TT216E-00 Circit

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 cor- ual.
rect 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 redelivery 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.
IN-01
INTRODUCTION
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
SAFETY ALERT SYMBOL AND HEADLINE

NOTATIONS
• CAUTION:
In this manual, the following safety alert symbol and Indicated potentially hazardous situation which
signal words are used to alert the reader to the could, if not avoided, result in personal injury or
potential for personal injury of machine damage. death.
This is the safety alert symbol. When you see this • IMPORTANT:
symbol, be alert to the potential for personal injury. Indicates a situation which, if not conformed to the
Never fail to follow the safety instructions prescribed instructions, could result in damage to the machine.
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights. • NOTE:
To avoid injury and damage, be sure to use appropri- Indicates supplementary technical information or
ate lifting techniques and equipment when lifting know-how.
heavy parts.
IN-02
INTRODUCTION
UNITS USED
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA 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
Length mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 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-03
INTRODUCTION
(Blank)
IN-04
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
designated signal words above after the safety
alert symbol are occasionally used on this
machine. SA-1223
• 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 this manual is damaged or
missing, order a replacement from your author-
ized dealer in the same way you order other re-
placement parts (be sure to state machine model
and serial number when ordering).
• Learn how to operate the machine and its controls
correctly and safely.
• Allow only trained, qualified, authorized personnel SA-003
to operate the machine.

• Keep your machine in proper working condition.
• Unauthorized modifications of the machine may
impair its function and/or safety and affect ma-
chine life.
• The safety messages in this SAFETY chapter are
intended to illustrate basic safety procedures of
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 au-
thorized dealer before operating or performing
maintenance work on the machine.
003-E01B-0003
SA-2
SAFETY
PREPARE FOR EMERGENCIES
• Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.
• Thoroughly read and understand the label at-
tached on the fire extinguisher to use it properly.
• To ensure that a fire-extinguisher can be always
used when necessary, check and service the
fire-extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
• Establish emergency procedure guidelines to
cope with fires and accidents.
• Keep emergency numbers for doctors, ambu-
lance service, hospital, and fire department SA-437
posted near your telephone.
004-E01A-0437
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
Respirator or filter mask. SA-438
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
SA-3
SAFETY
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-4
SAFETY
GENERAL PRECAUTIONS FOR CAB
• Before entering the cab, thoroughly remove all

dirt and/or oil from the soles of your work boots. If
any controls such as a pedal is operated while
with dirt and/or oil on the soles of the operator’s
work boots the operator’s foot may slip off the
pedal, possibly resulting in a personal accident.
• Don’t leave parts and/or tools lying around the
operator’s seat. Store them in their specified lo-
cations.
• Avoid storing transparent bottles in the cab. Don’t
attach any transparent type window decorations
on the windowpanes as they may focus sunlight,
possibly starting a fire.
• Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab
while operating the machine.
• Keep all flammable objects and/or explosives
away from the machine.
• After using the ashtray, always cover it to extin-
guish the match and/or tobacco.
• Don’t leave cigarette lighters in the cab. When
the temperature in the cab increases, the lighter
may explode.
524-E01A-0000
SA-5
SAFETY
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.

• When you mounting and dismounting the ma-
chine, always face the machine and maintain a
three-point contact with the steps and handrails.
• Do not use any controls as hand-holds.
• Never jump on or off the machine. Never mount
or dismount a moving machine.
• Be careful of slippery conditions on platforms,
steps, and handrails when mounting and dis-
mounting the machine.
SA-439
008-E01B-0439
ADJUST THE OPERATOR'S SEAT

• A poorly adjusted seat for either the operator or for
the work at hand may quickly fatigue the operator
leading to misoperations.
• The seat should be adjusted whenever changing
the operator for the machine.
• The operator should be able to fully depress the
pedals and to correctly operate the control levers
with his back against the seat back.
• If not, move the seat forward or backward, and
check again.
SA-378
009-E01A-0378
SA-6
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-083
011-E01A-0426
SA-7
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.
• Before starting the engine, confirm that all control
levers are in neutral.
SA-084
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
could result in a battery explosion or a runaway SA-032
machine.
S013-E01A-0032
SA-8
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-0379
SA-091
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 coordi-
nate 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 steering wheel shift lever operation may

result in serious injury death.
• Before driving the machine, confirm the position
of the undercarriage in relation to the operator’s
position. 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-0491
SA-092
SA-9
SAFETY
DRIVE MACHINE SAFELY (WORK SITE)
• Before driving the machine, always confirm that the

steering wheel/shift lever 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 SA-090
death.
• When driving up or down a slope, keep the
bucket facing the direction of travel, approxi-
mately 0.5 to 1.0 m (A) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop.
SA-288
• Driving across the face of a slope or steering on

a slope may cause the machine to skid or over-
turn. If the direction must be changed, move the
machine to level ground, then, change the direc-
tion to ensure sage operation.
019-E05B-0090
SA-10
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCI-DENTS
• 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 ma-
chine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Place the shift lever in neutral, and put the brake
switch in the P (parking brake) position.
• Turn the auto-idle switch and the H/P mode
switch off.
• Run the engine at slow idle speed without load
for 5 minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK posi-
SA-278
tion.
• Block both tires 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-E01A-0270
SA-11
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.
• Keep the travel alarm in working condition (if SA-383
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.
• No machine motions shall be made unless
signals are clearly understood by both signalman SA-384
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-12
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-012
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 5 degrees if crossing the grade is
unavoidable. SA-562
• Reduce swing speed as necessary when

swinging loads.
• Be careful when working on frozen ground.
• Temperature increases will cause the ground to
become soft and make ground travel unstable.
S025-E01B-0495
SA-13
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-089
site.
029-E01A-0381
OBJECT HANDLING
• If a lifted load should fall, any person nearby may

be struck by the falling load or may be crushed
underneath it, resulting in serious injury or death.
• When using the machine for craning operations,
be sure to comply with all local regulations.
• Do not use damaged chains or frayed cables,
sables, slings, or ropes.
• Before craning, position the upperstructure with
the travel motors at the rear.
• Move the load slowly and carefully. Never move it
suddenly.
• Keep all persons well away from the load.
• Never move a load over a person's head.
• Do not allow anyone to approach the load until it
is safely and securely situated on supporting
SA-014
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-14
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.
031-E01A-0432
SA-432
PARK MACHINE SAFELY

To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Place the shift lever in neutral, and put the brake
switch in the P (parking brake) position.
• Turn auto-idle switch and auto-acceleration
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 up the pilot shut-off lever further to release
SA-093
the catch, so that the left console can be moved

upward (“CONSOLE UP” position).
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.
033-E07B-0093
SA-15
SAFETY
HANDLE FLUIDS SAFELY－AVOID FIRES
• Handle fuel with care; it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur,
possibly resulting in serious injury or death.
• Do not refuel the machine while smoking or when
near open flame or sparks.
• Always stop the engine before refueling the
machine.
• Fill the fuel tank outdoors.
• All fuels, most lubricants, and some coolants are

flammable. SA-018
• Store flammable fluids well away from fire

hazards.
• Do not incinerate or puncture pressurized
containers.
• Do not store oily rags; they can ignite and burn
spontaneously.
• Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-019
SA-16
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 load-

Less than 15°
ing/unloading the machine:
1. Select firm level ground.
SA-094
2. Be sure to use a loading dock or ramp.
3. Be sure to have a signal person when load-
ing/unloading the machine.
4. Always turn the auto-idle switch,
auto-acceleration switch and the H/P mode
switch OFF when loading or unloading the ma-
chine, to avoid unexpected speed increase due
to unintentional operation of a control lever.
5. Always select the slow travel with the fast/slow
travel switches.
6. Avoid steering while driving up or down the ramp
as it is extremely dangerous. If steering is un-
avoidable, first move back to the ground or flat-
bed, modify traveling direction, and begin to
drive again.
7. Do not operate any levers besides the travel lev-
ers when driving up or down the ramp.
8. The top end of the ramp where it meets the flat-
bed 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 up- Less than 15°
perstructure slowly for best stability.
11.Turn the brake switch to the parking (P) position. SA-095
Place blocks in front of and behind the tires to

secure the machine.
12.Securely fasten chain or cables to the machine
frame. Refer to "transporting" chapter in the op-
erator’s manual for details.
035-E06A-0395
SA-17
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
• Understand service procedures before doing

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

1) Park the machine on a level surface.
2) Lower the bucket to the ground.
3) Turn the auto-idle / acceleration selecltor off.
4) Run the engine at slow idle speed without load
for 5 minutes.
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.
SA-18
SAFETY
• If a maintenance procedure must be performed
with the engine running, do not leave machine
unattended.
• If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
• Never work under a machine raised by the boom.
• Inspect certain parts periodically and repair or
replace as necessary. Refer to the section
discussing that part in the “MAINTENANCE”
chapter in the operator’s manual.
• Keep all parts in good condition and properly
installed.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or
debris.
• When cleaning parts, always use nonflammable
SA-028
detergent oil. Never use highly frammable oil
such as fuel oil and gasoline to clean parts or
surfaces.
• Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
• Illuminate your work area adequately but safely.
• Use a portable safety light for working inside or
under the machine.
• Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
• Sufficiently illuminate the work site. Use a
maintence work light when working under or SA-527
inside the machine.

• Always use a work light protected with a guard.
In case the light bulb is broken, spilled fuel, oil
antifreeze fluid, or window washer fluid may
catch fire.
S500-E02B-0497
SA-037
SA-19
SAFETY
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause serious

injury.
• Before performing any work on the machine, at-
tach a “Do Not Operate” tag on the control lever.
This tag is available from your authorized dealer.
SS2045102
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
SA-527
jack.
519-E01A-0527
STAY CLEAR OF MOVING PARTS

• Entanglement in moving parts can cause serious
injury.
• To prevent accidents, care should be taken to
ensure that hands, feet, clothing, jewelry and hair
do not become entangled when working around
rotating parts.
502-E01A-0026
SA-026
SA-20
SAFETY
PREVENT PARTS FROM FLYING
• Travel reduction gears are under pressure.

• 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-E03A-0344
SA-344
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
SUPPORT MAINTENANCE PROPERLY

• Explosive separation of a tire and rim parts can
cause serious injury or death.
• Do not attempt to mount a tire unless you have
the proper equipment and experience to perform
the job. Have it done by your authorized dealer or
a qualified repair service.
• Always maintain the correct tire pressure. DO
NOT inflate tire above the recommended pres-
sure.
• When inflating tires, use a chip-on chuck and
extension hose long enough to allow you to stand
to one side and not in front of or over the tire as-
sembly. Use a safety cage it available.
• Inspect tires and wheels daily. Do not operate
with low pressure, cuts bubbles, damaged rims,
or missing lug bolts and nuts. SA-249
• Never cut or weld on an inflated tire or rim as-

sembly. Heat from welding could cause an in-
crease in pressure and may result in tire explo-
sion.
521-E02A-0249
SA-21
SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under
pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
• To avoid possible injury from hot spraying water.
DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the
stop. Allow all pressure to be released before
removing the cap. SA-039
• 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.
• Wait for the oil and components to cool before
starting any maintenance or inspection work.
505-E01B-0498 SA-225
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.)
• Failure to periodically replace rubber hoses may
cause a fire, fluid injection into skin, or the front SA-019
attachment to fall on a person nearby, which may

result in severe burns, gangrene, or otherwise
serious injury or death.
S506-E01A-0019
SA-22
SAFETY
AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under

pressure can penetrate the skin or eyes causing
serious injury, blindness or death.
• Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take
care to protect hands and body from
high-pressure fluids. Wear a face shield or SA-031
goggles for eye protection.

• If an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.
SA-292
507-E03A-0499
SA-044
SA-23
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-cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or SA-019
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.
SA-24
SAFETY
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.
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
SA-25
SAFETY
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 and/or the front SA-393
window cannot be opened, break the front or rear

window panes with the emergency evacuation
hammer to escape from the cab.
Refer to the explanation page on “EMERGENCY
EXIT” in Operator’s Manual.
518-E02B-0393
SS-1510
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
SA-26
SAFETY
PRECAUTIONS FOR WELDING AND
GRINDING
• Welding may generate gas and/or small fires.
• Be sure to perform welding in a well ventilated
and prepared area. Store flammable objects in a
safe place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
• Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before
starting grinding.
• After finishing welding and grinding, recheck that SA-818
there are no abnormalities such as the area sur-

rounding the welded area still smoldering.
523-E01A-0818
AVOID HEATING NEAR PRESSURIZED

FLUID LINES
• Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
• Do not heat by welding, soldering, or using a
torch near pressurized fluid lines or other
flammable materials.
• Pressurized lines can be accidentally cut when
heat goes beyond the immediate flame area.
Install temporary fire-resistant guards to protect
hoses or other materials before engaging in
welding, soldering, etc..
SA-030
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-27
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
dust. SA-029
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
object 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. Ex-
plosion of the battery may result. SA-032
• Loose terminals may produce sparks. Securely

tighten all terminals.
• Battery electrolyte is poisonous. If the battery
should explode battery electrolyte may be splashed
into eyes, possibly resulting in blindness.
• Be sure to wear eye protection when checking
electrolyte specific gravity.
512-E01C-0032
SA-28
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
• If spilled onto skin, refrigerant may cause a cold
contact burn.
• Refer to the freon container for proper use when
servicing the air conditioning system.
• Use a recovery and recycling system to avoid
venting freon into the atmosphere.
• Never let the freon stream make contact with the
skin.
SA-405
513-E01A-0405
HANDLE CHEMICAL PRODUCTS SAFELY

• Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals
used with your machine include such items as
lubricants, coolants, paints, and adhesives.
• A Material Safety Data Sheet (MSDS) provides
specific details on chemical products: physical
and health hazards, safety procedures, and
emergency response techniques.
• Check the MSDS before you start any job using a
hazardous chemical. That way you will know
exactly what the risks are and how to do the job SA-309
safely. Then follow procedures and use

recommended equipment.
S515-E01A-0309
SA-29
SAFETY
DISPOSE OF WASTE PROPERLY
• Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids.
Do not use food or beverage containers that may
mislead someone into drinking from them.
• Do not pour waste onto the ground, down a drain,
or into any water source.
• Air conditioning refrigerants escaping into the air
can damage the Earth’s atmosphere. SA-226
Government regulations may require a certified

air conditioning service center to recover and
recycle used air conditioning refrigerants.
• Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center.
S516-E01A-0226
BEFORE RETURNING THE MACHINE TO

THE CUSTOMER
• After maintenance or repair work is complete,
confirm that:
• The machine is functioning properly, especially
the safety systems.
• Worn or damaged parts have been repaired or
replaced
S517-E01A-0435 SA-435
SA-30
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 Electrical System Inspection
Group 7 ICX
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Control System Group 5 Travel Device
Group 2 Hydraulic System Group 6 Signal Control Valve
Group 3 Electrical System Group 7 Steering Valve
All information, illustrations and speci- Group 8 Brake Valve
fications in this manual are based on Group 9 Transmission Control Valve
the latest product information available Group 10 Others (Upperstructure)
at the time of publication. The right is Group 11 Others (Undercarriage)
reserved to make changes at any time
without notice.
COPYRIGHT(C)2003
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
WORKSHOP MANUAL
SECTION 1 GENERAL INFORMATION SECTION 3 UNDERCARRIAGE
Group 1 Precautions for Disassem- Group 1 Swing Bearing
bling and Assembling Group 2 Travel Motor
Group 2 Tightening Torque Group 3 Center Joint
Group 3 Painting Group 4 Transmission
Group 4 Bleeding Air from Hydrau- Group 5 Axle
lic Oil Tank Group 6 Axle Lock Cylinder
SECTION 2 UPPERSTRUCTURE Group 7 Check Valve
Group 1 Cab (Axle Lock Cylinder)
Group 2 Counterweight Group 8 Propeller Shaft
Group 3 Main Frame SECTION 4 FRONT ATTACHMENT
Group 4 Pump Device Group 1 Front Attachment
Group 5 Control Valve Group 2 Cylinder
Group 6 Swing Device Group 3 Hose-Rupture Safety Valve
Group 7 Pilot Valve Group 4 Check Valve
Group 8 Pilot Shut-Off Valve (Blade/Stabilizer)
Group 9 Signal Control Valve SECTION 5 ENGINE
Group 10 Travel Shockless Valve
Group 11 Solenoid Valve
Group 12 Pilot Relief Valve
Group 13 Steering Valve
Group 14 Brake Valve
Group 15 Accumulator Charging Valve
Group 16 Transmission Control Valve
SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction Group 4 Excavator Test
Operational Performance Tests....................T4-1-1 Travel Speed ................................................ T4-4-1
Preparation for Performance Tests...............T4-1-2 Service Brake Function Check .................... T4-4-2
Parking Brake Function Check .................... T4-4-3
Group 2 Standard Swing Speed ................................................ T4-4-4
Operational Performance Swing Function Drift Check ......................... T4-4-5
Standard Table............................................T4-2-1 Swing Motor Leakage .................................. T4-4-6
Main Pump P-Q Diagram .............................T4-2-6 Maximum Swingable Slant Angle ................ T4-4-7
Injection Pump..............................................T4-2-8 Swing Bearing Play...................................... T4-4-8
Dr.ZX Monitor Indicating Hydraulic Cylinder Cycle Time................... T4-4-10
Values .........................................................T4-2-9 Dig Function Drift Check............................ T4-4-12
Sensor Activating Range ............................T4-2-14 Control Lever Operating Force .................. T4-4-14
Control Lever Stroke .................................. T4-4-15
Group 3 Engine Test Combined Boom Raise/Swing
Engine Speed ...............................................T4-3-1 Function Check ........................................ T4-4-16
Engine Compression Pressure ....................T4-3-4
Valve Clearance Adjustment ........................T4-3-6
Nozzle Check ...............................................T4-3-8
Injection Timing ..........................................T4-3-10
Lubricant Consumption ..............................T4-3-12
CABT-4-1
Group 5 Component Test
Primary Pilot Pressure..................................T4-5-1
Secondary Pilot Pressure.............................T4-5-4
Solenoid Valve Set Pressure........................T4-5-6
Main Pump Delivery Pressure......................T4-5-9
Main Relief Valve Set Pressure..................T4-5-10
Relief Pressure (When relieving Swing) ....T4-5-13
Relief Pressure (When relieving Travel) ....T4-5-14
Overload Relief Valve Set Pressure...........T4-5-15
Main Pump Flow Rate Measurement.........T4-5-18
Regulator Adjustment .................................T4-5-22
Swing Motor Drainage................................T4-5-25
Travel Motor Drainage................................T4-5-28
Steering Valve Relief Valve Set Pressure ..T4-5-31
Brake Pressure (Front and Rear)...............T4-5-32
Brake Accumulate Pressure.......................T4-5-34
Brake Warning Set Pressure (Decrease)...T4-5-36
Brake Warning Set Pressure (Increase) ....T4-5-38
Group 6 Adjustment
Engine Speed Adjustment and Engine
Learning......................................................T4-6-1
Governor Lever and Fuel Cut Lever
Position .......................................................T4-6-4
CABT-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedure to quan- The machine performance does not always deterio-
titatively check all system and functions on the ma- rate as the working hours increase. However, the
chine. machine performance is normally considered to re-
duce in proportion to the increase of the operation
Purpose of Performance Tests hours. Accordingly, restoring the machine perform-
1. To comprehensively evaluate each operational ance by repair, adjustment, or replacement shall con-
function by comparing the performance test data sider the number of the machine’s working hours.
with the standard values.
2. According to the evaluation results, repair, adjust, Definition of “Performance Standard”
or replace parts or components as necessary to 1. Operation speed values and dimensions of the
restore the machine’s performance to the desired new machine.
standard. 2. Operational performance of new components
3. To economically operate the machine under op- adjusted to specifications. Allowable errors will be
timal conditions. indicated as necessary.
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the op-
erational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
“Performance Standard” is shown in tables to evalu-
ate the performance test data.
Precautions for Evaluation of Test Data

1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out
performance tests accurately and safely.
THE MACHINE
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.
TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to
run straight more than 300 m (984 ft 3 in), and to
make a full swing with the front attachment ex-
tended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to T105-06-01-003
be employed for communication among cowork-

ers. Once the test is started, be sure to commu-
nicate 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 escaping oil.
Pay special attention to this when removing hy-
draulic pipings.
MAKE PRECISE MEASUREMENT T212-07-01-003
1. Accurately calibrate test instruments in advance

to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.
T4-1-2
OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE
STANDARD TABLE
The standard Performance values are listed in the Engine Control Dial : Fast Idle
table below. Refer to the Group T4-3 to T4-5 for Power Mode Switch : P Mode
performance test procedures. Values indicated in Auto-Idle/Acceleration Selector : OFF
parentheses are reference values. Work Mode Switch : Digging Mode
Engine Speed Control Mode Selection Switch:
The following switch positions shall be selected and Dial Mode
the hydraulic oil temperature shall be maintained as Hydraulic Oil Temperature : 50±5 °C (122±9 °F)
indicated below as the preconditions of performance
tests unless otherwise instructed in each performance
test procedure: NOTE: 1 mm=0.03937 in
ZAXIS130W
Reference
PERFORMANCE TEST DESIGNATION Performance Remarks
Page
Standard
ENGINE SPEED min
-1
T4-3-1
Slow Idle Speed 950+150-100 Value indicated on Dr. ZX.
Fast Idle Speed (P mode) 1800±50 ↑
Fast Idle Speed (P mode Wirh ECO
1900±50 ↑
deactivated)
Extend the arm cylinder to
Fast Idle Speed (P mode and Relief relieve the arm roll-in
1750+80-20
Operation) circuit.Value indicated on Dr.
ZX.
Fast Idle Speed (E mode) 1800±50 Value indicated on Dr. ZX.
Extend the arm cylinder to
Fast Idle Speed (HP mode and Relief relieve the arm roll-in
1950+80-20
Operation) circuit.Value indicated on Dr.
ZX.
Shift Lever: D or L.
Brake Swithch: OFF or Axle
Slow Idle Speed (Pedal Mode) 950+150-100
Lock.
Value indicated on Dr. ZX.
Shift Lever: N.
Fast Idle Speed (Pedal Mode With Work
2100±50 Brake Swithch: S.
Brake)
Shift Lever: D.
Brake Swithch: OFF or Axle
Fast Idle Speed (Pedal Mode and Relief Lock. Machine jacked up.
2250±50
Operation) Keep brake pedal depressed
for travel operation.
Auto-Idle Speed 1200±100 Value indicated on Dr. ZX.
Auto-Acceleration Speed 1500±100 ↑
Warming Up Speed 1150±100 ↑
ENGINE COMPRESSION PRESSURE After engine warm-up T4-3-4
3.04 (31,440)
(After engine warm-up) 2
MPa (kgf/cm , psi)
VALVE CLEARANCE (IN, EX) 0.4 With the engine cold T4-3-7
NOZZLE INJECTION PRESSURE T4-3-8
2 18.14 (185, 2640)
MPa (kgf/cm , psi)
INJECTION TIMING T4-3-10
9°
(Degrees before TDC) deg.
T4-2-1
NOTE: 1 mm=0.03937 in
ZAXIS130W
Reference
Page
Standard
LUBRICANT CONSUMPTION Hour meter: 1000 hours or
48 or less T4-3-12
(Rated output) mL/h less
TRAVEL SPEED km/h(100 m) T4-4-1
Engine speed control mode
Fast Speed 33.0±2.0 selection switch: Pedal
Shift Lever: D
Slow Speed 8.6±0.5 selection switch: Pedal
Shift Lever: L
Creeper 2.1±0.3 selection switch: Creeper
Shift Lever: L
TRAVEL SPEED (for Germany) km/h(100 m) T4-4-1
Fast Speed 20.0±2.0 selection switch: Pedal
Shift Lever: D
Slow Speed 5.2±0.5 selection switch: Pedal
Shift Lever: L
Creeper 2.1±0.3 selection switch: Creeper
Shift Lever: L
SERVICE BRAKE FUNCTION CHECK T4-4-2
m
Braking distance at travel speed of 33
14.3 or less
km/h
Braking distance at travel speed of 20
6.4 or less
km/h
PARKING BRAKE FUNCTION CHECK T4-4-3
mm/5 min
0
SWING SPEED sec/3 rev 13.1±1.0 Bucket empty T4-4-4

SWING FUNCTION DRIFT CHECK T4-4-5
720 or less Bucket empty
mm /90°
SWING MOTOR LEAKAGE mm/5 min 0 Bucket loaded T4-4-6
MAXIMUM SWINGABLE SLANT ANGLE 18.5° or possibly Bucket loaded T4-4-7
deg. more
SWING BEARING PLAY mm 0.2 to 1.25 Allowable limit: 2.0 to 3.05 T4-4-8
T4-2-2
NOTE: 1 mm=0.03937 in
ZAXIS130W
Reference
Page
Standard
HYDRAULIC CYLINDER CYCLE TIME 0.50 m3 (PCSA heaped) T4-4-10
sec bucket, bucket empty.
Mono boom with 2.52 m arm.
2 piece boom with 2.52 m
arm.
Boom Raise (Mono Boom) 3.4±0.3
Boom Raise (2 Piece Boom) 3.7±0.3
Boom Lower (Mono Boom) 2.7±0.3
Boom Lower (2 Piece Boom) 3.0±0.3
Arm Roll-In 3.5±0.3
Arm Roll-Out 2.9±0.3
Bucket Roll-In 3.5±0.3
Bucket Roll-Out 2.4±0.3
Positioning Raise 6.5±0.5
Positioning Lower 3.2±0.3
Stabilizer Raise 1.6±0.3
Stabilizer Lower 2.0±0.3
Blade Raise 1.6±0.5
Blade Lower 2.0±0.5
DIG FUNCTION DRIFT CHECK mm/5 min 0.50 m3 (PCSA heaped) T4-4-12
bucket, bucket empty.
Mono boom with 2.52 m arm.
arm.
Boom Cylinder
15 or less Bucket loaded
(Maximum Reach Position)
Arm Cylinder
Bucket Cylinder
Positioning Cylinder
(Maximum Reach Position) 10 or less Bucket loaded
Front Sink Amount (Bucket Bottom)

CONTROL LEVER OPERATING FORCE T4-4-14
N (kgf, lbf)
Right Hand Lever: Forward/Backward 16 (1.6, 3.6) or
less
Right Hand Lever: Right/Left 16 (1.6, 3.6) or
less
Left Hand Lever: Forward/Backward 16 (1.6, 3.6) or
less
Left Hand Lever: Right/Left 16 (1.6, 3.6) or
less
Steering 20 (1.6, 4.5) or
less
T4-2-3
NOTE: 1 mm=0.03937 in
ZAXIS130W
Reference
Page
Standard
CONTROL LEVER STROKE mm T4-4-15
Right Hand Lever: Forward/Backward 74±10
Right Hand Lever: Right/Left 62±10
Left Hand Lever: Forward/Backward 74±10
Left Hand Lever: Right/Left 62±10
Steering Wheel Turns (lock-to-lock) 5.7±0.5
COMBINED BOOM RAISE/SWING sec 0.50 m3 (PCSA heaped) T4-4-16
bucket, bucket empty.
3.7±0.3
arm. bucket empty
(Bucket Teeth Height: H) mm 5300 or more
PRIMARY PILOT PRESSURE T4-5-1
(Brake Pilot Pressure) 2
MPa (kgf/cm , psi)
Engine: Fast Idle Accumulator pressure (when
4.0+1.0-0.5
charged): 15 (153, 2180) or
(41 -5, 582+145-73)
+10
higher.
SECONDARY PILOT PRESSURE) 3.3 to 3.9 (34 to Value indicated on Dr. ZX T4-5-4
(Engine: Fast Idle and Slow Idle) 40, 480 to 567) (Lever: Full stroke)
2
MPa (kgf/cm , psi) Travel, extra and blade/out-
riggers: 2.7 to 3.3 (28 to 34,
393 to 480)
SOLENOID VALVE SET PRESSURE Value Indicated On Value Indicated On Dr. ZX T4-5-6
2
MPa (kgf/cm , psi) Dr. ZX
[SE (Brake switch:
OFF): 3.7+1.0-0.5
(38+10-5, 538+145-73)]
MAIN PUMP DELIVERY PRESSURE 1.4 (14, 204) or Value indicated on Dr. ZX T4-5-9
2
MPa (kgf/cm , psi) less
MAIN RELIEF VALVE SET PRESSURE T4-5-10
2
MPa (kgf/cm , psi)
Boom, Arm, and Bucket 34.3±1.0 Value indicated on Dr. ZX
(350±10,
4980±145)
RELIEF PRESSURE 33.3+2.3-0 Value indicated on Dr. ZX T4-5-13
2
MPa (kgf/cm , psi)
(When Relieving Swing) (340+25-0,
4840+356-0)
RELIEF PRESSURE 34.3+2.0-0 Value indicated on Dr. ZX T4-5-14
2
MPa (kgf/cm , psi)
(When Relieving Travel) (350+20-0, Travel motor relief set pres-
sure: 40 (408, 5815)
4980+284-0)
RELIEF PRESSURE 2
MPa (kgf/cm , psi) 30.0±2.5 Value indicated on Dr. ZX
(When Relieving Stabilizer) (raise/lower) (306±25,
4360±356)
RELIEF PRESSURE 2
MPa (kgf/cm , psi) 30.0±2.5 Value indicated on Dr. ZX
(When Relieving Blade) (raise/lower) (306±25,
4360±356)
T4-2-4
NOTE: 1 mm=0.03937 in
ZAXIS130W Reference
PERFORMANCE TEST DESIGNATION Performance Remarks Page
Standard
OVERLOAD RELIEF VALVE SET PRES- (Reference values T4-5-15
SURE MPa (kgf/cm , psi) at 50 L/min)
2
Boom (Raise/Lower), Arm Roll-In, and 37.3+1.0-0

Bucket Roll-In (380+10-0,
5400+142-0)
Arm Roll-Out, Bucket Roll-Out, Position- 39.2+1.0-0
ing (Raise/Lower) (400+10-0,
5690+142-0)
MAIN PUMP FLOW RATE TEST (L/min) - Refer to T4-2-6 page. T4-5-18
SWING MOTOR DRAINAGE (L/min) T4-5-25
With constant maximum speed 0.4 or less Allowable limit: 0.6
With the motor relieved 1.6 or less Allowable limit: 2.0
TRAVEL MOTOR DRAINAGE (L/min) T4-5-28
With the jacked up machine Contact Hitachi for Contact Hitachi for details.
details.
With the motor relieved Contact Hitachi for Contact Hitachi for details.
details.
STEERING VALVE RELIEF VALVE 17.2+2.0-0 T4-5-31
SET PRESSURE 2
MPa (kgf/cm , psi) (175+20-0, Value indicated on Dr. ZX.
2490+284-0)
BRAKE PRESSURE (F/R) MPa (kgf/cm2, psi) 7.0±1.0 T4-5-32
Including working brake pressure (70±10, 995±142)
BRAKE ACCUMLATE PRESSURE 15.0±1.0 T4-5-34
2
MPa (kgf/cm , psi) (153±10,
2180±142)
BRAKE WARNING SET PRESSURE 5.2±0.3 T4-5-36
(DECREASE) 2
MPa (kgf/cm , psi) (53±3, 754±43)
BRAKE WARNING SET PRESSURE 5.2±0.3 T4-5-38
(INCREASE) 2
MPa (kgf/cm , psi) (53±3, 754±43) to
6.4±0.3
(65±3, 924±43)
T4-2-5
MAIN PUMP P-Q DIAGRAM
• P-Q Control (Torque Control)

(REFERENCE: Measured at Test Stand) • Points on P-Q Line
Delivery Pressure Flow Rate
• Rated Pump Speed: 1750 min-1 (rpm) MPa (kgf/cm2, psi) L/min (gpm)
(This pump device is not equipped with a trans-
A 2.0 (20, 290) P1: 105±2.5
mission so that the pump speed is equal to the
engine speed. Therefore, measure the pump flow (27.7±0.7)
rate with the engine running at the rated pump P2: 105±1.0
speed.) (27.7±0.3)
• Hydraulic Oil Temperature: 50±5 °C (122±9 °F) B 18.1 (185, 2630) [103 (27.2)]
• Output current value of torque control solenoid C 19.1 (195, 2780) 92±5 (24.3±1.3)
value: 540 mA
D 20.6 (210, 3000) 83±5 (21.9±1.3)
NOTE: Refer to T4-5-18. E 22.6 (231, 3290) 74±5 (19.5±1.3)
F 34.3 (350, 4990) [42 (11.1)]
The value indicated in parentheses is only a reference
value.
A B
L/min
C
D
Flow F
Rate
Delivery Pressure MPa (kgf/cm2)

TCAB-04-02-001
T4-2-6
• Pilot Characteristics
(REFERENCE: Measured at Test Stand) • Points on P-Q Line
Pump Control
Flow Rate
• Rated Pump Speed: 1750 min-1 (rpm) pressure
L/min (gpm)
(This pump device is not equipped with a MPa (kgf/cm2, psi)
transmission so that the pump speed is equal to 1.4±0.05 56±1.0
the engine speed. Therefore, measure the pump A
(14±0.5, 204±7.3) (14.8±0.3)
flow rate with the engine running at the rated [2.5
pump speed.) B -
(26, 363)]
• Hydraulic Oil Temperature: 50±5 °C (122±9 °F) 2.9+0.05-0.3 132 ±3.5
C
(30 -3.1, 422+7.3-43.6)
+0.5
(34.9±0.9)
NOTE: Refer to T4-5-20.
L/min C
Flow
Rate A
Pump Control Pressure MPa (kgf/cm2) TCAB-04-02-002
T4-2-7
INJECTION PUMP
Test Conditions:
1. Injection pump: PES4AD 101041-8950
2. Governor: EP/RSV 105411-2470 7. Test fuel: ISO 4113 or SAE J967d
3. Nozzle and nozzle holder assembly: 8. Transfer pump pressure:
105780-8140 (Bosch No. EF8511/9A) 157 kPa (1.6 kgf/cm2, 33 psi)
4. Nozzle: 105780-0000 (Bosch No. DN12SD12T) 9. Injection pipe: Inner Dia. 2 mm×Outer Dia. 6
5. Nozzle holder: 105780-2080 mm-Length 600 mm (0.079×0.236-23.6 in)
(Bosch No. EF8511/9) 10. Fuel temperature: 40+5 °C (104+9 °F)
6. Nozzle opening pressure: 11. Overflow valve opening pressure:
17.2 MPa (175 kgf/cm2, 2490 psi) 255 kPa (2.6 kgf/cm2, 37 psi)
Injection rate adjustment

Average Injection Maximum Variance
Adjusting Pump Speed Rack Position
-1 Rate Between Cylinders Fixed Remarks
Point (min ) (mm) 3
(cm /1000 Stroke) (%)
A 1100 10.4 90±1.1 ±2 Lever Basic
475 7.7±0.5 8.8±1.4 ±14 Rack
E 100 - 120±5 - Lever Rack limit
Governor adjustment
Rack Limit
Difference in Rack Posi-
-1
Idle-sub Spring Setting tion between 1100 min
-1
Above 14.0 and 550 min
Boost Compensator
Rack Position Stroke
(mm)
Governor Spring
Setting
-1
Pump Speed min (rpm)
T1F1-04-02-001
T4-2-8
Dr. ZX MONITOR INDICATING VALUES
Unless specified, test under the following conditions.
Engine Control Dial : Fast Idle ∗
NOTE: Items marked ( ) are measurable with the
Power Mode Switch : P Mode built-in diagnosing system.
Auto-Idle/Acceleration Selector : OFF ∗∗
Items marked ( ) are measurable with the
Work Mode Switch : Digging Mode
built-in diagnosing system. However, it
Engine Control Mode Selector Switch : Dial Mode
may be difficult to read the measured value
Hydraulic Oil Temperature : 50±5 °C (122±9 °F)
while operating the machine.
Reference Measured Value

Item Remarks
Value First Second Third Average
PUMP 1 PRESSURE (MPa)
Control Lever in Neutral∗ 0.8

Boom Raise∗ 34.8 When relieving
∗
Boom Lower
∗
Arm Roll-In 34.5 When relieving
∗
Arm Roll-Out 34.5 When relieving
∗
Bucket Roll-Out 35.2 When relieving
Bucket Roll-In* 35.5 When relieving
Boom Raise + Arm Roll-In
+ Bucket Roll-In Combined 35.0 When relieving
∗
Operation
PUMP 2 PRESSURE (MPa)
∗
Control Lever in Neutral 0.8
∗
Boom Raise 34.5 When relieving
∗
Boom Lower
∗
∗
∗
∗
Bucket Roll-In 0.8 When relieving
+ Bucket Roll-In Combined 3.5° When relieving
∗
Operation
T4-2-9

Item Remarks
PUMP 1 PUMP CONTROL
PRESSURE (MPa)
Control Lever in Neutral∗ 1.06
Boom Raise∗ 3.61 When relieving
∗
Boom Lower
∗
∗
∗
∗
+ Bucket Roll-In Combined 3.56 When relieving
∗
Operation
PUMP 2 PUMP CONTROL
PRESSURE (MPa)
∗
Control Lever in Neutral 1.09
∗
Boom Raise 3.64 When relieving
∗
Boom Lower
∗
∗
∗
∗
Boom Raise + Arm Roll-In +
Bucket Roll-In Combined 3.56 When relieving
∗
Operation
T4-2-10

Item Remarks
TARGET ENGINE SPEED -1
(min )
Fast Idle∗ 1650

Fast Idle 1750
(With ECO deactivated) ∗
Fast Idle When reliev-
(When operating a control lever)∗ 1750 ing arm roll-in
circuit
Fast Idle (HP Mode) 1950 When reliev-
(When operating a control lever)∗ ing arm roll-in
circuit
∗
Fast Idle (E Mode) 1650
∗∗
Auto-Accel 1350
∗
Auto-Idle 1050
∗
Slow Idle 800
∗
Slow Idle (Pedal Mode) 800 Axle Lock.
Shift Lever: L or D
∗
Fast Idle (Pedal Mode) 1950 Break Switch:
Shift Lever: N S.
∗
Fast Idle (Pedal Mode) 2250 Jack-up trav-
Shift Lever: D eling. Axle
Lock.
ACTUAL ENGINE SPEED -1
(min )
∗
Fast Idle 1810
Fast Idle 1910
(With ECO deactivated) ∗
Fast Idle When reliev-
∗
(When operating a control lever) 1790 ing arm roll-in
circuit
Fast Idle (HP Mode) 2000 When reliev-
(When operating a control lever)∗ ing arm roll-in
circuit
∗
∗∗
Auto-Accel 1510
∗
Auto-Idle 1200
∗
Slow Idle 930
∗
Slow Idle (Pedal Mode) 930 Axle Lock.
Shift Lever: L or D
∗
Fast Idle (Pedal Mode) 2110 Break Switch:
Shift Lever: N S.
∗
Fast Idle (Pedal Mode) 2300 Jack-up trav-
Shift Lever: D eling. Axle
Lock.
T4-2-11

Item Remarks
EC ANGLE (Volt)
∗
Minimum 2.51
∗
Maximum 3.00
DIAL ANGLE (Volt)
∗
Minimum 0.58
∗
Maximum 4.39
TRAVEL MOTOR SPEED (min-1) Jack-up traveling.
Pedal Mode. Ax-
leLock.
Drive 2128
Low 2336
VEHICLE SPEED Traveling. Pedal
Mode.
Drive -
Low -
BOOM RAISE PILOT
∗ 3.83 When relieving
CONTROL PRESSURE (MPa)
ARM ROLL-IN PILOT
∗ 3.81 When relieving
CONTROL PRESSURE (MPa)
SWING CONTROL PILOT
PRESSURE
∗
(MPa)
-
Jack-up traveling.
FORWARD TRAVEL CON- Pedal Mode. Shift
TROL PILOT PRESSURE (MPa) 3.02 Lever L or D. Axle
Lock.
Jack-up traveling.
REAR TRAVEL CONTROL Pedal Mode. Shift
PILOT PRESSURE (MPa)
3.04 Lever L or D. Axle
Lock.
FRONT ATTACHMENT “ON-OFF” is dis-
CONTROL PRESSURE
∗ - played
PUMP FLOW CHANGEOVER 0 Jack-up traveling.
PROPORTIONAL VALVE (When stop Pedal Mode. Shift
OUTPUT traveling: Lever D. Axle
(MPa) 3.91) Lock.
T4-2-12

Item Remarks
ARM REGENERATIVE PRO-
PORTIONAL VALVE OUTPUT
(MPa)
Lever in Neutral 1.48
Swing, Arm Roll-In, and Boom
Raise Combined Operation -
TRAVEL MOTOR TILT PRO-
Jack-up traveling.
PORTIONAL VALVE Axle Lock.
OUTPUT (MPa)
Drive or Low 0 Pedal Mode.
Creeper 2.93 Creeper Mode.
WORKING BREAK PROPOR- 3.34 Brake Switch: S.
TIONAL VALVE (Brake Off:
OUTPUT (MPa) 0)
When relieving
EC MOTOR POSITION (Step) 272 arm roll-in circuit
TRAVEL DRAIN PRESSURE
(MPa)
Low 0.15 Jack-up traveling.
Axle Lock.
Drive 0.15 Jack-up traveling.
Axle Lock.
ENGINE SPEED DEVIATION
-1
(min )
Fast Idle 160
Fast Idle 160
(With ECO deactivated)
Fast Idle When relieving
(When operating a control lever) 40 arm roll-in circuit
Fast Idle (HP Mode) 50 When relieving
(When operating a control lever) arm roll-in circuit
Auto-Accel 160
Auto-Idle 150
Slow Idle 130
Slow Idle (Pedal Mode) 130 Jack-up traveling.
Shift Lever: L or D Axle Lock.
Fast Idle (Pedal Mode) 160 Break Switch: S.
Shift Lever: N
Fast Idle (Pedal Mode) 50 Jack-up traveling.
Shift Lever: D Axle Lock.
PUMP TORQUE PROPOR-
0.84 Lever in neutral
TIONAL VALVE OUTPUT (MPa)
PUMP2 PROPORTIONAL
VALVE OUTPUT (MPa)
PUMP1 PROPORTIONAL
VALVE OUTPUT (MPa)
T4-2-13
SENSOR ACTIVATING RANGE
1. Checking Method
• Hydraulic Oil Temperature: 50 ± 5 °C

• Unless specified:
Engine Power Auto-Idle

Work Mode
Control Mode /Auto-Accelerati
Switch
Dial Switch -on Selector
Fast Idle P Digging OFF
• Monitor each sensor using Dr. ZX.
2. Sensor Activating Range
Sensor Operation Specification

Minimum Speed 0.3 to 1.0 V
Engine Control Dial
Maximum Speed 4.0 to 4.7 V
Minimum Speed 2.5 to 2.7 V
Maximum Speed (Power Mode Switch: P) 2.9 to 3.3 V
EC Sensor
Maximum Speed (Power Mode Switch: HP) Maximum Speed
(Mode Switch: OFF) +0.2 V or more
Control Lever: Neutral 0 to 0.1 MPa (0 to 1.0 kgf/cm2)
Pressure Sensor
Pilot Control Shut-Off Lever: LOCK
(Boom Raise, Arm
Control Lever: Full Stroke 3.3 to 3.9 MPa (34 to 40 kgf/cm2)
Roll-in, Swing)
Pilot Control Shut-Off Lever: UNLOCK
Pedal: Neutral 0 to 0.1 MPa (0 to 1.0 kgf/cm2)
Pressure Sensor Pilot Control Shut-Off Lever: LOCK
(Travel) Pedal: Full Stroke 2.7 to 3.3 MPa (28 to 34 kgf/cm2)
Pilot Control Shut-Off Lever: UNLOCK
Pump Control Control Lever: Neutral 0.7 to 1.3 MPa (7 to 13 kgf/cm2)
Pressure Sensor Control Lever: Full Stroke 2.9 to 3.9 MPa (30 to 40 kgf/cm2)
Travel Drain Pres- 0 to 0.3 MPa (0 to 3 kgf/cm2)
sure Sensor
N Sensor 20°C (Between Ground to Signal) 810 ± 240 Ω
T4-2-14
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary
1. Measure the engine speed using the built-in di- 2
agnosing system or Dr. ZX. If the built-in diag-
nosing system or Dr. ZX is not available, use an 1
engine speed meter or a pulse counter. (Refer to
the TROUBLESHOOTING / General group.)
2. Measure the engine speeds in each mode.
NOTE: Measure the engine speed before per-

forming all other tests to check that the
engine speed meets specification. Be-
cause, if the engine speed is not adjusted
correctly, all other performance data will be
unreliable. T107-06-02-002
3
Preparation:
1. Select the monitor function of the built-in diag-
nosing system (In case of Dr. ZX, connect it first).
When using an engine speed meter, install speed
pickup (2) to injection pipe (1).
When using a pulse counter, disconnect the
N-sensor connector.
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 stop-

per (3).
T1F3-04-02-001
T4-3-1
Measurement: Evaluation:
1. Check engine speeds for auto-warm up (when Refer to T4-2 Operational Performance Standard.
starting the engine), auto-idle, slow idle, fast idle
(when normal), fast idle (when the ECO is deac- Remedy:
tivated), fast idle (in the E mode), fast idle (in the Refer to T5-4 Troubleshooting B.
HP mode) and, slow idle (in the pedal mode), fast
idle (in the pedal mode with work brake) and fast NOTE: ECO stands for the auto engine speed re-
idle in the pedal mode and relief operation. duction system by 100 min-1.
2. Select the switch positions and the test condi-
tions corresponding to the engine speed to be
measured as shown in the table below.
3. When using the pulse counter, read the pulse
counter. Calculate the engine speed using the
following formula: Engine Speed (min-1) =
Pulse Numbers (Hz) × 60 / 32
Engine Speed Control Mode Selection Switch：Dial Mode

Engine Power Auto-Idle/ Auto- Work
Control Mode Acceleration Mode Test Conditions
Dial Switch Selector Switch
Digging
Slow Idle Min. Speed P OFF
Mode
Fast Idle Digging
Max. Speed P OFF
(P model) Mode
Fast Idle Check in the Dr. ZX special
Digging
(P model With Max. Speed P OFF functions with ECO deacti-
Mode
ECO deactivated) vated.
Fast Idle Check the engine speed while
Digging
(P model relief Max. Speed P OFF relieving the arm roll-in circuit.
Mode
operation)
Fast Idle Digging
Max. Speed E OFF
(E mode) Mode
Fast Idle Digging Check the engine speed while
Max. Speed HP OFF
(HP mode) Mode relieving the arm roll-in circuit.
Check engine speed 4 seconds
Digging
Auto-Idle Max. Speed P Auto-Idle after returning all control levers
Mode
to neutral.
Check reduced engine speed
Digging
Auto-Acceleration Max. Speed P Auto-Acceleration within 3 seconds after returning
Mode
all control levers to neutral.
Digging Check only when oil tempera-
Warming Up Min. Speed P OFF
Mode ture is lower than 0 °C (32 °F).
T4-3-2
Engine Speed Control Mode Selection Switch：Pedal Mode

