure. Connect a vacuum pump. leaks at this time.
NOTE: Operate the vacuum pump while connect-
ing the hydraulic portable tester to the main Measurement:
pump. 1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
2. Remove the plug at the main pump delivery port. 2. Select the following switch positions:
Install adapter (ST 6069), hose (ST 6943) and Engine Control Auto-Idle
pressure gauge (ST 6941). (Fig. A) Dial Switch
: 6 mm Fast Idle OFF
3. Disconnect hoses A and B with adapters. Install 3. While gradually closing the hydraulic tester load-
plug (ST 6254) into the disconnected hose end. ing valve, measure the flow rates, and engine
: 32 mm speeds at the set oil pressures. (Refer to page
T4-2-3.)
4. Install adapters (ST 6025), test hoses (ST 6145) 4. Repeat the measurement three times and calcu-
(3 used), adapters (ST6012) (3 used), block (ST late the average values.
6289) (2 used), adapter (ST 6146) (2 used), hy-
draulic tester (ST 6299), test hoses (ST 6145) (2 Evaluation:
used), and adapter (ST 6003) (3 used) to the Convert the measured pump flow rate into the one
pump delivery ports. (Fig. B) for the rated pump speed. Then, refer to the Per-
: 32 mm, 36 mm, 41 mm formance Standard Table in Group T4-2.
5. Remove the plug on the return pipe from the oil Qc = (Np × Q) / (i × Ne)
cooler Connect test hose (ST 6145) to the return
pipe plug hole via adapter (ST 6025) (Fig. C) Qc : Converted Pump Flow Rate
: 36 mm Q : Measured Pump Flow Rate
i : Pump Transmission Gear Ratio (=1)
Np : Rated Pump Speed (1900 min-1)
Ne : Measured Engine Speed
T4-5-14
Fig. A
Pressure Gauge(ST 6941)
Hose A Hose(ST 6943)
Hose B
Adapter(ST 6069)
T190-06-04-002
Fig. B
Hose Hyd. Tester Test Hose
Adapter（ST 6025）（ST 6145） Adapter(ST 6012）（ST 6299）（ST 6145） Return Pipe
Front
Port
Rear
Port
Main Pump
T192-04-04-002
Block Test Hose Adapter Adapter Adapter
（ST 6289）（ST 6145）（ST 6146）（ST 6003）（ST 6025）
Fig. C
Plug (Return Pipe)
View A
T197-04-04-003
T4-5-15
Adjusting Pump Flow Rate
NOTE: The pump flow rate is adjusted by chang-

ing the swash plate set pressure.
Adjustment:
Loosen the lock nut and turn the adjusting screw as
necessary.
A 18.8 MPa (192 kgf/cm 2 )
2. Turn the adjusting screw clockwise to increase ㈦
(Flow Rate)
pressure and counterclockwise to decrease pres-
sure.
: 27 mm
: 8 mm
4. Recheck the flow rate after the set adjusting
pressure.

Change in MPa 1.35 2.70 4.05 5.39 Pump 1+Pump 2 (Pressure)
Set Pres- (kgf/cm2) (13.8) (27.5) (41.3) (55)
sure from (psi) (196) (391) (587) (782)
point A
Lock Nut
Adjusting Screw
T196-03-01-001
T4-5-16
(Blank)
T4-5-17
SWING MOTOR DRAINAGE
Summary:
1. To check the swing motor performance by meas-
uring the oil drainage from the swing motor while
rotating the upperstructure.
NOTE: The amount of drain oil from the swing mo-

tor will change depending on hydraulic oil
temperature. Maintain hydraulic oil tem-
perature at 50±5 °C (122±9 °F) during the
measurement.
Preparation:
(122±9 °F). Rotate the swing motor to warm the
inside of the motor.
2. Stop the engine. Press the air release valve on
top of the hydraulic oil tank to release any remain-
ing pressure.
3. Disconnect the swing motor drain hose at the
swing motor end. Install a plug to the discon-
nected end on the hydraulic oil tank. Connect test
hose (9/16-18UNF) to the disconnected end on
T105-06-06-001
swing motor.
: 19 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
Drain Hose
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. Also, take care
not to fall off the machine while the meas-
urement.
Preconditions for Measurement:

Dial
Fast Idle OFF
T152-04-04-005
T4-5-18
Measurement:
1. Amount of Oil Drained While Swinging the Up-
perstructure
(1) With the arm cylinder fully retracted and the
bucket cylinder fully extended, raise the boom
so that the bucket hinge pin height is flush with
the boom foot pin height. Be sure that the
bucket is empty. Same Level as Boom
(2) Start the engine. Operate and hold the swing Foot Pin
lever full stroke. After the swing speed reaches
a constant maximum speed, start to receive the T105-06-03-013
amount of oil drained from the drain hose with a

container and measure the time.
(3) The measuring time should be more than 45
seconds.
(4) Repeat the measurement at least three times in
both clockwise and counterclockwise directions,
2. Amount of Oil Drained While Relieving Swing Mo-

tor
(1) Securely thrust the bucket teeth into the ground
to prevent the upperstructure from rotating.
(2) Start the engine. Operate and hold the swing
lever full stroke. Receive the amount of oil T107-06-06-005
drained from the drain hose with a container

and measure the time.
(3) The measuring time should be more than 45
seconds.
(4) Repeat the measurement at least three times in
Evaluation:
* Conversion of the amount of drain oil measured
into the per-minute value.
First measure the amount of the drain oil using a
calibrated container. The, convert the measured
drain oil into the per-minute value using the for-
mula below:
Qc = 60 × q / t
Where:
Qc: Amount of Drain Oil Per-Minute (L/min)
t : Measuring Time (sec)
q : Measured Drain Oil (L)
T4-5-19
TRAVEL MOTOR DRAINAGE
Summary:
To check the travel motor performance by measuring
the oil drainage from the travel motor while rotating
the travel motor with the corresponding track raised
off the ground.
NOTE: The amount of drain oil from the swing mo-

tor will change depending on hydraulic oil
temperature. Maintain hydraulic oil tem-
perature at 50±5 °C (122±9 °F) during the
measurement.
Preparation:
(122±9 °F). Rotate the travel motor to warm the
inside of the motor.
2. Stop the engine. Press the air release valve on
top of the hydraulic oil tank to release any remain-
ing pressure.
3. Disconnect the drain hose at the travel motor end.
Install a plug to the disconnected hose end. Con-
nect test hose (9/16-18UNF) to the disconnected
T105-06-06-001
end on the travel motor.
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) Drain Hose
Preconditions for Measurement:

Dial
Fast Idle OFF
T155-05-04-004
T4-5-20
Measurement:
CAUTION: To prevent accidents, care
should be taken to ensure that hands, feet,
and clothing do not become entangled when
working around rotating parts.
Securely support the raised track with 90 to 110°
wooden blocks.
1. Start the engine. Raise the measuring side track

using the front attachment as illustrated.
M195-07-003
2. Rotate the raised track with the travel lever oper-
ated full stroke. Receive the drain oil from the test
hose and measure the time at the same time.
3. The measuring time should be more than 45 sec-
onds.
4. Repeat the measurement at least three times in
Evaluation:
NOTE: Operational performance of the travel mo-

tor should be totally evaluated taking test
results on the travel speed and mistrack
into consideration.
* Conversion of the amount of drain oil measured

into the per-minute value. T157-05-04-019
First measure the amount of the drain oil using a
calibrated container. The, convert the measured
drain oil into the per-minute value using the for-
mula below:
Qc = 60 × q / t
Where:
Qc: Amount of Drain Oil Per-Minute (L/min)
t : Measuring Time (sec)
q : Measured Drain Oil (L)
T4-5-21
(Blank)
T4-5-22
OPERATIONAL PERFORMANCE TEST / Adjustment
ENGINE SPEED ADJUSTMENT AND
ENGINE LEARNING
When the following repair or inspection is made, or
when engine speeds deviate from the specifications,
perform the engine speed adjustment and engine
learning.
• When the engine, engine control cable, or EC

motor is removed.
• When MC is replaced.
Engine Speed Adjustment: Bolt

1. Turn the key switch to START and run the engine.
(Note: Turn the air-conditioner switch OFF.) Control Lever
2. Turn the engine control dial to the minimum speed
position. (EC sensor voltage is set to 2.5 V.)
3. Loosen the bolt tightening the control lever to the
EC motor output axis.
4. While checking the engine actual speed with
Dr.EX or a tachometer, adjust the control lever to
conform the slow idle speed specification.
Specification: Refer to Operational Performance
Test section.
5. Tighten the bolt to secure the control lever to the
EC motor output axis.
: 13 N·m (1.3 kgf·m, 9.4 lbf·ft)
IMPORTANT: Take care not to allow oil or grease

to stick to the motor output axis.
T191-05-04-004
6. Perform engine learning.
Engine Learning:
1. Turn the key switch OFF.
NOTE: If the engine does not stop with the key

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

3. Connect engine learning plug.
4. Turn the key switch ON. Wait for 5 seconds.
5. Turn the key switch OFF. Wait for 5 seconds.
6. Disconnect engine learning plug.
7. Check the engine speed.
T4-6-1
BOOM LOWERING METHOD WHEN EN-
GINE STALLING
If the engine has stalled with the boom raised and is

difficult to restart due to some reason, lower the boom
in the following procedures:
Overload
Relief Valve
In case the bucket is empty: (Boom Raise)
1. Put an alignment mark on the overload relief valve
in the boom raise circuit and the control valve
housing.
CAUTION: If the overload relief valve is loos- Machine
ened rapidly, the boom may be lowered Front
Side
quickly. Be sure to loosen slowly.
In addition, if loosened approx. more than 3/4
turn, hydraulic oil may spout. Never loosen
further than 3/4 turn.
2. While watching the boom movement, slowly
loosen the overload relief valve.
: 24 mm T197-03-03-002
: 49 to 54 N·m
(5 to 5.5 kgf·m, 36 to 40 lbf·ft)
3. After checking that the boom has lowered com-

pletely, tighten the overload relief valve.
Adjusting
Lock Nut Screw
In case a load is in the bucket:
1. Put an alignment mark on the lock nut and the ad-
justing screw on the overload relief valve in the
boom raise circuit.
CAUTION: If the adjusting screw is loosened
rapidly, the boom may be lowered quickly. Be
sure to loosen slowly.
2. Loosen the lock nut. While watching the boom
movement, slowly loosen the adjusting screw.
: 17 mm
: 27 to 31 N·m
T152-05-04-003
(2.8 to 3.2 kgf·m, 20 to 23 lbf·ft)
: 6 mm
3. After checking that the boom has lowered com-

pletely, retighten the adjusting screw and lock nut
until the alignment marks align.
IMPORTANT: After retightening the overload relief

valve, check the overload relief valve
set pressure.
T4-6-2
(Blank)
T4-6-3
CHECK OF GOVERNOR LEVER AND
FUEL CUT LEVER POSITION
Check the fuel cut lever position during cranking in
case of below.
• Although starter rotates, engine doesn’t start.
• Governor Lever and Fuel Cut Lever
1 2 3 4
T105-07-04-003
1 - Governor Cable (From EC Mo-
tor)
2 - Fuel Cut-Off Cable
(Fuel Cut-Off Handle)
3 - Fuel Cut Lever
4 - Governor Lever
T4-6-4
• Governor Lever Position
A - Key Switch OFF (Engine Stop Position)

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

B - Fuel Cut-Off Handle Returned Position
A
B
T105-07-04-003
T4-6-5
ASSEMBLY AND ADJUSTMENT OF LINK
FOR ARM ANGLE SENSOR (EX75UR-5)
IMPORTANT: Compared to other angle sensors, it
is more difficult to assemble or ad-
just the link for the arm angle sensor.
When replacing the arm angle sen-
sor, follow the assembly and ad-
justment procedures below.
Assembling the Link
IMPORTANT: In the case of pressing – in of a bush,

vertically press the bush by using
protective plate so that the sur- T197-05-06-001
rounding areas are not damaged.

1. Press the bush into the lever.
2. Press the bush 2 into the end rod.

Bushing 2
IMPORTANT: Before attaching the link, apply
grease generously to sliding and ro-
End Rod
tating areas.
Lever
3. Attach the link to the front attachment as shown at
right. Bushing
T197-05-06-002
Adjusting the Link
1. With the arm rolled in fully, position the link so that

a parallelogram is formed with four points A, B, C
and D shown at right. At this time, turn the end rod
so that a distance between A to D becomes 330 330 mm
mm.
End Rod
2. Tighten the lock nuts to clamp the end rods.
C
A
D
End Rod T197-05-06-006

Lock Nut
T4-6-6
INITIAL SETTING OF THE ANGLE SEN-
SOR (EX75UR-5)
Initial setting of the angle sensor is required when the
angle sensor or the front attachment (boom, arm) is
replaced.
Side Face of the Right Side Face of the
1. Set the front attachment in the following standard Side Cutter Operator's Cab
position.
Standard position:
Boom : Fully raised
(with the boom cylinder fully extended)
Arm : Fully rolled in
(with the arm cylinder fully extended)
Offset : Position the bucket so that the clearance be-
tween the side cutter of the bucket and the
operator's cab is 220 mm. T191-04-03-015
When equipped with an optional bucket, set

the offset position by referring to the below
table.
Clearance between the

side cutter of the
Bucket Type
bucket and the opera-
tor’s cab. (Unit: mm)
Standard 220
0.2 220
Slope finishing plate 1 220
Slope finishing plate 2 220
0.25 (Level finishing plate) 220
Left Console
2. Stop the engine and disconnect the initial setting

connector.
3. Start the engine and connect the initial setting
connector. Initial Setting Connector
4. Disconnect the initial setting connector again. The
setting is complete if the buzzer sounds a short
(beep).
5. Connect initial setting connector if setting is com-
plate.
NOTE: If the system failure indicator comes ON or

the buzzer sounds continuously, the initial
setting is failed. Check the angle sensor
system for abnormalities and repair if nec-
essary. Then, perform the initial setting
again.
T197-02-01-009
T4-6-7
INITIALIZING THE DEPTH LIMIT CON-
TROL SYSTEM (EX75UR-5)
It is required to initialize the Depth Limit Control Sys-
tem in the following case:
• The front attachment, angle sensor, link for angle
sensor, 9-port solenoid valve or auto-MARCCINO
control unit is exchanged.
CAUTION: When initializing the depth limit

control system, the front attachment will be
automatically moved through the auto-
MARCCINO control unit. Therefore, the ini-
tialization must be carried out on firm level
ground in a wide space so that work crew is
not hit or injured by the moving front attach-
ment.
IMPORTANT: If initialization is interrupted, stop T197-05-01-001

the engine, and reset Dr. EX to re- Dr. EX Connector
start initialization. (Auto-MARCCINO
Control Unit)
Depth Limit Control System Initializing Proce-
dures
1. Connect Dr. EX to the auto-MARCCINO control

unit, and connect the service switch. Confirm that
hydraulic oil temperature is 20ºC or higher. (Refer
to T5-1-12.)
2. Choose the Target Digging Range Correction Left Console
from the Service Modes of Dr. EX. Follow the in-
structions on the window of Dr. EX.
3. Choose the Boom Metering Adjustment from the
Service Modes of Dr. EX. Follow the instructions Service Switch (Plug)
on the window of Dr. EX.
4. Choose the Arm Metering Adjustment from the
Service Modes of Dr. EX. Follow the instructions
on the window of Dr. EX.
5. Choose the Auto Adjustment Of Level Crowd Op-
eration (for Standard Monitor) from the Service
Modes of Dr. EX. (If an optional system monitor is
used, choose the Auto Adjustment Of Level
Crowd Operation (for Optional Monitor).) Follow
the instructions on the window of Dr. EX.
6. Stop the engine.
T197-02-01-009
T4-6-8
Operational Check
1. With Dr. EX connected, start the engine.
NOTE: If Dr. EX is not connected to the auto-

MARCCINO control unit, or the service
switch is not connected, setting the depth to
plus side cannot be made.
2. Set the depth to ‘‘+0.1’’ m on the system monitor.
3. Align the bucket teeth with an extension straight-

line passing through the boom top pin and arm top
pin, and make full boom lowering and arm roll-in
at the same time.
Evaluation
Setting is OK when the bucket tooth tip can be level-

crowded at height of 0.1 m above the ground, without T197-05-06-005
touching the ground, in the above operation.
T4-6-9
(Blank)
T4-6-10
MEMO
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SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 General Group 4 Troubleshooting B
Introduction ..............................................T5-1-1 Troubleshooting B Procedure ...................T5-4-1
Diagnostic Procedures .............................T5-1-2 Relationship between Machine Trouble
Dr.EX Operation .......................................T5-1-4 Symptoms and Suspected Parts .............T5-4-2
Main Controller Fault Code List ................T5-1-5 Correlation between Trouble
Auto-Marccino Symptoms and Part Failures ...................T5-4-8
Control Unit Fault Code List....................T5-1-6 Engine System Troubleshooting .............T5-4-14
Main Controller Monitoring Function .......T5-1-10 All Actuator Control System
Auto-Marccino Control Unit Troubleshooting ....................................T5-4-24
Monitoring Function (EX75UR-5) ...........T5-1-11 Front Attachment Control System
Dr.EX Special Function Troubleshooting ....................................T5-4-26
(Service Mode) (EX75UR-5)..................T5-1-12 Swing System Troubleshooting...............T5-4-32
Travel System Troubleshooting ..............T5-4-34
Group 2 Component Layout Blade System Troubleshooting ...............T5-4-37
Main Components ....................................T5-2-1
Electrical System Group 5 Troubleshooting C
(Overview)..............................................T5-2-2 Troubleshooting C
Electrical System (Troubleshooting for Monitor) Procedure.T5-5-1
(Monitor and Switches) ...........................T5-2-4 Malfunction of Coolant Temperature
Component in Control Valve .....................T5-2-8 Gauge ...................................................T5-5-2
Malfunction of Fuel Gauge .......................T5-5-4
Group 3 Troubleshooting A Malfunction of Indicator Light Check
Troubleshooting A Procedure ...................T5-3-1 System ...................................................T5-5-6
Fault Code 01 (Abnormal EC Sensor).......T5-3-2 Malfunction of Alternator Indicator ...........T5-5-8
Fault Code 07 Malfunction of Engine Oil Pressure
(Abnormal Engine Control Dial Angle).....T5-3-3 Indicator ...............................................T5-5-10
Malfunction of Overheat Indicator ..........T5-5-12
Malfunction of Fuel Level Indicator ........T5-5-14
Malfunction of Air Filter Restriction
Indicator ...............................................T5-5-16
Malfunction of Buzzer ............................T5-5-18
Malfunction of Hour Meter .....................T5-5-20
197T-5-1
Group 6 Troubleshooting D (EX75UR-5)
Troubleshooting D Procedure ...................T5-6-1
Auto-Marccino Control Unit
System Fault Code List...........................T5-6-2
Fault Code 03...........................................T5-6-6
Fault Code 05, 06.....................................T5-6-7
Fault Code 07, 08.....................................T5-6-8
Fault Code 09...........................................T5-6-9
Fault Code 11, 12, 13 .............................T5-6-10
Fault Code 14, 15, 16, 19 .......................T5-6-12
Fault Code 24.........................................T5-6-14
Fault Code 40, 41...................................T5-6-16
Fault Code 43, 45, 47 .............................T5-6-17
Fault Code 50, 51, 52 .............................T5-6-18
Fault Code 60, 61, 62 .............................T5-6-20
Fault Code 80, 81, 82, 83 .......................T5-6-21
Fault Code 90.........................................T5-6-22
Fault Code 91.........................................T5-6-23
Group 7 Electrical System Inspection

Precautions for Inspection and
Maintenance ...........................................T5-7-1
Instructions for Disconnecting
Connectors .............................................T5-7-3
Fuse Continuity Test ................................T5-7-4
Fusible Link Inspection .............................T5-7-5
Battery Voltage Check..............................T5-7-6
How to Troubleshooting Alternator
Malfunctions Alternator Check ................T5-7-7
Continuity Check ......................................T5-7-8
Voltage and Current Check ....................T5-7-10
Check by False Signal............................T5-7-13
Test Harness..........................................T5-7-14
197T-5-2
TROUBLESHOOTING / General
INTRODUCTION
Use the troubleshooting section to help you locate the • Troubleshooting D (troubleshooting of the front at-
source of any problems that may arise. Each trouble- tachment operational control using fault codes
shooting section is presented in an orderly fashion so (EX75UR-5))
as to make inspecting and troubleshooting easy. Use these charts when the self-diagnosing func-
tion of Dr.EX shows any fault codes in diagnosing
The troubleshooting section consists of 7 groups: the Auto-MARCCINO Control Unit. Some fault
General, Component Layout, Troubleshooting A (using codes may be displayed on the system monitor.
fault codes), Troubleshooting B (starting with symp-
toms), Troubleshooting C (gauges and indicators), Example:
Troubleshooting D (troubleshooting of the front at- Dr.EX : Fault Code 11 --- Arm Roll-Out
tachment operational control using fault codes), and Malfunction
Electrical System Inspection groups. System Monitor : Fault Code E11 --- Arm Roll-Out
Malfunction
• General
• Electrical System Inspection
• Component Layout Refer to this group when precautions for electrical
system inspection or information on inspection
• Troubleshooting A (using fault codes) procedures is required.
Use these charts when the self-diagnosing func-
tion of Dr.EX shows any fault codes in diagnosing Example: Fuse Inspection
the main controller (MC). (The controller auto-
matically diagnoses and memorizes malfunctions
that have occurred in the signal sending system.)
Example: Fault Code 01: Abnormal EC Sensor
• 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: Engine speed does not change even

when the engine speed control lever or
acceleration pedal is operated.
• Troubleshooting C (monitor diagrpsis)

Use these charts when any gauges or indicators
malfunction.
Example: The fuel gauge does not operate.
T5-1-1
DIAGNOSTIC PROCEDURES
These six basic steps are essential for efficient

troubleshooting:
1. Study the System

• Know the system configuration.
• Study 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 from the
operator.
• Operating Conditions: Check what kinds of work

the machine was doing and if the machine was
being operated correctly.
• Time of Trouble: Check when the trouble
occurred.
• Symptoms: What are the details ? Was the
trouble getting worse, or did it appear suddenly for
the first time ?
• Background Record: Check if the machine had
any other problems previously, if so, which parts
were repaired/replaced before ?
T107-07-01-002
3. Pre-Inspection
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 problems in the electrical system,
such as low battery voltage, loose connections
and blown fuses, will result in malfunction of the
controllers, causing total failure of the machine.
Cracked fuses are often very difficult to visually
check so inspecting with a tester is
recommended.
T107-07-01-003
T5-1-2
4. Check the Trouble Yourself
Try to identify the trouble by operating the ma-
chine yourself. If the symptoms are difficult to re-
produce, obtain detailed information on the cir-
cumstances when the trouble occurred from the
operator. In addition, check if a simple failure such
as a loose connection of the wire harness is pres-
ent by slightly moving the wire harness by hand.
5. Perform Troubleshooting
T107-07-01-004
CAUTION: Never attempt to disconnect har-

ness or hydraulic lines while the engine is
running. The machine malfunction may result
or pressure oil may spout, possibly resulting
in personal injury. Be sure to stop the engine
before disconnecting the wire harnesses or
hydraulic lines.
Connect Dr.EX to the MC to obtain malfunction

records.
If any fault codes are displayed, record them. After
deleting the fault codes (∗), run the self-
diagnosing function again. In case the fault codes T107-07-01-005
are displayed again, start checking following