Power Auto-Idle/ Auto- Work
Travel Pedal Mode Acceleration Mode Test Conditions
Switch Selector Switch
Shift Lever: D or L. Brake
Slow Idle Digging
Don’t Touch P OFF Switch: OFF or Axle Lock.
(Pedal Mode) Mode
Engine Control Dial: Minimum.
Fast Idle Shift Lever: N
Digging
(Pedal Mod With Full Stroke P OFF Brake Switch: S
Mode
Work Brake)
Shift Lever: D. Brake Switch:
Fast Idle OFF or Axle Lock.
Digging
(Pedal Mode and Full Stroke P OFF Machine Jacked up.
Mode
Relief Operation) Keep Brake Pedal Depressed
for Travel Operation.
Jacking Up:
Raise the undercarriage with the stabilizer and blade
provided at the front and rear of the undercarriage.
CAUTION: Securely support the raised track

using wooden blocks.
When the machine is equipped with the stabilizer or

blade at only the rear of the undercarriage, lower the
front attachment, and raise the front wheels as shown
at right.
T1F3-04-02-002
Monitor Panel Switch Panel
Engine Con-
trol Dial
Engine Speed Con-

trol Mode Selection
Switch
Work Mode
Switch
Power Mode
Switch
Auto-Idle/Acceleration
Selector
MCBB-01-012
MCBB-01-014
T4-3-3
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, in-
cluding the air filter.
Preparation:
1. Confirm that valve clearances are correct.
2. Confirm that the batteries are charged properly.
3. Run the engine until the coolant temperature
gauge reaches the operating range.
4. Stop the engine. Remove glow plugs from each
cylinder.
NOTE: Unless the fuel delivery pipes are discon-

nected, fuel will ignite in the cylinders so
that pressure in the cylinders will increase.
T105-06-02-001
5. Install an adaptor (Isuzu 5-85317-001-0) 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 cylin-
der and calculate the mean values.
Evaluation:
Refer to T4-2 Operational Performance Standard.
Remedy:
Refer to engine shop manual.
T4-3-4
(Blank)
T4-3-5
VALVE CLEARANCE ADJUSTMENT
Summary:
1. Perform the measurement when the engine is
cold.
2. Before starting work, clean the head cover
mounting area to avoid contamination in the en-
gine.
Preparation:
1. Locate the top dead center (TDC) in the com-
pression stroke. Top Mark
Align the TDC mark on the crank pulley with the
pointer located on the timing gear case as illus-
TDC Mark
trated. Piston No.1 (or piston No.4) is now posi-
tioned at the TDC in its compression stroke.
Timing Gear
Case
NOTE: When rotating the crank pulley, remove the
fan guard. Then, rotate the fan while hold- Crank Pulley
ing the fan belt. If it is difficult to rotate,
remove all glow plugs to release the com-
pression pressure.
T157-05-02-002
2. Remove the head cover.
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.
T4-3-6
Measurement:
1. Insert a thickness gauge into the clearance be-
tween the rocker arm and the valve stem end to
measure the valve clearance.
NOTE: The cylinders are aligned from No.1 to

No.4 in that order, as viewed from the fan
side.
2. When the measurement is started from No.1 cyl-

inder, 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 “×”.) T107-02-12-005
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 0.4
mm, adjust the adjusting screws.
2. After adjusting, retighten the lock nuts to the
specification.
Recheck the valve clearance after the lock nuts
are tightened.
: 25.5±4.9 N⋅m
(2.6±0.5 kgf⋅m, 18.8±3.6 lbf⋅ft)
T4-3-7
NOZZLE CHECK
Summary:
1. Check the injection pressure and the spray pat-
tern with a nozzle tester.
2. Before starting work, clean the nozzle holder
mounting area to avoid contamination in the en-
gine.
Preparation:
1. Remove the nozzle holders.
Remove all nozzle holders and fuel injection pip-
ings 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 pene-
trates 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 T107-06-02-006
approx. 60 time strokes a minute, measure the
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 by-
pass the pressure gauge. Attach the nozzle
holder to the nozzle tester. Strongly make several
strokes of the tester and check the fuel spray pat-
tern.
3. Oil tight condition
Keep the pressure slightly below the injection
pressure. Check for fuel leak from around the
nozzle tip.
NOTE: Use clean diesel oil.
T4-3-8
Evaluation:
1. Standard Injection Pressure:
Normal
2. Spray Pattern
• Large-size spray should not be visible to the na-
ked 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.
3. Oil Tight Condition
No fuel leaks.
T102-02-11-005
Abnormal
Adjustment:
1. To adjust the injection pressure, loosen the lock
nuts. Adjust the adjusting screw. T102-02-11-006
Turn clockwise to increase the pressure, and

counterclockwise to decrease the pressure.
2. After adjusting, retighten the lock nuts.
T107-06-02-007
T4-3-9
INJECTION TIMING
Timing Mark
Inspection:
1. Position No.1 piston to the top dead center. Turn Top Mark
the crank pulley in the direction of rotation (clock-
wise as seen from the front of the engine) to set a
TDC Mark
“TDC” mark on the crank pulley under the “Top
mark”, located on the timing gear case.
Timing Gear
Case
NOTE: When rotating the crank pulley, remove the
fan guard. Then, rotate the fan while hold- Crank Pulley
ing the fan belt. If it is difficult to rotate,
remove all glow plugs to release the com-
pression pressure.
T157-05-02-002
2. Remove the timing check hole cover on the front
section of the fuel injection pump. Gear Case
Projection
When the mark on the injection pump is set un-
der the projection of the gear case, No.1 piston is
positioned at the top dead center. If the mark is
not set under the projection, keep turning to ad-
just. Check
Hole
NOTE: The alignment mark on the injection pump

cannot be directly seen through the check Injection Pump
hole. Use a mirror for checking. Alignment Mark
3. Remove the injection piping from No.1 cylinder. T107-02-12-007
4. Remove the delivery valve holder for No.1 cylin- Gear Case
der from the injection pump to pull the delivery Projection
valve and the spring out. Reinstall the delivery
valve holder.
: 39 to 44 N⋅m
(4 to 4.5 kgf⋅m, 28.9 to 32.6 lbf⋅ft)
Injection Pump
Alignment Mark T107-02-12-008
T4-3-10
5. Turn the crank pulley at approx. 30 degrees
counterclockwise.
6. While supplying fuel with the feed pump, turn the
crank pulley slowly clockwise just until fuel can-
not be seen from the top of the delivery valve
hole. This is the position where the injection
starts.
7. Check the “TDC” mark, located on the crank pul-
ley for what degrees the “TDC” mark indicates.
Adjustment:
1. Turn the crank pulley so that the “TDC” mark
comes just above the correct timing position on
the timing gear case.
2. Loosen the mounting nuts of the injection pump.
3. When advancing timing, tilt the injection pump
outward against the cylinder block. T107-02-12-009
When delaying timing, tilt the injection pump in-

ward against the cylinder block.
T4-3-11
LUBRICANT CONSUMPTION
Measuring Method
1. Place the machine on level firm ground, and
leave it for at least one hour to let the lubricant
lower to the oil pan.
At this time, confirm that the machine is level,
using a leveler.
2. Record the read-out A (unit: hour) of the hour
meter.
3. Replenish the lubricant up to the high-level
gauge.
4. Operate the machine for at least 100 hours or un-
til the oil level lowers to the low-level gauge.
IMPORTANT: Make sure to keep the ma-

chine-leaving time in Step 1 above.
5. Place the machine on level firm ground, and
leave it for at least one hour to let the lubricant
lower to the oil pan.
At this time, confirm that the machine is level,
using a leveler.
6. Record the read-out B (unit: hour) of the hour
meter.
7. Replenish the lubricant up to the high-level
gauge while measuring the oil-replenishing vol-
ume C.
NOTE: For measuring, use a high-precision
measuring cylinder or the like.
8. Determine lubricant consumption from the fol-

lowing equation:
Oil replenishing volume (C) [mL] / Operating
hours (B-A) [hr]
Evaluation:
T4-3-12
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary: Evaluation:
1. Measure the time required for the machine to Refer to the Performance Standard Table in Group
travel a 100 m (328 ft) test track. T4-2.
Preparation: Remedy:
Refer to the Troubleshooting B in Group T5-4.
CAUTION: Be sure to place the swing lock
lever to the LOCK position before traveling.
1. Adjust the air pressure in all tires equally.

Air Pressure: 640 kPa (6.5 kgf/cm2, 93 psi)
2. Prepare a 100 m long straight test track on level
firm ground with a 200 m long approach runway.
3. Position front attachment for travel as instructed
End
in Operator’s Manual.
4. Maintain hydraulic oil temperature at 50±5 °C 100 m (328 ft)
(122±9 °F).
Start
Measurement: Acceleration Zone
200 m (656 ft) T1F3-04-04-003
CAUTION: Measurement in reverse travel

operation is dangerous. Perform measure-
ment in forward travel operation.
1. Measure the fast, slow and creep speeds of the
machine.
2. Select the following switch positions:

Engine Speed Control Power Mode Work Mode Auto-Idle/ Accel-
Shift Lever Travel Pedal
Mode Selection Switch Switch Switch eration Selector
Fast Speed D Pedal Full Stroke P Digging OFF
Low Speed L Pedal Full Stroke P Digging OFF
Creep L Creep Full Stroke P Digging OFF
3. Start traveling the machine in the acceleration

zone with the Forward/Reverse travel pedal
moved to the Forward position and full stroke.
4. Measure the travel speed in each travel speed.
5. Repeat steps 3. to 5. Three times in each direc-
tion and calculate the average values.
6. Convert the measured value to “km/h” unit using
the formula below:
Where:
Measured Value = S (sec)
Converted Value = A (km/h)
100×3600
A=
S×1000
T4-4-1
SERVICE BRAKE FUNCTION CHECK
Summary:
1. Determine the collective capacity of the hydraulic
pressure circuit, master cylinder and service
brake.
2. The braking capacity test is the maintenance item.
Be sure to perform the capacity test.
Preparation:
CAUTION: Be sure to place the swing lock
lever to the LOCK position before traveling.
1. Adjust the air pressure in all tires equally.

Air Pressure: 640 kPa (6.5 kgf/cm2, 93 psi)
2. Prepare a dry and solid test track 200 m (656 ft)
in length, and mark the brake starting point.
in Operator’s Manual. Stop Position
4. Maintain hydraulic oil temperature at 50±5 °C Stop Distance
(122±9 °F).
Brake Starting Po-
sition
Measurement: T1F3-04-04-004
CAUTION: Measurement in reverse travel

operation is dangerous. Perform measure-
ment in forward travel operation.
1. Measure fast speed of the machine.
Engine Speed Control Power Mode Work Mode Auto-Idle/ Accel-
Shift Lever Travel Pedal
Mode Selection Switch Switch Switch eration Selector
D Pedal Full Stroke P Digging OFF
3. Start traveling the machine in the acceleration
zone with Forward/Reverse travel pedal moved
to the Forward position and full stroke, then travel
in 33 km/h (14.3 mph) or 20 km/h (12.4 mph).
4. Depress the brake at the brake starting point to
stop the machine completely.
5. Measure the distance between the brake starting
point and the ground contacting point of the front
tire.
6. Repeat steps 3. to 5. three times in each direc-
tion and calculate the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
T4-4-2
PARKING BRAKE FUNCTION CHECK
Summary:
1. Measure the parking brake function on the speci-
fied slope.
2. The braking capacity test is the maintenance item.
Be sure to perform the capacity test.
Preparation:
1. Prepare a flat and solid test slope of 11.31°.
in Operator’s Manual.
3. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Climb up the slope, then move the brake switch
to the parking position.
2. Stop the engine. T1F3-04-04-005
3. After the machine stops, mark white lines on the

tire and the slope.
4. Wait for 5 minutes, then measure the distance
between the white lines on the tire and the slope.
Evaluation:
T4-2.
T4-4-3
SWING SPEED
Summary:
1. Measure the time required to swing three com-
plete turns.
Preparation:
1. Check the lubrication of the swing gear and
swing bearing.
2. Place the machine on flat, solid ground with am-
ple space for swinging. Do not conduct this test
on a slope.
3. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
the same as the boom foot pin. The bucket must
be empty. The same height as
the boom foot pin.
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F). T1F3-04-04-006
NOTE: In case a sufficient space for the meas-

urement is difficult to find, carry out the
measurement with the boom fully raised
and the arm fully rolled-in.
CAUTION: Prevent personal injury. Always

make sure that the area is clear and that
co-workers are out of the swing area before
starting the measurement.
Measurement:
Auto-Idle/
Engine Con- Power Mode Work Mode
Acceleration Brake Switch
trol Dial Switch Switch
Selector
Fast Idle P Digging OFF S (Working)
2. Operate swing control lever fully.
3. Measure the time required to swing 3 turns in
one direction.
4. Operate swing control lever fully in the opposite
direction and measure the time required for 3
turns.
5. Repeat steps 2. to 4. three times and calculate
the average values.
Evaluation:
T4-2.
Remedy:
T4-4-4
SWING FUNCTION DRIFT CHECK
Summary:
1. Measure the swing drift on the bearing outer cir-
cumference when stopping after a 90° full-speed
swing.
Preparation:
swing bearing.
2. Place the machine on flat, solid ground with am-
ple space for swinging. Do not conduct this test
on a slope.
the bucket so that the height of the bucket pin is Two Check Marks T202-07-03-005
the same as the boom foot pin. The bucket must Start the test from the position where the upper-
be empty. structure is rotated 90°
4. Make two chalk marks: one on the swing bearing
and one directly below it on the chassis frame.
5. Swing the upperstructure 90°.
(122±9 °F).
Measurement: T1F3-04-04-007

Auto-Idle/
Engine Con- Power Mode Work Mode Brake
Acceleration
trol Dial Switch Switch Switch
Selector
2. Operate the swing control lever fully and return it
to the neutral position when the mark on the up-
perstructure aligns with that on the chassis frame
after swinging 90°. Measure Difference Between Marks
3. Measure the distance between the two marks.
4. Align the marks again, swing 90°, then test in the
opposite direction.
5. Repeat steps 2. to 4. three times each and cal-
culate the average values.
Marking on Track Frame
Evaluation:
Marking on Swing Bearing
T4-2.
T105-06-03-010
Remedy:
T4-4-5
SWING MOTOR LEAKAGE
Summary:
1. Check for upperstructure drift while suspending a
load on a slope.
Preparation:
swing bearing.
2. Park the machine on a smooth slope with a
gradient of 26.8 %(15°)
3. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
W=750 kg (1650 lb)
4. With the arm rolled out, and bucket rolled in,
position the arm top pin height to be level with the
boom foot pin.
5. Swing the upperstructure to position it 90° to the
slope. Make aligning marks on the swing bearing
periphery and chassis frame using tape, as T212-07-03-001
illustrated.
(122±9 °F).
Measurement:
1. Select the following switch position:
Auto-Idle/
Engine Con- Power Mode Work Mode Brake
Acceleration
trol Dial Switch Switch Switch
Selector
Slow Idle P Digging OFF S (Working)
2. Maintain the engine at slow idle. After five
minutes, measure the difference between the
marks along the swing bearing periphery and the
chassis frame.
3. Perform the measurement in both right and left Measure Difference Between Marks
swing directions.
4. Perform the measurement three times in each
direction and calculate the average values.
Evaluation:
Refer to the Performance Standard Table in Group Marking on the Chassis Frame
T4-2.
Marking on the Swing Bearing
Remedy:
Refer to the Troubleshooting B in Group T5-4. T105-06-03-010
T4-4-6
MAXIMUM SWINGABLE SLANT ANGLE
CAUTION: Do not turn the brake switch OFF

during swing, since the machine can cause
tipping.
Summary:
1. With the upperstructure swung 90° to the slope,
check the maximum slant angle on which the
upperstructure can swing to the uphill side.
Preparation:
1. Check that the swing gear and bearing are well
lubricated.
2. Load bucket fully, In lieu of loading the bucket,
weight (W) of the following specification used.
W=750 kg (1650 lb)
the same as the boom foot pin.
4. Climb a slope and swing the upperstructure 90°
to the slope.
(122±9 °F).
T212-07-03-001
Measurement:
Auto-Idle/
Acceleration Brake Switch
Selector
2. Operate the swing lever to full stroke to swing the
upperstructure to the uphill side.
3. If the machine can swing, measure the cab floor
slant angle.
4. Increase the slope angle and repeat steps 2. and
3. Check both clockwise and counterclockwise.
5. Perform the measurement three times.
Evaluation:
T4-2.
Remedy:
T4-4-7
SWING BEARING PLAY
Summary:
1. Measure the swing bearing play using a dial
Dial Gauge
gauge to check the wear of bearing races and
balls.
Preparation:
1. Check swing bearing mounting bolts for loose-
ness.
2. Check the lubrication of the swing bearing. Con-
firm that bearing rotation is smooth and without
noise.
3. Install a dial gauge on the chassis frame as
shown, using a magnetic base. Magnetic
4. Position the front attachment to the front of the Base
machine.
5. Position the dial gauge so that its needle point
comes into contact with the bottom face of the
bearing outer race. T202-07-03-008
6. Bucket should be empty.
Measurement:
the same as the boom foot pin. Record the dial
gauge reading (h1). Round Frame
2. Lower the bucket to the ground and use it to Chassis
raise the front tires 0.5 m (20 in). Record the dial
gauge reading (h2).
3. Calculate bearing play (H) from this data (h1 and
h2) as follows: Magnetic Dial Gauge T105-06-03-015
H = h2 − h1 Base
Measurement (h1) Measurement (h2)
The same
height as the
boom foot pin
height.
T1F3-04-04-008
T212-07-05-003
Evaluation:
T4-2.
T4-4-8
(Blank)
T4-4-9
HYDRAULIC CYLINDER CYCLE TIME
Summary:
1. Measure the cycle time of the boom, arm, bucket,
positioning (if equipped), blade (optional) and Boom Cylinder:
stabilizer (optional) cylinders.
2. The bucket should be empty.
Preparation:
1. Be sure to measure at the position as follows.
• To measure the cycle time of the boom cylinders:
With the arm rolled out and the empty bucket
rolled in, lower the bucket to the ground, as T1F3-04-04-009
shown. Arm Cylinder:
• To measure the cycle time of the arm cylinder:
With the empty bucket rolled in, position the arm
so that it is vertical to the ground. Lower the
boom until the bucket is 0.5 m (20 in) above the
ground.
• To measure the cycle time of the bucket cylinder:
The empty bucket should be positioned at 0.5 m
mid-stroke between roll-in and roll-out, so that
the sideplate edges are vertical to the ground.
• To measure the cycle time of the positioning
T1F3-04-04-010
Bucket Cylinder:
cylinder: With the boom raise, arm rolled out and
the empty bucket rolled in, as shown.
• To measure the cycle time of the blade cylinder:
Lower the bucket to the ground and use it to lift
the machine to allow the blade cylinder to move
fully upwards and downwards.
• To measure the cycle time of the stabilizer
cylinder:
Lower the bucket to the ground and use it to lift
the machine to allow the stabilizer cylinder to
move fully upwards and downwards.

(122±9 °F). T105-06-03-018
Positioning Cylinder:
T1F3-04-04-002
T4-4-10
Measurement: Evaluation:
1. Select the following switch positions: Refer to the Performance Standard Table in Group
Auto-Idle/ T4-2.
Acceleration
Selector Remedy:
Fast Idle P Digging OFF Refer to the Troubleshooting B in Group T5-4.
2. To measure cylinder cycle times:
(Cylinder full stroke includes cylinder cushioning
zone.)
• Boom cylinders:
Measure the time it takes to raise the boom, and
the time it takes to lower the boom. To do so,
position the boom at one stroke end, then move
the control lever to the other stroke end as
quickly as possible.
• Arm cylinder:
Measure the time it takes to roll in the arm, and
the time it takes to roll out the arm. To do so,
position the arm at one stroke end, then move
• Bucket cylinder:
Measure the time it takes to roll in the bucket,
and the time it takes to roll out the bucket. To do
so, position the bucket at one stroke end, then
move the control lever to the other stroke end as
• Positioning cylinder:
Measure the time it takes to raise the positioning,
and the time it takes to lower the positioning. To
do so, position the positioning at one stroke end,
then move the control pedal to the other stroke
end as quickly as possible.
• Blade Cylinder:
Measure the time it takes to raise the blade, and
the time it takes to lower the blade. To do so,
position the blade at one stroke end, then move
• Stabilizer Cylinder:
Measure the time it takes to raise the stabilizer,
and the time it takes to lower the stabilizer. To do
so, position the stabilizer at one stroke end, then
move the control lever to the other stroke end as
quickly as possible. Move stabilizer cylinders, if
provided at front and/or rear on both sides, one
by one to measure each cycle time.
3. Repeat each measurement three times and
calculate the average values.
T4-4-11
DIG FUNCTION DRIFT CHECK
• Maximum Reach Position Retracted Extended

Distance Distance
Retracted
Summary: Distance
Measure dig function drift, which can be caused by
oil leakage in the control valve and boom, arm,
bucket and positioning(If equipped) cylinders, with The arm top pin
the loaded bucket. and the boom foot
pin are at the same
height. Drifting
Amount
NOTE: When testing the dig function drift just after
cylinder replacement, slowly operate each T1F3-04-04-011
cylinder for ten minutes to its stroke end to
purge air. 2-piece Boom
Preparation:
1. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used. W=750 kg (1650 lb)
Retracted
2. Position the arm cylinder with the rod 50 mm (2 Distance
in) extended from the fully retracted position.
3. Position the bucket cylinder with the rod 50 mm
(2 in) retracted from the fully extended position.
4. Position the positioning cylinder with the rod 50
mm (2 in) retracted from the fully extended
position.
5. With the arm rolled out and the bucket rolled in, T1F3-04-04-001
hold the bucket so that the height of the bucket

Arm Cylinder Extension
pin is the same as the boom foot pin.
(122±9 °F).
Measurement:
1. Stop the engine. Mark
2. Five minutes after the engine has been stopped,
measure the change in the position of the bottom
of the bucket and positioning, as well as the
boom, arm and bucket cylinders.
3. Repeat step 2. three times and calculate the
average values.
T110-06-03-001
Evalution:
Boom, Bucket and Positioning Cylinder Retraction
Refer to the Operational Performance Standard in
Group T4-2. Mark Mark
Remedy:
T110-06-03-002
T4-4-12
(Blank)
T4-4-13
CONTROL LEVER OPERATING FORCE
Summary:
1. Check the operation of each control lever and the
steering wheel, and measure their operating
force.
2. Measure the maximum operating force of the
control lever for the front attachment and the
steering wheel.
3. Measure the force at the center of the control
lever grip.
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F). T107-06-03-003
CAUTION: Prevent personal injury. Always Knob

Measurement:
1. Measure the force at steering wheel and each
control lever.
MCBB-01-022
Auto-Idle/
Acceleration
Selector
3. Operate each boom (raise), arm and bucket lever
to the fully and measure the maximum operating
force for each with each actuator relieved.
4. Operate boom (lower) lever and measure the
maximum operating force with the boom (lower)
relieved by jacking up the machine in a safe
area.
5. Operate swing lever and measure the maximum
operating force with swing relieved after securing
the front attachment to prevent swinging.
6. To measure the steering wheel, attach the spring
scale on the knob and measure the maximum
operating force when moving the steering wheel.
the average values.
Evaluation:
T4-2.
T4-4-14
CONTROL LEVER STROKE
Summary:
1. Measure each lever stroke at the lever top using
a ruler.
Stroke Stroke
2. Measure the lever stroke at the grip center of
each control lever.
3. In case lever stroke play is present in the neutral
position, add half (1/2) the play present to both
side lever strokes.
Neutral
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F). T1F3-04-04-012
Measurement:
1. Stop the engine.
2. Measure each lever stroke at the lever top from
neutral to the stroke end using a ruler.
3. For steering, measure the rotation frequency
necessary for the right to left stroke end or vice
versa.
4. Repeat step 2. to 3. three times and calculate the
average values.
Evaluation:
T4-2.
T4-4-15
COMBINED BOOM RAISE / SWING FUNC-
TION CHECK
Summary:
1. Check boom raise and swing movement and
speeds while operating both functions
simultaneously.
2. Make sure that the cylinders don’t hesitate while
operating the cylinder with the engine running at
fast idle.
Preparation:
1. With the arm fully rolled out and bucket fully
rolled in, lower the bucket to the ground. The
bucket must be empty. T212-07-03-005

(122±9 °F).

Measurement:
T212-07-03-006
Auto-Idle/
Acceleration
Selector
2. Raise the boom and swing simultaneously, both
at full stroke.
3. When the upperstructure rotates 90°, release the
control levers to stop both functions. Measure the
time required to swing 90° and the height (H) of
the bucket teeth. (The bucket must be empty.)
the average values. H
Evaluation:
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4. 90° T212-07-03-007
T4-4-16
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
(Including Brake Circuit)
CAUTION: If air is mixed in the brake system,

the brake function is reduced, possibly re-
sulting in serious hazard. Be sure to bleed
air from the brake system after disconnect-
ing and reconnecting the pipe lines.
Refer to the Troubleshooting B in Group
T5-4.
Pilot Filter
IMPORTANT: Primary pilot pressure circuit shuts
off a circuit connecting to pilot relief
valve if pressure in the accumulator
is insufficient, and delivers primary
pilot pressure to accumulator circuit.
At this time, primary pilot pressure
reaches 15 MPa (153 kgf/cm2, 2180
psi) or high, so use a pressure
gauge capable of measuring 15 MPa
(153 kgf/cm2, 2180 psi) or higher. MCBB-07-026
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Disconnect the hose end from the pilot filter inlet or
outlet port Install tee 3/4-16UNF(ST 6477), fitting
(ST 6069), pressure gauge (ST 6314) and cou-
pling (ST 6332).
: 22 mm, 24 mm
4. Start the engine. Confirm that no oil leakage is

T1F3-04-05-001
observed at the pressure gauge connection.
(122±9 °F).
Measurement:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector
2. Measure the pilot pressure in each specified set-

ting above.
3. Repeat the measurement three times and calcu-
late the average values.
Evaluation:
T4-2.
T4-5-1
Primary Pilot Pressure Adjustment Procedure
Adjustment: Pilot Relief Valve

Adjust the relief valve set-pressure as necessary.
1. Remove plug (1) from the relief valve.

: 36 mm
2. Remove shims (2) from the relief valve.

3. Install the estimated number of shims (2).
4. Tighten plug (1).
: 58.8±5.9 N⋅m (6±0.6 kgf⋅m, 43±4 lbf⋅ft)
5. Check the set-relief pressure.
NOTE: Standard Change in Pressure

Set the thickness of shims at less than 1.5 mm. W1F3-02-05-001
Shim Thickness Change in Relief Pressure 1
(mm) kPa (kgf/cm2) (psi) 2
0.2 61.8 (0.63) (9)

0.4 124.6 (1.27) (18)
0.8 249.2 (2.54) (36)
T1F3-03-08-002
T4-5-2
(Blank)
T4-5-3
SECONDARY PILOT PRESSURE
Preparation:
Signal Control Valve
3. Measure pressure at the location between the
pilot valve and the signal control valve:
Disconnect the pilot circuit hose to be measured
from the signal control valve. Connect hose
(9/16-18UNF approx. 400 mm long) to the signal
control valve. Install tee (4351843), adapter (ST
6460) fitting (ST 6069), coupling (ST 6332) and
pressure gauge (ST 6315) between the hoses.
: 17 mm, 19 mm
NOTE: When disconnecting the pilot lines from the

signal control valve, use tool (SNAP-ON
GAN850812B: size 19.05 mm) to easily
disconnect the lines.

(122±9 °F). T1F3-04-05-008
T4-5-4
Measurement:
Auto-Idle /
Acceleration
Selector
2. Measure the pilot pressure in each specified set-

ting above with the corresponding control lever
operated full stroke.
Evaluation:
T4-2.
Remedy:
T4-5-5
SOLENOID VALVE SET PRESSURE
Solenoid Valve Unit
Measure solenoid valve set pressure with both the
Dr.ZX and the pressure gauge.
SC SE SI SG
Preparation:
3. Disconnect line (1) from the solenoid valve to be
measured. Install hose (Parts Number: 4216453),
tee (ST 6451), adapter (ST 6461), and pressure
gauge (ST 6942) to the disconnected end at the
solenoid valve side, as illustrated.
: 17 mm, 19 mm, 22 mm
Connect Dr.ZX to the machine for solenoid valve T1F3-03-10-017
set pressure monitoring.

observed at the pressure gauge connection. Solenoid Valve
Pressure Gauge
(122±9 °F).
Hose Tee Adapter T157-05-04-002
T4-5-6
Measurement:
Auto-Idle /
Acceleration
Selector
Slow Idle P Digging OFF
2. Operate as instructed below for each measuring

solenoid valve:
Solenoid Valve SC: Perform a combined opera-
tion of boom raise and arm roll-in.
Solenoid Valve SE: Set the brake switch to OFF
position. (ON-OFF Valve)
Solenoid Valve SI: Set the engine speed control
mode selection switch to Creeper.
Solenoid Valve SG: Set the brake switch to S
(Working).
3. Read the values on both Dr.ZX and the pressure
gauge. The solenoid valve SE cannot be meas-
ured with Dr.ZX.
Evaluation:
Refer to the performance Standard Table in Group
T4-2.
T4-5-7
Solenoid Valve Set Pressure Adjustment Proce-
dure 7
IMPORTANT: Do not loosen the adjusting screw

excessively. 8
The O-ring on the threads may come
off the sealing surface, causing oil
to leak. Be sure not to loosen more
than 2 turns.
1. Loosen lock nut (7). Turn adjusting screw (8) to T107-06-04-020
adjust the set pressure of the solenoid valve.
2. Retighten lock nut (7). The distance between the
lock nut end and screw end
: 10 mm should be 2.0 mm (0.079 in)
: 3 mm or less.
: 5 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)
3. Check the set pressure of the solenoid valve.

NOTE: Standard Change in Pressure (Reference)
Screw Turns 1/4 1/2 3/4 1
Change kPa 78 156 234 312
in Pres- (kgf/cm2) (0.8) (1.6) (2.4) (3.2)
sure (psi) (11) (23) (34) (46)
8
7
T107-06-05-001
7 8
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-8
MAIN PUMP DELIVERY PRESSURE
The main pump delivery pressure can also be meas-
ured with Dr.ZX.
Preparation:
3. Remove the plug from the main pump delivery
port. Install adapter G1/4(ST 6067), hose (ST
6943) and pressure gauge (ST 6941) on the port.
: 19 mm
Or connect Dr.ZX to the machine for main pump

delivery pressure monitoring.
4. Start the engine. Confirm that no oil leakage is Pump2: Pump1:
observed at the pressure gauge connection. Delivery Port a2 Delivery Port a1
5. Maintain the hydraulic oil temperature at 50±5 °C T1F3-01-02-008
(122±9 °F).
Measurement:
Auto-Idle /
Acceleration
Selector
2. Measure the pressure with the control levers in

neutral.
Evaluation:
T4-2.
Remedy:
T4-5-9
MAIN RELIEF VALVE SET PRESSURE
The main relief pressure can also be measured with
Dr.ZX.
Summary:
Measure the main relief valve setting pressure at the
main pump delivery port.
Preparation:
3. Remove the plug from the main pump delivery
port. Install adapter G1/4 (ST 6067), hose (ST
6943) and pressure gauge (ST 6941) on the port.
: 19 mm
Or connect Dr.ZX to monitor the main pump de- Pump2: Pump1:

livery pressure. Delivery Port a2 Delivery Port a1
4. Start the engine. Confirm that no oil leakage is T1F3-01-02-008
(122±9 °F).
T4-5-10
Measurement:
Auto-Idle /
Acceleration
Selector
2. Relieve each actuator to measure main relief

pressures.
First, slowly operate bucket, arm, and boom con-
trol levers to the stroke end to relieve each func-
tion at a time.
3. As for the swing function, place the swing lock
lever to the Lock position so the upperstructure is
immovable. Slowly operate the swing lever to re-
lieve the swing function.
4. For travel operation, set the engine speed control
model selection switch to the pedal mode. Slowly
depress travel pedal for forward travel, while de-
pressing positively the brake pedal not to allow
the machine to move.
Evaluation:
T4-2.
NOTE: If the measure pressures for all functions

are lower than the specified range, the
probable cause is a decrease of the main
relief valve setting pressure.
If the relief pressure of a particular function
is lower, the probable cause is other than
main relief valve.
T4-5-11
Main Relief Pressure Setting Adjustment Proce-
dure
Adjustment:
1. Loosen lock nut (1). Main Relief
: 17 mm Valve
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
2. Turn adjusting screw (2) to adjust the main relief

set pressure referring to the table below.
3. Retighten lock nut (1).
4. Recheck the set pressures.

Plug Turns 1/4 1/2 3/4 1
Change in MPa 2.79 5.59 8.36 11.2
Relief (kgf/cm2) (28.5) (57) (85.2) (114) T176-03-03-035
Pressure (psi) (405) (811) (1212) (1620)

1 2
T176-03-03-010
Adjusting
Screw
Pressure Pressure
Increase Decrease
T105-06-05-002
T4-5-12
RELIEF PRESSURE (When relieving Swing Relief
Swing) Valve
1. Loosen lock nut (1).

: 24 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
2. Turn adjustiing screw (2) to adjust the swing relief

pressure setting referring to the table below.
: 8 mm

Screw Turns 1/4 1/2 3/4 1
Change in MPa 0.9 2.0 2.9 3.9
2
Relief (kgf/cm ) (10) (20) (30) (40)
Pressure (psi) (142) (284) (427) (570)
T176-01-02-002
1 2
T176-04-04-004
Adjusting
Screw
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-13
RELIEF PRESSURE (When relieving
Travel)
Adjustment
Loosen lock nut (2) to adjust adjusting screw (1).

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

: 6 mm
3. Tighten lock nut (2).

: 20±2 N⋅m (2±0.2kgf⋅m, 14.5±1.5 lbf⋅ft)
Travel Relief Valve
NOTE: Standard Change in Pressure (Reference) W1F3-03-02-001
Adjusting Screw
1
Turns
1
MPa 15
Change in
(kgf/cm2) 153
Pressure
(psi) 2180
2
NOTE: Relief valve at travel motor works when
T1F3-03-05-035
brake is applied. Main relief valve at control
valve works during normal travel.
2 1
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-14
OVERLOAD RELIEF VALVE SET
PRESSURE
Summary:
1. The circuit pressure must be increased by 3. If the overload relief valve performance must be
applying an external force while blocking the checked on the machine, however, measure the
return circuit from the control valve. This main relief pressure while releasing each front
measuring method is hazardous and the results function respective to the measuring overload
obtained with this method are unreliable. relief valve. And, assume that the overload relief
2. The oil flow rate used to set the overload relief valve is functioning correctly if the obtained main
pressure is far less than that used to set the main relief pressure is within the specified value range.
relief pressure. Therefore, measuring the overload Measure the main pressure of the front functions
pressure in the main circuit by increasing the main as follows:
relief set-pressure more than the overload valve
set-pressure is not a proper method. In addition, in Preparation:
case a main relief valve designed to leak a small 1. Properly shut down the engine.
quantity of oil before reliving is used, its 2. Press the air release valve on top of the hydraulic
pre-leaking start pressure must be increased oil tank to release any remaining pressure.
more than the overload relief valve set-pressure. 3. Remove the plug from the main pump delivery
However, the pre-leaking start pressure is not port. Install adapter G1/4 (ST 6067), hose (ST
always increased more than the overload relief 6943) and pressure gauge (ST 6941) on the port.
valve set-pressure as the adjustable upper limit of : 19 mm
the main relief valve set-pressure is provided.
Accordingly, the overload relief valve assembly 4. Connect Dr.ZX to the machine for main pump
should be removed from the machine and delivery pressure monitoring.
checked on a specified test stand at a correct oil Start the engine. Confirm that no oil leakage is
flow rate. Some overload relief valves come in observed at the pressure gauge connection.
contact with the control valve body to block the oil 5. Maintain the hydraulic oil temperature at 50±5 °C
passage. When this type of overload relief valve is (122±9 °F).
checked, the control valve body must be precisely
finished as the test unit. Provide one control valve
other than that on the machine as a test kit.
Pump2: Pump1:
Delivery Port a2 Delivery Port a1
T1F3-01-02-008
T4-5-15
Measurement:
Auto-Idle /
Acceleration
Selector
2. Slowly operate bucket, arm, and boom control

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

T4-2.
T4-5-16
Overload Relief Valve Set Pressure Adjusting
Procedure
NOTE: In principle, adjust the overload relief valve 1 2

set pressure on a test stand.
Adjustment:
: 17 mm
: 31.5 N⋅m (3.2 kgf⋅m, 23.2 lbf⋅ft)
2. Turn adjustiing screw (2) to adjust the overload

relief pressure setting referring to the table below. T176-03-03-012

Adjusting
Screw
Plug Turns 1/4 1/2 3/4 1
Change in MPa 2.79 5.59 8.36 11.2
Pressure Pressure
Relief (kgf/cm2) (28.5) (57) (85.2) (114) Increase Decreas
Pressure (psi) (405) (811) (1212) (1620) e
T105-06-05-002
T4-5-17
MAIN PUMP FLOW RATE MEASUREMENT
• P-Q Control (Torque Control) 5. Install a pressure gauge to the main pump to be
Summary: measured. (Refer to T4-5-10 Main Relief Pressure
Main pump performance is checked by measuring Check.)
the pump flow rate with a hydraulic tester installed at
： 19 mm
the main pump delivery port (one side) to be 6. Disconnect the vacuum pump. Loosen plug (10)
measured. Use Dr. ZX and a pressure gauge at the on the top of the pump casing to bleed air from the
same time. main pump casing until oil only comes out of the
plug clearance.
IMPORTANT: This measurement procedure is a 7. Fully open the loading valve of the hydraulic
simple method. The measured data tester.
will be lower by approx. 5 % than the 8. Start the engine. Check the pressure gauge
accurately measured value. To connection for any oil leaks. Install Dr. ZX and
measure accurately, disconnect the select the monitor function.
return circuit from the control valve
and connect it to the hydraulic oil Measurement:
tank. 1. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Preparation: 2. Measure the maximum flow rate.
1. Stop the engine. Push the air bleed valve to bleed 3. Select each switch position as follows:
air. Connect a vacuum pump to the oil filler port. Auto-Idle /
NOTE: Operate the vacuum pump while Engine Power Mode Work Mode
Acceleration
connecting the pump flow rate test line. Control Dial Switch Switch
Selector
2. Disconnect the delivery hose from the main pump
(one side) to be measured. Connect pipe (1) to
the pump delivery port using the split flanges and 4. Adjust the main relief valve set-pressure in the
bolts which were used to connect the control valve to each pressure point specified
disconnected delivery hose. along the main pump P-Q curve. (Refer to T4-2-6)
: 41 mm : 8 mm Slowly close the loading valve of the hydraulic
tester while relieving the pressure in the arm roll-in
3. Connect pipe (1) to hydraulic tester (4) using test circuit. Measure the flow rates and engine speeds
hose (2) and adapter (3). Connect adapter (5), at the pressure points specified in the P-Q curve.
test hose (6) and flange (7) to hydraulic tester (4). 5. Repeat each measurement three times and
: 41 mm calculate the average values.
4. Connect the delivery hose to flange (7) with split
flanges (8) and bolts (9).
: 8 mm
T4-5-18
Evaluation:
1. Convert the measured flow rates to those at the 2. Standard Flow Rate
specified pump speed using the following Refer to T4-2 Operational Performance Standard.
formulas: NOTE: When actually measuring, install pipe (1)
only to the pump to be measured.
Qc = (Ns × Q) ⁄ Ne
Qc : Converted Flow Rate

Q: Measured Flow Rate
Ns : Specified Pump Speed:1750 min-1
Ne : Measured Engine Speed: Dr.ZX
1 2 3 4 5 6 7 8 9
Delivery Hose (To

Control Valve)
T1F3-04-05-010
10
MCBB-07-055
1 - Pipe (ST 6192) 4 - Hydraulic Tester (ST 6299) 7 - Flange (ST 6121) 9 - Bolt (J781030) (4 Used)
2 - Test Hose (ST 6145) 5 - Adapter G1 × UNF1-7/8 8 - Split Flange (4506459) 10 - Plug
(ST 6146)
3 - Adapter G1 × UNF1-7/8 6 - Test Hose (ST 6145)
(ST 6146)
T4-5-19
• Pilot Characteristics
7. Disconnect the vacuum pump. Loosen plug (10)
the brake function is reduced, possibly on the top of the pump casing. Bleed air from the
resulting in serious hazard. Be sure to bleed pump casing until oil only comes out of the plug.
air from the brake system after disconnecting 8. Fully open the loading valve of the hydraulic
and reconnecting the pipe lines. tester.
Refer to the Troubleshooting B in Group T5-4. 9. Start the engine. Check the line connections for
any oil leaks.
Summary:
Main pump performance is checked by measuring Measurement:
the pump flow rate with a hydraulic tester installed at 1. The pump flow rate in response to the external
the main pump delivery port (one side) to be command pilot pressure is measured.
measured. Use Dr. ZX and a pressure gauge at the 2. Select each switch position as follows:
same time.
Auto-Idle /
Acceleration
IMPORTANT: This measurement procedure is a Control Dial Switch Switch
Selector
simple method. The measured data
will be lower by approx. 5 % than the
accurately measured value. To
measure accurately, disconnect the 3. Adjust the reducing valve set-pressure to each
return circuit from the control valve pressure point specified along the main pump
and connect it to the hydraulic oil P-Q curve. (Pilot Characteristics) (Refer to
tank. T4-2-7) Measure the flow rates and engine
speeds at the pressure points specified in the P-Q
curve.
Preparation: 4. Repeat each measurement three times and
1. Referring to steps 1 to 5 on page T4-5-18, calculate the average values.
connect a hydraulic tester to the main pump to be
measured. Evaluation:
2. Disconnect the hose from regulator port Pi of the 1. Convert the measured flow rates to those at the
pump to be measured. Connect plug (4174545) specified pump speed using the following
(9/16 UNF) to the disconnected hose. formulas:
: 19 mm
3. Install adapters (14) (3 used) to reducing valve Qc = (Ns × Q) / Ne
(15). Disconnect the hose (PE) from P3 port of the
3-unit solenoid valve, and install tee (11), adapter Qc : Converted Flow Rate
(12) and hose (13). Q: Measured Flow Rate
Connect the other end of hose (13) to regulator Ns : Specified Pump Speed (1750 min-1)
port P1 on reducing valve (15). Ne : Measured Engine Speed: Dr.ZX
: 19 mm
4. Install tee (16) to port P2 on reducing valve (15). 2. Standard Flow Rate
Connect pressure gauge (17) and hose (13) to Refer to T4-2 Operational Performance Standard.
tee (16). Connect hose (13) to the regulator.
: 19 mm
5. Connect hose (13) and adapter (14) to port T on
reducing valve (15). Remove plug L from the
return pipe. Connect hose (13) to the plug L port.
: 19 mm
6. Remove all the connectors from the 3-unit
solenoid valve for pump control.
T4-5-20
1 2 3 4 5 6 7 8 9
Delivery Hose (To

Control Valve)
Hose (PE) T1F3-04-05-010
Pi port (opposite faces) Pi port
T1F3-03-01-002
10
T1F3-01-02-010
3-Unit Solenoid Valve
Reducing Valve
Port Position
Reducing Return Pipe
Valve
T
L
14
To 3-Unit Solenoid
17 Valve P3 Prt
13
P1 P2
14
To Regulator
Port Pi
13 16 14 15 14 13 12 11
T1F3-04-05-009
1 - Pipe (ST 6192) 6 - Test Hose (ST 6145) 11 - Tee 7/16-20UNF x 15 - Reducing Valve (4325439)
7/16-20UNF x G1/4
(ST6456)
2 - Test Hose (ST 6145) 7 - Flange (ST 6121) 12 - Adapter 9/16 UNF x G1/4 16 - Tee 9/16 UNF x G1/4
(A852123) (ST 6450)
3 - Adapter G1 × UNF1-7/8 8 - Split Flange (4506459) 13 - Hose 9/16 UNF (4304905) 17 - Pressure Gauge
(ST 6146) (ST 6931)
4 - Hydraulic Tester (ST 6299) 9 - Bolt (J781030) (4 Used) 14 - Adapter 9/16 UNF x G3/8
(A852133)
5 - Adapter G1 × UNF1-7/8 10 - Plug
(ST 6146)
T4-5-21
REGULATOR ADJUSTMENT
• Minimum and Maximum Flow Rate Adjustment

This regulator can adjust minimum and maximum
flow rates with adjusting screws (1) and (2) at each
main pump body.
3 4 2 4 3
1 1
Main Pump1 Main Pump2 T1F3-03-01-003
1 - Adjusting Screw (For 2- Adjusting Screw (For 3- Lock Nut (For Minimum 4- Lock Nut (For Maximum
Minimum Flow Adjustment) Maximum Flow Flow Adjustment) Flow Adjustment)
Adjustment)
Adjustment Item Adjustment Procedure Remarks

1. Minimum Flow Rate Loosen lock nut (3) and turn 1) Other control characteristics remain
adjusting screw (1). unchanged. Notice that the required
Q
Rotating adjusting screw (1) 1/4 power is increased at maximum
a turn clockwise increases the delivery pressure if tightened
minimum pump flow rate by 3.0 excessively.
L/min. (183 in3/min). 2) Securely retighten lock nut (3) after
: 24 mm Nut (3) the adjustment.
: 130 N･m (13.3 kgf･m)
Pi
2. Maximum Flow Rate Loosen lock nut (4) and turn 1) Other control characteristics remain
adjusting screw (2). unchanged, except that only
Q
Rotating adjusting screw (2) 1/4 maximum oil rate varies.
a turn clockwise decreases the 2) Securely retighten lock nut (4) after
maximum pump flow rate by 3.0 the adjustment.
L/min. (183 in3/min).
: 24 mm Nut (4)
: 130 N･m (13.3 kgf･m)
Pi
T4-5-22
• Torque Adjustment (P-Q Control)
For torque adjustment, similarly adjust both the
adjusting screws (5) and (6) at the main pumps 1
and 2. Pressure change due to adjustment is that
when both the pumps are pressurized at the same
time.
9 8
5
10
T1F3-03-01-008

1. Outer Spring Adjustment Loosen lock nut (7) and turn 1) When adjusting screw (5) is
adjusting screw (5). turned, inner spring (8) set-force
varies. Therefore, when adjusting
Q Rotating adjusting screw (5) 1/4 screw (5) is turned clockwise, turn
a turn clockwise: adjusting screw (6) 1.69 times
• Compensating: + 1.75Mpa turns of adjusting screw (5)
(17.8 kgf/cm2) counterclockwise to keep inner
• Torque: + 36.5 N･m (3.63 kgf･ spring (8) set-force unchanged.
m) 2) Securely retighten lock nut (7) and
: 36 mm : Nut (7) nut (10) after the adjustment.
P1+P2 Pd : 160 N⋅m (16.3 kgf⋅m)
2. Inner Spring Adjustment Loosen lock nut (10) and turn 1) Securely retighten lock nut (10)
adjusting screw (6). after the adjustment.
Q Rotating adjusting screw (6) 1/4
a turn clockwise:
• Pump flow rate: + 7.1 L/min.
(433 in3/min).
• Torque: + 38.1 N･m (3.88 kgf･
m)
: 13 mm : Nut (10)
: 16 N⋅m (1.63 kgf⋅m)
P1+P2 Pd
T4-5-23
• Pilot Pressure Characteristics
11
12
T1F3-03-01-007

Pilot Pressure Characteristics Loosen lock nut (11) and turn 1) Securely retighten lock nut (11) after
adjusting screw (12). the adjustment.
Rotating adjusting screw (12) 1/4

Q
a turn clockwise:
• Pump flow rate: + 12.6 L/min.
(769 in3/min).
• Flow rate control starting
pressure: + 177 kPa (1.8
kgf/cm2)
: 13 mm : Nut (11)
: 16 N⋅m (1.63 kgf⋅m)
Pi
T4-5-24
SWING MOTOR DRAINAGE
Summary:
To check swing motor performance, measure the
amount of oil draining from the swing motor while
swinging the upperstructure.
NOTE: The amount of drain oil from the swing

motor will change depending on hydraulic
oil temperature.
1
Also, take care not to fall off the machine
while the measurement.
Preparation:
(122±9 °F). Rotate the swing motor to warm the
inside of the motor.
T157-05-04-014
2. Properly shut down the engine. Press air release
valve (1) on the top of the hydraulic oil tank to
release any remaining pressure. 2
3. Disconnect swing motor drain hose (2) at the

hydraulic oil tank end. Install plug (ST 6213) to the
disconnected end on the hydraulic oil tank.
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
T176-04-04-005
T4-5-25
Preconditions for Measurement:
Auto-Idle /
Acceleration
Selector
Measurement:
1. Amount of Oil Drained While Swinging the
Upperstructure
(1) Fully retract the arm cylinder. Fully extend the
bucket cylinder. Raise the boom so that the The same height as
arm tip pin height is the same as the boom boom foot pin height
foot pin height. Be sure that the bucket is
empty. T212-07-04-001
(2) Start the engine. Operate and hold the swing
lever full stroke. Start draining oil
measurement after the swing speed reaches a
constant maximum speed. The measuring
time should be more than 45 seconds.
(3) Repeat the measurement at least three times
in both clockwise and counterclockwise
directions, and calculate the average values.
2. Amount of Oil Drained While Relieving Swing

Motor Circuit
(1) Lower the swing lock pin to the Lock position
so that the upperstructure does not move.
(2) Thrust the bucket teeth into the ground as
illustrated so that the upperstructure does not
rotate when the swing lever is operated full
stroke. Swing Lock Pin M216-05-004
(3) Start the engine. Operate and hold the swing

lever full stroke. Start drain oil measurement
when drain oil starts coming out of the drain
hose end. The measuring time should be more
than 45 seconds.
(4) Repeat the measurement at least three times
in both clockwise and counterclockwise
directions, and calculate the average values.
T212-07-04-002
T4-5-26
Evaluation:
Refer to the Operational Performance Standard Table
in Group T4-2.
∗ Conversion of the amount of drain oil measured into

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

calibrated container. Then, convert the measured
drain oil into the per-minute value using the formula
below:
△Q = 60 × q / t
Where: T107-06-05-008
△Q : Amount of drain oil per minute (L/min)

t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-5-27
TRAVEL MOTOR DRAINAGE
Summary:
To check travel motor performance, measure the
amount of oil draining from the travel motor while
rotating the travel motor with the measuring jacked
up.
Be sure to secure the safety of the personnel during
the measurement, and pay good attention to the
safety of the surroundings.
1
NOTE: The amount of drain oil from the travel

motor will change depending on hydraulic
oil temperature.
Preparation:
1. Main hydraulic oil temperature at 50±5 °C (122±9
°F). Rotate the travel motor to warm the inside of
the motor.
2. Properly shut down the engine. Press the air MCBB-07-025

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

travel motor end. Install plug (3/4-16UNF)
(4174546) to the disconnected end. Connect the
drain hose (3/4-16UNF) to the travel motor.
: 22 mm, 27 mm

Auto-Idle /
Acceleration
Selector
Full P Digging OFF
Shift Lever Brake Switch T1F3-04-05-007
D A (Ale Lock)
T4-5-28
Measurement:
1. Amount of Oil Drained While Rotating Travel

Motor
1-1. Start the engine.
CAUTION: Securely support the raised track

using wooden blocks. When working around
moving parts is unavoidable, pay special
attention to ensure that hands, feet, and
clothing do not become entangled.
1-2. Raise the undercarriage with the stabilizer and

blade provided at the front and rear of the
undercarriage.
When the machine is equipped with the
stabilizer or blade at only the rear of the
undercarriage, lower the front attachment, and T1F3-04-02-002
raise the front wheels as shown at right.
1-3. Rotate the travel motor with the travel pedal
operated full stroke. Receive the drain oil from
the test hose and measure the time at the same
time. The measuring time should be more than
45 seconds.
1-4. Repeat the measurement at least three times in
forward and reverse directions, and calculate
the average values.
2. Amount of Oil Drained While Relieving Travel

Motor
2-1. Start the engine.
2-2. With the service brake depressed, depress the
travel pedal gradually to relieve the travel motor.
2-3. Start drain oil measurement when drain oil starts
coming out of the drain hose end while relieving
travel motor. The measuring time should be
more than 45 seconds.
2-4. Repeat the measurement at least three times in
both directions, and calculate the average
values.
T4-5-29
Evaluation:
T4-2.
∗ Conversion of the amount of drain oil measured into

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

calibrated container. Then, convert the measured
drain oil into the per-minute value using the formula
below:
∆Q = 60 × q / t
Where:
∆Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-5-30
STEERING VALVE RELIEF VALVE SET
PRESSURE
Measure steering valve relief valve set pressure with
both the Dr.ZX and the pressure gauge.
Summary:
The steering circuit has the steering valve relief valve.
When the steering valve relief valve is malfunctioning, 1
the steering wheel may become heavier.
Preparation:
2. Press the air release valve (1) on top of the
hydraulic oil tank to release any remaining
pressure.
3. Disconnect the hose end from the steering pilot
filter inlet or outlet port. Install tee 3/4-16UNF(ST
6477), fitting (ST 6069) and pressure gauge
assembly (ST 6933).
MCBB-07-025
: 22 mm, 24 mm
Connect Dr.ZX to the machine for pump3 delivery

pressure monitoring.
4. Start the engine. Check the pressure gauge
connection for any oil leakage.
(122±9 °F).
Measurement:
Auto-Idle /
Acceleration
Selector
2. Turn the steering wheel to the right or left stroke T1F3-04-05-006
end to measure the steering pressure using the Steering Pilot Filter
pressure gauge.
3. Repeat the measurement three times, and
Evaluation:
T4-2.
Remedy:
The steering valve relief valve cannot be adjusted. If
it does not fulfill the standard, replace as a unit.
T4-5-31
BRAKE PRESSURE (Front and Rear)

the brake function is reduced, possibly
resulting in serious hazard. Be sure to bleed
air from the brake system after disconnecting
and reconnecting the pipe lines.
Summary:
Brake pressure is measured on the output side of the
brake valve. Measure the pressure when the brake
pedal is depressed, and that when the working brake
is applied.
Preparation:
CAUTION: Attaching the measuring devices

is carried out under the machine. To avoid
unintended travel or operation of the
machine, the machine must be parked on the SA-1140
level firm ground with the bucket penetrated

into the ground as shown.

2. Press air release valve on the top of the hydraulic
3. Press and release the brake at least 50 strokes to Front Axle
reduce the accumulated pressure left in the brake
circuit.
4. Attach the measuring devices to the front and rear
wheel brake circuits.
4-1. Front wheel brake circuit pressure:
Disconnect the front wheel brake hose (1).
Connect tee 9/16-18UNF (ST 6485), fitting (ST
6069) and pressure gauge assembly (ST 6932)
in the disconnected hose. T1F3-04-05-003
: 19 mm, 22 mm 1
4-2. Rear wheel brake circuit pressure:
Disconnect the rear wheel brake hose (2).
6069) and pressure gauge assembly (ST 6932)
in the disconnected hose.
Rear Axle
: 19 mm, 22 mm

(122±9 °F).
T1F3-04-05-004
T4-5-32
Select the following switch positions:
Auto-Idle /
Acceleration Shift Lever Brake Switch
Selector
Fast Idle P Digging OFF N OFF
Measurement:
1. Measure the pressure when fully depressing the
brake pedal to the floor.
2. Measure the pressure when setting the brake
switch to S (working), without depressing the
brake pedal.
Evaluation:
T4-2.
Remedy:
Normally, the front and rear wheel brake pressures
become equal. If not, malfunction of the brake valve
and dirt caught in the valve are suspected.
T4-5-33
BRAKE ACCUMLATE PRESSURE

Summary:
The accumulated brake pressure is measured at
output port of the accumulator. The accumulated
brake pressure varies according to operation of the
brake. Record the maximum value.
Preparation:

machine, the machine must be parked on the
1. Properly shut down the engine. SA-1140

3. Press and release the brake at least 50 strokes to
circuit.
4. Remove the cover from the bottom of the cab.
Disconnect the brake hose (1).
6069) and pressure gauge assembly (ST 6932) in
the disconnected hose.
: 19 mm, 22 mm

(122±9 °F). T1F3-04-05-005
T4-5-34
Auto-Idle /
Selector
Fast Idle P Digging OFF N OFF
Measurement:
1. Measure maximum pressure when depressing
the brake pedal slowly.
Evaluation:
T4-2.
Remedy:
T4-5-35
BRAKE WARNING SET PRESSURE
(DECREASE)

Summary:
When the warning buzzer sounds by reducing the
accumulated brake pressure, the pressure is
measured at the output port of the accumulator.
Preparation:

into the ground as shown. SA-1140

circuit.
: 19 mm, 22 mm

observed at the pressure gauge connection. T1F3-04-05-005
6. Maintain the hydraulic oil temperature at 50±5 °C 1

(122±9 °F).
T4-5-36
Shift Lever Brake Switch
N P (Parking)
Measurement:
1. Properly shut down the engine. Turn key switch to
ON position.
2. Measure the pressure when warning buzzer
sounds by slowly depressing the brake pedal
several times.
Evaluation:
T4-2.
Remedy:
T4-5-37
BRAKE WARNING SET PRESSURE
(INCREASE)

Summary:
When sounding of the warning buzzer stops by
increasing the accumulated brake pressure, the
pressure is measured at the output port of the
accumulator.
Preparation:

level firm ground with the bucket penetrated SA-1140

circuit.
: 19 mm, 22 mm
5. Start the engine. Confirm that no oil leakage is T1F3-04-05-005
observed at the pressure gauge connection. 1

(122±9 °F).
T4-5-38
Auto-Idle /
Selector
Digging
Minimum P Mode OFF N P (Parking)
Mode
Measurement:
1. Properly shut down the engine. Turn key switch to
ON position.
2. Depress the brake pedal several times to make
the warning buzzer sound.
3. Start the engine. Measure the pressure when
sounding of the warning buzzer stops. Notice that
it is difficult to read the gauge because the
pressure increases rapidly.
Evaluation:
T4-2.
Remedy:
T4-5-39
(Blank)
T4-5-40
OPERATIONAL PERFORMANCE TEST / Adjustment
ENGINE SPEED ADJUSTMENT AND
ENGINE LEARNING
After removing and/or replacing the components as
described below for repair and/or inspection, or if error
in engine speed is found, readjust engine speed and
perform engine learning.
• Removal of the engine, engine control cable, or

EC motor
• Replacement of MC
Adjustment of Engine Speed:

1. Turn the key switch to the START position to start
the engine.
NOTE: Turn the air conditioner OFF.
2. Rotate the engine control dial to the minimum

speed position. (The output voltage from the EC
sensor is 2.5 V.)
3. Deactivate the auto warming up and ECO control

systems by Dr. ZX.
4. When Dr. ZX is not available, keep the engine

running for about 15 minutes to warm coolant
temperature to more than 30 °C (86 F°) until the
auto warming up control system is deactivated.
5. Loosen the bolt holding the control lever to the EC Holding Bolt
motor output shaft.
Control Lever T157-07-04-015
6. While monitoring the actual engine speed with Dr.
ZX or the engine speed meter, adjust the control
lever so that the minimum speed (slow idle)
matches the specification.
Specification: Refer to T4-2 OPERATIONAL PER
FORMANCE TEST.
7. Tighten the lever holding bolt to secure the control

lever to the motor output shaft.
: 13 N⋅m (1.3 kgf⋅m, 9.4 lbf⋅ft)
NOTE: Don’t lubricate the motor output shaft.
8. Perform engine learning.
T4-6-1
Engine Learning:
1. Turn the key switch OFF
Learning
NOTE: In case the engine doesn’t stop when the Switch
key switch is turned OFF, pull the handle
located under the seat to stop the engine.
Dr.ZX
2. Disconnect Dr. ZX. Wait for 5 seconds. Connector
to MC
3. Turn the learning switch ON.
4. Turn the key switch ON. Wait for 5 seconds.
5. Turn the key switch OFF. Wait for 5 seconds.
6. Turn the learning switch OFF.
7. Check the engine speed. T178-01-02-006
Learning Switch is
Turned to Stamp E
Learning Switch
Stamp
T1CC-05-01-001
T4-6-2
(Blank)
T4-6-3
GOVERNOR LEVER AND FUEL CUT
LEVER POSITION
• Check the fuel cut lever position during cranking.

If the position is normal, the engine unit and/or
fuel system may have trouble.
• Governor Lever and Fuel Cut Lever
1 2 3 4
T1F3-05-04-002
1 - Governor Cable (From EC Motor)

2 - Governor Lever
3 - Fuel Cut-Off Cable
(Fuel Cut-Off Handle)
4 - Fuel Cut Lever
T4-6-4
• Governor Lever Position
A - Key Switch OFF (Engine Stop Position)

B - Key Switch ON (Engine Start Position)
B FULL
STOP
A
T1F3-05-04-002
FULL STOP
• Fuel Cut Lever Position
A - Fuel Cut-Off Handle Pulled Position

B - Fuel Cut-Off Handle Returned Position A
B
T1F3-05-04-002
T4-6-5
(Blank)
T4-6-6
MEMO
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SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 General Components in Control Valve ..................T5-2-12
Introduction ............................................... T5-1-1 Signal Control Valve
Diagnosing Procedure .............................. T5-1-2 Port Location .......................................T5-2-26
Built-In Diagnosing System Operation ...... T5-1-6
Built-In Diagnosing Function Group 3 Troubleshooting A
Display List............................................ T5-1-7 Troubleshooting A Procedure ....................T5-3-1
Dr. ZX Operation ....................................... T5-1-8 Fault Code List ..........................................T5-3-2
Dr. ZX Fault Code List (MC).................... T5-1-10 Fault Code 01, 02, 03................................T5-3-3
Dr. ZX Monitoring Item List ..................... T5-1-12 Fault Code 04............................................T5-3-3
Dr. ZX Special Function .......................... T5-1-14 Fault Code 06............................................T5-3-4
Dr. ZX Service Mode............................... T5-1-15 Fault Code 07............................................T5-3-5
Adjustment Data List............................... T5-1-25 Fault Code 10, 11 ......................................T5-3-6
Fault Code 12, 13......................................T5-3-7
Group 2 Component Layout Fault Code 14, 15, 16, 18, 23, 24 ..............T5-3-8
Main Component Layout ........................... T5-2-1 Fault Code 19..........................................T5-3-10
Electrical Component Layout .................... T5-2-4 Fault Code 20.......................................... T5-3-11
(Overview) Fault Code 22..........................................T5-3-12
Electrical System (Relays) ........................ T5-2-5
Electrical System ...................................... T5-2-7
(Monitors and Switches)
Electrical System (Column Box)................ T5-2-8
Pump Device ............................................ T5-2-9
Swing Device ............................................ T5-2-9
Signal Control Valve.................................. T5-2-9
Control Valve .......................................... T5-2-10
Auxiliary control Valve............................. T5-2-10
4-Unit Solenoid Valve Unit ...................... T5-2-10
3-Unit Solenoid Valve Unit ...................... T5-2-10
Travel Shockless Valve /
Accumulator Chrging Valve ................... T5-2-11
Transmission Control Valve .................... T5-2-11
Travel Device .......................................... T5-2-11
Filter ....................................................... T5-2-11
CABT-5-1
Group 4 Troubleshooting B Malfunction of Overload Alarm
Troubleshooting B Procedure ................... T5-4-1 Indicator (Optional)................................T5-5-20
Relationship between Machine Trouble Malfunction of Auto-Acceleration
Symptoms and Related Parts.................. T5-4-2 Indicator ................................................T5-5-24
Correlation between Trouble Malfunction of Auto-Idle Indicator ............T5-5-26
Symptoms and Part Failures ................. T5-4-26 Malfunction of Digging Mode Indicator
Engine System Troubleshooting ............. T5-4-40 or Attachment Mode Indicator................T5-5-27
All Actuator System Troubleshooting ...... T5-4-66 Malfunction of LCD..................................T5-5-28
Front Attachment System Malfunction of Hour Meter .......................T5-5-29
Troubleshooting .................................... T5-4-72 Malfunction of Blade/Stabilizer
Swing System Troubleshooting ............... T5-4-80 Indicator ................................................T5-5-30
Travel System Troubleshooting............... T5-4-82 Malfunction of Buzzer..............................T5-5-34
Brake System Troubleshooting ............... T5-4-92 Malfunction of Turn Signal Indicator ........T5-5-36
Steering System Troubleshooting ........... T5-4-97 Malfunction of Travel Motor Indicator ......T5-5-37
Other System Troubleshooting................ T5-4-98 Malfunction of Work Light Indicator .........T5-5-38
Exchange Inspection............................. T5-4-114 Malfunction of Shift Lever Indicator .........T5-5-40
Bleeding Air from Transmission............. T5-4-116 Malfunction of Work Brake Indicator........T5-5-42
Bleeding Air from Brake (Axle) .............. T5-4-117 Malfunction of Parking Brake Indicator ....T5-5-44
Emergency Boom Lowering Procedure Malfunction of Axle Lock Indicator ...........T5-5-46
(without Hose-Rupture Safety Valve) .. T5-4-118 Malfunction of Clearance Light
Emergency Boom Lowering Procedure Indicator ................................................T5-5-48
(with Hose-Rupture Safety Valve) ....... T5-4-119 Malfunction of Hazard Light Indicator ......T5-5-49
Group 5 Troubleshooting C Malfunction of High-Beam Indicator ........T5-5-50

Troubleshooting C Procedure ................... T5-5-1 Malfunction of Buzzer in Column Box......T5-5-52
Malfunction of Coolant Malfunction of Brake Oil Pressure
Temperature Gauge ................................ T5-5-2 Gauge ...................................................T5-5-54
Malfunction of Fuel Gauge ........................ T5-5-4 Malfunction of Speed Meter.....................T5-5-56
Malfunction of Indicator Light Malfunction of Brake Oil Pressure
Check System ......................................... T5-5-6 Indicator ................................................T5-5-58
Malfunction of Preheat Indicator ............... T5-5-7
Malfunction of Overheat Indicator ............. T5-5-8
Malfunction of Air Filter Restriction
Indicator ................................................ T5-5-10
Malfunction of Fuel Level Indicator ......... T5-5-12
Malfunction of Alternator Indicator .......... T5-5-14
Malfunction of Engine Oil Pressure
Indicator ................................................ T5-5-16
Malfunction of Hydraulic Oil Filter
Indicator (Optional) ............................... T5-5-18
CABT-5-2
Group 6 Electrical System Inspection
Precautions for Inspection and
Maintenance ........................................... T5-6-1
Instructions for Disconnecting
Connectors ............................................. T5-6-3
Fuse Inspection ........................................ T5-6-4
Fusible Link Inspection ............................. T5-6-6
Battery Voltage Check .............................. T5-6-7
How to Troubleshoot Alternator
Malfunctions............................................ T5-6-8
Continuity Check..................................... T5-6-10
Voltage and Current Measurement ......... T5-6-13
Check by False Signal ............................ T5-6-17
Test Harness........................................... T5-6-18
Group 7 ICX
Outline ...................................................... T5-7-1
ICX Fault Code List................................... T5-7-6
Fault Code 1 to 6 ...................................... T5-7-7
Fault Code 7 to 10 .................................... T5-7-7
Some Parts of Data in Daily Report,
Frequency Distribution, Cumulative
Operation Hours are not Recorded ......... T5-7-8
Downloading From And Uploading
To The Icx............................................ T5-7-10
CABT-5-3
(Blank)
CABT-5-4
TROUBLESHOOTING / General
INTRODUCTION
Refer to the inspection and troubleshooting proce- • Troubleshooting B (base machine diagnosis start-
dures after any machine trouble has occurred. The ing with inspection of abnormal operational
inspection and troubleshooting procedures are pre- status)
sented in an orderly fashion in this section to quickly Refer to these procedures when no fault codes
find the cause of the machine trouble and solution. are displayed after diagnosing the machine with
Dr. ZX (or the built-in diagnosing system). Trace
The troubleshooting section in this manual consists of the cause of trouble based on the inspected re-
7 groups; General, Component Layout, Troubleshoot- sult of the abnormal symptom.
ing A (base machine diagnosis using fault codes),
Troubleshooting B (base machine diagnosis starting Example: Even if the engine control dial is oper-
with inspection of abnormal operational status), Trou- ated, engine speed remains unchanged.
bleshooting C (monitor diagnosis), Electrical System
Inspection, and ICX. • Troubleshooting C (monitor diagnosis)
Refer to these procedures when gauges and/or
• General indicators are malfunctioning.
• Component Layout Example: Malfunction of fuel gauge
• Troubleshooting A (base machine diagnosis using • Electrical System Inspection

fault codes) Refer to this group when required to obtain pre-
Refer to these procedures if any fault codes are cautions and/or information for the electrical sys-
displayed when the main controller (MC) is diag- tem inspection.
nosed with Dr. ZX (or the built-in diagnosing sys-
tem). Example: Fuse Inspection
(MC self-diagnosing function retains a record of
the electrical signal system malfunction in the • ICX
form of fault codes.) Refer to these procedures after any fault code is
displayed after diagnosing ICX (Information Con-
Example: Fault Code 06: Abnormal EC Sensor troller) with Dr. ZX. (The controller self-diagnosing
function retains a record of the electrical signal
system malfunction in the form of fault codes.)
Example: ICX Fault Code 7: MC Communication

Time Out
T5-1-1
DIAGNOSING PROCEDURE
These six basic steps are essential for efficient
troubleshooting:
1. Study the System

Study the machine’s technical manuals. Know the
system and how it works, and what the
construction, functions and specifications of the
system components are.
2. Ask the operator T107-07-01-001
Before inspecting, get the full story of

malfunctions from the operator below.
(a) How is the machine being used? (Find out if

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

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

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

previously? If so, which parts were repaired
before?
T107-07-01-002
T5-1-2
3. Inspect the machine
Before starting the troubleshooting procedure,
check the machine’s daily maintenance points, as
shown in the operator's manual.
Also, check the electrical system, including the

batteries, as troubles in the electrical system
such as low battery voltage, loose connections
and blown fuses will result in malfunction of the
controllers, causing total operational failure of the
machine.
If troubleshooting is started without checking for
blown fuses, a wrong diagnosis may result,
wasting time. Be sure to check for blown fuses
before troubleshooting. Even if a fuse looks
normal by visual inspection, a fine crack is
difficult to find. Always use a tester when
checking the fuses. T107-07-01-003
4. Operate the machine yourself

Try to identify the trouble by operating the
machine yourself.
If the trouble cannot be confirmed, stop the
engine and obtain further details of the
malfunction from the operator.
Also, check for any incomplete connections of the
wire harnesses.
T5-1-3
5. Perform troubleshooting
CAUTION: Never attempt to disconnect
harnesses or hydraulic lines while the engine
is running. The machine may malfunction or
pressurized oil may spout, possibly resulting
in personal injury. Be sure to stop the engine
before disconnecting harnesses or hydraulic
lines.
Perform diagnosis by connecting Dr. ZX to the

machine or by operating the built-in diagnosing
system. In case any fault code has been dis-
played by diagnosis using Dr. ZX (or the built-in
diagnosing system), delete the fault code once T107-07-01-005
and retry self-diagnosis again. If the fault code is

displayed again, check the cause of the trouble
by referring to Troubleshooting A in this section.
After the machine trouble has been corrected, the
fault code (displayed by the built-in diagnosing
function) will be deleted. Therefore, in case prob-
lems, which are not easily re-predicable are
encountered, use Dr. ZX to display the fault code.
In case no fault codes are displayed, check all re-
lated parts/component operating condition using
the monitor function of Dr. ZX (or the built-in di-
agnosing system) while referring to troubleshoot-
ing B in this section.
※ Note that the fault codes displayed do not

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

Before reaching a conclusion, check the most
likely causes again. Try to identify the actual
cause of the trouble.
Based on your conclusion, make a plan for T107-07-01-007
appropriate repairs to avoid consequent

malfunctions.
T5-1-4
(Blank)
T5-1-5
BUILT-IN DIAGNOSING SYSTEM OPERA-
TION
IMPORTANT: This system is to be operated by the
HITACHI Dealer Only. Don’t explain
this system function to the cus-
tomer.
In the service mode, the monitor LCD displays the

diagnosing items, fault codes and monitored results
(not all of them) without using Dr. ZX.
Built-In Diagnosing System Activation

1. While pressing the monitor SET switch, turn the
key switch ON.
Built-In Diagnosing System Operation Display Selection

1. Each time the display selection switch is pressed, Switch
the displayed item will be changed as shown on
next page. SET Switch
NOTE: The fault code is indicated in the display

order 8. All fault codes (Dr. ZX fault code
list) can be indicated. In case more than LCD
one fault code is indicated, they will be dis-
played with an interval of 1 second in order.
After the machine malfunction has been
repaired, the fault codes are automatically
deleted. Accordingly, if any trouble, which
is not reproducible, is encountered, it is
recommended to use Dr. ZX.
• The built-in diagnosing system displays only the
item No. on the left and the monitored result on the
right. The item description is not displayed.
MCBB-01-012
T5-1-6
BUILT-IN DIAGNOSING FUNCTION DISPLAY LIST
Display
Description Monitored Result Unit Remarks
Order
1 Hour Meter {{{{{ h Standard Mode
2 Trip 1 {{{{{ h Standard Mode (Subtraction)
3 Trip 2 {{{{{ h Standard Mode (Subtraction)
-1
4 Engine Actual Speed n {{{{ min User Mode (Required to set
in the Dr. ZX service mode)
5 Hydraulic Oil Tempera- {{{ °C User Mode (Required to set
ture in the Dr. ZX service mode)
6 L1 E － Display Purpose Only
7 L2 E － Display Purpose Only
8 Fault Code* 0 {{ － Possible to display
9 ML Switch** 1 {{ 0: Switch OFF Possible to display
1: Switch ON
10 Pump 1 Delivery Pres- 2 {{ MPa Possible to display
sure
11 Pump 2 Delivery Pres- 3 {{ MPa Possible to display
sure
12 Pump 1 Pump (Flow) 4 {{ MPa Possible to display
Control Pressure
13 Pump 2 Pump (Flow) 5 {{ MPa Possible to display
Control Pressure
-1
14 Engine Target Speed 6 {{ min Possible to display
15 EC Angle 7 {{ V Possible to display
16 Dial Angle 8 {{ V Possible to display
17 Boom Raise Pilot Pres- 9 {{ MPa Possible to display
sure
18 Arm Roll-In Pilot Pres- A {{ MPa Possible to display
sure
19 Swing Control Pilot b {{ MPa Possible to display
Pressure
20 Travel Control Pilot c {{ MPa Possible to display
Pressure
21 Front Att. Operation d {{ 0: Not Operating Possible to display
1: Operating
22 Att. Control Pressure E {{ MPa Possible to display
23 Work Mode F {{ 0: Digging Possible to display
1: Breaker
2: Secondary
Crusher
(Demolisher)
3: Crusher
4: Vibro-Hammer
NOTE: *: Refer to T5-1-10 for the Fault Codes.

**: ML specification is only available in Japanese domestic market.
T5-1-7
Dr. ZX OPERATION
Dr. ZX is a troubleshooting tool to diagnose the elec- Rear Console Fuse Box Dr. ZX
Connector
tronic control system including the MC (main Control- (MC)
ler) and ICX (Information Controller). When Dr. ZX is
connected to either the MC or the ICX, it displays
whether the controllers and sensors operate normally
in the form of fault codes (Self-Diagnosing Result Dis-
play Function).
In addition, Dr. ZX can display the inputs from sensors
and switches to the MC and/or the outputs to actua-
tors such as solenoid valves from the MC in real time
while operating the machine (Monitor Display Func-
tion).
NOTE: This group describes how to operate Dr.

ZX connected to the MC. Refer to Group 7
“ICX” for operation of Dr. ZX connected to
the ICX.
Dr. ZX Connector
(ICX)
T1F3-01-02-012
Palm
（Dr. ZX）
Hot Sync Cable
Battery Box
Cable
T178-05-01-167
T5-1-8
Operation
1. Connect palm (Dr. ZX) to the diagnosis connec-
tors (MC and ICX) located in the cab, using Hot Start
Sync cable and battery box cable.
2. Turn the key switch ON, or start the engine.

3. When the palm power is turned ON, palm dis- Title Screen
plays the following screens in order.
3-1. Title Screen
Select the Dr. ZX icon
3-2. Controller Screen Controller
Cannot
Screen
+ Select the EPVC-Mid Communicate
3-3. Menu Screen
· Check harness
Select the Start. · Check fuse
3-4. Model Name Screen Menu Screen
(Example) Model: ZX130W
3-5. Function Selection Screen
+ Self-Diagnostic Results
Model Name
+ Monitor Display Confirmation
+ Special Function
NOTE: Special functions allow the ECO and WU NOT OK
deactivation. (Refer to T5-1-14) OK ?
4. Select Self-Diagnostic Results. Then, continue to OK

Replace software
operate palm by following instructions to be dis-
played at the screen bottom hereafter.
Self-Diagnosing
NOTE: Refer to the Dr. ZX Operation Manual for Result Display Special
Function Select Monitor Function
the detailed operation of Dr. ZX.
function
Self-diagnostic
Result by control- Enter model
ler is displayed Record
code and serial
No.
Retry B
Select data to
be monitored
Self-diagnostic
Result is displayed Monitored data
is displayed
T5-1-9
FAULT CODE LIST (MC)
Fault code Problem Cause
01 Abnormal EEPROM • Faulty MC
02 Abnormal RAM
03 Abnormal A/D Conversion
04 Abnormal Sensor Voltage • Faulty MC
• Faulty Harness
• Faulty Sensor
06 Abnormal EC Sensor • Faulty MC
• Faulty Harness
• Faulty EC Sensor
07 Abnormal Engine Control Dial Angle • Faulty MC
• Faulty Harness
• Faulty Engine Control Dial
10 Abnormal Pump 1 Delivery Pressure • Faulty MC
11 Abnormal Pump 2 Delivery Pressure • Faulty Harness
• Faulty Pump Delivery Pressure Sensor
12 Abnormal Pump 1 Pump Control Pressure • Faulty MC
13 Abnormal Pump 2 Pump Control Pressure • Faulty Harness
• Faulty Pump Control Pressure Sensor
14 Abnormal Swing Pilot Pressure Sensor • Faulty MC
15 Abnormal Boom Raise Pilot Pressure Sensor • Faulty Harness
16 Abnormal Arm Roll-In Pilot Pressure Sensor • Faulty Pilot Pressure Sensor
18 Abnormal Travel Pilot Pressure Sensor
19 Abnormal Hydraulic Oil Temperature • Faulty MC
• Faulty Harness
• Faulty Hydraulic Oil Temperature Sensor
20 Abnormal Travel Motor Drain Pressure Sensor • Faulty MC
• Faulty Harness
• Faulty Travel Motor Drain Pressure Sensor
22 Abnormal Travel Motor • Faulty MC
• Faulty Harness
23 Abnormal Travel Forward Pilot Pressure Sensor • Faulty MC
24 Abnormal Travel Reverse Pilot Pressure Sensor • Faulty Harness
• Faulty Travel Pilot Pressure Sensor
*26 Travel Motor Over-rev. • Travel Motor Over-rev.
NOTE: In case the travel motor runs at an exces-

sive speed, fault code 26 is displayed. Us-
ing Dr. ZX service mode, check the exces-
sive speed rotation numbers (the exces-
sive speed running is not caused by the
faulty travel motor). Select the retry when
deleting the fault code.
T5-1-10
(Blank)
T5-1-11
Dr. ZX MONITORING ITEM LIST
Dr. ZX displays the input signals from the switches
and sensors to the MC and the control signals to the
actuators from the MC.
Item Data Unit

Pump 1 Delivery Pressure Input signals from pump 1 delivery pressure sensor MPa
Pump 1 Pump Flow Control Input signals from pump 1 control pressure sensor MPa
Pressure
Pump 2 Delivery Pressure Input signals from pump 2 delivery pressure sensor MPa
Pump 2 Pump Flow Control Input signals from pump 2 control pressure sensor MPa
Pressure
Pump 2 Max. Displacement Control signal to pump 2 flow rate control solenoid valve cm3
Engine Target Speed Target speed when loaded. Approx. 150 min-1 differs from min-1
speed when unloaded.
Engine Actual Speed Input signal from N sensor (engine speed sensor) min-1
Travel Motor Speed Input signal from N sensor (travel speed sensor) min-1
Vehicle Speed Input signal from N sensor (travel speed sensor) km/h
EC Angle Input signal from EC sensor V
Dial Angle Input signal from engine control dial V
Boom Raise Pilot Pressure Input signal from pressure sensor (boom raise) MPa
Arm Roll-In Pilot Pressure Input signal from pressure sensor (arm roll-in) MPa
Swing Control Pilot Pressure Input signal from pressure sensor (swing) MPa
Forward Travel Control Pilot Input signal from pressure sensor (travel forward) MPa
Pressure
Rear Travel Control Pilot Input signal from pressure sensor (travel reverse) MPa
Pressure
Front Att. Operation Input signal from pressure sensor (front att.) Fr (ON: Outline
Type Font)
Hydraulic Oil Temperature Input signal from oil temperature sensor °C
E/P/HP Mode Switch Power mode switch selection status E, P, HP (ON:
Outline Type Font)
Auto-Idle/Auto-Accel Switch Auto-Idle/Auto-Acceleration selector selection status AI, AA (ON: Out-
line Type Font)
Creeper Mode Switch Engine speed control mode selection switch selection Trpr (ON: Outline
status Type Font)
Neutral Switch Shift lever selection status N (ON: Outline
Type Font)
Key Switch Key switch selection status Ky (ON: Outline
Type Font)
Mission Switch Shift lever selection status High, Low (ON:
Outline Type Font)
Pedal EC Switch Engine speed control mode selection switch selection PEC (ON: Outline
status Type Font)
Working/Parking Switch Brake switch selection status Wk, Pk (ON: Out-
line Type Font)
T5-1-12
Item Data Unit

Working Mode Work mode switch selection status STD, ATT (ON:
Outline Type Font)
ATT. Mode Work mode switch selection status BU, CS, CL, HB
(ON: Outline Type
Font)
Engine Learning Control Done, Undone,
Aborted (ON: Out-
line Type Font)
Pump Torque P/S Valve Control signal to torque control solenoid valve MPa
Pump Flow Changeover P/S Valve Control signal to max. pump 1 flow rate shift so- MPa
Output lenoid valve
Travel Motor Tilt P/S Valve Output Control signal to solenoid valve SI MPa
Working Brake P/S Valve Output Control signal to solenoid valve SG MPa
Parking Brake Relay Signal to buzzer of parking brake alarm ON, OFF (ON:
Outline Type Font)
Fw/Bk Cut Relay Signal to travel forward/reverse Pi cut solenoid FW, BK (ON: Out-
valve line Type Font)
EC Motor Position Step
Pump 3 Delivery Pressure Input signal from steering pump delivery pressure MPa
sensor
Travel Drain Pressure Input signal from travel motor drain pressure MPa
sensor
Pump 1 Max. Displacement Control signal to pump 1 flow rate control sole- cm3
noid valve
Engine Speed Differential Calculated Value min-1
(Target Engine Speed - Actual Engine Speed)
Pump 2 P/S Valve Output Control signal to pump 2 flow rate control sole- MPa
noid valve
Pump 1 P/S Valve Output Control signal to pump 1 flow rate control sole- MPa
noid valve
Arm Regenerative P/S Valve Output Control signal to solenoid valve SC MPa
Optional
Item Data Unit
Boom Cylinder Bottom Pressure Input signal from pressure sensor (boom raise) MPa
Arm Roll-Out Pilot Pressure Input signal from pressure sensor (arm roll-out) MPa
ATT. Control Pilot Pressure Input signal from pressure sensor (auxiliary) MPa
ATT. P/S Valve Output Control signal to auxiliary flow rate control sole- MPa
noid valve
Tr/Sw/OverLoad Alarm Signal to each alarm Tr, Sw, Load (ON:
Outline Type Font)
T5-1-13
Dr. ZX SPECIAL FUNCTION
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS130W.
Start the service software in the Select a special function

operation mode
If the following screen appears, Select the function you want to
you are in the operation mode. execute.
Select Special Function.
Fig. A Fig. B
T178-05-01-013 T178-05-01-168
Select ESC to return
to Fig. A.
Special function
Select Execute to execute the

function.
WU deactivation ECO control deactivation
Execute Execute
T178-05-01-030 T178-05-01-031 T178-05-01-032 T178-05-01-033

Select ESC to return Select ESC to return Select ESC to return Select ESC to return
to Fig. B. to Fig. B. to Fig. B. to Fig. B.
T5-1-14
Dr. ZX SERVICE MODE
Dr. ZX Engine
Dr. ZX has three modes, learning value display, Connector (MC) Learning
parameter change, and monitor display information Switch
setting.
Learning Value Display

Displays the values set by learning function.
Parameter Change
Engine speed, pump delivery flow rate, and solenoid
valve output pressure can be adjusted.
Monitor Display Information Setting

Items to be displayed on the monitor LCD can be
added.
• Accessing Service Mode

1. After turning the key switch OFF, wait for more
than 10 seconds.
2. Connect Dr. ZX to the connector to MC on the
base machine.
3. Turn the engine learning switch to the learning Dr. ZX Connector
(ICX)
position (the stamped mark E side).
4. Turn the key switch ON. Don’t start the engine at T1F3-01-02-012
this time.
5. Turn Dr. ZX switch ON.
The learning switch is
turned to the stamped
mark E
Learning Switch
Stamped
Mark E
T1CC-05-01-001
T5-1-15
Item Data
Learning Data Display
EC Motor Stop Position Display of the engine stop value in engine learning
EC Motor Maximum Speed Position Display of max. engine speed valve in engine learning
Parameter Change
Li Speed Adjustment Adjustment of minimum engine speed
WU Speed Adjustment Adjustment of warming up engine speed
AI Speed Adjustment Adjustment of auto-idle engine speed
E Speed Adjustment Adjustment of E-mode engine speed
P Speed Adjustment Adjustment of P-mode engine speed
Breaker Engine Speed Adjustment Adjustment of breaker operation engine speed
Secondary Crusher (Demolisher) Engine Speed Adjustment of secondary crusher (demolisher) operation
Adjustment engine speed
Crusher Engine Speed Adjustment Adjustment of crusher operation engine speed
Vibro-Hammer Speed Adjustment Adjustment of vibratory hammer operation engine speed
Travel Li Speed Adjustment Adjustment of traveling engine speed
Hyd. Breaker P1 Max. Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in breaker
operation
Secondary Crusher (Demolisher) P1 Max. Adjustment of lowest pump 1 max. flow rate in secondary
Swash Angle Adjustment crusher operation
Crusher P1 Max. Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in crusher
operation
Vibro P1 Max. Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in vibratory
hammer operation
Hyd. Breaker P2 Max. Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in breaker
operation
Secondary Crusher (Demolisher) P2 Max. Adjustment of lowest pump 2 max. flow rate in secondary
Swash Angle Adjustment crusher operation
Crusher P2 Max. Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in crusher
operation
Vibro P2 Max. Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in vibratory
hammer operation
Pump PQ Base Torque Correction Adjustment of pump P-Q curve
ATT P/S Valve Adjustment Adjustment of optional solenoid valve
ATT. Speed Increase Down Waiting Time Setting of time required for engine speed increase
*Max. ML Crane Speed Adjustment Setting of engine speed in crane mode
Min. Boom CYL. Bottom Pressure Over Balance
Travel Motor Over-rev. Counter Display of the travel motor excessive speed rotation
NOTE: *: ML specification is only available in Japanese domestic market.
T5-1-16
(Blank)
T5-1-17
Displaying Engine Learning Data and Angle Sensor Correction Valve
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS200.
Start the service software in The service software will

the service mode start in the service mode
Select Start from the Press Correct if the Confirm that you are in the Select Special Function.
EPVC_Mid software menu. displayed model name is service mode, and select
correct. Rechecked.
Fig. A T178-05-01-006 Fig. B T178-05-01-012 Fig.C T178-05-01-034 Fig. D T178-05-01-035

Select ESC to return Select ESC to return Select ESC to return
to Fig. A. to Fig. A. to Fig. A.
Select the function you Learning data items will

want to execute be displayed
The menu will be displayed. Select the item you want to
Select Learning Data Display execute.
from the menu.
Fig. E T178-05-01-036 Fig. F T178-05-01-037

Select ESC to return Select ESC to return
to Fig. D. to Fig. F.
T5-1-18
EC Motor stop position EC Motor Maximum Boom angle sensor Arm angle sensor correction
engine speed position correction value value
T178-05-01-038 T178-05-01-039 T178-05-01-040 T178-05-01-041

Select ESC to return Select ESC to return Select ESC to return Select ESC to return
to Fig. F. to Fig. F. to Fig. F. to Fig. F.
T5-1-19
Changing Parameters In The Controller
Start the service mode on the condition that the engine learning switch is turned on.
To change the parameter, it is necessary to enter the password. To change the password, refer to the “Changing the password”
section.
Start the service software in The service software will start in

the service mode the service mode
Select Start from the Press Correct if the displayed Confirm that you are in the Select Special Function.
EPVC_Mid software menu. model name is correct. service mode, and select
Rechecked.
Fig. A T178-05-01-006 Fig. B T178-05-01-012 Fig. C T178-05-01-034 Fig. D T178-05-01-035

to Fig. A. to Fig. A. to Fig. A
Execute the parameter Select a parameter change

change Enter the password
item
The menu will be displayed. Enter the password to change Select the item you want to change. The
Select Parameter Change from the parameter. up- and down-arrow buttons can be
the menu. used to scroll through the item list.
Fig. F
Fig. E T178-05-01-042
T178-05-01-043
Fig. G
Select ESC to return T178-05-01-044
Select ESC to return to Fig. E. Select ESC to return
to Fig. D. to Fig. E.
T5-1-20
Enter the new value Confirm the new value Parameter adjustment
result
Enter the new value in the The new value will be displayed
The adjusted value will be
Adjustment space, and press in the Adjustment space. Select
displayed.
Execution. Execute to change to this value.
T178-05-01-045 T178-05-01-046 T178-05-01-047

to Fig. G. to Fig. G. to Fig. G.
T5-1-21
Changing The User Mode Display on The Monitor Panel
Start the service mode on the condition that the engine learning switch is turned on.
Start the service software in The service software will start in

the service mode the service mode
Select Start from the Press Correct if the displayed Confirm that you are in the
EPVC_Mid software menu. model name is correct. service mode, and select Select Special Function.
Rechecked.
Fig. A T178-05-01-006 Fig. B T178-05-01-012 Fig. C T178-05-01-034 Fig. D T178-05-01-035

to Fig. A. to Fig. A. to Fig. A.
Execute the monitor display Select a display change Select Display or

change item No Display
The menu will be displayed. Select the monitor display Select Disp or No Disp.
Select Monitor Display from change item you want to
the menu. execute.
Fig. E T178-05-01-042 Fig. F T178-05-01-048 Fig. G T178-05-01-049

to Fig. D. to Fig. E. to Fig. F.
T5-1-22
Confirm Disp/No Disp Confirm the result

Confirm that the Monitor space
shows Disp or No Disp. If it is It has been changed as shown
correctly displayed, select on-screen. Select ESC.
Execute.
Fig. H T178-05-01-050 Fig. I T178-05-01-051

Select ESC to return
to Fig.F. Select ESC to return to Fig. F.
T5-1-23
• Operational Performance Check After Adjustment

(Check that pump flow rate and engine speed
have been changed.)
IMPORTANT: After adjusting the engine speed and

flow rate to the attachment, turn the
engine learning switch to neutral. If
the engine is started with the engine
learning switch in the engine
learning position, the MC will not
control the engine, pumps, and
valves so that change in the pump
flow rate and the engine speed
cannot be checked.
1. Turn the key switch OFF.

2. Wait approx. 10 seconds.
3. Turn the engine learning switch to neutral.
4. Disconnect the Dr. ZX. connector (When
monitoring with Dr. ZX, pass this step.)
5. Turn the key switch ON.
6. Start the engine.
7. Check operational performances of the machine.
T5-1-24
ADJUSTMENT DATA LIST
Min. Adjustment Standard

Adjustment Data Adjustable Range Remarks
Value Adjustment
Li Speed 10 min-1 0 to 120 0 min-1
WU Speed 10 min-1 -120 to 120 0 min-1
AI Speed 10 min-1 -120 to 120 0 min-1
E Speed 10 min-1 -120 to 120 0 min-1
P Speed 10 min-1 -120 to 100 0 min-1
Breaker Speed 10 min-1 -500 to 100 0 min-1
Secondary Crusher
10 min-1 -500 to 100 100 min-1
(Demolisher) Speed
Crusher Speed 10 min-1 -500 to 100 100 min-1
Vibro-Hammer Speed 10 min-1 -500 to 100 0 min-1
Travel Li Speed 10 min-1 -120 to 120 0 min-1
Hyd. Breaker P1 Max.
0.6 cm3/rev 51.0 to 112.8 112.8 cm3/rev
Swash Angle
Secondary (Demolisher) P1
0.6 cm3/rev 51.0 to 112.8 112.8 cm3/rev
Max. Crusher Swash Angle
Crusher P1 Max. Swash
0.6 cm3/rev 51.0 to 112.8 112.8 cm3/rev
Angle
Vibro P1 Max. Swash Angle 0.6 cm3/rev 51.0 to 112.8 112.8 cm3/rev
Hyd. Breaker P2 Max.
0.6 cm3/rev 51.0 to 112.8 112.8 cm3/rev
Swash Angle
Secondary Crusher
(Demolisher) P2 Max. 0.6 cm3/rev 51.0 to 112.8 112.8 cm3/rev
Swash Angle
Crusher P2 Max. Swash
0.6 cm3/rev 51.0 to 112.8 112.8 cm3/rev
Angle
Vibro P2 Max. Swash Angle 0.6 cm3/rev 51.0 to 112.8 112.8 cm3/rev
Pump PQ Base Torque 2.45 N⋅m -78.4 to 0 0 N⋅m
ATT. P/S Valve 0.03 MPa -0.89 to 0.89 0 MPa
ATT. Speed Increase Down
12.5 ms 0 to 3000 3000 ms
Wait Time
-1
*Max. ML Crane Speed 10 min -500 to 300 0 min-1
Min. Boom CYL. Bottom
0.1 MPa -9.81 to 9.81 0 MPa
Pressure Over Balance
Travel Motor Over-rev.
1 digit 0 to 255 0 digit
Counter
NOTE: *: ML specification is only available in Japanese domestic market.