Troubleshooting A in this section.
If no fault code is indicated, perform Troubleshoot-
ing B in this section and also check each compo-
nent performance using Dr.EX’s monitor function.
* Note that fault codes do not always indicate ma-

chine trouble. The controller, for example, stores
such records as a drop in battery output voltage
or disconnection of the sensors for inspection
purpose.
Before performing troubleshooting based on the

fault codes, delete the fault codes once and re- T107-07-01-006
check whether the fault codes are displayed again

(RETRIAL).
6. Recheck Possible Causes

Before reaching a conclusion, recheck the most
likely causes. Identify the fundamental causes by
making clear the reason why the trouble occurred.
Take appropriate corrective measures so that
consequent malfunction will not occur after repair-
ing.
T107-07-01-007
T5-1-3
Dr.EX OPERATION
Dr.Ex is a diagnosing tool to be used for checking the

electronic system including the MC on the machine.
When Dr.EX is connected to the MC, malfunction

records in the MC and/or each sensor are indicated as
fault codes on the Dr.EX display. (Self-Diagnosing
Function)
Input signals from the sensors or switches that are

connected to the MC, or output signals from the MC to
actuators, such as solenoid valves, can be monitored T197-05-01-001
on a real-time basis while the machine is being Dr.EX Connector (MC) Dr.EX Connector
operated. (Monitor Function) (Auto-MARCCINO
Control Unit
Operation
IMPORTANT: Only this connecting harness can be Start

used to connect the Dr.EX to the
controller. Do not use any other har-
ness to connect Dr.EX to the control-
ler. Initial Screen
1. Connect Dr.EX’s harness to the diagnostic

connector in the cab.
2. Turn the key switch ON or start the engine. Communication Model Code
Failure Confirmation
3. Turn Dr.EX ON. The following screens will
successively appear on Dr.EX’s display. ・ Check
3-1. Initial Screen communication
harness NOT OK
3-2. Model Code Screen OK ?
・ Check fuse
Example:
Model : EX75UR-5 OK Replace
Ver : 0100 Dr.EX Soft-
3-3. Function Selection Screen
F1:Self-Diagnosing Results
F2:Monitor Data Self- Monitor Special
F3:Special Functions Diagnosing Data Functions
Function
Selection
4. Select key F1. Then, proceed according to the in-
structions shown at the bottom of the screen.
Controller Record Monitor Data
Self-Diagnosing
NOTE: Refer to the Dr.EX Operator’s Manual for Results
Selection
detailed operation procedures.
Monitored Data
Retrial B Screen
Self-Diagnosing
Results
T5-1-4
MAIN CONTROLLER FAULT CODE LIST
Fault Code Trouble Corrective Action

1) Check harness
01 Abnormal EC angle sensor
2) Replace EC sensor
1) Check harness
07 Abnormal engine control dial angle sensor
2) Replace engine control sensor
T5-1-5
AUTO-MARCCINO CONTROL UNIT FAULT
CODE LIST (EX75UR-5)
Fault Code
System
System Buzzer Sound Cause of Trouble
Dr. EX Indicator
Monitor
Continuously
03 E03 ON Abnormal RAM in CPU
sounds
05 − − ON Faulty monitor communication
06 − − ON Abnormal metering correction value

Continuously
07 E07 ON Abnormal front angle sensor calibration value
sounds
Continuously
08 E08 ON Abnormal code setting
sounds
09 − − − Abnormal monitor setting value
11 E11 Abnormal arm roll-out function
12 E12 Continuously Abnormal right offset function
ON
13 E13 sounds Abnormal left offset function
17 E17 Abnormal boom raise function
14 − − Abnormal arm roll-out acceleration pilot pressure sensor
15 − − Abnormal right offset acceleration pilot pressure sensor
16 − − Abnormal left offset acceleration pilot pressure sensor
19 − − Abnormal boom raise acceleration pilot pressure sensor
ON
20 − − Abnormal boom raise pilot pressure sensor
21 − − Abnormal boom lower pilot pressure sensor
22 − − Abnormal arm roll-in pilot pressure sensor
24 − − Abnormal 5 spool side pump pressure sensor
Long beep
40 E40 Faulty 9 spool-solenoid valve unit (boom raise deceleration)
sounds ON
41 E41 Faulty 9 spool-solenoid valve unit (arm roll-in deceleration)
intermittently
43 − − Faulty 9 spool-solenoid valve unit (right offset acceleration)
45 − − Faulty 9 spool-solenoid valve unit (arm roll-out acceleration)
ON
47 − − Faulty 9 spool-solenoid valve unit (left offset acceleration)
48 − − Faulty 9 spool-solenoid valve unit (boom raise acceleration)
50 E50 Abnormal boom angle sensor
51 E51 Abnormal arm angle sensor
52 E52 Abnormal offset angle sensor
53 E53 Abnormal slide arm sensor
80 E80 Boom angle sensor deviation
Continuously ON Arm angle sensor deviation
81 E81
sounds Offset angle sensor deviation
82 E82
83 E83 Slide arm sensor deviation
NOTE: *Unless the solenoid valve has failed, boom NOTE: If two or more trouble occurs at the same
raise operation is correctly controlled in the time, the system monitor displays the fault
range lower than boom foot pin height. code for the lower group number only.
T5-1-6
Trouble on the Machine Corrective Action Group
1) Replace the controller if the ma-

* Movement to the cab stops. G1
chine does not operate correctly.
1) Check harness.
− 2) Replace the controller. G4
3) Replace the system monitor.
1) Abnormal metering correction
Depth limit control stops G4
value.
* Movement to the cab stops. 1) Replace the controller if the ma-
G1
1) Input the front and bucket codes
again.
− −
1) Check harness.
2) Replace the pilot pressure sen-
All movement stops.(No pilot pressure) G0
sor.
3) Replace the solenoid valve.
Cab collison prevention control stops. 1) Check harness.
Offset movement by offset switch stops. 2) Replace pilot pressure sensor.
Offset movement by offset switch stops.
Depth limit control stops
G4
Cab collison prevention control stops, depth limit control stops
Cab collison prevention control stops.
Arm oil flow combining control stops.
Boom raise movement stops. 1) Check harness.
Arm roll-out movement stops. 2) Replace the solenoid valve. G3
Offset movement by offset switch stops. 1) Check harness.

Cab collison prevention control stops. 2) Replace the solenoid valve.
G4
Depth limit control stops.
* Interference prevention control system functions as if boom 1) Check harness.
is raised to the highest position. Interference prevention con- 2) Replace the angle sensor.
trol system functions as if arm is fully rolled in. Interference
prevention control system functions as if the front attachment
is fully offset to the left side. Interference prevention control
system functions as if slide arm is fully extension. Interference
prevention control system functions as if boom is raised to the G2
highest position. Interference prevention control system func-
tions as if arm is fully rolled in. Interference prevention control
system functions as if the front attachment is fully offset to the
left side. Interference prevention control system functions as if
slide arm is fully extension.
T5-1-7
Fault Code
System
Dr. EX Indicator
Monitor
60 E60 Faulty boom angle sensor initial setting.
61 E61 Continuously Faulty arm angle sensor initial setting.
ON
62 E62 sounds Faulty offset angle sensor initial setting.
63 E63 Faulty slide arm sensor initial setting.
Faulty hydraulic oil temperature sensor.
90 − − ON
Continuously Abnormal sensor power source.
91 E91 ON
sounds
Complete angle sensor initial setting.
F0 − − −
Continuously Invasion of hazardous area by emergency evacuation switch.
F2 − −
sounds
Escape out of hazardous area.
F3 − − −
Short beep Invasion of hazardous area by interference prevention mode.
F4 E00 sounds ON
intermittently
T5-1-8
1) Initialize the angle sensor again.

2) Replace the angle sensor
Interference prevention control system functions 1) Check harness.

G4
as if oil temperature is lowest. 2) Replace the hydraulic oil temperature sensor.
Depth limit control stops 1) Initialize the angle sensor again.
G1
Cab collison control stops. 2) Replace the angle sensor.
* Movement to the cab stops.
G5
− G7
− G8
T5-1-9
MAIN CONTROLLER MONITORING FUNC-
TION
Dr.EX has a function to monitor the command signals

from the MC and the input signals (to MC) from various
switches and sensors.
Monitor Item Descriptions Unit

Target engine speed Command signal value to EC motor rpm
EC angle Input from EC sensor V
Dial angle Input from engine speed control dial V
Accelerator angle Input from engine speed control sensor V
E mode switch ON/OFF signal from E mode switch *EP
Auto-idle switch ON/OFF signal from auto-idle switch *AI
Pressure switch ON/OFF signal from all pressure switches *Fr, Tr
Key switch ON/OFF signal from key switch *Ky
Engine learning control * Successful, EC
failed, Ky failed
Pump control solenoid valve ON/OFF signal from pump control solenoid ON, OFF
output valve
Travel mode pressure ON/OFF signal from pump control solenoid ON, OFF
valve
EC motor position step
NOTE: * White letters (or figures) are shown on the

black screen when the switches are ON
(connected).
T5-1-10
AUTO-MARCCINO CONTROL UNIT MONI-
TORING FUNCTION (EX75UR-5)
Dr.EX has a function to monitor the command signals

from the Auto-MARCCINO Control Unit and input sig-
nals from various switches and sensors.
Data Unit Data Unit

Boom angle sensor voltage V ON/OFF signal from slide arm extended sole- Dsd
Arm angle sensor voltage V noid valve
Offset angle sensor voltage V ON/OFF signal from slide arm solenoid valve Dss
Slide arm sensor voltage V ON/OFF signal from right offset solenoid valve Dor
Oil temperature ºC Boom angle sensor correction value V
Boom raise deceleration solenoid valve current mA Arm angle sensor calibration value V
Boom lower deceleration solenoid valve current mA Offset angle sensor calibration value V
Arm roll-in deceleration solenoid valve current mA Slide Arm angle sensor calibration value V
Arm roll-out deceleration solenoid valve current mA Boom angle sensor standard value V
Left offset deceleration solenoid valve current mA Arm angle sensor standard value V
Boom raise acceleration solenoid valve current mA Offset angle sensor standard value V
Arm roll-out acceleration solenoid mA Slide Arm angle sensor standard value V
Left offset deceleration solenoid valve current mA Monitored height m
Right offset deceleration solenoid valve current mA monitored reach m
Arm oil flow combining solenoid valve mA Monitored offset amount m
Boom raise pilot pressure MPa NOTE: * White letters (or figures) are shown on the
Boom raise acceleration pilot pressure MPa black screen when the switches are ON
Boom lower pilot pressure MPa (connected).
Arm roll-in pilot pressure MPa
Arm roll-out pilot pressure MPa
Right offset acceleration pilot pressure MPa
Left offset acceleration pilot pressure MPa
5-spool side pump delivery pressure MPa
ON/OFF signal from right offset switch Sor *
ON/OFF signal from left offset switch Sor *
ON/OFF signal from range limit release switch Sav *
ON/OFF signal from interference prevention Sin *
mode switch
ON/OFF signal from emergency evacuation Spr *
switch
ON/OFF signal from initial setting switch Scl *
ON/OFF signal from service switch Ssv *
ON/OFF signal from range limit release switch Slm *
Buzzer Output Dbz *
Lock/Unlock signal of pilot pressure Dpi *
T5-1-11
Dr.EX SPECIAL FUNCTION (Service Mode)
(EX75UR-5)
When the optional front attachment or bucket is used,

the bucket may contact with the cab depending on the
size and shape of the bucket. To prevent contact, in-
putting the size of the optional front attachment or
bucket into the Auto-MARCCINO Control Unit is re-
quired.
Procedures
1. Turn the key switch to the OFF position and wait
for 10 seconds. Then, connect Dr.EX to the Auto-
MARCCINO Control Unit.
2. Connect the service switch (plug type).
3. Start the engine.
4. Select the service mode on Dr.EX to input the
front and bucket data.
5. When using the optional front attachment, per-
form the initial setting of the angle sensor (when
using the optional bucket, this step is not re-
quired).
6. After completing the data input, stop the engine T197-05-01-001
and disconnect the service switch (plug type). Dr.EX Connector

(Auto-MARCCINO
Then, start the engine again. Control Unit)
7. Confirm that the interference prevention device
and Auto-MARCCINO Control correctly operate.
Left Console
NOTE: After completing the data input in the serv-
ice mode, be sure to disconnect the service
switch. Failure to do so may cause the fol-
lowing trouble to occur: Service Switch (Plug)
• Self-diagnosing by Dr.EX doesn’t operate.

• Fault codes are not stored in the Auto-
MARCCINO Control Unit memory.
• Initial setting of the angle sensor cannot be made.
• The switches in the system monitor (limiting range,
indicating distance) becomes inoperative.
T197-02-01-009
T5-1-12
Dr. EX Operation Procedure
Start
Start-Up Screen
Machine Model Menu
Select the displayed No. for the ”Medium Size UR.”
Program Version Confirmation
Execute (F1) after confirming.
EX
HITACHI
Dr.
(C) Hitachi Construction
UR V1.00
Machinery Co., Ltd. 1996

F1: Start F10: Machine Model Menu
F1
Front Attachment Compatibility
Base Machine and Front Attachment:
EX75UR-5, STD Front Attachment
Bucket:
EX75UR-5 STD
C/V Program Version: 01.00
F1: Next F10: Exit
F1
Select operation mode.
F5: Self-Diagnostic Result Screen

F6: Monitor Screen
F7: Service Mode
F5: Exit
F1 F2 F3
1 To T5-1-14 2 To T5-1-15 3 To T5-1-16
T5-1-13
Self-Diagnostic Result Screen
1 From T5-1-13
Trouble exists. No trouble exists.
Following fault codes are detected by No trouble exists or trouble beyond

self-diagnostic function. the scope of Dr. EX. Check by moni-
41 2 3 4 5 6 tor function hereafter referring to
789 troubleshooting manual.
F1: Details F2: Retrial F10: Exit F10: Exit
F1 F2
Fault Code: 41 Retrial successful.

Slow Arm Roll-in Speed
Abnormal Proportional Valve Self-diagnostic function will operate
Output again when key F1 is pushed.
F3: Next F10: Exit F1:Self Diagnostic Operation

F1
Trouble exists. No trouble exists.
T5-1-14
Monitor Screen
2 From T5-1-13
F2
Select data to be monitored.

F5: Boom Angle Sensor Voltage NOTE: Refer to the table on
F6: Arm Angle Sensor Voltage page T5-1-11 in the
F7: Offset Angle Sensor Voltage Monitor Function Group
F8: Slide Arm Sensor Voltage for the monitor data
F9: Hydraulic Oil Temperature items.
F1: START
F2: CLEAR ( Selected Data No.: 0)
F3: NEXT↓ F10: EXIT.
Touch F1 after selecting the item to be monitored.
Boom Angle Voltage V
Arm Angle Voltage V
Offset Angle Voltage V
F1: FREEZE F5:PREV.

F5
T5-1-15
Service Mode
From T5-1-13, T5-1-
3 19, T5-1-17
Example:
Select Functions Changing bucket code
F5: Setting Front Codes, etc. F5

F6: Correcting Target Digging Range 4
F7:
To T5-1-17
F3: ↓ F5: Exit
F3
Select Functions
F5: Boom Metering Adjustment

F6: Arm Metering Adjustment
F7:
F3: ↓ F4:↑ F5: Exit
F3
Select Functions
F5: Auto Adjustment of Level Crowd
Operation (For Standard Monitor)
F6: Auto Adjustment of Level Crowd
Operation (For Optional Monitor) Select Functions
F7: F5: Changing Boom Raise Metering
F3: ↓ F4:↑ F5: Exit Value
F6: Changing Boom Lower Metering
F3 Value
F7: Changing Arm Roll-in Metering
Value
F3 ↓ F5: Exit
F3
Select Functions
F5: Changing Arm Dump Metering
Value
F6: Changing Target Digging Range
Correction Value
F7:
F4:↑ F5: Exit
T5-1-16
4 From T5-1-16, 19
SW2 Current Data Setting

Base Machine: EX75UR-5
Front Attachment: (000)
STD Front Attachment
Bucket: (000)
STD Front Attachment
F1: SETTING (Table)
F2: SETTING (Input)
F5: EXIT
Use when inputting the code No.
F1 F2
Front Code Setting Front Code Setting

Select front attachment code. Select front attachment code.
Code 00: STD Front Attachment Code ( ) :
Refer to the Front

Attachment Code Table.
Touch F1 to change
F1: NEXT the code No.
F3: SELECT F10: EXIT ENT: End of Input
F3 Touch ENT
after inputting.
Bucket Code Setting Front Code Setting

Select bucket code. Select front attachment code.
Code 00: STD Bucket Code (00): STD Front Attachment
Touch F1 to change
the code No.
F1: NEXT In case “255” special
bucket is selected,
F3: SELECT F10: EXIT refer to 7 on page
F3: SELECT F10: EXIT
T5-1-19.
F3 F3
5 To T5-1-18 6 To T5-1-18
Front Attachment Code Table Bucket Code Table

Code No. Variation of Front
Code No. Bucket Variation
Attachment
00 STD Front 00 0.25 (STD)
Attachment 01 0.20
01 Long Arm 02 0.25 (Level finishing plate)
03 Extention Arm 03 0.10
04 Slope-Finishing Blade
05 Slope-Finishing Blade
255 Special Bucket
T5-1-17
6 From T5-1-17
Bucket Code Setting

Select bucket code.
Code ( ):
Refer to the Bucket
Code Table.
In case “255” special
bucket is selected,
refer to 7 on page
T5-1-19.
ENT: END OF INPUT

Touch ENT after
inputting the code.
Bucket Code Setting

Select bucket code.
4 Code ( 0): STD Bucket
F5
F3: SELECT F10: EXIT
From T5-1-17,
T5-1-19
5
F3
Front Attachment/Bucket Code

Do you want to store the front at-
tachment/bucket code data ?
Base Machine:
Front Attachment: (Code: 000)
The display is
STD Front Attachment different according
Bucket: (Code: 000) to the set-code.
STD Bucket
F1: STORE F10: Exit
F1
Successful Failed
Bucket Switch Setting

To T5-1-17 7
Front attachment/Bucket code set- To T5-1-16 F1
ting has been completed. Transaction in controller failed.
3
F10 F10
F10: EXIT F1: RETRY F5: EXIT
T5-1-18
7 From T5-1-18
Setting Bucket Code

Check for special bucket
dimensions
F1
Bucket Arc : mm
4 Bucket Width : mm
To T5-1-17 F10
F1: OK
F3: NG F10: EXIT
F3
Setting Bucket Code

Check for special bucket
dimensions
Bucket Arc : mm
Bucket Width : mm
ENT: End of Input
Touch ENT after inputting.
Setting Bucket Code

Are special bucket dimensions
stored?
Bucket Arc : mm
5 Bucket Width : mm 4
To T5-1-18 F3 Initial Voltage : . V F10 T5-1-17
F1: Yes
F3: NO F10: EXIT
F1
Successful Failed
To T5-1-17 4
Setting Bucket Code
F1
To T5-1-16 3
Special bucket dimensions Transaction in
are stored. F1 F10 controlled failed.
5
F1: NEXT To T5-1-18 F1: RETRY F10: EXIT
T5-1-19
(Blank)
T5-1-20
TROUBLESHOOTING / Component Layout
MAIN COMPONENTS 2

EX75UR-5. 1
EX75UR-5 2
M197-01-023
EX75US-5
29 4
5
6
7
8
9
10
11
28 12
13
27
26
25
24
23
22
21
20
19 14
18
15, 16
17
T197-01-01-001
1- Bucket Cylinder 9- Fuel Tank 16 - Oil Cooler 23 - Pilot Shut-Off Valve
2- Arm Cylinder 10 - Hydraulic Oil Tank 17 - Swing Device 24 - Blade Pilot Valve*
3- Boom Cylinder 11 - Engine 18 - Center Joint 25 - Travel Pilot Valve
4- Pilot Filter 12 - Pump Device 19 - Swing Bearing 26 - Offset Pilot Valve*
5- Control Valve 1 13 - Auto Air Bleed Solenoid 20 - Shockless Valve 27 - Offset Pilot Valve
Valve
6 - Solenoid Valve Unit 14 - Blade Cylinder 21 - 9-Unit Solenoid Valve* 28 - Offset Anti-Drift Valve*
7 - Shuttle Valve 15 - Radiator 22 - Travel Device 29 - Offset Cylinder*
8 - Control Valve 2
T5-2-1
ELECTRICAL SYSTEM (OVERVIEW)

EX75UR-5.
EX75UR-5
M197-01-023
1 EX75US-5
4
5
6 View A
7
8
9
10
11
30
12
13
29 14
28
27
26
25
24
23 15, 16
22 17
21
18
20 19
T197-01-01-002
1 - Arm Angle Sensor* 9 - Horn 17 - Alternator 24 - Battery Relay
2 - Offset Angle Sensor* 10 - EC Motor and EC Sensor 18 - Air Cleaner Restriction 25 - 9-Unit Solenoid Valve*
Switch
3 - Work Light 11 - Pump Delivery Pressure 19 - Diode D2, D3, D4, D5, and 26 - Travel Mode Switch
Sensor D20
4 - Diode D6, D7, D8, D9, 12 - Pump Control Solenoid Valve 20 - Diode D12, D13, D14, D15, 27 - Auto-MARCCINO Control
and D10* and D16* Unit*
5 - Diode D21 13 - Starter 21 - Battery 28 - Fuse Box
6 - Boom Angle Sensor* 14 - Auto Air Bleed Solenoid Valve 22 - Glow Plug Relay 29 - MC (Main Controller)
7 - Solenoid Valve Unit 15 - Coolant Temperature Sensor 23 - Starter Relay 30 - System Monitor*
8 - Fuel Sensor 16 - Overheat Switch
T5-2-2

EX75UR-5.
• View A • 9-Unit Solenoid Valve*
27 Front
34
7 33
28
49 35
29
48
30 36
47
31 46 Outside
Inside Base Base
Machine Machine
45 37
32 44
38
T197-01-02-003
43
39
• Relays 42
41
Rear 40 T197-01-02-007
• View B
50
51
52 56
53
View B
22 54
55
T197-01-02-005
50 51 52 53 54 55
T197-01-02-004
27 - Pressure Switch (Travel) 35 - Arm Roll-In Deceleration 43 - Boom Raise Acceleration 50 - Buzzer*
28 - Emergency Stop Solenoid 36 - Arm Roll-Out Deceleration 44 - Right Offset Acceleration Pilot 51 - Horn Relay
Valve* Solenoid Valve* Pressure Sensor*
29 - Arm Oil Flow Combining 37 - Left Offset Deceleration 45 - Right Offset Acceleration 52 - Wiper Relay
Solenoid Valve* Solenoid Valve* Solenoid Valve*
30 - Travel Mode Solenoid Valve 38 - Boom Lower Deceleration 46 - Left Offset Acceleration 53 - Washer Relay
31 - Pilot Relief Valve 39 - Boom Raise Deceleration 47 - Left Offset Acceleration Pilot 54 - Load Damp Relay
Solenoid Valve* Pressure Sensor*
32 - Pressure Switch 40 - Boom Raise Pilot Pressure 48 - Arm Roll-Out Acceleration 55 - Work Light Relay
(Front Attachment/Swing) Sensor* Solenoid Valve*
33 - Arm Roll-In Pilot Pressure 41 - Boom Lower Pilot Pressure 49 - Arm Roll-Out Acceleration 56 - Fuel Pump Relay
Sensor* Sensor* Pilot Pressure Sensor*
34 - Oil Temperature Sensor* 42 - Boom Raise Acceleration
Pilot Pressure Sensor*
T5-2-3
ELECTRICAL SYSTEM
(Monitor and Switches)

EX75UR-5.
××××
1 2 3 4 5 6
M197-01-015
7 8 9 10 11 12
M197-01-006
15 14 13
M197-01-017
System Monitor
16 17
19
×××× ××××
20
21
×× ××
×××
22
18 M197-03-003
M197-05-029
T5-2-4
Seat Rear Side Seat Left-Rear Side
24
M197-01-001
T191-02-02-001
23
1 - Auto-Idle Switch 7 - Alternator Indicator 13 - Hour Meter 19 - LCD Monitor*

2 - E Mode Switch 8 - Engine Oil Pressure 14 - Fuel Gauge 20 - System Malfunction
Indicator Indicator*
3 - Work Light Switch 9 - Preheat Indicator 15 - Coolant Temperature Gauge 21 - Depth Restriction
Switch*
4 - Buzzer Deactivation Switch 10 - Overheat Indicator 16 - Left Offset Switch* 22 - Depth-Set Dial*
5 - Wiper Switch 11 - Air Filter Restriction 17 - Right Offset Switch* 23 - Fuse Box
Indicator
6 - Auto-MARCCINO Mode 12 - Fuel Level Indicator 18 - Depth Restriction 24 - Emergency Evacuation
Switch* Deactivation Switch* Switch*
T5-2-5
PUMP DEVICE 3
SWING DEVICE
6
2
4 8
1
7
5
T197-01-02-006
T152-01-02-003
TRAVEL DEVICE
10 T192-01-02-003
1 - Main Pump (1 and 2) 4 - Pump Control Solenoid Valve 7 - Parking Brake Switch Valve 9 - Counter Balance Valve
2 - Main Pump 3 5 - Delivery Pressure Sensor 8 - Swing Relief Valve 10 - Travel Relief Valve
3 - Pilot Pump 6 - Make-Up Valve
T5-2-6
(Blank)
T5-2-7
COMPONENT IN CONTROL VALVE
Control Valve 1
1 2 3 4 5 6
23
22 7
21
9
10
20
19 11
18
17 12
13
16 15 14
T197-03-03-010
Circuit)
4 - Check Valve (Bucket Flow 10 - Boom Anti-Drift Valve 16 - Check Valve 22 - Check Valve (Left Travel
Combining Circuit) (Check Valve) (Auxiliary Parallel Circuit) Parallel Circuit)
T5-2-8
1 10
Cross Section A
12
21
19 1
21
19
T197-03-03-001
Cross Section G
T152-03-03-003
Cross Section F
Cross Section E
Cross Section C
Cross Section D
Cross Section C
Cross Section B
Cross Section A
T197-03-03-002
2 View 3
Cross Section B
22, 23
6 5
T197-03-03-004
T152-03-03-004
T5-2-9
• Control Valve 1
1 2 3 4 5 6
23
22 7
21
9
10
20
19 11
18
17 12
13
16 15 14
T197-03-03-010
Circuit)
4 - Check Valve (Bucket Flow 10 - Boom Anti-Drift Valve 16 - Check Valve (Auxiliary 22 - Check Valve (Left
Combining Circuit) (Check Valve) Parallel Circuit) Travel Parallel Circuit)
T5-2-10
Cross Section D Cross Section E
10
21
8
11
7 20
8 21 12
T197-03-03-003 T152-03-03-006
Cross Section F Cross Section G
19
12
14
16
17
13 18
15
19 T152-03-03-009
T152-03-03-008
T5-2-11
• Control Valve 2
Only EX75UR-5
24 25
26 27 28
Pilot Pump
Main Pump 3 T197-03-03-011
24 - Main Relief Valve 26 - Load Check Valve 27 - Load Check Valve 28 - Load Check Valve
(Control Valve 2) (Blade) (Swing Parallel Circuit) (Only EX75UR-5)
(Arm 3 Tandem Circuit)
25 - Overload Relief Valve
(Blade)
Cross Section A
Cross 24
Cross Section D
Cross Section B (Only EX75UR-5 )
Cross
Section A
Section C
T197-03-03-005
T196-03-03-008
T5-2-12
Cross Section B 25 Cross Section C
26
27
25
T197-03-03-007
T196-03-03-009
Cross Section D (Only EX75UR-5) Cross Section E
Cross Section E
T197-03-03-008
T197-03-03-006
T5-2-13
(Blank)
T5-2-14
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Use troubleshooting A procedure when fault codes are

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

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

Open End
Side
Harness End Connector
T158-05-03-001
T5-3-1
FAULT CODE 01 (ABNORMAL EC SEN-
SOR)
Check if the harness NO

Faulty MC.
between terminal
YES No.15 on MC ・ Refer to page T4-6-1.
connector D and
Disconnect EC sensor terminal No.2 on EC
connector, check if sensor is broken or MC と EC
Faulty センサ間
harness
Disconnect EC sensor
short-circuited.
connector, check if YES voltage between のハーネス不良
between MC and
resistance between terminal No.1 and No.3 YES EC sensor.
terminal No.1 and No.3 on the harness
on the sensor connector connector is within the
is within the range of 2.0 range of 5 ± 0.5 V. Faulty harness
± 0.4 kΩ. In addition, ・ Key switch: ON between MC and
attach test harness NO EC sensor.
(ST7129) to EC sensor.
While turning engine
control dial, check if Faulty EC sensor.
voltage meets the NO
standard values.
・ Standard values: Refer to
page T5-3-4.
Connector (Harness End Connector Viewed from the Open End Side.)
MC Connector D EC Sensor Connector
1 2 5 6 8 9 10 11 1 2 3
12 13 15 20 21 22
T5-3-2
FAULT CODE 07 (ABNORMAL ENGINE
CONTROL DIAL ANGLE)
Check harness Faulty harness

YES
between MC between MC and
connector D harness engine control dial
YES terminal #D21 and
engine control dial
terminal #S for
Disconnect engine breakage or short Faulty MC
control dial. Check if circuit. NO
・ Refer to T4-6-1.
YES voltage between
harness connector Broken harness
Disconnect engine control
terminals plus and YES between MC and
dial. Check if resistance Check if voltage
minus is 5±0.5 V. engine control dial
between plus and minus between harness
terminals on the sensor (terminal minus).
・ Key switch: ON end connector
connector is 5±0.5 kΩ. terminal plus and
Reconnect engine control NO Broken harness
vehicle frame
dial. Insert tester probe between MC and
matches
into connector from the NO engine control dial
specification.
reverse side. Check if (terminal minus).
voltage varies as ・ Key switch: ON
specified when engine ・ Specification: 5±1.5 V
control dial is turned. Faulty engine control
・ Specification: Refer to NO dial
T4-2-5.
Connector (Harness End Connector Viewed from the Open End Side.)
MC Connector D Engine Control Dial Engine Control Sensor Connector
1 2 5 6 8 9 10 11 1 2 3
+ S -
12 13 15 20 21 22
T5-3-3
(Blank)
T5-3-4
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Use troubleshooting B when no fault code is displayed

on Dr. EX although machine operation is abnormal.
On the front section pages of this group (T5-4), are

tables indicating the relashionship between machine
symptoms and related parts which may cause such
trouble if failed. Start diagnosing after focusing on
possible causes refering to these tables.
YES (OK)
(2)
After checking or measuring in step (1), select either YES(OK) or
・ (1) NO(NOT OK) depending on the result obtained in step (1) and
proceed to step (2) or (3).
(3)
NO
(NOT OK)
・ Special instructions or reference items may be indicated under the box. Incorrect
measuring or checking methods will not only render troubleshooting impossible but may
damage components.
・ Use Dr.EX for steps shown in double line boxes.

· Key switch: ON
・ Causes are described in a thick-line box. Scanning the descriptions in thick-line boxes wiil
indicate suspected sections and possible causes.
Explanation of how to use lampharness kit required.

・ Refer to “Electrical System Inspection (Group 7)” in this section.
T5-4-1
RELATIONSHIP BETWEEN MACHINE
SYMPTOMS AND PROBLEM PARTS
This table indicates the probable machine symptoms

caused by part failures and procedures to determine if
the part has failed.
Part Name
EC Motor EC Sensor Engine Control Dial
・To operate governor lever. ・To detect the slow-idle speed gov- ・To instruct MC (Main Control-
ernor lever position (2.5 V). ler) the engine target speed
Part function ・(The governor lever position is not position.
detected through the stroke.)
・Governor lever does not move. ・Governor lever position is de- ・Even if engine control dial is
signed to learn as the slow-idle operated, engine speed is un-
Control System Status speed position whenever key changed.
When Trouble Oc- switch is turned ON. Accordingly, ・If harness to engine control dial
once discrepancy occurs, the en- is broken, target speed 1600
curs. gine continues to run with discrep- min-1 is used as the backup
ancy. value.
・Even if engine control dial is ・If the discrepancy occurred to the ・Engine speed is constantly
operated, engine speed does not slower side, engine speed is held at 1600 min-1 .
increase from slow speed range. changed by engine control dial. (Auto-idle function operates,
・Starter rotates but engine fails to However, engine speed control and engine can be stopped by
start occasionally. range stays slower than normal. turning key switch.)
(Note: If the discrepancy occurred
・While engine is running at a
to the faster side, when engine
faster than specific speed, if
control dial is turned to the fastest
harness to EC motor is broken,
Machine Symptom position, EC motor continues mov-
engine stalls.
ing. However, EC motor is a worm
When Trouble Oc- ・While engine is running at a gear type so that governor lever is
slower than specific speed, if kept holding at the full stroke posi-
curs. harness to EC motor is broken, tion. If engine control dial is turned
engine becomes uncontrollable. to the slowest position, governor
Engine does not stop even if key lever returns to the slow idle posi-
switch is turned OFF. tion.)
・When engine is started, engine
speed fluctuates.
・Engine start may become difficult.
By Dr.EX Self- Fault code 01 is displayed. Fault code 07 is displayed.

Diagnosing ―
Function
Monitor Item: EC Angle Monitor Item: Dial Angle
By Dr.EX
Trouble Monitor ―
Function
shooting
Proce-
・ Install lamp harness (ST7125).
dures By Lamp
Then, check output signal from
Harness ― ―
EC and check if harness is nor-
Check
mal.
By Other
Check/ ― ― ―
Measurements
・Engine is stopped by the EC mo-・If the EC sensor fails, engine learn-
tor. ing does not operate.
Note Engine stop solenoid is not pro- ―
vided. However, a fuel cutoff ca-
ble is installed.
Descriptions of Con- T2-1 T2-1 T2-1

trol (Operational
Principle Section in
T/M)
T5-4-2
Pressure
Pressure Switch(Travel) Switch(Front/Swing) Travel Mode Switch Learning Plug Connector
・To detect that travel spool is ・To detect that front and/or ・Controls travel motor dis- ・To start learning engine control.
operated(for auto-idle and pump swing spool is operated(for placement angle control pres-
flow control) auto-idle and pump flow con- sure. ON : 0 V→Learning
trol) OFF : 5 V→Normal Control
・No signal is sent to MC. ・No signal is sent to MC. ・No signal is sent to MC. ・Engine learning function does
not operate.
・Engine speed does not increase ・Even if front and/or swing ・Travel speed does not change, ・If problem is caused by broken
when traveling with auto-idle control lever is operated with when travel mode switch is harness, only engine learning
switch ON. auto-idle switch ON, engine operated. function fails. (Engine control
・Travel function speed is slow. speed does not increase. system operates normally.)
・Front and swing function speed ・If problem is caused by short
are slow. circuit, learning mode starts to
operate when key switch is
turned ON. Therefore, engine
may stall 5 seconds after engine
starts.
― ― ― ―
Monitor Item: Pressure Switch Monitor Item: Pressure Switch Monitor Item: Travel Motor Con- Monitor Item: Engine Learning
While traveling, monitor if pres- While operating front/swing trol Pressure Operation
sure switch is turned ON or OFF. function, monitor if pressure Operate travel mode switch
switch is turned ON or OFF. while monitoring control pres-
sure.
― ― ― ―
・If travel mode switch is normal,

― ― ―
solenoid valve is faulty.
・It is possible to ckeck if pres- ・It is possible to ckeck if pres-
sure switch has failed or if the sure switch has failed or if the
port is clogged by switching port is clogged by switching ― ―
pressure switch with an adja- pressure switch with an adja-
cent one (for front/swing). cent one (for travel).
T2-1 T2-1 T2-1 T2-1
T5-4-3
Part Name
MC(Main Controller) Flow Combiner Valve E Mode Switch
・To control engine and pump. ・ To supply hydraulic oil to both ・To select E mode.
right and left travel spools from the
Part Function rear port of pump when combined ON : 0 V→E Mode
operation of travel and front/swing
OFF : 5 V→Standard Mode
is made.
・Problems may differ. ・When the combined operation of ―
(The following machine symp- travel and front/swing is made, hy-
toms signify that the logic circuit draulic oil is not routed to the left
Control System Status in MC has failed.) travel spool, or oil flow to the left
When Trouble Occurs. travel spool is insufficient.
・EC motor does not rotate to the ・While traveling straight, when ・Broken Wire:Engine runs at full
start position even if key switch swing lever is operated, machine speed even if E mode switch is
is turned ON. Thereby, engine mistracks. depressed.
does not start. Even if engine
・Short Circuit: Engine speed does not
starts, engine speed does not
increase to full speed.
increase.
Machine Symptom
When Trouble Occurs
By Dr.EX Self- Procedures may differ depending

―
Diagnosing on the location of the failure. ―
Function
Monitor Item: E Mode Switch
By Dr.EX
Troubles Monitor ― ―
Function
hooting
Proce- By Lamp ―
dures Harness ― ―
Check
By Other
―
Check/ ― ―
Measurement
・Before suspecting a failure in ―
MC, check the fuses in this con-
Note trol circuit. ―
Descriptions of T2-2, T3-3 T2-1

Control (Operational
Principle Section in ―
T/M)
T5-4-4
Pump Control Solenoid Pump Delivery Pressure Auto Air Bleed Solenoid Travel Mode Solenoid
Valve Sensor Valve Valve
・To control pump swash angle. ・With the key switch ON, the ・With the key switch ON, the air ・Controls travel motor
air cannot be bled automati- is bled automatically from displacement angle control
cally. between fuel tank and engine. pressure.
・Pump swash angle does not ・The arm roll-in load is detected ・With the key switch ON, the air ・If solenoid valve is not operated,
change if solenoid valve does by the pump delivery pressure cannot be bled automatically. motor swash angle is fixed.
not operate. sensor. Therefore, if this sensor
fails, oil flow combining control
by the main pump 3 cannot be
achieved correctly during arm
roll-in.
・Travel speed does not ・Arm roll-in speed is slow or arm ・The engine might not start ・Travel speed does not change.
change. (Travel mode is fro- roll-in power is weak. depending on the air volume.
zen in either fast or slow Manual air bleeding is possible.
mode.)
・Front/swing function speed is
fast or slow.
Fault code 24 is displayed.

― ― ―
Monitor Item: 5-spool side pump Monitor Item:Engine Learning Monitor Item: Travel Motor Con-
pressure. Operation trol Pressure
― Operate travel mode switch
while monitoring control pres-
sure
― ― ― ―
・If travel mode switch is normal,

― ― ― solenoid valve is faulty.
― ―
T2-1 T2-2 T2-1 T2-1
T5-4-5
Part Name 9-Spool Solenoid Valve Emergency Stop Solenoid Arm Oil Flow Combining
(EX75UR-5) Valve (EX75UR-5) Solenoid Valve
・To control pilot pressure to con- ・If front control fails, the emergency ・Actuated by signals from the auto-
trol front function (Automatic stop solenoid valve shuts off the MARCCINO control unit, this
Work Range Restriction, Cab pilot pressure to stop all opera- solenoid valve works to apply the
Part Function collision Prevention, Auto- tions. pilot pressure to the arm 3 spool to
MARCCINO control. combine with the flow from the main
pump 3.
・Front does not move or stop. ・When fault code is not displayed ・If the solenoid valve is stuck, the
(this is normal state), the emer- pressurized oil from the main
gency stop solenoid valve works. pump 3 is not combined with the
Control System Status flow in the arm bottom circuit, or
When Trouble Occurs. flow combining control cannot be
cancelled.
・When work range restriction and ・If this solenoid valve is stuck dur- ・During arm roll-in, arm speed is slow
cab collison prevention control ing its operation, it becomes inop- or arm roll-in power is weak.
deceleration solenoid valve erative. If stuck with the solenoid
spool stuck open causing the valve open, the pilot pressure can-
front function not to stop or de- not be shut off even if front control
celerate. fails.
・Deceleration solenoid valve spool
stuck shut making the front
function immovable.
Machine Symptom ・Acceleration solenoid valve spool
When Trouble Occurs stuck open causing the front
function not to stop.
・Acceleration solenoid valve spool
stuck shut making the front
function immovable.
By Dr.EX Self- Fault code 40, 41, 42, 43, 44, 45,
Diagnosing 47, 48 is displayed (Auto- ― ―
Function MARCCINO system)
Monitor Item: Boom Raise/Boom Monitor Item: Arm
Lower/Arm Roll-In/Arm Roll- 5-Spool Side Pump Pressure
By Dr.EX
Out/Left Offset Deceleration
Troubles Monitor ―
Solenoid Valve. Boom Raise/Right
Function
hooting Offset/Left Offset/Arm Roll-Out
Acceleration Solenoid Valve.
Proce-
dures By Lamp
Harness ― ― ―
Check
By Other
Check/ ― ― ―
Measurement
Note ― ― ―
Descriptions of T2-2
Control (Operational
Principle Section in
T/M)
T5-4-6
Front Angle Sensor

・The position of the bucket is
detected by angle sensors for
the boom, arm and offset; and
the detected data is sent to
the auto-MARCCINO control
unit.
・If one of angle sensors fails,
the auto-MARCCINO control
unit works to input a maximum
value as a data on the failed
angle sensor in order to avoid
interference.
・Part of the front attachment

fitted with a sensor that seems
to be failed does not move to-
ward the cab.
Fault code 50, 51, 52, 53, 80, 81,

82, 83 is displayed (Auto-
MARCCINO system)
Monitor Item:
Boom Angle Sensor Voltate,
Arm Angle Sensor Voltage,
Offset Angle Sensor Voltage
T2-2
T5-4-7
CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
This table indicates the relationship between machine

troubles and parts contributing to the cause of the
trouble if failed.
Engine System Troubleshooting

E-1 E-2 E-3 E-4
Starter doesn’t rotate Although starter ro- Engine runs slower that Even if engine control
Trouble tates, engine doesn’t normal at all operation dial is rotated, engine
Symptom start. speeds. speed remains un-
Slow idle speed is faster or changed.
slower than normal.
Parts
MC(Main Controller) z z z
EC Motor z z
EC Sensor { z
Pressure Sensor
(Front Att./Swing)
Key Switch z z
Engine Control Dial z
Auto-Idle Switch
E Mode Switch
Learning Plug z
Engine Electrical Equipment z z z
Engine Unit z z z
Governor z
Remarks
T5-4-8
NOTE: The trouble symptoms in this table are de-

scribed provided that each trouble occurs
independently.
In case more than one trouble occurs at the
same time, find out all faulty components
while checking all suspected components
in each trouble symptom.
E-5 E-6 E-7 E-8

Even if key switch is Auto-idle system is inop- Even if E mode switch is Engine stalls within
turned OFF, engine erable. depressed, engine several seconds after
doesn’t stop. speed is unchanged. engine has started.
{ { z
{ { {
z
z
{
{
z
z
{ z
Check fuel system for

clogging.
z : Related, required to check

{ : Related. However, in case this component fails, other trouble
symptom will be more noticeable so that this component will not
be the direct cause of the trouble concerned.
T5-4-9
All Actuator/Front Attachment System Troubleshooting

A-1 A-2 F-1 F-2
All actuator speeds are Actuator doesn’t stop All front function are Some cylinder are in-
Trouble slow. even if control lever is weak. operable or speeds are
Symptom returned to neutral. slow.
Parts
MC (Main Controller) {
Auto MARCCINO Control
z { z
Unit *
Emergency Stop Solenoid
z
Valve *
Valve Solenoid *
Pressure Sensor (Front
{ z
Attachment, Swing)
Engine Unit {
Governor {
Main Pump { {
Pilot Pump { z
Pump Control Solenoid
{ {
Valve
Spool z z
Main Relief Valve z z
Overload Relief Valve z
Load Check Valve
Relief Valve Change Valve z
Pilot Valve z z
Pilot Relief Valve z
Shockless Valve z
Cylinder z
9-Spool Solenoid Valve
z z
Unit
Remarks
T5-4-10
F-3 F-4 F-5 F-6 F-7

Front attchment drifts When boom raise or arm Not to control front func- Arm is slow in arm roll- Arm roll-in power is
remarkably. roll-out is operated, tion * in operation. * weak. *
boom or arm starts to
move after slightly mov-
ing downward.
z
z
z z z
z
z z
z
z z
z z
z

NOTE: The trouble symptoms in this table are de- { : Related. However, in case this component fails, other trouble
scribed provided that each trouble occurs symptom will be more noticeable so that this component will not
independently. In case more than one trou- be the direct cause of the trouble concerned.
ble occurs at the same time, find out all *: EX75UR-5 only.
faulty components while checking all sus-
pected components in each trouble symp-
tom.
T5-4-11
Swing/Travel/Blade System Troubleshooting

S-1 T-1 T-2 T-3
Swing is slow or unmov- One side track doesn’t Machine mistracks dur- Travel speed does not
Trouble ing. rotate or rotates slowly. ing travel and front at- change.
Symptom tachment combined
operation.
Parts
Travel Mode Switch z

MC (Main Controller) z
Main Pump
Pump Control Solenoid Valve {
Spool z z
Main Relief Valve
Overload Relief Valve
Load Check Valve z
Flow Combiner Valve z
Swing Device z
Travel Device z z
Center Joint z
Pilot Valve z
Shockless Valve z
Cylinder
Remarks
T5-4-12
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at the
scribed provided that each trouble occurs same time, find out all faulty components
independently. while checking all suspected components
in each trouble symptom.
B-1 B-2 B-3

Blade does not move, Blade drifts remarkably. Engine stalls when blade
weak or its speed is or swing is operated dur-
slow. ing front attachment
opeation.
z z
z
z {
z z
z z

{ : Related. However, in case this component fails, other trouble
symptom will be more noticeable so that this component will not
be the direct cause of the trouble concerned.
T5-4-13
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter does not rotate.
Related Fault Code: None

YES
• Check each voltage by referring to the table be-
low.
• Electronic system such as MC has nothing to do Regardless of key switch posi-
with the trouble obstructing the rotation of starter. tion ON or START, voltage at
terminal B on starter and
starter relay is 0 volts.
With key switch positioned as
YES shown in the table below,
· Key switch:
check if each terminal voltage
ON ⇔ Start
on starter and safety relay is
normal.
Starter Unit (V) With key switch positioned at

START, voltage at terminal C
Key Switch NO on starter relay does not in-
ON START crease to 24 volts.
Terminal
B 24 24 · Key switch: Start
S 0 24
Starter Relay
Check if battery voltage and
electrolyte density are normal. Key Switch
ON START With key switch positioned at
Terminal START, voltages at terminal S
Voltage: 24 volts or more B 24 24 on starter and terminal S on
Density: 1.25 to 1.28
C 0 24 starter relay do not increase to
S 0 24 24 volts.
Starter Relay Connector (Harness End Connector)
Terminal S Terminal C (Yellow) Terminal B (Red)
NO (When key switch is turned to the START position, if voltage at

terminal B is lower than 18 volts, battery may be faulty.)
S
B
T554-07-02-001
T5-4-14
Faulty starter.
YES Faulty harness between bat-

When key switch is turned tery relay and starter.
from the ON position to the
OFF position, check if battery
relay sounds. Check battery relay or diode
NO D2.
· Key switch: ON⇔OFF
YES Faulty harness between fusi-

Voltage at ble link and key switch.
terminal No.1: 0 V Check if fusible link (40A)
is normal (not blown).
Measure each voltage at ter- · Visual check Faulty fusible link.
minal No.1 and No.6 on key NO
switch. Voltage at terminal No.1: 24 V
· Key switch: START Voltage at terminal No.6: 0 V
Faulty key switch.
Voltage at terminal No.1: 24 V

Voltage at terminal No.6: 24 V Faulty harness between key
switch terminal No.6 and
starter relay terminal S.
Faulty starter relay
Diode
D2
Faulty battery
• Key Switch Voltage Check
NOTE: Remove the key switch from the console.