NOTE: 1 MPa=10.197 kgf/cm2
1 kgf/cm2=0.098 MPa
T5-1-25
(Blank)
T5-1-26
TROUBLESHOOTING / Component Layout
MAIN COMPONENT LAYOUT
Upperstructure
2 3 4 5 6 7 8 9 10 11 12
13
14
15
16
17
29
18
28 19
27
20
26
25
24
TCAB-01-02-001
23 22 21
1 - Pilot Valve (Left) 9 - Center Joint 16 - Accumulator 23 - Shuttle Valve

(Pilot Circuit) (Swing Parking Brake
Release Circuit)
2 - Positioning/Auxiliary 10 - Signal Control Valve 17 - 4-Unit Solenoid Valve Unit 24 - Accumulator
Pilot Valve Charging Valve
3 - Steering Valve 11 - Swing Device 18 - 3-Unit Solenoid Valve Unit 25 - Travel Shockless Valve
4 - Brake Valve 12 - Control Valve 19 - Pilot Filter 26 - Shuttle Valve
(Blade/Stabilizer Circuit)
5 - Travel Pilot Valve 13 - Accumulator 20 - Steering Filter 27 - Blade/Stabilizer
(Transmission Circuit) Signal Shift Valve
6 - Pilot Valve (Right) 14 - Transmission Control Valve 21 - Pump Device 28 - Accumulator
(Brake Circuit)
7 - Blade/Stabilizer Pilot Valve 15 - Pilot Relief Valve 22 - Engine 29 - Pilot Shut-Off Valve
8 - Auxiliary Control Valve
T5-2-1
Undercarriage
2
1
8
7
T1F3-01-02-002
1 - Blade Cylinder 3- 2-Unit Solenoid Valve 5- Front Axle 7- Transmission

(Blade/Stabilizer)
2 - Rear Axle 4 - Axle Lock Cylinder 6- Stabilizer Cylinder 8- Travel Motor
T5-2-2
Front Attachment
2-Piece Boom Monoblock Boom
1
2
3 2
7 7
4
1
5
6 T1F3-01-02-004
T1F3-01-02-003
1 - Bucket Cylinder 3- Positioning Cylinder 5- Hose-Rupture Safety Valve 7- Hose-Rupture Safety Valve
(Positioning) (Arm)
2 - Arm Cylinder 4- Boom Cylinder 6 - Hose-Rupture Safety Valve
(Boom)
NOTE: Hose-rupture safety valves (5), (6), (7) are

optional.
T5-2-3
ELECTRICAL COMPONENT LAYOUT (Overview)
2 Refer to the
Transmission
Control Valve.
(T1-2-11)
Refer to the
Signal Control
Valve. (T1-2-9)
Refer to the
Control Valve.
Refer to the (T1-2-10)
Swing Device. 3
(T1-2-9)
4
14
5
13 Refer to the
Pump Device.
(T1-2-9)
12
Refer to the Travel Shockless Refer to the

Valve and Accumulator Charging Filter.
Valve. (T1-2-11) (T1-2-11)
TCAB-01-02-002
11 10 9 8
1 - Service Brake Pressure 5 - EC Motor/EC Sensor 9 - Coolant Temperature 12 - Air Cleaner Restriction
Switch Sensor Switch
2 - Fuel Sensor 6 - 3-Unit Solenoid Valve Unit 10 - Battery Relay 13 - Brake Remaining Pressure
Switch
3 - 4-Unit Solenoid Valve Unit 7 - Engine Oil Pressure Switch 11 - Glow Plug Relay 14 - Slip Ring
4 - Hydraulic Oil Temperature 8 - Overheat Switch
Sensor
T5-2-4
ELECTRICAL SYSTEM (RELAYS)
1 2 3 4 5 6 7
Relay Position
(T1-2-6)
10
T1F3-01-02-012
1 - QOS Controller 4- Transistor Unit 1 7- Learning Switch 9 - MC (Main Controller)

2 - Transistor Unit 2 5- Fuse Box 8- ICX (Information 10 - Dr. ZX Connector to ICX
Controller)
3 - Flasher Relay 6- Dr. ZX Connector to MC
T5-2-5
Relay Position
T1F3-01-02-012
3
View A
4
30 5
6
29 7
8
28 9
27 10
26 11
25 12
24 13
23 14
22 15
21 16
20
T1F3-01-02-013
19 18 17
1 - Head Lamp Relay 9- Head Lamp Relay 17 - Left Turn Signal Relay 24 - Stop Lamp Relay (R17)
(Left-Lower) (R29) (Right-Lower) (R13) (R15)
2 - Parking Brake Relay 3 10 - Wiper Relay A (R6) 18 - Work Brake Indicator Relay 25 - Travel Reverse Pi Cut
(R30) (R18) Relay (R25)
3 - Parking Brake Relay 2 11 - Wiper Relay B-3 (R9) 19 - Neutral Signal Relay (R21) 26 - Parking Brake Alarm Relay
(R11) (R23)
4 - Work Light Relay 2 (R4) 12 - Washer Relay (R2) 20 - Right Turn Signal Relay 27 - Transmission Changeover
(R16) Relay (R20)
5 - High Beam Relay (R14) 13 - Right Clearance Light 21 - Travel Forward Pi Cut 28 - Auto-Acceleration Cancel
Relay (R12) Relay (R24) Relay (R26)
6 - Wiper Relay B-1 (R7) 14 - Horn Relay (R5) 22 - Axle Lock Relay (R19) 29 - Parking Brake Relay 1
(R27)
7 - Starter Relay (R10) 15 - Wiper Relay B-2 (R8) 23 - Travel Motor Alarm Relay 30 - Left Clearance Light Relay
(R22) (R28)
8 - Work Light Relay 1 (R3) 16 - Load Damp Relay (R1)
T5-2-6
ELECTRICAL SYSTEM
(Monitors and Switches)
1
2
19
18
3
17
16 4
15
MCBB-01-022 5
14
6
7
13
20 8
12
21 11
10
MCBB-01-012
22
9
23
24 25
26
MCBB-01-014 M216-01-021
1 - Coolant Temperature 8- Blade/Stabilizer Operation 15 - Digging Mode Indicator 22 - Work Light Switch
Gauge Indicator
2 - Fuel Gauge 9- Overload Alarm Indicator 16 - Attachment Mode 23 - Power Mode Switch
(Optional) Indicator
3 - Display Selection Switch 10 - Hydraulic Oil Filter Restriction 17 - Liquid Crystal Display 24 - Auto-Idle/Acceleration
Indicator (LCD) Selector
4 - Set Switch 11 - Engine Oil Pressure 18 - Auto-Idle Indicator 25 - Brake Switch
Indicator
5 - Work Mode Switch 12 - Preheat Indicator 19 - Auto-Acceleration 26 - Shift Lever
Indicator
6 - Fuel Level Indicator 13 - Air Filter Restriction 20 - Engine Control Dial
Indicator
7 - Alternator Indicator 14 - Overheat Indicator 21 - Engine Speed Control
Mode Selection Switch
T5-2-7
ELECTRICAL SYSTEM
(Around the Steering Wheel)
1, 2, 3, 4 5 6 8 9 10 11 12 8
13 12
MCBB-01-004
MCBB-01-005 14 15 16 17 18 19 20
7
22 21
MCBB-01-006
1 - Turn Signal Switch 7- Horn Switch 13 - Auxiliary 1 18 - Clearance Light Indicator

2 - Light Switch 8- Turn Signal Indicator 14 - Brake Oil Pressure Gauge 19 - Parking Brake Indicator
3 - Dimmer Switch 9- Abnormal Travel Motor 15 - Speed Meter 20 - Work Brake Indicator
Indicator
4 - Passing Switch 10 - Work Light Indicator 16 - Hazard Light Indicator 21 - Axle Lock Indicator
5 - Hazard Light Switch 11 - Travel Mode Indicator 17 - High-Beam Indicator 22 - Brake Oil Pressure
Indicator
6 - Wiper Switch 12 - Auxiliary 2
T5-2-8
PUMP DEVICE
1 2 5 6
T1F3-01-02-008 T1F3-01-02-007
4 3 10 9 8 7
SWING DEVICE SIGNAL CONTROL VALVE
12
11 13
T1F3-03-06-003
T176-01-02-002
1 - Steering Pump 5- N sensor (Engine) 8- Pump 2 Delivery Pressure 11 - Pressure Sensor (Front
Sensor Attachment)
2 - Pilot Pump 6- Torque Control Solenoid 9 - Pump 1 Control Pressure 12 - Pressure Sensor
Valve Sensor (Auxiliary)
3 - Pump 1 7 - Pump 2 Control Pressure 10 - Pump 1 Delivery Pressure 13 - Pressure Sensor (Swing)
Sensor Sensor
4 - Pump 2
T5-2-9
CONTROL VALVE AUXILIARY CONTROL VALVE
1
TCAB-01-02-003
T176-01-02-003
3
4-UNIT SOLENOID VALVE UNIT 3-UNIT SOLENOID VALVE UNIT

9 10 11
5 6 7 8 T178-01-02-003
T1F3-01-02-010
1 - Pressure Sensor 4- Overload Relief Valve 7- Solenoid Valve Unit (SI) 10 - Max. Pump 2 Flow Rate
(Arm Roll-In) (Auxiliary Control Valve) Limit Solenoid Valve
2 - Main Relief Valve 5 - Solenoid Valve Unit (SC) 8- Solenoid Valve Unit (SG) 11 - Max. Pump 1 Flow Rate
Shift Solenoid Valve
3 - Pressure Sensor 6- Solenoid Valve Unit (SE) 9- Max. Pump 1 Flow Rate
(Boom Raise) Limit Solenoid Valve
T5-2-10
TRAVEL SHOCKLESS VALVE/ TRANSMISSION CONTROL VALVE
ACCUMULATOR CHARGING VALVE 9
10
1
2 3 4 8
5
11
12
T1F3-01-02-006
7 6
T1F3-01-02-005
TRAVEL DEVICE FILTER
17
13
14
18
15
19
16
T1F3-01-02-009 MCBB-07-026
1 - Travel Shockless Valve 6- Travel Reverse Pi Cut 11 - Accumulator 16 - Travel Motor Drain Pressure
Solenoid Valve (Transmission Circuit) Switch
2 - Pressure Sensor (Travel 7 - Pressure Sensor 12 - Parking Brake Pressure 17 - Pilot Filter
Forward) (Travel Reverse) Switch
3 - Travel Forward Pi Cut 8 - Transmission Control Valve 13 - N sensor (Travel) 18 - Steering Pump Delivery
Solenoid Valve Pressure Sensor
4 - Pressure Sensor (Brake Oil 9- Transmission Changeover 14 - Transmission 19 - Steering Filter
Pressure Gauge) Solenoid Valve
5 - Accumulator Charging 10 - Parking Brake Solenoid 15 - Travel Motor
Valve Valve
T5-2-11
COMPONENTS IN CONTROL VALVE
1 2 3 4 5 6 7 9 10 11
35
12
34 13
33
32
31
14
30
15
16
29
28 17
27
26
25 24 23
22 21 20 19 18
T1F3-03-03-014
T5-2-12
16
26
29
18, 19
7
21
12
9, 10
Front
T176-03-03-038
1 - Load Check Valve (Po- 11 - Bucket Regenerative Circuit 20 - Load Check Valve 29 - Overload Relief Valve (Arm
sitioning Tandem Circuit) (Arm 2 Tandem Circuit) Rod Side)
2 - Load Check Valve (Po- 12 - Overload Relief Valve (Bucket 21 - Bypass Shut-Out Valve 30 - Arm Anti-Drift Valve (Check
sitioning Parallel Circuit) Rod Side) Valve)
3 - Check Valve 13 - Overload Relief Valve (Bucket 22 - Check Valve (Orifice) (Arm 31 - Arm Anti-Drift Valve (Se-
(Main Relief Circuit) Bottom Side) 2 Parallel Circuit) lector Valve)
4 - Main Relief Valve 14 - Load Check Valve (Boom 1 23 - Load Check Valve (Arm 1 32 - Load Check Valve (Boom 2
Parallel Circuit) Parallel Circuit) Parallel Circuit)
5 - Auxiliary Flow Combiner 15 - Boom Regenerative Circuit 24 - Load Check Valve 33 - Aux. Flow Rate Control
Valve (Arm 1 Tandem Circuit) Valve (Poppet Valve)
6 - Check Valve 16 - Overload Relief Valve (Boom 25 - Load Check Valve 34 - Aux. Flow Rate Control
(Auxiliary Flow Combin- Bottom Side) (Swing Circuit) Valve (Selector Valve)
ing Circuit)
7 - Check Valve 17 - Overload Relief Valve (Boom 26 - Arm Regenerative Valve 35 - Load Check Valve (Bucket
(Main Relief Circuit) Rod Side) (Selector Valve) Parallel Circuit)
9 - Bucket Flow Rate Con- 18 - Boom Anti-Drift Valve (Check 27 - Arm Regenerative Circuit
trol Valve (Selector Valve)
Valve)
10 - Bucket Flow Rate Con- 19 - Boom Anti-Drift Valve (Selec- 28 - Overload Relief Valve (Arm
trol Valve (Poppet Valve) tor Valve) Bottom Side)
T5-2-13
1 2 3 4 5 6 7 9 10 11
35
12
34 13
33
32
31
14
30
15
16
29
28 17
27
26
25 24 23
22 21 20 19 18
T1F3-03-03-014
T5-2-14
30, 31
33, 34
28
Front
5 17 T176-03-03-036
13
6 35
1- Load Check Valve (Po- 11- Bucket Regenerative Circuit 20- Load Check Valve 29- Overload Relief Valve (Arm
2- Load Check Valve (Po- 12- Overload Relief Valve (Bucket 21- Bypass Shut-Out Valve 30- Arm Anti-Drift Valve (Check
3- Check Valve 13- Overload Relief Valve (Bucket 22- Check Valve (Orifice) (Arm 31- Arm Anti-Drift Valve (Se-
4- Main Relief Valve 14- Load Check Valve (Boom 1 23- Load Check Valve (Arm 1 32- Load Check Valve (Boom 2
5- Auxiliary Flow Combiner 15- Boom Regenerative Circuit 24- Load Check Valve 33- Aux. Flow Rate Control
6- Check Valve 16- Overload Relief Valve (Boom 25- Load Check Valve 34- Aux. Flow Rate Control
ing Circuit)
7- Check Valve 17- Overload Relief Valve (Boom 26- Arm Regenerative Valve 35- Load Check Valve (Bucket
9 - Bucket Flow Rate Con- 18- Boom Anti-Drift Valve (Check 27- Arm Regenerative Circuit
Valve)
10 - Bucket Flow Rate Con- 19- Boom Anti-Drift Valve (Selec- 28- Overload Relief Valve (Arm
T5-2-15
1 2 3 4 5 6 7 9 10 11
35
12
34 13
33
32
31
14
30
15
16
29
28 17
27
26
25 24 23
22 21 20 19 18
T1F3-03-03-014
T5-2-16
F
E Cross Section A 4
D
C
B
7
A
35
6
5
a T1F3-03-03-013
T176-03-03-035
NOTE: Valve (a) is not used.
ing Circuit)
9- Bucket Flow Rate Con- 18- Boom Anti-Drift Valve (Check 27- Arm Regenerative Circuit
Valve)
10- Bucket Flow Rate Con- 19- Boom Anti-Drift Valve (Selec- 28- Overload Relief Valve (Arm
T5-2-17
1 2 3 4 5 6 7 9 10 11
35
12
34 13
33
32
31
14
30
15
16
29
28 17
27
26
25 24 23
22 21 20 19 18
T1F3-03-03-014
T5-2-18
Cross Section B Cross Section C
Travel Positioning Bucket Auxiliary
12
1
10 33
2 34
9
11
13
T1F3-03-03-012
T176-03-03-004
ing Circuit)
Valve)
T5-2-19
1 2 3 4 5 6 7 9 10 11
35
12
34 13
33
32
31
14
30
15
16
29
28 17
27
26
25 24 23
22 21 20 19 18
T1F3-03-03-014
T5-2-20
Cross Section D Cross Section E
Boom 1 Boom 2 Arm 2 Arm 1
19 31
16 29
18 30
14 20 23
32
22
24
27
15
28
17
T176-03-03-006
T176-03-03-005
ing Circuit)
Valve)
T5-2-21
1 2 3 4 5 6 7 9 10 11
35
12
34 13
33
32
31
14
30
15
16
29
28 17
27
26
25 24 23
22 21 20 19 18
T1F3-03-03-014
T5-2-22
Cross Section F
Swing
26
25
21
T176-03-03-007
ing Circuit)
Valve)
T5-2-23
Auxiliary Control
Valve
2
T1F3-03-03-014
T5-2-24
Cross Section X-X
X
2
T1GL-03-03-004
T1GL-03-03-003
1 - Load Check Valve 2- Overload Relief Valve 3- Overload Relief Valve

(Blade/Stabilizer Tandem Circuit) (Blade/Stabilizer Rod Side) (Blade/Stabilizer Bottom Side)
T5-2-25
SIGNAL CONTROL VALVE PORT LOCA-
TION
Pilot Valve Side
PH
C
A
E
M
D
H
B
F
SB
PI G
Pilot Valve Side
K N
I
SH
J
DF
SA L
T178-03-06-016
Pilot Valve Side (HITACHI Pattern)

Port Name Connecting to Note
Port A Right Pilot Valve Boom Raise Pilot Pressure
Port B Right Pilot Valve Boom Lower Pilot Pressure
Port C Left Pilot Valve Arm Roll-Out Pilot Pressure
Port D Left Pilot Valve Arm Roll-In Pilot Pressure
Port E Left Pilot Valve Left Swing Pilot Pressure
Port F Left Pilot Valve Right Swing Pilot Pressure
Port G Right Pilot Valve Bucket Roll-In Pilot Pressure
Port H Right Pilot Valve Bucket Roll-Out Pilot Pressure
Port I  Plug
Port J  Plug
Port K Travel Shocless Valve Travel Reverse Pilot Pressure
(Travel Pilot Valve)
Port L Travel Shocless Valve Travel Forward Pilot Pressure
(Travel Pilot Valve)
Port M Positioning/Auxiliary Pilot Valve Positioning Raise/Auxiliary Open Pilot Pressure
Port N Positioning/Auxiliary Pilot Valve Positioning Lower/Auxiliary Close Pilot Pressure
Port SA Pump 1 Regulator Pump 1 Control Pressure
Port SB Pump 2 Regulator Pump 2 Control Pressure
Port PI 4-Unit Solenoid Valve Unit Primary Pilot Pressure
Port PH Pilot Shut-Off Valve Primary Pilot Pressure (Heating Circuit)
Port SH Shuttle Valve Brake Release Pressure
(Swing Parking Brake)
Port DF Hydraulic Oil Tank Returning to Hydraulic Oil Tank
T5-2-26
Control Valve Side
3
1
Pressure Sensor 5
(Auxiliary)
13
2 4
SK SE
Pressure Sensor 8
(Swing)
14
Control 7
Valve Side
9
6
10
SN
SL
11
T1F3-03-06-003
12 SP
Control Valve Side
Port 1 Control Valve Boom Raise Pilot Pressure
Port 2 Control Valve Boom Lower Pilot Pressure
Port 3 Control Valve Arm Roll-Out Pilot Pressure
Port 4 Control Valve Arm Roll-In Pilot Pressure
Port 5 Control Valve Left Swing Pilot Pressure
Port 6 Control Valve Right Swing Pilot Pressure
Port 7 Control Valve Bucket Roll-In Pilot Pressure
Port 8 Control Valve Bucket Roll-Out Pilot Pressure
Port 9 Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port 10  Plug
Port 11 Control Valve Travel Reverse Pilot Pressure
Port 12 Control Valve Travel Forward Pilot Pressure
Port 13 Pilot Pressure Shift Valve Positioning Raise/Auxiliary Open Pilot Pressure
Port 14 Pilot Pressure Shift Valve Positioning Lower/Auxiliary Close Pilot Pressure
Port SE  Plug
Port SN  Plug
Port SP Shuttle Valve Pump 1 Flow Rate Control Valve Control Pressure
Port SL  Plug
Port SK Control Valve Bucket Flow Rate Control Valve Control Pressure
T5-2-27
NOTE: Machines equipped with optional auxiliary

flow combining system.
Control Valve Side

SM
Control
Valve Side
SN
T1F3-03-06-004
Control Valve Side

Port SM Auxiliary Flow Combiner Solenoid Valve Auxiliary Flow Combiner Valve Shift Pressure
Port SN Auxiliary Flow Combiner Reducing Valve Auxiliary Flow Combiner Valve Shift Pressure
NOTE: The reducing valve and the auxiliary flow

combiner solenoid valve are installed only
on the machines equipped with the op-
tional auxiliary flow combining system.
T5-2-28
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Refer to troubleshooting A procedure in case any fault
codes are displayed after diagnosing the main con-
troller (MC) using Dr. ZX (or the built-in diagnosing
system).
• How to Read Troubleshooting Flow Charts
YES(OK)
(2)
(1) After completing the checking and/or measuring procedures in box
・ (1) (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
(3)
NO(NOT OK)
Instructions, reference, and/or inspection methods and/or measurements are occasionally

・
described under the box. If incorrectly checked or measured, not only will troubleshooting
· Key switch: ON be unsuccessful but also damage to the components may result.
・ Refer to “Electrical System Inspection” Group (Group 6) for descriptions in the dotted-line
box.
・ Use Dr. ZX (or the built-in diagnosing system) for descriptions in the double-line box.
・ Causes of machine problems are stated in the thick-line box. Scanning quickly through the
thick-line boxes allows you to estimate the possible causes before actually following the
flow chart.
NOTE: All harness end connectors are seen from

the open-end side.
Harness
Open End
Side
Harness End Connector
T158-05-03-001
T5-3-1
FAULT CODE LIST
Fault code Problem Cause
01 Abnormal EEPROM • Faulty MC
02 Abnormal RAM
04 Abnormal Sensor Voltage • Faulty MC
• Faulty Harness
• Faulty Sensor
06 Abnormal EC Sensor • Faulty MC
• Faulty Harness
• Faulty EC Sensor
07 Abnormal Engine Control Dial Angle • Faulty MC
• Faulty Harness
• Faulty Engine Control Dial
10 Abnormal Pump 1 Delivery Pressure • Faulty MC
11 Abnormal Pump 2 Delivery Pressure • Faulty Harness
• Faulty Pump Delivery Pressure Sensor
12 Abnormal Pump 1 Pump Control Pressure • Faulty MC
13 Abnormal Pump 2 Pump Control Pressure • Faulty Harness
• Faulty Pump Control Pressure Sensor
14 Abnormal Swing Pilot Pressure Sensor • Faulty MC
15 Abnormal Boom Raise Pilot Pressure Sensor • Faulty Harness
16 Abnormal Arm Roll-In Pilot Pressure Sensor • Faulty Pilot Pressure Sensor
18 Abnormal Travel Pilot Pressure Sensor
19 Abnormal Hydraulic Oil Temperature • Faulty MC
• Faulty Harness
• Faulty Hydraulic Oil Temperature Sensor
20 Abnormal Travel Motor Drain Pressure Sensor • Faulty MC
• Faulty Harness
22 Abnormal Travel Motor • Faulty MC
• Faulty Harness
23 Abnormal Travel Forward Pilot Pressure Sensor • Faulty MC
24 Abnormal Travel Reverse Pilot Pressure Sensor • Faulty Harness
• Faulty Travel Pilot Pressure Sensor
*26 Travel Motor Over-rev. • Travel Motor Over-rev.
NOTE: In case the travel motor runs at an exces-

sive speed, fault code 26 is displayed.
Using Dr. ZX service mode, check the ex-
cessive speed rotation numbers (the
excessive speed running is not caused by
the faulty travel motor). Select the retry
when deleting the fault code.
T5-3-2
FAULT CODE 01 (ABNORMAL EEPROM)
FAULT CODE 02 (ABNORMAL RAM)
FAULT CODE 03
(ABNORMAL A/D CONVERSION)
YES * Faulty MC.
Check if engine and machine

actuators operate normally.
Faulty MC.
NO
· Refer to T4-6-1.
* Even if any fault codes are still displayed after re-
trying, as long as the engine and machine operate
normally, the machine can be operated as it is.
FAULT CODE 04
(ABNORMAL SENSOR VOLTAGE)
YES Faulty sensor.
Disconnect connectors from

all sensors relating to the in- Short-circuited harness be-
dicated fault code, and retry. YES tween MC and sensor in
Does fault code 04 disappear? Disconnect all con- section where continuity is
nectors from MC. present.
NOTE: If fault code 04 Is there continuity be-
(abnormal sensor NO
tween terminals #1 and
voltage) appears, #3 of harness at each
sensor? Faulty MC.
other fault codes
NO
appear at the same · Key switch: OFF
time. · Refer to T4-6-1.
T5-3-3
FAULT CODE 06
(ABNORMAL EC SENSOR)
Faulty harness be-

Check harness between YES tween MC and EC
MC connector C (31P) sensor.
YES terminal #18 and EC
sensor terminal #2 for
breakage or short circuit.
Disconnect EC sensor. Faulty MC.
Check if voltage be-
tween harness end NO
YES connectors #1 and #3 is · Refer to T4-6-1.
Disconnect EC sensor. Check 5±0.5 V.
if resistance between sensor Broken harness be-
side connector terminals #1 Check if voltage between YES tween MC and EC
and #3 is less than 2.0±0.4 EC sensor harness end sensor terminal #3.
kΩ. Connect test harness · Key switch: ON connector terminal #1
between EC sensor and base and vehicle frame
machine side harness. Check NO matches specification.
if voltage changes in accor- Broken harness be-
dance with specifications tween MC and EC
NO
when engine control dial is sensor terminal #1.
rotated. · Key switch: ON
· Specification: 5±0.5 V
Faulty EC sensor.
NO
· Test Harness: ST 7129 · Refer to T4-6-1.
· Specification: Refer to the
table below.
EC Sensor Specification Connector (Harness End Connector Viewed from the

Slow Idle 2.5 to 2.7 V Open End Side)
Fast Idle (HP mode 2.9 to 3.3 V
Switch: OFF)
MC Connector C
Fast Idle (HP mode Voltage at Fast Idle (HP Mode
Switch: ON) Switch: OFF) plus 0.2 V or C1 C10
more
C23 C31
#18
EC Sensor
1 2 3
T5-3-4
FAULT CODE 07
(ABNORMAL ENGINE CONTROL DIAL
ANGLE)
Faulty harness be-

Check harness between tween MC and engine
MC connector C (31P) YES control dial.
harness end terminal #6
YES and switch panel terminal
#3 for breakage or short
circuit.
Disconnect switch panel.
Faulty MC.
Check if voltage between
harness end connector NO
Disconnect switch panel. · Refer to T4-6-1.
Check if resistance between YES terminals #2 and #4 is
switch panel side connector 5±0.5 V. Broken harness be-
terminals #2 and #4 is 5±0.5 Check if voltage between YES tween MC and engine
kΩ. switch panel harness end control dial terminal #4.
Reconnect switch panel. In- connector terminal #2 and
sert tester probe into · Key switch: ON vehicle frame matches
connector terminal #3 from NO specification. Broken harness be-
the reverse side. Check if tween MC and engine
voltage varies as specified NO control dial terminal #2.
when engine control dial is
turned. · Key switch: ON
Faulty engine control
NO dial.

table below.
Engine Control Dial Specification Connector (Harness End Connector Viewed from the
Minimum Speed 0.3 to 1.0 V Open End Side)
Maximum Speed 4.0 to 4.7 V
MC Connector C
#6
C1 C10
C23 C31
Switch Panel
#4 #3 #2
T5-3-5
FAULT CODE 10
(ABNORMAL PUMP 1 DELIVERY PRES-
SURE)
FAULT CODE 11
(ABNORMAL PUMP 2 DELIVERY PRES-
SURE)
Checking Instruction
• Both pump 1 and pump 2 delivery pressure sen-
sors seldom fail at the same time. Accordingly, if
both fault codes 10 and 11 are displayed simulta- Faulty harness be-
neously, faulty harness may be the cause of this Check harness between MC and pump
problem. tween MC connector C delivery pressure
(31P) harness end sensor.
YES
terminal #1 (pump 1)
or #4 (pump 2) and
YES pump delivery pres-
sure sensor terminal
#2 for breakage or
Faulty MC.
short circuit.
Disconnect pump de- NO
livery pressure sensor.
Check if voltage be- · Refer to T4-6-1.
tween harness end
NO connector terminals #1 Broken harness be-
and #3 is 5±0.5 V. tween MC and pump
Check if voltage be- delivery pressure
Check if fault codes are tween pump delivery YES sensor terminal #3.
switched after switching pressure sensor har-
pump 1 delivery pres- ness end connector
· Key switch: ON
sure sensor with pump 2 terminal #1 and vehi-
delivery pressure sensor cle frame matches
NO Broken harness be-
and retrying. specification. tween MC and pump
delivery pressure
NO sensor terminal #1.
· Key switch: ON
· Specification: 5±0.5 V Faulty pump delivery
pressure sensor.
YES
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#1 #4
C1 C10
C23 C31
Pump Delivery Pressure Sensor
3 2 1
T5-3-6
FAULT CODE 12
(ABNORMAL PUMP 1 CONTROL PRES-
SURE)
FAULT CODE 13
(ABNORMAL PUMP 2 CONTROL PRES-
SURE)
Checking Instruction
• Both pump 1 and pump 2 control pressure sen-
sors seldom fail at the same time. Accordingly, if
both fault codes 12 and 13 are displayed simul-
taneously, faulty harness may be the cause of Check harness be- Faulty harness be-
this problem. tween MC connector C tween MC and pump
(31P) harness end control pressure sen-
terminal #7 (pump 1) sor.
YES
or #13 (pump 2) and
pump control pressure
YES sensor terminal #2 for
breakage or short cir-
cuit.
Disconnect pump con- Faulty MC.

trol pressure sensor. NO
Check if voltage be-
tween harness end · Refer to T4-6-1.
NO connector terminals #1
and #3 is 5±0.5 V. Broken harness be-
Check if voltage between MC and pump
tween pump control control pressure sen-
Check if fault codes are pressure sensor har- YES sor terminal #3.
switched after switching ness end connector
pump 1 control pressure · Key switch: ON terminal #1 and vehicle
sensor with pump 2 con- frame matches speci-
trol pressure sensor and NO fication. Broken harness be-
retrying. tween MC and pump
NO control pressure sen-
sor terminal #1.
· Key switch: ON
Faulty pump control

pressure sensor.
YES
MC Connector C
#13 #7
C1 C10
C23 C31
Pump Control Pressure Sensor
1 2 3
T5-3-7
FAULT CODE 14
(ABNORMAL SWING PILOT PRESSURE)
FAULT CODE 15
(ABNORMAL BOOM RAISE PILOT
PRESSURE) NOTE: Fault code 18 (abnormal travel pilot pres-
FAULT CODE 16 sure sensor) will be displayed together
(ABNORMAL ARM ROLL-IN PILOT with fault code (23 or 24) simultaneously in
PRESSURE) case either the travel forward pilot pres-
FAULT CODE 18 sure sensor or the travel reverse pilot
(ABNORMAL TRAVEL PILOT PRESSURE) pressure sensor is abnormal.
FAULT CODE 23
(ABNORMAL TRAVEL FORWARD PILOT
PRESSURE)
FAULT CODE 24
(ABNORMAL TRAVEL REVERSE PILOT
PRESSURE)
Check harness between MC
connector C (31P) harness
Checking Instruction end each corresponding
• All pressure sensors seldom fail at the same time. YES terminal and pressure sen-
Accordingly, if fault codes 14, 15, 16, 18, 23 and sor terminal #2 for breakage
24 are displayed simultaneously, faulty harness or short circuit.
may be the cause of this problem.
Connector C Terminal:
#14: Pressure Sensor (Swing)
#2: Pressure Sensor (Boom Raise)
Disconnect pressure #5: Pressure Sensor (Arm Roll-In)
sensor. Check if voltage #17: Pressure Sensor (Travel Forward)
NO between harness end #23: Pressure Sensor (Travel Reverse)
connector terminals #1
and #3 is 5±0.5 V.
Check if fault code dis-
appears after switching
pressure sensor with Check if voltage between
· Key switch: ON
another pressure sensor pressure sensor harness
and retrying. end connector terminal
#1 and vehicle frame
NO matches specification.
Fault Code:
14: Pressure Sensor (Swing)
15: Pressure Sensor (Boom Raise)
16: Pressure Sensor (Arm Roll-In) · Key switch: ON
23: Pressure Sensor (Travel Forward) · Specification: 5±0.5 V
24: Pressure Sensor (Travel Reverse)
YES
T5-3-8
YES Faulty harness between MC and

pressure sensor.
Faulty MC.
NO
· Refer to T4-6-1.
Broken harness between MC and

pressure sensor terminal #3.
YES

pressure sensor terminal #1.
NO
Faulty pressure sensor.
MC Connector C Pilot Pressure Sensor
#2 #5
C1 C10
1 2 3
C23 C31
#23 #14 #17
T5-3-9
FAULT CODE 19
(ABNORMAL HYDRAULIC OIL
TEMPERATURE)
Connect hydraulic oil
temperature sensor Faulty MC.
YES
harness end connector
terminal #1 to #2 with a
clip. Remove connec- · Refer to T4-6-1.
tor B (25P) and
connector C (31P) Broken harness be-
Connect MC con- tween MC and
YES from MC. Check for
nector B (25P) YES hydraulic oil tem-
continuity between
harness end terminal perature sensor
connector B harness
#22 to vehicle frame. terminal #1.
end terminal #22 and
Check for continuity
connector C terminal
Disconnect hydraulic oil between hydraulic oil
#24.
temperature sensor. NO temperature sensor
Check if sensor side harness end con- Broken harness be-
connector resistance nector terminal #2 tween MC and
matches specification. and vehicle frame. hydraulic oil tem-
NO perature sensor
terminal #2.
· Specification: Refer to
the table below.
Faulty hydraulic oil
temperature sensor.
NO
Oil Temperature Specification
Oil Temperature Resistance MC Connector B
(°C) (kΩ)
B1 B8
−20 16.2±1.6
0 (5.88)
20 2.45±0.24
40 (1.14) B19 B25
60 (0.534) #22
80 0.322
MC Connector C
C1 C10
C23 C31
#24
Hydraulic Oil Temperature Sensor
1 2
T5-3-10
FAULT CODE 20 (ABNORMAL TRAVEL
MOTOR DRAIN PRESSURE SENSOR)
Faulty harness be-

Check harness be- YES tween MC and
tween MC connector C pressure sensor.
(31P) terminal #3 and
YES
pressure sensor ter-
minal #2 for breakage
or short circuit. Faulty MC.
Disconnect pressure NO
sensor. Check if voltage
between harness end · Refer to T4-6-1.
NO connector terminals #1
and #3 is 5±0.5 V.
· Key Switch: ON Broken ground line

Check if voltage be- YES cable of pressure
Check if fault code is deleted tween pressure sensor sensor (terminal #3).
when retry is performed after harness connector ter-
replacing pressure sensor minal #1 and vehicle
with other pressure sensor.
NO frame matches specifi- Broken harness be-
cation.
tween MC connector
· Replaceable Pressure Sensor: NO B terminal #20 and
pressure sensor ter-
· Pressure Sensor (Swing) minal #1.
· Key Switch: ON
· Pressure Sensor (Boom Raise)
· Pressure Sensor (Arm Roll-in)
· Pressure Sensor (Travel Forward)
· Pressure Sensor (Travel Reverse)
Faulty pressure sen-
YES sor.
MC: Connector C Travel Motor Drain Pressure Sensor

#2 #3
C1 C10
1 2 3
C23 C31
T5-3-11
FAULT CODE 22 (ABNORMAL TRAVEL
MOTOR)
• This fault code is displayed when input signal
value from the travel motor drain pressure sensor
is more than 1.6 MPa and when this status con-
tinues for longer than 50 ms. Faulty travel motor or
MC may be the cause of this trouble.
NOTE: 50 ms (milli-second)=0.05 second
T5-3-12
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault code
is displayed on the Dr.ZX (or the built-in diagnosing
system) although the machine’s operation is
abnormal.
On the front section pages of this group T5-4, are
tables indicating the relationship between machine
trouble symptoms and related parts which may cause
such trouble if failed.
Start the troubleshooting with more probable causes
selected by referring to these tables.
• How to Read the Troubleshoting Flow Charts
YES(OK)
(2)
• After checking or measuring item (1), select either YES (OK) or
・ (1) NO (NOT OK) and proceed to item (2) or (3), as appropriate.
(3)
NO(NOT OK)
・ • Special instructions or reference item are indicated in the spaces under the box.
Incorrect measuring or checking methods will render troubleshooting impossible,
· Key switch: ON and may damage components as well.
• Explanation of how to use test harness kit required. Refer to “Electrical System
・
Inspection” Group (Group 6) in this section.
・ • Use Dr.ZX (or the built-in diagnosing system) function.
・ • Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes can be seen without going through the flow chart.
T5-4-1
RELATIONSHIP BETWEEN MACHINE
TROUBLE SYMPTOMS AND RELATED
PARTS
This table indicates the relationship between machine
trouble symptoms and the potential problem parts,
which may cause trouble if failed, and the evaluation
methods of these components.
Parts
EC Motor EC Sensor
• Moves governor. • Detects minimum governor speed position
(2.5 V) only when key switch is turned ON.
• Detects minimum and maximum speed posi-
tion when engine learning is conducted.
Function
• Governor lever doesn’t move. • Engine speed is controlled based on idle posi-
tion set when key switch is turned ON. There-
fore, engine speed is always controlled with
Symptoms in control sys- error in idle position setting if set incorrectly.
tem when trouble occurs.
• Even if engine control dial is turned, engine • Error in setting will seldom occur so that
speed doesn’t increase from slow idle speed. change in machine operation will not be no-
• Engine start may be difficult though starter ticed.
rotates. • In case error is set on lower side, engine
• Engine will stall if discontinuity occurs in EC speed changes but runs slower than normal
motor while engine is running at more than a through the full range when engine control dial
specified speed. is turned. (Note: In case error is set on upper
• Engine will become uncontrollable if disconti- side, EC motor is driven so that it runs faster
nuity occurs in EC motor while engine is run- than the control range. However, motor, a
ning at lower than a specified speed. Engine worm gear type, holds governor lever at
cannot be stopped with key switch. maximum constant position, preventing en-
Symptoms in machine gine stall. When engine control dial is turned
operation when trouble to minimum speed position, governor lever is
returned to idle position.)
occurs. • When starting engine, engine speed fluctu-
ates.
• Starting engine is occasionally difficult.
By Fault Code Fault code 06 is displayed.


Monitor Item: EC Angle (Displayed by built-in
By Monitor diagnosing system)

Evalua- Function
tion • Install lamp harness (ST 7125) to check EC
Using Test output signal and harness for any abnormality.

Harness
Others  
• Engine is stopped by EC motor. (Engine stop • If EC sensor is faulty, engine learning is not
motor is not provided.) performed.
NOTE Fuel cut-off cable is provided.
Descriptions of Control T2-1 T2-1

(Operational Principle Sec-
tion in T/M)
T5-4-2
Engine Control Dial Pump Control Pressure Sensor Pump 1 Delivery Pressure Sensor
• Indicates governor lever position (engine • Monitors pump control pressure to con- • Monitors pump delivery pressure to con-
target speed). trol auto-acceleration system. trol HP mode, auto-acceleration and
forward/reverse travel pedal.
• Engine speed doesn’t change even if • No signals arrive to MC • If pump delivery pressure sensor output
engine control dial is turned. is 0 or 5 V, following symptoms will be
• If discontinuity or short circuit occurs in presented by back-up mode function.
engine control dial, slow idle is used as
back-up value.
• Engine speed is kept unchanged from • Auto-acceleration control is inoperable • HP mode is inoperable.
slow idle. (Engine can be stopped by (but not noticeable). • Auto-acceleration control is inoperable.
key switch.) • When the machine travels, the engine
speed doesn’t increase.
Fault code 07 is displayed. Fault codes 12 and 13 are displayed. Fault code 10 is displayed.
Monitor Item: Engine Target Speed, Dial Monitor Item: Pump 1 and 2 Pump Flow Monitor Item: Pump 1 Delivery Pressure
Angle (Displayed by built-in diagnosing Control Pressure (Displayed by built-in di- (Displayed by built-in diagnostic system)
system) agnostic system)
  
  
• Evaluation by Dr. ZX
Broken Circuit: 0.25 V or less
 Short Circuit: 0.75 V or more 
T2-1 T2-1 T2-1
T5-4-3
Parts Steering Pump Delivery Pressure

Pump 2 Delivery Pressure Sensor
Sensor
• Monitors pump delivery pressure to control HP • Monitors pump delivery pressure to control
mode, auto-acceleration and arm regenera- steering pump torque decrease.
tive.
Function
• If pump delivery pressure sensor output is 0 or • Engine stalls if pump torque is increased.
5 V, following symptoms will be presented by
Symptoms in control sys- back-up mode function.
• HP mode is inoperable. • Engine stalls if pump torque is increased.

• Auto-acceleration control is inoperable.
• Arm is slow when arm roll-in and swing com-
bined operation is made.
Symptoms in machine op-

eration when trouble oc-
curs.
By Fault Code Fault code 11 is displayed. 

Monitor Item: Pump 2 Delivery Pressure (Dis- Monitor Item: Pump 3 Delivery Pressure
played by built-in diagnostic system)
By Monitor
Evalua- Function
tion
Using Test
 
Harness
Others  
NOTE  

tion in T/M)
T5-4-4
Pressure Sensor Pressure Sensor Pressure Sensor

(Travel Forward) (Travel Reverse) (Front Attachment)
• Monitors travel forward pilot pressure to • Monitors travel reverse pilot pressure to • Monitors front attachment pilot pressure
control forward/reverse travel pedal, control forward/reverse travel pedal, to control auto-idle, idle speed-up and
auto-idle, auto-acceleration and idle auto-idle, auto-acceleration and idle parking brake alarm.
speed-up. speed-up.
• No signals arrive to MC • No signals arrive to MC • When the pressure sensor (front attach-
ment) or the harness between the pres-
sure sensor and the MC is faulty, the MC
judges that the pressure sensor (front
attachment) is ON.
• Engine speed doesn’t increase even if • Engine speed doesn’t increase even if • Engine speed doesn’t increase even if
auto-idle/auto-acceleration selector is auto-idle/auto-acceleration selector is any front attachment actuator is operated
auto-idle position. auto-idle position. with auto-idle/auto-acceleration selector
• Even if the pedal is stepped on with the • Even if the pedal is stepped on with the is auto-idle position.
engine speed control mode selection engine speed control mode selection • Occasionally, engine speed hunts while
switch in the pedal position, the engine switch in the pedal position, the engine operating front attachment at slow idle.
speed doesn’t increase. speed doesn’t increase. • When the parking brake is applied or
• Occasionally, engine speed hunts while • Occasionally, engine speed hunts while when the front attachment is operated,
traveling at slow idle. traveling at slow idle. the buzzer doesn’t sound.
• Even though the machine is driven with • Even though the machine is driven with
the forward/reverse travel pedal fully the forward/reverse travel pedal fully
stepped on, the engine speed doesn’t in- stepped on, the engine speed doesn’t in-
crease. crease.
• Even though the machine travels forward • Even though the machine travels reverse
with the auto-acceleration switch ON, the with the auto-acceleration switch ON, the
engine speed doesn’t increase. engine speed doesn’t increase.
Fault codes 18 and 23 are displayed. Fault codes 18 and 24 are displayed. 
Monitor Item: Forward Travel Control Pilot Monitor Item: Reverse Travel Control Pilot Monitor Item: Front ATT. Operation (Dis-
Pressure (Displayed built-in diagnostic sys- Pressure (Displayed built-in diagnostic sys- played built-in diagnostic system).
tem) tem) Monitor pressure change while operating
Monitor pressure change while traveling Monitor Pressure change while traveling front attachment.
forward. reverse.
  
  
• Judge if pressure sensor is faulty or port • Judge if pressure sensor is faulty or port • Judge if pressure sensor is faulty or port
is clogged by switching pressure sensor is clogged by switching pressure sensor is clogged by switching pressure sensor
with another pressure sensor. with another pressure sensor. with another pressure sensor.
T2-1 T2-1 T2-1
T5-4-5
Parts Pressure Sensor

Pressure Sensor (Swing)
(Boom Raise)
• Monitors swing pilot pressure to control arm re- • Monitors boom raise pilot pressure to
generative system. control HP mode, auto-acceleration and
arm regenerative controls.
Function
• No signals arrive to MC • No signals arrive to MC
Symptoms in control system

when trouble occurs.
• During arm level crowding operation, arm speed • Even if boom is raised with HP mode
is slightly slow. switch ON, engine speed doesn’t in-
crease.
• Even if boom is raised with
auto-idle/auto-acceleration selector is
auto-acceleration position, engine speed
doesn’t increase.
• Arm roll-in speed becomes slightly slower
Symptoms in machine op- than normal in boom raise and arm roll-in
combined operation as arm regenerative
eration when trouble occurs. system doesn’t work. (Not remarkable)
• Arm roll-in and boom raise speeds be-
come slightly slower at the beginning
stage of arm level crowd operation.
By Fault Code Fault code 15 is displayed. Fault code 16 is displayed.
By Monitor Monitor Item: Swing Control Pilot Pressure (Dis- Monitor Item: Boom Raise Pilot Pressure
played built-in diagnosing system) (Displayed built-in diagnosing system).
Function Monitor pressure change while swinging upper- Monitor pressure change while raising
structure. boom.
Evalua-
tion
Using Test Har-
 
ness
Others  
• Judge if pressure sensor is faulty or port is • Judge if pressure sensor is faulty or port
clogged by switching pressure sensor with an- is clogged by switching pressure sensor
other pressure sensor. with another pressure sensor.
NOTE
Descriptions of Control (Op- T2-1 T2-1

erational Principle Section in
T/M)
T5-4-6
Pressure Sensor Travel Motor Drain Pressure Sensor

(Arm Roll-In) Pressure Sensor (Auxiliary) (Optional)
• Monitors arm roll-in pilot pressure to • Detects the travel motor drain pressure. • Monitors attachment pilot pressure
control HP mode, auto-acceleration, and when attachment is installed to control
arm regenerative controls. attachment operation speed increase,
pump 1 and pump 2 flow rate limit,
and auxiliary flow rate controls.
• No signals arrive to MC • No signals arrive to MC • No signals arrive to MC
• Even if arm is rolled-in with HP mode • When the MC judges that the sensor is ab- • Engine speed doesn’t increase when
switch ON, engine speed doesn’t in- normal, the MC displays any stored fault attachment is operated.
crease. codes (indicator light) and continues to control • When attachment is operated, opera-
• Even if arm is rolled-in with the machine operation normally using the tion speed increases.
auto-idle/auto-acceleration selector is backup value (0 MPa).
auto-acceleration position, engine speed
doesn’t increase.
• Arm speed is slow in arm level crowd
operation.
Fault code 16 is displayed.  

Monitor Item: Arm Roll-In Pilot Pressure Monitor Item: Travel Drain Pressure Monitor Item: ATT Control Pilot Pressure
(Displayed built-in diagnosing system). Monitor pressure change while Traveling. (Displayed built-in diagnosing system).
Monitor pressure change while rolling arm Monitor pressure change while operating
in. attachment.
  