View A
ST G1 ACC
V
A
B G2 M
T105-07-04-002
T5-4-15
E-2 Although starter rotates, engine does not
start.
Related fault Code: None
• Check the governor lever position and the fuel cut

lever position while the engine is cranking. If they
are in normal position, a faulty engine or fuel sys-
tem may be a cause of the trouble.
• After the fuel system becomes empty, refill the
fuel. In case this symptom occurs, air bleed of the
fuel system or auto air bleed solenoid valve may
be faulty.
YES
Faulty engine.
· Refer to Engine Shop Manual.

Check if governor lever moves
to the start position with key
switch ON.
· Key switch: ON Check EC motor drive circuit.
NO
· Refer to to T5-7-14.
• Governor Lever and Fuel Cut Lever
1 2 3 4
T105-07-04-003
1 - Governor Cable (From EC Mo-
tor)
2 - Fuel Cut-Off Cable
(Fuel Cut-Off Handle)
3 - Fuel Cut Lever
4 - Governor Lever
T5-4-16
• Governor Lever Position
A - Key Switch OFF (Engine Stop Position)

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

B - Fuel Cut-Off Handle Returned Position
A
B
T105-07-04-003
T5-4-17
E-3 Engine runs slower than normal at all opera-
tion speeds, slow idle speed is either slower
or faster than normal.
Related Fault Code: 01 (MC System)
Checking Instructions
• Before the engine learning operation is carried out,
or if the engine learning operation is performed in- • Refer to the control group pages titled with
correctly, the engine speed may be slower in all “Engine Learning Control” in the System Section
operation speeds. in the Technical Manual.
• If the EC sensor is faulty, the governor lever posi- • Even if the EC motor control becomes abnormal,
tion which is located when the key switch is turned the governor lever position is constantly kept at
ON, is learned as the idle position. Accordingly, full stroke since the EC motor is a worm gear type.
the engine speed is different from the standard Accordingly, the engine does not stall.
control speed. Further more, this trouble symptom • Check for loose harness connections beforehand.
may not be re-developed as the governor lever
position differs each time when the key switch is
turned ON.
YES Return fuel cut

lever to the original
position.
Check if fuel cut

lever is held at half YES
stroke. Faulty EC sensor.
· Refer to T4-6-1.
Check if fault code

01 is displayed.
NO YES
End.
Check engine op-
eration is normal
after engine learn-
NO ing operation is
conducted. Monitor the en-
gine learning op-
· Refer to Engine NO eration.
Learning Procedures
(T4-6-1). · Monitor item:
Engine learning
control
T5-4-18
YES Faulty engine or

fuel system.
Check if governor
OK lever touches the
stopper when con-
ducting engine Faulty control ca-
learning operation. ble. Incorrect en-
NO gine governor
lever adjustment.
· Refer to Engine
Speed Adjustment
(T4-6-1).
Failure in MC.
Faulty learning
plug, or harness
NOT OK between learning
plug and MC is
broken.
· Refer to T4-6-1.
T5-4-19
E-4 Even if engine control dial is turned, engine
speed is unchanged.
Related Fault Code: 07 (MC System)
Checking Instruction
• Refer to the Control Group pages titled with
“Engine Learning Control” in the System Section
in Technical Manual.
• Check for loose harness connections beforehand.
Faulty engine con-

trol dial (sensor) ,
YES or harness be-
tween engine con-
trol dial (sensor)
and MC is broken.
Check if fault code

07 is displayed.
YES
Faulty EC Motor.
With lamp harness
(ST 7125) connected · Refer to T4-6-1.
to EC motor, check if
lamp comes ON when
NO engine control dial is Faulty MC, or har-
turned. ness between MC
NO and EC motor is
· Refer to T5-7-14. broken.
· Refer to T4-6-1.
T5-4-20
E-5 Even If key switch is turned OFF, engine does
not stop.
(In case the engine does not stop, pull the en-
gine stop handle provided under the seat
stand as a first step. After the engine stops,
check the cause of the trouble.)
Related Fault Codes: 01 and 07
• Trouble symptoms such as “Engine Runs Slower
than Normal at All Operation speeds” or “Engine
Speed is Unchanged Even If engine control dial is
Operated” should be recognized. Conduct the
troubleshooting of them.
E-6 Auto-idle does not function.
Check Instructions
• If E-1 to E-5 trouble symptoms are recognized,
conduct the troubleshooting of them beforehand.
• Refer to the Control System group pages titled
with “Auto-Idle Control” in the System Section in
Faulty pressure switch (travel,
the Technical Manual. front attachment or swing).
• Check for loose harness connections beforehand. Faulty harness between MC
and pressure switch.
NO Pilot signal circuit filter is
clogged.
Monitor pressure switches
(travel, front attachment
YES and swing). Check if indi-
cation of “Tr” or “Fr” is NOTE: Pressure switches
displayed or deleted by (travel and front attach-
operating each control ment ) are provided on
lever. control valve.
Monitor auto-idle · Monitor item:

switch. Check if indi- Pressure switch
cation of “AI” is dis- Faulty MC.
YES
played or deleted by · Refer to T4-6-1.
operating auto-idle
switch.
Faulty auto-idle switch, or
· Monitor item:
harness between auto-idle
Auto-idle switch NO switch and MC is broken.
T5-4-21
E-7 Even If E mode switch is depressed, engine
speed is unchanged .
• If E-1 to E-6 trouble symptoms are recognized,
conduct the troubleshooting of them beforehand.
• Refer to the Control System group pages titled
with “E Mode Control” in the System Section in the
Technical Manual.
Broken E mode
NO switch or harness
between E mode
switch and MC.
Monitor E mode
switch. Check if indi-
cations of “EP” are
displayed or deleted
by operating E mode
switch.
· Monitor item :
E mode switch Faulty MC.
YES
· Refer to T4-6-1.
E-8 Engine stalls several seconds after starting.
• Refer to the Control System Group Pages titled
with “Engine Learning Control” in the System Sec-
tion in the Technical Manual.
• With the engine learning plug connected, engine
stalls five seconds after the engine starts.
YES Disconnect engine

learning plug. End.
Check if engine
learning plug is con-
nected.
Short circuit of
harness between
learning plug and
NO MC, or fuel supply
line is clogged.
T5-4-22
(Blank)
T5-4-23
ALL ACTUATOR SYSTEM TROUBLE-
SHOOTING
A-1 All actuator speeds are slow.
• Swing and blade operations use different control

valve from that of front attachment operation.
Therefore, there is a small possibility to have Faulty pump control sole-
faulty main relief valves of two control valves at YES noid valve or trace cause of
the same time. trouble by checking other
symptoms.
NO Check if primary pilot pres-
sure is normal.
· Refer to the Operational Check if pilot filter is
Performance Test section clogged. C
Check if engine speed is NO
corrected.
· Refer to the Operational Faulty engine.
Performance Test section YES
YES Clogged pilot filter.
C
Faulty pilot relief valve or
pilot pump.
NO
• EX75UR-5
Related Fault Code: 11, 12 13 and 17 (Auto-
MARCCINO Control Unit System)
• Be sure to inspect wiring connections prior to
troubleshooting. NO Faulty emergency
stop solenoid valve.
Check if trouble
symptom is corrected Disconnect auto-
NO
by disconnecting MARCCINO control B
emergency stop so- YES unit connector termi-
lenoid valve. nal #2.
Disconnect emergency Check if circuit be-
A stop relay. Check if tween harness end
circuit between har- connector terminal
YES ness end connector
Check if fault codes #16 and vehicle
are displayed. terminal #1 and vehicle frame has continuity.
frame.
Bound emergency
Check suspected parts refer- NO
stop solenoid valve.
ring to the displayed fault code.
YES
Connector (Harness End Connector Viewed from Short circuit harness

between auto-
the Open End Side) YES MARCCINO control
unit and emergency
Emergency Stop Auto-MARCCINO Control Unit B stop solenoid valve.
Solenoid Valve (Connector Terminal #2)
Faulty auto-
1 2 3 46 5 7 8 MARCCINO control
NO unit.
1 2 9 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 25
T5-4-24
A-2 Actuator doesn’t stop even if control lever is
returned to neutral.
YES
Bound spool in pilot
valve.
Check if actuator stop when · When control lever is in
pilot control shut-off lever is neutral, pilot pressure is
raised (to the LOCK posi- routed to spool end in
tion). control valve.
Bound spool in control
NO valve.
· Although pilot pressure
is not routed to spool
end in control valve,
spool is kept opened
due to binding of spool.
T5-4-25
FRONT ATTACHMENT SYSTEM TROU-
BLESHOOTING
F-1 All front attachment actuator power is weak.

• The faulty main relief valve is suspected if speed
is enough but the power is weak.
The faulty main pump 1, 2 or faulty pump control
system is suspected if speed is extremely slow.
The faulty pilot system is suspected if swing and
blade operations are also slow or the power is
weak.
0 Faulty MC.
Connect pump con-
YES trol solenoid valve
terminal #2 to vehi-
cle frame. Check if
trouble is corrected. Faulty pump control
Approx. solenoid valve.
· Without disconnecting con- 400 mA
YES Check if auto-idle nector, ground to the vehi-
functions correctly. cle frame using a jumper
wire such as a clip. YES Faulty pressure
· Auto-idle switch: ON sensor (Front Att.,
· Front attachment lever Connect MC connector swing).
is operated D terminal #9 to vehicle
NO frame. Check if trouble
Check if primary is corrected.
pilot pressure is Faulty MC.
correct. NO
· Without disconnecting con-
· Refer to the Opera- nector, ground to the vehi-
tional Performance cle frame using a jumper
Test section NO wire such as a clip. Faulty pilot relief
valve or pilot pump.
Check if pilot filter
NO is clogged.
Clogged pilot filter.
YES
Connector
(Harness End Connector Viewed from the Open End
Side)
MC (Connector D)
1 2 5 6 8 9 10 11
12 13 15 20 21 22
Pump Control Solenoid Valve
1 2
T5-4-26
F-2 Some cylinders are inoperatable or speeds
are slow.
• Determine whether the cause of the trouble is in

the pilot system or in the main circuit system. YES End (Bound spool
• In case arm roll-in is slow and the phenomenon is Disassemble and clean in control valve).
not corrected by F-2, refer to F-6. control valve
YES corresponding to the
Check if overload cylinder.
relief pressure corre- Check if trouble is
YES sponding to the cylin- Faulty cylinder sea.
corrected.
der is correct. NO
· Refer to the Operational
Performance Test section.
· Replace overload relief Faulty overload
Check if secondary valve with other overload NO relief valve.
pilot pressure corre- relief valve (same specifica-
sponding to the cylin- tion).
der is correct. EX75US-5
YES Faulty shockless
· Refer to the Opera- Check if secondary valve.
tional Performance pilot pressure at inlet
Test section. port of shockless
NO valve is correct.
Faulty pilot valve
· Only boom corresponding to
raise/lower, arm roll- NO the cylinder.
out and swing are to
be checked. Other
functions should go to Faulty auto-
step ”NO”. YES
MARCCINO con-
Remove solenoid trol unit.
EX75UR-5 NO valve corresponding
to the cylinder.
Check if secondary Check if trouble is
pilot pressure at Faulty solenoid
corrected. valve correspond-
inlet port of 9-spool NO
solenoid valve is ing to the cylinder.
correct.
NO YES Faulty shockless
· Check only boom Check if secondary
raise/lower, arm roll- pilot pressure at inlet valve.
in/roll-out and left off- port of shockless
set. For other func- valve is correct.
9-Spool Solenoid Valve tions go to “Yes”. YES
· Only boom Faulty pilot valve
3 corresponding to
raise/lower, arm roll-
NO the cylinder.
4 out and swing are to
3
6 be checked. Other
functions should go to
5 step ”NO”.
2
Shockless Valve
1
4
2
1
7
T197-01-02-007
8
1 - From the boom raise 5 - From the right offset pilot
pilot valve valve
2 - From the boom lower 6 - From the left offset pilot
pilot valve valve
3 - From the arm roll-in pilot 7 - From the right swing pilot
valve valve T197-05-04-001
4 - From the arm roll-out 8 - From the left swing pilot
pilot valve valve
T5-4-27
F-3 Front attachment cylinder drift is large.
Rlated Fault Code: None
YES Normal
Check if each front

attachment YES Faulty cylinder
cylinder drift is seals.
within specified NO Check if cylinder
value. internal leakage is
present. Scored control
valve spool,
Check if cylinder
broken spring, or
drift is reduced NO loosened spool
NO when pilot shut-off
end.
valve is closed.
Faulty pilot valve

YES
• Boom Cylinder Internal Leakage Check
1. With the bucket cylinder fully retracted and the

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

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

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

the hoses were disconnected and the boom
cylinder is retracted, internal leakage in the boom
cylinder exists.
If no oil flows out of the pipes from which the
hoses were disconnected but the the boom
cylinder is retracted, internal leakage in the control
valve exists.
T5-4-28
F-4 When boom raise or arm roll-out is operated,
boom or arm starts to move after moving
slightly downward.
YES Oil leaks in cylinder.
Check if load check

valve in control
valve is normal.
· Disassemble /
Faulty load check
Visual Inspection
NO valve.
NOTE: 1. During the initial stage of operation, oil

pressure and flow rate from the pump is
low. Therefore, if the load check valve is
malfunctioning, the oil in the bottom side (B)
of the boom cylinder flows back into the
circuit through the load check valve, When the load check
causing the boom cylinder to temporar- valve is faulty: (A)
ily retract.
2. Since oil pressure and flow rate from the
pump is low, if oil leaks from bottom side
(A) to rod side (B) due to faulty boom
cylinder piston or cylinder barrel, the
boom cylinder is temporarily retracted
during the initial stage of operation. In
addition, cylinder force is reduced, in-
creasing the cylinder drift in this case. T105-07-04-012
T5-4-29
F-5 Front control (automatic work range restric-
tion, cab collision prevention, auto-
MARCCINO) is abnormal. (Only EX75UR-5)
• When a fault code is displayed, refer to T5-6

(Trouble shooting D).
• When adjusting front speed, refer to the following
procedure.
YES End (Binding 9-
spool solenoid
valve.)
Disassemble and
clean 9-spool sole-
noid valve.
Reassemble. YES
Check if trouble is Check solenoid Replace harness.
corrected. valve harness
NO breakage or short Failure in Auto
circuit. MARCCINO con-
NO trol unit.
Adjusting method of front acceleration speed

and deceleration speed
Adjust solenoid valve set pressure to change front

acceleration or deceleration.
Lock Nut
Repeat adjusting pressure and operating front.
NOTE: Do not adjust arm acceleration solenoid Adjusting

valve (for arm keep off control). Screw

Auto-
Engine Speed E Mode
MARCCINO
Control Lever Switch
Mode Switch
Fast Idle OFF ON T107-06-05-001
2. Paint matching marks on adjusting screw and lock Lock Nut Adjusting Screw
nut before working. (Note do not paint on threads
of adjusting screw)
3. Loosen lock nut and adjust by adjusting screw.
Clockwise :acceleration
Counterclockwise :deceleration
Increase Decrease
: 18 mm Pressure Pressure
: 8.8 N⋅m (0.9 kgf⋅m, 0.08 lbf⋅in)
: 4 mm
W107-02-05-129
Reference: Standard Pressure Change

kPa 66 132 198 265
2
(kgf/cm ) 0.7 1.3 2.2 2.7
(psi) 10 18 31 38
4. Tighten lock nut.
T5-4-30
F-6 Arm is slow in arm roll-in operation (Only
EX75UR-5)

(Troubleshooting D).
• During arm roll-in, the main pump 3 works to feed
the oil flow into the arm cylinder bottom to in-
crease the arm roll-in speed. If the main pump 3
fails, it seems that swing and blade speeds are
reduced. Refer to Arm Oil Flow Combining Con-
trol (T2-2-16), in the System Section in the Tech-
nical Manual. Short circuited har-
YES ness between auto-
MARCCINO control
Check if trouble unit and solenoid
symptom is cor- valve.
rected by discon-
necting arm oil flow 3.32 MPa (33.9 kgf/cm2) or less Bound arm spool 3 in
Check if deliver pres-
combining solenoid control valve 2.
sure is 3.33 MPa or
valve.
lower when the engine
starts after installing a
NO pressure gauge to SB
port of the solenoid Bound arm oil flow
valve. combining solenoid
More than 3.33 MPa (34.0 kgf/cm2) valve.
F-7 Arm roll-in power is weak (Speed is normal)

(Only EX75UR-5) Solenoid Valve Unit

Port SB
(Troubleshooting D).
• When subjected to the load during arm roll-in, the
oil flow from the main pump 3 is shut off: arm roll-
in is carried out by the oil flow from the main pump
1 and 2. If the oil flow from the main pump 3 can-
not be cancelled, low-pressure relief is made be-
cause the main relief pressure at the arm 3 spool
is low. Refer to Arm Oil Flow Combining Control
(T2-2-16), in the System Section in the Technical T197-03-06-007
Manual.
NO
Faulty main relief
valve in control valve
2.
Check if main relief

valve in control Check if delivery pres- Bound arm spool 3 in
sure is 3.33 MPa or More than 3.33 MPa (34.0 kgf/cm2)
valve 2 is cor- control valve 2.
rected. higher when the load
is applied during arm
roll-in after installing a
YES pressure gauge to SB Faulty arm oil flow
port of the solenoid combining solenoid
valve. 3.32 MPa (33.9 kgf/cm2) or less valve.
T5-4-31
SWING SYSTEM TROUBLESHOOTING
S-1 Swing is slow or unmoving.
• Check whether the pilot system is faulty or the

main circuit is faulty.
• In case other functions (front attachment and
travel) operate normally, the pilot pump is consid-
ered to be normal. If the pilot system is displaying
a problem, the cause of the trouble may exist in
the circuit after the pilot valve.
NO
Check if swing mo-

YES tor drain volume is
correct.
· Refer to the Opera-
YES Check if swing re- tional Performance
lief pressure is cor- Test section.
rect.
YES
tional Performance Faulty swing relief
Test section. NO valve.
Check if secondary
pilot pressure for
swing is correct.
tional Performance NO Faulty pilot valve.
Test section. Check if secondary
pilot pressure at inlet
NO port of shockless
valve is correct. Faulty shockless
YES valve.
T5-4-32
Faulty swing mo-

tor.
YES Faulty swing motor

parking brake re-
lease valve.
Check if swing mo-
NO
tor parking brake
Disassemble and release valve is
clean swing spool in YES
galling or binding. Faulty shuttle
control valve 2. Check if shuttle valve.
Check if trouble is valve is galling or
corrected. NO binding.
Faulty swing re-
NO duction gear.
End (Bound spool

in control valve).
YES
T5-4-33
TRAVEL SYSTEM TROUBLESHOOTING
T-1 One side track does not move or moves
slowly, or machine cannot travel straight
(Mistrack)
• If one side system only does not operate, control

valve, travel motor, or center joint might be faulty.
YES Check if travel motor oil

drain quantity is nor-
mal.
Check if travel re- · Refer to the Opera-

lief pressure in tional Performance
NO
slow speed side Test section.
system is normal.
Check if symptom is
reversed when right · Refer to the Opera-
and left travel line tional Performance Switch rear and front or
hoses connected to Test section. right and left travel re-
top of center joint are lief valves each other.
NO Check if symptom is
switched each other.
reversed.
Bound spool in control

YES valve.
Relation between Faulty Seal Position and Mistrack Direction

Seal No Symptom
1 Mistracks to the left when traveling reverse.
2 Reverse travel side motor becomes slow
when making a pivot turn.
3 Mistracks to the left when traveling forward.
Mistracks to the right when traveling reverse.
4 Forward travel side motor becomes slow
１
when making a pivot turn.
Left Travel 2
5 Mistracks to the right when traveling forward. （Reverse） Right Travel
（Reverse）
Left Travel 3
（Forward） 4
Right Travel
（Forward）
5
T191-05-04-002
T5-4-34
NO Faulty travel motor.
YES End (Faulty counter-

Disassemble and clean
travel motor counterbal- balance valve).
ance valve. Recheck if
YES
same symptom arises.
Faulty travel reduc-
NO tion device.
NO Faulty center joint.
Faulty travel relief

YES valve.
Layout of Hydraulic Lines on Center Joint

Front
Left Travel (Forward) Right Travel (Forward)
Right Travel (Reverse)