  
• Judge if pressure sensor is faulty or port • Judge if pressure sensor is faulty or port is • Judge if pressure sensor is faulty or
is clogged by switching pressure sensor clogged by switching pressure sensor with port is clogged by switching pressure
with another pressure sensor. another pressure sensor. sensor with another pressure sensor.
T2-1 T2-1 T2-1
T5-4-7
Parts
Torque Control Solenoid Valve Solenoid Valve Unit (SE)
• Supplies control pressure to pumps 1 and 2 to • Releases the operate check valve provided in
control speed sensing. the axle lock cylinder
Function
• Iftorque control solenoid valve is not acti- • When the solenoid valve is seized, the oper-
vated, output pressure from solenoid valve is ate check valve doesn’t open (close).
2
0 MPa (0 kgf/cm ).
Symptoms in control sys-
• Occasionally the engine stalls during travel • The axle lock is not released even though the
operation. brake switch is turned OFF.
• The axle lock cylinder is not locked even
though the brake switch is turned to the axle
lock position.

eration when trouble oc-
curs.
By Fault Code  
Monitor Item: Pump Torque P/S Valve Output
By Monitor
Evalua- 
Function
tion
Using Test
Harness  
Others  
NOTE  
T2-1 T2-1
Descriptions of Control
tion in T/M)
T5-4-8
Solenoid Valve Unit (SG) Solenoid Valve Unit (SC) Solenoid Valve Unit (SI)
• When the work mode is selected with • Routes return oil from arm cylinder rod side • The valve is shifted when the superfine
the brake switch, the valve is shifted so to bottom side when rolling arm in to in- travel mode is selected so that the travel
that the pilot pressure shifts the brake crease arm speed. motor displacement angle is increased
valve (work brake control). to the maximum (superfine travel speed
control).
• When descending a slope, the travel
motor displacement angle is increased
to apply the hydraulic brake.
• In case solenoid valve unit (SG) is not • In case solenoid valve unit (SC) is not ac- • In case solenoid valve unit (SI) is not
activated, pressure at port SE becomes tivated, pressure at port SC becomes 0 activated, pressure at port SI becomes
2 2 2
0 MPa (0 kgf/cm ). MPa (0 kgf/cm ). Arm regenerative valve 0 MPa (0 kgf/cm ).
will not operate at this time.
Solenoid valve unit (SG) is closed: Solenoid valve unit (SC) is closed: Solenoid valve unit (SI) is closed:
• The work brake doesn’t operate. • Arm speed is slow in arm level crowd op- • Even of the super fine travel mode is
eration. selected, the travel speed is not re-
Solenoid valve unit (SG) is open: duced.
• The work brake is kept apply so that the Solenoid valve unit (SC) is open:
machine cannot travel. • Arm speed is fast as the arm regeneration Solenoid valve unit (SI) is open:
is always operated. • Since the travel motor displacement an-
gle is constantly kept at the maximum,
the travel speed doesn’t increase.
  
Monitor Item: Working Brake P/S Valve Monitor Item: Arm Regenerative P/S Valve Monitor Item: Travel Motor Tilt P/S Valve
Output Output Output
• Install lamp harness (ST 7226) to check • Install lamp harness (ST 7226) to check • Install lamp harness (ST 7226) to check
output signals from MC and harness output signals from MC and harness con- output signals from MC and harness
condition. dition. condition.
  
  
T2-1 T2-1 T2-1
T5-4-9
Parts Max. Pump 1 Flow Rate Max. Pump 2 Flow Rate

Limit Solenoid Valve Limit Solenoid Valve
• When the front attachment is operated, the • When operating attachment, limits
maximum flow rate of pump 1 is restricted. maximum pump 2 flow rate.
Function
• In case max. pump 1 flow rate limit solenoid • In case max. pump 2 flow rate limit so-
valve is not activated, pressure at output lenoid valve is not activated, pressure at
2 2
port becomes 0 MPa (0 kgf/cm ). output port becomes 0 MPa (0 kgf/cm ).

Max. pump 1 flow rate limit solenoid valve is Max. pump 2 flow late limit solenoid valve
closed: is closed:
• When operating attachment, operating • Arm, boom and swing speeds are slow
speed increases. as maximum flow rate of pump 2 de-
creases.
Max. pump 1 flow rate limit solenoid valve is
open: Max. pump 2 flow rate limit solenoid valve
• Travel, bucket, arm and boom speeds are is open:
slow as maximum flow rate of pump 1 de- • When operating attachment, operating
creases. speed increases.
Symptoms in machine operation
Evalua- By Monitor Function  

tion
Using Test Harness  
Others  
NOTE  
Descriptions of Control (Opera- T2-1 T2-1

tional Principle Section in T/M)
T5-4-10
Max. Pump 1 Flow Rate Shift So-

lenoid Valve N Sensor (Engine Speed Sensor) N Sensor (Travel Speed Sensor)
• Shifts the maximum pump 1 flow rate • Monitors engine speed to operate en- • Detects the travel motor speed and sends
(maximum travel pump 1 flow rate shift gine speed sensing control. a signal to the speed display meter.
control). • The travel motor speed is detected to ac-
tivate the superfine travel speed, to pre-
vent the travel motor from excessive rota-
tion, and/or to restrict the forward/reverse
shifting.
• If the maximum pump 1 flow rate shift • Speed sensing control is inoperable. • The speed display meter doesn’t operate.
solenoid valve is not activated, the oil • The superfine travel speed, travel motor
pressure at the output port is reduced to excessive rotation, and/or the for-
2
0 MPa (0 kgf/cm ). The pump 1 flow rate ward/reverse shifting restriction control is
stays at the maximum flow rate at this inoperable.
time.
Max. pump 1 flow rate shift solenoid valve • Engine stalls under adverse operating • The speed display meter doesn’t operate.
is closed: conditions such as at high altitude. • When descending a slope, the engine
• Since the maximum pump 1 flow rate speed is not reduced.
increases, the arm and boom operation
speeds become faster than usual.
Max. pump 1 flow rate shift solenoid valve

is open:
• When traveling, the pump 1 flow rate is
not shifted to the maximum so that the
travel speed doesn’t increase.
  
Monitor Item: Pump Flow Changeover P/S Monitor Item: Actual engine speed (If N
Valve Output sensor fails, engine speed is not meas- 
ured.)
  
  
• Even if signals from N sensor are not
delivered due to broken circuit or poor
sensor installation, few changes in op-
erational performance occur, making
troubleshooting difficult. Use monitor 
function.
T2-1 T2-1 T2-1
T5-4-11
Parts
Hydraulic Oil Temperature Sensor Engine Learning Switch
• Monitors hydraulic oil temperature to control • Starts engine learning.
auto-warming up and arm regenerative con- ON: 0 V→Learning
trol. OFF: 5 V→Normal Control
Function
• If circuit breakage occurs, system operates as • Engine learning is not performed.

if hydraulic oil temperature is 120 °C (Dr. ZX
or monitor will not indicate 120 °C in diagnosis
Symptoms in control sys- operation).
• Even if oil temperature is lower than 0 °C, Engine learning:

auto-warming up control doesn’t operate so • Machine will operate normally problem is
that engine runs at idle speed when engine is caused by broken circuit or discontinuity of
started. switch. (Only learning cannot be performed.)
• When oil temperature is lower than 10 °C, arm • If short circuit occurs, learning mode operation
Symptoms in machine op- regenerative control is inoperable. starts when key switch is turned ON. There-
fore, engine will stall at 2 second or 20 sec-
eration when trouble oc- onds after engine starts.
curs.
Fault code 19 is displayed.

By Fault Code 
By Monitor Monitor Item: Hydraulic Oil Temperature Monitor Item: Engine Learning Control
Evalua-
tion Function
Using Test  
Harness
Others  
• In case temperature is extremely low (below
-20°C), the control system is inoperable.
NOTE 

tion in T/M)
T5-4-12
Engine Speed Control Mode

Shift Lever Brake Switch
Selection Switch
• Shifts the Hi/Low solenoid valve corre- • Shifts the engine speed control mode by • The work brake, parking brake, axle
sponding to operation of the shift lever operating the switch. (Engine control dial lock, and OFF, are selected by operating
(D, L, N). control, forward/reverse travel pedal the switch.
control and superfine travel speed con-
trol)
• When broken or short circuit occurs in • Depending on failure of the switch, the • Depending on failure of the switch, the
the switch, the Hi/Low solenoid valve is engine control mode may not be se- brake mode may not be selected. (Work
held in either Hi or Low position. lected. (Engine control dial, pedal, su- brake, parking brake, axle lock, and
perfine travel speed) OFF)
• Even if the shift lever is placed in the D • Even though the engine control mode • Even though the work brake is selected,
position, the fast travel speed mode is switch is turned to the pedal position, the work brake isn’t operable.
not selected. the engine speed cannot be controlled • Even though the parking brake is se-
• Even if the shift lever is placed in the L with the travel pilot valve. lected, the parking brake isn’t operable.
position, the slow travel speed mode is • Even though the engine control mode • Even though the axle lock is selected,
not selected. switch is turned to the superfine posi- the axle cylinder is not locked.
• Even though the shift lever is placed to tion, the superfine travel speed mode • Even though the OFF position is se-
neutral, indicator (N) on the column box isn’t operable. lected, either the work brake, parking
doesn’t light. brake, or axle lock isn’t operable.
  
Monitor Item: Neutral Switch, Mission Monitor Item: Creeper Mode Switch, Pedal Monitor Item: Working/Parking Switch
Switch EC Switch
  
  
  
T2-1
T5-4-13
Parts Auto-Idle/Auto-Acceleration Selector

MC (Auto-Idle)
• Controls engine, pump and valve operation. • Activates auto-idle control.
ON: 0 V → Auto-idle is operable.
OFF: 5 V → Inoperable.
Function
• Depending on trouble situations, control sys- • Broken Circuit:

tem malfunction may differ. (The following Auto-idle system is inoperable.
symptoms in machine operation indicates that Short Circuit:
MC logic circuit has failed.) Even if auto-idle/auto-acceleration selector is
OFF, auto-idle control is always performed.
Symptoms in control
system when trouble oc-
curs.
• Even if key switch is turned ON, step motor • Same as described above.
will not move to the START position so that
engine cannot start. Even though engine
Symptoms in machine starts, speed stays slow.
operation when trouble • Since pump displacement is held at minimum,
all actuator speeds are slow.
occurs.
Fault codes 01, 02, and 03 are displayed. Other

By Fault fault codes may be displayed. 
Code
By Monitor Monitor Item: Auto-Idle/Auto-Accel Switch
Evalua- 
tion Function
Using Test  
Harness
Others  
• Before suspecting a failure in MC, be sure to
check the fuses in control system. If any sen-
sor in 5 V system is short-circuited, all sensor
NOTE fault codes will be displayed. 

(Operational Principle
Section in T/M)
T5-4-14
Auto-Idle/Auto-Acceleration Power Mode Switch Power Mode Switch

Selector (Auto-Acceleration) (HP Mode) (E Mode)
• Activates auto-acceleration control. • Selects HP mode. • Selects E mode.
ON: 0 V → Auto-acceleration is oper- ON: 0 V → HP mode ON: 0 V → E mode
able. OFF: 5 V → Normal OFF: 5 V → Normal
OFF: 5 V → Inoperable.
• Broken Circuit: • Broken Circuit: • Broken Circuit:

Auto-acceleration control is inoperable. Even if HP mode is selected, HP mode Even if E mode is selected, engine
• Short Circuit: is inoperable. speed doesn’t decrease.
Even if auto-idle/auto-acceleration se- • Short Circuit: • Short Circuit:
lector is OFF, auto-acceleration control Even if HP mode switch is turned OFF, Engine speed doesn’t increase to the
is always performed. HP mode system is not deactivated. At- maximum. Auto-idle control is inoper-
tachment speed increase control (op- able.
tional) becomes inoperable.
• Same as described above. • Same as described above. • Same as described above
  
Monitor Item: Auto-Idle/Auto-Accel Switch Monitor Item: E/P/HP Mode Switch Monitor Item: E/P/HP Mode Switch
  
  
  
T2-1 T2-1 T2-1
T5-4-15
Parts Work Mode Switch Work Mode Switch

(Digging Mode) (Attachment Mode)
• Allows normal control to be performed. • Functions only when optional attachment
kit is equipped. (Attachment operation
speed increase/limit control)
Function
• In response to operation of the auxiliary

valve, engine speed related to the at-
tachment is controlled.


• Even if auxiliary valve is operated, engine

speed doesn’t increase.
• Even if attachment mode is selected,
maximum engine speed doesn’t decrease.


eration when trouble occurs.
By Monitor Monitor Item: Work Mode Switch Monitor Item: Work Mode Switch
Evalua- Function
tion Using Test Har-  
ness
Others  
NOTE  

T/M)
T5-4-16
Auxiliary Mode Switch Bucket Flow Rate Auxiliary Flow Rate

(Optional) Control Valve Control Valve
• Functions only when optional at- • Restricts oil flow to bucket during 3-combined • To be shifted by pilot pressure from aux-
tachment kit is equipped. (Attach- operation of bucket, arm roll-in and boom iliary flow rate control solenoid valve.
ment operation speed increase/limit raise to allow boom to raise.
control)
• In response to operation of the auxil- • If switch valve is bound with valve activated, • If spool is bound or spring is broken,
iary valve, engine speed related to bucket circuit is always restricted. orifice doesn’t vary.
the attachment is controlled.
• Even if auxiliary valve is operated, • If poppet valve is bound at fully closed posi- • If bound at fully closed position, attach-
engine speed doesn’t increase. tion or if switch valve is bound when poppet ment speed becomes slow.
• Even if attachment mode is selected, valve is fully closed, bucket speed becomes • If bound at fully opened position, boom
maximum engine speed doesn’t de- slow. doesn’t move during 3-combined opera-
crease. • If poppet valve is bound at fully opened position of swing, arm roll-in, and boom
tion or if switch valve is bound when poppet raise.
valve is fully opened, boom doesn’t move
during 3-combined operation of bucket, arm
roll-in, and boom raise.
  
  
  
  
  
T2-1 T3-3 T3-3
T5-4-17
Parts
Boom Regenerative Valve Arm Regenerative Valve
• Prevents boom cylinder hesitation by routing • To be shifted by pilot pressure from solenoid
return oil from boom cylinder bottom side to valve unit (SC).
rod side. • Increases arm speed by routing return oil
from arm cylinder rod side to bottom side.
Function
• If check valve is kept closed, boom is not • Arm regenerative function is inoperable.
smoothly lowered.
• If check valve is kept open, machine cannot
be raised off ground with front attachment.

• Same as described above. • Arm speed is extremely slow during arm level
crowd operation while arm regenerative
valve is kept closed.
• The lever operated first is given priority dur-
ing combined operation of arm roll-in and
swing while arm regenerative valve is kept
Symptoms in machine op- open.
By Monitor  
Evalua- Function
ness
Others  
NOTE  

T/M)
T5-4-18
Bucket Regenerative Valve Boom Anti-Drift Valve Arm Anti-Drift Valve

• Prevents bucket cylinder hesitation by • Prevents boom from drifting due to oil • Prevents arm from drifting due to oil
routing return oil from bucket cylinder rod leaks in control valve. Check valve in leaks in control valve. Check valve in
side to bottom side. boom lower return circuit is forcibly arm roll-in return circuit is forcibly
opened to allow boom to move only opened to allow arm to move only
when boom is lowered. when arm is rolled in.
• If check valve is kept closed, bucket is not • If switch valve is bound, check valve • If switch valve is bound, check valve
smoothly rolled in. doesn’t open. doesn’t open.
• If check valve is kept open, bucket power is
weak.
• Same as described above. • If check valve is kept closed, boom • If check valve is kept closed, arm roll-in
doesn’t lower. speed becomes slow.
• If check valve is kept open, front attach- • If check valve is kept open, front at-
ment drift increases due to oil leaks in tachment drift increases due to oil
control valve. leaks in control valve.
• Boom moves jerky or arm speed be- • Arm moves jerky or arm speed be-
comes slow depending on valve bound comes slow depending on valve bound
conditions. conditions.
  
  
  
  
  
T3-3 T3-3 T3-3
T5-4-19
Parts
Auxiliary Flow Combiner Valve Bypass Shut-Out Valve
• Supplies pressure oil from pump 1 to auxiliary • Supplies pressure oil from pump 1 to aux-
spool when auxiliary spool is operated. iliary spool when auxiliary spool is oper-
ated.
Function
• Ifcontrol valve is kept closed, operating speed • If spool is bound in the fully open position,
doesn’t increase in single auxiliary operation. single attachment operation speed be-
comes slow.
• If spool is bound in the fully closed posi-
tion, main relief valve continues to relieve
with all control levers positioned in neutral.
• If spool is bound in opened position, when
all control levers are in neutral, pump 1
pressure is higher than pump 2 pressure.

• Same as described above. • Same as described above.

By Monitor  
Evalua- Function
ness
Others  
NOTE  

T/M)
T5-4-20
Swing Parking Brake

Pump 1 Flow Control Valve Pump 2 Flow Control Valve
Release Spool
• Supplies flow rate control pressure Pi to • Supplies flow rate control pressure Pi to • Supplies swing parking brake release
pump 1 regulator in response to lever pump 2 regulator in response to lever pressure when shifted by boom, arm,
stroke when boom (raise/lower), arm stroke when boom (raise), arm (roll out/in), bucket, swing or positioning/auxiliary
(roll out/in), bucket (roll-out/in), travel, or swing (right/left), or positioning/auxiliary is pressure.
blade/stabilizer is operated. operated.
• If spool is bound in the fully open posi- • If spool is bound in the fully open position, • If spool is bound in the fully open posi-
tion, even if control lever is in neutral, even if control lever is in neutral, pump 2 tion, swing parking brake is kept re-
pump 1 swash angle is tilted to maxi- swash angle is tilted to maximum. leased. (Machine vibrates while travel-
mum. • If spool is bound in the fully open position, ing.)
• If spool is bound in the fully open posi- pump 2 control pressure sensor monitors • If spool is bound in the fully open posi-
tion, pump 1 control pressure sensor the maximum pressure. tion, the pressure sensor (front) is al-
monitors the maximum pressure. • If spool is bound in the fully closed position, ways turned into ON.
• If spool is bound in the fully closed posi- even if control lever is operated, pump 2 Thus, engine speed doesn’t decrease
tion, even if control lever is operated, swash angle is held to minimum. (Swing when the control lever is in neutral dur-
pump 1 swash angle is held to mini- speed is very slow.) ing auto-idle/acceleration control.
mum. (Bucket speed is very slow.) • If spool is bound in the fully open position, • If spool is bound in the fully closed posi-
• If spool is bound in the fully open posi- pump 2 control pressure sensor can’t tion, swing parking brake is kept ap-
tion, pump 1 control pressure sensor monitor the pump control pressure. plied. (Dragging is felt.)
can’t monitor the pump control pres- • If spool is bound in the fully closed posi-
sure. tion, the pressure sensor (front) is al-
ways turned into OFF.
Thus, engine speed doesn’t increase
when the control lever is operated dur-
ing auto-idle/acceleration control.
• Same as described above. • Same as described above. • Same as described above.
  
  
  
  
  
T3-6 T3-6 T3-3
T5-4-21
Parts Bucket Flow Rate Control Valve Blade/Stabilizer

Control Spool Signal Shift Valve
• Supplies boom raise pilot pressure to bucket • Supplies the pilot pressure to the 2-unit so-
flow rate control valve when shifted by arm lenoid valve (blade/stabilizer) when shifted
roll-in pilot pressure. by the blade/stabilizer pilot pressure.
Function
• If spool is bound in the fully open position, • Even though the blade/stabilizer lever is op-
bucket speed becomes slow when boom raise erated, the pilot oil pressure is not supplied
and bucket combined operation is made. to the 2-unit solenoid valve.
(Bucket flow rate control is inoperable.)
• If spool is bound in the fully closed position,
boom doesn’t move during 3-combined opera-
tion of bucket, arm roll-in, and boom raise.

• Same as described above. • Even though the blade/stabilizer lever is op-

erated, the blade and stabilizer don’t move.

By Monitor  
Evalua- Function
ness
Others  
NOTE  

T/M)
T5-4-22
Accumulator
Steering Valve Brake Valve
Charging Valve
• Supplies the pressure oil from the • Supplies the pressure oil to the front and • Charges the pressure oil into the accu-
steering pump to the steering cylinder rear axle brakes corresponding to the mulator provided in the brake circuit and
corresponding to the steering wheel ro- brake pedal operating stroke. holds the charged pressure oil for the
tation. set period of time.
• The pressure oil is not supplied to the • Even though the brake pedal is stepped on, • The pressure oil is not charged into the
steering cylinder in proportion to the the brake is not applied. accumulator.
steering wheel rotation. However, the • Even though the brake pedal is not oper- • The brake circuit oil pressure stays low.
steering valve acts as a pump, the ated, the brake is applied.
steering cylinder can operate.
• Turning force of the steering wheel in- • The same as described above. • The service brake isn’t operable.
creases. • The service brake doesn’t work effec-
tively.
  
  
  
  
  
T3-3 T2-2 T2-2
T5-4-23
Parts Travel Forward Pi Cut

Transmission Control Valve
Solenoid Valve
• Includes parking brake solenoid valve and • When the shift lever is placed to neutral,
transmission changeover solenoid valve. the travel forward pilot pressure oil flow is
Controls the parking brake and the D (Hi) mode cut so that the travel forward system is in-
/ L (Low) mode in the transmission. operable.
Function
• If the parking brake solenoid valve is seized, • Travel forward Pi cut solenoid valve is
the parking brake doesn’t operate (or is kept closed:
applied) even if the brake switch is operated. Even though the shift lever is in neutral, the
• If the transmission changeover solenoid valve machine travels forward.
is seized, shifting of the transmission is not • Travel forward Pi cut solenoid valve is
achieved even if the travel mode switch is op- open:
erated. Even when the shift lever is in position L or
D, the machine doesn’t travel forward.

• Same as described above. • Same as described above.

By Monitor Monitor Item: Fw/Bk Cut Relay

Evalua- Function
ness
Others  
NOTE  

T/M)
T5-4-24
Travel Reverse Pi Cut

Solenoid Valve
• When the shift lever is placed to neutral,
the travel reverse pilot pressure oil flow is
cut so that the travel reverse system is
inoperable.
• Travel reverse Pi cut solenoid valve is

closed:
Even though the shift lever is in neutral,
the machine travels reverse.
• Travel reverse Pi cut solenoid valve is
open:
Even when the shift lever is in position L
or D, the machine doesn’t travel reverse.
• Same as described above.

Monitor Item: Fw/Bk Cut Relay


T2-1
T5-4-25
CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
This table indicates the relationship between machine z : Related, required to check
{ : Related. However, in case this component fails, other trouble
troubles and parts contributing to the cause of the symptom will be more noticeable so that this component will not
trouble if failed. be the direct cause of the trouble concerned.
Engine System Troubleshooting

E-1 E-2 E-3
Starter doesn’t rotate Although starter ro- When engine control dial is fully rotated, engine
Trouble tates, engine doesn’t stalls. Occasionally engine stalls during opera-
Symptom start. tion with engine control dial fully rotated and
auto-idle ON. Engine speed is slower than
specification in all operating range. Idle speed
is faster or slower than specification.
Parts
MC (Main Controller) z z
QOS Controller
EC Motor z
EC Sensor { z
Pressure Sensor (Travel)
Pressure Sensor (Front Attachment)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Auxiliary)
N Sensor (Engine Speed Sensor)
Hyd. Oil Temperature Sensor
Coolant Temperature Sensor
Key Switch z
Engine Control Dial
Auto-Idle/Acceleration Selector
Power Mode Switch
Work Mode Switch
Auxiliary Mode Switch
Engine Learning Switch z
Battery Relay z
Grow Plug Relay
Starter Relay z
Engine Electrical Equipment z
Engine Unit z z
Governor z z
Swing Parking Brake Release Spool

(Signal Control Valve)
Check batteries. Check fuel system Check fuel cut-off handle and engine control
(filters and piping). cable. Be sure to perform engine learning after
Remarks replacing engine.
T5-4-26
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 compo-
nents while checking all suspected com-
ponents in each trouble symptom.
E-4 E-5 E-6 E-7 E-8 E-9

Even if engine con- Engine speed Faulty HP mode. Even if key switch is Faulty auto-idle Faulty E mode.
trol dial is rotated, doesn’t increase turned OFF, engine system.
engine speed re- after engine is doesn’t stop.
mains unchanged. started.
z z z { z z
z { {
{ {
{
{
{
{
{
{
{ {
z
z
z { z
z {
z {
Check engine con-

trol cable.
T5-4-27
E-10 E-11 E-12

Faulty auto-acceleration When traveling or oper- Engine speed doesn’t
Trouble system. ating front attachment increase even if at-
Symptom with engine running at tachment is operated in
slow idle, engine hunts. attachment mode.
Parts
MC (Main Controller) z z z
QOS Controller
Torque Control Solenoid Valve
Pump 1 Delivery Pressure Sensor {
Pump 1 Control Pressure Sensor {
Pump 2 Control Pressure Sensor {
Pressure Sensor (Travel Forward) {
Pressure Sensor (Travel Reverse) {
Pressure Sensor (Front Attachment)
Pressure Sensor (Swing) {
Pressure Sensor (Boom Raise) {
Pressure Sensor (Arm Roll-In) {
Pressure Sensor (Auxiliary) z
N Sensor (Engine Speed Sensor)
Hyd. Oil Temperature Sensor
Coolant Temperature Switch
Parking Brake Pressure Switch
Auto-Idle/Acceleration Selector z
Power Mode Switch
Work Mode Switch z
Auxiliary Mode Switch z
Engine Learning Switch
Brake Switch
Shift Lever
Engine Speed Control Mode Selection Switch
z
Grow Plug Relay
Engine Unit z
Governor
Pump Regulator
Remarks
z : Related, required to check

symptom will be more noticeable so that this component will not
be the direct cause of the trouble concerned.
T5-4-28
E-13 E-14 E-15 E-16 E-17 E-18

When attachment Engine stalls within Engine stalls during Engine is difficult to The engine speed The engine speed
mode is selected, several seconds af- operation under ad- start at low tem- remains un- remains un-
engine speed ter engine has verse condition such perature. changed even changed even
doesn’t decrease. started. as at high altitude. though the pedal is though the pedal is
stepped on during stepped on during
traveling. excavation.
z z z z
z
z
{ {
{
z
{ {
z
z
z
z z
z
z z
z
z
{
Check fuel system Check batteries.
for clogging.

independently.
T5-4-29
All Actuator System Troubleshooting

A-1 A-2 A-3
All actuator speeds are Positioning is slow. Single The travel speed is slow in
Trouble slow. swing operation speed is travel single operation.
Symptom slow. Arm is slightly slow Single bucket operation
during arm level crowding. speed is slow. Boom is not
raised properly during arm
level crowding.
Parts
Torque Control Solenoid Valve z

N Sensor {
Spool
Main Relief Valve {
Main Pump z z z
Regulator { z z
Max. Pump 1 Flow Rate Limit Solenoid Valve
z
Max. Pump 2 Flow Rate Limit Solenoid Valve

z
Pilot Pump z
Pilot Valve
Pilot Relief Valve z
Pump 1 Flow Rate Control Valve
z
Pump 2 Flow Rate Control Valve
z
Remarks
NOTE: The trouble symptoms in this table are de- z : Related, required to check
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
faulty components while checking all sus-
pected components in each trouble symp-
tom.
T5-4-30
A-4 A-5
Actuator doesn’t stop Actuator speed is faster
even if control lever is than normal.
returned to neutral. Precise control can not
be performed.
T5-4-31
Front Attachment System Troubleshooting

F-1 F-2 F-3
All front attachment ac- Some cylinder are inop- Arm speed is slow in a
Trouble tuator power is weak. erable or speeds are combined operation. Arm
Symptom slow. speed is slow during arm
level crowding.
Parts
MC (Main Controller) z
Solenoid Valve Unit (SC) z
Pressure Sensor (Swing) {
Pressure Sensor (Boom Raise) {
Pressure Sensor (Arm Roll-In) {
Spool z
Main Relief Valve z
Overload Relief Valve z
Load Check Valve
Boom Regenerative Valve
Arm Regenerative Valve z
Bucket Regenerative Valve
Bucket Flow Rate Control Valve
Boom Anti-Drift Valve
Arm Anti-Drift Valve
Emergency Valve
Shockless Valve (Signal Control Valve) z
Shuttle Valve (Signal Control Valve) z
Bucket Flow Rate Control Valve Control Spool

Pilot Valve z
Cylinder
Remarks

T5-4-32
F-4 F-5 F-6 F-7 F-8

Bucket is slow in bucket When starting to move in When starting to move in When boom raise or Front attachment
roll-in single operation. combined operation, arm combined operation, boom arm roll-out is oper- drifts remarkably.
Bucket doesn’t move doesn’t smoothly move. Arm doesn’t smoothly move. ated, boom or arm
smoothly in bucket roll-in starts to move slow slightly in Boom starts to move slow starts to move after
single operation. arm roll-in single operation. slightly in boom lower sin- slightly moving down-
These troubles often occur gle operation. ward.
when oil temperature is low.
z
z
z
z
z
z
z z z
z z z
z
z z

independently.
T5-4-33
Swing System Troubleshooting

S-1
Swing is slow or unmoving.
Trouble
Symptom
Parts
MC (Main Controller)
Torque Control Solenoid Valve
Solenoid Valve Unit (SC)
Pump 1 Control Pressure Sensor
Pump 2 Control Pressure Sensor
Pressure Sensor (Travel)
Shift Lever
Pump Device
Spool
Load Check Valve
Swing Parking Brake Release Spool
z
Pump 1 Flow Control Valve
Pump 2 Flow Control Valve
z
Shuttle Valve (Signal Control Valve) {
Swing Device z
Travel Device
Center Joint
Pilot Valve z
Remarks

NOTE: The trouble symptoms in this table are de- { : Related. However, in case this component fails, other trouble
tom.
T5-4-34
(Blank)
T5-4-35
Travel/Brake System Troubleshooting

T-1 T-2 T-3
The machine doesn’t travel. Either forward or reverse Both forward and reverse
Trouble travel system doesn’t operate travel speeds are slow and
Symptom or the travel speed is slow. the travel power is weak.
Parts
Monitor Controller
Solenoid Valve Unit (SG) z
Solenoid Valve Unit (SI) z
Max. Pump 1 Flow Rate
Shift Solenoid Valve
Parking Brake Solenoid Valve
Transmission Changeover Solenoid
Valve
Transistor Unit 2 z z
Relay z
Shift Lever
Brake Switch
Engine Speed Control Mode Selection
z
Switch
Control Valve z z z
Travel Shockless Valve z
Transmission Control Valve
Accumulator Charging Valve
Brake Valve
Transmission z {
Front Axle z {
Rear Axle z {
Travel Motor z z z
Center Joint z z
Pilot Valve z
Remarks

T5-4-36
T-4 T-5 T-6 B-1 B-2 B-3

Even though the Maximum travel Hi/Low shift in the The parking brake is The parking brake is The service brake
travel pilot valve is speed is slow (trac- transmission is not not released. inoperable (not ap- isn’t operable.
released, the hy- tion force is normal). performed. plied).
draulic brake is in-
operable (the ma-
chine runs away.)
z
z z
z
{ z z
z z z
z
z z
z
z
z z z
z
z z
z

independently. In case more than one trou-
tom.
T5-4-37
Steering/Other System Troubleshooting

H-1 H-2 O-1 O-2
The steering wheel can Even though the Wiper is Air Conditioner
Trouble be turned but is difficult steering wheel is inoperable or not Malfunction.
Symptom to rotate. turned, the machine retracted.
doesn’t change the
travel direction.
Parts
Steering Pump z
Steering Valve z z
Center Joint z
Front Axle { {
Other Electrical Equipment z z
Remarks

NOTE: The trouble symptoms in this table are de- { : Related. However, in case this component fails, other trouble
tom.
T5-4-38
(Blank)
T5-4-39
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter Does Not Rotate.
Related Fault Code: None

YES
• Measure each voltage by referring to the table
below.
• Electronic system such as MC has nothing to do
with the trouble obstructing the rotation of starter.
• When the brake switch is in the accelerator lock Regardless of key switch posi-
or OFF position, the starter doesn’t rotate due to tion ON or START, voltage at
terminal B is 0 volts.
starter relay (R10) operation. (Refer to the SYS-
TEM / Electrical System group.) · Key switch: ON ⇔ START
• Be sure to inspect wiring connections prior to
troubleshooting.
With key switch positioned as
YES shown in table below, check if
each terminal voltage at starter
and starter relay is normal.
Unit: V With key switch positioned at

Key Switch START, voltage at terminal S
ON START does not increase to 24 volts.
NO
Terminal · Key switch: START
B 24 24
C 0 24
S 0 24
Check if battery voltage and R 0 to 5 0 to 5
electrolyte density are normal.
· Voltage: 24 volts or more

· Density: 1.26 or more
With key switch positioned at
START, voltages at terminals
B, C, and S do not increase to
24 volts.
NO (When key switch is turned to the START position, if voltage at

terminal B is lower than 18 volts, battery may be faulty.)
T5-4-40
Faulty starter.
YES Faulty harness between bat-

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

ble link and key switch.
Check if fusible link (40 A) is
Voltage at terminal #1: 0 V normal (is not cut).
Faulty fusible link.
· Visual check
Measure each voltage at termi- NO
nal #1 and #6 on key switch. Voltage at terminal #1: 24 V
Voltage at terminal #6: 0 V Faulty key switch.
· Key switch: START
Faulty harness between key

NO switch terminal #6 and starter
Check if trouble improves
when replacing engine relay terminal S.
starter relay (R10) and horn
Voltage at terminal #1: 24 V relay (R5) each other.
Voltage at terminal #6: 24 V Faulty engine starter relay
· Use horn relay after sound- (R10).
YES
ing horn several times to
check if operates normally.
Faulty starter relay.
Faulty battery.
• Key Switch Voltage Check
NOTE: Remove the key switch from the console. View A
V ST G1 ACC
B G2 M
T105-07-04-002
T5-4-41
E-2 Although starter rotates, engine doesn’t
start.
• Check the fuel cut lever position during cranking.

If the position is normal, the engine unit and/or
fuel system may have trouble.
• Check for loose harness connections before-
hand.
YES Faulty engine.
Check if governor lever · Refer to engine shop manual.

moves to the START position
when key switch is turned ON.
YES Faulty EC motor.

· Refer to T4-6-1.
· Key switch: ON Check if EC motor drive
circuit is normal.
NO
· Test harness: 4274589 Faulty MC.

(ST 7125) NO · Refer to T4-6-1.
• Governor Lever and Fuel Cut Lever
1 2 3 4
T1F3-05-04-002
1- Governor Cable (From EC Motor)
2- Governor Lever
3- Fuel Cut-Off Cable (Fuel Cut-Off Handle)
4- Fuel Cut Lever
T5-4-42
• Governor Lever Position
A - Key Switch OFF (Engine Stop Position)

B - Key Switch ON (Engine Start Position)
B FULL
STOP
A
FULL STOP T1F3-05-04-002
• Fuel Cut Lever Position
A - Fuel Cut-Off Handle Pulled Position

B - Fuel Cut-Off Handle Returned Position A
B
T1F3-05-04-002
T5-4-43
E-3 When engine control dial is fully rotated,
engine stalls.
Occasionally engine stalls during operation
with engine control dial fully rotated and
auto-idle ON.
Engine speed is slower than specification in
all operating ranges.
Idle speed is faster or slower than specifica-
tion.
Related Fault Code: 06
• In case engine learning has not been performed • Refer to pages for Engine Learning in the SYS-
or engine learning has been incorrectly per- TEM/Control System group in the T/M (Opera-
formed, engine speed becomes slower than tional Principle).
specification across the operating range. • Check for loose harness connections before-
• In case the EC sensor is faulty, engine speed is hand.
controlled based on the governor lever position,
which is judged as the idle position when the key
switch is turned ON. Accordingly, discrepancies
in engine speed from specification will result.
Depending on where the governor lever is posi-
tioned when the key switch is turned ON, dis-
crepancy will differ, causing this trouble to be not
reproducible.
Return fuel cut

lever to original po-
YES sition.
Check if fuel cut

lever has been
moved up to half YES Faulty EC sensor.
way stroke.
Check if fault code · Refer to T4-6-1.

06 is displayed.
NO YES End.
Check if problem is
corrected after en-
gine learning.
NO
Monitor engine
learning status.
· Refer to T4-6-1 for NO
engine learning
procedures.
· Monitor item:
Engine learning
control
T5-4-44
Faulty engine and/or fuel sys-

YES tem.
Check if governor lever

OK comes in contact with stopper
when performing engine Faulty control cable and/or in-
learning. correctly adjusted engine gov-
ernor lever.
NO
· Adjust engine speed.

(Refer to T4-6-1.)
Faulty MC, faulty learning

switch, or broken harness be-
tween learning switch and MC.
NOT OK
· Refer to T4-6-1.
T5-4-45
E-4 Even if engine control dial is rotated, engine
speed remains unchanged.
• If the EC motor fails, the engine will not stop with

the key switch OFF.
hand.
Faulty engine control dial or

broken harness between en-
gine control dial and MC.
YES
Check if fault code 07 is dis-
played. Using Dr. ZX, monitor
engine control dial angles
(standard voltages). Check if
voltages are normal. Faulty EC motor.
YES
Install test harness (ST 7125)
to EC motor. Check if lamp
comes ON while turning en- · Refer to T4-6-1.
gine control dial.
· Standard voltages NO
Slow idle position: 0.3 to 1 V Faulty MC or broken harness
Fast idle position: 4.0 to 4.7 V between MC and EC motor.
· Possible to display with built-in
diagnosing system. NO
· Refer to T4-6-1.
T5-4-46
E-5 Engine speed doesn’t increase after engine
is started.
• Refer to the pages for the Auto Warming Up Con-

trol in the SYSTEM / Control System group in the
T/M (Operational Principle).
hand.
When starting
engine, oil tem-
perature is over
0°C or below
-20°C. Normal.
Monitor oil tem-

NO perature.
· Monitor item: Hydraulic oil

temperature
· Possible to display with Faulty MC.
built-in diagnosing system
When starting en-
gine, oil tempera- · Refer to T4-6-1.
Check if fault code ture is between
19 is displayed. -19°C and 0°C.
Faulty hyd. oil tem-

perature sensor or
broken harness be-
tween oil tempera-
ture sensor and MC.
YES
T5-4-47
E-6 Faulty HP mode
• Even if power mode switch is turned to the HP

mode position, HP mode is inoperable. (General
mode normally operates.)
Related Fault Codes: 10, 11, 15, and 16
• Sensors detect the conditions necessary to oper- • Refer to the pages for HP Mode Control in the
ate the HP mode. Therefore, if any of these sen- SYSTEM / Control System group in the T/M (Op-
sor fails, the HP mode becomes inoperable. erational Principle).
• Pressure sensors (arm roll-in and boom raise) • Check for loose harness connections before-
and pump 1 and 2 delivery pressure sensors are hand.
also engaged in the HP mode control. However, if
these sensors fail, other operating functions will
be also affected. (Refer to the relationship be-
tween machine trouble symptoms and related
parts on page T5-4-2.)
Faulty power mode
switch or broken
harness between
NO power mode switch
and MC.
Monitor power mode
switch. Check if indica-
tion HP is highlighted
when power mode
NO switch is turned to “HP Check if the symptom
mode”. disappears after com- YES End.
pleting engine learn-
ing.
YES
Check if any fault Faulty MC or faulty
codes are displayed. · Monitor item: E/P/HP engine.
mode switch NO
· Refer to T4-6-1.
Faulty corresponding
sensor or broken
harness between
sensor and MC.
YES
· Fault codes:
Pump 1 delivery pressure sensor: 10
Pump 2 delivery pressure sensor: 11
Pilot pressure sensor (boom raise): 15
Pilot pressure sensor (arm roll-in): 16
T5-4-48
• Although the power mode switch isn’t turned to the

HP mode position, HP mode is operable.
• Boom raise and arm roll-in must be operated

when the average delivery pressures of pump 1
and 2 are high, if HP mode control is performed.
The sensors related to this condition may not be
broken at the same time.
Short circuited harness
between MC and power
YES mode switch.
Monitor the power

mode switch. Check
if “HP” is displayed.
Check if the symp- End.

tom disappears after YES
completing engine
· Monitor item: E/P/HP learning.
mode switch NO
Faulty MC or faulty engine.
· Power mode switch:
P mode NO
· Refer to T4-6-1.
T5-4-49
E-7 Even if key switch is turned OFF, engine
doesn’t stop. (In case the engine doesn’t
stop, stop the engine by pulling the engine
stop handle located under the seat stand.
Then, begin inspection.)
Related Fault Codes: 06 and 07
• Probably symptoms such as “Engine speed is

slower than specification in all operating ranges”
or “Even if engine control dial is rotated, engine
speed remains unchanged” will come up. Per-
form troubleshooting for these symptoms.
T5-4-50
E-8 Faulty auto-idle system
• Even if control lever is turned to neutral. Auto-idle

system is inoperable.
• In case trouble symptoms E1 to E7 are recog- • Refer to the pages for Auto-Idle Control in the
nized, perform the troubleshooting of these trou- SYSTEM / Control System group in the T/M (Op-
bles beforehand. erational Principle).
• Although the failure in pressure sensors (travel • Check for loose harness connections before-
and front attachment) will have relevance to mal- hand.
function of the auto-idle control. However, if these
sensors fail, other operating functions will also be
affected. (Refer to the relationship between ma-
chine trouble symptoms and related parts on
page T5-4-2.)
Faulty MC or harness
YES between the MC and
the front attachment
Check, on monitor, if pressure sensor.
“Fr (outline type
font)” is displayed · Refer to T4-6-1.
when pressure
YES sensor (front at-
tachment) is acti- Faulty pressure sen-
vated. YES sor (front attachment).
Check if symptom is
corrected when
· Engine: Running pressure sensor
Monitor auto-idle switch. · Monitor item: (front attachment) is
Check if displayed “AI” is Front attachment NO
replaced with an-
turned OFF or ON in re- operation other sensor. Bound swing parking
sponse to auto-idle /
brake release spool in
auto- acceleration selec-
NO the signal control
tor operation.
valve.
Faulty auto-idle / auto-

acceleration selector
· Monitor item: or broken harness
Auto-idle / auto-accel between auto-idle
switch switch and MC.
NO
T5-4-51
• Although the auto-idle / auto-acceleration selector is

turned OFF, the auto-idle control is operated.
• Be sure to separate auto-idle control from Short circuited harness

auto-acceleration control. between MC and auto-idle
/ auto-acceleration selec-
YES tor.
Monitor auto-idle /
auto-acceleration se-
lector. Check if “AI” is
displayed.
Faulty MC.
· Monitor item: Auto-idle / NO
auto-accel switch
· Auto-idle / · Refer to T4-6-1.
auto-acceleration selec-
tor: OFF
T5-4-52
E-9 Faulty E mode
• Even if power mode switch is turned to the E mode

position, engine speed remains unchanged. (En-
gine speed doesn’t decrease.)
• In case trouble symptoms E-1 to E-8 are recog-

nized, perform the troubleshooting of these trou-
bles beforehand.
• Refer to the pages for E Mode Control in the
SYSTEM / Control System group in the T/M (Op-
erational Principle).
hand. Faulty power mode switch or
broken harness between
NO power mode switch and MC.
Monitor power mode switch.
Check if displayed “E Mode” is
turned OFF or ON in re-
sponse to power mode switch
operation.
Faulty MC.
YES
· Monitor item: · Refer to T4-6-1.
E/P/HP mode switch
• Although power mode switch isn’t turned into E

mode, engine speed decrease.
Short circuited harness be-

tween MC and power mode
YES
switch.
Monitor power mode switch.
Check if “E” is displayed.
Faulty MC.
· Monitor item: E/P/HP switch NO
· Power mode switch: P mode
· Refer to T4-6-1.
T5-4-53
E-10 Faulty auto-acceleration system
• Auto-acceleration system is inoperable.
Related Fault Code: 10, 11, 12, 13, 14, 15, 16, and
18
• The auto-acceleration system doesn’t operate if • Although the failure in pressure sensors (travel,
the following conditions are not met. swing, boom raise, and arm roll-in), pump 1 and
Engine Speed Control Mode Selection Switch: 2 delivery pressure sensors, and pump 1 and 2
Dial or Creeper Position control pressure sensors will have relevance to
Auto-Idle/Auto-Acceleration Selector: malfunction of the auto-acceleration control.
Auto-Acceleration Position However, if these sensors fail, other operating
Power Mode Switch: functions will also be affected. (Refer to the rela-
HP or P Position tionship between machine trouble symptoms and
• In case trouble symptoms E-1 to E-9 are recog- related parts on page T5-4-2.)
nized, perform the troubleshooting of these trou- • Refer to the pages for Auto-Acceleration Control
bles beforehand. in the SYSTEM / Control System group in the
T/M (Operational Principle).
Faulty engine speed control

YES mode selection switch, or faulty
harnesses and relays
Monitor pedal EC switch.
YES
Check if indicator comes ON.
Monitor auto-idle /
auto-acceleration selector. · Monitor item: Pedal EC switch Faulty MC.
Check if displayed “AA” is
turned OFF or ON in response NO
to auto-acceleration switch · Refer to T4-6-1.
operation.
Faulty auto-idle /
· Monitor item: auto-acceleration selector or
Auto-idle/auto-accel switch NO broken harness between
auto-acceleration switch and MC.
T5-4-54
• Although auto-idle / auto-acceleration selector is

turned OFF, the auto-idle acceleration control is op-
erated.
• Be sure to separate the auto-idle control from the

auto-acceleration control. Short circuited harness between
MC and auto-idle /
YES auto-acceleration selector.
Monitor auto-idle /
auto-acceleration selector.
Check if “AA” is displayed.
Faulty MC.
· Monitor item: Auto-idle / NO
auto-accel switch
· Auto-idle / auto-acceleration se- · Refer to T4-6-1.
lector:
Auto-idle position
T5-4-55
E-11 When traveling or operating front attach-
ment with engine running at slow idle, en-
gine hunts.
Related Fault Code: 18, 23, 24
• Although the failure in pressure sensors (travel

and front attachment) will have relevance to mal-
function of the engine speed increase control.
However, if these sensors fail, other operating
functions will also be affected. (Refer to the rela-
tionship between machine trouble symptoms and
related parts on page T5-4-2.)
• Refer to the pages for Idle Speed-Up Control in
the SYSTEM / Control System group in the T/M
(Operational Principle).
YES Faulty engine.
Check if engine speed is

faster than increased idle · Refer to the Engine Shop
speed. Manual.
Faulty MC.
· Monitor item: NO
Engine target speed
· Possible to display with built-in · Refer to T4-6-1.
diagnosing system
T5-4-56
E-12 Engine speed doesn’t increase even if at-
tachment is operated in attachment mode.
• In case trouble symptoms E-1 to E-11 are recog- • Refer to the pages for Attachment Operation
nized, perform the troubleshooting of these trou- Speed Increase Control in the SYSTEM / Control
bles beforehand. System group in the T/M (Operational Principle).
• Although the failure in pressure sensor (auxiliary) • Check for loose harness connections before-
and power mode switch will have relevance to hand.
the malfunction of the attachment operation
speed increase control. However, if these sensor
and switches fail, other operating functions will
also be affected. (Refer to the relationship be-
tween machine trouble symptoms and related
parts on page T5-4-2.)
Set to “Increase (+)”.
NO
Check if attachment
speed adjustment
has been set to “In-
NO crease (+)” in Dr. ZX Monitor attachment
service mode. pilot pressure. Check YES
if pressure varies in To A
response to lever
Check if P speed ad-
stroke.
justment has been YES
set to “Decrease” in Faulty auxiliary pres-
Dr. ZX service mode. sure sensor.
NO
· Monitor item: Att. con-

trol pilot pressure Normal (If set to “De-
crease”, this control
system is deacti-
YES vated.)
YES Faulty MC.

Monitor work mode
switch. Check if display
switches in response · Refer to T4-6-1.
to work mode switch
A operation.
Faulty work mode

switch.
NO
· Monitor item:
Work mode switch
T5-4-57
E-13 When attachment mode is selected, engine
speed doesn’t decrease.
• In case trouble symptoms E-1 to E-11 are recog-

nized, perform the troubleshooting of these trou-
bles beforehand.
• Refer to the pages for Attachment Operation
Speed Limit Control in the SYSTEM / Control
System group in the T/M (Operational Principle).
hand.
YES Faulty MC.