Left Travel (Reverse)
Rear
T191-05-04-008
T5-4-35
T-2 During a combined operation of travel and
front function, the machine mistracks.
NO Faulty load check valve.
NO Check if load check

valve is normal.
Trace the cause of the
trouble by checking
Check if flow com-biner YES other symptoms.
valve is normal.
Faulty flow combiner

YES valve.
T-3 Travel mode is not selected.
YES Faulty travel mode

switch.
Remove travel mode
switch plug. Connect
Fast Speed the harness side both
ends plug. Check if YES End. (Bound solenoid
travel speed is fast. Check if fast travel mode valve)
is selected after disas-
sembling and cleaning
· Travel Mode Switch: NO travel mode solenoid Broken harness be-
Fast valve. tween travel mode
NO switch and MC.
Check what travel
mode is not selected.
YES Faulty travel mode

switch.
Remove travel mode

switch plug. Check if YES End. (Bound solenoid
Slow Speed travel speed is slow. Check if fast travel mode valve)
is selected after disas-
· Travel mode switch: sembling and cleaning
Slow NO travel mode solenoid Faulty MC or Short-
valve. circuited harness MC
NO and travel mode
switch.
T5-4-36
BLADE SYSTEM TROUBLESHOOTING
B-1 Blade does not move, weak or its speed is
slow.
• If swing is also malfunctioning, faulty main relief

valve of control valve 2, or faulty main pump is
suspected.
YES Faulty cylinder or

center joint seal.
Check if main relief
YES pressure and overload
relief pressure in blade
Disassemble and circuit are normal. Faulty main relief
clean blade spool in valve or overload
control valve 2. NO relief valve.
Check if same symp-
tom occurs.
End (Bound blade
spool in control valve
NO 2).
B-2 Blade drifts remarkably.
YES End. (Bound blade

spool in control valve
2).
Disassemble and clean
blade spool in control
valve 2. Check if trou-
ble system is cor- Remove blade cylin- YES Faulty cylinder.
rected. der and fully retract
it. Then, connect
hydraulic line to cyl-
inder rod side only
and perform blade NO Faulty center joint
NO raise operation.
Connect center joint seal.
Check if oil flows out
of cylinder bottom upper hose and lower
side oil port. NO hose directly. Check if
symptom disappears. Faulty overload relief
valve in control valve
YES 2.
T5-4-37
B-3 Engine stalls when blade or swing is oper-
ated during front attachment operation.
• When blade or swing is operated, oil pressure

from main pump 3 activates control piston 4 of
main pump 1, 2 to decrease flow rate.
When control piston 4 is bound, the displacement
angle does not decrease and may lead the engine
to stall.
NO End (Bound control pis-

ton 4).
Disassemble and
clean control piston 4
in main pump 1, 2.
Check if same symp-
tom occurs. Find out cause of trouble
by tracing other trouble
YES symptoms.
Main Pump 1, 2
Control Piston 4
Main Pump 3 Oil Chamber T196-03-01-003

(Oil Pressure from Main Pump 3)
T5-4-38
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C PROCEDURE
(Troubleshooting for Monitor)
Use troubleshooting C when any monitors, such as

gauges or indicators malfunction.
YES (OK)
(2) After checking or measuring in step (1), select either YES(OK) or
NO(NOT OK) depending on the result obtained in step (1) and
・ (1)
proceed to step (2) or (3).
(3)
NO
(NOT OK)
・ Special instructions or reference items may be indicated under the box. Incorrect
measuring or checking methods will not only render troubleshooting impossible but may
· Key switch: ON damage components.
・ Causes are described in a thick-line box. Scanning the descriptions in the thick-line boxes
wiil indicate suspected sections and possible causes.

Wire Harness Side
Open End Side

Harness End Connector
T158-05-03-001
T5-5-1
MALFUNCTION OF COOLANT
TEMPERATURE GAUGE
• Be sure to inspect wiring connections prior to

troubleshooting. YES
Remove coolant temperature

Gauge pointer does not move sensor terminal, ground
at all. (It does not rise from harness side terminal to With coolant temperature
zero.) vehicle. Does pointer swing to sensor terminal disconnected,
the (H) side? remove 12P connector from
monitor, and check continuity
· Key switch : ON NO between terminal No.11 and
sensor terminal.
When removing coolant

Gauge pointer swings over temperature sensor, does
scale. pointer swing back to zero? With coolant temperature
sensor terminal disconnected,
remove 12P connector from
monitor, and check continuity
NO
between vehicle frame and
sensor terminal.
YES
Remove coolant temperature
sensor terminal, and ground
Gauge pointer swings harness side terminal to vehi-
unstably. cle. Does the pointer swing to
(H) side, and stably?
· Key switch : ON NO
T5-5-2
Approximate Temperature on Coolant Temperature

Gauge
105 °C
Faulty coolant temperature (221 °F)
sensor. 95 °C
(203 °F)
YES Faulty monitor (coolant 70 °C

temperature gauge). (158 °F)
Broken harness between

monitor (coolant temperature
NO
gauge) and coolant
temperature sensor. T157-07-05-001
Coolant Temperature Sensor

Faulty coolant temperature
sensor.
Coolant Resistance
Temperature
Short circuit of harness 50±0.2 °C

between monitor (coolant
112.4±10 Ω
YES (122±0.4 °F)
temperature gauge) and
coolant temperature sensor. 60±0.2 °C
79.3±5 Ω
(140±0.4 °F)
Faulty monitor (coolant 80±0.2 °C
NO temperature gauge). 41.8±2.5 Ω
(176±0.4 °F)
100±0.3 °C
23.6±0.9 Ω
Faulty coolant temperature (212±0.5 °F)
sensor.
105±0.3 °C
20.7±0.6 Ω
(221±0.5 °F)
Faulty monitor.
120±0.3 °C
14.2±0.3 Ω
(248±0.5 °F)
Connector (Harness End Connector Viewed from the

Open End Side)
Monitor (12P)
6 5 4 3 2 1
12 11 10 9 8 7
T5-5-3
MALFUNCTION OF FUEL GAUGE
YES
Remove connector of fuel

Gauge pointer does not swing. sensor, terminals No.2 and
No.3 of harness connector by
using a clip. Does pointer With the fuel sensor connector
swing to the right end? disconnected, remove 12P
connector from monitor, and
check continuity between
· Key switch : ON NO monitor terminal No.12 and
sensor terminal No.2.
YES
Gauge pointer swing over When fuel sensor connector is

scale. removed, does pointer swing With the fuel sensor connector
back to zero? disconnected, remove 12P
connector from monitor, and
· Key switch : ON check continuity between
NO vehicle frame and sensor
terminal No.2.
Remove connector of fuel YES

sensor, and terminals No.2
Gauge pointer swings and No.3 of harness
unstably. connector by using a clip. Is
pointer swung to the right end,
and stabilized?
· Key switch : ON NO
T5-5-4
Fuel Sensor
1 mm=0.03937 in
Float
FULL
Faulty fuel sensor.

279 mm
R363
YES Faulty monitor (fuel gauge). 1/2
104°
Broken harness between 293 mm

monitor (fuel gauge) and fuel
NO sensor.
EMPTY
Faulty fuel sensor.
T190-04-04-001
Short circuit harness between
YES monitor (fuel gauge) and fuel
sensor. Float Position Resistance (Ω)
+0
FULL 10 -4
Faulty monitor (fuel gauge). 1/2 38±5

NO +0
Empty 90 -4
Faulty fuel sensor.

Connector (Harness End Connector Viewed from
the Open End Side)
Faulty monitor (fuel gauge).
Monitor (12P) Fuel Sensor
6 5 4 3 2 1
12 11 10 9 8 7 1 2 3
T5-5-5
MALFUNCTION OF INDICATOR LIGHT
CHECK SYSTEM
YES Faulty fuse or monitor.

Remove connector
12P from monitor.
Check for continuity
YES between harness end
terminals No.2 No.8
and fuse terminal
No.8. Broken harness between
Indicator doesn’t light NO fuse and monitor.
when indicator light Check if all indicators
check operation is don’t light.
performed.
Troubleshoot unlit indicator

NO individually.
Connector (Harness End Connector Viewed from

the Open End Side)
Monitor (12P)
6 5 4 3 2 1
12 11 10 9 8 7
T5-5-6
(Blank)
T5-5-7
MALFUNCTION OF ALTERNATOR
INDICATOR
13 to 14.5 V
Measure voltage at
13 V or higher monitor 12P
connector terminal
No.5.
Alternator indicator Measure voltage at · Engine : Running Less than 13 V
does not go off after alternator terminal
engine is started. L.
· Engine : Running
Less than 13 V
Less than 10 V
YES Check voltage at

regulator terminal
L.
Although alternator Check if indicator
comes on when · Key switch : ON
output is low, · Engine : Stopped 10 V or more
alternator indicator key switch is
does not come on. turned to ON
position.
· Key switch : ON
NO
T5-5-8
Connector (Harness End Connector Viewed from the Open

Faulty monitor. End Side)
Monitor (12P) Alternator
6 5 4 3 2 1 R
Broken harness between 12 11 10 9 8 7 L
regulator terminal L and
monitor terminal No.5.
Faulty regulator or faulty

alternator.
Faulty monitor.
Faulty regulator.
Blown indicator bulb.
T5-5-9
MALFUNCTION OF ENGINE OIL
PRESSURE INDICATOR

YES
NOTE: During one to two minutes after the engine

is stopped, engine oil pressure may exist.
This phenomenon is normal. With engine oil
pressure switch
disconnected,
check if indicator
YES comes ON when
harness side PLUS Reconnect engine
terminal oil pressure switch.
(lightgreen/red line) Check if indicator
is grounded to comes ON when
vehicle. NO monitor 16P
Check if indicator
Although engine oil comes ON when ・Key switch : ON connector terminal
pressure is low, key switch is No.23 is grounded
indicator does not turned to ON to vehicle.
come ON. position. · Key switch: ON
・Key switch : ON · Key switch : ON · Without disconnecting,
· Engine: Stopped ground connector to
vehicle using a clip from
the reverse side of the
connector.
NO
YES
Check if indicator
Indicator stays ON goes OFF when
after engine is engine oil pressure
started. switch is Reconnect engine YES
disconnected. oil pressure switch
· Check if oil filter is
and remove
clogged or not. · Key switch : ON connector B from
· Engine : Stopped MC.
NO Check continuity
between harness Check if indicator
end connector goes OFF when
terminal No.2 and connector A is
vehicle frame. NO
removed from MC.
・Key switch : ON
T5-5-10
Faulty engine oil

pressure switch.
Engine Oil Pressure Switch
Faulty MC or bro-
Remove connector ken harness be- Pressure Indicator
YES
A from MC. Check if tween MC and
indicator comes ON engine oil pressure Approx.39 kPa
YES when harness end switch. 2
connector terminal (0.4 kgf/cm ) or ON
No.18 is grounded Broken harness less
to vehicle. between monitor
NO
and MC. Approx.39 kPa
・Key switch : ON 2
(0.4 kgf/cm ) or OFF
higher
Faulty monitor. Connector (Harness End Connector Viewed from the Open
NO
End Side)
Monitor(16P)
Burned out 20 19 18 17 16 15 14 13
indicator light. 28 27 26 25 24 23 22 21
MC(Connector A)
Faulty engine oil 1 2 3 4 5 6 7 8 9 10 11 12 13

pressure switch, 14 15 16 17 18 19 20 21 22 23 24 25 26
failure in engine oil
lubrication system,
or clogged oil filter. MC(Connector B)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
Short circuit of
harness between
MC and engine oil
pressure switch.
YES Faulty MC.
Faulty monitor or
short circuit of
NO harness between
monitor and MC.
T5-5-11
MALFUNCTION OF OVERHEAT
INDICATOR
YES
With overheat switch

disconnected, check
YES Reconnect
if indicator comes
ON when harness is overheat switch.
grounded to vehicle. Check if indicator
comes ON when
· Key switch : ON monitor 16P
connector terminal
NO No.22 is grounded
Check if indicator
Indicator does not to vehicle.
comes ON when
come ON even if key switch is
engine overheats. · Key switch : ON
turned to ON · Without disconnecting,
position. ground connector to
· Key switch : ON vehicle using a clip from
the reverse side of the
connector.
NO
YES
Check if indicator
Indicator comes ON goes OFF when
even if coolant overheat switch is YES
temperature is low. disconnected. Disconnect overheat
switch and remove
· Key switch : ON connector B from MC.
Check continuity
NO between MC harness
end connector
terminal No.10 and
vehicle frame.
NO
T5-5-12
Overheat Switch
Faulty overheat Coolant Indicator

switch.
Temperature
Lower than 105 °C
YES Broken harness OFF
between monitor (221 °F)
and MC. 105 °C (221 °F) or
ON
More
Remove connector A YES Faulty MC.
from MC. Check if
indicator comes ON
NO when harness end
connector terminal Faulty monitor or
No.4 is grounded to broken harness
vehicle. NO between MC and
overheat switch.
· Key switch : ON Connector (Harness End Connector Viewed from
Burned out the Open End Side)
indicator light. Monitor (16P)
20 19 18 17 16 15 14 13
28 27 26 25 24 23 22 21
MC(Connector A)
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Faulty overheat
switch.
MC(Connector B)
1 2 3 4 5 6 7 8
Short circuit of 9 10 11 12 13 14 15 16
harness between
MC and overheat
switch.
YES Faulty MC.

Check if indicator
goes OFF when
connector A is Faulty monitor or
removed from MC. broken harness
NO between monitor
and MC.
T5-5-13
MALFUNCTION OF FUEL LEVEL INDICA-
TOR
NOTE: Fuel level indicator lights when fuel be-

comes about 10L (about 72 mm from fuel
tank bottom).
YES
Disconnect fuel senser

and connect harness
YES side terminal No.1 to
No.3.
Check if indicator
lights.
· Key switch: ON
NO
Although fuel gauge
pointer indicates E, Check if indicator
indicator does not lights with key
light. switch ON.
· Key switch: ON
NO
YES
Check if indicator
Indicator lights even if goes OFF by
fuel is remaining in disconnecting
fuel sensor. YES
tank.
· Key switch: ON
Reconnect the fuel sensor.
Check if indicator goes OFF
NO by disconnecting monitor
(16P) connector.
NO
T5-5-14

Open End Side)
Fuel Sensor
1 2 3
Faulty fuel sensor.

Monitor (16P)
20 19 18 17 16 15 14 13
28 27 26 25 24 23 22 21

indicator and fuel sensor.
Burned out indicator or

broken harness between
MC and indicator.
Faulty fuel sensor.
Faulty Monitor.
Short circuit of fuel sen-

sor or harness between
MC and indicator.
T5-5-15
MALFUNCTION OF AIR FILTER
RESTRICTION INDICATOR
YES
Disconnect restriction
switch.Check if
YES indicator comes ON
when harness end
Reconnect restriction
PLUS terminal is
switch.Remove 16P
grounded to vehicle.
connector from
· Key switch : ON monitor. Check
continuity between
NO
Check if indicator harness end
When air filter is comes ON when connector terminal
clogged, indicator key switch is No.13 and vehicle
does not come ON turned to ON frame.
position
· Key switch : ON
NO
YES
Although air filter is When air filter

not clogged, restriction switch
indicator lights. is disconnected, YES
does the indicator Remove 16P
· Disassembled goes OFF? connector from
and visual check · Key switch : ON monitor. Check
· Confirm that air continuity between
filter is not moist. monitor harness end
NO
connector terminal
No.13 and vehicle
frame.
NO
T5-5-16
Air Filter Restriction Switch

Faulty air filter
restriction switch. Pressure Indicator
5.1 kPa (520 mmH2O)
OFF
or Less
More than
YES Faulty monitor. ON
6.2 kPa (630 mmH2O)
Broken harness
between monitor
NO and air filter Connector (Harness End Connector Viewed from the
restriction switch. Open End Side)
Monitor (16P)
Burned out
indicator light. 20 19 18 17 16 15 14 13
28 27 26 25 24 23 22 21
Faulty air filter

restriction switch.
Short circuit of
harness between
monitor and air
filter restriction
switch.
Faulty monitor.
T5-5-17
MALFUNTION OF BUZZER
Providing that:
YES
Faulty MC.
Buzzer keeps sounding Check if buzzer stops
when key switch is sounding when con-
turned ON before nector A is removed
starting engine. from MC. Faulty buzzer or
short circuit of
· Key Switch : ON NO harness between
· Engine is stopped. buzzer and MC.
YES
Faulty engine oil
pressure system.
Buzzer keeps Check if engine oil

sounding when pressure indicator YES Overheat of
engine is started. is ON. engine.
Check if overheat
NO indicator is ON.
Check if buzzer
stops when buzzer
NO stop switch is
depressed.
YES Normal.
Buzzer does not

sound even if Check if engine is
engine oil pressure running at 1000 Perform
indicator or min 1 (rpm) or
－
troubleshooting for
overheat indicator faster. YES
the individual
comes ON. indicator which
Check if alternator comes ON.
NO indicator is ON.
Check voltage at
NO alternator terminal
L.
· Engine speed:
1000 min 1 (rpm)
－
or faster.
T5-5-18

End Side)
Buzzer Alternator
R
2 1 L
YES Faulty MC.
YES Faulty MC.

Check if buzzer stops
sounding when connector
NO A is removed from MC.
Faulty buzzer.
NO
Less than 13 V Faulty alternator.
Broken harness
Less than 13 V between alternator
terminal L and
Measure voltage at
buzzer terminal
buzzer connector
No.2.
13 V or more terminal No.2.
· Engine speed:
1000 min 1 (rpm)
－ Faulty buzzer.
or faster. 13 V or more
T5-5-19
MALFUNCTION OF HOUR METER
Broken harness
0V between monitor
12P connector
Check voltage at terminal No.10 and
NO monitor 12P fuse No.6.
connector terminal
No.10.
Faulty monitor.
24 V
Hour meter does
not count operating
hours when engine Check if alternator
is running. indicator is ON.
Less than 13 V Faulty alternator.
· Engine : Running
Check voltage at
alternator terminal
YES L. 13 to 14.5 V or more Faulty monitor.
· Engine speed: Check voltage at
-1
1 000 min (rpm) monitor 12P
or faster connector terminal
13 V No.5. Broken harness
or more between alternator
Less than terminal L and
13V monitor 12P
connector terminal
No.5.

End Side)
Monitor (12P) Alternator
6 5 4 3 2 1 R
12 11 10 9 8 7 L
T5-5-20
TROUBLESHOOTING / Troubleshooting D
TROUBLESHOOTING D PROCEDURE
(EX75UR-5)
Troubleshooting D procedures are to be applied to the front
attachment control system.
Use troubleshooting D procedure when fault codes are
shown on Dr. EX after monitoring the main controller
(MC) with Dr. EX or on the system monitor.
• How to Read the Troubleshooting Flow Charts
YES (OK)
(2)
• After checking or measuring item (1), according to the results
・ (1) select either YES (OK) or NO (NOT OK) and proceed to next
item (2) or (3), as appropriate.
(3)
NO (NOT OK)
・ • Special instructions or reference items are indicated in the space under the box. In-
correct checking or measuring methods will render the troubleshooting impossible,
· Key switch: ON and may damage components as well.
・ • Use Dr. EX when the item is shown in a double line frame.
・ • Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes and locations can be found.

Wire Harness Side
Open End
Side Harness End Connector
T158-05-03-001
T5-6-1
AUTO-MARCCINO CONTROL UNIT FAULT
CODE LIST
Fault Code
System
Dr. EX Indicator
Monitor
Continuously
03 E03 ON Abnormal RAM in CPU
sounds
05 − − ON Faulty monitor communication
06 − − ON Abnormal metering correction value

Continuously
07 E07 ON Abnormal front angle sensor calibration value
sounds
Continuously
08 E08 ON Abnormal code setting
sounds
09 − − − Abnormal monitor setting value
11 E11 Abnormal arm roll-out function
12 E12 Continuously Abnormal right offset function
ON
13 E13 sounds Abnormal left offset function
17 E17 Abnormal boom raise function
14 − − Abnormal arm roll-out acceleration pilot pressure sensor
15 − − Abnormal right offset acceleration pilot pressure sensor
16 − − Abnormal left offset acceleration pilot pressure sensor
19 − − Abnormal boom raise acceleration pilot pressure sensor
ON
20 − − Abnormal boom raise pilot pressure sensor
21 − − Abnormal boom lower pilot pressure sensor
22 − − Abnormal arm roll-in pilot pressure sensor
24 − − Abnormal 5 spool side pump pressure sensor
Long beep
40 E40 Faulty 9 spool-solenoid valve unit (boom raise deceleration)
sounds ON
41 E41 Faulty 9 spool-solenoid valve unit (arm roll-in deceleration)
intermittently
43 − − Faulty 9 spool-solenoid valve unit (right offset acceleration)
45 − − Faulty 9 spool-solenoid valve unit (arm roll-out acceleration)
ON
47 − − Faulty 9 spool-solenoid valve unit (left offset acceleration)
48 − − Faulty 9 spool-solenoid valve unit (boom raise acceleration)
50 E50 Abnormal boom angle sensor
51 E51 Abnormal arm angle sensor
52 E52 Abnormal offset angle sensor
53 E53 Abnormal slide arm sensor
80 E80 Boom angle sensor deviation
Continuously ON Arm angle sensor deviation
81 E81
sounds Offset angle sensor deviation
82 E82
83 E83 Slide arm sensor deviation
NOTE: *Unless the solenoid valve has failed, boom NOTE: If two or more trouble occurs at the same
raise operation is correctly controlled in the time, the system monitor displays the fault
range lower than boom foot pin height. code for the lower group number only.
T5-6-2
1) Replace the controller if the ma-

1) Check harness.
− 2) Replace the controller. G4
3) Replace the system monitor.
1) Abnormal metering correction
Depth limit control stops G4
value.
* Movement to the cab stops. 1) Replace the controller if the ma-
G1
1) Input the front and bucket codes
again.
− −
1) Check harness.
2) Replace the pilot pressure sen-
sor.
3) Replace the solenoid valve.
Cab collison prevention control stops. 1) Check harness.
Offset movement by offset switch stops. 2) Replace pilot pressure sensor.
Depth limit control stops
G4
Cab collison prevention control stops, depth limit control stops
Arm oil flow combining control stops.
Boom raise movement stops. 1) Check harness.
Arm roll-out movement stops. 2) Replace the solenoid valve. G3
Offset movement by offset switch stops. 1) Check harness.