Monitor work mode
switch. Check if dis-
play switches in re-
sponse to work mode · Refer to T4-6-1.
YES switch operation.
Check if attachment Faulty work mode switch.

speed adjustment has NO
been set to “Decrease
(-)” in Dr. ZX service · Monitor item:
mode. Work mode switch
Set to “Increase (+)”.
NO
T5-4-58
E-14 Engine stalls within several seconds after
engine has started.
• Refer to the pages for Engine Learning Control in

the SYSTEM / Control System group in the T/M
(Operational Principle).
• If the engine-learning switch is turned to the
learning position, the engine will stall in 5 sec-
onds after the engine starts.
hand.
Normal (Return switch to

YES neutral.)
Check if engine learn-

ing switch is turned to
the learning position.
Faulty learning switch, or
short-circuited harness be-
tween learning switch and
MC, or check fuel system for
clogging.
NO
T5-4-59
E-15 Engine stalls during operation under ad-
verse condition such as at high altitude.
• If speed-sensing control is inoperable, the engine

will stall under adverse operating conditions.
hand.
Disconnect torque control

solenoid valve. Connect
test harness (ST 7226)
Monitor torque control sole- between solenoid valve
noid valve output. Install NO and harness. Check if
pressure gauge to output port test harness lamp comes To A
so that pressure can be ON.
measured by pressure gauge
and Dr. ZX. Check if both
NO measured pressure values by
pressure gauge and Dr. ZX
vary identically.
Disassemble to check
regulator.
YES
Monitor actual engine
speed. Check if engine
speed is abnormal. · Monitor item: Pump torque
proportional solenoid valve
output
· Refer to the Operational Per-
· Monitor item: formance Test section.
Engine actual speed Faulty N sensor, or faulty
harness between N
sensor and MC.
YES
Faulty torque control

YES solenoid valve.
A
Broken harness be-
tween torque control so-
lenoid valve and MC.
NO
T5-4-60
(Blank)
T5-4-61
E-16 Engine is difficult to start at low tempera-
ture. (During cold weather or in cold dis-
tricts, the engine is difficult to start or
doesn’t start although pre-heated.)
• Check if electricity is routed to the glow plugs. • Check battery at the same time.
Check the glow plugs for any abnormality. • Check for loose harness connections before-
• The pre-heat system operates only when coolant hand.
temperature is below 10 °C (50 °F). When cool-
ant temperature is higher than 10 °C (50 °F), the
pre-heat system doesn’t operate.
Faulty coolant temperature

YES switch.
Disconnect coolant tempera-

ture switch. Check if voltage at
glow plug is 20 to 24 V.
YES Faulty QOS controller.
Disconnect QOS controller.
Ground harness end connector
· Key switch: ON terminal #4 to vehicle frame.
Check if problem is corrected.
NO
Measure each glow plug re-
sistance.
· Using a clip, ground from the NO
reverse side of the connector
without disconnecting. · Key switch: OFF
· Before measuring, remove
copper plates connecting
each glow plug.
• Measurement of Glow Plug Voltage and Resistance

Voltage Check
Resistance Check
Remove
the
copper
plate.
Specification: 20 to 24 V
Specification: Below 10 Ω
T105-07-04-006
T105-07-04-007
T5-4-62
QOS Controller Glow Plug Relay
1 2 3 1
4
4 5 6 3
2
Faulty glow plug.

∞Ω
Faulty glow plug relay, or bro-

NO ken harness between glow
Disconnect glow plug re- plug relay and glow plug.
lay. Connect harness end
connector terminal #4 to
YES vehicle frame. Check if
voltage is 20 to 24 V.
Broken harness between glow

plug relay and QOS controller,
Disconnect glow plug re- · Key switch: ON YES or faulty engine unit.
lay. Check if voltage at
glow plug relay harness
end connector terminals · Refer to the engine shop manual.
#1 or #3 is 20 to 24 V.
Below 10 Ω
In case voltage at terminal #1
is 0 V, harness between glow
relay and batteries is broken.
· Key switch: ON In case voltage at terminal #3
is 0 V, harness between glow
relay and key switch terminal
NO M is broken.
· Verify that fuse #19 is normal.
T5-4-63
E-17 The engine speed remains unchanged Connector (Harness End Connector Viewed from the Open
even though the pedal is stepped on dur- End Side
ing traveling.
MC: Connector B
Related Fault Code: 18, 23, 24 #3
B1 B8
• Check that: #9
Brake switch: OFF or Axle Lock Position
Pedal Position B19 B25
Shift Lever: D or L Position
• Faulty pressure sensor (travel forward and re-
verse) may be the cause of this problem. In this
case, other functions should become abnormal.
Faulty brake switch or

YES short-circuited harness
Check if continuity between MC and brake
between harness switch.
end terminal #9 and
“Wk (outline type vehicle frame exists
font)” is displayed. when MC connector
B is removed.
Faulty MC
NO
· Refer to T4-6-1.
Monitor working /
parking switch with Faulty travel system, or
Dr. ZX parking brake system.
YES Refer to the travel system
troubleshooting and the
brake system trouble-
Check if column box shooting.
“Pk (outline type parking brake indi-
font)” is displayed. cator is ON. Short-circuited harness
Check if continuity YES between MC and parking
between harness brake pressure switch.
end terminal #3 and
NO vehicle frame exists
when MC connector Faulty MC
B is removed. NO
· Refer to T4-6-1.
Faulty engine speed con-
“PEC” is trol mode selection switch,
displayed. or broken harness be-
tween MC and engine
speed control mode selec-
Monitor pedal EC tion switch.
“Wk/Pk” is switch with Dr. ZX.
displayed. “N” is
displayed. Faulty MC
Monitor neutral · Refer to T4-6-1.

“PEC (outline type switch with Dr. ZX.
font)” is displayed. Faulty shift lever or broken
harness between MC and
“N (outline type shift lever.
font)” is displayed.
T5-4-64
E-18 The engine speed remains unchanged
even though the pedal is stepped on dur- Connector (Harness End Connector Viewed from the Open
ing excavation. End Side
MC: Connector B
Related Fault Code: 18, 23
#3
• Check that: B1 B8
Brake switch: Work Position #9
Pedal Position
Shift Lever: N Position B19 B25
• Faulty pressure sensor (travel forward and re-
verse) may be the cause of this problem. In this
case, other functions should become abnormal.
YES Faulty MC
Check if continuity
between harness · Refer to T4-6-1.
“Wk/Pk” is
displayed. end terminal #9 and
vehicle frame exists
when MC connector Faulty brake switch or
B is removed. short-circuited harness
NO between MC and brake
switch.
Monitor working /
parking switch with
Faulty travel system, or
Dr. ZX.
parking brake system.
YES Refer to the travel system
troubleshooting and the
Check if column box brake system trouble-
parking brake indi- shooting.
“Pk (outline type cator is ON.
font)” is displayed. Short-circuited harness
Check if continuity YES
between MC and parking
between harness
brake pressure switch.
end terminal #3 and
NO vehicle frame exists
when MC connector Faulty MC
B is removed. NO
· Refer to T4-6-1.
Faulty engine speed con-

“PEC” is trol mode selection switch,
displayed. or broken harness be-
tween MC and engine
speed control mode selec-
Monitor pedal EC tion switch.
“Wk (outline type switch with Dr. ZX. “N (outline type
font)” is displayed. font)” is displayed. Faulty MC
· Refer to T4-6-1.
Monitor neutral
“PEC (outline type switch with Dr. ZX. Faulty shift lever or broken
font)” is displayed. harness between MC and
“N” is shift lever.
displayed.
T5-4-65
ALL ACTUATOR SYSTEM TROUBLE-
SHOOTING
A-1 All actuator speeds are slow.
• Reduction in pump 1 and 2 flow rate due to some • Although speed is satisfactory, in case power is
reasons or faulty pilot system may cause this weak, refer to the troubleshooting for faulty relief
trouble. valve (F-1).
• Also, check for fuse of the torque control solenoid • Check for loose harness connections before-
valve. hand.
YES Faulty pilot pump or

Check if same symp-
tom still appears after clogged pilot filter or
disassembling, clean- faulty accumulator
NO ing, and adjusting pilot charging valve.
relief valve.
End.
NO
Check if primary pilot
pressure is normal.
YES Faulty N sensor or broken
harness in N sensor cir-
· Fully boom raised or arm cuit.
roll-in
· Monitor item: Boom raise Monitor actual engine
pilot pressure, arm roll-in speed. Check if ab-
pilot pressure normal speed is indi-
cated.
YES
YES
Monitor pump torque

· Monitor item: Engine P/S valve. Check if
actual speed NO output from torque
· Possible to display in control solenoid valve
service mode of is normal.
monitor.
· Monitor item: NO
Pump Torque P/S
Valve
· Measurement: Refer
to the Operational
Performance Test
Section.
T5-4-66
Torque Control
Solenoid Valve
Connector (Harness End Connector from the Open End Side)
MC: Connector A
#5 #6
A1 A11
T1F3-05-04-003
Port a3
A25 A32
Connect the discon-

nected connectors.
Remove connector A Install a pressure
gauge to the port a3 YES Faulty pump device.
(32P) from the MC
and disconnect the on the torque control
YES solenoid valve.
torque control sole-
noid valve. Check if Check if the pointer Faulty torque control solenoid
continuity between moves. valve.
NO
MC harness end
connector terminal #5
and the vehicle frame,
and terminal #6 and
the vehicle frame is Faulty harness between MC
present respectively. and torque control solenoid
NO valve.
· Key Switch: OFF

Faulty MC.
· Refer to T4-6-1.
T5-4-67
A-2 Positioning cylinder and swing single op-
eration speeds are slow. Arm speed be-
comes slightly slow in level crowding op-
eration. (All these symptoms occur at the
same time.)
• The pump 2 flow rate is minimized due to some

reasons. Accordingly, the positioning and swing
motor, which are driven by pressure oil from
pump 2, moves very slow.
• Pressure oil from pump 1 is also routed to the
arm and boom cylinders so that the arm and
boom can move at a slightly slow speed in single
operation. However, in level crowd operation,
pressure oil is routed to the boom prior to the arm
so that arm speed becomes very slow.
• Refer to the SYSTEM / Hydraulic System group
in the T/M (Operational Principle).
YES Faulty pump 2 regulator.

Monitor pump 2 pump
control pressure. Check
if pressure increases in
proportion to swing lever
stroke. Faulty MC.
YES
Check if symptom is cor-
rected when maximum · Refer to T4-6-1.
pump 2 flow rate limit sole-
NO noid valve is disconnected.
· Monitor item: Pump 2
Seized pump 2 flow rate
flow control pressure
control valve in signal con-
· Possible to display with
trol valve or faulty maximum
built-in diagnosing sys-
pump 2 flow rate limit sole-
tem. NO
noid valve.
T5-4-68
A-3 Travel is inoperable during single travel op-
eration. Single bucket operation speed is
slow. Boom is not raised properly during
arm level crowding. (All problems occur at
the same time.)
• The pump 1 flow rate is minimized due to some

reasons. Accordingly, the travel motor and bucket
cylinder, which are actuated by pressure oil from
pump 1, moves very slow.
• Pressure oil from pump 2 is also routed to the
arm and boom cylinders so that the arm and
boom can move at a slightly slow speed in single
operation. However, in level crowd operation,
pressure oil is routed to the arm prior to the boom
so that boom is scarcely raised.
YES Faulty pump 1 regulator.

Monitor pump 1 pump
control pressure. Check if
pressure increases in
proportion to travel lever
stroke. YES Faulty MC.
Check if symptom is cor-
rected when maximum pump · Refer to T4-6-1.
1 flow rate limit solenoid
NO valve is disconnected.
· Monitor item: Pump 1 flow
control pressure Seized pump 1 flow rate
· Possible to display with control valve in signal control
built-in diagnosing sys- valve or faulty maximum
tem. NO pump 1 flow rate limit sole-
noid valve.
T5-4-69
A-4 Actuator doesn’t stop even if control lever
is returned to neutral.
• Bound spool in the pilot valve or bound main

spool in the control valve is suspected.
Faulty pilot valve.

YES
· When control lever is in neu-

Check if actuator stops when tral, pilot pressure is routed to
pilot control shut-off lever is spool end in control valve.
raised.
Faulty control valve.
NO
· Although pilot pressure is not
routed to spool end in control
valve, spool is kept opened
due to binding of spool.
T5-4-70
A-5 Actuator speed is faster than normal
Machine mistracks when travel lever is op-
erated at half stroke. Precise control cannot
be performed.
• The pump 1 or 2 flow rate is maximized due to

some reasons.
Therefore, the maximum flow rate is supplied and
actuator speed is faster though the control lever
doesn’t reach the full stroke.
YES Faulty max. pump 1 flow rate

shift solenoid valve.
Install a pressure gauge to
outlet port of max. pump 1
YES flow rate shift solenoid valve
to check if pressure is 0
MPa.
Faulty pump regulator.
Monitor pump control pressure NO
of pump 1 and 2. Check if the
pressure changes in response
to the lever operation.
Bound pump flow rate control

valve in signal control valve.
NO
· Pump 1: Bucket operation
· Pump 2: Swing operation
· Monitor item: Pump 1 and 2
pump control pressures
diagnosing system.
T5-4-71
FRONT ATTACHMENT SYSTEM TROU-
BLESHOOTING
F-1 All front attachment actuator power is weak.
• In case operating speeds are extremely slow,

pump control may be malfunctioning (A-2 and/or
A-3). Faulty pilot system may also cause this
trouble.
Main relief valve should be
34.3 to 36.3 MPa normal. Find out cause of trou-
(350 to 370 kgf/cm2) ble by tracing other trouble
symptoms.
Monitor pump 1 and 2 delivery

pressures.
· Monitor item: Pump 1 and 2 de-

livery pressure Adjust main relief valve.
diagnosing system Less than 34.3 MPa
· Relieve boom, arm, and bucket (Less than 350 kgf/cm2)
circuits.
· Power mode switch: OFF
· Work mode: Digging
T5-4-72
F-2 Some cylinders are inoperable or speeds
are slow.
• When other actuators (travel and swing motors)

operate normally, the pilot pump (primary pilot
pressure) is considered to be normal.
• In case single bucket operation speed is slow,
refer to F-5.
• In case single arm roll-in operation speed is slow,
refer to F-6.
• In case single boom lower operation speed is
Bound control valve
slow, refer to F-7.
spool or faulty cylinder
• In case a hose-rupture safety valve is equipped, YES (faulty seal kit).
check operation of the hose-rupture safety valve
also. Check if overload
YES relief pressure is nor-
mal.
Monitor pump control
pressure. Check if
pump control pres- Faulty overload relief
sure changes valve.
NO
smoothly while mov-
YES ing control lever
slowly.
Faulty shuttle valve in

signal control valve.
Monitor or measure NO
secondary pilot · Monitor item:
pressure. Check if Pump 1 flow control
secondary pilot pressure, pump 2 flow
pressure is normal. control pressure
built-in diagnosing sys-
tem
Bound shockless valve

YES spool.
· Secondary pilot Measure the secon-
pressure: dary pilot pressure.
Refer to Operational Check if secondary
Performance Test pilot pressure at outlet
Section. NO port to signal control Faulty pilot valve or
· Monitor item: Boom valve is normal. shuttle valve in signal
raise pilot pressure, control valve.
NO
arm roll-in pilot pres-
sure · Check only when
· Possible to display boom is not raised.
with built-in diagnos- In case cylinders
ing system other than boom are
abnormal, skip this
step and proceed to
the NO line.
T5-4-73
F-3 Arm speed is slow in a combined operation.
Arm speed is slow during arm level crowd-
ing.
Related Fault Codes: 11, 14, 15 and 16
• Refer to the pages for the Arm Regenerative

Control in the SYSTEM / Control System group in
the T/M (Operational Principle).
Disconnect solenoid
• In case a hose-rupture safety valve is equipped, valve unit (SC). Con-
check operation of the hose-rupture safety valve nect test harness (ST
also. 7226) between sole- YES Faulty solenoid valve
unit (SC).
noid valve unit (SC)
and harness. Check if
NO test harness lamp
Monitor output from comes ON. Broken harness be-
solenoid valve unit tween solenoid valve
(SC). Install pressure unit (SC) and MC.
NO
gauge to port SC.
NO Compare pressure · Perform boom raise and
measured by Dr. ZX arm roll-in combined
with that measured by operation. Faulty arm flow rate
pressure gauge. Check YES control valve control
if both pressure values spool (signal control
vary identically. Check if arm regenera- valve).
tive valve in 5-spool sec-
tion of control valve is
Check if any fault scored or bound.
· Monitor item: YES
codes are dis-
played. Arm regenerative propor- Find out cause of trou-
tional solenoid valve out- ble by tracing other
put NO trouble symptoms.
· Perform boom raise and
· Fault codes: arm roll-in combined op-
11: Pump 2 delivery eration.
pressure sensor · Refer to the Operational
14: Pressure sensor Performance Test.
(Swing)
15: Pressure sensor
(Boom raise)
16: Pressure sensor
(Arm roll-In)
Faulty corresponding
sensor or faulty MC, or
YES broken harness be-
tween MC and sensor.
NOTE: In case other fault
codes are displayed,
perform troubleshooting
corresponding to the · Refer to T4-6-1.
displayed fault code.
T5-4-74
F-4 Bucket is slow in bucket roll-in single op-
eration. Bucket doesn’t move smoothly in
bucket roll-in single operation.
• Faulty bucket flow rate control valve or bucket

regenerative valve may cause this trouble. Faulty bucket regen-
erative valve. (Disas-
• Refer to the COMPONENT OPERATION / Con- semble and clean, or
YES
trol Valve group in the T/M (Operational Princi- replace.)
ple).
Check if bucket re-
YES generative valve in
bucket spool is
Install pressure gauge Find out cause of trou-
bound or scored.
to hose SK connecting ble by tracing other
signal control valve to NO trouble symptoms.
bucket flow rate con-
NO trol valve in control
valve. Check if relief
pressure is approx. 3.9
MPa (40 kgf/cm2)
while performing Bound bucket flow rate
Check if bucket flow 3-function combined control valve control
rate control valve in operation of boom NO spool in signal control
control valve is raise, arm roll-in, and valve.
bound or scored. bucket roll-in.
Faulty bucket flow rate

control valve. (Disas-
semble and clean, or
YES replace.)
Signal Control Valve
Hose (SK)
Bucket Flow
Rate Control
Valve
T1GL-05-04-002
T5-4-75
F-5 When starting to move in combined opera-
tion, arm doesn’t smoothly move. Arm starts
to move slightly slow in arm roll-in single
operation. These troubles often occur when
oil temperature is low.
• Refer to the COMPONENT OPERATION / Con-

trol Valve group in the T/M (Operational Princi-
ple).
• In case a hose-rupture safety valve is equipped, Faulty arm regenerative
valve. (Disassemble to clean,
check operation of the hose-rupture safety valve
YES or replace.)
also.
Check if arm regenera-
NO tive valve is bound or
scored.
Find out cause of trouble by
tracing other trouble symp-
Check if arm anti-drift valve is toms.
NO
bound or scored.
Faulty arm anti-drift valve.

(Disassemble to clean, or
replace.)
YES
F-6 When starting to move in combined opera-

tion, boom doesn’t move smoothly. Boom
starts to move slow slightly in boom lower
single operation.
• Refer to the COMPONENT OPERATION / Con-

trol Valve group in the T/M (Operational Princi-
ple).
• In case a hose-rupture safety valve is equipped, Find out cause of trouble by
check operation of the hose-rupture safety valve tracing other trouble symp-
NO toms.
also.
Check if boom regen-
erative valve is bound or
NO scored.
Faulty boom regenerative

valve. (Disassemble to
clean, or replace.)
Check if boom anti-drift valve YES
is bound or scored.
Faulty boom anti-drift valve.

(Disassemble to clean, or
replace.)
YES
T5-4-76
F-7 When boom raise or arm roll-out is operated,
boom or arm starts to move after moving
slightly downward.
Related Fault Code: None YES Faulty anti-drift valve.
Check if anti-drift valves

(arm and boom) are
YES bound or scored.
Oil leaks in cylinder.

Check if load check valve in NO
control valve is normal.
· Disassemble / Visual
Inspection Faulty load check valve.
NO
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 (B)
side of the boom cylinder flows back When the Load
into the circuit through the load check Check Valve is
valve, causing the boom cylinder to Faulty:
(A)
temporarily 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 re-
tracted during the initial stage of opera-
tion. In addition, cylinder force is re-
duced, increasing the cylinder drift in T105-07-04-012
this case.
T5-4-77
F-8 Front attachment drifts remarkably.
• In case the hose-rupture safety valves (boom

and arm) are equipped on the machine, discon-
nect the drain hoses and the pilot hoses from the
hose-rupture safety valves. Then, measure the
amount of drain oil and the discharged oil from
the drain ports and pilot ports. If the amounts of
drain oil are large, faulty hose-rupture safety
valves may be the cause of this trouble.
Normal.
YES
Correctly adjust
emergency valve and
Check if each front lock it up.
attachment cylin- NO
der drift is within Check if emergency
specification. valve at boom 1 sec-
NO
tion in control valve Check if symptom is
4-spool block is cor- deleted when overload
rectly adjusted. relief valve is tempo-
Check if cylinder drift YES rarily switched with
is reduced when pilot another overload relief
NO shut-off valve is valve.
closed.
Faulty pilot valve.

YES
T5-4-78
Emergency
Valve
Scored control
valve spool, broken
NO spring, or loose
spool end.
NO Check if oil
leaks in cylin-
ders. Faulty cylinder. T155-06-04-001
(Replace seal kit.)

YES Adjustment Procedure:
Turn screw (1) counterclockwise to the stop, then
tighten lock nut (2).
Faulty overload
relief valve.
YES : 4 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf·ft)
• Boom Cylinder Internal Leakage Check
1. With the bucket cylinder fully retracted and the

arm cylinder slightly extended from the fully re-
tracted position, lower the bucket tooth tips onto
the ground.
2. Disconnect hoses from the boom cylinder rod

side. Drain oil from the hoses and cylinders.
(Plug the disconnected hose ends.)
3. Retract the arm cylinder to lift the bucket off the

ground. If oil flows out of the hose disconnected
T216-05-04-001
pipe ends and the boom cylinders are retracted
at this time, oil leaks in the boom cylinders. In
case no oil flows out of the hose disconnected
pipe ends but the boom cylinders are retracted,
oil leaks in the control valve.
T5-4-79
SWING SYSTEM TROUBLESHOOTING
S-1 Swing is slow or unmoving.

• Check whether the pilot system is faulty or the • In case the left travel speed is also slow, refer to
main circuit is faulty. A-2.
• In case other functions (front attachment and
travel) operate normally, the pilot pump is con-
sidered to be normal. If the pilot system is dis-
playing a problem, the cause of the trouble may
exist in the circuit after the pilot valve.
Check if swing parking
brake release valve is
YES scored or bound.
Check if swing parking

brake release pressure is
Monitor pump control YES approx. 3.9 MPa (40
Monitor secondary pressure while slowly kgf/cm2).
pilot pressure. Check if operating swing lever.
secondary pilot pres- YES Check if pump control
sure is normal. pressure varies
smoothly.
· Relieve arm circuit.
NO
· Monitor item:
· Monitor item: · Front attachment op-
· Specification: · Pump 2 flow control eration
· Refer to Operational pressure · Possible to display with
Performance Test · Possible to display with built-in diagnosing sys-
tem Bound pump 2 flow
Section. built-in diagnosing sys- rate control valve in
· Monitor item: tem signal control valve.
· Swing control pilot
pressure NO
built-in diagnosing
system Faulty pilot valve.
NO
T5-4-80
YES Faulty swing reduction

Check if swing motor drain gear.
YES oil amount is normal.
Check if swing relief Faulty swing motor.

NO pressure is normal. · Measurement: NO
· Refer to Operational Per-
formance Test Section.
· Relieve swing circuit.
· Monitor item: Pump 2 de- Faulty swing relief
livery pressure NO valve.
· Specification:
· Refer to Operational Per- Faulty swing motor
formance Test Section. parking brake release
YES valve.
YES Faulty swing parking

brake pressure selec-
Check if secondary pilot tion shuttle valve.
pressure at signal control
valve outlet is normal.
Faulty swing parking

brake release spool in
NO signal control valve.
T5-4-81
TRAVEL SYSTEM TROUBLESHOOTING
T-1 The machine doesn’t travel.
• The travel system is inoperable unless the fol- • Air mixing in the transmission hydraulic circuit
lowing conditions are met. may cause the parking brake to drag. Bleed air
Shift Lever: D or L position from the transmission by referring to T5-4-116.
Brake Switch: OFF or Axle Lock Position • When other actuators (front attachment and
• In case the travel motor fails, it can be deter- swing motor) operate normally, the pilot pump,
mined by means of the indicator in the column pilot filter and pilot relief valve are considered to
box and the buzzer. be normal.
• Failure in the transmission and/or axle (front • Check for loose harness connections before-
and/or rear) may be the cause of the trouble. hand.
Check if a noise is emitted from each section.
• Check if the parking brake indicator is OFF.
Check if trouble is cor-

YES
rected when solenoid
valve unit (SG) is dis-
Check by operating if connected.
YES brake pedal is difficult to

move as if the brake is
applied.
Faulty either front or rear

NO axle.
Check by monitoring
with Dr. ZX if pump 1
NO
delivery pressure in-
creases in proportion to
travel lever stroke.
Faulty control valve
NO (seized spool).
· Monitor Item: Pump 1
delivery pressure
Performance Test section.
Check if trouble is corrected

Faulty MC or
when travel forward and re- YES
Check if continuity be- short-circuited harness
verse Pi-cut solenoid valves
tween harness end con- between MC and tran-
are disconnected.
nector terminals #1 and sistor unit 2.
YES vehicle frame, and #2 · Refer to T4-6-1.
and vehicle frame exists
respectively with transis-
tor unit 2 disconnected. Faulty transistor unit 2.
NO
rected when transistor
YES unit 2 is disconnected.
Faulty shift lever or

short-circuited harness
between shift lever and
NO travel forward and reverse
Pi-cut relay.
T5-4-82
YES Short circuited harness be-

tween MC and brake switch.
Check if continuity be-

tween harness end
YES connector terminal #9
and vehicle frame exists
when MC connector B is Faulty MC.
removed.
NO
· Refer to T4-6-1.
Faulty solenoid valve unit

(SG).
NO
Connector (Harness End Connector Seen from Open End Side)
Transister Unit 2 MC Connector B
#9 B1 B8
7 1
#1 B19 B25
#2
T5-4-83
T-2 The machine doesn’t travel in both forward
and reverse directions or moves slowly.
• Failure in the transmission and/or axle (front

and/or rear) may be the cause of the trouble.
Check if a noise is emitted from each section.
• When other actuators (front attachment and
swing motor) operate normally, the pilot pump,
pilot filter and pilot relief valve are considered to
be normal.
hand.
Check if travel motor

NO
counterbalance valve is
Check if control valve abnormal.
NO
travel spool is abnormal.
Check if trouble is corrected Faulty control valve

NO when travel motor relief YES (seized spool).
valves are switched between
those in forward and reverse
systems.
Faulty travel motor relief
YES valve.
Monitor pump 1 deliv-
ery pressure with Dr.
ZX. Check if relief
pressure in travel for- NO Faulty travel pilot valve.
ward and reverse op-
eration is normal. Check if travel shockless
· Specification: Refer to the NO valves (travel forward
and reverse Pi-cut sole-
Performance Test section. noid valves) are abnor-
mal. Faulty travel shockless
valve.
YES
when either travel forward or
YES reverse Pi-cut solenoid valve
is disconnected.
NO tween vehicle frame and
terminals shown below
exists with transistor unit
2 connected.
Check if trouble is cor- · Travel Forward: Terminal #1
rected when travel for- · Travel Reverse: Terminal #2
ward Pi-cut relay is
YES switched with travel re-
verse Pi-cut relay.
Faulty travel forward

Pi-cut relay or travel re-
YES verse Pi-cut relay.
T5-4-84
YES Faulty counterbalance

valve.
YES Faulty make-up valve.
Check if make-up valve in

control valve is abnormal.
NO
Faulty center joint.
NO
Faulty MC or
YES
Short-circuited harness
between MC and tran-
sistor unit 2.
· Refer to T4-6-1.
Faulty transistor unit 2.

NO
Connector (Harness End Connector Seen from Open End Side)
Transistor Unit 2
7 1
#1
#2
T5-4-85
T-3 Travel speed is slow and travel power is
weak in both forward and reverse directions.
• In case the travel motor fails, it can be deter- • When other actuators (front attachment and
mined by means of the indicator in the column swing motor) operate normally, the pilot pump,
box and the buzzer. pilot filter and pilot relief valve is considered to be
• Failure in the transmission and/or axle (front normal.
and/or rear) may be the cause of the trouble. • Pump 1 flow rate reduction may be the cause of
Check if a noise is emitted from each section. this trouble when bucket single operation speed
• Air mixing in the transmission hydraulic circuit is slow. Refer to A-3.
may cause the parking brake to drag. Bleed air • Check for loose harness connections before-
from the transmission by referring to T5-4-116. hand.
NO
Check if travel spool in

YES control valve is abnor-
mal.
Faulty control valve.
YES
Install a pressure
gauge to outlet port of
NO solenoid valve unit (SI)
to check if pressure is 0
NO Faulty (seized) solenoid
MPa.
valve unit (SI).
Check if pressure stays
at 0 MPa when sole-
NO noid valve unit (SI) is
disconnected. Faulty MC or short-circuited
Monitor creeper mode harness between MC and
switch with Dr. ZX to YES solenoid valve unit (SI).
check if creeper mode
is operable. · Refer to T4-6-1.
NO Faulty MC.
Disconnect connector C
from MC. Check if con- · Refer to T4-6-1.
tinuity between harness
YES end connector terminal
#8 and vehicle frame
exists. Faulty engine speed control
mode selection switch or
YES tween MC and engine speed
control mode selection
switch.
T5-4-86
YES Faulty center joint.
Check by measuring if
drain amount from
travel motor is normal.
· Refer to the Opera- Faulty travel motor.
tional Performance NO
Test section.
Connector (Harness End Connector Seen from

Open End Side)
MC Connector C
#8
C1 C10
C23 C31
T5-4-87
T-4 Even though foot is left from the travel pilot
valve, the hydraulic brake doesn’t operate
(the machine continues to runaway).
• Similar symptom may appear when the travel pi-

lot valve, travel shuttle valve and/or travel spool
is faulty.
NO Faulty control valve.
Check if travel motor

NO counterbalance valve is
abnormal.
Switch travel motor re-
lief valves between
forward and reverse
sides. Check if trouble Faulty counterbalance valve.
is corrected. YES
Faulty travel motor relief

YES valve.
T5-4-88
T-5 Maximum travel speed is slow (traction
force is normal).
• Refer to the descriptions for ”Travel Pump 1 Flow

Rate Shit Control” in the SYSTEM / Travel Pump
group.
• Similar symptom may occur if the travel pilot
valve, travel shockless valve, or travel spool fails.
Check these parts at the same time.
• If the travel motor fails, the indicator lights and
the buzzer sounds in the column box, informing
that the travel motor is faulty.
• In case any fault code is displayed, first repair
and check the machine according to the faulty
YES Faulty maximum pump 1
code. flow rate shift solenoid valve.
Check by disassem-
bling if maximum pump
Remove connector A
YES 1 flow rate shift sole-
from MC with maximum
noid valve is abnormal.
pump 1 flow rate shift
solenoid valve discon- Faulty pump 1 regulator or
NO nected. Check if conti-
MC.
nuity between terminals NO
described below is
present.
Broken harness between
Check if the trouble NO MC and maximum pump 1
symptom is corrected flow rate shift solenoid valve.
· Between maximum pump
when maximum pump 1 1 flow rate shift solenoid
flow rate shift solenoid valve connector terminal
valve is disconnected. #1 and MC connector A
terminal #19.
· Between maximum pump
1 flow rate shift solenoid
valve connector terminal
#2 and MC connector A
terminal #20. YES Faulty MC.
Check by monitoring
the vehicle speed with
YES Dr. ZX if the speed me-
ter on column box indi- Faulty harness between
column box and MC.
cates the same vehicle NO
speed.
Connector (Harness End Connector Seen from Open End SIde)
MC: Connector A
A1 A11
A25 A32
#19 #20
T5-4-89
T-6 Travel mode (Hi/Low) doesn’t shift.
• Air mixed in the transmission hydraulic circuit

may prevent the transmission from being shifted.
Bleed air from the transmission by referring to
T5-4-116.
• Place the brake switch in the position other than
the parking position. Perform the troubleshooting.
hand.
Disconnect blown colored

connector from transmis-
sion control valve trans-
NO mission changeover so-
lenoid valve. Check if
voltage at harness end
Install pressure gauges to connector terminal #1 is
ports A and B on transmis- 24 V.
YES sion control valve. Check if · Shift Lever: L position
pressure at each port varies
as shown below when shift
lever is operated.
· When shift lever is in the L position:

→ Pressure at port A: 0 MPa Faulty transmission.
→ Pressure at port B: 3.0 MPa YES
· When shift lever is in the D position:
→ Pressure at port A: 3.0 MPa
Transmission
Check if column box indicator → Pressure at port B: 0 MPa Control Valve
normally lights when shift
lever is operated.
Port B Port A
Machine
Front Side
T1F3-05-04-001
Faulty shift lever, or faulty

harness between neutral re-
NO lay and transmission
changeover relay or shift
lever and transmission
changeover relay.
when neutral relay and
NO transmission changeover re-
lay are switched with other
function relays. Faulty neutral relay or trans-
YES mission changeover relay.
T5-4-90

NO transmission changeover sole-
noid valve and transmission
changeover relay.
YES Faulty transmission changeover

solenoid valve (seized spool).
Check if continuity between
harness end connector ter-
minal #2 and vehicle frame
exists with transmission
YES changeover solenoid valve
disconnected. Broken ground cable of trans-
mission changeover solenoid
NO valve.
T5-4-91
BRAKE SYSTEM TROUBLESHOOTING
B-1 Parking brake is difficult to release.
• First check brake lining, bleed air from brake

system and transmission by following the Opera-
tor’s Manual.
• In case even though the parking brake is re-
leased, the machine doesn’t travel (parking brake Front View of the
indicator stays ON), faulty parking brake pressure Transmission
Control Valve
switch or short-circuited harness between MC
and parking brake pressure switch may be the Reducing
cause of this trouble. Valve
hand.
Port M
T1F3-03-03-002

YES tween harness end
connector terminal #2
and vehicle frame ex-
ists with parking brake
Disconnect gray color solenoid valve discon-
connector from parking nected.
NO brake solenoid valve.
Check if voltage at
After stopping engine, terminal #1 is 24 V.
install pressure gauge Check if trouble is cor-
to port M on transmis- rected when parking
sion control valve. brake relays 1, 2, and 3
Check if measured NO are switched with other
pressure is over 3.0 function relays.
MPa when engine is
started.
· Shift Lever: D or L
position Faulty transmission.
· Brake Switch: Position YES
other than parking
IMPORTANT:
Accumulators are pro-
vided in the circuit con-
nected to port M. Suffi-
ciently relieve the circuit
pressure before installing
the pressure gauge.
T5-4-92
Parking Brake Circuit Diagram

Key Switch
From Alternator
Terminal L
Monitor
Controller
From Fusible
Link (45A)
Column Box
From Fusible (Brake Switch)
Link (65A)
Parking Brake
Relay 3 Parking Parking
Brake Brake
Relay 1 Relay 2
Parking Brake
Solenoid Valve T1GL-05-04-001
NO Faulty pressure reduc-

ing valve in transmis-
Disassemble to check sion control valve.
YES parking brake solenoid
valve for any abnormali-
ties. Faulty (seized) parking
YES brake solenoid valve.
Faulty (broken) ground

line cable of parking
NO brake solenoid valve.
YES Faulty parking brake

relay 1, 2, or 3.
Check if each harness YES

between electrical Faulty harness.
components is broken
or short-circuited while
NO referring the parking
brake circuit illustrated
above. Is any abnor- Faulty monitor control-
mality found? NO ler.
T5-4-93
B-2 Parking brake doesn’t operate (is not ap-
plied).
• Bleed air from the transmission by referring to

T5-4-116 before starting troubleshooting.
Front View of the Relief Valve

Transmission
Control Valve
Port M
T1F3-03-03-002
Faulty relief valve in

YES
Disassemble to check if transmission control
relief valve in transmis- valve.
NO
sion control valve is
abnormal.
Faulty parking brake
NO solenoid valve.
Check if pressure is
NO reduced to below 1.2
MPa when parking
brake solenoid valve is
disconnected.
After stopping engine,
rected when parking
install pressure gauge
YES brake relays 1, 2, and 3
to port M on transmis-
are switched with other
sion control valve.
function relays.
Check if measured
pressure is below 1.2
MPa when engine is
started.
· Shift Lever: N position

· Brake Switch: Parking
position
IMPORTANT:
Faulty transmission.
Accumulators are provided
in the circuit connected to YES
port M. Sufficiently relieve
the circuit pressure before
installing the pressure
gauge.
T5-4-94
Parking Brake Circuit Diagram

Key Switch
From Alternator
Terminal L
Monitor
Controller
From Fusible
Link (45A)
Column Box
From Fusible (Brake Switch)
Link (65A)
Parking Brake
Relay 3 Parking Parking
Brake Brake
Relay 1 Relay 2
Parking Brake
Solenoid Valve T1GL-05-04-001
YES Faulty parking brake

relay 1, 2, or 3.
Check if each harness YES Faulty harness.

between electrical
components is broken
or short-circuited while
NO referring to the parking
brake circuit illustrated
above. Is any abnor- Faulty monitor control-
mality found? NO ler.
T5-4-95
B-3 Service brake doesn’t operate, or is not ap-
plied effectively.
• The front and rear wheel service brake circuits

are independently designed each other. When
either the front or the rear wheel brake circuit fails,
overall service brake system will not operate
properly. Check the brake lining and the accu-
mulator for any abnormalities, and bleed air from
the brake system by referring to the Operator’s
Manual before starting the troubleshooting.
• When other actuators (front attachment, travel
and swing motors) operate normally, the pilot
pump is considered to be normal.
hand.
YES Faulty accumulator charging

valve
Does brake pressure

gauge on column box in-
dicates less than 12.3
MPa. YES Faulty axle side brake device.
Disconnect hose from brake
valve outlet port. Install pres-
sure gauge to brake valve
NO port. Check if pressure in-
creases to 7 MPa when brake
pedal is stepped on. To A
NO
· Brake Switch:
Position other than work.
YES Faulty brake valve.
Install pressure gauge to

outlet port on solenoid
A valve unit (SG). Check if YES Faulty solenoid valve unit (SG).
pressure is over 3 MPa. Disconnect solenoid valve unit
· Brake Switch: (SG). Connect test harness
Work position. (ST 7226) to the section be-
NO tween solenoid valve unit (SG)
and harness end. Check if Faulty harness between sole-
lamp lights. noid valve unit (SG) and MC.
NO
T5-4-96
STEERING SYSTEM TROUBLESHOOTING
H-1 Steering Wheel Rotates, But Steering is

Heavy.
• Check the steering filter beforehand.
YES Faulty steering pump.
Disconnect hoses from

steering pump and pilot
pump output port. Check
if the symptom disap-
pears by connecting YES Faulty steering valve.
hoses each other to the
other side.
Monitor to check with Dr. ZX
if steering pump delivery
NO pressure is normal.
Faulty the relief valve into steer-
· Monitor item: Pump 3 delivery NO ing valve.
pressure
H-2 Steering is Impossible Even if Steering

Wheel is Rotated.
• In case the machine can steer to only either right

or left direction, faulty center joint or overload re-
lief valve in the steering valve may be the cause
of this trouble.
T5-4-97
OTHER SYSTEM TROUBLESHOOTING
O-1 Wiper is inoperable or not retracted.
Checking Instructions
• The wiper is driven by electric power routed via • If the front window is open, the wiper won’t oper-
the relay circuit controlled by the monitor assem- ate. Check that the front window is securely
bly. In case the wiper is inoperable, first check closed.
the wiper motor and links for any abnormality us-
ing an auxiliary electric power and the test har-
ness.
Faulty front window
open/close switch or
short-circuited harness
between front window
YES open/close switch and
monitor.
Disconnect front win-

dow open / close Remove test harness
switch. Check if wiper and reconnect circuit to
YES Faulty wiper relay.
operates. the original position.
Replace wiper relay
Connect test harness YES one at a time to see if
(ST 7227) between wiper operates.
auxiliary electric power
· Key switch: ON
(fuse box #12) and To A
wiper motor as illus- NO
trated to the right.
Check if wiper oper-
NO · Key switch: ON
ates.
Faulty wiper motor or

links.
NO or test har-
· Key switch: ON
ness lamp doesn’t
light normally.
NOTE: When the wiper motor
is normal, lamp S lights while
the wiper is moving within the
operating range. Both lamps B
and S light for a moment at the YES End (Faulty monitor).
Replace monitor as-
same time only when the wiper sembly to see if wiper
reaches the intermittent stop A operates.
position.
Faulty cab harness.
NO
T5-4-98
Test Harness Application Circuit

Fuse Box #12
Lamp S
M B S
Lamp B Wiper Motor
L E
Ground
T178-05-04-004
Wiper Operating Range Intermittent Stop Position
Retracted Position
Operating Range
T178-05-04-005
Test Harness Connection Method
Wiper Motor Lamp B
Lamp S
Test Harness Fuse Box
T157-07-04-004
T5-4-99
O-2 Air Conditioner Malfunction
The air conditioner has a self-diagnosis function.

The self-diagnosis functions to:
1) Display Fault Codes
2) Change Displayed Fault Codes
3) Delete Fault Code
4) End Fault Code Display
• Display Fault Code

1. Press the fan OFF switch to turn the fan OFF.
2. Press and hold both the upper and lower sides of
the temperature control switch on the air condi-
tioner control panel at the same time for more Temperature
than 3 seconds with the key switch ON. Fan OFF Switch Control Switch
NOTE: After operation has been performed, the
buzzer will sound.
3. If any fault codes are found, the LCD displays the

fault codes as E{{.
NOTE: If more than one fault code is found, the
lower number fault code will be displayed M178-01-017
first. LCD
T5-4-100
Fault Code List

Fault
Location in Trouble Cause Symptom
Code
Abnormal circulation E11 Broken circuit in air circulation Y value (air flow-in temperature) cannot
air sensor sensor be adjusted in response to the
E12 Short-circuited circulation air set-temperature.
sensor
Abnormal fresh air E13 Broken circuit in fresh air sensor Operation is controlled under such cir-
sensor E14 Short-circuited fresh air sensor cumstance as no fresh air sensor is pro-
vided.
Abnormal solar E18 Short-circuited solar radiation Operation is controlled under such cir-
radiation sensor sensor cumstance as no solar radiation sensor is
provided.
Abnormal evapora- E21 Broken circuit in evaporator sen- Operation is controlled under such cir-
tor sensor sor cumstance as the evaporator temperature
E22 Short-circuited evaporator sen- is set to 10 °C (50 °F).
sor
Abnormal damper E43 Abnormal air vent damper Corresponding damper servo becomes
E44 Abnormal air mix damper inoperable.
E45 Abnormal circulation/fresh air
damper
Water temperature E15 Broken circuit in water tempera- Operation is controlled under such cir-
sensor ture sensor cumstance as the water temperature is
E16 Short-circuited water tempera- set to 60 °C (140 °F). (Warm-up control is
ture sensor not performed.)
Abnormal refrigerant E51 Abnormal high/low refrigerant The compressor clutch is disengaged.
pressure (The compressor stops.)
T5-4-101
• Change Displayed Fault Code
1. When displaying more than one fault code, press Temperature
either the upper or bottom side of the tempera- Control Switch
ture control switch key. The following fault code is
displayed.
NOTE: Each time the displayed fault code is
changed, the buzzer sounds. In case only
one fault code exists, the displayed fault
code remains unchanged.
M178-01-017
LCD
• Delete Fault Code

LCD
1. Press and hold both the circulation air switch and
the fresh air vent switch for more than 3 seconds
at the same time to delete the fault code.
NOTE: After the fault code is deleted, the buzzer
will sound.
2. After the fault code has been deleted, the LCD

displays E{{. M178-01-017
Circulation Fresh Air vent
Air Switch Switch
Fan OFF Switch
• End Fault Code Display

1. Press the fan OFF switch, or press the upper
side of the fan switch key. The self-diagnostic
mode is complete.
M178-01-017
Fan Switch
T5-4-102
(Blank)
T5-4-103
※ Please fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to Hitachi Tsuchiura Works Quality Assurance Dept. after
experiencing a problem with your machine’s air conditioning system.
< AIR CONDITIONER TROUBLE REPORT > File No.
(1) What Checked by:
Model (Serial No. )
Operation Type Manual Semi-Auto Full-Auto
Delivery Date Year Month
(2) When
Date Year Month Day Operating Hour ( h)
Time Morning Daytime Evening Night
Frequency Every Day Once a Week Once a Month Times per
(3) Where
Job Site Address State County Town
Access Road Condition Paved Not Paved (Gravel Sand Soil)
(4) How (Operating Conditions)
Weather Fine Cloudy Rain Snow
Atmospheric Temperature Very Hot Hot Cold Very Cold
Operating Conditions Parking Traveling Working
Temperature Control Paint blanks equal to red indicators. / Fill in set-temperature when
full-auto operation
A/C ON OFF
Control Air Induction Re-Circulation Fresh Air Circulation
Panel AUTO ON OFF Not Available
Fill following items when operated in manual mode or when manual control type unit is used.
Vent Position Front Front / Rear Foot Front / Rear and Foot
Fan First Second Third Fourth Fifth Sixth
(5) How (Problem Symptom)
Abnormal Compressor Operation
Symptom Not turned ON <Check Result>
Not turned OFF (1) Is problem reproducible ?
Others Reproducible
Uncontrollable air temperature Not reproducible
(2) Pressure (To be measured at gauge manifold)
Symptom No cool air
Low Pressure
No warm air
High Pressure
Others
(3) Which parts have been replaced ?
Uncontrollable air volume
1
Symptom Air flows in Hi mode only
No air flows
2
Small air volume
Others
Uncontrollable vent hole
∗ Before replacing the control amplifier, be sure to
check that the connectors are correctly connected
Symptom Vent hole isn’t selected
while repeatedly disconnecting and reconnecting
Others connectors.
Abnormal panel indication
Faulty Indicator Vent Hole
A/C
AUTO
Fresh Air Circulation
Fan OFF
Fan (Lo • •• Hi)
Temperature Control
Symptom Stays OFF
Stays ON
Blinks
Others
T5-4-104
Refrigerant Quantity ....................... 1000±50 g

Compressor Oil Quantity................ 180 cm3
T5-4-105
Cooling Circuit
Refrigerant pressure Bubbles can be seen in sight Piping and/or parts are stained with oil,
in both high and glass. respond to gas detector.
low-pressure sides is
low.
No oil stain is found or gas detector
doesn’t respond. Refrigerant has not
been refilled for longer than one sea-
son.
No bubbles are seen in sight
glass.
After cooling at fast speed continu-

ously, cooling power is reduced. Air
flow volume remains unchanged.
Air flow volume is reduced.
Refrigerant pressure
in low-pressure side Bubbles can be seen in sight Compressor cylinder is extremely hot,
Insuffi- is high. glass. emitting a smell.
cient
Cooling
Power
Refrigerant pressure in Compressor cylinder is extremely hot,
high-pressure side is low. emitting a smell.
Heater unit emits hot air.
Refrigerant pressure
in high-pressure side Bubbles can be seen in sight Refrigerant pressure in low-pressure
is high. glass. side is low.
Condenser is stained and clogged.
Even if condenser is sprayed with water, few bubbles appear. Receiver dryer tem-
perature is low.
After cooling at fast speed continu-

ously, cooling power is reduced. Air Frost forms. Thermistor doesn’t cool.
flow volume is reduced.
Thermistor cools.
T5-4-106
Gas leaks from pipe joints and/or parts. Re-tighten or replace parts.
Normal leakage of refrigerant from hoses. Refill refrigerant.
Improper adjustment (excessive restriction) of expansion Readjust or replace expansion valve.

valve.
Clogged expansion valve. Remove clog, or replace receiver and/or expansion

valve.
Clogged low-pressure circuit and/or evaporator. Remove clog, or replace parts.
Frozen expansion valve or water in circuit. After evacuation, refill refrigerant and/or replace re-
ceiver dryer.
Gas leaks from case. Seal gaps using vinyl tape or packing compound.
Poor contact of expansion valve temperature sensing cylinder. Make good contact. Replace temperature sensing
stay.
Improper adjustment (excessive open) of expansion valve. Readjust or replace.
Insufficient compressor discharge (faulty gasket and/or valve). Replace.
Improper water stop valve wire adjustment and/or faulty stop

valve. Check and readjust or replace.
Poor airtight fitting of outside air damper (outside air induction

Repair.
type).
Clogged high-pressure circuit before receiver dryer. Remove clog, or replace parts.
Clean Condenser.
Excessive refrigerant. Remove excessive refrigerant to proper level.
After evacuation, refill refrigerant and/or replace re-

Air is mixed in system.
ceiver dryer.
Incorrect thermistor location. Correct thermistor location.
Gas leaks from case. Seal gaps using vinyl tape or packing compound.
Faulty thermistor (stays ON). Disconnected thermistor cord.
Even if function and performance are normal, when Instruct user on correct air-conditioner operation.
air-conditioner is kept operated for a long time with thermistor (Reset thermistor to either minimum or middle cooling
in max. cooling position and air flow in M or L mode, frost may position or increase air flow.)
form.
T5-4-107
Cooling Circuit
Case connection. Louver resonance.
Fan contacts case, or foreign matter enters case.