Cab collison prevention control stops. 2) Replace the solenoid valve.
G4
Depth limit control stops.
* Interference prevention control system functions as if boom 1) Check harness.
is raised to the highest position. Interference prevention con- 2) Replace the angle sensor.
trol system functions as if arm is fully rolled in. Interference
prevention control system functions as if the front attachment
is fully offset to the left side. Interference prevention control
system functions as if slide arm is fully extension. Interference
prevention control system functions as if boom is raised to the G2
highest position. Interference prevention control system func-
tions as if arm is fully rolled in. Interference prevention control
system functions as if the front attachment is fully offset to the
left side. Interference prevention control system functions as if
slide arm is fully extension.
T5-6-3
Fault Code
System
Dr. EX Indicator
Monitor
60 E60 Faulty boom angle sensor initial setting.
61 E61 Continuously Faulty arm angle sensor initial setting.
ON
62 E62 sounds Faulty offset angle sensor initial setting.
63 E63 Faulty slide arm sensor initial setting.
Faulty hydraulic oil temperature sensor.
90 − − ON
Continuously Abnormal sensor power source.
91 E91 ON
sounds
Complete angle sensor initial setting.
F0 − − −
Continuously Invasion of hazardous area by emergency evacuation switch.
F2 − −
sounds
Escape out of hazardous area.
F3 − − −
Short beep Invasion of hazardous area by interference prevention mode.
F4 E00 sounds ON
intermittently
T5-6-4
1) Initialize the angle sensor again.

2) Replace the angle sensor
Interference prevention control system functions 1) Check harness.

G4
as if oil temperature is lowest. 2) Replace the hydraulic oil temperature sensor.
Depth limit control stops 1) Initialize the angle sensor again.
G1
Cab collison control stops. 2) Replace the angle sensor.
* Movement to the cab stops.
G5
− G7
− G8
T5-6-5
FAULT CODE 03 (ABNORMAL RAM IN
CPU)
YES
Normal.
Check if any fault codes are

deleted when retrial is per-
formed.
YES Normal.
In case all machine operations
are normal, retry several
NO times. Check if any fault codes
are deleted.
Replace auto-MARCCINO
NO control unit with new one.
T5-6-6
FAULT CODE 05 (FAULT MONITOR COM-
MUNICATION)
YES Broken harness. Short circuit

of harness.
Disconnect 4P connector
(black) from system monitor
and connector 4 from auto-
MARCCINO control unit. Check
for continuity between terminals
below or short-circuited har-
ness. Check if trouble occurs.
System Auto- Replace auto-MARCCINO

Monitor 4P MARCCINO NO control unit with a new one.
Connector Control Unit
(Black) Connector 4
No. 1 No. 12
No. 2 No. 11
No. 3 No. 3
No. 4 No. 2
FAULT CODE 06 (ABNORMAL METERING

CORRECTION VALUE)
YES Normal.
Adjust metering by Dr.EX. Check

if fault code disappears.
Replace auto-MARCCINO
NO control unit with a new one.
Connector (Harness Connector Viewed from the Open End Side)
System Monitor 4P Connector (Black) Auto-MARCCINO Control Unit (Connector 4)
1 2 1 2 3 4 5
6 7 8 9 10 11 12
3 4
13 14 15 16
T5-6-7
FAULT CODE 07 (ABNORMAL CALIBRA-
TION VALUE)
• Calibration values are input into the auto-

MARCCINO control unit beforehand. Accordingly,
this fault code is rarely displayed during machine
operation.
YES
Normal.
Check if any fault codes on

system monitor are deleted
when sensor is initialized.
· Refer to T4-6-5, 6.
· After initializing, re-start the
engine Replace auto-MARCCINO
NO control unit with new one.
FAULT CODE 08 (ABNORMAL CODE SET-

TING)
Checking Instruction
• When no front attachment or bucket codes are
registered, this fault code is displayed. Register
the front attachment or bucket code.
YES
Normal.
Register front attachment or

bucket code using the Dr. EX.
Check if fault codes displayed
on system monitor are de-
leted.
· After initializing, restart the
engine. Replace auto-MARCCINO
control unit with new one.
T5-6-8
FAULT CODE 09 (ABNORMAL MONITOR
SETTING VALUE)
• In case other fault code is displayed, perform the

corresponding troubleshooting first.
• In case fault code 09 only is displayed, set to
depth “+0.1 m” with the system monitor. Push the
depth limit control switch for 3 seconds. After that
the fault code 09 will disappear.
T5-6-9
FAULT CODE 11
(ABNORMAL ARM ROLL-OUT OPERA-
TION)
FAULT CODE 12
(ABNORMAL RIGHT OFFSET OPERA-
TION)
FAULT CODE 13
(ABNORMAL LEFT OFFSET OPERATION)
FAULT CODE 17
(ABNORMAL BOOM RAISE)
• Fault code 11 is displayed when the arm roll-out • Fault code 17 is displayed when the boom raise
pilot-pressure sensor sends a signal correspond- acceleration pilot-pressure sensor sends a signal
ing to a pressure of 0.98 MPa (10 kgf/cm ) or
2 corresponding to a pressure of 0.98 MPa (10
2
more to the auto-MARCCINO control unit while kgf/cm ) or more to the auto-MARCCINO control
the auto-MARCCINO control unit sends no signal unit while the auto-MARCCINO control unit sends
to the 9-spool solenoid valve unit (arm roll-out ac- no signal to the 9-spool solenoid valve unit (boom
celeration) by arm keep-off. raise acceleration) by depth limit control.
• Fault codes 12 and 13 are displayed when right or
left offset pilot pressure sensor sends a signal
corresponding to a pressure of 0.98 MPa (10
2
kgf/cm ) or more to the auto-MARCCINO control
unit while the offset switch is not depressed.
Sticking solenoid valve or delayed response in the
hydraulic system at very low temperature may be
the cause of these troubles. With pilot control shut-off lever
• Check for loose harness connections beforehand. held in the LOCK position,
monitor pilot pressure sensor
With pilot control shut-off lever YES corresponding to the fault code
held in the UNLOCK position, using Dr. EX. Check if 0
2
monitor pilot pressure sensor kgf/cm pressure is displayed.
NO corresponding to the fault
code using Dr. EX. Check if 10
2
kgf/cm or more pressure is · Engine: Running
displayed. · System deactivation switch:
ON
· Engine: Running
· System deactivation switch:
Check if any fault codes are ON
deleted when engine is re- Faulty auto-MARCCINO con-
started. NO trol unit.
· Refer to corrective Measures -
2.
Normal.
YES
· Check operation of the arm
keep-off control, depth limit
control and the offset switch.
T5-6-10
YES
Faulty solenoid valve
· Refer to Corrective Measure
- 1.
Faulty pilot pressure sensor

NO
· Refer to Corrective Measure
- 2.
The Corrective Measures -1 and 2 described below

should be applied when the machine must be oper-
ated.
• Corrective Measure -1
Disconnect the hose from port P on the 9-spool
solenoid valve unit. Plug port P and the hose end.
Then, the arm keep-off control and offset switch Port P
function are deactivated.
• Corrective Measure -2
Remove the emergency stop solenoid valve con- T197-01-02-007
nector provided on the pilot filter.
T5-6-11
FAULT CODE 14 FAULT CODE 20
(ABNORMAL ARM ROLL-OUT ACCEL- (ABNORMAL BOOM RAISE PILOT PRES-
ERATION PILOT PRESSURE SENSOR) SURE SENSOR)
(ABNORMAL RIGHT OFFSET ACCELERA- (ABNORMAL BOOM LOWER PILOT
TION PILOT PRESSURE SENSOR) PRESSURE SENSOR)
(ABNORMAL LEFT OFFSET ACCELERA- (ABNORMAL ARM ROLL-IN PILOT PRES-
TION PILOT PRESSURE SENSOR) SURE SENSOR)
FAULT CODE 19
(ABNORMAL BOOM RAISE ACCELERA-
TION PILOT PRESSURE SENSOR)
• These fault codes are displayed when signal volt-

age from the pilot pressure sensor to the auto- Disconnect pilot pressure sen-
sor and auto-MARCCINO con-
MARCCINO control unit is in the range of 0.25 V
trol unit. Check continuity be-
or less, or 4.75 V or more. tween sensor harness side
NO
• Check for loose harness connections beforehand. connector terminal No.2 and
auto-MARCCINO control unit
Disconnect pilot pressure harness side connector 3 termi-
sensor and connect harness nal.
connector terminal No.1 to
YES terminal No.3. With connector · TERMINALS:
2 removed from auto- Boom raise (Terminal No. 17)
MARCCINO control unit, Boom raise acceleration (Terminal No. 5)
check for continuity between Boom lower (Terminal No. 16)
harness connector terminal Arm roll-out acceleration (Terminal No. 15)
Disconnect pilot pressure No.19 or No.21 and machine.
sensor and connect harness Arm roll-in (Terminal No. 6)
side connector terminal No.1 Right Offset (Terminal No.12)
to terminal No.3. With connec- Left Offset (Terminal No. 2)
tor 1 removed from auto-
MARCCINO control unit, Short circuit of harness be-
check continuity between har- tween pilot pressure sensor
ness side connector terminal and auto-MARCCINO control
YES
No.19 and No.21. unit.
Broken harness between pilot

pressure sensor and auto-
NO MARCCINO control unit.

Open End Side)
Pilot Pressure Sensor Auto-MARCCINO Control Unit (Connector 1)
1 2 3 4 5 6 7 8 9 10 11
1 3
12 13 14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32
2
T5-6-12
Short circuit of harness be-

tween pilot pressure sensor
YES and auto-MARCCINO control
Disconnect pilot pressure unit.
sensor and connector 3 of
YES auto-MARCCINO control unit.
Check for continuity between
sensor harness side connec-
tor terminal No.2 and vehicle. NO Faulty auto-MARCCINO con-
Switch pilot pressure sensor trol unit.
with arm roll-in pilot pressure
NO sensor, and retry. Check if the
fault code is deleted.
Faulty pilot pressure sensor.
YES

Auto-MARCCINO Control Unit (Connector 2) Auto-MARCCINO Control Unit (Connector 3)
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10
9 10 11 12 13 14 15 16 17 18 11 12 13 14 15 16 17 18 19 20 21 22
19 20 21 22 23 24 25 23 24 25 26 27 28 29 30 31
T5-6-13
FAULT CODE 24 (ABNORMAL PUMP
PRESSURE SENSOR)
• This fault code is displayed when input voltage

from the pressure sensor to the auto-MARCCINO
control unit is 0.25 V or less, or 4.75 V or more.
Disconnect pump pressure

sensor and auto-MARCCINO
control unit. Check for continuity
NO between sensor harness
connector terminal No.2 and
auto-MARCCINO control unit
harness connector 3 terminal
No.14.
sensor. Connect harness end
connector terminal No.1 to No.3.
YES Remove connector 2 from auto-
MARCCINO control unit. Check
for continuity between harness
end connector terminal No.19 or
No.21 and vehicle.
sensor. Connect harness end
connector terminal No.1 and Short circuit of harness
No.3. Remove connector 2 between pump pressure
from auto-MARCCINO control YES sensor and auto-MARCCINO
unit. Check for continuity control unit.
between harness end
connector terminal No.19 and
No.21.
pump pressure sensor and
NO auto-MARCCINO control unit.

Open End Side)
Pump Delivery Pressure Sensor
1 2 3
T5-6-14
Short circuit between pilot

YES
Disconnect pump pressure MARCCINO control unit.
sensor connector and auto-
MARCCINO control unit
YES
connector 3. Check for
continuity between sensor YES Faulty auto-MARCCINO
harness end connector Install the connector, and start control unit.
vehicle. the engine. Check if voltage at
pump pressure sensor connec-
NO
tor terminal No.2 is in the range
of 0.25 to 4.75 V. Faulty pilot pressure sensor.
NO
· Keeping connection made,
ground connector to vehicle us-
ing a clip from the side of the
connector.

NO MARCCINO contrtol unit.
Auto-MARCCINO Control Unit (Connector 2) Auto-MARCCINO Control Unit (Connector 3)
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10
9 10 11 12 13 14 15 16 17 18 11 12 13 14 15 16 17 18 19 20 21 22
19 20 21 22 23 24 25 23 24 25 26 27 28 29 30 31
T5-6-15
FAULT CODE 40
(ABNORMAL 9-SPOOL SOLENOID VALVE
UNIT [BOOM RAISE DECELERATION])
FAULT CODE 41
UNIT [ARM ROLL-IN DECELERATION])
NO Faulty auto-MARCCINO
control unit.
Disconnect solenoid
valve. Disconnect con-
YES nector from auto-
MARCCINO control unit.
Check for continuity be-
tween harness connector
Disconnect solenoid valve. terminal and vehicle. Short circuit of harness
Connect harness side con- between solenoid valve
nector terminal No.1 to · Boom raise (No. 8 and
YES No.2. 19) YES and auto-MARCCINO
control unit.
Remove connector 1 from · Arm roll-In (No. 7 and
auto-MARCCINO control 18)
unit. Check for continuity
between harness end con-
Disconnect solenoid nector terminals. Broken harness between
valve. Check if solenoid solenoid valve and auto-
· Boom raise (No. 16 and 23)
valve electrical resis- NO MARCCINO control unit.
· Arm roll-In (No. 6 and 11)
tance is approx. 2.24
kΩ.
Faulty solenoid valve.

NO

Open End Side)
Auto-MARCCINO Control Unit (Connector 1)
Solenoid Valve
1 2 3 4 5 6 7 8 9 10 11
1 2 12 13 14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32
T5-6-16
FAULT CODE 43
UNIT [RIGHT OFFSET ACCELERATION])
FAULT CODE 45
UNIT [ARM ROLL-OUT ACCELERATION])
FAULT CODE 47
UNIT [LEFT OFFSET ACCELERATION])
FAULT CODE 48
UNIT [BOOM RAISE ACCELERATION])
NO Faulty auto-MARCCINO
Disconnect solenoid control unit.
valve. Connect
Check forharness
continu-
side
ity between
connector
auto-
terminal
YES MARCCINO
NO. 1 to No. control
2. Remove
unit
connector 41 from
harness
auto-
MARCCINO
connector terminal
controland
unit.
Check continuity be-
vehicle.
Disconnect solenoid valve. tween harness side con- Short circuit of harness
Connect harness side connector and vehicle. between solenoid valve
nector terminal No.1 to
YES No.2. Remove connector 1 YES and auto-MARCCINO
control unit.
from auto-MARCCINO con- · Right offset (No. 7 and 29)
trol unit. Check for continu- · Arm roll-out (No.18 and 32)
ity between harness side · Left offset (No.19 and 30)
connector terminals. · Boom raise (No.20 and 31)
With solenoid valve Broken harness between
disconnected, check if solenoid valve and auto-
solenoid valve electrical · Right offset (No. 7 and 29) NO MARCCINO control unit.
resistance is approx. · Arm roll-out (No.18 and 32)
2.24 kΩ. · Left offset (No.19 and 30)
· Boom raise (No.20 and 31)
Faulty solenoid valve.

NO

Open End Side)
Solenoid Valve Auto-MARCCINO Control Unit (Connector 4)
1 2 3 4 5
1 2
6 7 8 9 10 11 12
13 14 15 16
T5-6-17
FAULT CODE 50
(ABNORMAL BOOM ANGLE SENSOR)
FAULT CODE 51
(ABNORMAL ARM ANGLE SENSOR)
FAULT CODE 52
(ABNORMAL OFFSET ANGLE SENSOR)
FAULT CODE 53
(ABNORMAL SLIDE ARM SENSOR)
• Fault codes 50 to 52 are displayed when input

voltage from the angle sensor to the auto-
MARCCINO control unit is 0.1 V or less, or 4.9 V
or more.
• Fault code 53 is displayed when input voltage
from the angle sensor to the auto-MARCCINO
control unit is 0.5 V or less, or 4.9 V or more.
Disconnect angle sensor.

YES auto-MARCCINO control unit
connector 2 harness connec-
Disconnect angle sensor. tor terminal No.20 or No. 22
Connect harness end connec- and vehicle.
tor terminal No.1 to No.3. Re-
YES move connector 2 from auto-
harness connector terminal
No.20 and No.22. Broken harness between an-
gle sensor and auto-
With angle sensor discon-
nected, check if angle sensor
electrical resistance is 5±1.0
kΩ.
Faulty angle sensor.

NO
· Refer to T4-6-4, 5, 6.

Open End Side)
Angle Sensor Auto-MARCCINO Control Unit (Connector 2)
1 2 3 4 5 6 7 8
1 2
9 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 25
3
T5-6-18

YES tween angle sensor and auto-
Disconnect angle sensor con- MARCCINO control unit.
nector and auto-MARCCINO
YES control unit connector 3.
Disconnect angle sensor con- Check for continuity between
nector and auto-MARCCINO sensor harness connector
control unit connector 3. terminal No.2 and vehicle. Faulty auto-MARCCINO con-
NO Check for continuity between NO trol unit.
sensor harness connector
terminal No.2 and auto-
MARCCINO control unit har-
ness terminal.
Broken harness between an-
· TERMINALS: gle sensor and auto-
Boom (Terminal No.7)
Arm (Terminal No.19)
Offset (Terminal No.18)
Slide Arm (Terminal No.11)

tween angle sensor and auto-
YES MARCCINO control unit.
Auto-MARCCINO Control Unit (Connector 3)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31
T5-6-19
FAULT CODE 60
(FAULTY INITIAL SETTING OF BOOM AN-
GLE SENSOR)
FAULT CODE 61
(FAULTY INITIAL SETTING OF ARM AN-
GLE SENSOR)
FAULT CODE 62
(FAULTY INITIAL SETTING OF OFFSET
ANGLE SENSOR)
FAULT CODE 63
(FAULTY INITIAL SETTING OF SLIDE ARM
SENSOR)
• Fault codes 60 to 62 are displayed when input

voltage from the angle sensor to the auto-
MARCCINO control unit is at the deviation of ±0.3
V or more from the specified value.
• Fault code 63 is displayed when input voltage
from the angle sensor to the auto-MARCCINO
control unit is at the deviation of ±0.1 V or more
from the specified value .
• Check for loose harness connections before
hand.
Faulty auto-MARCCINO con-

YES trol unit.
Measure the voltage at angle
sensor with the front attach-
ment in angle sensor initializa-
YES
tion position. Check if signal
voltage is within ±0.3 V of the
specification.
· Specifications:
Boom : 0.665 V±0.3 V Faulty angle sensor.
Arm : 4.246 V±0.3 V NO
Check if fault codes dis- Offset : 2.092 V±0.3 V
appear when angle sen- · With the connector connected,
sor is initialized. ground connector to vehicle us-
ing a clip from the rear side of
the connector.
End.
NO

Open End Side)
Angle Sensor
1 2
T5-6-20
FAULT CODE 80
(BOOM ANGLE SENSOR DEVIATION)
FAULT CODE 81
(ARM ANGLE SENSOR DEVIATION)
FAULT CODE 82
(OFFSET ANGLE SENSOR DEVIATION)
FAULT CODE 83
(SLIDE ARM SENSOR DEVIATION)
NOTE: The attachments marked with “*” are op-

tional.
• Check for deformation in the link part of angle

sensor first.
• These fault codes are displayed if the value be-
yond the sensor operating range below is output
to the auto-MARCCINO control unit.
Sensor Activating Range
Sensor
Boom Angle Sensor Arm Angle Sensor Offset Angle Sensor *Slide Arm Sensor
Attachment
Standard Arm 0.165 V to 4.835 V 0.255 V to 4.746 V 0.833 V to 4.167 V －
*Long Arm ↑ 0.323 V to 4.678 V ↑ －
*Extention Arm ↑ 0.255 V to 4.746 V ↑ －
*Slide Arm (Box Type) ↑ 0.243 V to 4.734 V ↑ 0.530 V to 2.660 V
*Slide Arm (Slide Type) ↑ 0.183 V to 4.679 V ↑ ↑
YES Faulty auto-MARCCINO con-

trol unit.
Measure voltage at terminal

#2 on angle sensor connector
on fault code. Check if voltage
is within sensor operating
range above.
· Using a clip, ground from the Faulty angle sensor installing.

rear side of the connector NO
without disconnecting. · Refer to T5-6-24.
Connector (Harness End Connector Viewed from the Open End Side)
Angle Sensor
1 2
T5-6-21
FAULT CODE 90
(FAULTY OIL TEMPERATURE SENSOR)
• Fault code 90 is displayed when signal voltage

corresponding to -30° C or lower, or +100° C or
more is sent out of the oil temperature sensor to
the auto-MARCCINO control unit.
Oil Temperature Sensor

Oil Temperature Electrical Resis-
(°C) tance (kΩ)
-20 15.0±1.5
0 (5.74)
20 2.45±0.24
40 (1.15)
60 (0.584)
80 0.318±0.031
Short circuit of harness
YES between oil temperature
Disconnect oil tempera-
sensor and auto-
ture sensor.
Check for continuity be-
YES
tween auto-MARCCINO
Disconnect oil tempera- control unit connector 2
ture sensor, and connect terminal No.22 and con-
nector 4 terminal No.4 Faulty auto-MARCCINO
harness side connector
and vehicle. NO control unit.
YES terminal No.1 and No.2.
Disconnect auto-
MARCCINO control unit
connector, check for con-
tinuity between harness
Disconnect oil Broken harness between
side terminals.
temperature sen- oil temperature sensor
sor. Check if oil · TERMINALS: and auto-MARCCINO
NO
temperature sen- Connector 2: Terminal No.22 control unit.
sor electrical resis- Connector 4: Terminal No.4
tance is within
specification.
Faulty oil temperature

NO sensor.
Connectors (Harness End Connector Viewed from the Open End Side)
Oil Temperature Sensor Auto-MARCCINO Control Unit (Connector 2) Auto-MARCCINO Control Unit (Connector 4)
1 2 3 4 5 6 7 8
1 2 3 4 5
1 2 9 10 11 12 13 14 15 16 17 18
19 20 21 22 23 24 25 6 7 8 9 10 11 12
13 14 15 16
T5-6-22
FAULT CODE 91 (ABNORMAL SENSOR
POWER SOURCE)
• Fault code 91 means that the voltage of the sen-

sor in the auto-MARCCINO control unit is abnor-
mal. In case fault code is displayed after the retrial,
replace the auto-MARCCINO control unit.
T5-6-23
(Blank)
T5-6-24
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source.