Blower fan connection.
Brush friction noise, metal and/or thrust washer con-
tact noise.
Gas blowing sound (roaring). Gas vibration noise (compressor discharge and/or
suction gas noise).
Expansion valve connection, whistle Abnormal noise from expansion valve (Expansion
Noise sound, gas blowing sound. valve is normally functioning.).
Faulty clutch bearing, and/or idle pulley bearing.
Clutch disengaging sound.

Contact of clutch amature due to resonance, or loose
belt and/or screws.
Noisy compressor.
Compressor rotating sound.
Vibration and/or loose screws due to excessive drive
belt looseness.
Broken heater core and/or hose.

Water leak and/or splash.
Clogged case drain port and/or drain hose.
Others
Absorbed cigarette and dust smell on evaporator fins.

Abnormal smell.
T5-4-108
Repair or replace.
Remove foreign matter. Readjust fan motor location.
Slight noise is unavoidable.

Replace if loud.
No functional problem exists.

Provide silencer if intolerable.
Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.
Replace.
Repair or replace clutch. Re-tighten screws.
Repair or replace.
Re-adjust drive belt.
Replace.
Clean.
Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min-1 in
L mode for more than 10 minutes, flush smell out by condensed water.
T5-4-109
Compressor
Compressor doesn’t rotate. Clutch terminal voltage is normal 24 V.
Inoperable
cooling Clutch terminal voltage is low.
system.
Clutch terminal voltage is 0 V.
Bubbles exist even after refrigerant is refilled.
Both high and

low side Check for oil and refrigerant leaks from parts other than
pressures are compressor and pipe joints using gas detector.
low.
Both com- Check for oil and refrigerant leaks from compressor (no
pressor and leaks from parts other than compressor) using gas de-
blower mo- tector. (Refer to NOTE 2 on page T5-4-113.)
tor rotate.
Stain on exterior.
(Refer to NOTE 1
on page T5-4-113.)
Refrigerant has not been refilled for longer

than one season.
Refrigerant is discharged within 1 to 2

months after being recharged. Check for
refrigerant leaks using gas detector.
Refrigerant is kept charged for longer than

2 years.
Compressor cylinder is not hot. (Refrigerant returns to com-

High pressure side is pressor in liquid form.)
slightly low and low pres-
sure side is high.
No refrigerant returns in liquid form. High pressure side is low.
Bubbles can be seen through Others

sight glass.
High pressure side is high.
Refer to the Cooling Circuit Troubleshooting
Table on page T5-4-106.
Temperature is not cooled when compressor is
operated at fast speed continuously.
Air flow from blower is insufficient.
T5-4-110
Seized clutch. Replace.
Improper gap between amature and rotor (improper air gap).

Replace.
Broken or short-circuited core cable.
Shaft doesn’t rotate (internally locked). Replace.
Faulty Electrical System.
Faulty Electrical System.
Oil leaks from mechanical seal, gasket, and/or charge valve.

Replace.
Oil leaks from oil plug.
Oil and refrigerant leaks from front housing, and/or cylinder block joint. Replace.
Normal leaks from hoses. Charge

refrigerant.
No leaks (normal).
Refer to the Cooling Circuit Troubleshooting Table on page T5-4-106.
Broken valve (Refer to NOTE 3 on page T5-4-113.)
Replace.
Blown gasket (Refer to NOTE 3 on page T5-4-113.)
Check and adjust

Excessive oil. oil level.
T5-4-111
Compressor
Compressor rotation is abnormally draggy.

Overheating
is susceptible
to occur.
Trouble other than compressor. Refer to the Cooling Circuit Troubleshooting Ta-
ble on page T5-4-106.
Noise is heard when clutch is OFF.
Abnormal
noise
Noise is heard when clutch is ON.
T5-4-112
Broken clutch bearing due to overly tightened belt. Replace.
Shaft doesn’t rotate.

Replace.
Shaft rotates draggy.
Broken clutch bearing.

Replace.
Contact or slip due to poor air gap.
Faulty idle pulley bearing.
Refer to the Cooling Circuit

Saggy belt. Troubleshooting Table on
page T5-4-106.
Loose screws.
Broken valve.
Replace.
Blown gasket.
Abnormal internal noise. Replace.
Vibration due to saggy belt.

Refer to the Cooling Circuit
Troubleshooting Table on
Loose screws. page T5-4-106.
NOTE:
1. Don’t quickly decide that oil is leaking when a stain around the clutch and/or gasket is found. A
slight oil seepage will appear due to the seal construction. However, this oil seepage will not
cause malfunction. Be sure to accurately check whether oil is leaking or seeping only.
2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose sur-
face may be detected. As long as the specified rubber hoses are used, the problem should not
occur. (In case a large leaks is detected, the hose may be broken.)
3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between
high-pressure side and low-pressure side is 0.49 MPa (5 kgf/cm2) or less. When the clutch is
turned OFF, the pressure difference between high-pressure side and low-pressure side will
disappear within about 10 seconds.
T5-4-113
EXCHANGE INSPECTION
Exchange inspection method is a troubleshooting
method to find the trouble location by exchanging the
suspected part / component with another part
/component having identical characteristics.
Many sensors and solenoid valves used on this ma-

chine are identical. Therefore, using this switch-check
method, faulty part /component, and/or harness can
be easily found.
Example:
Abnormal pump 1 delivery pressure (Fault code: 10)
Check Method:
1. Switch two delivery pressure sensor connectors
located.
2. Retry troubleshooting.
Result:
In case the pump 2 delivery pressure is abnormal
(fault code 11), the pump 1 delivery pressure sensor
is considered to be faulty.
Pump 1 Pump 2
(4-Spool (5-Spool
In case the pump 1 delivery pressure is abnormal Section) Section)
(fault code 10), the pump 1 delivery pressure sensor Delivery Pressure Sensor
harness is considered to be faulty. T1F3-01-02-007
T5-4-114
Applicability of Switch-Check Method

Fault Code Trouble Applicability
01 Abnormal EEPROM Not Applicable
02 Abnormal RAM
04 Abnormal Sensor Voltage
06 Abnormal EC Angle Sensor Not Applicable
07 Abnormal EC Dial Not Applicable
10 Abnormal Pump 1 Delivery Pressure Applicable (Harness)
11 Abnormal Pump 2 Delivery Pressure
12 Abnormal Pump 1 Control Pressure Applicable (Harness)
13 Abnormal Pump 2 Control Pressure
14 Abnormal Swing Pilot Pressure Applicable (Harness/Sensor)
15 Abnormal Boom Raise Pilot Pressure
16 Abnormal Arm Roll-In Pilot Pressure
18 Abnormal Travel Pilot Pressure
20 Abnormal Travel Motor Drain
Pressure Sensor
23 Abnormal Travel Forward
Pilot Pressure Sensor
24 Abnormal Travel Reverse
Pilot Pressure Sensor
19 Abnormal Hydraulic Oil Temperature Not Applicable
Sensor
22 Abnormal Travel Motor Not Applicable
26 Travel Motor Over-rev. Not Applicable
T5-4-115
BLEEDING AIR FROM TRANSMISSION
1
IMPORTANT: Be sure to bleed air from the trans-
mission after disconnecting and
reconnecting the pipe lines, or
changing the hydraulic oil. If air is
mixed in the transmission gearshift
circuit, malfunction of the transmis-
sion may result.
NOTE: Bleed air by the teamwork of two or more

persons.
1. Start the engine. Park the machine on a level

solid ground. Lower the bucket on the ground. MCBB-07-021
2. Turn the brake switch on the column box to the S

(working) position. 1
NOTE: Air is not bled when the brake switch is in

the P (parking) position.
3. Connect transparent vinyl tube (2) to the tip end

of air bleed plug (1) on the transmission. Put the 2
other end of vinyl tube (2) into transparent vessel
filled (3) with hydraulic oil.
4. Reciprocate shift lever (4) between positions D
(Hi) and L (Low) 4 to 5 times.
5. Place shift lever (4) in position D (Hi). Loosen air
bleed plug (1). Allow the hydraulic oil together
with air to flow out for 15 to 20 seconds. Tighten 3
air bleed plug (1).
6. Place shift lever (4) in position L (Low). Keep the
lever in that position and wait for 15 to 20 sec- M202-07-023
onds.
7. Repeat step 5 to 6 until no bubbles are found in
the discharged oil.
8. Tighten air bleed plug (1).
4 MCBB-01-010
T5-4-116
BLEEDING AIR FROM BRAKE (AXLE)
IMPORTANT: If air is mixed in the brake system,
the brake function is reduced, pos- 1
sibly resulting in serious hazard. Be
sure to bleed air from the brake
system after disconnecting and re-
connecting the pipe lines, or
changing the hydraulic oil. Bleed air
until hydraulic oil of approx. 500 mL
(0.13 US gal.) is drained from each
wheel (4 places) after air bubbles
disappear.
NOTE: Bleed air from four wheels by the team-

work of two or more persons.
1. Turn the brake switch on the column box to posi-

tion P (parking). Start the engine to increase the
MCBB-07-044
brake hydraulic oil pressure.
2. Connect transparent vinyl tube (2) to the tip end
1
of air bleed plug (1). Put the other end of vinyl
tube (2) into transparent vessel filled (3) with hy-
draulic oil.
3. Fully stroke brake pedal (4) several times. Then,
hold brake pedal (4) in the fully stepped position.
4. While holding brake pedal (4) in the fully stepped 2
position, loosen air bleed plug (1). Keep dis-
charging hydraulic oil and air for several sec-
onds.
5. Tighten air bleed plug (1).
6. Repeat steps 3 to 5 until no air bubble is found in
the discharged hydraulic oil.
NOTE: Even after hydraulic oil of 500 mL (0.13 US 3
gal.) is discharged, if air bubbles are still
remaining in the discharged hydraulic oil,
continuously repeat steps 3 to 5. M202-07-023
7. Bleed air from other three places by the same

procedure explained in steps 3 to 5.
IMPORTANT: After bleeding air from all four

places, bleed air from all four places
once more. After bleeding air by fol-
lowing steps 3 to 6 twice, make sure
that air is completely bled.
MCBB-01-008
T5-4-117
EMERGENCY BOOM LOWERING PRO- Rear
CEDURE (without hose-rupture safety
1 Boom 1
valve)
CAUTION: Never allow anyone to come

under the front attachment while performing
the emergency boom lowering procedure. 2
If the engine stalls and cannot be restarted, lower the

boom and the bucket to the ground referring to the
emergency boom lowering procedure stated below.
1. Remove rubber caps (1) and (2) from the boom I

section of the 4-spool control valve.
2. Remove lock nut (8) using a wrench (17 mm). Be

sure to turn the wrench counterclockwise to
remove lock nut (8).
Control Valve M175-05-001
3. Turn socket-head screw (7) clockwise to the stop

using an allen wrench (4 mm).
6
4. Turn lock nut (5) counterclockwise to loosen it, 3
using a wrench (17 mm). 4
1
5. Loosen socket-head screw (6) clockwise using
5
an allen wrench (4 mm) while closely watching
the boom lower. Note that the loosened degree of
screw (6) determines the boom lowering speed. 7
Adjust the boom lowering speed with the allen
wrench as required. 2
Take care not to remove snap ring (3) and
washer (4) at this time. Also, do not loosen screw 8
(6) excessively or cause washer (4) to be
deformed.
6. After the bucket is lowered to the ground, turn

screws (6) and (7) counterclockwise to the stop.
Loosen screw (7) 1/8 of a turn clockwise. Tighten M154-05-001
lock nuts (5) and (8).

Tightening Torque: 19.5 N⋅m (2 kgf⋅m)
7. Re-install rubber caps (1) and (2). Be sure to

return them to their original positions.
NOTE: Be sure to work on screw (7) first, then, on

screw (6), as stated above.
T5-4-118
EMERGENCY BOOM LOWERING PRO-
CEDURE (with hose-rupture safety valve) Hose-Rupture
Safety Valve
CAUTION: Prevent personal injury. Confirm

that no one is under the front attachment
before starting the procedure below.
If the engine stalls and cannot be restarted, lower the

boom to lower the bucket to the ground referring to
the emergency boom lowering procedure stated be-
low.
2. Loosen very slowly adjusting screw (2) in order to M1G6-05-017
lower the front attachment till to ground.
1 2
NOTE: Never loosen screw (2) more than 1.5
turns. Adjusting screw (2) may come off.
3. After the front attachment is lowered to the

ground, retighten adjusting screw (2), then lock
nut (1) to the specifications below.
Lock Nut (1)

: 17 mm
: 30±2 N⋅m
M1G6-05-013
Adjusting Screw (2)
: 6 mm 1 2
NOTE: It is enough to perform the above proce-

dure only on one of the hose-rupture
safety valve.
M1G6-05-014
T5-4-119
(Blank)
T5-4-120
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C (TROUBLE-
SHOOTING FOR MONITOR) PROCEDURE
Use troubleshooting C when any monitors, such as
gauges or indicators malfunction.
• How to Read the Troubleshoting Flow Charts
YES(OK)
(2)
• After checking or measuring item (1), select either YES (OK) or
・ (1) NO (NOT OK) and proceed to item (2) or (3), as appropriate.
(3)
NO(NOT OK)
• Special instructions or reference item are indicated in the spaces under the box.
・ Incorrect measuring or checking methods will render troubleshooting impossible,
and may damage components as well.
· Key switch: ON
・ • Use Dr.ZX (or the built-in diagnosing system) 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: All harness end connector are seen from

the open-end side.
Harness End
Connector
Harness
T6L4-05-03-001
Open End Side
T5-5-1
MALFUNCTION OF COOLANT TEM-
PERATURE GAUGE
• Check for loose harness connections beforehand.

YES sensor.
Disconnect coolant
temperature sensor.
Gauge pointer Ground harness end
doesn’t move terminal to vehicle frame.
at all. Broken harness between
Check if pointer swings to YES
Remove connector B (20P) monitor and sensor.
(H) side.
from monitor. Check if voltage
at monitor harness end con-
NO nector terminal #18 is 5 V.
· Key switch: ON Faulty monitor.
NO

YES sensor.
Disconnect coolant
Gauge pointer temperature sensor.
swings over Check if pointer returns Short-circuited harness be-
scale. YES tween monitor and sensor.
to zero.
Remove connector B (20P)
from monitor. Check if voltage
· Key switch: ON at monitor harness end ter-
NO minal #18 is 5 V.
Faulty monitor.
NO

sensor.
Disconnect coolant YES
temperature sensor.
Ground harness end
Gauge pointer terminal to vehicle
keeps moving frame, Check if pointer
unstably. swings and is stabilized
to (H) side.
Faulty monitor.
NO
· Key switch: ON
T5-5-2
Coolant Temperature Gauge
M178-01-104
Coolant Temperature Sensor
Coolant Temperature Resistance (kΩ)

°C (°F)
25 (77) 7.6±0.76
40 (104) 4.0±0.35
50 (122) 2.7±0.22
80 (176) 0.92±0.07
95 (203) 0.56±0.04
105 (221) 0.42±0.03
120 (248) 0.28±0.01
Connector (Harness end connector terminals seen

from the open end side)
Monitor Connector B (20P)
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-3
MALFUNCTION OF FUEL GAUGE
YES Faulty fuel sensor.

Disconnect fuel sensor.
Connect harness end con-
Fuel gauge nector terminal #1 to
pointer doesn’t terminal #2 using jumper
wire such as clip. Check if Broken harness between
move at all. YES monitor and sensor.
pointer swings to (FULL) Remove connector B
side. (20P) from monitor.
Check if voltage at moni-
NO tor terminal #19 is 5 V.
· Key switch: ON Faulty monitor.
NO
YES Faulty fuel sensor.

Fuel gauge pointer Check if pointer returns to
swings over scale. zero. Short-circuited harness be-
YES tween monitor and sensor.
Remove connector B
(20P) from monitor. Check
· Key switch: ON if voltage monitor harness
NO end terminal #19 is 5 V.
Faulty monitor.
NO
Disconnect fuel sensor. YES Faulty fuel sensor.

Connect harness end con-
nector terminal #1 to
Fuel gauge pointer terminal #2 using jumper
keeps moving un- wire such as clip. Check if
stably. pointer swings and is stabi-
lized to (FULL) side.
Faulty monitor.
NO
· Key switch: ON
T5-5-4
Fuel Sensor
Fuel Gauge
Float Upper Limit
FULL 1/2
R381.9 mm
257 mm 3/4
Lower Limit
93 mm
70.5 mm M178-01-105
1/2
204 mm
1/4
338 mm
EMPTY
T178-05-05-001
NOTE: 1 mm = 0.03937 in
Float Position Resistance (Ω)

Upper Limit (FULL) 10+0-4
3/4 26
1/2 38±5
1/4 53
Warning Level 85±3
Lower Limit (EMPTY) 90+10-0

Monitor Connector B (20P) Fuel Sensor
10 9 8 7 6 5 4 3 2 1
1 2
20 19 18 17 16 15 14 13 12 11
T5-5-5
MALFUNCTION OF INDICATOR LIGHT
CHECK SYSTEM

Burnt fuse or broken har-
Disconnect monitor con- YES ness between fuse #5 and
nector C. Check if there is monitor.
continuity between harness
end connector terminal
YES #1(power input) and fuse
box terminal #5(switch box).
Indicator doesn’t light Check if all in-
when indicator light dicators don’t Faulty monitor.
check operation is per- light. NO
formed.
Conduct troubleshooting of
each indicator, which does
not light.
NO

Monitor Connector C (20P)
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-6
MALFUNCTION OF PREHEAT INDICATOR
• The preheat system operates only when coolant • In case the preheat system malfunctions, refer to
temperature is below 10 °C (50 °F), lighting the the troubleshooting B for E-16 Engine is difficult to
preheat indicator for 8 seconds. (Refer to the start at low temperature.
SYSTEM /Electrical Circuit group.) • Check for loose harness connections beforehand.
Faulty coolant tem-

YES perature switch.
Preheat indicator Remove connector
lights even though from coolant tem-
preheat system perature switch. YES Faulty QOS con-
doesn’t operate Check if indicator troller.
(coolant tempera- goes OFF.
ture is more than
10 °C (50 °F)). Without connecting
Disconnect QOS Short-circuited har-
QOS controller, re-
controller. Check if ness between QOS
move connector B YES
indicator goes controller and moni-
· Key switch: ON (20P) from monitor.
NO OFF. Check for continuity tor.
between monitor
harness end con-
· Key switch: ON NO nector terminal #20
and vehicle frame. Faulty monitor.
NO
Remove connector Faulty coolant tem-

YES perature switch.
from coolant tem-
Preheat indicator perature switch.
doesn’t light al- Check if indicator
though preheat comes ON by YES Faulty QOS control-
system operates grounding harness ler.
end connector to Disconnect QOS
(coolant tempera- controller. Check if
ture is lower than vehicle frame.
indicator comes
10 °C (50 °F)). ON by grounding Ground monitor Broken harness
harness end con- connector B (20P) YES between QOS con-
nector terminal #6 terminal #20 to ve- troller and monitor.
NO to vehicle frame. hicle frame. Check
· Key switch: ON if indicator comes
NO ON.
Faulty monitor.
· Key switch: ON NO
· Without discon-
necting connector,
ground connector to
vehicle frame using
Connector (Harness end connector terminals seen jumper wire such as
from the open end side) clip from the back of
connector.
Monitor Connector B (20P) QOS Controller
10 9 8 7 6 5 4 3 2 1 1 2 3
20 19 18 17 16 15 14 13 12 11 4 5 6
T5-5-7
MALFUNCTION OF OVERHEAT INDICA-
TOR
YES Faulty overheat switch.

Remove connector (red
and blue cable) from
overheat switch. Check
if indicator lights when
YES harness end terminal is
Reconnect overheat switch.
grounded to vehicle Check if indicator lights when
frame. monitor connector B (20P)
terminal #6 is grounded to To A
NO vehicle frame.
· Key switch: ON
Indicator doesn’t Check if indicator
light even if engine lights when key · Key switch: ON
overheats. switch is turned ON. · Without disconnecting connector,
ground connector to vehicle frame
using such jumper wire as clip from
· Key switch: ON the back of connector.
Burned indicator bulb.

NO

YES monitor and overheat switch.
Faulty monitor.
NO
YES Faulty overheat switch.
Check if indicator
Indicator lights even goes OFF when
if coolant tempera- overheat switch is Short-circuited harness be-
ture is low. disconnected. tween monitor and overheat
YES
Check if indicator goes switch.
OFF when connector B
· Key switch: ON (20P) is disconnected
· Engine: Stopped NO from monitor.
Faulty monitor.
T5-5-8
Overheat Switch
Coolant Temperature Operation
Lower than 105 °C OFF
(221 °F)
105 °C (221 °F) or ON
higher

10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-9
MALFUNCTION OF AIR FILTER RESTRIC-
TION INDICATOR
Faulty air filter restriction

Disconnect air filter re- YES switch.
striction switch at plug
receptacle with green
and blue cable. Check if
indicator lights when
YES
harness end plug con-
nector is grounded to Remove connector B (20P)
vehicle frame. from monitor. Check for
continuity between monitor
harness end connector and
Even if air filter is Check if indicator air filter restriction switch at To A
lights when key NO plug receptacle.
clogged, indicator
doesn’t light. switch is turned ON. · Key switch: ON
· Key switch: ON
Burned indicator bulb.

NO
YES Faulty monitor.
A
monitor and air filter restriction
NO switch.
YES Faulty air filter restriction

switch.
Check if indicator
goes OFF when air
Although air filter is filter restriction
not clogged, indi- switch is discon- Short-circuited harness be-
cator lights. nected. tween monitor and air filter
YES
Check if indicator goes restriction switch.
OFF when connector B
· Disassemble and
(20P) is disconnected
visually inspect. · Key switch: ON
NO from monitor.
· Verify that air filter
is not moist.
Faulty monitor.
T5-5-10
Air Filter Restriction Switch
Pressure Operation
5.1 kPa (520 mmH2O) OFF
6.2 kPa (630 mmH2O) ON

10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-11
MALFUNCTION OF FUEL LEVEL INDICA-
TOR
YES

Check if indicator comes
YES ON by grounding har-
ness end connector to
vehicle frame.
Disconnect monitor
connector B (20P).
Indicator does not Turn key switch to Check if voltage at
come ON even if fuel ON position. monitor connector
gauge pointer Check if indicator NO terminal #19 is 5 V.
reaches "E". comes ON.
NO
YES
Disconnect fuel
Indicator comes ON sensor. Check if
even if fuel still re- indicator goes
mains. OFF.
YES
Check if indicator goes

· Key switch: ON OFF when connector B
(20P) is disconnected
from monitor.
NO
· Key switch: ON
NO
T5-5-12
Faulty fuel sensor.

YES monitor controller and fuel
sensor.
Faulty monitor controller.

NO
Burned indicator bulb, or

faulty monitor controller.
Faulty fuel sensor. Connector (Harness end connector terminals seen

10 9 8 7 6 5 4 3 2 1
Short-circuited harness be- 20 19 18 17 16 15 14 13 12 11
tween monitor controller and
fuel sensor.
Faulty monitor controller.
T5-5-13
MALFUNCTION OF ALTERNATOR INDI-
CATOR
• Check for loose harness connections beforehand. NOTE: *Regulator terminals L are water-resistant
type connectors so that it is not practical to
measure voltage at these terminals. Meas-
ure voltage at starter relay terminal R in-
stead. Check for continuity between starter
relay terminal R and regulator terminal L
beforehand.
Between 12 V Measure voltage at

and 35 V monitor connector A
(16P) terminal #2.
Alternator indicator
stays ON after en- Measure voltage at
· Engine: Running
gine is started. regulator terminal L.*
· Engine: Running
Less than 12 V or
higher than 35 V
YES Measure voltage at

regulator terminal L.*
YES Does engine start? · Engine: Running
Although alternator
output is low, alter- Check if indicator
nator indicator lights when key switch
doesn’t light. is turned ON. NO
· Key switch: ON
NO

Starter Relay Monitor Connector A (16P)
E
8 7 6 5 4 3 2 1
S R 16 15 14 13 12 11 10 9
T5-5-14
Between 12 V
and 35 V Faulty monitor.
Broken harness between regula-

tor terminal L and monitor.
Less than 12 V or
higher than 35 V
Faulty regulator or alternator.
Between 12 V
and 35 V Faulty monitor.
Between 12 V Measure voltage at
and 35 V monitor connector A
(16P) terminal #2.
Broken harness between regula-
Less than 12 V or tor terminal L and monitor.
· Engine: Running higher than 35 V
Faulty regulator.
Less than 12 V or
higher than 35 V
Go to the troubleshooting B (en-
gine troubleshooting).
Burned indicator light.
T5-5-15
MALFUNCTION OF ENGINE OIL PRES-
SURE INDICATOR
• Check for loose harness connections beforehand. NOTE: During one or two minutes after the engine
is stopped, engine oil pressure may still
exist. When the engine is restarted under
this condition, the indicator may not light.
Disconnect engine oil

pressure switch. Check Faulty engine oil pressure
YES switch.
if indicator lights when
terminal #1 (white and
YES red cable) is grounded Reconnect engine oil pres-
to vehicle frame. sure switch. Check if indica-
tor lights when monitor con-
nector C (20P) terminal #18
is grounded to vehicle frame. To A
NO
· Key switch: ON
Indicator doesn’t Check if indicator
light even if engine lights when key
oil pressure is low. switch is turned ON. · Key switch: ON
· Without disconnecting connector,
ground connector to vehicle frame us-
· Key switch: ON ing such jumper wire as clip from the
· Engine: Stopped back of connector.
Burned indicator light.

NO

YES monitor and engine oil pres-
sure switch.
Faulty monitor.
NO
Faulty engine oil pressure

YES switch or engine oil pressure
system, or clogged oil filter.
Check if indicator
goes OFF when
Indicator stays ON engine oil pressure
after engine is switch is discon-
started. Short-circuited harness be-
nected. YES tween monitor and engine oil
Check if indicator goes pressure switch.
· Check oil filter for OFF when connector C
clogging. · Key switch: ON (20P) is disconnected
· Engine: Stopped NO from monitor.
Faulty monitor.
NO
· Key switch: ON
T5-5-16
Engine Oil Pressure Switch

Pressure Operation
Approx. 98 kPa
(1.0 kgf/cm2, 14.22 psi) ON
or less
Approx. 98 kPa
(1.0 kgf/cm2, 14.22 psi) OFF
or higher

10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-17
MALFUNCTION OF HYDRAULIC OIL FIL-
TER INDICATOR (OPTIONAL)
Disconnect hydraulic oil filter YES

restriction switch at plug re-
ceptacle with white and blue
cable. Check if indicator
YES lights when harness end plug
connector is grounded to Reconnect hydraulic oil filter
vehicle frame. restriction switch. Check if in-
dicator lights when monitor
connector C (20P) terminal
#14 is grounded to vehicle
NO frame.
· Key switch: ON
Even if hydraulic oil Check if indicator
filter is clogged, lights when key
indicator doesn’t switch is turned ON.
light. · Key switch: ON
· Without disconnecting connector,
· Key switch: ON ground connector to vehicle
frame using jumper wire such as
clip from the back of connector.
NO
YES
OFF when hydraulic oil
Although hydraulic filter restriction switch at
oil filter is not plug receptacle with white
clogged, indicator and blue cable is discon-
lights. nected.
Check if indicator goes OFF
when connector C (20P) is
disconnected from monitor.
· Engine: Stopped
· Key switch: ON
T5-5-18
Faulty hydraulic oil filter restric-

tion switch.
Broken harness between moni-

YES tor and hydraulic oil filter restric-
tion switch.
Faulty monitor.
NO
Burned indicator bulb. 10 9 8 7 6 5 4 3 2 1

20 19 18 17 16 15 14 13 12 11
Faulty hydraulic oil filter restric-

tion switch.
Short-circuited harness between

YES monitor and hydraulic oil filter
restriction switch.
Faulty monitor.
NO
T5-5-19
MALFUNCTION OF OVERLOAD ALARM
INDICATOR (OPTIONAL) Connector (Harness end connector terminals seen
• By bulb blow inspection, check that bulb is not Monitor Connector C (20P)
blown.
• Check that cancellation switch is at ON position 10 9 8 7 6 5 4 3 2 1
(cancellation release position). 20 19 18 17 16 15 14 13 12 11
Connector (Monitor end connector terminals seen from
Alarm indicator does not go ON even when lifting the open end side)
a load over the setting.
Connector (1)
1 2 3 4
5 6 7 8 9 10
Disconnect monitor
connector C (20P) and
connector (1).
Check for continuity YES
between monitor harness
YES end connector terminal
#20 and connector (1)
terminal #8. NO
Check if alarm buzzer
YES YES
sounds.
· Boom raise
Check if alarm indicator
(When relieving)
goes ON when overload
alarm relay and work light
NO relay 2 (R4).
Disconnect overload
alarm relay connector.
Check if alarm
· Key switch: ON indicator goes ON
Using Dr. ZX, monitor when connecting relay
boom bottom pressure and NO terminal #2 to the
overload alarm. body.
Check if the following
conditions are met:
· Monitor items: Conditions

Boom bottom pressure :
14.3 MPa or higher
Tr/Sw/Overload alarm :
Load are displayed by outline
type fonts.
NO
T5-5-20
Monitor
From Fuse #18
Connector (1)
MC
Boom Bottom
Pressure Sensor
Diode
Transistor Unit Cancellation Switch

Overload Alarm Relay
T1GL-05-05-001
Faulty Monitor.

monitor and connector (1).
Faulty overload alarm relay.
Faulty transistor unit, or

broken harness between
YES overload alarm relay terminal
#2 and transistor unit terminal
#4.
Disconnect overload alarm

circuit connector (1). YES Faulty diode.
Check if there is continuity at
Disconnect cancellation YES the following harnesses:
switch connector. Broken harness across
Check if there is connection without continuity.
continuity between NO
cancellation switch
connector terminals A · between connector (1) terminal #8 and diode A terminal
NO and C. · between diode terminal K and overload alarm relay
terminal #3
· between overload alarm relay terminal #5 and
cancellation switch C terminal
· between cancellation switch terminal A and connector (1)
terminal #3
Faulty cancellation switch.

NO
Faulty boom bottom pressure
sensor or faulty MC.
· Refer to T4-6-1.
T5-5-21

10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
Connector (Monitor end connector terminals seen from

the open end side)
Connector (1)
1 2 3 4
5 6 7 8 9 10
Normally, alarm indicator goes ON.
YES
Using Dr.ZX, monitor boom

Check if alarm indicator goes
bottom pressure and overload
OFF when overload alarm
alarm to check if the following
YES relay and work light relay 2
conditions are met:
(R4) are switched.
· Monitor items: Conditions

Boom bottom pressure : Check if load alarm
14.3 MPa or higher buzzer sounds.
Tr/Sw/Overload alarm: NO
Load are displayed by outline
type fonts.
Check if alarm indicator goes

OFF when disconnecting
monitor connector C (20P).
NO
T5-5-22
Monitor
From Fuse #18
Connector (1)
MC
Boom Bottom
Pressure Sensor
Diode
Cancellation Switch
Transistor Unit
Overload Alarm Relay
T1GL-05-05-001
Faulty boom bottom pressure

sensor or faulty MC.
· Refer T4-6-1.
YES Faulty overload alarm relay.
Check if alarm indicator goes YES Faulty transistor unit.

OFF when exchanging
transistor unit with transistor
NO unit 1 on the body. Short-circuited harness between
overload alarm relay and transistor
NO unit.

YES monitor and diode A terminal.
Faulty monitor.
NO
T5-5-23
MALFUNCTION OF
AUTO-ACCELERATION INDICATOR
YES
Auto-acceleration Disconnect monitor end
indicator does not go connector B (20P).
ON even when Check if voltage at
Check if indicator goes YES
selecting monitor end connector
auto-acceleration. terminal #11 is 5 V. ON when exchanging
auto-acceleration
cancellation relay (R26)
· Engine speed control NO with parking brake alarm Disconnect switch box
mode selection switch: relay (R23). connector.
Dial or Creeper position Check if indicator goes
ON when connecting
NO harness end connector
terminal #9 to the body.
YES Faulty switch box.
Auto-acceleration Check if indicator

indicator goes ON even goes OFF when
if auto-acceleration is disconnecting switch
not selected. box connector. Short-circuited harness
Check if indicator YES between monitor and
goes OFF when switch box.
disconnecting monitor
· Auto-idle/acceleration · Key switch: ON
end connector B
selection switch:
NO (20P).
Auto-Idle or OFF
Faulty monitor.
NO
· Key switch: ON
T5-5-24
Blown indicator bulb or faulty

monitor.
Faulty auto-acceleration
cancellation relay (R26).
YES Faulty switch box.
Broken harness between switch

box and auto-acceleration
cancellation relay (R26).
NO

Switch Box Monitor Connector B (20P)
7 6 5 ● 4 3 2 1 10 9 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 20 19 18 17 16 15 14 13 12 11
T5-5-25
MALFUNCTION OF AUTO-IDLE
INDICATOR
YES Blown indicator bulb or

Disconnect monitor end faulty monitor.
connector B (20P).
Check if indicator does Check if voltage at
not go ON even when monitor end connector
auto-idle is working. terminal #10 is 5 V.
switch box and monitor.
NO
Reconnect connector. YES Faulty monitor.

ON when
YES disconnecting monitor
end connector B
(20P).
Disconnect switch box between switch box and
Indicator goes ON connector. NO monitor.
even if auto-idle is not Check if indicator goes
working. ON.
Faulty switch box.

NO

Switch Box
7 6 5 ● 4 3 2 1
16 15 14 13 12 11 10 9 8
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-26
MALFUNCTION OF DIGGING MODE
INDICATOR OR ATTACHMENT MODE
INDICATOR
• If digging mode indicator or attachment mode

indicator is malfunctioning, blown bulb or faulty
monitor is suspected, respectively. If
malfunctioning is not remedied even after
replacing a faulty bulb with a new one, replace
monitor assembly.
T5-5-27
MALFUNCTION OF LCD
• The following items are described:

1 to 3: To be displayed in the standard mode.
4 to 5: To be displayed in the user’s mode.
8 to 23: To be displayed with built-in diagnosing
system
• In case only LCD is abnormal, the machine will
normally operate.
Display
Description Cause of Trouble
Order
1 Hour Meter Refer to the next page.
2 Trip 1 Faulty Monitor.
3 Trip 2
4 Actual Engine Speed In case Dr. ZX can display data, monitor is abnormal or communication
5 Hydraulic Oil between monitor and MC is interrupted. In case Dr. ZX doesn’t display
Temperature data, corresponding signal sensor is faulty. (The machine must have
any abnormality in the control system. Refer to Troubleshooting B.)
8 Fault Code* In case Dr. ZX can display data, monitor is abnormal or communication
9 ML Switch** between monitor and MC is interrupted. In case Dr. ZX doesn’t display
10 Pump 1 Delivery data, corresponding signal sensor is faulty. (The machine must have
Pressure any abnormality in the control system. Refer to Troubleshooting B.)
11 Pump 2 Delivery
Pressure
12 Pump 1 Pump (Flow)
Control Pressure
13 Pump 2 Pump (Flow)
Control Pressure
14 Engine Target Speed
15 EC Angle
16 Dial Angle
17 Boom Raise Pilot
Pressure
18 Arm Roll-In Pilot
Pressure
19 Swing Pilot Pressure
20 Travel Pilot Pressure
21 Front Attachment
Operation
22 Attachment Pilot
Pressure
23 Work Mode Position
NOTE * : Refer to T5-1-10 for the Fault Codes.

** : ML specification is only available in
Japanese domestic market.
T5-5-28
MALFUNCTION OF HOUR METER
• Check for loose harness connections beforehand. NOTE: ∗

Regulator terminals L are water-resistant
measure voltage at these terminals.
Measure voltage at starter relay terminal R
instead. Check for continuity between
starter relay terminal R and regulator
terminal L beforehand.
Lower than
Faulty regulator or
12 V
alternator.
Hour meter doesn’t

count operating hours Measure voltage at
with engine running. ∗ Higher than
regulator terminal L. 12 V Faulty monitor.
-1
· Engine speed: 900 min Measure voltage at
· Engine: Running (rpm) or faster monitor connector A
Higher than (16P) terminal #2. Broken harness
12 V between regulator
terminal L and
Lower than monitor.
12 V

Monitor Connector A (16P) Starter Relay
8 7 6 5 4 3 2 1 E
16 15 14 13 12 11 10 9 S R
T5-5-29
MALFUNCTION OF BLADE/STABILIZER
INDICATOR
• Check that indicator bulb is not blown. from the open end side)
Monitor Connector C (16P) Connector (1)
8 7 6 5 4 3 2 1 2 1
16 15 14 13 12 11 10 9 4 3
Blade/Stabilizer Front/Rear Left/Right

Selection Switch Selection Switch Selection Switch
1 2 3 1 2 3 1 2 3
4 5 6 4 5 6 4 5 6
YES
Check if voltage at
YES diode (D2) terminal
#1 is 12 V. Disconnect connector (1).
Check if voltage at monitor
end connector terminal #2
is 12 V.
NO
Indicator does not go ON Check if

even if blade/ stabilizer (front
stabilizer selection switch right) operates.
is ON.
Check if there is continuity
YES across the following
· Blade/Stabilizer connections.
Selection Switch: ON
· Front/Rear Selection
Switch: Front · Between diode (D2) terminal #2 and
· Left/Right Selection front/rear selection switch terminal #1
Switch: Right · Between front/rear selection switch
Disconnect each switch
terminal #2 and left/right selection
connector.
switch terminal #4
· Between left/right selection switch
across the following
NO connections. terminal #5 and blade/stabilizer
selection switch terminal #1
· Between blade/stabilizer selection
switch terminal #2 and body
· Blade/stabilizer selection switch
between terminals #1 and #2
· Front/rear selection switch
between terminals #1 and #2
· Left/right selection switch
between terminals 4 and #5 NO
T5-5-30
Monitor
Front/Rear Left/Right
Blade/Stabilizer Selection Selection
Selection Switch Switch Switch
Diode (D2)
Connector (1)
T1GL-05-05-002
Faulty diode (D2).
YES Broken harness between connector

(1) and diode (D2).
YES Broken harness between monitor

Check if voltage at and connector (1).
monitor end connector
NO terminal #14 is 12 V.
Faulty monitor.
NO
YES Faulty diode (D2).
Broken harness without continuity.

NO
Faulty switch without continuity.
T5-5-31

Monitor Connector C (16P) Connector (1)
8 7 6 5 4 3 2 1 2 1
16 15 14 13 12 11 10 9 4 3
Blade/Stabilizer Front/Rear Left/Right

Selection Switch Selection Switch Selection Switch
1 2 3 1 2 3 1 2 3
4 5 6 4 5 6 4 5 6
YES
Check if continuity
Check if indicator between left/right
Indicator goes ON goes OFF when selection switch harness
even if blade/stabilizer disconnecting blade/ end connector terminal
selection switch is stabilizer selection YES #5 and blade/stabilizer
OFF. switch connector. selection switch harness
end connector terminal
#1.
· Blade/Stabilizer Check if indicator

Selection Switch: OFF goes OFF when
· Front/Rear Selection disconnecting
Switch: Front left/right selection
· Left/Right Selection NO switch connector.
Switch: Right

OFF when
disconnecting front/rear
selection switch
NO connector.
T5-5-32
Monitor
Front/Rear Left/Right
Blade/Stabilizer Selection Selection
Selection Switch Switch Switch
Diode (D2)
Connector (1)
T1GL-05-05-002
Faulty blade/stabilizer selection switch.
Short-circuited harness between left/right

selection switch terminal #5 and
YES blade/stabilizer selection switch terminal
#1.
Faulty left/right selection switch.

NO

Check if continuity between front/rear selection switch terminal #2
front/rear selection switch YES and left/right selection switch terminal
harness end connector #1.
terminal #2 and left/right
YES selection switch harness
end connector terminal #4.
Faulty front/rear selection switch.
NO

YES connector (1) and front/rear selection
switch.
OFF when disconnecting
connector (1) Check if indicator Short-circuited harness between monitor
NO YES
goes OFF when and connector (1).
disconnecting
monitor end
NO connector C (16P).
Faulty monitor.
NO
T5-5-33
MALFUNCTION OF BUZZER
• Check for loose harness connections beforehand. NOTE: *Regulator terminals L are water-resistant
measure voltage at these terminals.
Measure voltage at starter relay terminal R
instead. Check for continuity between
starter relay terminal R and regulator
terminal L beforehand.
Faulty engine oil

YES pressure system.
Buzzer continues to Check if engine oil

sound when engine pressure indicator
is started. lights. YES Overheat of engine.
Check if overheat
indicator lights.
NO
Faulty monitor.
NO
Buzzer doesn’t NO Normal.

sound even if engine
oil pressure indicator
Check if engine
or overheat indicator Perform troubleshooting
speed is 900 min-1 NO
lights with engine of indicator staying ON.
(rpm) or faster.
running.
Check if alternator
indicator lights.
YES
Measure voltage at
regulator terminal L.*
YES
-1
· Engine speed: 900 min
(rpm) or faster.
T5-5-34

Monitor Connector A (16P) Starter Relay
8 7 6 5 4 3 2 1 E
16 15 14 13 12 11 10 9 S R
Lower than 12 V or
more than 35 V Faulty regulator and
alternator.
Lower than 12 V or Broken harness between

higher than 35 V regulator terminal L and
monitor.
Measure voltage at monitor
connector A (16P) terminal #2.
Between 12 V
and 35 V -1 Faulty monitor.
· Engine speed: 900 min
(rpm) or faster Between 12 V
and 35 V
T5-5-35
MALFUNCTION OF TURN SIGNAL INDI-
CATOR
hand.
• If turn signal does not flash, MALFUNCTION of
flasher relay is suspected.
YES Faulty turn signal switch.
Although turn signal Check if all turn lights

switch is turned ON, turn and turn signal indi-
light on one side and cators go ON or flash
turn signal indicator do when hazard switch Check if phenomena is
is turned ON. YES Faulty turn signal relay.
not flash. reversed between left
and right when left turn
signal relay (R15) and · Left: Relay R15
right turn signal (R16) · Right: Relay R16
NO are exchanged.
Blown bulb or broken har-
ness between column box
NO and turn signal relay.
YES Faulty turn signal relay.

Check if phenomenon
is reversed between · Left: Relay R15
Turn light and turn signal left and right when left · Right: Relay R16
indicator flash even if turn signal relay (R15)
turn signal switch is not and right relay (R16)
turned ON. are exchanged.
Faulty turn signal switch, or
tween column box and turn
NO signal relay.
T5-5-36
MALFUNCTION OF TRAVEL MOTOR IN-
DICATOR
• Malfunction of travel motor can be found by
buzzer and indicator.
• Notice that buzzer does not sound, and indicator Column Box: Connector D (12P)
does not go ON if both column box buzzer circuit
and travel motor indicator circuit are faulty, even
in the case of malfunction of travel motor. １ 2 ○ 3 4 5
In this case, make judgment depending on trav- 6 7 8 9 10 11 12
eling conditions. Refer to troubleshooting B “T-1
The machine doesn’t travel” and “T-3 Travel
speed is slow and travel power is weak in both
forward and reverse directions”.
hand.
YES Refer to troubleshooting A.
Buzzer sounds, but Check if fault code 20

indicator does not go is displayed. YES Faulty travel motor alarm re-
ON.
Check if indicator lay (R22).
goes ON when travel
· Brake oil pressure in- · 20: Abnormal travel motor alarm relay
dicator must be OFF. motor drain pressure (R22) and travel re-
verse Pi cut relay Disconnect column box
sensor
NO (R25) are exchanged. connector D (12P). Check
· Refer to T5-3-11.
if voltage at harness end
connector terminal #11 is To A
NO 24 V.
YES Faulty travel motor indicator.
A
travel motor alarm relay
NO (R22) and column box.
YES Refer to troubleshooting A.
Indicator goes ON Check if fault code 20

even if buzzer does not is displayed. YES Faulty travel motor alarm re-
sound. Check if indicator goes lay (R22).
OFF when travel motor
· 20: Faulty travel motor alarm relay (R22) and
drain pressure sensor travel reverse Pi cut relay
· Refer to T5-3-11. NO (R25) are exchanged.
Faulty column box.
NO
T5-5-37
MALFUNCTION OF WORK LIGHT INDI-
CATOR
• Confirm that work light switch (switch box) and

light switch (column box) are ON.
• If clearance light indicator cannot goes ON, mal-
function of common circuit for both clearance
light indicator and work light indicator is sus-
pected. Refer to “Malfunction of Clearance Light
Indicator”.
hand.
Disconnect column box YES Faulty work light indicator.

connector D (12P). Check
if voltage at harness con-
YES nector #12 terminal is 24
Broken harness between work
V. light relay 1 (R3) and column
Work light indicator box.
does not go ON even NO
Check if work light
if work light switch is
goes ON.
turned ON. Blown fuse #11, or broken har-
NO ness between fuse #11 and
Check if voltage at work
work light relay 1 (R3).
light relay 1 (R3) terminal
#3 is 24 V.
NO
Check if indicator goes ON
YES when work light relays 1 (R3)
and 2 (R4) are exchanged.
Check if indicator goes YES Faulty work light relay 1 (R3).