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

with white fine-line marking.
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 wires.
3. Precautions for connecting and disconnecting T107-07-06-001
terminal connectors.
1) When disconnecting harnesses, grasp them
by their connectors. Do not pull on the wire
itself. Be sure to release the lock first before Right
attempting to separate connectors, if a lock is
Rust
provided. (Refer to “Instructions for
Wrong
Disconnecting Connector” on page T5-7-3.)
(Deformation)
2) Water-resistant connectors keep water out so
that if water enters them, water will not easily Wrong
drain from them. When checking water- (Separation)
resistant connectors, take extra care not to T107-07-06-002
allow water to enter the connectors. In case

water should enter the connectors, reconnect
only after the connectors are thoroughly dried.
3) Before connecting terminal connectors, check
that no terminals are bent or coming off. In
addition, as most connectors are made of
brass, check that no terminals are rusting.
4) When connecting terminal connectors
provided with a lock, be sure to insert them
together until the lock clicks.
T5-7-1
4. Precautions for using a circuit tester
1) Before using a circuit tester, set the circuit
tester to meet the object to be measured,
voltage range and current polarity by referring Wind a piece of wire. Tester Probe
to the instructions in the circuit tester manual.
2) Before starting the connector test, always
check the connector terminal numbers,
referring to the circuit diagram and the
Sharpen the wire tip.
connector drawing. When the connector size is T107-07-06-003
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.
3) When performing the connector test with the
circuit tester, be sure to insert the tester probe
from the connector harness side in order not to
damage the terminals in the connector.
T5-7-2
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
• Push the Unlock and Separate Type
NOTE: Connectors may not be separated if the

lock is pushed while the connectors are
pulled. Push the lock first before pulling the
connectors.
The lock is provided on the female connec-
tor (harness side).
T107-04-05-002
Locations of This Type Connector
Fuel Gauge Washer Alternator Heater

Coolant Temperature Sensor EC Motor Engine Control Dial Starter Relay
Horn EC Sensor Engine Control Sensor Wiper
Cab Harness Diode Radio Monitor
Pressure Switch (Travel) Buzzer Air-Conditioner Generalized Relay
Pump Control Solenoid Valve Key Switch Heater Relay
• Pull Up to Unlock and Separate Type
Pressure Switch (Front Attachment/Swing)

Pilot Pressure Sensor (EX75UR-5)
T107-04-05-003
• Pull to Separate Type.
9-Spool Solenoid Valve Unit (EX75UR-5)

Oil Temperature Sensor (EX75UR-5)
Dr. EX
T107-04-05-004
T5-7-3
FUSE CONTINUITY TEST
Fuse failure is often caused by a fine crack in the fuse,

and such fine cracks are very hard to detect by visual
inspection. Checking fuse continuity with a tester is far
superior to visual inspection. Fuse continuity test with a Fuse Box
tester is introduced in the following.
1. Turn the key switch ON.

With the key switch ON, the battery relay is acti-
vated by the current from key switch terminal BR.
Then, electric power is supplied to all circuits ex-
cept the glow plug relay circuit. (Refer to the cir-
cuit diagram.)
2. Remove the fuse box cover and set the correct
voltage measurement range of the tester.
M197-01-001
(Measurement Range: 0 to 30 V)
3. Ground the negative probe to the vehicle and NOTE: All the inward terminals of the fuses in the
touch the fuse box outward terminal of each fuse fuse box are connected to the power
with the positive probe of the tester. When normal source, while the outward terminals are
continuity of a fuse is intact, the tester will indicate connected to the accessories. Test all
20 to 25 volts. fuses using the same method, except the
fuse for the glow plug relay circuit.
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
M191-07-066
Fuse Capacity Fuse Capacity

Connection Connection
No. (A) No. (A)
1 5A Optional 11 20A Work Light Relay
2 10A MC (Power Source) 12 10A Washer Relay, Wiper Relay, Wiper Motor
3 10A MC (EC Motor Power Source) 13 10A Heater, Air Conditioner
4 5A Radio, Monitor (Backup Power Source) 14 10A Emergency Evacuation Switch
5 10A Optional 15 5A MC (Power Source ON Signal)
6 5A Optional 16 10A Horn Relay
7 5A Solenoid Valve Power Source (Pump, Auto-Air 17 5A Radio (Power Source)
Bleed)
8 5A System Monitor, Buzzer, Switch Panel, Monitor 18 10A Auxiliary
Panel, Hour Meter
9 5A Auto-MARCCINO Control Unit (Power Source) 19 10A Room Light
10 10A Auto-MARCCINO Control Unit (Solenoid Valve 20 5A Spare
Power Source), Emergency Stop Solenoid Valve
T5-7-4
FUSIBLE LINK INSPECTION
Inspection Battery Relay
1. Remove the negative cable from the battery.
2. Loosen bolt M8 connecting the cable in front of
the fusible link box. Turn the cable to the horizon-
tal position as illustrated.
3. Open the front cover of the fusible link box and
visually inspect the fusible link inside. Fusible Link Box
Cable
Bolt M8
T107-04-02-006
Cover
T107-04-05-007
Replacement Battery Relay

1. Make sure that the negative cable is removed
Bolt M8
from the battery.
2. Remove bolt M8 and take the fusible link box off
the battery relay.
3. Open the top and bottom covers of the fusible link
box and remove screws M6 (two used).
4. Take out the fusible link and replace it.
5. Retighten screws M6 (two used).
6. Connect the fusible link box cable to the battery
relay.
7. Connect the negative cable to the battery.
Screw M6
Cable
T107-04-05-008
T5-7-5
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between

the battery positive terminal and the vehicle
ground.
Specification: 24 V
NOTE: If voltage is out of the specification, re-

charge or replace the battery.
2. Start the engine. Check voltage between the bat-

tery positive terminal and the vehicle ground.
Specification: 26 V to 28 V
NOTE: If voltage is out of the specification, check

the charging system.
T157-07-06-007
T5-7-6
HOW TO TROUBLESHOOTING ALTERNA-
TOR MALFUNCTIONS
Normally, the alternator indicator remains OFF as long

as the alternator is generating power. In case the alter-
nator indicator lights while the engine is running, the
alternator may be malfunctioning.
1. Turn the key switch ON. Check that the alternator E

indicator lights.
2. Measure voltage between the alternator terminals
B and E. When the measured voltage is around
24 V, the alternator circuit is regarded as normal.
If the measured voltage is lower, a shortage of
battery capacity or looseness of the wire connec-
B
tors of the alternator circuit might be the cause of
the trouble. In case the voltage is 0V, the circuit
cable between the fuse box and the alternator, or
the alternator ground cable may be broken.
3. Next, start the engine. Measure the alternator
generating voltage. As described above, measure M197-07-072
the voltage between alternator terminals B and E
in this case. When the measured voltage is
around 28 V, the alternator is operating normally.
If the measured voltage stays around 24 V, the al-
ternator or the regulator may be malfunctioning.
T5-7-7
CONTINUITY CHECK Harness
A a
Single-Line Continuity Check
Disconnect both end connectors of the harness and
check continuity between both ends:
When the ohm-meter reading is:
0 Ω = Continuity Ω
∞ Ω = Discontinuity
NOTE: When the one end connector is far apart Ground to the
A a
from the other, connect one end connector Vehicle.
(A) to the vehicle using a clip. Then, check
continuity of the wire through the vehicle as
illustrated.
Ground to the Ω
When the ohm-meter reading is: Vehicle.
0 Ω = Continuity
∞ Ω = Discontinuity
A a
Single-Line Short Circuit Check Short Circuit

Disconnect both end connectors of the harness and between the
check continuity between one end connector of the harness and
the Vehicle
harness and the vehicle. Ω
0 Ω = Short circuit is present.
∞ Ω = No short circuit is present.
T107-07-05-003
Multi-Line Continuity Check First Short Circuit (with clip)

Disconnect both end connectors of the harness, and
short-circuit two terminals (A and B) at one end con-
nector as illustrated. Then, check continuity between A a
terminals (a and b) at the other connector. B b
C c
When the ohm-meter reading is ∞Ω, either line (A) -
(a), or (B) - (b) is in discontinuity. To find out which
line is discontinued, conduct the single line continuity Second Connect
check on both lines individually, or after changing the
short-circuited terminals from (A) - (B) to (A) - (C),
check once more between terminals (a) and (c). Ω
NOTE: Repeat checking twice to find out which line

is discontinued. With terminals (A) and (C)
T107-07-05-004
short-circuited, check continuity between
terminals (a) and (c).
When the ohm-meter reading is: Short Circuit between Harnesses

0 Ω = Line (B) - (b) has discontinuity.
∞ Ω = Line (A) - (a) has discontinuity. A a
B
× b
C c
Multi-Line Short Circuit Check
Disconnect both end connectors of the harness, and
check continuity between terminals (A) and (B) or (C).
0 Ω = Short circuit exists between the lines.
∞ Ω = No short circuit exists between the lines. Ω
T107-07-05-005
T5-7-8
(Blank)
T5-7-9
VOLTAGE AND CURRENT CHECK
Turn switch ON so that the specified voltage (current) 24 Voltage Circuit

is applied to the point to be measured. Then, start Start checking in order up to the point where voltage
measuring either voltage or current. Judge if the speci- is measured from either power source or actuator
fied voltage is applied. side. Thereby, the faulty location in the circuit will be
found.
Black Probe (Minus) of Tester : To vehicle ground.
Red Probe (Plus) of Tester : To location to be
measured.
Key
Engine Check Point Specification
Switch
Power Source Circuit
Stopped OFF Between (2) and (1): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (2): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (1): Two Battery 20 to 25 V
Stopped OFF Between (4) and Ground: Power Source 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link 20 to 25 V
Stopped OFF Between (1) and Ground: Backup Current* 6 mA
Preheat Circuit
Stopped HEAT Between (6) and Ground: Key Switch 20 to 25 V
Stopped HEAT Between (7) and Ground: Glow Plug 20 to 25 V
Starting Circuit
Started START Between (8) and Ground: Key Switch 20 to 25 V
Started START Between (9) and Ground: Battery Relay (Coil) 20 to 25 V
Started START Between (10) and Ground: Battery Relay (Switch) 20 to 25 V
Started START Between (11) and Ground: Starter (B) 20 to 25 V
Started START Between (13) and Ground: Starter Relay (C) 20 to 25 V
Charging Circuit
Fast Speed ON Between (14) and Ground: Alternator (B) Generating Voltage 26 to 30 V
Fast Speed ON Between (10) and Ground: Battery Relay Generating Voltage 26 to 30 V
Fast Speed ON Between (15) and Ground: Alternator Generating Voltage 26 to 30 V
Fast Speed ON Between (16) and Ground: Alternator Generating Voltage (L) 13 to 30 V
Fast Speed ON Between (17) and Ground: MC, Monitor 13 to 30 V
Surge Voltage
Prevention Circuit
Slow Idling ON Between (14) and Ground: Alternator (B) 26 to 30 V
Slow Idling ON Between (16) and Ground: Starter Relay (R) 13 to 30 V
Slow Idling ON Between (18) and Ground: Load Dump Relay 26 to 30 V
Slow Idling ON Between (10) and Ground: Battery Relay (A) 26 to 30 V
Accessory Circuit
Stopped ON Between (19) and Ground: Room Light 20 to 25 V
Stopped ON Between (20) and Ground: Auxiliary 20 to 25 V
Stopped ON Between (21) and Ground: Radio 20 to 25 V
Stopped ON Between (21) and Ground: Horn 20 to 25 V
* After disconnecting the negative cable from the bat-

tery, start measuring.
T5-7-10
Key Switch
1 2 3 4 5 9
15 6 8
Battery
Battery Load
Relay A Dump Fuse Box
Relay
Starter
B 10
18
22 21 20 19
C 11
Fuse Box
Starter
Relay
13
16
14
17
Alternator
17
B-1
5
Monitor MC
7
T197-05-07-001
T5-7-11
5 Voltage Circuit
Power Source Signal or
Ground
• Voltage between terminal No.1 and the vehicle 1 2
ground Two Polarities
With the key switch OFF, disconnect the sensor
connector. Measure the voltage between terminal
No.1 on the machine harness end connector and
the vehicle under the following conditions.
V
• Key Switch: ON
• Tester Black Probe (Negative):
Connected to the vehicle
• Tester Red Probe (Positive):
Connected to terminal No. 1. T107-07-05-006
Evaluation: Power Source Signal Ground

When the measured voltage is within 5±0.5 volts,
1 2 3
the circuit up to terminal No.1 is normal. Three Polarities
T107-07-05-007
• Voltage between terminal No.1 and the ground

terminal
With the key switch OFF, disconnect the sensor 1 2
Two Polarities
connector. Measure the voltage between terminal
No.1 on the machine harness end connector and
the ground terminal (terminal No.2 for the two po-
larities, or terminal No.3 for the three polarities) V
under the following conditions.
• Key Switch: ON
• Tester Black Probe (Negative):
Connected to the ground terminal
(terminal No.2 or No.3) T107-07-05-008
• Tester Red Probe (Positive):
Connected to terminal No. 1.
Evaluation: 1 2 3
Three Polarities
When the measured voltage is within 5±0.5 volts,
the circuit up to terminal No.1 or the ground termi-
nal (terminal No.2 or No.3) is normal.
V
T107-07-05-009
T5-7-12
CHECK BY FALSE SIGNAL
With the key switch OFF, disconnect the sensor or

switch connector. Short-circuit terminal No.1 (power 1 2
source) on the machine harness end connector to ter-
minal No. 2 (signal) with a wire and supply the power Two Polarity
source voltage as a false signal to the connector.
Check this condition using Dr. EX monitor function. (Pressure Sensor)
When checking sensor, if the maximum value is dis-
played, the system up to the MC and the machine har-
ness end connector is normal. Connect
When checking pressure switch, if the status ON is
displayed, the system up to the MC and the machine
harness end connector is normal.
T107-07-05-010
IMPORTANT: On three-polarity connectors, do not

short-circuit terminal No.1 or No.2 to
terminal No.3 or to the vehicle . 1 2 3
Three Polarity
(EC Sensor)
Connect
T107-07-05-011
T5-7-13
TEST HARNESS
With a test harness installed between connectors, the
circuit condition is checked depending on whether the
test harness lamp lights or extinguishes during opera-
tion.
Parts Number 4283594 (ST 7126)

Use to check a single-line (discontinuity and/or volt-
age).
During Operation: Lamp is ON. To Location to be measured.
To Ground
Parts Number 4283594 (ST 7126) T107-07-05-012

Use to check the EC motor circuit.
(Refer to T5-4-16.) 5
6
50
• EC Motor Circuit
1 2 150 50 2 1
When the engine control dial is rotated:
Both lamps ON: Normal 50
3 4 4 3
Only one lamp ON: Check for continuity of the cir-
7 50
cuit connected to the lamp OFF.
Both lamps OFF: Check the harness together with 8
the relay.

T107-07-06-024

Use to measure the EC sensor or pump displacement (Red)
sensor circuit signal line voltage (between terminals #2
and #3).
(Black)

T107-07-03-009
T5-7-14
MEMO
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THE ATTACHED DIAGRAM LIST
(The following diagrams are attached to this manual.)
• EX75UR-5 HYDRAULIC CIRCUIT DIAGRAM

• EX75US-5 HYDRAULIC CIRCUIT DIAGRAM
• EX75UR-5 ELECTRICAL CIRCUIT DIAGRAM
• EX75US-5 ELECTRICAL CIRCUIT DIAGRAM
• EX75UR-5 CONNECTORS
• EX75US-5 CONNECTORS
• EX75UR-5 ENGINE HARNESS
• EX75US-5 ENGINE HARNESS
• EX75UR-5 CAB HARNESS
• EX75US-5 CAB HARNESS
Attach to Vol. No. :TT197E-00
NOTE : Refer to the PEFORMANCE STANDARD in the technical
EX75UR-5 HYDRAULIC CIRCUIT DIAGRAM manual for the relief valve pressure setting value.
spool
Joint Bracket
NOTE : Refer to the PEFORMANCE STANDARD in the technical
EX75US-5 HYDRAULIC CIRCUIT DIAGRAM manual for the relief valve pressure setting value.
Joint Bracket
EX75UR-5 ELECTRICAL CIRCUIT DIAGRAM
REDUNDANCY SW UNDER FLOOR

OUTSIDE CAB INSIDE CAB INSIDE CAB
KEY SWITCH
K
A
K
A
ACC LOAD RECEPTION REDUNDANCY SW ACCEL.

ALT LOAD LCD DISPLAY TRANSMISSION
RECEPTION
ACCEL.
TRANSMISSION
ISUZU LOAD DUMP RELAY 16 11
DECEL.
20A
10A
DECEL.
ROOM LIGHT
WIPER
REDUNDANCY SW
BIUP
LCD MONITOR
HEATER
RADIO
HORN
LIGHT
GLOW
AUX.
LCD LAMP
ISUZU DECEL.
DECEL.
WASHER
LEFT
POWER ACCEL.
WASHER RELAY
ROOM LIGHT
RIGHT
OUTSIDE CAB
INSIDE CAB DEPTH RESTRICTION SWITCH
K
ACCEL.
ISUZU
RIGHT CONTOROL
A
LEVER CONTACT
DECEL.
CAB WALL
WAIPER RELAY CAB WALL

RADIO INTIAL SETTING OF SENSOR PRES. SENSOR
BOOM RAISE PRES. BOOM RAISE
ALTERNATOR PRES. SENSOR
SERVICE SWITCH ARM DUMP (PRES. SENSOR)
ARM DUMP
RELAY
BUZZER
BOOM RAISE
REGULATOR BUZZER
SWING MODE ARM ROLL-IN
WAIPER MOTOR BOOM LOWER
BOOM RAISE ACCEL. PRES.
OFFSET RIGHT ACCEL. PRES.
SLIDE ADDITION
POWER
AUX. POWER AUX. POWER OFFSET LEFT ACCEL. PRES.
ARM ROLL-IN DECEL. PRES.
SWING PI PRES.
BOOM LOWER DECEL. PRES.
CONNECT DETECTION
CHECKER TRANSMISSION 5V(ANGLE SEN.)
SLIDE RECEPTION OFFSET RIGHT ACCEL. PRES.
UNDER FLOOR
POWER ON SIG.
BOOM ANGLE
EC MOTOR
POWER
MONITOR LAMP UNIT GLOW
3B
SLIDE SENSOR GND(ANGLE SEN.)
LAMP 5 ARM RETRACT SOL. OFFSET LEFT ACCEL.
LAMP 1
ALTERNATOR GLOW A 6 SLIDE VALVE OFFSET RIGHT SOL. ARM ANGLE PRES.
COOLANT TEMP. SENSOR LAMP 6 LAMP 2
ARM EXTEND SOL.
OVER ENG. OIL SENSOR EMERGENCY OFFSET ANGLE
1 0.85WR
LIGHT 2
HEAT PRES.
STOP VALVE
INSIDE CAB
2 W THERMISTER
LAMP 3 SLIDE SENSOR
AIR CLEANER 3 0.85WB SLIDE ARM
LAMP 4 PUMP
FUEL LEVEL
FLOAT
LOAD DUMP OUTPUT HOUR
METER BUZZER
BOOM ANGLE SENSOR
ENGINE OIL PRESSURE SWITCH FUEL COOLANT ILLUMINATION ARM ANGLE SENSOR
LAMP
OVERHEAT SWITCH
OFFSET ANGLE SENSOR
MORE THAN ACCELERATION PEDAL
GTS HYD. OIL TEMP. SENSOR

AIR CLEANER RESTRICTION SWITCH WIPER BACK-UP MAIN ( STANDARD_OPEN )
EN INPUT POWER POWER
GOVERNER EMERGENCY STOP
MONITOR CONTROL LOGIC ANGLE
REGULATOR C POINT OUTPUT ENG. CONTROL DIAL TEACHI VALVE
CON.
INDICATOR LIGHT
B
BUZZER HOUR METER
CANCEL LOAD DUMP
A SWITCH CONTROL LOGIC GND-D
WIPER WIPER
E MODE
AUTO-IDLE OUTPUT LIGHT LIGHT
EC MOTOR (SENSOR) ALTNATOR GLOW
AUTO-MARCCINO WIPER
A OUTPUT (SENSOR) INPUT
VOLTAGE
INPUT VALVE PUMP DISPLACEMENT
WIPER A4 OVERHEAT
E MODE E MODE B OUTPUT
SMOLE
WIPER A5 LARGE
AUTO M AUTO M B OUTPUT ALTERNATOR
4
AUTO-IDLE LIGHT A6
AUTO-IDLE GLOW SIGNAL
3
OUTPUT
SOL. PUMP AUTO AIR BLEED
2 5
A18
1
ENGINE OIL PRESSURE
D6
A/I
D5 PROPOTIONAL VALVE
E MODE EC MOTOR LOAD DUMP TRAVEL MODE SW PROPOTIONAL TRAVEL MODE
d10
BUZZER CANCEL VALVE
BW D8
BL D9
B2
ENG. OIL PRES. SW
WR B10 OVERHEAT SW.
SIDE
HEATER
BLOWER
RESISTER TEMP. FUSE MOTOR
1 3
HORN RELAY
SUB/H HORN
HORN SWITCH 2 5 4
SUB/H
AIR-CON(OPTION)
BLOWER
(BOOM) RESISTER TEMP. FUSE MOTOR TRAVEL MODE SW
FRT 1
TRV 1
EC MOTOR
MO1FW PRSW PRSW AIR-CONPRESSOR
MO1MW 0.85YW LOW HI
WORK LIGHT Y ENG
A/C
RELAY 1 THERMO SW. MICRO SW. COOLER RELAY (OPT)
2
2
PRESSURE_SWITCHES
(BASE)
OUTSIDE INSIDE
WORK LIGHT OUTSIDE CAB INSIDE CAB CAB CAB
EX75US-5 ELECTRICAL CIRCUIT DIAGRAM
OUTSIDE CAB INSIDE CAB

KYE SW
ACC LOAD
ALT LOAD
LOAD DUMP RELAY

ISUZU
1A 16 11
20A
10A
ROOM LIGHT
WIPER
GLOW
BIUP
LCD MONITOR
HEATER
RADIO
HORN
LIGHT
AUX.
ISUZU
WASHER
POWER
WASHER RELAY OUTSIDE CAB ROOM LIGHT
INSIDE CAB
STARTER
K
ISUZU
A
CAB WALL
WIPER RELAY CAB WALL
RADIO
ALTERNATOR GLOW RELAY
REGULATOR
WIPER MOTOR
POWER ON
INSIDE CAB UNDER FLOOR
UNDER FLOOR
POWER
POWER ON SIG.
E.C. MOTOR
MONITOR GLOW
LAMP UNIT 3B
LAMP 5 LAMP 1
ALTERNATOR GLOW A 6
COOLANT TEMP. GAUGE LAMP 6 LAMP 2
OVER ENG. OIL
HEAT PRES.
INSIDE CAB
LIGHT
LAMP 3
AIR CLEANER
LAMP 4
FUEL LEVEL
FLOAT
LOAD DUMP OUTPUT HOUR BUZZER
METER
ENG.OIL PRES. SW FUEL COOLANT ILLUMINATION

LAMP
OVER HEAT SW
MORE THAN ACCELERATOR PEDAL

GTS
AIR CLEANER SW WIPER
BACK-UP MAIN ( STANDARD_OPEN )
EN INPUT POWER POWER
GOVERNER
MONITOR CONTROL LOGIC ANGLE
REGULATOR C POINT OUTPUT ENG. CONTROL DIAL TEACHI
INDICATOR LIGHT CON.
B
BUZZER HOUR METER
CANCEL LOAD DUMP
A SWITCH CONTROL LOGIC GND-D
WIPER WIPER
E MODE
AUTO-IDLE OUTPUT LIGHT LIGHT
EC MOTOR SENSOR GLOW INPUT
WIPER
A OUTPUT SENSOR VOLTAGE VALVE PUMP DISPLACEMENT
A4
E MODE E MODE WIPER
B OUTPUT OVER HEAT INPUT
SMOLE
AUTO M AUTO M WIPER A5 LARGE
B OUTPUT ALTERNATOR
4
AUTO-IDLE AUTO-IDLE LIGHT A6
3
OUTPUT
GLOW SIGNAL VALVE AUTO AIR BLEED
2 5
A18
1
ENG. OIL PRESS.
D6
A/I
D5 PROPOTIONAL VALVE
E MODE
EC MOTOR LOAD DUMP TRAVEL SW PROPOTIONAL TRAVEL MODE
d10
BUZZER CANCEL VALVE
BW D8
BL D9
B2
ENG. OIL PRES. SW
WR B10
OVER HEAT SW
SIDE
HEATER
BLOWER
REG. TEMP. FUSE MOTOR
1 3
HORN RELAY
SUB/H HORN
HORN 2 5 4
SUB/H AIR CON.

BLOWER
(BOOM) REG. TEMP. FUSE MOTOR TRAVEL MODE SW
FRT
TRV
EC MOTOR
MO1FW PRSW PRSW AIR COMPRESSOR
MO1MW 0.85YW LOW HI
1
1
Y ENG
A/C
LIGHT RELAY 1 THERMO SW. MICRO SW. COOLER RELAY
(OPT)
2
2
PRESSURE_SWITCHES
WORK LIGHT OUTSIDE CAB INSIDE CAB INSIDE CAB OUTSIDE CAB
EX75UR-5 CONNECTORS
THESE CONNECTORS ARE THE HARNESS END
CONNECTORS, UNLESS OTHERWISE SPECIFIED.
GLOW PLUG RELAY

SOL BOOM ANGLE SENSOR ARM ANGLE SENSOR
LCD DISPLAY REDUNDANCY SW/RESI
ATT_CON. OFFSET ANGLE SENSOR LCD LAMP
4 1
1 2 1 2 1 2
1 2 3 1 2 3 3
1 2 3 3 4
4 5 OPEN OPEN OPEN 3 4 5 6 2
JFC02P-GY Z03M SUMITOMO HM090 6189-4171
PB185-02326-B YAZAKI YAZAKI
C08FW YAZAKI 7323-6234-40 CONNECTOR COLOR ARM ANGLE -BR BLACK M06_FW
7323-2228 7323-3010
OFFSET ANSLE -GY NATURAL
DIODE RELAY CHECKER HEATER POWER WIPER CN A WIPER CN B

#4414207 PILOT-SENSER IC/U BUZZER
P B F P B F
A 2 4 1 2
A 1-5V 3-GND
S E S E
K K 5 3 4 2 1 + -
2-SENS
3 YAZAKI 7323-2043 YAZAKI 7323-2446 YAZAKI 7323-2044
PH065-02010 SJD PH025-04010 SUMITOMO 6030-2981
PH065-04010
SUMITOMO 6098-1493 PACARD12052895 N-SLC-4F(N) C02FB
OPTION POWER OFFSET SW WASHER SWITCH VALVE FUEL GAUGE
LB
1 2 3 2 1 L
2 1 1 2 3
4 5 6
AMP 174056-2 YAZAKI 7323-2228
M06_FW Z02F-GY Z03F-GY
CAB/H ENG/H HYD. OIL SENSOR PRES. SWITCH RADIO_CAB/H

RADIO
AM-SANYO
SPL+ SPR+ ACC (ALM)
1 1 NC SP+ ACC ALM
2 1 1 2 SPL- SPR- GND B.UP ILL
2 2 NC SP- GND B.UP ILL
SJD L02-FB SJD PH 481-02020 C10FW YAZAKI 7119-3090

AMP 174374-6 YAZAKI7323-9327
090-2-WP {PA-9P}
A/S,EC/S EC MOTOR INITINAL SETTING

COOLER RELAY HORN RADIO AM-FM
FUJITU-TEN
SPR+ SPL+ +ACC B.UP
YAZAKI 7322-2215 SPR- SPL- GND- NC NC ILL

1 2 3 1 2
3 4
Z03F-GY
YAZAKI 0902-10P
SJD M01-FW SJD SET-1P [B] Z04F-GY AUDIO
YAZAKI 7323-2215 YAZAKI 7283-1100
SMC-B SMC-A MONITOR-A MONITOR-B

SMC-D
1 11 1 8 1 13
6 1 8 1
12 22 9 16 14 26
12 7 16 9
AMP-174515-6 AMP-174514-6 AMP-174516-6 AMP-174045-2 AMP-174046-2
FA-1 FA-2 FA-3 FA-4
11 1 8 1 10 1 5 1
24 12 18 9 22 11 12 6
32 25 25 19 31 23 16 13
AMP179681-6 AMP179679-6 AMP179680-5 AMP179678-6
FUEL GAUGE
DETAIL 2
500 ALTERNATOR
GLOW RELAY M6 CAB COVER
COL
5 B
BATTERY RELAY
DETAIL 1
ENG OIL PRES. SW ENG/H M10
CAB FLOOR
555
HORN CAB/H 554
FLAME
M10
3
3 COL
ACCESORY GND A.B
LINE
RADIO MONITOR WIPER
7-SPOOL SOL.
1.25 B
EFCT POW COL
2 GROUND LINE B.B MF
CAB FLOOR
GLASS CAB
ANGLE SENSOR Pi/SEN
1.25 COL F
EFCT CONT M
40 GROUND LINE C.B M A
F
EC MOTOR WIPER
1.25 COL
SMC POW
210 GROUND LINE D.B
EX75US-5 CONNECTORS
THESE CONNECTORS ARE THE HARNESS END
CONNECTORS, UNLESS OTHERWISE SPECIFIED.
GLOW PLUG RELAY

SOL CHEAKER SWITCH VALVE THERMO SENSOR
PILOT-SENSER OPTION POWER
ATT_CON.
4 1
1 2
1-5V 3-GND
1 2 1 2 3 3
3 4 2 1 1
4 5 OPEN OPEN OPEN
2-SENS
YAZAKI 7323-2043 4 5 2
JFC02P-GY SJD PH025-04010
PB185-02326-B Z02F-GY YAZAKI 7323-2710 YAZAKI YAZAKI
C08FW PACARD12052895 N-SLC-4F(N) M03_FW
7323-2228 7323-3010
DIODE RELAY WASHER ALTERNATOR FUEL GAUGE HEATER POWER WIPER CN A WIPER CN B
#4414207
LB R F F
P B P B
A A 2 4 L L + - S E S E
K K 5 1 2 3
3 YAZAKI 7323-2446 YAZAKI 7323-2044
YAZAKI 7323-2228 YAZAKI 7323-2128
PH065-02010 Z03F-GY PH065-04010
SUMITOMO 6098-1493 C02FB
OPTION POWER HEATER RELAY HID. TEMP. SENSOR INITIAL SETTING PRES. SWITCH STARTER RELAY-1 STARTER RELAY-2 STARTER RELAY-3
E C B
1 2 3 2 1 YAZAKI 7322-2215
1 2 S R
4 5 6
YAZAKI 7323-2215
M06_FW AMP 174374-6 YAZAKI7323-9327
YAZAKI 7323-2215 YAZAKI 7323-2830 YAZAKI 7323-3012 YAZAKI 7322-3012
090-2-WP
SOL. PUMP CAB/H ENG/H EC MOTOR RADIO_CAB/H

RADIO AM-SANYO
+ SPL+ SPR+ ACC (ALM)
1 1 NC SP+ ACC ALM
-
2 1 2 SPL- SPR- GND B.UP ILL
2 NC SP- GND B.UP ILL
3 4
SJD L02-FB SJD PH 481-02020 C10FW YAZAKI 7119-3090

Z04F-GY
YAZAKI 7323-9021 {PA-9P(FEMALE)}
COOLER RELAY HORN

A/S,EC/S
YOBI_CON. RADIO AM-FM
MONITOR-A
FUJITU-TEN
SPR+ SPL+ +ACC B.UP
1 2 3 4 SPR- SPL- GND- NC NC ILL 6 1

1 2 3 5 6 7 8 OPEN OPEN 12 7
Z03F-GY
YAZAKI 0902-10P
SJD M01-FW SJD SET-1P[B] C10FW AUDIO AMP-174045-2
YAZAKI 7283-1100
SMC-B SMC-A
SAC-D MONITOR-B
1 11 1 8 1 13
12 22 9 16 14 26 8 1
16 9
AMP-174515-6 AMP-174514-6 AMP-174516-6
AMP-174046-2
DETAIL 2
FUEL GAUGE
500 ALTERNATOR
GLOW RELAY M6 CAB COVER
COL
BATTERY RELAY 5 B
DETAIL 1
ENG/H M10
ENG OIL PRES. SW
CAB PLATE
555
CAB/H 554
HORN M10 FLAME
3
3 COL
ACCESORY A.B
GND LINE
RADIO MONITOR WIPER
7-SPOOL SOL.
1.25 COL
EFCT POW B
2 MF
CAB FLOOR GROUND LINE B.B
GLASS CAB
ANGLE SENSOR Pi/SEN
1.25 COL F
M
EFCT CONT
40 GROUND LINE C.B
M A
F
EC MOTOR WIPER
1.25 COL
SMC POW
210 GROUND LINE D.B
EX75UR-5 ENGINE HARNESS
STARTER
ARM ANGLE SENSOR

BOOM ANGLE SENSOR OFFSET ANGLE SENSOR
BOOM LIGHT
(WATER PROOF SLEEVE)
EC MOTOR
FUEL PUMP
STAY LIGHT (WATER PROOF PLUG)
(WATER PROOF SLEEVE) PUMP DISPLACEMENT
HORN SWITCH VALVE
ARM REGENERATIVE
GLOW PLUG
ARM REGENERATIVE
FUEL GAUGE
PUMP PRESSURE
SENSOR
AIR CONDITIONER
(WATER PROOF PLUG)
EMERGENCY STOP SOLENOID VALVE-2
ANGLE SENSOR
ALTERNATOR
ANGLE SENSOR
AIR CON. PRESSURE

(WATER PROOF PLUG)
ANGLE SENSOR CONNECT
PUMP PRESSURE SENSOR
ALTERNATOR
ENGINE OIL PRESSURE
ANGLE SENSOR TRAVEL MODE SUB HARNESS
ANGLE SENSOR SOLENOID VALVE
ALTERNATOR
GLOW YAZAKI
ARM REGENERATIVE
EMERGENCY STOP WASHER

SOLENOID VALVE YAZAKI
STARTER RELAY
YAZAKI
STARTER RELAY
YAZAKI
STARTER RELAY AIR CLEANER RESTRICTION

YAZAKI
AIR CLEANER RESTRICTION

(WATER PROOF PLUG)
ANGLE SENSOR
ANGLE SENSOR
ANGLE SENSOR
ANGLE SENSOR AIR CLEANER RESTRICTION SW-2
STAY LIGHT GLOW RELAY
YAZAKI
PUMP CONTROL VALVE 2 WASHER
TRAVEL MODE SOLENOID VALVE 1 COOLER RELAY
STARTER RELAY STARTER CONNECTED
EC MOTOR STARTER RELAY
TRAVEL MODE SOLENOID VALVE 2 STARTER RELAY GLOW RELAY
EC MOTOR STARTER RELAY YAZAKI
EC MOTOR
EC MOTOR GLOW
GLOW GLOW
GLOW
SUB HARNESS
COMPRESSURE
COOLER
PUMP PRESSURE SENSOR 1 BATTERY RELAY

PUMP PRESSURE SENSOR 3
EMERGENCY STOP SOLENOID VALVE-1
SUB HARNESS
AIR CLEANER RESTRICTION SW-1

FUEL LEVEL
STARTER RELAY
WASHER
BOOM LIGHT
PUMP CONTROL SOLENOID VALVE 1
FUEL POMP AUTO AIR BLEED

EX75US-5 ENGINE HARNESS

STARTER
BOOM LIGHT
STAY LIGHT
EC MOTOR
FUEL PUMP
(WATER PROOF PLUG)
PUMP DISPLACEMENT
HORN SWITCH VALVE
GLOW
PUMP CONTROL SOLENOID VALVE 2 GLOW PLUG
TRAVAL MODE SOLENOID VALVE 1
EC MOTOR FUEL GAUGE
TRAVAL MODE SOLENOID VALVE 2
EC MOTOR
EC MOTOR
EC MOTOR
AIR CONDITIONER
(WATER PROOF PLUG)
SUB HARNESS
ALTERNATOR
AIR CON. PRESSURE SW

(WATER PROOF PLUG)
CONNECT
SUB HARNESS
ENGINE OIL PRESSURE ALTERNATOR
AIR CLEANER RESTRICTION SW-1
FUEL LEVEL SUB HARNESS
ALTERNATOR
STARTER RELAY YAZAKI
TRAVEL MODE SOLENOID VALVE
WASHER
YAZAKI
STARTER RELAY
WASHER YAZAKI
STARTER RELAY
BOOM LIGHT YAZAKI
PUMP CONTROL SOLENOID VALVE 1

STARTER RELAY AIR CLEANER RESTRACTION
FUEL PUMP AUTO AIR BLEEL YAZAKI
AIR CLEANER RESTRACTION

(WATER PROOF PLUG)
AIR CLEANER
RESTRICTION SW-2
GLOW RELAY
STAY LIGHT YAZAKI
WASHER
COOLER RELAY
CONNCTED
STARTER RELAY C STARTER
STARTER RELAY B
GLOW RELAY
STARTER RELAY E
YAZAKI
STARTER RELAY R
GLOW
GLOW GLOW
GLOW
COMPRESSOR
COOLER BATTERY RELAY
EX75UR-5 CAB HARNESS
PRES. SENSOR LOAD DUMP RELAY

PRES. SENSOR SUMITOMO The harness drawer method of the fuse box.
PRES. SENSOR
PRES. SENSOR LIGHT RELAY
HORN RELAY
PRES. SENSOR SUMITOMO WASHER RELAY
SUMITOMO
PRES. SENSOR SUMITOMO
PRES. SENSOR WIPER RELAY
FUEL PUMP RELAY
PRES. SENSOR SUMITOMO SUMITOMO
PRES. SENSOR
70
PRES. SENSOR I C/U BUZZER
PRES. SENSOR SUMITOMO
PRES. SENSOR
PRES. SENSOR REDUNDANCY
500
PRES. SENSOR
POWER
OFFSET SW
SOL. VALVE
SOL. VALVE
SOL. VALVE AUX.
MONITOR BUZZER
REDUNDANCY
HID. OIL SENSOR
GLOW
SOL. VALVE
SOL. VALVE
SOL. VALVE
SOL. VALVE REDUNDANCY
SOL. VALVE PROPORTIONAL VALVE
SOL. VALVE
90˚
DEPTH RESTRICTION SW
(WATER PLOOF COVER)
70
LOAD DUMP
BUZZER BUZZER MONITOR BUZZER
SOL. VALVE
SOL. VALVE FUEL PUMP
SOL. VALVE PROPORTIONAL VALVE
SUMITOMO
SOL. VALVE SUMITOMO
DEPTH RESTRICTION SWITCH

POWER
SERVICE INPUT VOLTAGE WASHER SW
OIL PRES. YAZAKI
SLIDE LEARNING
SLIDE
The harness drawer course of the G point.
ENG. CON. SENSOR
OVER HEAT LIGHT
AUX
AUX
INITIAL SETTING
.
SUMITOMO
.
TRAVEL MODE (WATER PLOOF CONNECTOR)
DEPTH RESTRICTION SW
SLIDE
PRES. SENSOR
ANGLE SENSOR E MODE
PRES. SENSOR
ANGLE SENSOR
DISPLAY
BUZZER CANCEL
SUMITOMO
(WATER PLOOF CONNECTOR)
PRES. SENSOR HORN
LEARNI
NG
PRES. SENSOR LEARNING

PRES. SENSOR
ENG. CON.
ENG. CON. SENSOR FUEL PUMP
SLIDE FUEL PUMP LEARNING
PRESSURE. SENSOR
SLIDE ANGLE SENSOR

INITIAL SETTING
PRESSURE. SENSOR SLIDE ANGLE SENSOR

PRESSURE. SENSOR
PRESSURE. SENSOR
1 11
MONITOR BUZZER BUZZER INITIAL SETTING
ACCEL PEDAL 242 243 246 247 249 250 251 252
SERVICE
SERVICE
WASHER 253 254 256 261 262 263

TING
SET
12 22
IAL
LEARNING
INIT
WASHER
LCD DISPLAY 24V EMERGENCY STOP VALVE
LCD DISPLAY PRESSURE LIGHT ATT-SUB
SL
SLIDE ARM
ID
HID. OIL SENSOR LIGHT
E
LIGHT
LCD DISPLAY LOAD (WATER PLOOF COVER)

LCD DISPLAY LOAD
LOAD
100
DEPTH RESTRICTION SW 30
BUZZER BUZZER
INITIAL SETTING HID. OIL TEMP. SENSOR ATT-SUB DETAIL

SERVICE COOLANT TEMP. GAUGE HOUSING
FUEL GAUGE CONTACT
AIR CLEANER SW AUX. RUBBER PLUG GLAY
AUX. TO UPPER PART
TO UPPER PART NOTE:
FUEL LEVEL INDICATOR
N J 1. Between 0.5 to 1.25 may be CAVS wire, if no comment.
REDUNDANCY ROOM LIGHT TRAVEL MODE K But 2 to 5 is AVS wire, 8 is AV wire.
LIGHT 20˚ L
SUMITOMO
LIGHT HEATER (WATER PLOOF CONNECTOR)
LIGHT HEATER 2. Pin arrangement of this drawing indicate view
LIGHT REDUNDANCY points from the other side connector.
REDUNDANCY 3. No electrical branch point may be between A to B and H to I.
PUMP DISPLACEMENT 90˚ 4. The material of the connector should be brass.
5. Color sign due to JASO D607.
REDUNDANCY SW / RESI-1 POWER
REDUNDANCY SW / RESI-2 POWER 90˚ 6. Gilt pin may be used point.
REDUNDANCY SW / RESI-3 7. General express on the drawing dueto #4259303.
REDUNDANCY SW / RESI-4
REDUNDANCY SW / RESI-5 FUEL PUMP
1 3 1 3 1 3
E
SOL. VALVE 168 169 160 161 166 167 C
SOL. VALVE O 73 72 63
SOL. VALVE BOOM-D ARM-D-I ARM-C
SOL. VALVE TRAVEL MODE G 2 2 2
SOL. VALVE 6 Pi-SENSOR 2 Pi-SENSOR 5 D
The harness drawer course of the G point. PACKARD-12052895 PACKARD-12052895 PACKARD-12052895 The harness drawer course of the D point.
EX75US-5 CAB HARNESS
LOAD DUMP RELAY The harness drawer method of the fuse box.
SUMITOMO
LIGHT RELAY
HORN RELAY WASHER RELAY
SUMITOMO
SUMITOMO SUMITOMO
FUEL PUMP
FUEL PUMP WIPER RELAY
FUEL PUMP RELAY
SUMITOMO SUMITOMO
70
500
POWER
WASHER
LIGHT AUX.
LIGHT MONITOR BUZZER
LIGHT
LOAD GLOW
LOAD
PROPORTIONAL VALVE 1 LOAD
LOAD DUMP
MONITOR BUZZER
90˚
AUX.
70
FUEL PUMP AUX.
PROPORTIONAL VALVE 2
ROOM LIGHT
HEATER
INPUT VOLTAGE HEATER
ENG. OIL PRES. SW POWER
WASHER SW
PUMP DISPLACEMENT VALVE YAZAKI 1 11
LEARNING 242 243 246 247 249 250 251 252
Dr.EX POWER -1
Dr.EX POWER -2 253 254 256 261 262 263
12 22
AUX
ENG. CON. SENSOR
The harness drawer course of the E branch point.
AUX
OVER HEAT SW
.
.
TRAVEL MODE SW-1 FUEL PUMP
TRAVEL MODE SW-2

E MODE
BUZZER CANCEL
LEARN
ING
LEARNING
LEARNING
ENG. CON.
ENG. CON. SENSOR
MONITOR BUZZER BUZZER

ACCEL PEDAL
LEARNING
PRESSURE SW GND
ATT_SUB
(WATER PLOOF COVER)

100
30
ATT-SUB DETAIL
COOLANT TEMP. GAUGE
FUEL GAUGE
AIR CLEANER RESTRICTION SW TO UPPER PART
TO UPPER PART
FUEL LEVEL INDICATOR NOTE:
N J K 20˚ L 1. Between 0.5 to 1.25 may be CAVS wire, if no comment.
But 2 to 5 is AVS wire, 8 is AV wire.
2. Pin arrangement of this drawing indicate view

points from the other side connector.
3. No electrical branch point may be between A to B and H to I.
TRAVEL MODE 4. The material of the connector should be brass.
SUMITOMO 5. Color sign due to JASO D607.
90˚ (WATER PLOOF CONNECTOR) 90˚ 6. Gilt pin may be used point.
7. General express on the drawing dueto #4259303.
E
C
O
D
G
The harness drawer course of the D branch point.
The harness drawer course of the G branch point.

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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:

Group 2 Component Layout

NOTE: Dimensions marked Ȋ don’t include the

Item Category 1.75 m Arm

Item Category 1.62 m Arm

NOTE: Dimensions marked ∗ don’t include the

ENGINE STOP SYSTEM

201 Nѕm (20.5 kgfѕm) or more Output

Radiator Oil Cooler

MAIN PUMP 3 (SWING, BLADE, AND ARM 3)

SWING MOTOR VALVE UNIT

SWING PARKING BRAKE

TRAVEL BRAKE VALVE

TRAVEL PARKING BRAKE

CYLINDER (EX75UR-5) Boom Arm Bucket

CYLINDER (EX75US-5) Boom Arm Bucket

TRAVEL PILOT VALVE

OFFSET PILOT VALVE (EX75UR-5)

BLADE PILOT VALVE

9-UNIT SOLENOID VALVE (EX75UR-5)

PILOT SHUT-OFF VALVE

OIL COOLER BYPASS CHECK VALVE

GENERAL PURPOSE RELAY

NOTE: Components marked * are used only on the

NOTE: Components marked * are used only on the

NOTE: Components marked * are used only on the

NOTE: Components marked * are used only on the

Seat Rear Side Seat Left-Rear Side

1 - Auto-Idle Switch 7 - Alternator Indicator 13 - Hour Meter 19 - LCD Monitor*

Group 2 Front Control System

Group 3 Hydraulic System

Group 4 Electrical System

A microcomputer built-in main controller (MC) monitors

NOTE: EX75UR-5 has the front function control

• EC Sensor → → EC Motor Ÿ Speed Control

Operation: The engine control dial signals in re-

Engine Control Dial Stop Full

Operation: When the E mode switch ON signal

Operation: The MC drives the EC motor to move the

Pressure Switch Pressure Switch

Key Switch EC Motor

Governor Lever T197-02-01-008

Engine Control Dial

EC Motor Governor Lever

Pump Swash Angle Regulation

Operation: When receiving signals from the travel

Input Signal to MC Output Signal From MC Note

Travel Mode Switch

Pump Control T197-02-01-005

Operation: Slow Mode Operation: Fast Mode

Input Signal to MC Output Signal from MC

Pressure Switch Pressure Switch

Pump Control Solenoid Valve

Travel Mode Solenoid Valve

Auto-Air Bleed Control

Operation: When the key switch is ON or START, the