OFF when work light re-
YES lays 1 (R3) and 2 (R4) are
exchanged.
Work light indicator
goes ON even if work NO
light switch is at OFF Check if work light
position. goes ON.

work light relay 1 (R3) and col-
umn box.
NO
T5-5-38
Faulty work light relay 1

YES (R3).
Reconnect disconnected
connector. Disconnect YES Faulty work light.
column box connector D
YES (12P).
Check if there is con- Check if voltage at harness
tinuity between end connector terminal #12 Broken harness between
switch box end con- is 24 V. wok light relay 1 (R3) and
YES nector terminal #13 column box.
NO
Disconnect switch and body.
box connector. Check
if voltage at harness Faulty work light switch.
end connector termi- NO
NO nal #13 is 24 V. · Work light switch: ON
work light relay 1 (R3)
NO and switch box.
YES Faulty work light switch.

when switch box connector is
disconnected.
between work light relay 1
(R3) and switch box.
NO

Column Box: Connector D (12P) Switch Box
１ 2 ○ 3 4 5 7 6 5 ● 4 3 2 1
6 7 8 9 10 11 12 16 15 14 13 12 11 10 9 8
T5-5-39
MALFUNCTION OF SHIFT LEVER INDI-
CATOR

hand.
NOTE: An example of faulty indicator N is de-

scribed below.

YES Faulty neutral relay (R21).
when neutral relay (R21)
and travel alarm relay
YES (R22) are exchanged.
Disconnect shift lever con-
nector. Check if voltage at
harness end connector ter-
Indicator N does not Check if voltage at NO minal #1 is 24 V.
go ON even if shift neutral relay (R21)
lever is moved to N terminals #3 and #1
position. is 24 V. YES Faulty fuse #28.
when fuses #28 and #29
are exchanged.
NO Broken harness between fuse
#28 and neutral relay (R21).
NO
YES Faulty neutral relay (R21).

Check if indicator N
Indicator N goes ON goes OFF when neu-
even if shift lever is tral relay (R21) and
moved to position travel alarm relay
other than N position. (R22) are ex-
changed.
Check if indicator N goes
OFF when shift lever con-
nector is disconnected.
NO
T5-5-40
connector. Disconnect YES Faulty column box.
column box connector D
(12P). Check if voltage at
YES
Check if there is continuity terminal #5 is 24 V. Broken harness between neutral
between shift lever con- relay (R21) and column box.
YES nector end terminals #1 NO
and #5.
Faulty shift lever.
NO
YES Broken harness between diode

(D9) and shift lever.
Check if voltage at diode
YES (D9) terminal #2 is 24 V.
Check if voltage at diode Faulty diode (D9).

(D9) terminal #1 is 24 V. NO
NO
Faulty diode (D9), or broken har-
ness between neutral relay (R21)
NO and diode (D9).
YES Faulty shift lever.
YES Short-circuited harness between

diode (D9) and shift lever.
Remove diode (D9). Check

if voltage at diode (D9) ter-
minal #1 is 24 V.
NO Short-circuited harness between
neutral relay (R21) and diode
(D9).
NO
Column Box: Connector D (12P) Shift Lever
１ 2 ○ 3 4 5 1 2 3
6 7 8 9 10 11 12 4 5 6
T5-5-41
MALFUNCTION OF WORK BRAKE INDI-
CATOR

hand.
Reconnect discon-
nected connector.
Check if indicator goes Faulty work brake indicator
YES (R18).
OFF when work brake
YES indicator relay (R18) and
left turn signal relay
Check if indicator (R15) are exchanged. Short-circuited harness be-
Indicator goes ON even tween work brake indicator
goes OFF when col-
if brake switch is not at S (R18) and brake switch.
umn box connector B NO
(work) position.
(9P) is disconnected.
Faulty logic circuit in column

box.
NO
YES
Disconnect brake
switch connector.
Indicator does not go ON Check if indicator goes
even if brake switch is at ON when harness end
S (work) position. connector #3 is con-
nected to body.

when work brake indicator
relay (R18) and left turn
signal relay (R15) are ex-
NO changed.

Column Box: Connector B (9P)
１ 2 3
4 5 6
7 8 9
T5-5-42
Faulty brake switch.
Faulty work brake indicator

YES relay (R18).
Disconnect column box Faulty logic circuit in column

connector B (9P). YES box or blown bulb.
Check if voltage at
YES harness end connector
Disconnect brake terminal #5 is 24 V. Broken harness between
switch connector. work brake indicator relay
Check if voltage at (R18) and column box.
harness end connector NO
NO #3 is 24 V.
work brake indicator relay
NO (R18) and brake switch.
T5-5-43
MALFUNCTION OF PARKING BRAKE IN-
DICATOR
NOTE: Operating condition of parking brake pres-

sure switch:
(Holding pressures of transmission
High/Low Selection Circuit)
ON: 2.1 to 2.6 MPa
OFF: 2.6 MPa
YES
Indicator goes ON even OFF when parking brake
if brake switch is not at P pressure switch connec-
(parking) position. tor is disconnected. YES
OFF when diode (D19)
is removed.
NO
NO
Reconnect discon- YES

nected connector.
Check if voltage at di-
YES ode (D19) terminal #1
is 24 V.
Indicator does not go ON Disconnect column box con-
even though brake nector B (9P). Check if volt-
switch is at P (parking) age at column box connector
position. terminal #8 is 24 V.
NO
Connector (Harness end connector terminals seen NO

１ 2 3
4 5 6
7 8 9
T5-5-44
Faulty parking brake pressure switch.
Short-circuited harness between diode

(D19) and parking brake pressure
switch.
YES Short-circuited harness between col-

Check if indicator goes OFF umn box and diode (D19).
when column box connector B
Faulty logic circuit in column box.

NO
Disconnect parking brake

YES Faulty parking brake pressure switch.
pressure switch connector.
Check if voltage at harness
end connector terminal #2 is
24 V. Faulty diode (D19) or broken harness
between diode (D19) and parking
brake pressure switch.
NO
Broken harness between column box

and diode (D19).
Faulty logic circuit in column box or

blown bulb.
T5-5-45
MALFUNCTION OF AXLE LOCK INDICA-
TOR
• Confirm that brake switch is at position other than

OFF position.
If brake switch is at OFF position, axle lock is re-
leased, so indicator does not go ON. Refer to
SYSTEM/Control System group in the T/M (Op-
erating Principle).
hand.
Check if indicator goes YES

ON when axle lock
relay (R19) and right
YES turn signal relay (R16) Disconnect column box
are exchanged.
connector B (9P). Check
if voltage at harness end
terminal #3 is 24 V.
Check if voltage at
NO
Indicator does not go axle lock relay (R19)
ON. terminals #1 and #3 is
24 V.
· Brake switch: Other

than OFF position Check if indicator
goes ON when fuses
#28 and #29 are ex-
changed.
NO
YES
Check if indicator
goes OFF when axle
Indicator goes ON lock relay (R19) and Disconnect brake switch
even if brake switch is right turn signal relay connector. Check if con-
OFF position. (R16) are ex- tinuity between brake
YES switch end connector
changed.
Check if indicator terminal #4 and #6.
goes OFF when
· Brake switch: OFF connector B (9P) is
position disconnected from
NO column box.
NO
T5-5-46

Column Box: Connector B (9P) Brake Switch
１ 2 3
1 2 3
4 5 6
4 5 6
7 8 9
Faulty axle lock relay (R19).
YES Faulty logic circuit in column box.
Broken harness between axle

lock relay (R19) and column box.
NO
YES Faulty fuse #28.
Broken harness between fuse

#28 and axle lock relay (R19).
NO
Faulty axle lock relay (R19).
Broken harness between axle

YES lock relay (R19) and brake switch.
Faulty brake switch.

NO
Faulty column box.
T5-5-47
MALFUNCTION OF CLEARANCE LIGHT
INDICATOR
• If indicator goes ON when light switch is OFF and

clearance light is OFF, column box can malfunc-
tion. If clearance lights on front and rear on right
side as well as their indicators go ON when light
switch is OFF, right clearance light relay (R12)
can malfunction.
hand.
YES Faulty clearance left light relay

Clearance lights at front (R28).
Check if voltage at left
and rear on left side as well
clearance light relay (R28)
as their indicators does not
terminals #1 and #3 is 24
go ON.
V. Faulty fuse #31, or faulty harness
between fuse #31 and left clear-
NO ance light relay (R28).
· Light switch: ON
· Clearance lights at front/rear
on right side: ON
Disconnect column box YES Faulty logic circuit in column box or

connector B (9P). Check if blown bulb.
Clearance light goes ON, voltage at harness end
but indicator does not go connector terminal #9 is 24
ON. V. Broken harness between column
box terminal #9 and right clearance
· Light switch: ON NO light relay (R12).

１ 2 3
4 5 6
7 8 9
T5-5-48
MALFUNCTION OF HAZARD LIGHT INDI-
CATOR
• The hazard light indicator comes ON when light-
ing signal is inputted to the logic circuit in the col-
umn box from both left and right turn signals.
Therefore, the hazard light indicator does not
come ON when the signal is coming from only
one side. If the hazard light indicator does not
come ON even if both turn signals are lighting or
blinking, blown bulb, broken wiring within column
box, or failure in logic circuit may be suspected. If
only one side of turn signal indicator comes
ON/blinks, refer to Troubleshooting “Malfunction
of Turn Signal Indicator”.
hand.
T5-5-49
MALFUNCTION OF HIGH-BEAM INDICA-
TOR

hand.
Check if indicator goes YES Faulty high-beam relay (R14).

ON when high-beam re-
lay (R14) and parking
YES brake relay (R11) are
Disconnect light switch con-
exchanged. nector A (6P). Check if volt-
High-beam indicator Check if voltage at age at harness end connec-
does not go ON even if high-beam relay (R14) NO tor terminal #5 is 0 V.
light switch is at terminals #1 and #3 is
high-beam position. 24 V.
Faulty fuse #23, or broken

harness between fuse #23 and
NO high-beam relay (R14).
YES Faulty high-beam relay (R14).

Indicator goes ON even OFF when high-beam Reconnect disconnected
if light switch is not at relay (R14) and parking connector. Check if indica-
high-beam position. brake relay (R11) are tor goes OFF when light
exchanged. YES switch connector A (6P) is
Check if indicator goes disconnected.
OFF when column box
connector B (9P) is dis-
NO connected.
Faulty column box.
NO
T5-5-50
Broken harness between high-beam

YES relay (R14) and light switch.
connector. Disconnect YES Broken harness between high-beam
column box connector B relay (R14) and column box.
(9P). Check if voltage at
Check if there is conti- YES harness end connector
nuity between light terminal #2 is 0 V.
Faulty logic circuit in column box or
switch end connector blown bulb.
NO terminals #2 and #5. NO
Faulty light switch.

NO
YES Faulty light switch.

high-beam relay (R14) and light
NO switch.

Column Box: Connector B (9P) Light Switch: Connector A (6P)
１ 2 3
1 ● 2
4 5 6
3 4 5 6
7 8 9
T5-5-51
MALFUNCTION OF BUZZER IN COLUMN
BOX
• If buzzer in column box sounds, travel motor in- NOTE: An example of travel motor indicator is
dicator, parking brake indicator or brake oil indi- described below.
cator must go ON at the same time.
• If buzzer sounds even though each indicator is
not ON, or if buzzer does not sound even though
each indicator is ON, Check buzzer circuit and
each indicator circuit. (Refer to “Malfunction of
Indicator.)
hand.
Disconnect column box con-

nector I (9P). Check if voltage
YES
at column box connector ter-
Disconnect column box minal #1 is 0 V.
connector H (buzzer).
Check if voltage at har-
YES ness end connector ter-
minal #1 is 0 V.

between column box connec-
Travel motor light Check if voltage at di- NO tor terminals #1 and #2.
goes ON, but buzzer ode (D15) terminal #2
does not sound. is 0 V.
YES Broken harness between di-

odes (D15) and (D20).
Check if voltage at diode
(D20) terminal #2 is 0 V.
NO Broken harness between di-
ode (D20) and travel motor
alarm relay (R22).
NO
Reconnect disconnected con-

YES nector. Check if buzzing stops
Reconnect disconnected when diode (D15) is removed.
connector. Check if
buzzing stops when col-
YES umn box connector H
(buzzer) is disconnected.
Check if buzzing stops
Buzzer sounds even if
when column box con-
travel motor indicator
nector I (9P) is discon- NO
goes OFF.
nected.
NO
T5-5-52
Connector (Column box end connector terminals seen Connector (Harness end connector terminals seen
from the open end side) from the open end side)
Column Box: Connector H (Buzzer) Column Box: Connector I (9P)
１ 2 １ 2 3
4 5 6
7 8 9
YES Faulty logic circuit in column box.
Broken harness between connector I ter-

minal #1 and connector H (buzzer) termi-
NO nal #1.
YES Broken harness between connector H

(buzzer) terminal #2 and diode (D15).
Faulty buzzer in column box.

NO
YES Short-circuited harness between diodes

(D15) and (D20).
Short-circuited harness between column

box buzzer and diode (D15).
NO
Short-circuited harness between column

box terminals #I-1 and #H-1.
T5-5-53
MALFUNCTION OF BRAKE OIL PRES-
SURE GAUGE

hand.
Check if gauge pointer YES
swings toward upper
limit when pressure
YES Reconnect disconnected
sensor harness end
connecter terminals #1 connector. Disconnect
and #2 are connected. column box connector B
Disconnect pressure (9P). Check if voltage at
gauge connector. harness end connector
Pressure gauge Check if voltage at har-
does not swing NO terminal #6 is 0.5 V or
ness end connector more.
at all. terminal #1 is 5 V. · Key switch: ON
· Connection is made
using clip.
YES Faulty pressure sensor.

Check if the pointer re-
Pressure turns toward lower limit
gauge pointer when pressure sensor Disconnect column box
swings exces- connector is discon- YES Short-circuited harness
connector B (9P), with
sively. nected. pressure sensor con- between pressure sensor
nector disconnected. and column box.
Check if there is conti-
nuity between harness
NO end connector terminal
· Key switch: ON
#6 and body.
Faulty column box.
NO
Disconnect pressure
sensor connector.
Check if pointer swings YES Faulty pressure sensor.
Pressure toward upper limit when
gauge pointer harness end connector
fluctuates. terminals #1 and #2 are Short-circuited harness
Check if the pointer re-
connected. turns toward lower lim- YES between pressure sensor
and column box.
iter when column box
connector B (9P) is
NO disconnected.
Faulty column box.
· Key switch: ON
· Connection is made NO
using clip.
T5-5-54
Faulty pressure sensor.
YES Faulty column box.
Broken harness between pres-

sure sensor and column box.
NO

pressure sensor.
Brake Oil Pressure Gauge

１ 2 3
4 5 6
7 8 9
MCBB-01-006
Pressur Sensor
Pressure and Voltage of Pressure Gauge (Brake Oil Pressure Sensor)
Standard Pressure
bar 0 90 160 200
(MPa) (0) (9) (16) (20) 1 2 3
(kgf/cm2) (0) (92) (163) (204)
Voltage (V) 0.5 1.23 1.81 2.13
Tolerance ±3.75 ±7.5 － ±3.75
T5-5-55
MALFUNCTION OF SPEED METER

hand.
• If the malfunctioning occurs on the speed meter,
it difficult to decide safely and surely whether the
column box or the speed sensor is causing trou-
ble. Therefore, determine the cause by replacing
the speed sensor to the correctly functioning
sensor. If the symptom disappears, the speed
sensor is faulty. If the symptom still occurs, the
column box is malfunctioning.
YES Faulty speed meter in column

Using Dr. ZX, monitor box.
Speed meter travel motor speed.
pointer does not Disconnect column box connector C
Check if it is within (6P), both ring connector and brush
swing at all. specifications. connector of slip ring, and N sensor
connector. Check if there is continuity
NO among the following connections:
· Refer to Performance
Measurement.
· Between N sensor terminal #1 and
brush terminal #1 of slip ring
· Between brush terminal #1 and
ring terminal #1 of slip ring
· Between ring terminal #1 of slip ring and
connector C terminal #1 of column box
YES Faulty N sensor.

Speed meter Check if speed meter works
pointer swings normally when faulty N sensor is
excessively. replaced with a sound one.
Faulty column box.

NO
connectors. Check if YES Faulty N sensor.
speed meter works
Disconnect ring connector and normally when faulty N
brush connector of slip ring. YES sensor is replaced with a
Check if there is continuity be- sound one.
tween brush terminal #1 and
Speed meter ring terminal #1 of slip ring, and
pointer fluctu- Faulty column box.
between brush terminal #4 and
ates. ring terminal #4 of slip ring. NO
Faulty slip ring.

NO
T5-5-56
Check if speed meter YES Faulty N sensor.

works normally when
YES faulty N sensor is re-
placed with a sound one.
Faulty column box.
NO
Broken harness at connection

without continuity.
NO

Speed Meter
Column Box: Connector C (6P)
１ 2 3
4 5 6
Connector (Slip ring end connector terminals seen from

the open end side)
MCBB-01-006
Brush Side Ring Side
1 2 3 4 4 3 2 1
5 6 7 8 8 7 6 5
T5-5-57
MALFUNCTION OF BRAKE OIL PRES-
SURE INDICATOR

hand.
NOTE: Operating conditions of brake remaining

pressure switch:
(Holding pressures of brake circuit be-
tween accumulator charging valve and
brake valve)
ON: 5.2 MPa or lower
OFF: 5.2 to 6.4 MPa
Faulty diode (D18), or broken har-
YES ness between column box and di-
Disconnect column box con- ode (D18).
nector B (9P). Check if voltage
YES at column box connector ter-
minal #7 is 24 V.
Indicator does not Faulty logic circuit in column box.
Check if
go ON even though NO
buzzer
hydraulic pressure
sounds.
in brake circuit Faulty brake remaining pressure
drops. YES switch.
Disconnect brake remaining
Check if voltage at harness end
NO terminal #2 is 24 V. Broken harness between diode
(D18) and brake remaining pres-
NO sure switch.
YES Faulty brake remaining pressure

Disconnect brake remaining switch.
YES Check if voltage at harness
end connector terminal #2 is Short-circuited harness between
24 V. diode (D18) and brake remaining
Indicator goes ON Check if pressure switch.
NO
even in normal op- buzzer
eration. sounds.
YES Short-circuited harness between
connector B terminal #7 and diode
· Engine: Running (D18).
when column box connector B
NO
NO
Column Box: Connector B (9P) Brake Remaining Pressure Switch
１ 2 3
1 2 3
4 5 6
7 8 9
T5-5-58
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 taking wire harnesses
and connectors off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses, and fusible links and, in some
cases, cause fire due to short circuiting.
2. Color coding of wire harnesses. Code Color Code Color
The color codes of the wire harnesses in the R Red W White
electrical system are shown in the table on the L Blue G Green
right. Or Orange Lg Light
In cases on the design sheet where two colors green
are indicated for one wire, the left initial stands Y Yellow B Black
for the base color, while the right initial stands for Br Brown P Pink
the marking color.
Gr Gray V Violet
NOTE: 1) Code BW indicates a black base wire

with white fine-line marking.
2) Initials “O” and “Or” both stand for the
color orange.
3) Wires with longitudinal stripes printed
on them are not color coded. Be sure
not to confuse them with color coded
wires.
T5-6-1
3. Precautions for connecting and disconnecting
terminal connectors.
1) When disconnecting harnesses, grasp them
Right Wrong
by their connectors. Do not pull on the wire
itself. Be sure to release the lock first before
attempting to separate connectors, if a lock
is provided. (Refer to “Instructions for
Disconnecting Connector” on page T5-6-3.)
2) Water-resistant connectors keep water out T107-07-06-001
so that if water enters them, water will not

easily drain from them. When checking
water-resistant connectors, take extra care
not to allow water to enter the connectors. In
case water should enter the connectors,
reconnect only after the connectors are Right
thoroughly dried.
Rust
3) Before connecting terminal connectors,
check that no terminals are bent or coming Wrong
(Deformation)
off. In addition, as most connectors are
made of brass, check that no terminals are Wrong
rusting. (Separation)
4) When connecting terminal connectors T107-07-06-002
provided with a lock, be sure to insert them
together until the lock “clicks.”
5) Pull the harness near the connector to
check if it is correctly connected.
4. Precaution for using a circuit tester.

1) Before using a circuit tester, refer to the
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object
Wind a Piece of Wire Tester Probe
to be measured, voltage range and current
polarity.
2) Before starting the connector test, always
check the connector terminal numbers,
referring to the circuit diagram. Sharpen the end of the Wire
When the connector size is very small, and T107-07-06-003
the standard probe size is too large to be

used for testing, wind a fine piece of
sharpened wire or a pin around the probe to
make the test easier.
T5-6-2
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
• Push to Unlock and Separate Type
NOTE: Most of connectors are “Push to Unlock

and Separate Type”.
NOTE: Connectors will not be easily separated

even if the lock is pushed while being
pulled. Push the lock first before pulling the
connectors.
The lock is located on female side con-
nector (harness end side). T107-04-05-002
• Pull Up to Unlock and Separate Type
Locations of This Type Connector

Starter Relay
T107-04-05-003
• Pull to Separate Type
IMPORTANT: Generally, the solenoid valve con-

nector has a lock. Always pull to
separate the connector only after
unlocking using a tool such as a
pair of needle nose pliers.
Locations of This Type Connector T107-04-05-004

Hydraulic Oil Temperature Sensor
Dr. ZX
T5-6-3
FUSE INSPECTION
Cracks in a fuse are so fine that it is very difficult or NOTE: All terminals located along the lengthwise
impossible to find by visual inspection. Use a tester to centerline of the fuse box are connected to
correctly inspect fuse continuity by following the in- the power source, while terminals located
structions described below. away from the center of the fuse box are
connected to loads (accessories). There-
1. Turn Key Switch ON fore, test all fuses in the same method ex-
When the key switch is turned ON, current from cept for the glow plug relay circuit fuse.
key switch terminal M activates the battery relay Check the glow plug relay circuit fuse with
so that electric power is supplied to all circuits the key switch turned to the ON position
except the glow plug relay circuit. (Refer to the then follow the procedure in step 3.
circuit diagram.)
2. Remove the fuse box cover. Set the tester volt-
age to meet the circuit specification to be meas-
ured. (Measurement Range: 0 to 30 V)
3. Ground the negative probe of the tester to the
vehicle frame. Touch the terminals located away
from the center of the fuse box with the positive
probe of the tester one at a time. When normal
continuity of a fuse is intact, the tester will indi-
cate 20 to 25 V (battery voltage).
T5-6-4
10 20 30 40
9 19 29 39
8 18 38
28
7 17 27 37
26
6 16 36
25
5 15 35
24
4 14 34
23
3 13 33
22
2 12 32
21
1 11 31
M178-07-034 M178-07-034
Fuse Fuse
Capacity Connected to Capacity Connected to
No. No.
1 5A Radio, Monitor, ICX (Backup Power) 21 10 A Right Clearance Light Relay
2 5A MC (Main Power) 22 10 A Head Light Relay (Right-Lower)
3 10 A MC (EC Motor Power) 23 10 A High-Beam Relay
4 10 A MC (Solenoid Valve Power) 24 10 A Flasher Relay, Turn Signal Relay
(Left and Right)
5 5A Monitor 25 15 A Stop Lamp Relay
6 5A MC, ICX (Power ON Signal), Park- 26 10 A Reverse Light (Reverse Light is
ing Brake Relay 3 only available in Japanese do-
mestic market.)
7 5A Air Conditioner Unit 27 10 A Column Box (Power ON Signal)
8 5A Optional 1 28 10 A Starter Relay, Work Brake Indica-
tor Relay, Neutral Signal Relay,
Axle Lock Relay
9 10 A Optional 2 29 10 A Blade/Stabilizer Circuit (Optional)
10 5A Optional 3 30 10 A Assist Circuit (Optional)
11 20 A Work Light Relays 1 and 2 31 10 A Left Clearance Light Relay
12 10 A Wiper Relays A, B-1, B-2 and B-3, 32 10 A Head Light Relay (Left-Lower)
Wiper Motor, Washer Relay
13 20 A Heater (Air Conditioner Unit) 33 10 A Heater Seat (Optional)
14 10 A Horn Relay 34 10 A Seat Compressor (Optional)
15 5A Radio 35 15 A Warning Lamp (Optional)
16 10 A Cigarette Lighter 36 10 A Rear Cab Lamp (Optional)
17 5A Room Lamp 37 10 A Front Cab Lamp (Optional)
18 10 A Auxiliary 38 5A Quick Hitch (Optional)
19 5A QOS Controller, Glow Plug Relay 39 5A Auxiliary 2
20 10 A Parking Brake Relay 1, Travel Motor 40 10 A Auxiliary 3
Alarm Relay, Parking Brake Alarm
Relay, Transistor Units 1 and 2,
Travel Forward/Reverse Pi Cut Re-
lay, Auto-Acceleration Cancel Relay
T5-6-5
FUSIBLE LINK INSPECTION Battery Relay
Inspection
1. Remove the negative cable from the battery.

2. Loosen bolt M8 holding the cable routed in front
of the fusible link box to move the cable out of the
way of the front cover.
3. Visually inspect the fusible link.
Replacement
1. Check that the negative cable is removed from

the battery.
Fusible Link M178-07-049
2. Remove bolt M8 to take the fusible link off the
battery relay.
3. Take out the fusible link to replace it. Fusible Link
4. Install the fusible link box and the cable to the
battery relay.
5. Reconnect the negative cable to the battery.
T1GL-05-06-001
T5-6-6
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between
the battery positive terminal and the vehicle
frame.
Normal Voltage: 24 V
NOTE: If voltage is abnormal, recharge or replace

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

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

system.
T157-07-06-007
T5-6-7
HOW TO TROUBLESHOOT ALTERNATOR
MALFUNCTIONS
In general, the alternator indicator remains off when
the alternator is generating power.
If the alternator indicator comes on while the engine is
running, the alternator might be defective.
How to check the circuit
1. Stop the engine. Turn the key switch to the ON

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

terminals of the alternator. If the measured
voltage is around 24 V, the alternator circuit can
be considered normal. If the measured voltage
is low, a shortage in battery capacity or
looseness of the wire connectors of the alternator
circuit might be the cause of the malfunction.
When the voltage is 0 V, the wiring between the
fuse box and alternator might be loose or E
disconnected.
Also, the alternator cannot generate electricity if
the ground line is disconnected.
3. Next, start the engine and measure the voltage T157-07-06-003

generated while the alternator is rotating.
As described above, measure the voltage
between terminals B and E on the side of the
alternator. If the voltage is around 28 V, the
alternator is operating normally.
If the rated voltage is not being generated, there
is some trouble with the alternator or the regula-
tor.
T5-6-8
(Blank)
T5-6-9
CONTINUITY CHECK
Harness
Single-line continuity check A a
Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is: 0 Ω = Continuity
∞ Ω = Discontinuity
Ω
NOTE: When the one end connector is far apart

from the other, connect one end of Connect to
A a
connector (A) to the machine chassis the vehicle
using a clip. Then, check continuity of the frame.
harness through the vehicle frame as
illustrated.
Connect to
Ω
the vehicle
If the ohm-meter reading is: 0 Ω = Continuity frame.
∞ Ω = Discontinuity
A a
Single-line short-circuit check
Disconnect both end connectors of the harness and × Short-circuit
check continuity between one end connector of the between the
harness and
harness and the vehicle frame: the vehicle
If the ohm-meter reading is: Ω frame.
0 Ω = Short circuit is present.
∞ Ω = No short circuit is present.
T107-07-05-003
T5-6-10
Multi-line continuity check
Disconnect both end connectors of the harness, First short-circuit
and short-circuit two terminals, (A) and (B), at one
end connector, as illustrated. Then, check continuity
A a
between terminals (a) and (b) at the other connector. B b
If the ohm-meter reading is ∞ Ω, either line (A) - (a), C c
or (B) - (b) is in discontinuity. To find out which line
is discontinued, conduct the single line continuity Second short-circuit
check on both lines individually, or, after changing
the short-circuit terminals from (A) - (B) to (A) - (C),
check continuity once more between terminals (a)
Ω
and (c).
NOTE: By conducting the multi-line continuity T107-07-05-004

check twice, it is possible to find out which
line is discontinued. With terminals (A) and
(C) short-circuited, check continuity
between terminals (a) and (c).
If the ohm-meter reading is:
0 Ω = Line (B) - (b) has discontinuity.
∞ Ω = Line (A) - (a) has discontinuity. Short-circuit between harnesses.
Multi-line short-circuit check A a

×
Disconnect both end connectors of the harness, B b
C c
and check continuity between terminals (A) and (B)
or (C).
If the ohm-meter reading is:
0 Ω = Short-circuit exists between the lines.
∞ Ω = No short-circuit exists between the lines.
Ω
T107-07-05-005
T5-6-11
(Blank)
T5-6-12
VOLTAGE AND CURRENT MEASURE-
MENT
Turn key switch ON so that the specified voltage (cur-
rent) is supplied to the location to be measured.
Judge if the circuit is normal by evaluating whether
the measured voltage (current) matches the specifica-
tion.
24-Volt Circuit
Start checking the circuit in order up to the loca-
tion to be measured from either power source or
actuator side. Thereby, the faulty location in the
circuit will be found.
Black Probe (Minus) of Tester : To ground to the vehi-
cle frame
Red Probe (Plus) of Tester : To touch the location
to be measured
T5-6-13
Engine Key Switch Location to be Measured Specification

Power Source
Circuit
Stopped OFF Between (2) and (1): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (2): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (1): Two Batteries 20 to 25 V
Stopped OFF Between (4) and Ground: Battery Power 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 ON or START Between (6) and Ground: Key Switch 20 to 25 V
Stopped ON or START 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 (12) and Ground: Starter (C) 20 to 25 V
Started START Between (13) and Ground: Starter Relay (S) 20 to 25 V
Charging Circuit
Fast Speed ON Between (14) and Ground: Alternator (B) / Generating 26 to 30 V
Voltage
Fast Speed ON Between (10) and Ground: Battery Relay / Generating 26 to 30 V
Voltage
Fast Speed ON Between (15) and Ground: Fuse Box / Starter Relay (R) / 26 to 30 V
Generating Voltage
Fast Speed ON Between (16) and Ground: Generating Voltage 13 to 30 V
Fast Speed ON Between (17) and Ground: Monitor 13 to 30 V
Surge Voltage
Prevention Circuit
Slow Idle ON Between (14) and Ground: Alternator (B) 26 to 30 V
Slow Idle ON Between (16) and Ground: Starter Relay (R) 13 to 30 V
Slow Idle ON Between (18) and Ground: Load Damp Relay 26 to 30 V
Slow Idle ON Between (10) and Ground: Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (19) and Ground: Auxiliary 20 to 25 V
Stopped ON Between (20) and Ground: Room light 20 to 25 V
Stopped ON Between (21) and Ground: Lighter 20 to 25 V
Stopped ON Between (22) and Ground: Radio 20 to 25 V
Stopped ON Between (23) and Ground: Horn 20 to 25 V
Stopped ON Between (9) and Ground: Battery Relay 20 to 25 V
NOTE: *Measure after disconnecting the negative

cable from the battery.
T5-6-14
Key Switch
Battery
6 8
1 2 3 5 4 9
15
Battery Relay
Fuse
10 Box
Starter
18 Load
Damp
Relay
11
12 23 22 21 20 19 17
13 Monitor
Starter Relay
16
Alternator
Glow
Plug
Relay
14
Glow Plug
T178-05-06-001
T5-6-15
5 Voltage Circuit
Power Signal or
• Voltage between terminal #1 and the vehicle Two Polarities Source Ground
frame (ground) 1 2
With the key switch turned OFF, disconnect the
sensor connector.
Measure the voltage between terminal #1 on the
machine harness side connector and the vehicle
(ground) under the following conditions.
V
• Key switch position: ON
• Tester black terminal (negative):
Connected to the vehicle (ground)
• Tester red terminal (positive):
T107-07-05-006
Connected to terminal #1
Power
Three Polarities
Source Signal Ground
Evaluation: 1 2 3
If the measuring voltage is within 5±0.5 volts, the
circuit up to terminal #1 is normal.
• Voltage between terminal #1 and the ground T107-07-05-007
terminal
With the key switch turned OFF, disconnect the Two Polarities
1 2
sensor connector.
Measure the voltage between terminal #1 on the
machine harness side connector and the ground
terminal (terminal #2 for two polarities, or terminal
#3 for three polarities) under the following V
conditions.
• Key switch position: ON

• Tester black terminal (negative):
Connected to the ground terminal
(terminal #2 or 3) T107-07-05-008
• Tester red terminal (positive):
Connected to terminal #1 Three Polarities
1 2 3
Evaluation:
If the measuring voltage is within 5±0.5 volts, the
circuit up to terminal #1 or the ground terminal is
normal.
V
T107-07-05-009
T5-6-16
CHECK BY FALSE SIGNAL
Two Polarities
Turn the key switch OFF. After disconnecting the sen- (Hydraulic Oil
sor connector, turn the key switch ON. Then, connect Temperature Sensor)
(Fuel Sensor) 1 2
machine side harness end connector terminal #1 (N Sensor)
(power) to terminal #2 (signal). (Power voltage is used
as a false signal.) Check the controller using Dr. ZX
monitor function under this condition. When the
maximum value is displayed, the MC and the circuit
up to the machine side harness end connector are
normal. When the pressure switch circuits are normal, Connect
Dr. ZX displays “ON”.
IMPORTANT: Don’t connect terminal #1 or #2 to

terminal #3 or to the vehicle frame Three Polarities
T107-07-05-010
(ground) when checking a

three-polarity connector. (Pressure Sensor)
(Pump Delivery Pressure Sensor)
(Pump Control Pressure Sensor) 1 2 3
NOTE: Some kinds of sensors can be monitored (Travel Motor Drain Pressure
Sensor)
by the built-in diagnosing system. (Refer to (Service Brake Pressure Sensor)
the TROUBLESHOOTING / General (EC Sensor)
group.)
Connect
T107-07-05-011
T5-6-17
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).
To Location to be Measured.
During Operation: Lamp is ON. To Ground
T107-07-05-012
Parts Number (ST 7226)

Use to check the solenoid valve unit circuits.
When the corresponding control lever or switch is 4
operated: Lamp is ON. 3 50
(Refer to T5-4-60, 74 and 96.) 150 50 50
1 2 2 1
T107-07-06-015

Use to check the EC motor circuit.
(Refer to T5-4-42 and 46.) 5
6
50
• EC Motor Circuit
When the engine control dial is rotated: 1 2 2 1
150 50
Both lamps ON: Normal 50
Only one lamp ON: Check for continuity of the 4 3 4 3
circuit connected to the lamp OFF. 7 50
Both lamps OFF: Check the harness together 8
with the relay.
Parts Number 4274589 (ST 7125) T107-07-06-024
T5-6-18
Use to measure the EC sensor circuit signal line
voltage (between terminals #2 and #3).
(Red)
(Refer to T5-3-4.)
(Black)
Parts Number 4284347 (ST 7129) T107-07-03-009

Use to check the wiper circuit. 2
5 1
(Refer to T5-4-98.)
2 4 7
1
Parts Number (ST 7227) T178-05-06-003
T5-6-19
(Blank)
T5-6-20
TROUBLESHOOTING / ICX
OUTLINE
The ICX (information controller) stores signals from
various kinds of sensors and switches provided on the
machine as data. The various input signals are
grouped into “Daily Report Data List”, “Frequency Dis-
tribution Data List”, “Cumulative Operation Hour List”,
“Alarm List”, and “Trouble List” and are recorded in
the ICX.
Data stored in the ICX is downloadable by the PALM.

This data, after being uploaded to a personal com-
puter, can be read with the “data-viewer”, a data read-
ing software. Using the HAU from e-Service, the data
can be uploaded to a server to which customers,
distributor and Hitachi are accessible.
T5-7-1
Daily Report Data List
Data Details
1 Key Switch ON Time Time when key switch is first turned ON during daily operation
(Time is recorded by key switch ON signal.)
2 Key Switch OFF Time Time when key switch is last turned OFF during daily operation
(Time is recorded by key switch ON signal.)
3 Engine Start Time Time when engine is first started during daily operation
(Time is recorded by alternator output signal.)
4 Engine Stop Time Time when engine is last stopped during daily operation
(Time is recorded by alternator output signal.)
5 Hour Meter Hour meter cumulative hours
(Hours are recorded by hour meter signal from monitor.)
6 Remaining fuel level Remaining fuel level at the end of daily operation (Level is re-
corded by fuel sensor signal from monitor.)
7 Engine Operating Hours Total engine operating hours during daily operation
(Hours are recorded by alternator output signal.)
8 Travel Operating Hours Total travel operating hours during daily operation
(Hours are recorded by signals from travel pressure sensor.)
9 Front Attachment Operating Hours Total front attachment operating hours during daily operation
(Hours are recorded by signals from front attachment pressure
sensor.)
10 *ML Operating Hours Total *ML crane operating hours during daily operation
(Hours are recorded by signals from crane mode switch.)
11 Engine Operating Hour Distribution Engine operating hour distribution during daily operation
(Operating hours are recorded only when alternator output sig-
nal is continuously delivered for more than 10 minutes.)
NOTE: The daily operation in this table is equiva-

lent to the hours between 0:00 and
23:59:59 counted by the ICX built-in clock.
In case the engine is kept operated be-
yond 0:00, such data are recorded as
those for the following day.
* ML/ML crane specification is only avail-

able in Japanese domestic market.
T5-7-2
Frequency Distribution Data List
Data Details
1 Coolant Temperature in Radiator Frequency distribution of coolant temperature
(Temperatures are recorded by signals from coolant tempera-
ture sensor.)
Cumulative Operation Hour List
Data Details
1 Engine Operation Hour Cumulative engine operation hours
(Hours are recorded by alternator output signal.)
2 Travel Operation Hour Cumulative travel operation hours
(Hours are recorded by signals from travel pressure sensor.)
3 Front Attachment Operation Hour Cumulative front attachment operation hours
(Hours are recorded by signals from front attachment pressure
sensor.)
4 *ML Operation Hour Cumulative *ML operation hours
(Hours are recorded by signals from crane mode switch.)
NOTE: * ML specification is only available in Japa-

nese domestic market.
T5-7-3
Alarm List
Code Data Details

86 Hydraulic Oil Filter Date and time when hydraulic oil filter indicator lighted are recorded
by signals from hydraulic oil filter restriction switch.
89 Overheat Date and time when overheat indicator lighted are recorded by sig-
nals from overheat switch.
90 Engine Oil Pressure Date and time when engine oil pressure indicator lighted are re-
corded by signals from engine oil pressure switch.
93 Air Filter Restriction Date and time when air filter restriction indicator lighted are re-
corded by signals from air filter restriction switch.
94 Alternator Indicator Date and time when alternator indicator lighted are recorded by sig-
nals from monitor controller.
NOTE: In case the above alarms are recorded,

check individual item. If malfunction of the
monitor is found, refer to troubleshooting
C.
T5-7-4
Trouble List
Fault
Trouble Details
Code
01 Abnormal EEPROM Occurrence time and date of fault code 01
02 Abnormal RAM Occurrence time and date of fault code 02
03 Abnormal A/D Conversion Occurrence time and date of fault code 03
04 Abnormal Sensor Voltage Occurrence time and date of fault code 04
06 Abnormal EC Sensor Occurrence time and date of fault code 06
07 Abnormal Engine Control Dial Occurrence time and date of fault code 07
18 Abnormal Travel Lever Stroke Occurrence time and date of fault code 18
64 MC Communication Error Time and date when communication error between MC
and ICX occurred.
65 Monitor Communication Error Time and date when communication error between
monitor and ICX occurred.
66 Satellite Terminal Communication Error Time and date when communication error between sat-
ellite terminal and ICX occurred.
NOTE: In case the above fault codes are re-

corded, refer to troubleshooting A.
T5-7-5
ICX FAULT CODE LIST
Fault
Trouble Remarks
Code
1 Abnormal Internal Ram In case of SAM error
2 Abnormal Flush Memory In case of SAM error
3 Abnormal Exterior In case of SAM error or read-write error
4 Abnormal EEPROM In case of SAM error
5 Overwritten Data Save Area In case data save area was overwritten.
6 Abnormal Time In case RTC data was other than figures.
7 MC Communication Timeout In case MC communication lasted for less than 100 ms.
8 Monitor Communication Timeout In case monitor communication didn’t last for more than
12 seconds.
9* MC Communication Timeout In case MC communication didn’t last for more than 20
seconds.
10 Satellite Terminal Communication Timeout In case satellite communication didn’t last for more than
20 seconds.
NOTE: *Fault code 9 may be displayed on only

the machine to which the ICX is installed
later.
SATELLITE TERMINAL FAULT CODE LIST
Fault
Trouble Remarks
Code
101 Satellite Terminal: Internal Error Abnormal EEPROM
102 Satellite Terminal: Internal Error Abnormal sent data
103 Satellite Terminal: Internal Error In case reception is difficult.
104 Satellite Terminal: Communication Error In case satellite communication cannot be accom-
plished.
105 Satellite Terminal: Internal Error In case sending retry over occurred or local loop back
test failed with power ON.
106 Satellite Terminal: Communication Error In case sending retry over occurred.
107 Satellite Terminal: Abnormal Harness In case reception data doesn’t match sending data.
T5-7-6
FAULT CODE 1 TO 6
YES Faulty ICX
Check if all data are normally

cumulated.
Faulty ICX
NO
* Even if the fault code remains displayed after retry-

ing, the machine can be operated as it is when data
record is normally cumulated.
FAULT CODE 7 TO 10
YES Faulty ICX

Check for continuity between
ICX and corresponding com-
ponent while referring to the
following table.
Broken harness between ICX
and corresponding compo-
NO nent.
Fault Code ICX terminal # Corresponding component terminal #

7 Connector C terminal #11 MC connector D terminal #10
8 Connector C terminal #1 Monitor connector B terminal #3
10 Connector B terminal #5 Satellite terminal #2
T5-7-7
SOME PARTS OF DATA IN DAILY REPORT,
FREQUENCY DISTRIBUTION, CUMULA-
TIVE OPERATION HOURS ARE NOT RE-
CORDED
• All necessary data signals may not be input into
the ICX. Individual signals are utilized to record
more than one data. While referring to the table
below, check the corresponding system for any
abnormality.
Related Data Input Signal

Key switch ON and OFF time Key switch
Engine start and stop time, Engine operating hours (Daily report and cu- Alternator
mulative operation hour), Engine operating hour distribution
Hour meter Monitor controller
Coolant temperature distribution in radiator Coolant temperature sensor
Remaining fuel level (detected at regular data sending time) Fuel level sensor
Travel operating hours (Daily report and cumulative operation hour), Av- Travel pressure sensor
erage pump delivery pressure distribution in travel operation
Front attachment operating hours (Daily report and cumulative operation Front attachment pressure sensor
hour)
*ML operating hours (Daily report and cumulative operation hour) Crane mode switch
NOTE: *ML specification is available only in Japa-

nese domestic market.
T5-7-8
Corrective Action Remarks

Check harness between ICX terminal A5 and key In case engine doesn’t start, refer to troubleshooting B.
switch terminal M.
Check harness between ICX terminal A2 and alterna- In case alternator indicator malfunctions, refer to trou-
tor terminal L. bleshooting C.
Check harness between ICX terminal B1 and monitor In case hour meter malfunctions, refer to trouble-
terminal B3. shooting C.
Check harness between ICX terminal B1 and monitor In case coolant temperature gauge malfunctions, refer
terminal B3. to troubleshooting C.
Check harness between ICX terminal B1 and monitor In case fuel gauge malfunctions, refer to troubleshoot-
terminal B3. ing C.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
T5-7-9
DOWNLOADING FROM AND UPLOADING
TO THE ICX
The data stored in the ICX is downloadable by the
PALM using the “MIC Download” program or the “Dr.
ZX” program. Downloading using each program as
well as uploading to a PC are explained below. For
uploading of the downloaded data to a server using
the e-Service, refer to the “e-Service Manual”.
T5-7-10
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:

PUBLICATION NO.:
YOUR NAME: (Located at the right top corner in the cover page)
DATE: PAGE NO.:

(Located at the bottom center in the page. If two or more revi-
FAX: sions are requested, use the comment column)
YOUR COMMENTS / SUGGESTIONS:

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

THE ATTACHED DIAGRAM LIST
(The following diagrams are attached to this manual.)
ZAXIS130W/160W/180W/210W ELECTRICAL CIRCUIT DIAGRAM (ALL)
ZAXIS130W/160W/180W/210W ELECTRICAL CIRCUIT DIAGRAM (OVERLOAD ALARM)
ZAXIS130W/160W/180W/210W ELECTRICAL CIRCUIT DIAGRAM (BLADE/STABILIZER)
ZAXIS130W/160W/180W/210W CONNECTORS
ZAXIS130W/160W/180W/210W CAB HARNESS
ZAXIS130W ENGINE HARNESS
ZAXIS130W/160W/180W/210W MONITOR HARNESS
ZAXIS130W CHASSIS HARNESS
ZAXIS130W/160W/180W/210W BLADE/STABILIZER HARNESS
ZAXIS130W/160W/180W/210W OVERLOAD ALARM-1 HARNESS
ZAXIS130W/160W/180W/210W OVERLOAD ALARM-2 HARNESS
ZAXIS130W HYDRAULIC CIRCUIT DIAGRAM (STANDARD)
ZAXIS130W HYDRAULIC CIRCUIT DIAGRAM (FULL OPTION)

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INTRODUCTION

• Each page has a number, located on the center

Consecutive Page Number for Each Group

SAFETY ALERT SYMBOL AND HEADLINE

• This is the SAFETY ALERT SYMBOL.

UNDERSTAND SIGNAL WORDS

• CAUTION also calls attention to safety messages in

• NOTE indicates an additional explanation for an

• Carefully read and follow all safety signs on the

to operate the machine.

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

posted near your telephone.

WEAR PROTECTIVE CLOTHING

Be sure to wear the correct equipment and clothing

• Prolonged exposure to loud noise can cause

• Before entering the cab, thoroughly remove all

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

ADJUST THE OPERATOR'S SEAT

• If the machine should overturn, the operator may

securely fastened at all times when the machine

MOVE AND OPERATE MACHINE SAFELY

• Battery gas can explode, resulting in serious injury.

• Riders on machine are subject to injury such as

PROVIDE SIGNALS FOR FOBS INVOLV-

• For jobs involving multiple numbers of machines,

CONFIRM DIRECTION OF MACHINE TO

• Incorrect steering wheel shift lever operation may

• Before driving the machine, always confirm that the

• Driving on a slope may cause the machine to slip or

• Driving across the face of a slope or steering on

To avoid back-over and swing accidents:

MACHINE WILL TIP OVER FASTER THAN YOU

FASTEN YOUR SEAT BELT

• The danger of tipping is always present when

• Reduce swing speed as necessary when

• Serious injury or death can result if the machine or

• If a lifted load should fall, any person nearby may

• If flying debris hit eyes or any other part of the body,

PARK MACHINE SAFELY

the catch, so that the left console can be moved

• Handle fuel with care; it is highly flammable. If fuel

• All fuels, most lubricants, and some coolants are

• Store flammable fluids well away from fire

• The danger of tipping is present when

Take the following precautions when load-

Place blocks in front of and behind the tires to

• Understand service procedures before doing

• Before servicing the machine:

inside the machine.

• Unexpected machine movement can cause serious

SUPPORT MACHINE PROPERLY

STAY CLEAR OF MOVING PARTS

• Travel reduction gears are under pressure.

STORE ATTACHMENTS SAFELY

SUPPORT MAINTENANCE PROPERLY

• Never cut or weld on an inflated tire or rim as-

• The hydraulic oil tank is pressurized. Again, be

Hot fluids and surfaces:

REPLACE RUBBER HOSES

attachment to fall on a person nearby, which may

• Fluids such as diesel fuel or hydraulic oil under

goggles for eye protection.

Check for Shorts: