EX1200 5D Troubleshooting

INTRODUCTION
TO THE READER
This manual is written for an experienced technician
to provide technical information needed to maintain

and repair this machine.
Be sure to thoroughly read this manual for correct product information and service procedures.
If you have any questions or comments, at if you

found any errors regarding the contents of this
manual, please contact using Service Manual
Revision Request Form at the end of this manual.
(Note: Do not tear off the form. Copy it for usage.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7173
FAX: 81-29-831-1162
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition
to this manual.
The Operators Manual

The Parts Catalog
Operation Manual of the Engine

Parts Catalog of the Engine
Hitachi Training Material
MANUAL COMPOSITION
This manual consists of three portions: the Techni-
Information included in the Technical Manual

(Troubleshooting):
technical information needed for operational performance tests, and troubleshooting procedures.
Information included in the Technical Manual

(Operational Principle):
technical information needed for redelivery and
delivery, operation and activation of all devices
and systems.
Information included in the Workshop Manual:

technical information needed for maintenance
and repair of the machine, tools and devices
needed for maintenance and repair, maintenance
standards, and removal/installation and assemble/disassemble procedures.
cal Manual (Operational Principle), the Technical

Manual (Troubleshooting) and the Workshop Manual.
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
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the
potential for personal injury of machine damage.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting
heavy parts.
CAUTION:
Indicated potentially hazardous situation which
could, if not avoided, result in personal injury or
death.
IMPORTANT:
Indicates a situation which, if not conformed to the

instructions, could result in damage to the machine.
IN-02
NOTE:
Indicates supplementary technical information or
know-how.
INTRODUCTION
UNITS USED
Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
SI Units (International System of Units) are used in

this manual.
MKSA system units and English units are also
indicated in parenthheses just behind SI units.
Quantity
Length
Volume
Weight
Force
Torque
To Convert
From
mm
mm
L
L
m3
kg
N
N
Nm
Nm
Into
in
ft
US gal
US qt
yd3
lb
kgf
lbf
kgfm
lbfft
A table for conversion from SI units to other system

units is shown below for reference purposees.
Quantity
Multiply By
0.03937
0.003281
0.2642
1.057
1.308
2.205
0.10197
0.2248
1.0197
0.7375
Pressure
Power
Temperature
Velocity
Flow rate
IN-03
To Convert
From
MPa
MPa
kW
kW
C
km/h
min-1
L/min
mL/rev
Into
kgf/cm2
psi
PS
HP
F
mph
rpm
US gpm
cc/rev
Multiply By
10.197
145.0
1.360
1.341
C1.8+32
0.6214
1.0
0.2642
1.0
INTRODUCTION
(Blank)
IN-04
SAFETY
RECOGNIZE SAFETY INFORMATION
These are the SAFETY ALERT SYMBOLS.
When you see these symbols on your machine or in
this manual, be alert to the potential for personal injury.
Follow recommended precautions and safe operating

practices.
SA-688
001-E01A-0001
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 dont use any of the designated

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

manual.
To avoid confusing machine protection with personal
safety messages, a signal word IMPORTANT indicates

a situation which, if not avoided, could result in damage
to the machine.
NOTE indicates an additional explanation for an

element of information.
002-E01A-1223
SA-1
SA-1223
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 authorized dealer in
the same way you order other replacement parts (be
sure to state machine model and serial number when
ordering).
SA-003
Learn how to operate the machine and its controls correctly and safely.
Allow only trained, qualified, authorized personnel to

operate the machine.
Keep your machine in proper working condition.

Unauthorized modifications of the machine may impair its function and/or safety and affect machine life.
The safety messages in this SAFETY chapter are in-
tended to illustrate basic safety procedures of machines.

However it is impossible for these safety messages to
cover every hazardous situation you may encounter. If
you have any questions, you should first consult your
supervisor and/or your authorized dealer before operating or performing maintenance work on the machine.
003-E01B-0003
PREPARE FOR EMERGENCIES

Be prepared if a fire starts or if an accident occurs.
Keep a first aid kit and fire extinguisher on hand.
Thoroughly read and understand the label attached
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, ambulance

service, hospital, and fire department posted near
your telephone.
004-E01A-0437
SA-2
SA-437
SAFETY
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment appropriate to the job.
You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing for
the job. Do not take any chances.
SA-438
Avoid wearing loose clothing, jewelry, or other items

that can catch on control levers or other parts of the
machine.
Operating equipment safely requires the full attention of

the operator. Do not wear radio or music headphones
while operating the machine.
005-E01A-0438
PROTECT AGAINST NOISE

Prolonged exposure to loud noise can cause impairment
or loss of hearing.
Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable
or uncomfortably loud noises.
SA-434
006-E01A-0434
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 operators manual.
007-E01A-0435
SA-3
SA-435
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 operators work boots
the operators foot may slip off the pedal, possibly resulting in a personal accident.
Dont leave parts and/or tools lying around the operators seat. Store them in their specified locations.
Avoid storing transparent bottles in the cab. Dont 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 extinguish

the match and/or tobacco.
Dont leave cigarette lighters in the cab. When the

temperature in the cab increases, the lighter may explode.
524-E01A-0000
SA-4
SAFETY
USE HANDHOLDS AND STEPS
Falling is one of the major causes of personal injury.
When you get on and off the machine, always face
the machine and maintain a three-point contact with
the steps and handrails.
Do not use any controls as handholds.

Never jump on or off the machine. Never mount or
dismount a moving machine.
Be careful of slippery conditions on platforms, steps,

SA-439
and handrails when leaving the machine.
008-E01A-0439
ADJUST THE OPERATORS 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.
009-E01A-0378
SA-5
SA-378
SAFETY
FASTEN YOUR SEAT BELT
If the machine should overturn, the operator may be-
come 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 securely

fastened at all times when the machine is in operation
to minimize the chance of injury from an accident.
SA-237
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.
011-E01A-0426
SA-6
SA-426
SAFETY
OPERATE ONLY FROM OPERATORS SEAT
Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury
or death.
Start the engine only from the operators 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 lev-
SA-444
ers are in neutral.

012-E01B-0444
JUMP STARTING
Battery gas can explode, resulting in serious injury.
If the engine must be jump started, be sure to follow
the instructions shown in the OPERATING THE ENGINE chapter in the operator's manual.
The operator must be in the operators 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.
SA-032
Failure to follow correct jump starting procedures

could result in a battery explosion or a runaway machine.
S013-E01A-0032
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 allow the operator on the machine. Keep riders

off.
Riders also obstruct the operators view, resulting in

the machine being operated in an unsafe manner.
SA-379
014-E01B-0379
SA-7
SAFETY
INVESTIGATE JOB SITE BEFOREHAND
When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting
in serious injury or death.
Investigate the configuration and ground conditions of

the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles, or banks
from collapsing.
Make a work plan. Use machines appropriate to the

work and job site.
Reinforce ground, edges, and road shoulders as nec-
SA-380
essary. Keep the machine well back from the edges

of excavations and road shoulders.
When working on an incline or on a road shoulder,

employ a signal person as required.
Confirm that your machine is equipped a FOPS cab

before working in areas where the possibility of falling
stones or debris exist.
When the footing is weak, reinforce the ground before

starting work.
When working on frozen ground, be extremely alert.

As ambient temperatures rise, footing becomes loose
and slippery.
Beware the possibility of fire when operating the machine near flammable objects such as dry grass.
015-E01A-0380
PROTECT AGAINST FALLING STONES AND

DEBRIS
Confirm that your machine is FOPS cab equipped
before working in areas where the possibility of falling
stones or debris exist.
SA-490
015-E01A-0380
SA-8
SAFETY
PROVIDE SIGNALS FOR JOBS INVOLVING
MULTIPLE NUMBERS OF MACHINES
For jobs involving multiple numbers of machines, pro-
vide signals commonly known by all personnel involved.

Also, appoint a signal person to coordinate the job site.
Make sure that all personnel obey the signal persons
directions.
018-E01A-0481
SA-481
CONFIRM DIRECTION OF MACHINE TO BE

DRIVEN
Incorrect travel pedal/lever operation may result in serious injury death.
Before driving the machine, confirm the position of the

undercarriage in relation to the operators 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.
SA-491
017-E01A-0491
SA-9
SAFETY
DRIVE MACHINE SAFELY
Before driving the machine, always confirm that the
travel levers/pedals direction corresponds to the direction you wish to drive.
Be sure to detour around any obstructions.

Avoid traveling over obstructions. Soil, fragments of
rocks, and/or metal pieces may scatter around the
machine. Dont allow personnel to stay around the
machine while traveling.
SA-387
Driving on a slope may cause the machine to slip or
overturn, possibly resulting in serious injury or death.
When driving up or down a slope, keep the bucket

facing the direction of travel, approximately 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-388
SA-441
Driving across the face of a slope or steering on a

slope may cause the machine to skid or turnover. If
the direction must be changed, move the machine to
level ground, then, change the direction to ensure
safe operation.
SA-589
019-E01C-0492
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 machine.
Do not park the machine on a grade.

Lower the bucket and/or other work tools to the
ground.
Turn the auto-idle switch and the H/P mode switch off.
SA-391
Run the engine at slow idle speed without load for 5

minutes to cool down the engine.
Stop the engine and remove the key from the key
switch.
Pull the pilot control shut-off lever to LOCK position.

Block both tracks and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must
park on a grade.
Position the machine to prevent rolling.

Park a reasonable distance from other machines.
SA-392
020-E02A-0493
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

equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING
INTO THE WORK AREA. USE THE HORN OR
OTHER SIGNAL TO WARN BYSTANDERS BEFORE
MOVING MACHINE.
SA-383
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 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

operators manual.
021-E01A-0494
SA-12
SA-384
SAFETY
KEEP PERSON CLEAR FROM WORKING
AREA
A person may be hit severely by the swinging front attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.
Keep all persons clear from the area of operation and

machine movement.
Before operating the machine, set up barriers to the

sides and rear area of the bucket swing radius to prevent anyone from entering the work area.
SA-386
022-E01A-0386
NEVER POSITION BUCKET OVER ANYONE

Never lift, move, or swing bucket above anyone or a
truck cab.
Serious injury or machine damage may result due to
bucket load spill or due to collision with the bucket.
023-E01A-0487
SA-487
AVOID UNDERCUTTING
In order to retreat from the edge of an excavation if the
footing should collapse, always position the undercarriage perpendicular to the edge of the excavation with
the travel motors at the rear.
If the footing starts to collapse and if retreat is not

possible, do not panic. Often, the machine can be
secured by lowering the front attachment, in such
cases.
SA-488
024-E01A-0488
SA-13
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.
To avoid tipping:
SA-012
Be extra careful before operating on a grade.

Prepare machine operating area flat.
Keep the bucket low to the ground and close to the
machine.
Reduce operating speeds to avoid tipping or slipping.

Avoid changing direction when traveling on grades.
NEVER attempt to travel across a grade steeper than
15 degrees if crossing the grade is unavoidable.
Reduce swing speed as necessary when swinging

loads.
SA-440
Be careful when working on frozen ground.

Temperature increases will cause the ground to become soft and make ground travel unstable.
025-E01B-0495
NEVER UNDERCUT A HIGH BANK

The edges could collapse or a land slide could occur
causing serious injury or death.
SA-489
026-E01A-0489
SA-14
SAFETY
DIG WITH CAUTION
Accidental severing of underground cables or gas lines
may cause an explosion and/or fire, possibly resulting in

serious injury or death.
Before digging check the location of cables, gas lines,

and water lines.
Keep the minimum distance required, by law, from

cables, gas lines, and water lines.
If a fiber optic cable should be accidentally severed,

do not look into the end. Doing so may result in serious eye injury.
SA-382
Contact your local diggers hot line if available in

your area , and/or the utility companies directly.
Have them mark all underground utilities.
027-E01A-0382
OPERATE WITH CAUTION

If the front attachment or any other part of the machine
hits against an overhead obstacle, such as a bridge,
both the machine and the overhead obstacle will be
damaged, and personal injury may result as well.
Take care to avoid hitting overhead obstacles with the

boom or arm.
028-E01A-0389
SA-389
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 plus
twice the line insulator length.
Check and comply with any local regulations that may

apply.
Wet ground will expand the area that could cause any
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site.
SA-381
029-E01A-0381
SA-15
SAFETY
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.
SA-014
Move the load slowly and carefully. Never move it

suddenly.
Keep all persons will away from the load.

Never move a load over a persons head.
Do not allow anyone to approach the load until it is
safely and securely situated on supporting blocks or
on the ground.
Never attach a sling or chain to the bucket teeth. They

may come off, causing the load to fall.
030-E01A-0014
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-16
SA-432
SAFETY
PARK MACHINE SAFELY
To avoid accidents:
Park machine on a level surface.
Lower bucket to the ground.

Turn auto-idle switch and H/P mode switch off.
Run engine at slow idle speed without load for 5 minutes.
Turn key switch to OFF to stop engine.

Remove the key from the key switch.
Pull the pilot control shut-off lever to the LOCK posi-
SA-390
tion.
Close windows, roof vent, and cab door.

Lock all access doors and compartments.
033-E08B-0390
HANDLE FLUIDS SAFELYAVOID FIRES

Handle fuel with care; it is highly flammable. If fuel ig-
nites, 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.
SA-019
034-E01A-0496
SA-17
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
Understand service procedures before doing work.
Keep the 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.
SA-028
2. Lower the bucket to the ground.

3. Turn the auto-idle switch 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.
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 of this manual.
Keep all parts in good condition and properly installed.
Fix damage immediately. Replace worn or broken

parts. Remove any buildup of grease, oil, or debris.
When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as
fuel oil and gasoline to clean parts or surfaces.
Disconnect battery ground cable() before making

adjustments to electrical systems or before performing welding on the machine.
500-E02B-0497
SA-18
SA-527
SAFETY
Sufficiently illuminate the work site. Use a maintenance work light when working under or 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.
SA-037
WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause serious injury.
Before performing any work on the machine, attach a

Do Not Operate tag on the control lever.
This tag is available from your authorized dealer.
501-E01A-0287
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 jack.
SA-527
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-19
SAFETY
PREVENT PARTS FROM FLYING
Grease in the track adjuster is under high pressure.
Failure to follow the precautions below may result in serious injury, blindness, or death.
Do not attempt to remove GREASE FITTING or

VALVE ASSEMBLY.
As pieces may fly off, be sure to keep body and face

away from valve.
Travel reduction gears are under pressure.
SA-344
As pieces may fly off, be sure to keep body and face

away from AIR RELEASE PLUG to avoid injury.
GEAR OIL is hot.
Wait for GEAR OIL to cool, then gradually loosen AIR

RELEASE PLUG to release pressure.
503-E01B-0344
STORE ATTACHMENTS SAFELY

Stored attachments such as buckets, hydraulic ham-
mers, and blades can fall and cause serious injury or

death.
Securely store attachments and implements to prevent falling. Keep children and bystanders away from
storage areas.
SA-034
504-E01A-0034
SA-20
SAFETY
PREVENT BURNS
Hot spraying fluids:
After operation, engine coolant is hot and under pres-
sure. 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
SA-225
any maintenance or inspection work.

505-E01B-0498
REPLACE RUBBER HOSES PERIODICALLY

Rubber hoses that contain flammable fluids under pres-
sure 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 operators
manual).
Failure to periodically replace rubber hoses may cause

a fire, fluid injection into skin, or the front attachment to
fall on a person nearby, which may result in severe
burns, gangrene, or otherwise serious injury or death.
S506-E01A-0019
SA-21
SA-019
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
SA-031
to protect hands and body from high-pressure fluids.

Wear a face shield or goggles for eye protection.
If an accident occurs, see a doctor familiar with this

type of injury immediately. Any fluid injected into the
skin must be surgically removed within a few hours or
gangrene may result.
SA-292
507-E03A-0499
SA-22
SA-044
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.
SA-019
Never install bent or damaged lines, pipes or hoses.

Check for Shorts:
Short circuits can cause fires.
Clean and tighten all electrical connections.

Check before each shift or after eight (8) to ten (10)
hours operation for loose, kinked, hardened or frayed
electrical cables and wires.
Check before each shift or after eight (8) to ten (10)

hours operation for missing or damaged terminal
caps.
DO NOT OPERATE MACHINE if cable or wires are

loose, kinked, etc..
Clean up Flammables:
Spilled fuel, oil, antifreeze fluid and window washer fluid,
and trash, grease, debris, accumulated coal dust, and
other flammables may cause fires.
Prevent fires by inspecting and cleaning the machine

daily, and by removing spilled or accumulated flammables immediately.
Check Key Switch:
If fire breaks out, failure to stop the engine will escalate
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.
508-E02B-0019
SA-23
SAFETY
Check Emergency Engine Stop Switch:
If a fire breaks out, failure to release pressurized air inside the hydraulic tank will escalate fire, hampering fire
fighting.
Check the emergency engine stop switch function
every 250 hours:
1)
Start the engine and run it at slow Idle.
2)
Turn the emergency engine stop switch to the

EMERG. STOP position.
3)
Confirm that both engines stop and that pressurized air inside the hydraulic oil tank is released (a
hissing sound should be heard).
If any abnormalities are found, be sure to repair them

before operating the machine.
Check Heat Shields:
Damaged or missing heat shield may lead to fires.
Damaged or missing heat shields must be repaired or
replaced before operating the machine.
508-E02A-0393
EVACUATING IN CASE OF FIRE

If a fire breaks out, evacuate the machine in the following way:
Stop the engine by turning the key switch to the OFF

position if there is time.
Use a fire extinguisher if there is time.

Exit the machine.
In an emergency, if the cab door or front window can not
be opened, break the front or rear window panes with
the emergency evacuation hammer to escape from the
cab. Refer the explanation pages on the Emergency
Evacuation Method.
SA-393
518-E02B-0393
SS-1510
SA-24
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 there
are no abnormalities such as the area surrounding the
welded area still smoldering.
SA-818
523-E01A-0818
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-25
SA-016
SAFETY
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
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.
SA-029
Remove paint before welding or heating:

1. If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove 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
SA-26
SAFETY
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 hydrometer.
Do not charge a frozen battery; it may explode. Warm

the battery to 16 C (60 F) first.
Do not continue to use or charge the battery when

electrolyte level is lower than specified. Explosion 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-E01B-0032
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
SA-27
SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY
Direct exposure to hazardous chemicals can cause se-
rious 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 safely. Then
follow procedures and use recommended equipment.
SA-309
See your authorized dealer for MSDSs (available

only in English) on chemical products used with your
machine.
515-E01A-0309
DISPOSE OF WASTE PROPERLY

Improperly disposing of waste can threaten the envi-
ronment 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 Earths atmosphere. Government regulations may require a certified air conditioning service
center to recover and recycle used air conditioning
refrigerants.
Inquire on the proper way to recycle or dispose of

waste from your local environmental or recycling center, or from your authorized dealer.
516-E01A-0226
SA-28
SA-226
SECTION AND GROUP

CONTENTS
TECHNICAL MANUAL
(Troubleshooting)
SECTION 4 OPERATIONAL PERFORMANCE TEST

Group
Group
Group
Group
Group
1
2
3
4
5
Introduction
Standard
Engine Test
Excavator Test
Component Test
SECTION 5 TROUBLESHOOTING
Group
Group
Group
Group
Group
Group
Group
Group
1 General
2 Cross Reference Table
3 Component Layout
4 Troubleshooting A
5 Troubleshooting B
6 Troubleshooting C
7 Troubleshooting D
8 Electrical System Inspection
TECHNICAL MANUAL (Operational Principle)

SECTION 1 GENERAL
Group 1 Specification
Group 2 Component Layout
SECTION 2 SYSTEM
Group 1 Control System
Group 2 Hydraulic System
Group 3 Electrical System
All information, illustrations and specifications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.
COPYRIGHT(C)2006
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
SECTION 3 COMPONENT OPERATION

Group 1 Pump Device
Group 2 Swing Device
Group 3 Control Valve
Group 4 Pilot Valve
Group 5 Travel Device
Group 6 Signal Control Valve
Group 7 Others (Upperstructure)
Group 8 Others (Undercarriage)
WORKSHOP MANUAL
SECTION 1 GENERAL INFORMATION
Group 1 Precautions for Disassembling and Assembling
Group 2 Tightening Torque
SECTION 2 UPPERSTRUCTURE
Group 1 Cab
Group 2 Counterweight
Group 3 Pump Device
Group 4 Control Valve
Group 5 Swing Device
Group 6 Pilot Valve
Group 7 Pilot Shut-Off Valve
Group 8 Shockless Valve
Group 9 Solenoid Valve
Group 10 Signal Control Valve
Group 11 Oil Cooler Fan Motor
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
Group 3 Bushing and Point
SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction
Group 5 Component Test
Operational Performance Tests ................ T4-1-1
Primary Pilot Pressure .............................. T4-5-1
Preparation for Performance Tests ........... T4-1-2
Secondary Pilot Pressure ......................... T4-5-3

Solenoid Valve Set Pressure..................... T4-5-4
Group 2 Standard
Main Pump Delivery Pressure................... T4-5-7
Operational Performance Standard .......... T4-2-1
Main Relief Valve Set Pressure................. T4-5-8
Main Pump P-Q Diagram.......................... T4-2-4
Overload Relief Valve Set Pressure ........ T4-5-12
Oil Cooler Fan Motor Drive Pump
Main Pump Flow Rate Measurement ...... T4-5-16
P-Q Diagram........................................... T4-2-4

Flow Rate Measurement ....................... T4-5-22
Group 3 Engine Test
Swing Motor Drainage ............................ T4-5-28
Engine Speed ........................................... T4-3-1
Travel Motor Drainage ............................ T4-5-30
Group 4 Excavator Test

Travel Speed ............................................ T4-4-1
Track Revolution Speed............................ T4-4-2
Mistrack .................................................... T4-4-3
Travel Parking Function............................ T4-4-4
Swing Speed ............................................ T4-4-5
Swing Function Drift ................................. T4-4-6
Swing Motor Leakage ............................... T4-4-8
Maximum Swingable Slant Angle.............. T4-4-9
Swing Bearing Play ................................ T4-4-10
Hydraulic Cylinder Cycle Time................ T4-4-12
Cylinder Drift........................................... T4-4-14
Control Lever Operating Force ............... T4-4-15
Control Lever Stroke............................... T4-4-16
Boom Raise/Swing Combined
Operation Check................................... T4-4-17
18ET-4-1
(Blank)
18ET-4-2
OPERATIONAL PERFORMANCE TEST / Introduction

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

PREPARATION
TESTS
FOR
PERFORMANCE
Observe the following rules in order to carry out

performance tests accurately and safely.
THE MACHINE
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.
TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to
run straight more than 20 m (65 ft 7 in), and to
make a full swing with the front attachment extended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among coworkers. Once the test is started, be sure to communicate with each other using these signals, and to
follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid accidents due to landslides or contact with
high-voltage power lines. Always confirm that
there is sufficient space for full swings.
4. Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil.
Pay special attention to this when removing hydraulic pipings.
MAKE PRECISE MEASUREMENT
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
T105-06-01-003
T105-06-01-004
OPERATIONAL PERFORMANCE TEST / Standard

OPERATIONAL
DARD
PERFORMANCE
STAN-
The standard performance values are listen in the table below. Refer to the Groups 3 to 5 for performance
test procedures. Values indicated in parentheses are
reference values. The fuel lever shall be placed in the
fast idle position and the hydraulic oil temperature is
to be maintained at 50 5 C (122 9 F) unless otherwise specified.
EX1200-5C
(Standard
Performance)
Performance Test
ENGINE SPEED
Fast Idle Speed
Slow Idle Speed
Auto-Idle Speed
Quick Idle Speed
TRAVEL SPEED
Fast Speed Mode
Slow Speed Mode
TRACK REVOLUTION SPEED
Fast Speed Mode
Slow Speed mode
MISTRACK
(in both fast and slow mode)
TRAVEL MOTOR DRIFT
SWING SPEED
SWING FUNCTION DRIFT
(Backhoe)
(Loading Shovel)
SWING MOTOR DRIFT
MAXIMUM SWINGABLE SLANT ANGLE
min
Refer to T4-3-1
-1
185050
85050
1400100
85050
Refer to T4-4-1
sec /20 m
21.31.6
30.52.0
Refer to T4-4-2
sec /3 rev
42.04.0
61.04.0
mm /20 m
mm /5 min
sec /3 rev
200 or less
0
30.02.0
mm /180
mm /5 min
1100 or less
deg
(Backhoe)
Refer to T4-4-3
Refer to T4-4-4
Refer to T4-4-5
Refer to T4-4-6
Refer to T4-4-8
Refer to T4-4-9
12 or possibly
more
10 or possibly
more
(Loading Shovel)
SWING BEARING PLAY
Remarks
mm
2.0 or less
Allowable Limit: 6.3, Refer to

T4-4-10
NOTE: BH: Backhoe: With 5.0 m3 (PCSA heaped) Bucket, 3.4 m Arm, 9.1 Boom
LD: Loading Shovel: With 6.5 m3 Bucket
T4-2-1

EX1200-5C
(Standard
Performance)
Performance Test
CYLINDER CYCLE TIME
(Backhoe)
Boom Raise
Boom Lower
Arm Roll-In
Arm Roll-Out
Bucket Roll-In
Bucket Roll-Out
(Loading Shovel)
Boom Raise
Boom Lower
Arm Extend
Arm Retract
Bucket Tilt-In
Bucket Tilt-Out
Bucket Open
Bucket Close
DIG FUNCTION DRIFT
(Backhoe)
Boom Cylinder
Arm Cylinder
Bucket Cylinder
Bucket Bottom
(Loading Shovel)
Boom Cylinder
Arm Cylinder
Bucket Cylinder
Bucket Bottom
CONTROL LEVER OPERATING FORCE
(HITACHI Control Pattern)
Boom Lever
Remarks
Refer to T4-4-12
sec
4.30.5
3.10.5
4.50.5
3.50.5
3.00.5
2.30.5
BE: 4.50.5
BE: 3.30.5
BE: 4.50.5
BE: 4.00.5
BE: 3.30.5
BE: 2.70.5
5.50.5
4.00.5
2.90.5
2.50.5
3.30.5
2.20.5
1.10.5
1.60.5
Refer to T4-4-14
mm/5 min
20 or less
20 or less
30 or less
300 or less
BE: 30 or less
BE: 30 or less
BE: 30 or less
BE: 400 or less
20 or less
20 or less
30 or less
300 or less
Refer to T4-4-15
N (kgf)
Arm Lever (LD: Extend/Retract)

Arm Lever (BH: Roll-in/Roll-out)
Bucket Lever (*Roll-In/**Roll-Out)
Swing Lever (Right/Left)
Travel Lever
19.7 (2.0) or
less
16.7 (1.7) or
less
16.7 (1.7) or
less
16.7 (1.7) or
less
ISO Control Pattern: Swing Lever

(Right/Left)
ISO Control Pattern: Swing Lever
(Right/Left)
19.7 (2.0) or
less
ISO Control Pattern: Arm Lever

(LD: Extend/Retract,
BH: Roll-out, Roll-in)
24.5 (2.5) or
less
Bucket Open/Close Pedal

NOTE: * In the case of loading shovel specification, the operation is bucket tilt-in
**In the case of loading shovel specification, the operation is bucket tilt-out
BH: Backhoe: with 5.0 m3 (PCSA heaped) Bucket,

3.4 m Arm, 9.1 m Boom
LD: Loading Shovel: with 6.5 m3 Bucket
T4-2-2

EX1200-5C
(Standard
Performance)
Performance Test
LEVER STROKE (HITACHI Control Pattern)
Boom Lever
Arm Lever
Refer to T4-4-16
mm
10510
8310
Bucket Lever
Swing Lever
ISO Control Pattern:

Swing Lever
8310
10510
Travel Lever
Bucket Open/Close Pedal
BOOM RAISE/SWING COMBINED OPERATION (with
Empty Bucket) Time
sec/90
Bucket Tooth Tip Height (H) from Ground
mm
2
HYDRAULIC COMPONENT
MPa (kgf/cm )
PRIMARY PILOT PRESSURE: Fast Idle
Slow Idle
SECONDARY PILOT PRESSURE
2
SOLENOID VALVE SET PRESSURE
MPa (kgf/cm )
Travel Mode Solenoid Valve
Flow Rate Reducing Solenoid Valve
Power Decrease Solenoid Valve
Power Increase Solenoid Valve
Oil Cooler Fan Control Solenoid Valve
2
MAIN PUMP DELIVERY PRESSURE
MPa (kgf/cm )
2
MAIN RELIEF PRESSURE
MPa (kgf/cm )
Boom, Arm, Bucket, and Bucket Open (LD)
ISO Control Pattern:

Arm Lever
11510
5.50.6
7300 or more
4.90.5 (505)
3.90.5 (405)
3.6 (37) or less
BH (5.50.6: LD), Refer to

T4-4-17
BH (7500 or more: LD)
Refer to T4-5-1
Refer to T4-5-2
Refer to T4-5-3
3.6 (37) or less

3.6 (37) or less
3.6 (37) or less
0 to 2.7 (0 to 27)
0 to 1.36 (0 to 13.9)
Power Boost
Travel
Swing
OVERLOAD RELIEF PRESSURE
Arm Roll-out (BH), Arm Retract (LD)
Remarks
Refer to T4-5-8
31.51.0
(32010)
33.31.0
(34010)
29.41.0
(30010)
29.41
(30010)
MPa (kgf/cm )
Boom, Arm Roll-In (BH), Arm Extend (LD), Bucket,

Bucket Open (LD)
Bucket Close (LD)
MAIN PUMP FLOW RATE
L/min
OIL COOLER FAN DRIVE PUMP FLOW RATE
SWING MOTOR DRAINAGE
L/min
(at max. constant speed)
TRAVEL MOTOR DRAINAGE
L/min
(at slow speed with track raised off the ground)
NOTE: LD: Loading Shovel
BH: Backhoe
T4-2-3
34.31.0-0
(35010-0)
33.31.0-0
(34010-0)
17.71.0-0
(18010-0)
2 or less
5 or less
Refer to T4-5-12
Refer to T4-2-4, T4-5-16

Refer to T4-2-4, T4-5-22
Allowable Limit: 4, Refer to
T4-5-28
Allowable Limit: 10, Refer to
T4-5-30

MAIN PUMP P-Q DIAGRAM
OIL COOLER FAN MOTOR DRIVE PUMP

P-Q DIAGRAM
Hydraulic P-Q Control

Rated Pump Speed: 1787 min-1 (rpm)
Pump Gear Reduction Ratio: 1.083
Hydraulic Oil Temperature: 505 C (1229 F)
Hydraulic P-Q Control

Rated Pump Speed: 1825 min-1 (rpm)
Pump Gear Reduction Ratio: 1.106
NOTE: Refer to T4-5-17.

NOTE: Refer to T4-5-23.
Main Pump P-Q Diagram
Q
L/min (US gal/min)
A
490 (129)
B
312 (82)
C
107 (28)
D
485 (128)
E
307 (81)
F
151 (40)
G
477 (126)
H
299 (79)
I
220 (58)
P
MPa (kgf/cm2, psi)
8.4 (86, 1218)
15.7 (160, 2276)
33.3 (340, 4828)
12.6 (128, 1827)
19.9 (203,2885)
33.3 (340, 4828)
19.2 (196, 2784)
26.5 (270, 3842)
33.3 (340, 4828)
Q
(Flow
Rate)
L/min
Oil Cooler Fan Motor Drive Pump P-Q Diagram

Q
P
L/min (US gal/min)
MPa (kgf/cm2, psi)
A
100 (26)
4.9 (50, 710)
B
97 (25)
18.80.5 (1925,
272672.5)
C
82 (21)
21.6 (220, 3132)
Q
(Flow
Rate)
L/min
600
A
500
600
G
SP Mode Control
(Pz) = 3.30 MPa
500
400
400
300
200
H
300
E Mode Control
(PG) = 2.08 MPa
I
F
C
100
200
100
10
15
20
25
30
P (Pressure)
MPa
T183-04-04-005
B
C
10
15
20
25
30
P (Pressure)
MPa
T183-04-04-017
T4-2-4
OPERATIONAL PERFORMANCE TEST / Engine Test

ENGINE SPEED
Summary:
1. Measure engine speed by using the on-board
diagnostic system (Refer to the TROUBLESHOOTING / General group) or a pulse meter.
2. Measure the engine speeds in each mode.
NOTE: Unless engine speed is correctly adjusted,
all performance test results will be inaccurate. Therefore, check engine speed setting before performing any tests.
Test Condition:
Ground Conditions: Solid and level surface
Measurement:
1. Stop the engine. Turn the key switch OFF.
2. As for the pulse meter, remove the connector
from the engine speed sensor. Install the pulse
meter.
3. Start the engine. Measure the maximum and
minimum engine speeds. As for the pulse meter,
read the pulse of engine speed sensor and calculate the engine speed by using the following
formula.
Engine speed=Pulse value60/138 (min-1)
Evaluation:
Refer to T4-2 Operational Performance Standard.
T4-3-1
OPERATIONAL PERFORMANCE TEST / Engine Test

(Blank)
T4-3-2
OPERATIONAL PERFORMANCE TEST / Excavator Test

TRAVEL SPEED
Summary:
1. Check the overall operational performance of the
travel power system (between the hydraulic
pumps and travel motors) by measuring time
required for the machine to travel the specified
distance.
Preparation:
1. Equally adjust the track sag on both right and left
undercarriages.
2. Prepare a flat and firm travel test yard 20 m (65.5
ft) long with fringes 3 to 5 m (9.8 to 16 ft) on both
ends for machine acceleration and deceleration.
3. Empty the bucket and roll in the arm.
4. Maintain the hydraulic oil temperature at 505 C
(1229 F).
Deceleration Zone
3 to 5 m
Finish
Track Sag
490 to 550 mm
(19 to 22 in)
Travel Test Distance

20 m
Measurement:
1. Measure travel time at both fast and slow travel
speeds.
2. Engine Control Dial : Maximum Position
3. Start machine to travel from the rear end of the
acceleration zone by moving the travel levers full
stroke.
4. Measure the time required to travel the travel test
distance 20 m (65.5 ft).
5. After measuring the forward travel time, rotate
the machine upperstructure 180. Then, measure
the reverse travel time on the way back to the
starting position in the same method.
6. Repeat steps (4) and (5) three times and
calculate the average values.
Evaluation:
Remedy:
Refer to the T5-5 Troubleshooting B.
T4-4-1
T145-05-03-001
Start
Acceleration Zone
3 to 5 m
T142-05-03-001
T145-05-03-005

TRACK REVOLUTION SPEED
Summary:
travel power system (between the hydraulic
pumps and travel motors) by measuring the track
revolution cycle time.
Preparation:
undercarriages to 490 to 550 mm (19 to 22 in).
2. Mark one shoe with chalk or a piece of cloth on
the track to be measured.
3. Rotate the upperstructure 90 to the track and
lower the bucket to raise the track to be
measured off the ground. Keep the boom and
arm angle between 90 to 110 as illustrated.
(1229 F).
90 to 110
T142-05-03-011
CAUTION: Never work under a machine

raised and solely supported by the boom.
Place blocks under the machine frame to
support the machine.
90 to 110
Measurement:
1. Measure the track rotation time at both fast and
slow travel speeds.
3. Operate the travel control lever of the raised
track in full forward and reverse.
4. After the track revolution attains to constant
speed, measure the time required for the marked
shoe to rotate three times in both directions.
5. Raise the other side of the track and repeat the
procedure.
Evaluation:
T142-05-03-012
Forward
Reverse
T145-05-03-001
Remedy:
T4-4-2

MISTRACK
Summary:
1. Check the equilibrium in operational performance
between the right and left travel power systems
(between the hydraulic pumps and travel motors)
by measuring the amount of mistrack found while
the machine travels for the specified distance.
NOTE: When tested on a concrete surface road,
the amount of mistrack may be reduced.
Preparation:
undercarriages to 490 to 550 mm (19 to 22 in).
2. Prepare a flat and firm travel test yard 20 m (65.5
ft) long with fringes 3 to 5 m (9.8 to 16 ft) on both
ends for machine acceleration and deceleration.
3. Set the front attachment in the driving position.
(1229 F).
Measurement:
1. Measure the amount of mistracking in both fast
and slow travel speeds.
3. Start machine to travel from the rear end of the
acceleration zone by moving both travel levers
full stroke.
4. Draw a 20 m (65.5 ft) straight line along the rut
from the travel start point to the travel end point
as illustrated. Measure the maximum distance
between the rut and the straight line.
5. Conduct the measurement in both forward and
reverse travel operation in the same method.
T145-05-03-005
T145-05-03-006
Deceleration Zone
3 to 5 m
Maximum Distance (A)

20 m
Acceleration Zone
3 to 5 m
Evaluation:
T115-07-03-005
Remedy:
T4-4-3

TRAVEL PARKING FUNCTION
Summary:
To measure the parking brake function on a specified
slope.
0.5 to 1.0 m
Preparation:
1. The surface of the test slope shall be even with a
gradient of 20 % (11.31).
2. Hold the bucket 0.5 to 1.0 m (20 to 39 in) above
the ground with the arm and bucket fully rolled in.
(1229 F).
T142-05-03-002
Measurement:
1. Climb the slope and place the travel levers in
neutral.
2. Stop the engine.
3. After the machine stops, put alignment marks on
a track link or shoe, and the track side frame.
4. After 5 minutes, measure the distance between
the marks on the track link or shoe and the track
side frame.
Evaluation:
0.5 to 1.0 m
T118-04-03-001
Position where the machine

comes to a stop.
Alignment marks on the track

side frame and shoe when the
machine comes to a stop.
Displacement measured
after 5 minutes.
T105-06-03-006
T4-4-4

SWING SPEED
Summary:
Check the overall operational performance of the
swing power system (between the hydraulic pumps
and swing motors) by measuring time required for
the machine upperstructure to make three complete
turns.
Preparation:
1. Confirm that the swing gears and bearing are
sufficiently greased.
2. Secure a space wide enough for the machine
upperstructure to swing on a flat and firm surface.
Never attempt to perform this test on a slope.
3. Empty the bucket and position the front
attachment as described in the following.
Backhoe:
With the arm cylinders fully retracted and the
bucket cylinders fully extended, position the arm
top pin height flush with the boom foot pin height.
Loading shobel:
With the arm cylinder fully extended and the
NOTE: In case it is difficult to secure the space
wide enough, test the machine with the
boom raised and the arm retracted.
(1229 F).
T145-05-03-007
T145-05-03-008
CAUTION: Prevent personal injury. Always

make sure that the area is clear and that
coworkers are out of the swing area before
starting the measurement.
Measurement:
2. Auto-Idle Switch : OFF
3. Operate the swing control lever at full stroke.
4. After the swing attains to constant speed,
measure the time required for the upperstructure
to rotate three times.
5. Measure in both directions (clockwise and
counterclockwise).
Evaluation:
3 Revolutions
T145-05-03-009
Remedy:
T4-4-5

SWING FUNCTION DRIFT
Summary:
1. Measure the swing drift on the swing bearing
outer race circumference when stopping after a
180 full-speed swing.
NOTE: The swing motor is equipped with a swing
parking brake mechanical brake.
Preparation:
1. Confirm that the swing gears and bearing are
sufficiently greased.
2. Secure a space wide enough for the machine
upperstructure to swing on a flat and firm surface.
Never attempt to perform this test on a slope.
3. Empty the bucket and position the front
attachment as described in the following.
Backhoe:
Loading shovel:
4. Put aligning marks on the outer circumference of
the swing bearing and the track frame.
5. Swing the upperstructure 180.
(1229 F).
T4-4-6
T145-05-03-007
T145-05-03-008

Measurement:
Auto Idle Switch : OFF
2. Operate the swing lever full stroke. When the
upperstructure rotates 180 back to the original
position (when the marks on the swing bearing
and track frame aligns with each other), return
the swing lever to neutral.
3. After the upperstructure stops, measure the
distance between the two marks along the outer
circumference of the swing bearing.
4. Align the marks again. Then, measure in the
opposite direction.
5. Repeat steps (2) to (4) three times and calculate
the average values.
Return the
swing control
lever to the
neutral position.
Drift
Amount
Rotate 180
Evaluation:
Start Rotation
Remedy:
T142-05-03-003
T4-4-7

SWING MOTOR LEAKAGE
Summary:
Check for upperstructure drift while suspending a
load on a slope.
Preparation:
1. Check the lubrication of the swing gear and
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: tons) of the following specification can
be used.
Backhoe: W=6000 kg (13200 lb)
(Up to serial No. 2122)
W=6600 kg (14500 lb)
(Serial No. 2123 and later)
Loading Shovel:W=9450 kg (20800 lb)
4. Backhoe:
With the arm rolled out, and bucket rolled in,
position the arm top pin height to be level with the
boom foot pin. Apply a rated load to the bucket.
Loading Shovel:
With the arm cylinder and bucket cylinders fully
extended, position the arm top pin flush with the
boom foot pin height.
5. Swing the upperstructure to position it 90 to the
slope. Make aligning marks on the swing bearing
periphery and track frame using tape, as
illustrated.
(1229 F).
Measurement:
1. Stop the engine. After five minutes, measure the
difference between the marks along the swing
bearing periphery and the track frame.
2. Perform the measurement in both right and left
swing directions.
3. Perform the measurement three times in each
direction and calculate the average values.
Evaluation:
Remedy:
T4-4-8
T142-05-03-004
Measure Difference Between Marks
Marking on the Track Frame

Marking on the Swing Bearing
T105-06-03-010

MAXIMUM SWINGABLE SLANT ANGLE
Summary:
With the upperstructure swung 90 to the slope,
check the maximum slant angle on which the
upperstructure can swing to the uphill side.
Preparation:
1. Check that the swing gear and bearing are well
lubricated.
weight (W: tons) of the following specification can
be used.
Backhoe: W=6000 kg (13200 lb)
(Up to serial No. 2122)
W=6600 kg (14500 lb)
(Serial No. 2123 and later)
Loading Shovel:W=9450 kg (20800 lb)
3. Backhoe:
With the arm rolled out, and bucket rolled in,
position the arm top pin height to be level with the
boom foot pin. Apply a rated load to the bucket.
Loading Shovel:
With the arm cylinder and bucket cylinders fully
extended, position the arm top pin flush with the
boom foot pin height.
4. Climb a slope and swing the upperstructure 90
to the slope.
(1229 F).
Measurement:
Auto Idle Switch : OFF
2. Operate the swing lever to full stroke to swing the
upperstructure to the uphill side.
3. If the machine can swing, measure the cab floor
slant angle.
4. When the machine can swing, increase the slope
angle and repeat steps (2 and 3). Check in both
clockwise and counterclockwise directions.
5. Perform the measurement three times in each
direction and calculate the average values.
Evaluation:
Remedy:
T4-4-9
T142-05-03-004

SWING BEARING PLAY
Summary:
Wear on the swing bearing races and rollers is
checked by measuring the play between the outer
and inner races of the swing bearing.
Preparation:
1. Confirm that the swing bearing mounting bolts
are securely tightened.
2. Confirm that the swing bearing is well lubricated
and rotates smoothly with no noise.
3. Attach a dial gauge on the track frame using a
magnet base.
4. Position the upperstructure so that the bucket
faces toward the front idlers.
5. Position the dial gauge so that its needle point
comes in contact with the bottom face of the
swing bearing outer race.
6. Empty the bucket
NOTE The measured value will vary depending
on the location where the magnet base is
secured. Secure the magnet base onto the
round trunk or a location as close to the
round trunk as possible.
T4-4-10
Dial
Gauge
Round Trunk
Magnet
Base
T105-06-03-015

Measurement:
1. Take measurements of the play at positions A, B,
C, and D.
2. Position the front attachment as described in the
following.
Backhoe:
Loading shovel:
3. Record the dial gauge reading (h1). Lower the
bucket to the ground and use it to raise the front
idler 0.5 m (20 in). Record the dial gauge reading
(h2).
4. Calculate bearing play (H) from this data (h1 and
h2) as follows:
H=h2 h1
A
B
D
C
Measure the plays

at positions A, B, C
and D.
T145-05-03-023
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Backhoe
Measurement : (h1)
Measurement : (h2)
T142-05-03-006
Loading Shovel
Measurement : (h1)
Measurement : (h2)
T142-05-03-005
T4-4-11

HYDRAULIC CYLINDER CYCLE TIME
Summary:
front attachment hydraulic system (between the
hydraulic pumps and each cylinder) by
measuring the cycle time of the boom, arm,
bucket, and bucket dump (open/close) cylinders
with the bucket emptied.
Preparation:
(1229 F).
following.
Backhoe
Boom Cylinder:
With the bucket cylinder fully extended and the
arm cylinder fully retracted, lower the bucket to
the ground.
Arm Cylinder:
With the bucket cylinder fully extended while
positioning the center line between the arm and
bucket connection pin centers vertical with the
arm cylinder extended half stroke.
Bucket Cylinder:
Adjust the boom and arm cylinder so that the
center of full stroke movement of the bucket is
positioned vertically.
Loading Shovel
Boom Cylinder:
With the bucket cylinder and the arm cylinder
fully extended, lower the bucket to the ground.
Arm Cylinder:
With the arm fully retracted, position the bucket
so that the rear bucket does not come in contact
with the arm stopper. Then, adjust the boom
cylinder stroke to position the bucket bottom 1 m
(39 in) above the ground.
Bucket Cylinder:
With the bucket closed and held in a load dump
position, adjust the boom cylinder stroke so that
bucket bottom height is approx. 1 m (39 in) above
the ground.
Bucket Dump (Open-Close) Cylinder:
With the bucket cylinder and arm cylinder fully
extended, adjust the boom cylinder stroke so that
the bucket bottom height approx. 1 m (39 in)
above the ground.
Backhoe
Boom Cylinder
T145-05-03-012
Arm Cylinder
T118-04-03-003
Bucket Cylinder
T145-05-03-014
Loading Shovel
Boom Cylinder
T145-05-03-015
Arm Cylinder
T145-05-03-016
Bucket Cylinder
T145-05-03-017
Dump Cylinder
T145-05-03-018
T4-4-12

Measurement:
1. Select the following lever and switch positions:
Engine Control Lever: Maximum Position
Auto-Idle Switch: OFF
2. To measure cylinder cycle times:
(Cylinder full stroke includes cylinder cushioning
zone.)
2-1. Boom cylinders:
Measure the time it takes to raise the boom,
and the time it takes to lower the boom. To do
so, position the boom at one stroke end, then
move the control lever to the other stroke end
as quickly as possible.
2-2. Arm cylinder:
Measure the time it takes to roll in the arm, and
the time it takes to roll out the arm. To do so,
position the arm at one stroke end, then move
the control lever to the other stroke end as
quickly as possible.
2-3. Bucket cylinder:
Measure the time it takes to roll in the bucket,
and the time it takes to roll out the bucket. To
do so, position the bucket at one stroke end,
then move the control lever to the other stroke
end as quickly as possible.
2-4. Bucket dump (Open-Close) cylinder:
Mesure the time it takes to open the bucket,
and the time it takes to close the bucket. To do
so, position the bucket dump at one stroke end,
then move the bucket open-close pedal to the
other stroke end as quickly as possible.
3. Repeat the measurement three times and
Evaluation:
NOTE: Backhoe front : 9.1 m (29 ft) Boom
3.4 m (11 ft) Arm
4.6 m3 (6.0 yd3) Bucket
* 5.0 m3 (6.5 yd3) Bucket
(PCSA heaped)
Loading shovel front:
6.3 m3 (8.2 yd3) Bucket
When the bucket weight is increased by
welding wear-resist plates, cylinder cycle
times may become slower.
Remedy:
T4-4-13

CYLINDER DRIFT
Summary:
1. While holding the soil weight of or a specified
weight in the bucket, the dig function drift is
measured to check for internal oil leaks in the
control valve, boom, arm, and bucket cylinders.
2. After replacing the hydraulic cylinders, slowly
operate each cylinder for approx. 10 minutes to
bleed air from the hydraulic circuit before starting
the test.
Preparation:
weight (W) of the following specification can be
used.
Backhoe: W=6000 kg (13200 lb)(Up to Serial No.
2122)
W=6600 kg (14500 lb)(Serial No. 2123 and later)
Loading Shovel: W=9450 kg (20800 lb)
following.
Backhoe:
With the arm cylinder with rod approx.50 mm (2
in) extended from the fully retracted position, and
bucket cylinder with the rod approx. 50 mm (2 in)
retracted from the fully extended, position the
arm top pin height flush with the boom foot pin
height.
Loading shovel:
With the arm cylinder with the rod approx. 50 mm
(2 in) retracted from the fully extended position,
and bucket cylinder with the approx. 50 mm (2 in)
retracted from the fully extended, position the
arm top pin height flush with the boom foot pin
height.
(1229 F).
T145-05-03-020
BH: Boom and Bucket Cylinders Retraction

LD: Boom, Arm and Bucket Cylinders Retraction
Mark
Mark
T110-06-03-002
BH: Arm Cylinder Extension
Mark
Measurement:
1. Stop the engine.
2. After five minutes have passed, measure the retractions of the boom, arm, and bucket cylinders
as illustrated
3. Repeat step (2) three times and calculate the
average values.
T110-06-03-001
NOTE: BH: Backhoe

LD: Loading Shovel
Evaluation:
Solution:
Refer to T5-5 Troubleshooting B.
T4-4-14
T145-05-03-021

CONTROL LEVER OPERATING FORCE
Summary:
1. Use a spring scale to measure the maximum
resistance of each control lever as illustrated.
2. Measure the maximum operating force of the
front attachment control lever.
3. Measure the operating force at the grip center of
each control lever.
Preparation:
Maintain the hydraulic oil temperature at 505 C
(1229 F).
Measurement:
1. Measure all control levers.
2. Engine Control Dial : Maximum Position.
T107-06-03-003

co-workers are out of the swing area before
3. Operate each boom, arm, bucket and swing lever
to at full stroke and measure the maximum
operating force for each.
4. Lower the bucket to the ground to raise one track
off the ground. Operate the travel lever to full
stroke and measure the maximum operating
force required. When finished, lower the track
and then jack-up the other track.
5. Repeat steps 3. to 4. three times and calculate
the average values.
Evalution:
T4-2.
T4-4-15
T107-06-03-004

CONTROL LEVER STROKE
Summary:
1. Measure each control lever stroke and stroke
play, and check if it can be moved smoothly.
2. Measure each lever stroke at the lever grip center.
3. If a stroke play is present in the neutral position,
add half the value of the play to the one side
stroke.
Preparation:
1. Maintain the hydraulic oil temperature at 50 5
C (122 9 F).
Measurement:
1. Stop the engine.
2. Measure the boom, arm, bucket, swing, and
travel levers full stroke from the neutral position
at the lever grip top center.
3. Measure the stroke straight from the neutral position to the stroke end.
4. Repeat each measurement three times and calculate the average values.
Evaluation:
T4-4-16
T107-06-03-005

BOOM RAISE/SWING
ERATION CHECK
COMBINED
OP-
Summary:
1. Check the combined operation performance
while operating the boom raise and swing simultaneously.
2. Run the engine at full speed and check if the
boom cylinders move without hesitating.
T142-05-03-007
Preparation:
1. Empty the bucket and position the machine with
front attachment positioned as illustrated.
2. Maintain the hydraulic oil temperature at 50 5
C (122 9 F).
co-workers are out of the swing area before
T142-05-03-008
Measurement:
1. Run the engine at the maximum speed with the
auto idle switch OFF.
2. Operate the boom raise and swing levers full
stroke. Measure the time required for the machine to swing 90 and bucket tooth tip height H
raised while swinging.
3. Repeat the measurement in both directions three
times and calculate the average values.
T142-05-03-009
Evaluation:
Solution:
Refer to T5-5 Troubleshooting B.
T142-05-03-010
T4-4-17

(Blank)
T4-4-18
OPERATIONAL PERFORMANCE TEST / Component Test

PRIMARY PILOT PRESSURE
Preparation:
1. Stop the engine.
Tee
Pressure Gauge
CAUTION: Do not quickly loosen the cap on

the hydraulic oil tank. The cap may fly off
due to internal pressure. Always turn the cap
slowly to release any remaining pressure
before removing it.
2. Slowly loosen the cap to release air from the
hydraulic oil tank.
3. Disconnect the line end from the pilot filter.
Connect tee (ST 6477) and pressure gauge (ST
6942) between the pilot filer and the line end.
4. Start the engine. Check the connection for oil
leaks.
(12241 F).
Measurement:
1. Engine Control Dial:
Maximum Speed
(Fast Idle Position)
2. Read the primary pilot pressure on the gauge.
Turn the engine control dial to the slow idle, then
back to the fast idle.
Read the pressure gauge again.
3. Read the pressure gauge three times in total.
Calculate the average value.
Evaluation:
Refer to the Operational Performance Standard
group (T4-2).
T4-5-1
T142-05-04-001

Primary Pilot Pressure Adjustment Procedure
Adjustment:
Adjust the pilot relief valve setting if required.
Pilot Relief Valve
T183-04-04-001
1. Remove the plug.

: 22 mm
Plug
Shim
2. Adjust the set pressure using the shims. Adding

shim(s) increases the pressure setting, and vice
versa. Add or subtract shims to adjust the setting.
3. Retighten the plug.
: 24.5 Nm (2.5 kgfm, 18 lbfft)
4. Recheck the relief pressure setting.
T111-06-04-004
NOTE: Standard Change in Relief Pressure Setting (Reference)

Shim Thickness
kPa
(kgf/cm2)
(psi)
(mm)
0.25
78
(0.8)
(11)
0.5
147
(1.5)
(21)
1.0
294
(3.0)
(43)
T4-5-2

SECONDARY PILOT PRESSURE
Main Control Valve
The secondary pilot pressure can also be measured

Left Travel
with the built-in diagnosing system.
(Forward)
NOTE: BH: Backhoe
Bucket 2
LD: Loading Shovel
(BH: Roll-Out
Right Travel (Forward)

Bucket 1 (BH: Roll-Out,
LD: Tilt-Out)
Boom 1 (Lower)
LD: Tilt-Out)
Preparation:
1. Stop the engine.
Boom 2 (Lower)

before removing it.
hydraulic oil tank.
3. Connect tee (ST 6450) and pressure gauge (ST
6942) on the pilot port to be measured.
: 17 mm, 22 mm
4. Start the engine. Check the pressure gauge
connection for oil leaks.
(12241 F).
Measurement:
BH: Arm 1
(Roll-Out)
LD: Arm 1
(Roll-In)
Bucket 1
(BH: Roll-In,
LD: Tilt-In)
BH: Arm 2
(Roll-in)
LD: Arm 2
(Extend)
BH: Auxiliary
LD: Bucket
(Close)
Boom 2
(Raise)
Bucket 2
(BH: Roll-in,
LD: Tilt-in)
BH: Arm 1
(Roll-In) T183-03-03-027
LD: Arm 1
(Extend)
Swing Control Valve
Boom 3
(Lower)
Swing (Left)
BH: Bucket 3 (Roll-Out)
LD: Bucket 3 (Tilt-Out)
T183-03-03-030
2. Fully operate the control lever for the function to

be measured. Read the secondary pilot pressure
on the gauge.
Evaluation:
group (T4-2).
T183-03-03-028
Left Travel
(Reverse)
BH: Arm 3 (Roll-Out)

LD: Arm 3 (Retract)
3. Repeat the measurement three times. Calculate

the average value.
Right Travel (Reverse)
Boom 1
(Raise)
CAUTION: Before starting measurement,

check that there are no bystanders and/or
obstructions within the swing radius.
When measuring the boom lower secondary
pilot pressure operate the machine carefully
as the base machine front will be raised off
the ground. This will cause the base machine
to become imbalanced and possibly allow
the rear of the machine to come in contact
with the ground.
1. Engine Control Dial :Maximum Speed
BH: Arm 2
(Roll-Out)
LD: Arm 2
(Retract)
BH: Auxiliary
LD: Bucket (Open)
Boom 3 (Raise)
Swing (Right)
BH: Bucket 3 (Roll-In)
LD: Bucket 3 (Tilt-In)
BH: Arm 3 (Roll-In)
LD: Arm 3 (Extend)
T4-5-3
T183-03-03-031

SOLENOID VALVE SET PRESSURE
(Travel mode control solenoid valve, flow rate decrease solenoid valve, power decrease solenoid valve,
boom mode selection solenoid valve, heavy lift solenoid valve, power increase solenoid valve, oil cooler
fan control solenoid valve)
Travel Mode Control Solenoid Valve
Preparation:
1. Stop the engine.
Output Port

before removing it.
T183-05-04-019
Flow Rate Decrease Solenoid Valve
2. Slowly loosen the cap to release air from the hydraulic oil tank.
3. Connect tee (ST 6450. For the power decrease
solenoid valve, power increase solenoid valve
and oil cooler fan control solenoid valve, use ST
6451) and pressure gauge (ST 6942) on the solenoid valve output port.
: 17 mm, 22 mm
Output Port
T183-05-04-018
4. Start the engine. Check the pressure gauge connection for oil leaks.
Output Port

(12241 F).
Measurement:
1. Measure the pressure setting for each solenoid
valve as follows:
Measure the shifting pressure at fast and slow
speeds by the travel mode switch.
Turn the engine control dial to the slow idle position. Read the pressure while applying a load to
the front attachment.
Turn the engine control dial to the slow idle position. Read the pressure.
Boom Mode Selection Solenoid Valve
Turn on the boom mode selection switch. Read
the pressure.
T183-04-04-001
Boom Mode Selection Solenoid Valve
T4-5-4
Output Port
T183-04-04-001

Heavy Lift Solenoid Valve
Turn on the heavy lift switch. Read the pressure.
Observe the pressure change while turning the

engine control dial from the slow idle position to
the fast idle position.
Heat the hydraulic oil temperature sensor, and
read the pressure at 69 C (156 F), 70 to 79 C
(158 to 174 F) and 80 C (176 F).
2. Repeat the measurements three times and calculate the average values.
Output Port
T183-05-04-017
Evaluation:
group (T4-2).
Output Port
T183-05-04-016
Output Port
T4-5-5
T183-05-04-016

(Blank)
T4-5-6

MAIN PUMP DELIVERY PRESSURE
The main pump delivery pressure can also be measured with the built-in diagnosing system.
Preparation:
1. Stop the engine.
before removing it.
hydraulic oil tank.
3. Remove the plug from the test port on the main
pump delivery port. Connect adapter (ST 6069),
hose (ST 6943), and pressure gauge (ST 6941)
on the test port.
Test Port

(12241 F).
Test Port
Pressure Gauge
T183-04-04-002
Measurement:
1. Engine Control Dial : Maximum Speed
2. Measure the pressure with the control levers in
neutral.
3. Read the pressure gauge three times in total.
Calculate the average value.
Evaluation:
group (T4-2).
Remedy:
Refer to the Troubleshooting B group (T5-5).
T4-5-7
T183-04-04-003

MAIN RELIEF VALVE SET PRESSURE
The main pump delivery pressure can also be
measured with the built-in diagnosing system.
Summary:
Measure the main relief valve set pressure at the
main pump delivery port.
Preparation:
1. Stop the engine.
the hydraulic oil tank. The cap may pop off
before removing it.
hydraulic oil tank.
3. Remove the plug from the test port on the main
pump delivery port. Connect adapter (ST 6069),
hose (ST 6943), and pressure gauge (ST 6941)
on the test port.
Test Port
Test Port
Pressure Gauge

T183-04-04-002

(12241 F).
Measurement:
2. Operate the bucket, arm and boom control levers
to the stroke ends (fully extended and retracted)
to relieve the each function. (Operate the control
lever one function at a time.)
3. For the swing function, place one side of the
bucket against an immovable object and slowly
operate the swing lever to the stroke end to
relieve the swing function.
T183-04-04-003
Evaluation:
group (T4-2).
4. For the travel function, place the track to be

measured against a pile of soil to make it
immovable. Slowly operate the travel lever to the
stroke end to relieve the travel function.
5. Read the pressure gauge while relieving each
function.
T4-5-8
NOTE: If all measured values are lower than the

specified main relief pressure, the setting
of the main relief valve is suspected to be
the cause.
If the relief pressure for a particular
function is lower than the specified main
relief pressure, something other than the
main relief valve is the cause.

Main Relief
Procedure
Pressure
Setting
Adjustment
Main Control Valve
Adjustment:
Adjust the main relief valve pressure settings using
plug (for the low-side main relief pressure) and
sleeve (for high-side main relief pressure) after
loosening lock nut (4).
High-Side
Main Relief
Adjustment Procedure
Pressure
Main Relief
Valve
Setting
1. Loosen lock nut 2. Tighten plug until the bottom

of piston comes into contact with sleeve.
Retighten lock nut 2.
: 22 mm, 30 mm
: Lock nut 2 (4): 59 Nm (6 kgfm, 13 lbfft)
T183-03-03-029
Swing Control Valve
Main Relief
Valve
2. Loosen lock nut 1. Turn sleeve to adjust the relief

pressure setting, referring to the table below.
: 22 mm, 41 mm
: Lock nut 1: 98 Nm (10 kgfm, 22 lbfft)
Low-Side
Main Relief
Adjustment Procedure
Pressure
Setting
3. Loosen lock nut 2. Turn plug counterclockwise

until the specified value is obtained. Retighten
lock nut 2.
: 22 mm, 30 mm
: Lock nut 2: 59 Nm (6 kgfm, 13 lbfft)
Plug
T183-03-03-030
Lock Nut 2
Sleeve
Lock Nut 1
Piston
4. Recheck the set pressures.

NOTE: : Standard Change in Pressure Setting
Sleeve and
1/4
1/2
3/4
1
plug turns
MPa
4.4
8.8
13.2
17.7
(kgf/cm2)
(45)
(90)
(135)
(180)
(psi)
(640) (1280) (1920) (2560)
T162-04-04-010
Sleeve, Plug
Pressure
Increase
Pressure
Decrease
W107-02-05-127
T4-5-9

Swing Relief Valve
Swing Relief Valve Set Pressure Adjustment

Procedure
Adjustment:
Loosen the lock nut.
: 17 mm
1. Turn the adjusting screw to adjust the pressure
setting.
T142-01-02-011
Adjusting
Screw
2. Retighten the lock nut.

: 17 mm
: 19.5 to 29.5 Nm
(2 to 3 kgfm, 15 to 22 lbfft)
Lock Nut
T142-02-02-006
NOTE: Standard Change in Relief Pressure Setting

Screw Turns
1/4
1/2
3/4
1
MPa
2.75
5.49
8.24
11.0
(kgf/cm2)
(28)
(56)
(84)
(112)
(psi)
(340)
(796)
(1195) (1593)
Lock Nut
Pressure
Increase
Adjusting Screw
Pressure Decrease
T105-06-05-002
T4-5-10

Swing Relief Valve Set Pressure Adjustment
Procedure
Adjustment:
1. Loosen the lock nut.
: 19 mm
2. Turn the adjusting screw to adjust the pressure
setting.
: 6 mm
Travel Relief
Valve
T183-01-02-012
3. Retighten the lock nut.

: 19 mm
: 34.3 to 44.1 Nm
(3.5 to 4.5 kgfm, 25.3 to 32.5 lbfft)
Lock Nut
Adjusting
Screw
NOTE: Standard Change in Relief Pressure Setting

Screw Turns
1/4
1/2
3/4
1
MPa
1.96
3.92
5.88
7.85
(kgf/cm2)
(20)
(40)
(60)
(80)
(psi)
(280)
(570)
(850)
(1140)
T142-05-04-007
Lock Nut
Pressure
Increase
Adjusting Screw
Pressure
Decrease
W107-02-05-129
T4-5-11

OVERLOAD
PRESSURE
RELIEF
VALVE
SET
Summary:
1. The circuit pressure must be increased by
applying an external force while blocking the
return circuit from the control valve. This
measuring method is hazardous and the results
obtained with this method are unreliable.
2. The oil flow rate used to set the overload relief
pressure is far less than that used to set the main
relief pressure. Therefore, measuring the overload pressure in the main circuit by increasing
the main relief set-pressure more than the overload valve set-pressure is not a proper method.
In addition, in case a main relief valve designed
to leak a small quantity of oil before reliving is
used, its pre-leaking start pressure must be increased more than the overload relief valve
set-pressure. However, the pre-leaking start
pressure is not always increased more than the
overload relief valve set-pressure as the adjustable upper limit of the main relief valve
set-pressure is provided. Accordingly, the overload relief valve assembly should be removed
from the machine and checked on a specified
test stand at a correct oil flow rate. Some overload relief valves come in contact with the control
valve body to block the oil passage. When this
type of overload relief valve is 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.
3. If the overload relief valve performance must be
checked on the machine, however, measure the
main relief pressure while releasing each front
function respective to the measuring overload
relief valve. And, assume that the overload relief
valve is functioning correctly if the obtained main
relief pressure is within the specified value range.
Measure the main pressure of the front functions
as follows:
T4-5-12

Overload Relief Valve Set Pressure Adjusting
Procedure
Boom, Arm, Bucket 1, Bucket 2,
Auxiliary: BH/Bucket Open, Close :LD, Swing

NOTE: BH: Backhoe
LD: Loading Shovel
Adjusting
Screw
NOTE: In principle, adjust the overload relief valve

set pressure on a test stand.
Lock Nut
Adjustment:
Adjust the pressure setting of the overload relief
valve using adjusting screw after loosening lock nut.
1. Loosen lock nut.
: 19 mm
2. Turn adjusting screw to adjust the pressure
setting referring to the table below.
: 6 mm
T162-04-04-004
Adjusting Screw
3. Retighten lock nut.

: 19 mm
: 98 Nxm (10 kgfxm, 72 lbfxft)
Pressure Increase
NOTE: Standard Change in Pressure Setting
W107-02-05-129
Screw Turns
1/4
1/2
3/4
MPa
3.9
7.8
11.7
15.6
(kgf/cm )
(40)
(78)
(120)
(160)
(psi)
(566)
(1131)
(1697)
(2262)
Pressure Decrease
T4-5-13

Boom Mode Selection
NOTE: In principle, adjust the overload relief valve
set pressure on a test stand.
Adjustment:
Adjust the pressure setting of the overload relief valve
using sleeve after loosening lock nut (1).
1. Loosen lock nut (1).
: 36 mm
2. Turn sleeve to adjust the pressure setting
referring to the table below.
: 30 mm
Boom Mode
Selection
3. Retighten lock nut.

: 36 mm
: 98 Nm (10 kgfm, 72 lbfft)
T183-03-03-028
Sleeve
Lock Nut
NOTE: Standard Change in Pressure Setting

Screw Turns
1/4
1/2
3/4
MPa
8.9
17.8
26.7
35.6
(kgf/cm )
(90)
(180)
(270)
(360)
(psi)
(1290)
(2581)
(3872)
(5162)
T183-04-04-007
Sleeve
Pressure
Increase
Pressure
Decrease
W107-02-05-127
T4-5-14

(Blank)
T4-5-15

MAIN PUMP FLOW RATE MEASUREMENT
NOTE: MC/V: Main Control Valve
SC/V: Swing Control Valve
P-Q Control (Torque Control)

Summary:
Main pump performance is checked by measuring
the pump flow rate with a hydraulic tester installed
at the main pump delivery line. Measure the flow
rate by using the built-in diagnosing system and a
pressure gauge.
Preparation:
IMPORTANT: The method described here is a simplified method, so that the flow rate
is reduced by approx. 5% compared
to the actual measurement (ex.
bench test). If the actual measurement is required, connect the return
circuit to the hydraulic oil tank instead of the control valve.
before removing it.
1. Stop the engine. Slowly loosen the cap to release
air from the hydraulic oil tank. Connect the vacuum pump to the oil filler port.
NOTE: Keep operating the vacuum pump while
connecting the measurement piping.
to Main Pump 1,
2 and MC/V
to Main Pump 3
and SC/V
Delivery Hose
Split Flange
(ST 6133)
T183-04-04-013
Delivery Hose
Flange
(ST 6123)
Bolt
(ST 6458)
Test Hose
(ST 6145)
Adapter (ST 6146)

Hydraulic Tester (ST 6299)
Adapter
(ST 6146)
Main Pump
Test Hose
(ST 6145)
2. Remove the delivery hose from the main pump to

be measured, then install flange (ST 6123) on the
removed hose using split flange (ST 6133) and
bolt (ST 6458).
Split Flange
(ST 6133)
Bolt
(ST 6458)
3. Install test hose (ST 6145), adapter (ST 6146)

and hydraulic tester (ST 6299) on flange (ST
6123).
Pipe
(ST 6132)
T183-04-04-014
Pressure Gauge (ST 6941)
4. Install pipe (ST 6132) on the delivery port of the

main pump using split flange (ST 6133) and bolt
(ST 6458), then install test hose (ST 6145),
adapter (ST 6146) and hydraulic tester (ST 6299)
on the pipe.
Remove a plug from the pressure check port on
the main pump, then install adapter (ST 6069),
hose (ST 6943) and pressure gauge (ST 6941).
Hose
(ST 6943)
Adapter
(ST 6069)
T4-5-16
T183-04-04-003

5. Disconnect pipes from pump regulator ports Psv
and Pi. Install tee (ST 6640) to port Psv. Connect
tee (ST 6640) between port Psv and circuit Psv.
Connect hose (ST 6961) and elbow (ST 6635,
Code No. 0095) to tee (ST 6640). Connect the
other end of hose (ST 6961) to port Pi using elbow (ST 6635, Code No. 0095). Install a plug to
the pipe end disconnected from port Pi.
(By connecting the pump servo assist pressure
(Psv pressure) circuit to port Pi, the condition
similar to the maximum pump flow rate (maximum Pi pressure at full stroke operation of the
control lever) can be obtained.
6. Disconnect the power increase solenoid valve
connector and power decrease solenoid valve
connector.
7. Fully open the loading valve of the hydraulic
tester.
8. Start the engine. Check the line connections for
any oil leaks. Select the monitor function on the
built-in diagnosing system.
Measurement:
1. Hydraulic oil temperature: 505 C (12241 F)
Port Psv
Port Pi
T183-01-02-006
Psv Pressure
Hose (ST 6961)
Tee (ST 6640)
Elbow (ST 6635)
Elbow (ST 6635)
T183-04-04-004
2. Engine Control Dial: Maximum speed

3. Slowly close the loading valve of the hydraulic
tester to obtain the specified pressure on P-Q
curve, and measure the pump flow rate and engine speed at each pressure. (Refer to T4-2-4)
4. Repeat the measurement three times and calculate the average values.
Evaluation:
Convert the measured flow rates to the values at
the specified pump speed using the following formulas:
QC = (NPQ) / (iNe)
QC: Converted Flow Rate
Q: Measured Flow Rate
i: Pump Drive Gear Ratio (1.083)
NP: Specified Pump Speed (1787 min-1)
Ne: Measured Engine Speed
T4-5-17

Adjustment:
Adjustment of Minimum and Maximum Flow Rate
Pump flow rate can be adjusted by changing the
maximum stroke of the servo piston.
To adjust the maximum flow rate, loosen nut (1) and
turn adjusting screw (2) on the large chamber side
end of the servo piston. To adjust the minimum flow
rate, loosen nut (3) and turn adjusting screw (4) on
the small chamber side end of the servo piston.
: 30 mm for nut (1), (3)
: 13 mm for adjusting screw (2)
: 10 mm for adjusting screw (4)
NOTE: Turn adjusting screw (2) clockwise to

decrease the maximum flow rate and
counterclockwise to increase. Turning adjusting screw (2) one forth turns changes
approximately 9.2 L/min-1 of flow rate.
Turn adjusting screw (4) clockwise to
increase the minimum flow rate and
counterclockwise to decrease. Turning adjusting screw (4) one forth turns changes
approximately 9.2 L/min-1 of flow rate.
T183-04-04-006
(Pump
Flow Rate)
Q
Maximum Flow Rate Adjustment
(Pump
Flow Rate)
Q
Pi
Minimum Flow Rate Adjustment
Pi
(Flow Rate Control
Pressure)
T4-5-18

Adjustment of Torque Control
The torque control is performed by pump delivery
pressure P. Therefore, the torque constant control is
adjusted by changing the set-force of inner spring
(2) and outer spring (1).
(Before adjust the screws (4) and (6), mark the end
of the adjusting screw with a white marker for the
record of the original position.)
When resetting inner spring (2), loosen nut (5) and
adjust screw (6).
When resetting outer spring (1), loosen nut (3) and
adjust screw (4).
NOTE: When adjusting screw (4) is turned, inner

spring (2) set-force varies. Therefore,
when adjusting screw (4) is turned, turn
adjusting screw (6) 2.17 times the turns of
adjusting screw (4) in the opposite direction to keep inner spring (2) set-force unchanged.
: 36 mm : Nut (3)
: 24 mm : Adjusting Screw (4)
: 13 mm : Nut (5)
1
2
3
4
5
T117-05-04-005
Outer Spring Adjustment Data

Adjusting Screw Turn
1/4
Flow Rate Change
40.9 L/min
(10.8 US gal/min)
Pressure Change
1.74 MPa (17.8 kgf/cm2)
(252 psi)
Engine Torque Change
67.6 Nm (6.9 kgfm)
(50 lbfft)
(Pump Flow
Rate)
Q
Inner Spring Adjustment Data

1/4
Flow Rate Change
18.9 L/min
(5 US gal/min)
Pressure Change
1.80 MPa (18.4 kgf/cm2)
(261 psi)
45.1 Nm (4.6 kgfm)
(33 lbfft)
(Pump Flow
Rate)
Q
(Pump Delivery
Pressure)
T4-5-19
(Pump Delivery
Pressure)

Adjustment of Flow Rate Control
The flow rate control is performed by pump flow
rate control pressure Pi. Therefore, the flow rate
control is adjusted by resetting the set-force of
spring (1).
Loosen nut (2) and turn adjusting screw (3) to
reset the set-force of spring (1).
NOTE: When the flow rate control is adjusted, the

relief oil minimizing control is also changed
at the same time.
: 13 mm : Nut (2)
1
2
T117-05-04-006
Spring Adjustment Data

1/4
Pressure Change (Pi)
0.15 MPa (1.5 kgf/cm2)
(21.8 psi)
Flow Rate Change
42.7 L/min
(11.2 US gal/min)
(Pump Flow
Rate)
Q
Flow Rate Control
(Pump Flow
Rate)
Q
Pi (Flow Rate Control

Pressure)
T4-5-20
Relief Oil Minimizing Control
P (Pump Delivery
Pressure)

(Blank)
T4-5-21

OIL COOLER FAN MOTOR DRIVE PUMP
FLOW RATE MEASUREMENT
Delivery Hose
P-Q Control (Torque Control)

Summary:
Oil cooler fan motor drive pump performance is
checked by measuring the pump flow rate with a
hydraulic tester installed at the oil cooler fan motor
drive pump delivery line.
Preparation:
before removing it.
1. Stop the engine. Slowly loosen the cap to release
air from the hydraulic oil tank. Connect the vacuum pump to the oil filler port.
NOTE: Keep operating the vacuum pump while
connecting the measurement piping.
T183-04-04-015
Split Flange
(4506459)
Delivery Hose
Bolt
(ST 6408)
Adapter (ST 6146)
Test Hose
(ST 6145)
2. Remove the delivery hose, then install flange (ST

6574) on the removed hose using split flange
(4506459) and bolt (ST 6408).
Test Hose
(ST 6145)
Flange(ST 6574)
Adapter(ST 6146)
Hydraulic Tester (ST 6299)
Bolt (ST 6408)
Split Flange
Pipe
(4506459)
(ST 6575)
Oil Cooler Fan
Motor Drive Pump
3. Install test hose (ST 6145), adapter (ST 6146)

and hydraulic tester (ST 6299) on flange (ST
6574).
4. Install pipe (ST 6575) on the delivery port of the
main pump using split flange (4506459) and bolt
(ST 6408), then install test hose (ST 6145),
adapter (ST 6146) and hydraulic tester (ST 6299)
on the pipe.
Remove a plug from the pressure check port,
then install adapter (ST 6069), hose (ST 6943)
and pressure gauge (ST 6941).
T183-04-04-018
Hose (ST 6943)
Pressure Gauge (ST 6941)
Adapter (ST 6069)
T4-5-22
T183-04-04-019

5. Disconnect the pipe from regulator ports Pi.
Leave the port Pi open to the atmosphere. Plug
the disconnected pipe end.
6. Disconnect the connector of the oil cooler fan
control solenoid valve SF.
7. Fully open the loading valve of the hydraulic
tester.
8. Start the engine. Check the line connections for
any oil leaks.
Pi
Measurement:
1. Engine Control Dial: Maximum speed
T183-04-04-016
2. Slowly close the loading valve of the hydraulic

tester to obtain the specified pressure on P-Q
curve, and measure the pump flow rate and engine speed at each pressure. (Refer to T4-2-4)
3. Repeat the measurement three times and calculate the average values.
Evaluation:
Convert the measured flow rates to the values at
the specified pump speed using the following formulas:
QC = (NPQ) / (iNe)
QC: Converted Flow Rate
Q: Measured Flow Rate
i: Pump Drive Gear Ratio (1.106)
NP: Specified Pump Speed (1825 min-1)
Ne: Measured Engine Speed
T4-5-23

Adjustment:
Adjustment of Maximum and Minimum Flow Rate
The pump flow rate can be adjusted by changing
the maximum servo piston stroke. When adjusting
the maximum flow rate, loosen nut (1) and adjusting
screw (2) on the servo piston large chamber side.
When adjusting the minimum flow rate, loosen nut
(3) and adjusting screw (4) on the servo piston
small chamber side.
NOTE: Turning adjusting screw (2) clockwise decreases the maximum flow rate, and turning counterclockwise increases. 1/4 turn of
adjusting screw (2) changes the flow rate
approx. 3 L/min (0.8 US gal/min).
Turning adjusting screw (4) clockwise increases the minimum flow rate, and turning counterclockwise decreases. 1/4 turn
of adjusting screw (4) changes the flow
rate approx. 3 L/min (0.8 US gal/min).
: 24 mm : Nut (1), Nut (3)

T183-03-01-003
(Pump
Flow Rate)
Q
Maximum Flow Rate Adjustment
(Pump
Flow Rate)
Q
Pi
Minimum Flow Rate Adjustment
Pi
(Flow Rate Control
Pressure)
T4-5-24

Adjustment:
Adjustment of Torque Control
The torque control is performed by pump delivery
pressure P. Therefore, the torque constant control is
adjusted by changing the set-force of inner spring
(2) and outer spring (1).
(Before adjusting screws (4) and (6), mark the end
of the adjusting screw with a white marker for the
record of the original position.)
When resetting inner spring (2), loosen nut (5) and
adjusting screw (6).
When resetting outer spring (1), loosen nut (3) and
adjusting screw (4).
NOTE: When adjusting screw (4) is turned, inner

spring (2) set-force varies. Therefore,
when adjusting screw (4) is turned, turn
adjusting screw (6) 2.24 times the turns of
adjusting screw (4) in the opposite direction to keep inner spring (2) set-force unchanged.
: 36 mm : Nut (3)
: 13 mm : Nut (5)
1
W117-02-02-017
Outer Spring Adjustment Data

1/4
Flow Rate Change
9.3 L/min
(2.5 US gal/min)
Pressure Change
1.88 MPa (19.2 kgf/cm2)
(273 psi)
16.7 Nm (1.7 kgfm)
(12.3 lbfft)
(Pump Flow
Rate)
Q
(Pump Delivery
Pressure)
T4-5-25

Adjustment:
Adjustment of Flow Rate Control
The flow rate control is performed by pump flow
rate control pressure Pi. Therefore, the flow rate
control is adjusted by resetting the set-force of
spring (1).
Loosen nut (2) and turn adjusting screw (3) to
reset the set-force of spring (1).
NOTE: When the flow rate control is adjusted, the

relief oil minimizing control is also changed
at the same time.
: 13 mm : Nut (2)
1
2
T117-05-04-006
Spring Adjustment Data

1/4
Pressure Change (Pi)
0.13 MPa (1.3 kgf/cm2)
(18.9 psi)
Flow Rate Change
6.8 L/min (1.8 US gal/min)
(Pump Flow
Rate)
Q
Flow Rate Control
(Pump Flow
Rate)
Q
Pi (Flow Rate Control

Pressure)
T4-5-26
Relief Oil Minimizing Control
P (Pump Delivery
Pressure)

(Blank)
T4-5-27

SWING MOTOR DRAINAGE
Cap
Summary:
To check swing motor performance, measure the
amount of oil draining from the swing motor while
swinging the upperstructure.
Swing motor while swinging the upperstructure.
NOTE: The amount of drain oil from the swing
motor will change depending on hydraulic
oil temperature.
Maintain hydraulic oil temperature within
505 C (12241 F).
Preparation:
1. Maintain hydraulic oil temperature at 505 C
(12241 F). Rotate the swing motor to warm the
inside of the motor.
Drain Hose
M183-07-052
Front Side

before removing it.
2. Properly shut down the engine. Slowly loosen
cap to release air from the hydraulic oil tank.
3. Disconnect the swing motor drain hose at the
hydraulic oil tank end. Install plug (ST 6491) to
the disconnected end on the hydraulic oil tank.
: 27 mm
: 93 Nm (9.5 kgfm, 69 lbfft)
T183-04-04-008
Drain Hose
Preconditions for Measurement:

starting machine operation. Also, take care
not fall off the machine during the
measurement.
T183-04-04-009
ST 6491
T183-04-04-010
T4-5-28

Measurement:
1. Amount of Oil Drained While Swinging the
Upperstructure
1-1. Fully retract the arm cylinder. Fully extend the
bucket cylinder. Raise the boom so that the arm
tip pin height is the same as the boom foot pin
height. Be sure that the bucket is empty.
1-2. Start the engine. Operate and hold the swing
lever full stroke. Start draining oil measurement
after the swing speed reaches a constant
maximum speed. The measuring time should
be more than 20 seconds.
1-3. 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
2-1. Thrust the bucket teeth into the ground as
illustrated so that the upperstructure does not
rotate when the swing lever is operated full
stroke.
2-2. Start the engine. Operate and hold the swing
lever full stroke. Start drain oil measurement
when drain oil starts coming out of the drain
hose end. The measuring time should be more
than 20 seconds.
2-3. Repeat the measurement at least three times in
both clockwise and counterclockwise directions,
and calculate the average values.
T145-05-03-007
T145-05-03-008
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
T183-04-04-009
Where :
Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-5-29

TRAVEL MOTOR DRAINAGE
Cap
Summary:
To check travel motor performance, measure the
amount of oil draining from the travel motor, while
rotating the travel motor with the measuring side
track jacked up.
NOTE: The amount of drain oil from the travel

motor and the drain oil pressure will
change depending on hydraulic oil
temperature.
Maintain
hydraulic
oil
temperature within 505 C (12241 F).
Preparation:
1. Main main hydraulic oil temperature at 505 C
(12241 F). Rotate the travel motor to warm the
inside of the motor.
Drain Hose
M183-07-052

the hydraulic oil tank. The cap may pop off
before removing it.
2. Properly shut down the engine. Slowly loosen
cap to release air from the hydraulic oil tank.
3. Disconnect the travel motor drain hose at the
travel motor end. Install plug (ST 6637) to the
disconnected end. Connect the drain hose
(3/4-16UN) to the travel motor.
: 27 mm
: 93 Nm (9.5 kgfm, 69 lbfft)
M183-01-001
Drain Hose

Engine Control Dial: Maximum Position
Drain Hose
T157-05-04-019
ST 6637
T183-04-04-011
T4-5-30

Engine Control Dial : Maximum Speed
Measurement:
1. Start the engine. Jack up the measuring side
track using the front attachment, as illustrated.
90110
CAUTION: Securely support the raised track

using wooden blocks.
T142-05-03-011
2. Rotate the raised track with the travel lever

operated full stroke. Start drain oil measurement
after the track rotation speed reaches a constant
maximum speed. The measuring time should be
more than 20 seconds.
3. Repeat the measurement at least three times in
both forward and reverse directions and calculate
the average values.
Evaluation:
T4-2.
T142-05-03-012
Conversion of the amount of drain oil measured

into the paramount value
First measure the amount of drain oil using a
calibrated container. Then, convert the measured
drain oil into the paramount value using the
formula below:
Q = 60 q / t
Where :
Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T157-05-04-019
T4-5-31

(Blank)
T4-5-32
MEMO
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SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 General
Group 4 Troubleshooting A
Introduction .............................................. T5-1-1

Diagnosing Procedure .............................. T5-1-2
Built-In Diagnosing System Operation ...... T5-1-4
Built-In Diagnosing Function Display List.. T5-1-6
Binary Number Bit List.............................T5-1-11
Main Controller Fault Code List .............. T5-1-14
Group 2 Cross Reference Table

Electrical Circuit Diagram ......................... T5-2-1
Hydraulic Circuit Diagram (Backhoe)........ T5-2-6
Hydraulic Circuit Diagram (Loading
Shovel)................................................... T5-2-8
Group 3 Component Layout

Main Components .................................... T5-3-1
Electrical System Components (1)............ T5-3-2
Troubleshooting A Procedure .................... T5-4-1

Main Controller Fault Code List ................ T5-4-2
Main Controller A
Fault Code 01, 02, 03 ............................. T5-4-4
Fault Code 04 ......................................... T5-4-4
Fault Code 05 ......................................... T5-4-5
Fault Code 06 ......................................... T5-4-6
Fault Code 07 ......................................... T5-4-7
Fault Code 08, 09 ................................... T5-4-8
Fault Code 10 ....................................... T5-4-10
Fault Code 11, 12, 13............................ T5-4-12
Fault Code 25 ....................................... T5-4-13
Main Controller B
Fault Code 31, 32, 33 ........................... T5-4-14
Fault Code 34 ....................................... T5-4-14
Fault Code 37 ....................................... T5-4-15
Sensor Activating Range......................... T5-4-16
Group 5 Troubleshooting B
Troubleshooting B Procedure ................... T5-5-1
On and Around Pumps ........................... T5-3-10
Correlation between Trouble
Main Control Valve ................................. T5-3-12
Symptoms and Part Failures ................... T5-5-2
Swing Control Valve ............................... T5-3-16
Engine System Troubleshooting ............. T5-5-14
Signal Control Valve ............................... T5-3-21
All Actuator System Troubleshooting ...... T5-5-36
Others .................................................... T5-3-30
Front Attachment System

Troubleshooting .................................... T5-5-44
Swing System Troubleshooting ............... T5-5-58
Travel System Troubleshooting............... T5-5-61
Other System Troubleshooting................ T5-5-68
Work After Replacing Components ......... T5-5-92
Add Compressor oil ................................ T5-5-92
Charge Air Conditioner With
Refrigerant ............................................ T5-5-93
18ET-5-1
Group 6 Troubleshooting C
Group 7 Troubleshooting D
Troubleshooting C (Troubleshooting for Monitor)

Procedure .............................................T5-6-1
Troubleshooting D Procedures .................T5-7-1

Fault Code Indication by Indicator
Blinking Pattern ......................................T5-7-3
Malfunction of Coolant
Temperature Gauge................................T5-6-2
Fault Codes for Quantum Engines ............T5-7-5
Malfunction of Fuel Gauge .......................T5-6-4
Group 8 Electrical System Inspection
Malfunction of Indicator Light

Check System ........................................T5-6-6
Precautions for Inspection and
Malfunction of Overheat Indicator .............T5-6-8

Malfunction of Air Cleaner Restriction
Maintenance ...........................................T5-8-1
Inspections for Disconnecting
Indicator ...............................................T5-6-10
Connectors .............................................T5-8-3
Malfunction of Fuel Level Indicator .........T5-6-12
Fuse Inspection ........................................T5-8-4
Malfunction of Preheat Indicator .............T5-6-14
Fusible Link Inspection .............................T5-8-7
Malfunction of Download Indicator ..........T5-6-15
Battery Voltage Check ..............................T5-8-8
Malfunction of Alternator Indicator ..........T5-6-16
Alternator Check ......................................T5-8-8
Malfunction of Engine Oil Pressure
Voltage Check ........................................T5-8-10
Indicator ...............................................T5-6-18
Continuity Check ....................................T5-8-17
Malfunction of Pump Transmission

Oil Pressure Indicator ...........................T5-6-20
Malfunction of Engine Oil Level
Indicator ...............................................T5-6-22
Malfunction of Coolant Level Indicator ....T5-6-24
Malfunction of Hydraulic Oil Level
Indicator ...............................................T5-6-26
Malfunction of Auto-Lubrication
Indicator ...............................................T5-6-30
Malfunction of Engine Stop Indicator ......T5-6-32
Malfunction of Engine Warning
Indicator ...............................................T5-6-34
Malfunction of Quick-Idle Indicator .........T5-6-36
Malfunction of Auto-Idle Indicator ...........T5-6-38
Malfunction of Hourmeter .......................T5-6-40
Malfunction of Buzzer .............................T5-6-42
Malfunction of Liquid Crystal Display (LCD)...T5-6-44
Malfunction of Engine Troubleshooting
Operation .............................................T5-6-46
18ET-5-2
TROUBLESHOOTING / General
INTRODUCTION
Refer to the inspection and troubleshooting procedures after any machine trouble has occurred. The
inspection and troubleshooting procedures are presented in an orderly fashion in this section to help you
quickly find the cause and solution of the machine
trouble.
The troubleshooting section in this manual consists of
8 groups; General, Cross Reference Table, Component Layout, Troubleshooting A (base machine diagnosis using the built-in diagnosing systems fault
codes), Troubleshooting B (base machine diagnosis
starting with inspection of abnormal operational
status), Troubleshooting C (monitor diagnosis), Troubleshooting D (engine diagnosis indicated by the
flashing pattern of indicator lights), and Electrical
System Inspection.
General
Cross Reference Table
Component Layout
Troubleshooting A (base machine diagnosis using the built-in diagnosing systems fault codes)
Troubleshooting B (base machine diagnosis
starting with inspection of abnormal operational
status)
Refer to these procedures when troubleshooting
by inspecting abnormal machine operational
status.
Example: Even if the fuel lever is operated, engine speed doesnt change.
Troubleshooting C (monitor diagnosis)
Refer to these procedures when gauges and/or
indicators are malfunctioning.
Example: The fuel gauge doesnt operate.
Troubleshooting D (engine diagnosis relies on
the flashing pattern of indicator lights)
The engine is diagnosed by referring to the flashing pattern of the engine warning indicator.
Electrical System Inspection
Refer to this group when required to obtain precautions and/or information for the electrical system
inspection.
Example: Fuse Inspection
T5-1-1
DIAGNOSING PROCEDURE
These six basic steps are essential for efficient
troubleshooting:
1. Study the system
Study the machines technical manuals. Know the
system and how it works, and what the
construction, functions and specifications of the
system components are.
T107-07-01-001
2. Ask the operator

Before inspecting, get the full story of
malfunctions from your star witness --- the
operator.
How is the machine being used? (Find out if the
machine is being operated correctly)
When was the trouble noticed, and what types of
work the machine doing at that time?
What are the details of the trouble? Is the trouble
getting worse, or did it appear suddenly for the
first time?
Did the machine have any other troubles
previously? If so, which parts were repaired
before?
T107-07-01-002
3. Inspect the machine

Before starting the troubleshooting procedure,
check the machines 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.
T5-1-2
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.
5. Perform troubleshooting
T107-07-01-004
CAUTION: If a harness or pipe is disconnected with the engine running, the machine
may operate incorrectly, or high pressure oil
may spray, causing personal injury. Be sure
to disconnect harnesses or pipes after stopping the engine.
Perform self-diagnosis by operating the built-in
self-diagnosing system. In case any fault code
has been displayed by diagnosis using the
built-in self-diagnosing system, check the cause
of the trouble by referring to Troubleshooting A in
this section. After the machine trouble has been
corrected, the fault code will be deleted. If the
engine stop indicator and the engine warning indicator in the cab start flashing by the ECM diagnosis system, check the cause of the trouble
by referring to Troubleshooting D in this section.
Therefore, in case problems which are not easily
repredicable are encountered, use the built-in
self-diagnosing system and ECM diagnosis system to display the fault code. In case no fault
codes are displayed, check all related
parts/component operating condition using the
monitor function of the built-in self-diagnosing
system while referring to troubleshooting B in this
section.
T107-07-01-006
6. Trace possible causes

Before reaching a conclusion, check the most
likely causes again. Try to identify the actual
cause of the trouble.
Based on your conclusion, make a plan for
appropriate repairs to avoid consequent
malfunctions.
T107-07-01-007
T5-1-3
BUILT-IN
DIAGNOSING
OPERATION
SYSTEM
IMPORTANT: This system is to be operated by the

HITACHI Dealer Only. Don't explain
this system function to the customer.
In the service mode, the monitor LDC displays the diagnosing items, fault codes and monitored results (not
all of them).
Built-In Diagnosing System Activation
1. While pressing the monitor SET switch, turn the
key switch ON.
Display
Selection Switch
Built-In Diagnosing System Operation

1. Each time the display selection switch is pressed,
the displayed item will be changed as shown in
the table on T5-1-6 or T5-1-7.
SET Switch
NOTE: The fault code is indicated in the display

order 8. Fifteen fault codes for the main
controller A and five fault codes for the
main controller B are indicated. In case
more than one fault code is indicated, they
will be displayed with an interval of 1 second in order.
The LCD in the service mode displays only the item
No. on the left and the monitored result on the right.
The item description is not displayed.
Liquid Crystal
Display (LCD)
T183-01-02-013
Display Selection between Main Controller A and

B
1. Remove the side cover on the left console.
2. Switch the MC display selection switch.
ON: Displays the main controller A value
OFF: Displays the main controller B value
NOTE: The main controller A value is displayed
when the MC display selection switch is in
neutral position.
Side Cover
M183-01-008
MC
Display
Selection
Switch
Machine
Front
ON
Neutral
OFF
T5-1-4
T183-05-01-001
(Blank)
T5-1-5
BUILT-IN
DIAGNOSING
DISPLAY LIST
Main Controller A
Display
Description
Order
1.
Hour Meter
2.
Trip1
3.
Trip2
4.
Engine Actual Speed
5.
Hydraulic Oil Temperature
6.
7.
8.
Fault Code *
9.
Main Pump 1 Pressure
10.
11.
12.
Front Operation Pressure
13.
Travel Operation Pressure
Engine Exhaust Gas
14.
Temperature
15.
FUNCTION
Monitored
Result
Unit
{{{{{ h
{{{{{ h
{{{{{ h
n {{{{
{{{
L1 {{
L2 {{{
0
{{
1
{{{{
2
{{{{
3
{{{{
4
{{{{
5
{{{{
6
0
min-1
C
MPa
MPa
MPa
MPa
MPa
C
EC Angle
Digital Input 0
7
8
{{{{
{{
Digital Input 1
{{
Digital Input 2
{{
Digital Input 3
{{
Digital Output
{{
Proportional Valve
ON/OFF Output
{{
Hydraulic Oil Cooling

Output Current
Power Increase Output
Current
{{{{
V
2 Digits displayed in
Hexadecimal Number
**
Hexadecimal Number
**
Hexadecimal Number
**
Hexadecimal Number
**
Hexadecimal Number
**
Hexadecimal Number
**
mA
{{{{
mA
16.
17.
18.
19.
20.
21.
22.
23.
NOTE: * Refer to T5-1-14 for the Fault Codes.

** Refer to T5-1-8 and T5-1-11 for 2 Digits
displayed in Hexadecimal Number.
T5-1-6
Remarks
Standard Mode
Standard Mode (Subtraction)
Possible to display
Possible to display
Display Purpose Only
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Fixed by 0 C (32 F)
(Not used for the CUMMINS
engine)
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Main Controller B
Display
Description
Order
1.
Hour Meter
2.
Trip1
3.
Trip2
4.
Engine Actual Speed
5.
6.
7.
8.
Fault Code *
9.
Digital Input 0
Monitored
Result
{{{{{ h
{{{{{ h
{{{{{ h
n {{{{
{{{
L1 {{
L2 {{{
0
{{
1
{{
10.
Digital Input 1
{{
11.
Digital Input 2
{{
12.
Digital Input 3
{{
13.
Digital Output 1
{{
14.
Proportional Valve
ON/OFF Output
{{
15.
Auto-Lubrication Status 1
{{
16.
(upper 4 bits)
(lower 4 bits)
Auto-Lubrication Interval
Selection
{{{{
{{{{
{{
Digital Output 2
(upper 4 bits)
Digital Output 2
(lower 4 bits)
{{{{
{{{{
17.
18.
19.
20.
21.
22.
23.
NOTE:
Unit
min-1
C
Hexadecimal Number
**
Hexadecimal Number
**
Hexadecimal Number
**
Hexadecimal Number
**
Hexadecimal Number
**
Hexadecimal Number
**
Hexadecimal Number
**
Binary Number ***
Binary Number ***
Hexadecimal Number
**
Binary Number ***
Binary Number ***
d
E
F
* Refer to T5-1-15 for the Fault Codes.

** Refer to T5-1-8 and T5-1-11 for 2 Digits displayed in Hexadecimal Number.
*** Refer to T5-1-13 for 4 Digits displayed
in Binary Number.
T5-1-7
Remarks
Standard Mode
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Hexadecimal Number and 2 Digits Display
Correspondence Chart between
Number and Binary Number
Hexadecimal
Number
Binary Number
Hexadecimal
0000
0001
0010
0011
0100
0101
0110
0111
1000
1001
1010
1011
1100
1101
1110
1111
In Case of Digital Input of Main Controller A

(Ex.) Monitor Display
60
8
Upper
Hexadecimal Number 2 Digits Display Section

Lower
1. Convert the upper and lower number in the

hexadecimal number 2 digits display section.
(Refer to Correspondence Chart between Hexadecimal Number and Binary Number).
Upper 6
0110
Lower 0
0000
Therefore, binary number 01100000 can be obtained.
2. This value corresponds the bit on the Binary
Number Bit List (refer to T5-1-11), as follows:
bit
bit
bit
bit
bit
bit
bit
bit
7
6
5
4
3
2
1
0
0
1
1
0
0
0
0
0
Main Controller Selection Switch = 0

Engine Oil Level Indicator
Heavy Lift Switch
Display Selection = 0
Checker Connection
Blank = 0
Blank = 0
Blank = 0
Main Controller A
bit Status of
Main Controller
(0)
Contact Terminal is
GND
Opened
Current
(1)
Contact Terminal
is Closed
Diagram 1. In Case of Digital Input
3. If the value is "1", the terminal point corresponding the bit is closed. The contact terminal is connected to ground, so that power flows.
If the value is "0", the terminal point is opened, so
that current does not flow. (Refer to Diagram 1)
From the above information, it becomes apparent
that the engine oil level indicator on the monitor is
switched on, the heavy lift switch is turned on,
and the checker is disconnected.
4. Convert the value for digital input 1, digital input 2,
digital input 3 of the main controller A, and digital
input 0, digital input 1, digital input 2 and digital
input 3 of the main controller B. Then, calculate
the corresponding bit values.
T5-1-8
GND
In Case of Digital Output of Main Controller A
51
c
Upper

Lower
1. Convert the upper and lower number on the

Upper 5
0101
lower 1
0001
bit 7
bit
bit
bit
bit
bit
bit
bit
1
0
1
0
0
0
1
6
5
4
3
2
1
0
Engine Exhaust Gas Temperature

Alarm Output
Engine Oil Pressure Alarm Output
Pump Cut-Off Output
Travel Alarm Output
Engine Protection Output
Blank = 0
Engine Stop Request
Auto-Idle Output
Main Controller A
bit Status of Main Controller
Current
Vcc
Load
(1)
GND
Vcc
Load
(0)
GND
Diagram 2. In Case of Digital Output
3. If the value is "1", the controller internal voltage at

the terminal corresponding the bit is connected to
ground, so that power flows.
If the value is "0", the controller internal voltage at
the terminal corresponding the bit does not connected to ground, so that power does not flow.
(Refer to Diagram 2)
that the engine oil pressure indicator is turned on,
and motion alarm and auto-idle control are activated.
4. Convert the value for digital output 1 of the main
controller B. Then, calculate the corresponding
bit values.
T5-1-9
Correspondence Chart between Hexadecimal Number and Binary Number
Hexadecimal
Number
Binary Number
0000
0001
0010
0011
0100
0101
0110
0111
1000
1001
1010
1011
1100
1101
1110
1111
In Case of Proportional Valve ON/OFF Output of Main

Controller A
60
d
Upper

Lower
1. Convert the upper and lower number on the

Upper 6
0110
lower 0
0000
bit 7
bit 6
0
1
bit 5
bit
bit
bit
bit
bit
0
0
0
0
0
4
3
2
1
0
Heavy Lift Solenoid Valve Output

#1,#2 Pump Power Decrease Solenoid
Valve Output
#3 Pump Power Decrease Solenoid
Valve Output
Blank = 0
Blank = 0
Blank = 0
Blank = 0
Blank = 0
3. If the value is "1", power flows at the terminal

corresponding the bit.
If the value is "0", current does not flow at the
terminal. (Refer to Diagram 3)
that power flows on the #1, #2 power decrease
solenoid valve and #3 pump power decrease solenoid valve.
4. Convert the value for the proportional valve
On/Off output of the main controller B. Then, calculate the corresponding bit values.
T5-1-10
Main Controller A
bit Status of Main Controller
Current
Solenoid Valve
(1) Energized
Solenoid Valve
(0) De-energized
Diagram 3. Proportional Valve ON/OFF Output
BINARY NUMBER BIT LIST
Upper
Lower
Hexadecimal
Number
Binary
Number
bit 7
Main Controller A
Display
Description
Order
16
Digital Input 0
17
Digital Input 1
18
Digital Input 2
bit 6
bit
Digital Input 3
Digital Output
21
Proportional
Valve ON/OFF
Output
bit 3
bit 2
bit 1
Upper
bit 0
bit
Lower
Main Controller Selection Switch

Engine Oil Level Indicator
Heavy Lift Switch
Display Selection Switch
Blank = 0
Auto-Idle Switch
Overheat Switch
S/P Mode Switch
Blank = 0
3
2
1
0
3
2
1
0
3
Air Filter Restriction Indication

Switch
Coolant Level Switch
Engine Oil Pressure Switch
(Low Pressure)
Blank = 1
Fuel Level Indicator
Alternator Indicator
Engine Oil Pressure Switch
(High Pressure)
Engine Exhaust Gas Temperature
Alarm Output
Engine Oil Pressure Alarm Output
Pump Cut-Off Output
Travel Alarm Output
Heavy Lift Solenoid Valve Output
#1, #2 Pump Power Decrease
Solenoid Valve Output
#3 Pump Power Decrease Solenoid
Valve Output
Blank = 0
Checker Connection Switch

Blank = 0
Blank = 0
Blank = 0
E Mode Switch
Blank = 0
Blank = 0
Blank = 0
Pump Contamination Sensor
Input (Optional)
Blank = 0
0
1
Blank = 0
Blank = 0
3
2
1
0
Blank = 0
Blank = 0
Blank = 0
Blank = 0
Engine Protection Output
2
1
0
3
2
Blank = 0
Engine Stop Output
Auto-Idle Output
Blank = 0
Blank = 0
Blank = 0
Blank = 0
7
6
5
4
7
20
bit 4
7
6
5
4
7
6
5
4
7
5
4
19
bit 5
6
5
4
7
6
5
4
T5-1-11
Upper
Lower
Hexadecimal
Number
Binary
Number
bit 7
Main Controller B
Display
Description
Order
bit 6
bit
bit 5
bit 4
bit 3
bit 2
bit 1
Upper
bit 0
bit
Lower
Digital Input 0
10
Digital Input 1
6
5
4
7
Hydraulic Oil Level Switch (2)

Boom Mode Selection Switch
Auto-Lubrication Interval Set (A)
Blank = 0
2
1
0
3
11
Digital Input 2
6
5
4
7
Blank = 0
Travel Mode Switch
Auto-Lubrication Timer Switch (B)
Blank = 1
2
1
0
3
12
Digital Input 3
13
Digital
1
6
5
4
7
6
5
4
7
2
1
0
3
2
1
0
3
14
Proportional
Valve ON/OFF
Output
Blank = 0
Auto-Lubrication Interval Set (B)
Auto-Lubrication Cycle Switch (B)
Hydraulic Oil Level Alarm Output
Load Dump Prevention Output
Step Light Output
Auto-Lubrication Relay Output
Boom Mode Selection Solenoid
Valve Output
Output
Blank = 0
Blank = 0
Auto-Lubrication Activating
Auto-Lubrication Indication
Auto-Lubrication Error Occurrence
Blank = 0
Checker Connection Switch

Blank = 0
Blank = 0
Blank = 0
Auto-Lubrication Main Switch
(A)
Blank = 0
Blank = 0
Blank = 0
Auto-Lubrication Main Switch
(B)
Blank = 0
Blank = 0
Blank = 0
Auto-Lubrication Timer Switch
(A)
Blank = 0
Blank = 0
Blank = 0
Blank = 0
Blank = 0
Blank = 0
Auto-Lubrication Alarm Output
Blank = 0
Blank = 0
1
0
3
2
1
0
Blank = 0
Blank = 0
Blank = 0
Blank = 0
Lubrication Selection
15
Output
Auto-Lubricatio
n Status 1
7
6
5
4
7
Main Controller Selection Switch

Hydraulic Oil Level Switch (1)
Step Light Switch
Display Selection Switch
Blank = 0
3
2
1
0
3
6
5
4
7
6
5
4
NOTE: Lubrication status of

Status 1 are as follows:
Stopping: bit1=0 / bit0=0
Manual: bit1=0 / bit0=1
Auto: bit1=1 / bit0=0
Auto-Lubrication
T5-1-12
NOTE: No need to convert to binary number.
Display
Description
Upper
Data Set Value
Order
(Long, Middle, Short) =
0
(80, 70, 60) min
Selection of
18
Auto-Lubrication
1
(50, 40, 30) min
Interval
2
(30, 20, 10) min
Lower
Interval Value
Long
Middle
Short
Selection Pattern of Auto-Lubrication Interval

Auto-Lubrication
Upper
Lower
Interval (min.)
0
0
80
0
1
70
0
2
60
1
0
50
1
1
40
1
2
30
2
0
30
2
1
20
2
2
10
4 Digits Displayed in Binary Number
bit 3
Main Controller B
Display
Description
Order
16
Auto-Lubrication
Status 2
(upper 4 bits)
17
Auto-Lubrication
Status 2
(lower 4 bits)
19
Digital Output 2
(upper 4 bits)
20
Digital Output 2
(lower 4 bits)
bit 2
bit 1
bit 0
bit
3
2
1
0
3
2
1
0
3
2
1
0
3
2
1
0
Auto-Lubrication Activating
Auto-Lubrication Indicator
Auto-Lubrication Error Occurrence
Blank = 0
Blank = 0
Blank = 0
Hydraulic Oil Level Indicator
Load Dump Prevention Output
Step Light Output
Auto-Lubrication Relay Output
Auto-Lubrication Indicator Output
Blank = 0
Blank = 0
Blank = 0
NOTE: Lubrication status of Auto-Lubrication

Status 2 (lower 4 bits) are as follows:
Stopping: bit1=0 / bit0=0
T5-1-13
Manual: bit1=0 / bit0=1

Auto: bit1=1 / bit0=0
MAIN CONTROLLER FAULT CODE LIST
Main Controller A
Fault Code
Trouble
00
Normal
01
Abnormal EEPROM
02
Abnormal RAM
03
Abnormal A/D Conversion
04
Abnormal Sensor Voltage
05
Abnormal Engine Speed
06
07
08
09
10
11
12
13
14
25
Cause
Faulty Main Controller A
Abnormal Main Controller A Reception
(Between Main Controller A and Main

Controller B)
(Between Main Controller A and DLU, or

between Main Controller A and Built-In
Diagnosing System)
Abnormal Front Pilot Pressure
Abnormal Travel Pilot Pressure
Abnormal Engine Governor Angle
Abnormal Pump 1 Delivery Pressure
Abnormal Engine Exhaust Gas Tempera-

ture
Abnormal Oil Temperature Sensor
T5-1-14

Faulty Harness
Faulty Engine Speed Sensor 1
Faulty Harness
Faulty Harness

Faulty Harness
Faulty Pilot Pressure Sensor
Faulty ECM
Faulty Harness
Faulty Engine Governor Angle
Faulty Harness
Faulty Pump Delivery Pressure Sensor
Faulty Harness
Faulty Exhaust Gas Temperature Sensor
Faulty Harness
Faulty Oil Temperature Sensor
Main Controller B
Fault code
Trouble
30
Normal
31
Abnormal EEPROM
32
Abnormal RAM
33
34
37
Abnormal Main Controller B Reception
(Between Main Controller B and Built-In
Diagnosing System)
Cause
Faulty Main Controller B
Faulty Harness
T5-1-15
(Blank)
T5-1-16
TROUBLESHOOTING / Cross Reference Table

IMPORTANT: The No. indicates the component
number in the circuit diagram.
The position indicates the components position in the circuit diagram.
The number at left side is horizontal
lines of drawing frame, the alphabet
at right side is vertical lines of
drawing frame.
Refer to the page and item number
in the following group.
ELECTRICAL CIRCUIT DIAGRAM

No.
Position
001
002
003
004
005
006
007
008
009
010
011
012
013
014
015
016
017
018
019
020
021
022
023
024
025
026
027
028
029
030
031
032
033
1G
1G
2G
1H
2K
2B
4C
4I
5C
5F
6H
6H
6I
5J
8C
7C
7C
7D
7D
7D
7D
7E
7E
7E
8D
8D
8D
8D
8D
8D
8D
8D
8D
Component Name
Work Light (on Cab Roof)
Work Light (at the right side of Frame)
Work Light (Under Cab Floor)
Horn
Fresh Air Sensor (Air Conditioner)
DLU (Cummins)
Data Link Connector
RADIO
DLU (Mitsubishi)
Sunlight Sensor
Wiper Relay (Low)
Wiper Relay (High 1)
Wiper Relay (High 2)
Air Conditioner Unit
Monitor
Coolant Temperature Gauge
Fuel Gauge
Liquid Crystal Display (LCD)
Switch Panel 1
Auto-Idle Indicator
Quick-Idle Indicator
Lubrication Mode Indicator (OFF)
Lubrication Mode Indicator (Manual)
Lubrication Mode Indicator (Auto)
Overheat Indicator (L1)
Air Filter Restriction Indicator (L2)
Fuel Level Indicator (L3)
Preheat Indicator (L4)
Download Indicator (L5)
Alternator Indicator (L6)
Engine Oil Pressure Indicator (L7)
Pump Transmission Oil Pressure Indicator (L8)
Exhaust Gas Temperature Indicator (L9)
T5-2-1
Page
T5-3-2
T5-3-2
T5-3-2
T5-3-2
T5-3-2
T5-3-4
T5-3-3
T5-3-4
T5-3-2
T5-3-4
T5-3-4
T5-3-4
T5-3-2
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
Item
Number
1
4
31
8
10
10
10
32
26
25
24
2
14
15
33
16
34
35
32
32
32
30
31
17
28
29
18
27
26
19
Note
No.
Position
034
035
036
037
038
039
040
041
044
045
046
047
048
049
050
051
052
053
054
055
056
057
058
059
060
061
062
063
064
065
8D
8D
8D
8E
8E
8E
8I
8G
10G
10G
9L
9L
9L
9L
10K
10K
11K
11K
11K
12K
14K
11D
11F
12F
11G
11H
14D
14D
14D
14D
Component Name
Engine Oil Level Indicator (L10)
Coolant Level Indicator (L11)
Hydraulic Oil Level Indicator (L12)
Auto-Lubrication Indicator (L13)
Engine Stop Indicator (L14)
Engine Warning Indicator (L15)
Travel Alarm Stop Switch (Option)
Washer Relay (R3)
Work Light Relay 1 (R5)
Quick Idle Relay (R9)
Heavy Lift Solenoid Valve (SC)
Travel Mode Control Solenoid Valve (ST)
Oil Cooler Fan Control Solenoid Valve (SF)
Power Increase Solenoid Valve (ST)
Oil Pressure Sensor 3
Hydraulic Oil Temperature Sensor
Pilot Pressure Sensor (Travel)
Pilot Pressure Sensor (All)
Solenoid Valve Unit
Quick Idle Switch
Horn Switch
Horn Relay (R6)
Power Transistor Unit 2
Auto-Idle Switch
Work Light Switch
Wiper/Washer Switch
Engine Control Dial
T5-2-2
Page
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-3
T5-3-4
T5-3-4
T5-3-4
T5-3-2
T5-3-2
T5-3-10
T5-3-10
T5-3-2
T5-3-2
T5-3-2
T5-3-2
T5-3-2
T5-3-2
T5-3-2
T5-3-2
T5-3-2
T5-3-4
T5-3-4
T5-3-4
T5-3-9
T5-3-9
T5-3-9
T5-3-9
Item
Number
25
22
20
24
23
21
5
23
28
2
25
24
12
11
22
22
22
26
27
23
16
3
30
27
13
14
4
7
8
3
Note
No.
Position
066
067
068
069
070
071
072
073
074
075
076
077
078
079
080
081
082
083
084
085
086
087
088
089
091
092
093
094
095
096
097
14D
14D
13F
14F
13H
16A
16C
16D
16H
15K
16K
17F
17F
17F
17F
18H
18I
17K
18K
18H
19H
20K
17C
18C
18G
19G
19B
20C
22B
21C
21F
Component Name
Travel Mode Switch
Power Mode Switch
Auto-Idle Relay (R6)
Engine Protection Relay (R27)
Flow Rate Decrease Solenoid Valve Relay (R7)
Fuse Box 1
Fuse Box 2
DC/DC Converter
MC Display Selection Switch
Pump Transmission Oil Pressure Switch
Buzzer Cancel Switch
Heavy Lift Switch
Entrance Light Switch
Main Controller B (MCX-B)
Hydraulic Oil Level Switch1
Hydraulic Oil Level Switch2
Auto-Lubrication Relay (R11)
Auto-Lubrication (ALU) Timer Switch
Air Cleaner Restriction Switch
Entrance Light Relay
Load Dump Relay
Preheat Indicator Relay (R13)
Coolant Level Sensor Relay (R30)
Key Switch
Engine Stop Relay
Engine Stop Solenoid Relay (R18)
Entrance Light
Engine Warning Indicator Relay (R15)
T5-2-3
Page
T5-3-9
T5-3-9
T5-3-4
T5-3-4
T5-3-4
T5-3-4
T5-3-4
T5-3-2
T5-3-3
T5-3-10
T5-3-10
T5-3-9
T5-3-3
T5-3-9
T5-3-9
T5-3-4
T5-3-4
T5-3-2
T5-3-2
T5-3-4
T5-3-9
T5-3-2
T5-3-4
T5-3-4
T5-3-9
T5-3-4
T5-3-2
T5-3-4
Item
Number
6
5
6
7
1
17
18
29
3
14
5
13
4
12
36
12
16
28
28
3
11
14
20
4
9
21
33
9
Note
No.
Position
098
099
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
21G
21I
21I
22I
22I
23B
22F
25B
25B
25B
25B
25C
25C
25C
25C
26E
25F
26B
28C
28C
29D
29F
Component Name
Engine Stop Indicator Relay (R16)
Cummins Indicator Panel
Protction Indicator (L3)
Stop Indicator (L2)
Warning Indicator (L1)
Starter Relay (R19)
ECM Relay (R17)
Fusible Link 1 (45A)
Auto-Lubrication Device
Fuel Level Sensor
1 Pole Junction
Battery Relay 2
Battery Relay 1
Battery (12Vx2)
Alternator
T5-2-4
Page
T5-3-4
T5-3-6
T5-3-4
T5-3-6
T5-3-6
T5-3-6
T5-3-6
T5-3-6
T5-3-6
T5-3-6
T5-3-6
T5-3-1
T5-3-2
T5-3-6
T5-3-6
T5-3-6
T5-3-1
T5-3-8
Item
Number
8
2
11
13
12
11
10
4
9
7
8
10
9
6
5
3
8
2
Note
No.
Position
120
121
122
123
124
125
126
127
128
129
130
29G
29G
29H
31F
30F
30G
31H
29J
9G
9I
27F
Component Name
Engine Oil Level Switch
Grid Heater Relay 1
Grid Heater Relay 2
Coolant Temperature Sensor
Starter 2
Starter 1
Engine Speed Sensor (Pump)
ECM (Cummins)
Work Light Relay 2 (R4)
Main Controller A (MCX-A)
Coolant Level Sensor
Page
T5-3-8
T5-3-8
T5-3-2
T5-3-2
T5-3-2
T5-3-8
T5-3-4
T5-3-4
T5-3-2
T5-2-5
Item
Number
6
5
15
15
19
1
22
15
12
Note

HYDRAULIC CIRCUIT DIAGRAM (BACKHOE)
No.
Position
001
002
003
004
005
006
007
008
009
010
011
012
013
014
015
016
017
018
1G, H
1I
1J
3C, E
3D
4H
5K
4I
2K
4B
4B
3D
4G
5J
019
020
021
022
023
024
025
026
027
028
029
030
7D
6D
9F
8G
9H
10B
10F
10F
11F
11F
11G
10K
Component Name
Front / Swing Pilot Valve
Travel Pilot Valve
Accumulator
Boom Cylinder
Bucket Cylinder
Shuttle Valve (Bucket Roll-In)
Shock Reducing Valve
Shuttle Valve (Pilot Pressure Control)
Pilot Shut-Off Valve
Oil Cooler
Oil Cooler Fan Motor
Arm Cylinder
Hydraulic Oil Tank
Shuttle Valve
(For Switching Pump 3 Control Pressure)
Swing Device
Travel Device
Brake Release Pressure Switch Valve
Shuttle Valve (Boom Raise Priority)
Signal Control Valve
Main Control Valve
Reducing Valve
Shuttle Valve (Swing Brake Release)
Shuttle Valve (Auxiliary Circuit)
Arm Preference Valve
T5-2-6
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-30
T5-3-30
T5-3-30
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-30
Item
Number
6
30
29
5
1
18
16
17
27
13
14
3
7
10
T5-3-1
T5-3-1
T5-3-30
T5-3-30
T5-3-1
T5-3-1
T5-3-30
T5-3-30
T5-3-30
T5-3-30
T5-3-30
T5-3-30
11
21
6
9
19
12
4
3
7
5
2
11
Page
Note
No.
Position
031
032
033
034
035
036
037
038
039
040
041
042
043
044
045
046
047
048
12I
12K
15K
14K
16G
15I
16I
16I
17I
17I
18I
18H
20H
20H
20H
19I
19J
19J
Component Name
Swing Control Valve
Pump 3 Control Valve
Shockless Valve
Shuttle Valve (Swing Make-Up)
Engine
Main Pump 3
Main Pump 2
Pilot Pump
Transmission Lubrication Oil Pump
Main Pump 1
Power Decrease Solenoid Valve (SA)
Power Decrease Solenoid Valve (SB)
Boom Mode Selection Solenoid Valve (SC)
Pilot Filter
T5-2-7
Page
T5-3-1
T5-3-30
T5-3-30
T5-3-30
T5-3-1
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
Item
Number
24
13
14
15
17
10
8
4
7
6
3
14
16
17
18
11
12
13
Note

HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL)
No.
Position
001
002
003
004
005
006
007
008
009
010
011
012
013
014
015
016
017
018
1F, G
1H
1H
1I
1J
2C, E
2C, D
2D
3D
4H
5K
4I
2K
4B
4B
4D
4G
5J
019
020
021
022
023
024
025
026
027
028
029
030
7D
6D
9F
8G
9H
10B
10F
10F
11F
11F
11G
10K
Component Name
Pilot Valve (Bucket Open)
Travel Pilot Valve
Pilot Valve (Bucket Close)
Accumulator
Boom Cylinder
Bucket Cylinder
Dump Cylinder
Level Cylinder
Shuttle Valve (Bucket Roll-In)
Shock Reducing Valve
Shuttle Valve (Pilot Pressure Control)
Oil Cooler
Arm Cylinder
Hydraulic Oil Tank
Shuttle Valve
(For Switching Pump 3 Control Pressure)
Swing Device
Travel Device
Brake Release Pressure Switch Valve
Shuttle Valve (Boom Raise Priority)
Main Control Valve
Reducing Valve
Shuttle Valve (Swing Brake Release)
Shuttle Valve (Auxiliary Circuit)
T5-2-8
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-30
T5-3-30
T5-3-30
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-30
Item
Number
6
33
30
34
29
5
1
35
32
18
16
17
27
13
14
3
7
10
T5-3-1
T5-3-1
T5-3-30
T5-3-30
T5-3-1
T5-3-1
T5-3-30
T5-3-30
T5-3-30
T5-3-30
T5-3-30
T5-3-30
11
21
6
9
19
12
4
3
7
5
2
11
Page
Note
No.
Position
031
032
033
034
035
036
037
038
039
040
041
042
043
044
045
046
047
048
12I
12K
15K
14K
16G
15I
16I
16I
17I
17I
18I
18H
20H
20H
20H
19I
19J
19J
Component Name
Swing Control Valve
Shockless Valve
Shuttle Valve (Swing Make-Up)
Engine
Main Pump 3
Main Pump 2
Pilot Pump
Transmission Lubrication Oil Pump
Main Pump 1
Power Decrease Solenoid Valve (SB)
Boom Mode Selection Solenoid Valve (SC)
Pilot Filter
T5-2-9
Page
T5-3-1
T5-3-30
T5-3-30
T5-3-30
T5-3-1
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
Item
Number
24
13
14
15
17
10
8
4
7
6
3
14
16
17
18
11
12
13
Note

(Blank)
T5-2-10
TROUBLESHOOTING / Component Layout

MAIN COMPONENTS
Backhoe
2
1
5
6
7
8
9
10
36
37
11
12
31
13
14
15
16
30
29
28
27
Loading Shovel
26
25
5
32
24
3
2
35
31
17
23
18
22
6 21
19
20
30
33
34
T183-01-02-016
1 - Bucket Cylinder
2 - Arm
11 - Swing Device
12 - Main Control Valve
21 - Travel Device
22 - Upper Roller
3 - Arm Cylinder
13 - Oil Cooler
23 - Lower Roller
4 - Boom
14 - Oil Cooler Fan Motor
24 - Swing Control Valve
5 - Boom Cylinder
15 - Intercooler
25 - Center Joint
678910 -
16 17 18 19 20 -
26 27 28 29 30 -

Hydraulic Oil Tank
Battery (12Vx2)
Fuel Tank
Auto-Lubrication Device
Radiator
Engine
Pump Device
Swing Bearing
T5-3-1
Track Adjuster
Front Idler
Accumulator
Travel Pilot Valve
31 - Bucket
32 - Level Cylinder
(Loading Shovel Only)
33 - Pilot Valve (Bucket Open)
34 - Pilot Valve (Bucket Close)
35 - Dump Cylinder
36 - Condenser (Air Conditioner)
37 - Fuel Cooler

ELECTRICAL SYSTEM COMPONENTS (1)
Overall Layout
3
7
8
11
9
10
34
12
(Refer to T5-3-4)
(Refer to T5-3-11)
13
33
32
14
31
30
29
15
16 (Refer to T5-3-10)
(Refer to T5-3-3)
28
17 (Refer to T5-3-10)
18 (Refer to T5-3-10)
(Refer to T5-3-30) 27
26
25
19 (Refer to T5-3-8)
24
(Refer to T5-3-30) 23
1 - Work Light (on Cab Roof)
20
22
21
2 - Monitor
10 - Fresh Air Sensor

(Air Conditioner)
11 - Fuel Temperature
3 - Quick Idle Switch
12 - Coolant Level Sensor
4 - Work Light
(at the right side of Frame)
5 - Starter Relay 1
13 - Coolant Temperature Sensor
6 - Battery
15 - Starter 1,2
7 - Battery Relay
16 - Solenoid Valve Unit
8 - Horn
17 - Flow Rate Decrease

Solenoid Valve
18 - 2-Spool EHC Valve
9 - Fuel Level Sensor
14 - Air Cleaner Restriction Switch
19 - Engine Speed Sensor

(Pump)
20 - Engine Speed Sensor 2
(ECM)
21 - Pump Transmission Oil
Pressure Switch
22 - Oil Pressure Sensor 1, 2,
3
23 - Pilot Pressure Sensor
(All)
24 - Travel Mode Control
Solenoid Valve (ST)
25 - Heavy Lift Solenoid Valve
(SC)
26 - Hydraulic Oil
Temperature Sensor
(Travel)
T5-3-2
T18E-01-02-009
28 - Hydraulic Oil Level Switch

1, 2
29 - DC/DC Converter
30 - Horn Switch
31 - Work Light
(Under Cab Floor)
32 - Sunlight Sensor
33 - Entrance Light
34 - Electrical Equipment
Box

In the Cab
1
6
T18E-01-02-010
2
4
M18E-01-009
T18E-01-02-013
1 - 12 V Power Source
Terminal
2 - DC-DC Converter
4 - Buzzer Cancel Switch

5 - Travel Alarm Stop
Switch (Optional)
6-
Engine Fault Code Display

Panel
7 - Fault Diagnosing Switch A
3 - MC Display Selection
Switch
T5-3-3
8-
Fault Diagnosing Switch B
9-
DLU Check Switch

Electrical Equipment Box
10
28
27
26
25
11
24
23
22
21
20
19
18
17
16
15
14
13
12
T18E-01-02-003

Solenoid Valve Relay (R7)
2 - *Quick Idle Relay (R9)
3 - Auto-Lubrication Relay
(R11)
4 - Preheat Indicator Relay
(R13)
5 - *Coolant Lever Switch
Relay
6 - *Auto-Idle Relay (R6)
7 - *Engine Protection Relay
(R27)
8 - *Engine Stop Indicator

Relay (R16)
9 - *Engine Warning Indicator
Relay (R15)
10 - DLU (Cummins, Mitsubishi)
15 - Main Controller A
(MCX-A)
16 - Main Controller B
(MCX-B)
17 - Fuse Box 1
22 - Work Light Relay 2 (R4)
24 - Wiper Relay (High 2)
11 - *ECM Relay (R17)
18 - Fuse Box 2
25 - Wiper Relay (High 1)
12 - Power Transistor Unit 3
19 - Step Light Relay
26 - Wiper Relay (Low)

20 - Load Dump Relay

21 - *Engine Stop Relay
27 - Horn Relay (R6)

28 - Work Light Relay 1 (R5)
23 - Washer Relay (R3)
NOTE: The items with mark * are not used for the machine equipped with CUMMINS engine.
T5-3-4

(Blank)
T5-3-5

Around Batteries
12 13
10 11
3
4
5
6
1234-
Air Heater Signal Relay

Starter Relay (R19)
Battery Relay 1
567-
Battery Relay 2
1 Pole Junction
T183-01-02-015
8 - Fusible Link 8 (125A)

T5-3-6


Used Circuit Fusible Link
Part Name
Fusible Link 1
Fusible Link 2
Fusible Link 3
Fusible Link 4
Fusible Link 5
Fusible Link 6
Fusible Link 7
Fusible Link 8
Circuit
Monitor, Back up Power Circuit
Main Controller B, DLU Main Power Circuit
ECM Power Circuit
Work Light Relays 1, 2 Power Circuit
Washer Relay, Wiper Relay (L, H1, H2),
Wiper Motor Power Circuit
Air Conditioner Power Circuit
Auto-Lubrication Solenoid Valve Relay, Flow Rate
Decrease Solenoid Valve Relay, Power Transistors 1, 2
and 3
DC-DC Converter Power Circuit
Main Controller A, B Solenoid Power Circuit
Travel Alarm Power Circuit
Monitor, Main Controller A Main Power circuit
Step Light Relay Power Circuit
Air Conditioner
Air Heater Signal Relay Power Circuit
Starter Relay Power Circuit
Alternator
Preheat Relay 1 Power Circuit
Preheat Relay 2 Power Circuit
T5-3-7
Connected
Fuse Box 1 (#1, #2)
Fuse Box 2 (#1)
Fuse Box 2 (#1114)
Fuse Box 2 (#49)
Air Heater Signal Relay

Starter Relay 1
Alternator
Preheat Relay 1
Preheat Relay 2

On and Around Engine
5
9
11
10
12
T18E-01-02-011
1 - ECM (Cummins)
2 - Alternator
3 - Engine Speed Sensor 1
(ECM)
4-
Engine Speed Sensor 2

(Pump)
5 - Coolant Temperature
Sensor
6 - Engine Oil Level Sensor
7-
Preheat Relay
8-
Starter
9-
Coolant Temperature
Sensor (ECM)
T5-3-8
10 - Engine Oil Pressure

Sensor
11 - Suction Manifold
Temperature Sensor
12 - Fuel Temperature Sensor

Monitor Panel
Monitor and Switch Panels
14
15
1
35
34
16
33
32
31
3
30
29
28
5
6
27
26
7
8
25
17
18
19
20
T183-01-02-013
24 23
22 21
10
13
12
11
36
M183-01-035
T183-01-02-010
1 - Monitor Panel
2 - Quick Idle Switch
3 - Engine Control Dial
4 - Auto-Idle Switch
10 - Air Conditioner Control

Panel
11 - Auto-Lubrication (ALU)
Timer Switch
12 - Heavy Lift Switch
6 - Travel Mode Switch
13 - Boom Mode Selection

Switch
14 - Coolant Temperature
Gauge
15 - Fuel Gauge
7 - Work Light Switch
16 - Switch Panel 1
8 - Wiper/Washer Switch
17 - Fuel Level Indicator (L3)
9 - Key Switch
18 - Alternator Indicator (L6)
5 - Power Mode Switch
19 - *Exhaust Gas Temperature

Indicator (L9)
20 - Hydraulic Oil Level
Indicator (L12)
21 - Engine Warning Indicator
(L15)
22 - Coolant Level Indicator
(L11)
23 - Engine Stop Indicator
(L14)
24 - Auto-Lubrication Indicator
(L13)
25 - Engine Oil Level Indicator
(L10)
Pressure Indicator (L8)
27 - Engine Oil Pressure
Indicator (L7)
28 - Preheat Indicator (L4)

29 - Download Indicator (L5)
30 - Overheat Indicator (L1)
31 - Air Filter Restriction
Indicator (L2)
32 - Lubrication Mode Indicator
(OFF) (Manual) (Auto)
33 - Liquid Crystal Display
(LCD)
34 - Auto-Idle Indicator
35 - Quick-Idle Indicator
36 - Entrance Light Switch
NOTE: The Item with mark * is not used for the machine equipped with CUMMINS engine.
T5-3-9

1
ON AND AROUND PUMPS

Front
Pump Device
10
9
8
7
4
Solenoid Valves and Related Components
18
Solenoid Valve
Unit
T183-01-02-006
11
17
16
2-Spool EHC Valve
12
15
Front
13
14
T183-01-02-007
1 - Main Pump 3 Regulator

2 - Main Pump 1 Regulator
6 - Transmission Lubrication
Oil Pump
7 - Pilot Pump
3 - Main Pump 1
8 - Main Pump 2
4 - Oil Cooler Fan Motor Drive

Pump
Pressure Switch
9 - Main Pump 2 regulator
11 - Power Increase Solenoid

Valve (ST)
12 - Oil Cooler Fan Control
Solenoid Valve (SF)
13 - Pilot Filter
Solenoid Valve
10 - Main Pump 3
T5-3-10
15 - Pilot Relief Valve

16 - Power Decrease Solenoid
Valve (SA)
17 - Power Decrease Solenoid
Valve (SB)
18 - Boom Mode Selection
Solenoid Valve (SC)

T18E-01-02-012
T5-3-11

MAIN CONTROL VALVE
Auxiliary: BH
Bucket
Open/Close: LD
10
34
Arm 1
Arm 2
11
33
Boom 2
Boom 1
12
32
13
14
31
Bucket 2
15
Bucket 1
16
30
17
18
Left Travel
29
28
19
Right Travel
27
26
25
24
23
22 21
20
T18E-03-03-001
NOTE: BH: Backhoe

LD: Loading Shovel
1 - Holding Valve Switch Valve
(Boom)
2 - Load Check Valve
(Arm 2 Tandem Circuit)
(Arm 2 Parallel Circuit)
4 - Arm Regenerative Valve
(Arm 1 Parallel Circuit1)
(Auxiliary Tandem Circuit)
(Arm)
10 - Overload Relief Valve

(Aux.: BH, Bucket
Open/Close: LD)
(Arm)
12 - Holding Valve Check Valve
(Arm)
(Boom 2 Tandem Circuit)
(Boom 2 Parallel Circuit)
(Boom Mode Selection)
16 - Boom Overload Relief
Pressure Switch Valve
(Bucket 2 Tandem Circuit)
(Bucket 2)

(Left Travel Tandem Circuit)
27 - Main Relief Valve

(Left Travel Parallel Circuit)
(Bucket 2 Parallel Circuit)
22 - Check Valve (Main Relief
Pressure Combining Circuit)
23 - Flow Combiner Valve

(Bucket 1)
(Boom1 Parallel Circuit)
(Boom)
32 - Holding Valve Check
Valve (Boom)
33 - Slow Return Valve
24 - Check Valve (Travel Flow

Combine Circuit)
26 - Shuttle Valve
T5-3-12
34 - Make-Up Valve (Arm 2)

11
15, 16 18
E
Section A
26
27
25
10
Front
27
26
31
29
24
33
Section B
T183-03-03-003
23
T183-03-03-002
Section C
36
35
Right Travel
39
Bucket 1
Left Travel
40
Bucket 2
18
29
17
19
28
21
20
18
29
T183-03-03-004
37
T183-03-03-005
38
41
42
NOTE: BH: Backhoe

LD: Loading Shovel
35 - Right Travel (Forward) Port
37 - Left Travel (Reverse) Port
36 - Left Travel (Forward) Port
38 - Right Travel (Reverse) Port
39 - Bucket 1 (Roll-Out : BH,

Tilt-Out : LD) Port
40 - Bucket 2 (Roll-Out : BH,
Tilt-Out : LD) Port
T5-3-13
41 - Bucket 1 (Roll-In : BH,

Tilt-In : LD) Port
42 - Bucket 2 (Roll-In : BH,
Tilt-In : LD) Port

2
Auxiliary: BH
Bucket
Open/Close: LD
10
34
Arm 1
Arm 2
11
33
Boom 2
Boom 1
12
32
13
14
31
Bucket 2
15
Bucket 1
16
30
17
Left Travel
18
29
28
19
Right Travel
27
26
25
24
23
22 21
20
T18E-03-03-001
NOTE: BH: Backhoe

LD: Loading Shovel
(Boom)
4 - Arm Regenerative Valve
(Auxiliary Tandem Circuit)
(Arm)

(Aux.: BH,
Bucket Open/Close: LD)
(Arm)
(Arm)
(Boom 2 Tandem Circuit)
(Boom 2 Parallel Circuit)
(Boom Mode Selection)
16 - Boom Overload Relief
Pressure Switch Valve
(Bucket 2)

(Left Travel Tandem Circuit)

(Left Travel Parallel Circuit)
(Bucket 2 Parallel Circuit)
23 - Flow Combiner Valve

(Bucket 1)
(Boom1 Parallel Circuit)
(Boom)
(Boom)
33 - Slow Return Valve
24 - Check Valve (Travel Flow

Combine Circuit)
26 - Shuttle Valve
T5-3-14
34 - Make-Up Valve (Arm 2)

43
Section D
44
Boom 1
Section E
47
48
Boom 2
Arm 2
16
31
33
Arm 1
12
34
15
13
30
6
3
14
2
11
31
T183-03-03-007
32
49
46
50
T183-03-03-006
45
51
Auxiliary (BH)
Bucket Open/Close (LD)
Section F
10
Section G
11
T183-03-03-009
9
34
52
T183-03-03-008
43 - Boom 1 (Lower) Port
46 - Boom 2 (Raise) Port
47 - BH: Arm 2 (Roll-Out) Port

LD: Arm 2 (Retract) Port
LD: Arm 1 (Roll-In) Port
49 - BH: Arm 2 (Roll-In) Port

LD: Arm 2 (Extend) Port
50 - BH: Arm 1 (Retract) Port
T5-3-15
51 - BH: Auxiliary Port

LD: Bucket (Open) Port
52 - BH: Auxiliary Port
LD: Bucket (Open) Port

SWING CONTROL VALVE
1
11
Boom 3
10
Swing
Bucket 3
Arm 3

(Boom 3)
(Swing)

(Bucket 3)
(Arm 3)
7 - Check Valve
(Arm 3)
8 - Make-Up Valve
(Arm 3)
(Swing)
T5-3-16
T18E-03-03-002

(Boom 3)

12
Section A
14
16
18
1
B
10
T183-03-03-011
13
Section B
15
T183-03-03-012
19
14
Section C
11
17
Swing
Boom 3
3
2
10
11
15
T183-03-03-013
13
14 - Swing (Left) Port
T5-3-17
15 - Swing (Right) Port
T183-03-03-014
11
Boom 3
10
Swing
Bucket 3
Arm 3
12-
Main Relief Valve
Load Check Valve

(Boom 3)
(Swing)
4-
Load Check Valve

(Bucket 3)
(Arm 3)
7-
Check Valve
(Arm 3)
8 - Make-Up Valve
(Arm 3)
(Swing)
T5-3-18
T18E-03-03-002

(Boom 3)

16
18
Section D
Section E
Bucket 3
Arm 3
5
4
T183-03-03-015
17
19
T183-03-03-016
Section F
NOTE: BH: Backhoe

LD: Loading Shovel
16 - Bucket 3 (Roll-Out) Port
T183-03-03-017
17 - Bucket 3 (Roll-In) Port

LD: Arm 3 (Retract) Port
T5-3-19
19 - BH: Arm 3 (Roll-In) Port


(Blank)
T5-3-20

SIGNAL CONTROL VALVE
Pilot Valve
Side
T178-03-06-016
Cross Section A-A
Shockless Valve
Arm Flow Rate Control
Auxiliary
Pump 1 and 2 Flow Rate Control Valve
Auxiliary
Flow Combiner Valve

Control Spool
Priority Valve
T178-03-06-002
T5-3-21

Pilot Port
NOTE: BH: Backhoe
LD: Loading Shovel
Pilot Valve Side
Port Name
Port A
Port B
Port C
Connecting to
Right Pilot Valve
Right Pilot Valve
Left Pilot Valve
Port D
Port E
Port F
Right Pilot Valve

Hydraulic Oil Tank
Left Pilot Valve
Port G
Left Pilot Valve
Port H
Port I
Port J
Port K
Port L
Port M
Right Pilot Valve

Travel Pilot Valve
Travel Pilot Valve
Travel Pilot Valve
Travel Pilot Valve
Auxiliary Pilot Valve (BH)
Bucket Open Pilot Valve (LD)
Port N
Port SA
Port SB
Port PI
Port PH
Port SH
Port DF
Pump 1 and 2 Regulator

Hydraulic Oil Tank
T5-3-22
Note
Boom Raise Pilot Pressure
Boom Lower, Bucket Roll-Out Pilot Pressure
Arm Roll-Out Pilot Pressure (BH)
Arm Roll-In Pilot Pressure (LD)
Returning to Hydraulic Oil Tank
Arm Roll-In Pilot Pressure (BH)
Arm Roll-Out Pilot Pressure (LD)
Bucket Roll-In Pilot Pressure
Left Travel Forward Pilot Pressure
Right Travel Forward Pilot Pressure
Pump 1 and 2 Control Pressure
Plug
Primary Pilot Pressure
Primary Pilot Pressure (Heat Circuit)
Plug
Returning to Hydraulic Oil Tank
Pilot Valve Connecting Side

C
PH
A
E
M
D
H
B
SB
G
PI
Pilot Valve
Side
I
SH
J
DF
SA
L
T178-03-06-016
T5-3-23

NOTE: BH: Backhoe
LD: Loading Shovel
Control Valve Side
Port Name
Port 1
Port 2
Port 3
Port 4
Port 5
Port 6
Connecting to
Control Valve
Control Valve
Port 7
Control Valve
Port 8
Port 9
Port 10
Port 11
Port 12
Port 13
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Port 14
Control Valve
Port SE
Port SM
Port SN
Port SP
Port SL
Port SK
Shuttle Valve
Shuttle Valve
Shuttle Valve
Shuttle Valve
Control Valve
T5-3-24
Note
Plug
Plug
Plug
Plug
Arm Roll-In Pilot Pressure (BH)
Arm Roll-Out Pilot Pressure (LD)
Bucket Roll-In Pilot Pressure
Left Travel Reverse Pilot Pressure
Right Travel Reverse Pilot Pressure
Auxiliary Close Pilot Pressure (BH)
Bucket Close Pilot Pressure (LD)
Auxiliary Open Pilot Pressure (BH)
Bucket Open Pilot Pressure (LD)
Boom Raise Priority Pilot Pressure
Auxiliary
Swing Brake Release
Swing Brake Release
Combiner Valve Shifting Pressure
Plug
Control Valve Connecting Side

SM
3
5
1
13
2
SK
4
SE
8
S3
14
Control Valve
Side
7
9
6
10
SN
SL
11
Pressure Sensor (Travel)
12
T5-3-25
SP
T178-03-06-015

Shuttle Valve
NOTE: BH: Backhoe
LD: Loading Shovel
Pump 1 and 2 Flow

Control Valve
Boom Raise
Boom Lower
Arm Roll-Out (BH)
Arm Roll-In (LD)
Arm Roll-In (BH)
Arm Roll-Out (LD)
Bucket Roll-In
Bucket Roll-Out
Right Travel
Left Travel
Auxiliary (Close) (BH)
Bucket Close (LD)
Auxiliary (Open) (BH)
Bucket Open (LD)
Arm Flow Rate

Control Valve
Flow Combiner Valve

Control Spool
Priority Valve
{
{
{
{
{
{
{
{
{
T5-3-26

Swing Arm
Boom
Bucket
Left Travel
Right Travel
Shockless Valve
6
Valve
P1 and P2 Pump Flow
Rate Control Valve
Flow Combiner Valve
Control Spool
Priority Valve
T183-03-06-001
17 16 15 14 13 12
1 - Auxiliary (BH), Bucket
Open/Close (LD)
6 - Right Travel
2 - Arm Roll-Out (BH), Arm Roll-In

(LD), Auxiliary (BH), Bucket
Open/Close (LD)
(LD)
7 - Left Travel, Right

Travel
4 - Boom, Bucket Roll-Out
8 - Boom, Arm,
Bucket, Right
Travel
9 - Left Travel
11 10
7
14 - Boom, Arm, Bucket
10 - Boom Raise, Arm Roll-Out

(BH), Arm Roll-In (LD),
Auxiliary (BH), Bucket
Open/Close (LD), Left Travel
11 - Boom, Arm, Bucket, Right
Travel

(BH), Arm Roll-In (LD)
12 - Arm Roll-In (BH), Arm

Roll-Out (LD), Bucket Roll-In
16 - Boom Raise, Arm. Roll-Out

13 - Room Raise, Arm, Bucket
17 - Boom Raise, Arm. Roll-Out

Open/Close (LD)
5 - Boom, Arm Roll-Out (BH), Arm

Roll-In (LD), Bucket Roll-Out
NOTE: BH: Backhoe

LD: Loading Shovel
T5-3-27
Swing Arm
Boom
Left Travel
Bucket
Right Travel
Shockless Valve
6
Arm Flow Rate
Control Valve
P1 and P2 Pump Flow
Rate Control Valve
Flow Combiner Valve
Control Spool
Priority Valve
T183-03-06-001
17 16 15 14 13 12
11 10
NOTE: BH: Backhoe

LD: Loading Shovel
T5-3-28
Pilot Valve
Side
T178-03-06-016
Cross Section B-B

9
5
7
16
17
15
13
11
14
10
12
4
2
T178-03-06-009
1 - Auxiliary (BH), Bucket

Open/Close (LD)
6 - Right Travel

(LD), Auxiliary (BH), Bucket
Open/Close (LD)
(LD)
7 - Left Travel, Right

Travel
4 - Boom, Bucket Roll-Out

5 - Boom, Arm Roll-Out (BH), Arm
Roll-In (LD), Bucket Roll-Out
8 - Boom, Arm,
Bucket, Right
Travel
9 - Left Travel
14 - Boom, Arm, Bucket

Open/Close (LD), Left Travel
11 - Boom, Arm, Bucket, Right
Travel

12 - Arm Roll-In (BH), Arm

Roll-Out (LD), Bucket Roll-In

13 - Room Raise, Arm, Bucket

Open/Close (LD)
T5-3-29

OTHERS
Valves (1)
Swing Device
20
19
9
4
Front
Side
8
5
T142-01-02-011
T183-01-02-008
Travel Device
Valves (2)
10
11
21
12
18
22
17
16
13
Valves (1)
15
14
T18E-01-02-002
T183-01-02-012

(Travel)
2 - Shuttle Valve
(Auxiliary Circuit)
3 - Reducing Valve
4 - Heavy Lift Solenoid Valve
5 - Travel Mode Control

Solenoid Valve
6 - Brake Release Pressure
Switch Valve
7 - Shuttle Valve
(Swing Brake Release)
8 - Pilot Pressure Sensor (All)
(Front Operation)
9 - Shuttle Valve
(Boom Raise Priority)
10 - Shuttle Valve
(For Switching Pump 3
Control Pressure)
11 - Arm Preference Valve
13 - Pump 3 Control Valve

14 - Shockless Valve
15 - Shuttle Valve
(Swing Make-Up)
16 - Shock Reducing Valve
17 - Shuttle Valve
(Pilot Pressure Control)
12 - Signal Control Valve
T5-3-30
18 - Shuttle Valve
(Bucket Roll-In)
19 - Swing Parking Brake
Release Valve
20 - Swing Relief Valve
21 - Counterbalance Valve
22 - Travel Relief Valve
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Refer to troubleshooting A procedure in case any fault
codes are displayed after diagnosing the main
controller A and/or B using the built-in diagnosing
system.
How to Read Troubleshooting Flow Charts
YES (OK)
(2)
After completing the checking and/or measuring procedures in box

(1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
(1)
NO (NOT OK)
Key switch: ON
(3)
Instructions, reference, and/or inspection methods and/or measurements are

occasionally described under the box. If incorrectly checked or measured, not only will
troubleshooting be unsuccessful but also damage to the components may result.
Refer to "Electrical System Inspection" group (Group 8) for descriptions in the dotted-line
box.
Use 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
T5-4-1
MAIN CONTROLLER FAULT CODE LIST
Main Controller A
Fault Code
Trouble
00
Normal
01
Abnormal EEPROM
02
Abnormal RAM
03
04
05
Abnormal Engine Speed
06
Cause
08
09

(Between Main Controller A and Main
Controller B)
(Between Main Controller A and DLU, or
between Main Controller A and Built-In
Diagnosing System)
Abnormal Front Pilot Pressure
Abnormal Travel Pilot Pressure
10
Abnormal Engine Control Dial Angle
11
12
13
25

Abnormal Oil Temperature Sensor
07

Faulty Harness
Faulty Engine Speed Sensor 1
Faulty Harness

Faulty Harness
T5-4-2

Faulty Harness
Faulty Pilot Pressure Sensor
Faulty ECM
Faulty Harness
Faulty Engine Control Dial
Faulty Harness
Faulty Pump Delivery Pressure Sensor
Faulty Harness
Faulty Oil Temperature Sensor
Main Controller B
Fault Code
Trouble
Cause
30
Normal
31
Abnormal EEPROM
32
Abnormal RAM
33
34
37
Abnormal Main Controller B Reception
(Between Main Controller B and Built-In Faulty Harness
Diagnosing System)
T5-4-3
MAIN CONTROLLER A
FAULT CODE 01
ABNORMAL EEPROM
FAULT CODE 02
ABNORMAL RAM
FAULT CODE 03
ABNORMAL A/D CONVERSION
YES
Faulty main controller A.
Check if engine and machine

actuators operate normally.
NO
NO
YES
Look for the cause from other

fault phenomenon.
Exchange main controller A and

main controller B. Check if the
fault code is displayed.
* Even if any fault codes are still displayed after

retrying, the machine can be used unless there are
malfunctioning on the engine or machine.
FAULT CODE 04
ABNORMAL SENSOR VOLTAGE
YES
Check if voltage at alternator

terminal B is normal.
24V: With engine stopped
28V: With engine running
Faulty alternator.
NO
T5-4-4
FAULT CODE 05
ABNORMAL ENGINE SPEED
Disconnect connector
from engine speed
sensor 1. Check if
resistance between
sensor end connector
terminals #1 and #2
matches specification.
Specification: 200 to 300
Connect engine speed

sensor 1 harness end
connector terminals #1
and #2.
YES Disconnect connector
D from main controller
A. Check for continuity
between connector D
harness end terminals
#D13 and #D14.
NO
Main Controller A
Connector D
D14
Check for continuity

between connector D
harness end terminal
#D13 and engine
speed sensor 1
harness end
connector terminal
#2.
Broken harness
between main
YES
controller A and
engine speed sensor
1 (terminal #1).
NO
Broken harness
between main
controller A and
engine speed sensor
1 (terminal #2).
Faulty engine speed
sensor 1.
NO
Connector (Harness End Connector Viewed from the

Open End Side)
D13
Faulty main controller

A.
YES
T183-05-04-009
T18E-05-04-001
T5-4-5
FAULT CODE 06
ABNORMAL MAIN CONTROLLER A
RECEPTION
(BETWEEN MAIN CONTROLLER A AND
MAIN CONTROLLER B)
Exchange main
controller A and main
controller B.
Turn off MC display
selection switch to
change the monitor
display to main controller
B.
Display the faulty code.
Check if Code 37 is
displayed.
YES
NO
Broken harness between

main controller A and main
controller B.

Open End Side)
Main Controller A
Connector D
D9
T183-05-04-009
Main Controller B
Connector D
D10
T183-05-04-009
T5-4-6
FAULT CODE 07
ABNORMAL MAIN CONTROLLER A
RECEPTION
(BETWEEN MAIN CONTROLLER A AND
DLU, OR BETWEEN MAIN CONTROLLER
A AND BUILT-IN DIAGNOSING SYSTEM)
Between Main Controller A and DLU
YES
Disconnect connector 76B

from DLU.
Check if voltage between
harness end connector
terminals #41 and #33 is
50.5 V.
Disconnect joining
connector between
DLU and main
controller A.
between DLU harness
end connector 76B
terminal #32 and
joining connector DLU
end terminal #2.
YES
Faulty DLU.
NO
Faulty ground wire on

DLU.
YES
Key Switch: ON
NO
Reconnect connector
D to main controller A.
Connect DLU harness
end connector 76B
terminals #41 and #33
with a clip.

between connector
D harness end
terminals #D11 and
#D12.
Between Main Controller

Diagnosing System
and
NO

A.
Check harness
between DLU harness
end connector 76B
terminal #41 and
connector D harness
end terminal #D11 for
breakage or short
circuit.
Broken harness
between DLU harness
YES end connector 76B
terminal #41 and
connector D terminal
#D11.
NO
Built-In
Broken harness
between main controller
A and monitor
controller.
YES
Check harness
between main
controller A connector
#D10 and monitor
controller connector B
#B1 for breakage or
short circuit.
Broken harness
between DLU harness
end connector 76B
terminal #33 and
connector D terminal
#D12.

A.
NO
Connector
DLU
Main Controller
Connector D
Connector 76B
D10
D11
Monitor Controller
Connector B
D12
B1
Joining Connector
(Between DLU and
Main Controller A)
T18E-05-04-003
T183-05-04-013
T18E-05-04-002
T183-05-04-009
T5-4-7
FAULT CODE 08
ABNORMAL FRONT PILOT PRESSURE
FAULT CODE 09
ABNORMAL TRAVEL PILOT PRESSURE
Disconnect connectors
from all operation
pressure sensor and
NO travel pressure sensor.
Check if voltage
between harness end
and #3 is 50.5 V.
Key switch: ON
Check if fault codes are
switched after switching
all operation pressure
sensor with travel
pressure sensor and
retrying.
Check harness between

connector C terminal
#C1 (all operation
YES pressure) (or #C2 (travel
operation pressure)) and
all operation pressure
sensor (or travel
pressure sensor)
terminal #2 for breakage
or short circuit.
Check if voltage
between all operation
pressure sensor (or
travel pressure sensor)
NO terminal #1 and vehicle
frame matches
specification.
Key switch: ON
Specification: 50.5 V

Open End Side)
Main Controller A
Connector C
C2
C10
C1
C23
C31
All Operation Pressure Sensor, Travel Pressure Sensor
NO

A.
Broken harness
between main
YES controller A and all
operation pressure
sensor or travel
pressure sensor
(terminal #3).
NO
Broken harness
between main
controller A and all
operation pressure
sensor or travel
pressure sensor
(terminal #1).
Faulty pressure
sensor.
YES
C1
Broken harness
between main
YES
controller A and all
operation pressure
sensor or travel
pressure sensor.
T5-4-8
(Blank)
T5-4-9
FAULT CODE 10
ABNORMAL ENGINE
ANGLE
Disconnect switch box

connector.
Check if resistance
between switch box end
and #4 is 50.5 k.
Reconnect switch box
connector. Insert tester
probe into connector
terminal #3 from the
reverse side.
Check if voltage varies as
specified when engine
control dial is turned.
CONTROL
DIAL
Disconnect switch box

connector.
YES Check if voltage
between harness end
and #4 is 50.5 V.
Disconnect ECM
connector 31 poles.
Check harness
YES
between connector 31
poles harness end
terminal #5 and switch
box terminal #3 for
breakage or short
circuit.
Key switch: ON
NO
Specification: See table

below.
Disconnect ECM
connector 31 poles.
between switch box
harness end
connector terminal #4
and ECM harness
end connector
terminal #6.
YES Broken harness

between ECM and
engine control dial.
NO
NO
Faulty harness
between switch box
and engine control
dial.
Broken harness
between ECM and
engine control dial
(terminal #4).

between switch box
YES harness end
and ECM harness
end connector #4.
Faulty engine control

dial.
NO
Engine Control Dial Specification

Maximum Speed
0.3 to 1.0 V
Minimum Speed
4.0 to 4.7 V
Open End Side)
ECM
Connector 31 Poles
Switch Box
#4
#3
#2
T18E-05-04-004
T5-4-10
YES
NO
Faulty ECM.
Broken harness
between ECM and
engine control dial
(terminal #2).
T5-4-11
FAULT CODE 11
ABNORMAL PUMP 1 DELIVERY
PRESSURE
FAULT CODE 12
PRESSURE
FAULT CODE 13
PRESSURE
Disconnect pump
delivery pressure
NO sensor. Check if
voltage between
terminals #1 and #3 is
50.5 V.
Check if fault codes are

switched after switching
pump delivery pressure
sensor (pump 1) with
pump delivery pressure
sensor (pump 2) or
(pump 3) and retrying.
Key switch: ON
Check harness
between main
controller A connector
C (connector 31P)
YES #C4 (pump 1), #C5
(pump 2) or #C6
(pump 3) and pump
delivery pressure
sensor terminal #2 for
breakage or short
circuit.
NO
Check if voltage
between pump delivery
pressure sensor
terminal #1 and vehicle
frame matches
specification.
Key switch: ON

Open End Side)
Main Controller A
Connector C
C4
C23
C5
NO

A.
Broken harness
between main
YES controller A and
pump delivery
pressure sensor
(terminal #3).
NO
Broken harness
between main
controller A and
pump delivery
pressure sensor
(terminal #1).
Faulty pump delivery
pressure sensor.
YES
C1
Broken harness
YES between main
controller A and
pump delivery
pressure sensor.
C6
C10
C31
Pump Delivery Pressure Sensor
T146-05-03-006
T5-4-12
FAULT CODE 25
ABNORMAL OIL TEMPERATURE SENSOR
Connect oil
temperature sensor
terminals #1 and #2
YES with a clip.
Remove connector B
and connector C from
main controller A.
between connector B
#B22 and connector C
terminal #C24.
Disconnect oil
temperature sensor.
Check if sensor end
connector resistance
matches specification.
NO
Specification: See table

below.
Oil Temperature Sensor Specification

Oil Temperature
Resistance(k)
(C)
(F)
-20
-4
16.21.6
0
32
(5.88)
20
68
2.450.24
40
104
(1.14)
60
140
(0.534)
80
176
0.322
Open End Side)
Main Controller A
Connector B
B8
B19
B25
B22
Connector C
C10
C1
C23
C31
C24
Oil Temperature Sensor

1
Connect main controller

A connector B harness
end terminal #B22 to
vehicle frame.
between oil temperature
sensor harness end
and vehicle frame.
Broken harness
between main
YES controller A and oil
temperature sensor
(terminal #1).
NO
Broken harness
between main
controller A and oil
temperature sensor
(terminal #2).
Faulty oil temperature
sensor.
NO
B1

A.
YES
T5-4-13
MAIN CONTROLLER B
IMPORTANT: The fault code is displays on the
monitor by the fault signal from
main controller B which comes via
main controller A.
Check that main controller A
operates
normally
before
performing troubleshooting of main
controller B.
FAULT CODE 31
ABNORMAL EEPROM
FAULT CODE 32
ABNORMAL RAM
FAULT CODE 33
ABNORMAL A/D CONVERSION
YES
Check if machine operates

normally.
* Faulty main controller B.
Switch main controller B

with main controller A.
Turn on MC display
selection switch, then
switch the monitor display
NO to main controller A.
Check if code 01, 02 or 03
is displayed when fault
code is displayed.
YES
Look for the cause from other

fault phenomenon.
Faulty main controller B.

NO
* Even if any fault codes are still displayed after

retrying, the machine can be used unless there are
malfunctioning on the engine or machine.
FAULT CODE 34
ABNORMAL SENSOR VOLTAGE
Check if voltage at alternator

terminal B is normal.
Switch main controller B

with main controller A.
Turn on MC display
selection switch, then
YES
switch the monitor display
to main controller A.
Check if code 04 is
displayed when fault code
is displayed.
24 V: With engine stopped

28 V: With engine running
YES
NO

controller B.
(Refer to fault code 06)
Faulty alternator.
NO
T5-4-14
FAULT CODE 37
ABNORMAL MAIN CONTROLLER B
RECEPTION
(BETWEEN MAIN CONTROLLER B AND
BUILT-IN DIAGNOSING SYSTEM)
Switch main controller B with

main controller A.
Turn on MC display selection
switch, then switch the
monitor display to main
controller A.
Check if code 07 is displayed
YES

controller B.
(Refer to fault code 06)
NO
T5-4-15
SENSOR ACTIVATING RANGE
1. Checking Method
Hydraulic Oil Temperature: 505 C

Unless specified:
Engine
Control Dial
Power
Mode
Switch
Auto-Idle
Switch
S/P
OFF
Maximum
Speed
Monitor each sensor using the built-in diagnosing

system.
2. Sensor Activating Range
Sensor
Engine Control Dial
Pressure Sensor
Operation
Maximum Speed
Minimum Speed
Control Lever: Neutral
Pilot Control Shut-Off Lever: LOCK
Control Lever: Full Stroke
Pilot Control Shut-Off Lever: UNLOCK
T5-4-16
Specification
0.3 to 1.0 V
4.0 to 4.7 V
0 to 0.10 MPa
(0 to 1.0 kgf/cm2)
3.3 to 3.9 MPa
(34 to 40 kgf/cm2)
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when diagnosing
from the fault phenomenon.
On the front section pages of this group T5-5, there
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.

YES(OK)
(2)
After checking or measuring item (1), select YES (OK) or NO (NOT OK)
and proceed to item (2) or (3), as appropriate.
(1)
NO(NOT OK)
Key switch: ON
(3)
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.
Use the built-in diagnosing system for descriptions in the double-line box.
Causes are stated in the thick-line box. Scanning through the thick-line boxes, possible
causes can be seen without going through the flow chart.

the open end side.
Harness

Open End Side
T158-05-03-001
T5-5-1
CORRELATION
BETWEEN
TROUBLE
SYMPTOMS AND PART FAILURES
This table indicates the relationship between machine
troubles and parts contributing to the cause of the
trouble if failed.
Engine System Troubleshooting
Trouble Symptom
Main Controller A
ECM
Monitor Controller
Switch Box
Pilot Pressure Sensor
Quick-Idle Switch
Auto-Idle Switch
Battery Relay
Starter Relay
Starter Relay 1
Starter Relay 2
Flow Rate Decrease Solenoid Valve Relay
Preheat Relay 1
Preheat Relay 2
Power Transistor 1
Power Transistor 2
Power Decrease Solenoid
Valve
Pump 1 and 2 Control
Valve (Signal Control
Valve)
E-1
E-2
Starter does not rotate

even if key switch is
turned to START position.
Although starter rotates, engine does not

start.
z
z
z
z
z
z
z
z
Shuttle Valve
(Swing Make-Up)
Shockless Valve
(Pump 2 Regulator Pressure Pi Circuit Side)
Starter Motor
Engine Unit
Main Pump / Regulator
Shuttle Valve
E-3
Even if engine control
dial is rotated, engine
speed remains unchanged.
z
z
T5-5-2
E-4
Even if key switch is
turned OFF, engine
does not stop.
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently.
E-5
Engine speed is slow,
or does not increase.
E-6
Quick-idle system is
inoperable.
z
z
In case more than one trouble occurs at

the same time, find out all faulty components while checking all suspected components in each trouble symptom.
E-7
E-8
E-9
Auto-idle system is inoperable.
Even if control lever is

operated, speed does
not increase (with
auto-idle ON).
Engine speed does not

increase when a particular function is operated (with auto-idle
ON).
z
z
z
z
z
z
T5-5-3
Trouble Symptom
E-10
Engine stalls.
Main Controller A
ECM
Monitor Controller
Switch Box
Pilot Pressure Sensor
Quick-Idle Switch
Auto-Idle Switch
Battery Relay
Starter Relay
Starter Relay 1
Starter Relay 2
Flow Rate Decrease
Solenoid Valve Relay
Preheat Relay 1
Preheat Relay 2
Power Transistor 1
Power Transistor 2
Flow Rate Decrease
Solenoid Valve
Power Decrease
Solenoid Valve
Pump 1 and 2 Control
Valve
(Signal Control Valve)
Shuttle Valve
(Swing Make-Up)
Shockless Valve (Pump 2
Regulator Pressure Pi
Circuit Side)
Starter Motor
Engine Unit
Shuttle Valve
Air Heater (1)
Air Heater (2)
E-11
Even if preheat switch
is pressed, air heater
does not operate (Engine is difficult to start).
z
z
z
z
z
z
z
z
z
z
z
z
z
T5-5-4
(Blank)
T5-5-5
All Actuator System Troubleshooting

A-1
Trouble Symptom
All actuator speeds are

slow.
A-2
All actuators are inoperable.
A-3
A-4
Actuator does not stop

even if lever is returned
to neutral.
SP mode is inoperable.
Parts
Main Controller A
Switch Box
Power Decrease Solenoid
Valve
Power Increase Solenoid
Valve
Spool
Main Relief Valve
Pilot Pump
Pilot Valve
Pilot Relief Valve
Shuttle Valve
(Swing Make-Up)
Circuit Side)
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
T5-5-6
independently.
A-5
E mode is inoperable.
z
z
T5-5-7

Front Attachment System Troubleshooting

Trouble Symptom
F-1
F-2
F-3
F-4
Some front attachment

movement is slow, or is
inoperable.
Front attachment drifts

remarkably.
Front attachment
moves slightly to the
opposite direction
against the lever operation (boom raise, arm
roll-out (BH), arm retract (LD) or bucket
close (LD)).
Boom raise is slow at

combined arm roll-out
(BH)/arm retract (LD)
and boom raise operation.
Parts
Main Controller A
Main Controller B
Heavy Lift Switch
Boom Mode Selection
Switch
Flow Rate Decrease Solenoid Valve Relay
Power Transistor 1
Boom Mode Selection
Solenoid Valve
Spool
Overload Relief Valve
Load Check Valve
Shuttle Valve
Main Relief Valve
Boom Overload Relief
Change Valve
Pilot Valve
Cylinder
Slow-Return Valve
Shockless Valve (Signal
Control Valve)
Valve (Signal Control
Valve)
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
Shuttle Valve (Boom

Raising Priority)
Shuttle Valve
(Pilot Selection)
Shuttle Valve (Pump 3
Control Valve Selection)
Shuttle Valve
(Swing Make-Up)
Shockless Valve
(Pump 2 Regulator Pressure Pi Circuit Side)
T5-5-8
independently.

F-5
F-6
F-7
F-8
Arm cylinder move unevenly at combined arm

roll-out (BH)/arm retract
(LD) and bucket roll-in
(BH)/bucket tilt-in (LD),
boom raise or swing
operation.
Single arm roll-in

(BH)/arm extend (LD),
bucket roll-in (BH)/
bucket tilt-in (LD) or
boom raise operation is
slow.
Heavy lift function does

not operate.
Boom mode selection

function does not operate.
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
T5-5-9
Swing/Travel System Troubleshooting

Trouble Symptom
S-1
Swing is unmoving,
slow or weak in power.
S-2
Swing drift is large
when stopping.
T-1
Both right and left
tracks do not rotate or
rotate slowly.
T-2
Fast travel is inoperable.
Parts
Main Controller B
Switch Box
Spool
Overload Relief Valve
Load Check Valve
Flow Combiner Valve
Shuttle Valve (Swing
Brake Release)
Reducing Valve
Priority Valve (Signal
Control Valve)
Flow Combiner Valve
Selection Spool (Signal
Control Valve)
Counterbalance Valve
Pilot Valve
Shuttle Valve (Pilot Selection)
Shuttle Valve (Swing
Make-Up)
Circuit Side)
Swing Motor
Swing Parking Brake Release Valve
Swing Reduction Gear
Swing Relief Valve
Travel Parking Brake
Travel Motor
Travel Reduction Gear
Travel Relief Valve
Center Joint
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
T5-5-10
independently.
T-3
Slow travel is inoperable.
T-4
T-5
T-6
One side track does not

move, moves slowly or
mistracks.
Travel motor runs excessively fast when

combined left travel and
front attachment operation is performed with
left track off the ground.
Machine mistracks
during combined travel
and front attachment
operation.
z
z
z
z
z
z
z
z
z
z
z
z
z
T5-5-11
Other System Troubleshooting

Trouble Symptom
O-1
O-2
O-3
O-4
Auto-lubrication indicator comes ON. (Grease

pump does not operate.) (Empty grease in
pump)
Grease pump operates

excessively slow.
Grease pump does not

stop operating.
Oil cooler fan motor

does not rotate at
speed corresponding to
hydraulic oil temperature or does not rotate
at all.
Parts
Main Controller A
Main Controller B
Auto-Lubrication Selection Switch
Proximity Switch
Step Light Switch
Auto-Lubrication Relay
Step Light Relay
Power Transistor 3
Oil Cooler Fan Control
Solenoid Valve
Grease Pump
Drive Pump
Step Light
Follow Plate
z
z
z
z
z
z
z
z
z
z
T5-5-12
independently.
O-5
Step light does not
come ON.
O-6
Even if step light switch
is turned OFF, step light
does not come OFF
after 60 seconds.
O-7
Air conditioner.
T5-5-13

ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter does not rotate even if key switch is
turned to START position.
This problem is contributed to by many different
causes. Diagnose the power system and the relay
system separately to locate the cause of the problem.
The electrical system is diagnosed in this group.

In case the starter does not rotate due to failure
in the engine unit, refer to the engine service
manual.
The same problem will be presented in case either the valve switch or the engine stop switch is
activated. Check each switch condition first.
Check for loose harness connections beforehand.
0 V.
(2)
To Relay System
Troubleshooting
(T5-5-16)
YES Check for voltage at

starter motor terminal
C.
Key switch: START
Check if voltage at
starter motor terminal
B is 24 V or over.
24 V
Faulty starter unit, or faulty

engine unit.
Key switch: ON
(1)
NO
To Power System
Troubleshooting
(T5-5-15)
Terminal B
Terminal C
Terminal M
T18E-05-05-010
T5-5-14
(1) Power System Troubleshooting
Faulty battery reYES lay, or faulty

ground wire from
battery relay terminal E.
Check if voltage at
YES battery relay terminal S is 24 V or
over.
NO
Check if voltage at
Certain starter battery relay terindicates 0 V minal B connected
to corresponding
starter is 24 V or
over.
Key switch: ON
(1)
Key switch: ON
Check if voltage at
battery relay terminal A is 24 V or
over.
NO
NO
Broken harness
between battery
relay terminal S
and fuse #10.
Broken harness
between battery
relay terminal A
and battery.
Broken harness
between battery
relay terminal B
and starter terminal
B.
YES
Blown fuse #10, or

broken harness
between key
switch terminal M
and battery relay
terminal S.
All starters indicate 0 V
Connector
Battery Relay
T146-05-04-018
T5-5-15
(2) Relay System Troubleshooting
Check if voltage
YES at starter relay 1
and 2 terminal S
is beyond 24V.
Disconnect starter
relay 1 and 2 terYES minal E. Check for
continuity between
harness end terminal E and vehicle
frame.
Broken harness
YES between starter relay 1 and starter
YES Check for continumotor 1 or starter
ity between terrelay 2 and starter
minal B and C.
motor 2.
NO
Faulty starter relay

1 or 2 ground.
NO
Check if voltage
at starter relay
connector terminal #1 is beyond
24V.
Key switch: START
Check if voltage at
starter relay 1 and 2
NO output side is beyond 24V.
Faulty starter relay

1 or 2.
Broken harness
YES Remove starter
between starter
relay and starter
relay 1 and 2 terrelay 1 or 2.
minal #2. Check
for continuity between terminal #2 YES Faulty starter relay.
and vehicle frame.
NO
Faulty ground of
starter relay termiNO nal #2.
Blown fuse of fuse

box 2 terminal #19,
or broken harness
between key switch
terminal G2 and
starter relay connector terminal #1.
NO
Connector
Starter Relay 1
Starter Relay 2
Starter Relay 1
Starter Relay 2
T18E-05-05-002
T146-05-04-009
T18E-05-05-004
T18E-05-05-003
T5-5-16
(Blank)
T5-5-17
E-2 Although starter rotates, engine does not
start.
YES
YES
YES
Check if air is bled

from fuel pipe of
engine.
Remove connector
31 poles. Check if
voltage at harness
end connector terminal #1 is 24V.
NO
Key switch: ON
YES
Check if voltage at
input side of fuse
NO box 2 terminal #3 is
24V.
Key switch: ON
Remove ECM
connector 21
poles.
Check if voltage
at harness end
connector terminals #G and #D is
24V respectively.
NO
Key switch: OFF
Bleed air from coupling of engine injection pump.

Blown fuse of fuse
box terminal #3, or
broken harness between fuse box and
ECM.
Broken harness between fuse box and
key switch terminal
M.
Blown fuse terminal

#1, or broken harness between fuse
box 2 terminal #2
and ECM.
YES
NO
Faulty engine.
(Refer to the Engine
Manual)
Check if voltage at
fuse box terminal #2
is 24V.
Broken harness between fuse box and

key switch terminal
M.
NO
Connector
ECM Connector 21 Poles

#G
#D
#1
T18E-05-05-005
T5-5-18
T18E-05-04-004
TROUBLESHOOTING /Troubleshooting B
(Blank)
T5-5-19
E-3 Even if engine control dial is rotated, engine
speed remains unchanged.
The engine control dial, ECM and/or harness

may have trouble. In those cases, fault code 10 is
displayed on the built-in diagnosing system.
Refer to Troubleshooting A.
T5-5-20
E-4 Even if key switch is turned OFF, engine
does not stop.
The key switch may be faulty.

If the above are not the cause, the engine unit
may have trouble.
T5-5-21
E-5 Engine speed is slow, or does not increase.
The engine control dial system of the switch box

and/or ECM system may have trouble.
YES
YES
Disconnect switch box.

terminal #2 and terminal
#4 matches specification.
Key switch: ON
Check if resistance between

switch box terminals #2 and
#4 is normal.
Insert probe in switch box
connector rear terminals #2
and #3. Check if voltage at
those terminals matches
specification.
NO

switch box harness end connector terminal #4 and vehicle
frame matches specification.
Key switch: ON
Resistance specification:
50.5 k
Voltage specification:
0.3 to 1 V
(at maximum speed)
Connect switch box harness

end connector terminal #3 and
vehicle frame.
Disconnect EMC connector
31 poles.
Check for continuity between
ECM harness end connector
terminal #5 and vehicle frame.
Faulty engine control dial.
NO
T5-5-22
YES
Faulty ECM system.
NO

switch box and ECM (sensor
system).
YES
Faulty ECM system.
NO

switch box and ECM (ground
system).
Disconnect ECM connector

31 poles.
YES Check for continuity between
EMC connector 31 poles
terminal #6 and switch box
harness end connector terminal #2.

switch box and ECM (power
system).
NO
Connector
(Harness End Connector Viewed from the Open End
Side)
Switch Box
T183-05-04-004
T18E-05-04-004
T5-5-23
E-6 Quick-idle system is inoperable.

NOTE: When the auto-idle switch is turned ON,
the quick-idle system operates after 3
seconds.
YES
Faulty quick-idle
switch.
Disconnect
quick-idle switch.
Connect harness
end connector terminals with a clip.
Check if quick-idle
system is operated.
Engine: Running
Control lever: Neutral
NO
Disconnect monitor
controller connector
YES
C.
between monitor controller terminal #C3
Disconnect monitor
B.
between monitor
controller harness
end connector terminal #B11 and
quick-idle switch
end terminal.
NO
NO
Connector C
C3
T183-05-04-014
B11
T183-05-04-013
T5-5-24
Faulty monitor controller.

Broken harness between monitor controller and quick-idle
switch.
Connector
Monitor Controller
Connector B
Disconnect ECM
connector 31 poles.
YES between monitor controller connector terminal #C3 and ECM
connector 31 poles
#19.
Broken harness
between ECM and
monitor controller.
NO
Faulty ECM.
YES
19
T18E-05-04-004
T5-5-25
E-7 Auto-idle system is inoperable.
The auto-idle system will stop if one of pressure

switches is turned ON.
Disconnect harness from switch

box.
switch box connector terminal #8
and vehicle
Connect connector.
Disconnect main
controller A conYES nector B.
harness end
connector terminal #B16 and vehicle frame.
Key switch: START

Auto-idle switch: ON
Control lever: Neutral
Connect connector.
Disconnect main
controller A conYES nector A.
between main controller terminal #A29
and vehicle frame.
Disconnect ECM
YES Faulty ECM.
connector 31
poles.
Connect main
controller conYES nector A terminal
#A29 to vehicle
frame.
Check for continuity between ECM
connector 31
Broken harness
poles terminal #20
between main conand vehicle frame.
NO troller and ECM.
NO
Broken harness
between main controller A and switch
box.
NO
Faulty switch box.

NO
Connector
Main Controller A
Connector A
B16
Connector B
#20
Switch Box
T183-05-04-004
A29
T183-05-04-005
T18E-05-04-004
T5-5-26
(Blank)
T5-5-27
E-8 Even if control lever is operated, speed does
not increase.
(with auto-idle ON)
The pilot sensor (front attachment), main controller A and/or harness may have trouble. In either
cases, fault code 08 is displayed on the built-in
diagnosing system.
T5-5-28
E-9 Engine speed does not increase when a particular function is operated
(with auto-idle ON)
Faulty shuttle valve.
Speed does not increase

only at certain operation.
T5-5-29
E-10 Engine stalls.
Install pressure gauge
on hose entering flow
YES rate decrease solenoid
valve input port.
Measure the pressure.
The cause differs according to the engine speed.

If power decrease solenoid valve (SA) has a trouble, the swing speed does not change at E mode.
The engine speed sensor 1 and/or main controller A may have trouble. In either cases, fault code
05 is displayed on the built-in diagnosing system.
Disconnect lines from
flow rate decrease solenoid valve. Check if
engine stalls when disconnected lines are
connected each other
directly.
YES
Check if output to flow
rate decrease solenoid valve is
normal.
Around
850 min-1
Check engine
speed.
Built-in diagnosing system: Main

controller A
Monitor item:
Digital output: bit
5: Pump flow rate NO
cut-off output
Disconnect lines from
power decrease solenoid
valve (SA, SB). Check if
YES engine stalls when disconCheck if outnected lines are connected
put to flow
each other directly.
rate decrease solenoid valve is
normal.
Below
1400 min-1
Over
1400 min-1
NO

controller A
Monitor item:
Proportional
NO
valve ON/OFF
output: bit 6: #1,
2 pump power
decrease solenoid valve output
NOTE: All regulators are

unlikely to become inoperable
at the same time.
Disconnect and check lines
from one solenoid valve, then
check the other.
Disconnect flow rate decrease

solenoid valve.
Connect harness end connector terminals with a clip.
harness end connector terminals.
Faulty main controller.

YES
Disconnect power decrease
solenoid valve (SA, SB).
Connect harness end connector terminals with a clip.
Disconnect main controller A
connector A.
NO Check for continuity between
harness end connector terminals #A19 and #A20 (SB), and
terminals #A11 and #A14 (SA).
Faulty engine and

fuel system.
Connector
Main Controller A
Connector A
A19
A20
Connector D
Flow Rate Decrease Solenoid

Valve
Power Transistor 1
T183-05-04-011
A14
T183-05-04-010
T183-05-04-008
T183-05-04-009
D14
T5-5-30
Faulty pump 1 and/or 2
flow rate control valve in
signal control valve.
Less than 3.9 MPa (401 kgf/cm2)
Faulty shuttle valve

(swing make-up), shockless valve or regulator.
3.9 MPa (401 kgf/cm ) or over

NO
Check if voltage at
YES flow rate decrease solenoid valve relay
i 24 V
Faulty flow rate decrease

solenoid valve.
NO
Check if voltage at
flow rate decrease
solenoid valve relay connector terYES
minals #1 and #3
are 24 V.
Blown fuse #14.
NO
Check if voltage at
flow rate decrease
solenoid valve relay
YES connector terminal
#2 is 24 V.
NO
YES
Faulty flow rate decrease

solenoid valve relay, or
broken harness between
flow rate decrease solenoid valve relay and
power transistor 1.
(1)
flow rate decrease solenoid valve and flow rate
decrease solenoid valve
relay.
Faulty regulator.

power decrease solenoid
valve (SA, SB) and main
controller A.
NO
Faulty power decrease

solenoid valve.
YES
Flow Rate Decrease

Solenoid Valve
Input
Port
Flow Rate Decrease Solenoid

Valve Relay
T183-05-04-010
T183-05-04-003
T183-05-04-012
T5-5-31
T146-05-03-006
(1)
YES
Faulty power transistor 1.
NO

power transistor 1 and main
controller A.
Check if engine
stalls after switching
power transistor 1
with power transistor
2 or power transistor
3.
T5-5-32
(Blank)
T5-5-33
E-11 Preheat does not operate.
(Engine is difficult to start)
This troubleshooting should be applied only when
If preheat operates again after the preheat opera-
the air heater in the engine does not operate. In

case the preheat indicator only does not light,
refer to Troubleshooting C.
Preheat operates when temperature of engine
suction becomes below 0 C (32 F).
tion, turn the key switch OFF and after 5 minutes

try to operate preheat. (Preheat does not operate
within 5 minutes.)
Preheat stops automatically after 30 seconds
with preheat operated.
YES
YES
Disconnect preheat signal relay

connector.
Check if voltage
at preheat signal
relay terminal #1
is 24V.
Key switch: ON
Disconnect connector from preheat signal relay

terminal #2.
YES Check for continuity between
harness end
connector terminal #2 and vehicle frame.
Check voltage at
preheat signal
relay terminal #5
is 24V.
YES Faulty preheat

signal relay.
Check if voltage
at preheat signal
NO relay terminal #3
is 24V.
NO
Broken harness
between ECM terminal #1 and preheat signal relay
terminal #1.
YES
Disconnect ECM
connector 2
poles.
Check voltage at
NO ECM end connector terminal
#1 is 24V.
Broken harness
between battery
and preheat signal
relay, or broken
fusible link 4.
Faulty preheat signal relay terminal
#2 ground.
NO
Faulty ECM.
NO
Conector
Preheat Signal Relay
(A)
ECM
5
T146-05-04-009
T18E-05-05-002
M
T183-05-04-102
1 To ECM
2 To GND
T183-05-04-102
T5-5-34
YES
Check voltage at
YES
preheat relay
terminal M is
24V.
Check voltage at
YES
preheat relay
terminal B is 24V.
Check for contiYES nuity between
preheat relay
terminal #2 and
vehicle frame.
(A)
Check voltage at
preheat relay
terminal #1 is
24V.
NO
Faulty preheat relay.

Broken harness
between battery
and preheat relay
terminal #2, or
broken fusible links
7, 8.
Faulty preheat relay terminal #2

ground.
NO
Broken harness
between preheat
relay terminal #1
and preheat signal
relay terminal #5.
NO
YES
(B)
NO
(B)
Faulty air heater.

preheat relay and
air heater.
Broken harness
between preheat
relay and air
heater.
NO
T5-5-35
ALL ACTUATOR
SHOOTING
SYSTEM
TROUBLE-
A-1 All actuator speeds are slow.
Although speed is satisfactory, in case power is

weak, the faulty main relief valve is suspected.
If the flow rate decrease solenoid valve is bound
in OFF position, the main pump 1, 2 control

pressure Pi decreases, so that the main pump 1,
2 delivery volume decreases.
If the power decrease solenoid valve is bound in
ON position, pilot pressure PG is supplied to the
regulator, so that the pump delivery volume decreases.
If the engine speed is slow (refer to E-5) or SP
mode is inoperable (refer to A-4), faulty pilot system (refer to A-2) is suspected.
Faulty engine is suspected when engine speed
decreases remarkably after applying a load.
YES
YES Check if output to

flow rate decrease
solenoid valve is
normal.
Check if
power is sufficient.
Disconnect flow rate deYES crease solenoid valve and

reconnect line directly.
Check if delivery volume
from main pump 1, 2 decreases.
Check if output to
YES flow rate decrease
solenoid valve is
normal.
Built-in diagnosing system: Main controller A
Monitor item: Proportional valve ON/OFF
output: bit 6: #1, 2 pump
NO
power decrease solenoid valve output
NO

Monitor item: Digital output: bit 5: Pump cut-off
output
NO
A.

A.
Faulty main relief

valve.
NO
T5-5-36
Output Port
To Main Pump 2 Regulator
Port Pi
Shuttle Valve
(Swing Make-Up)
Power
Decrease
Solenoid
Valve SB
Power Decrease
Solenoid Valve SA
Machine Front Side
Flow Rate
Decrease
Solenoid Valve
T183-05-04-026
Shockless Valve
T183-05-04-015
Faulty engine speed sensor 1

system (refer to Troubleshooting A).
YES
Disconnect power
decrease solenoid
valve (SA, SB) output port. Place a
plug on port. Disconnected line is
left open to atmosphere.
Check if symptom
appears.
YES Check if fault

code 05 is displayed.
Faulty main pump or regulator.
NO
Mistracks to right: Pump 1

Mistracks to left: Pump 2
Swing is slow: Pump 3
Bound power decrease solenoid valve (SA or SB).
NO
YES
Only main pump
2 output volume
decreases.
NO
T5-5-37
Faulty shuttle valve (swing

make-up) and/or shockless
valve.
Bound flow rate decrease solenoid valve.
A-2 All actuators are inoperable.
It is unrealistic that all pumps break down at the

same time. Faulty pilot system is suspected.
Find out cause of trouble by tracing other

trouble symptoms.
YES
YES Check if primary pilot

pressure is normal.
Measurement: Refer
to the OPERATIONAL PERFORMANCE TEST
ti
Check if pilot control
shut-off lever is released.
YES Faulty pilot pump, or

clogged pilot filter.
Check if symptom
appears after adjusting, disassembling
NO and cleaning pilot relief valve.
NO
End
Release pilot control

shut-off lever.
NO
T5-5-38
A-3 Actuator does not stop even if lever is returned to neutral.
Bound spool in the pilot valve or bound spool in

the control valve is suspected.
YES
Faulty pilot valve.

When control lever is
returned to neutral, pilot
pressure is routed to
spool end in control
valve.
Check if actuator stops

when pilot control shut-off
lever is 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.
T5-5-39
A-4 SP mode is inoperable.
Faulty power increase solenoid valve ST and engine speed sensor 1 are suspected.
Find out cause of trouble by tracing other

trouble symptoms.
YES
Check if swing, travel right
YES and travel left single operation speed changes
when SP mode switch is
turned ON and OFF.
Faulty regulator or main

pump.
NO
Swing Main pump 3

Travel Right Main pump 2
Travel LeftMain pump 1
Disconnect line from

power increase solenoid
valve ST output port,
then install pressure
gauge.
Check if output pressure
changes in range of 0 to
3.7 MPa (0 to 38
kgf/cm2).
Check if current at
power increase solenoid valve ST changes
in range of 255 to 416
mA.
NO
SP mode switch: ON
Turn engine control dial
to change engine
speed, then observe
pilot pressure change.
Built-in diagnosing system: Main controller A:

Monitor item: Power increase output current
Turn engine control dial to
change engine speed.
Check if faulty code 05

is displayed on built-in
NO diagnosing system.
Faulty engine speed

sensor 1 system (refer
to Troubleshooting A).
YES
Output Port
Power
Increase
Solenoid
Valve ST
Connector
Main Controller A
Connector A
A3
A4
T183-05-04-016
T183-05-04-008
T5-5-40
Faulty power increase solenoid valve ST.
YES
NO
Connect line to engine

speed sensor 1.
Disconnect plug receptacle from power increase solenoid valve
ST.
Connect both disconnected harness end
plug receptacles.
between main controller
A connector A harness
end terminals #A4 and
#A3.

power increase solenoid valve
and main controller A.
NO
YES
Check for continuity between switch box end conYES nector terminals #6 and
#15.
SP mode switch: ON
NO
Connector
Switch Box
T183-05-04-004
T5-5-41
Faulty main controller A, or

switch box and main controller A.
Faulty switch box, or broken

harness between monitor
controller and switch box.
A-5 E mode is inoperable.
In case main controller, power decrease solenoid

valve or regulator of main pump 3 is inoperable,
engine may stall below 1400 min-1 even if E
mode switch is turned OFF.
NO
YES
Check if E mode
switch is normal.
E mode switch: ON
Built-in diagnosing system: Main controller A:
Monitor item: Digital
input: bit 3: E mode SW
Check if output to
power decrease solenoid valve is normal.
E mode switch: ON
monitor item: Proportional valve ON/OFF
output: bit 6: #1, 2
Pump power decrease
solenoid valve output
Disconnect power decrease solenoid valve

(SA).
Connect harness end
and #2 with a clip.
Disconnect main controlYES ler connector A.
Check for continuity between terminals #A11
and #A14.
Broken harness beNO tween power decrease

solenoid valve SA and
main controller A.
YES
YES
Disconnect main controller A connector B.

Check for continuity between harness end conNO nector terminal #B2 and
switch box harness end
connector terminal #7.
Broken harness between switch box and

NO main controller A.
Connector
Main Controller A
Connector A
A14
Connector B
B2
Faulty switch box dial.
T183-05-04-005
T5-5-42
T183-05-04-010
YES
Disconnect power decrease solenoid valve (SA)
from line, then connect
disconnected line directly.
Check if each operation
speed increases.
NO
Faulty power decrease solenoid valve (SA).
Faulty main pump 3, or regulator of main pump 3.
Output Port
Input Port
T18E-05-05-001
T5-5-43
FRONT ATTACHMENT SYSTEM TROUBLESHOOTING
F-1 Some front attachment movement is slow,
or is inoperable.
If the other operations (travel/swing) are normal,

the pilot pump (primary pilot pressure) is considered to be normal.
YES Faulty corresponding

cylinder.
YES Check for internal oil
leakage in corresponding cylinder.
Bound corresponding
NO control valve spool.
YES Check if corresponding

secondary pilot pressure
is normal.
Check if corresponding secondary pilot

pressure is normal.
Built-in diagnosing
system: Main controller A
Monitor item: Front
operation pressure
Measurement: Refer to
the OPERATIONAL
PERFORMANCE TEST
section.
Monitor item: Main
pump 1
NO
YES
Faulty corresponding
overload relief valve.
Bound shockless valve
spool in signal control
valve (at boom raise
only).
Check if secondary
NO pressure at signal control valve inlet is normal.
NO
T5-5-44
Faulty pilot valve.
F-2 Front attachment drifts remarkably.
YES
Faulty pilot valve.
YES Faulty corresponding

cylinder.
Check if cylinder drift
is reduced when pilot
shut-off valve is
closed.
YES Check if oil leaks in

corresponding cylinder.
control valve (broken
spring, loose spool
NO
end).
Check if corresponding
overload relief valve is
NO normal.
Measurement: Refer
to the OPERATIONAL
PERFORMANCE
TEST section.
NO
Boom Cylinder Internal Leakage Check

1. With the bucket cylinder fully retracted and the
arm cylinder slightly extended from the fully retracted position, lower the bucket tooth tips onto
the ground.
2. Disconnect hoses from the boom cylinder rod
side. Drain oil from the hoses and cylinders.
(Plug the disconnected hose ends.)
T105-07-04-009
3. Retract the arm cylinder to lift the bucket off the

ground. If oil flows out of the hose disconnected
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.
T5-5-45
F-3 Front attachment moves slightly to the opposite direction against the lever operation
(boom raise, arm roll-out (BH), arm retract
(LD) or bucket close (LD).
NOTE: BH: Backhoe
LD: Loading Shovel
YES
YES
Check if corresponding
load check valve in control valve is normal.
Disassemble / Visual
Inspection
Check if slow-return
valve of corresponding cylinder is normal.
Oil leaks in cylinder.
NO
Disassemble / Visual Inspection
Faulty load check valve.
slow-return 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
or slow-return valve is malfunctioning,
the oil in the bottom side of the cylinder
flows back into the circuit, causing the
cylinder rod to temporarily moves to the
other direction from the lever operation
direction.
2. Since oil pressure and flow rate from
the pump is low, if oil leaks from between bottom side (B) and rod side (A)
due to faulty cylinder piston ring or cylinder barrel, the cylinder rod is temporary lowered during the initial stage of
operation by the load.
In addition, cylinder force is reduced,
increasing the front attachment drift in
this case.
T5-5-46
When the load check

valve is faulty:
When the slow return

valve is faulty:
T141-05-04-001
(Blank)
T5-5-47
F-4 Boom raise is slow at combined arm roll-out
(BH)/arm retract (LD) and boom raise operation.
NOTE: BH: BH: Backhoe
LD: Loading Shovel
The arm flow rate control valve in the signal control valve is switched at combined boom raise
and arm roll-out (BH)/arm retract (LD) operation,
so that pilot pressure is applied on both sides of
the arm 2 spool. Therefore, the arm 2 spool becomes neutral.
Check if shuttle valve

YES (preferential boom raising) is bound or scored.
Check if arm 2 spool
YES neutral pressure at
signal control valve
outlet port SE is normal.
YES Check if boom 1 spool

selection pressure at
signal control valve outlet port #1 is normal.
Check if secondary
pressures at signal
control valve inlet
ports D, A and F are
normal.
NO
Bound arm flow rate

control valve spool in
signal control valve, or
faulty shuttle valve.
Bound shockless valve

spool in signal control
valve.
NO
Faulty pilot valve.

NO
Pilot Valve Connecting Side
Port A
Port #1
Port D
Port SE
Port F
Control
Valve Side
Pilot Valve
Side
T178-03-06-016
T5-5-48
T178-03-06-015
Clean or replace shuttle

valve (preferential boom
raising).
YES
Bound arm 2 spool.

NO
T5-5-49
F-5 Arm cylinder moves unevenly at combined
arm roll-out (BH)/arm retract (LD) and
bucket roll-in (BH)/bucket tilt-in (LD), boom
raise or swing operation.
NOTE: BH: Backhoe
LD: Loading Shovel
The arm preference valve is switched at combined arm roll-out (BH)/arm retract (LD) and
bucket roll-in (BH)/bucket tilt-in (LD), boom raise
or swing operation, so that the pilot pressure to
the arm 3 is blocked. Therefore, the arm 3 spool
does not move.
Clean or replace arm preference valve.
YES
Check if arm preference valve spool is

bound or scored.
YES
NO

valve (pilot selection).

(pilot selection) is
bound or scored.
NO
T5-5-50
Bound swing control valve

arm 3 spool.
(Blank)
T5-5-51
F-6 Single arm roll-in (BH)/arm extend (LD),
bucket roll-in (BH)/bucket tilt-in (LD) or
boom raise operation is slow.
NOTE: BH: Backhoe
LD: Loading Shovel
The pump 3 control valve is switched at single

arm roll-in/arm extend (LD), bucket roll-in
(BH)/bucket tilt-in or boom raise operation, so
that pressure oil from the pilot circuit is applied
directly to the main pump 3 regulator as flow rate
decrease pressure Pi. Therefore, the delivery
volume of the main pump 3 increases.
(Refer to the pages for the Pilot Circuit and Main
Pump 3 Flow Rate Control Circuit in the Hydraulic System group in the SYSTEM section in the
Technical Manual (Operational Principle))
NO
Faulty main pump 3 or

regulator (main pump
3).
Check if single bucket

NO roll-in (BH)/bucket
tilt-in (LD) or boom
raise operation is slow.
(pilot selection) is bound
YES
or scored.
NO Check if shuttle valve

(pump 3 control valve
selection) is bound or
scored.
YES
Check if pump 3 control valve is bound or
scored.

valve (pump 3 control
valve selection).
Clean or replace pump

3 control valve.
YES
T5-5-52
YES

Faulty pilot valve.

NO
T5-5-53
F-7 Heavy lift function does not operate.
If the flow rate does not decrease at heavy lift

operation, faulty flow rate decrease solenoid
valve system is suspected. Refer to Troubleshooting "E-10 Engine stalls" - "around 850
min-1."
NO
Check if front operation

speed is slow after
switching heavy lift
switch with boom mode
selection switch.
Heavy lift switch:
ON
Check if front attachment operation speed is

slower than normal.
NO
Faulty heavy lift

switch.
Disconnect heavy lift

switch and main controller A connector B.
between heavy lift
YES switch harness end
and connector B terminal #B11.
NO
Broken harness between heavy lift switch


YES A.
Heavy lift switch:

ON
YES
Disconnect heavy lift

switch and main controller A connector B.
between heavy lift
switch harness end
and connector B harness end connector
terminal #B11.
Heavy Lift Solenoid Valve (Upper Side)

Output Port
Broken harness between heavy lift switch

NO
Disconnect main controller A connector A

and heavy lift solenoid
valve.
Connect heavy lift solenoid valve harness
YES end connector terminal with a clip.
between connector A
harness end connector terminals #6 and
#7.
YES
T183-05-04-017
Connector
Heavy Lift Switch
Main Controller A
Connector A
A6
A7
Connector B
B11
T183-05-04-101
T5-5-54
T183-05-04-005
Broken harness between main controller

A and heavy lift solenoid valve.

heavy lift solenoid
valve output port, then
install pressure gauge
NO on the port.
Check if main control
valve main relief selection pressure is 3.9
MPa (40 kgf/cm2).
YES
Faulty shuttle valve in

main control valve, or
faulty main relief valve.
NO
Faulty heavy lift solenoid

valve, or faulty main controller A.
T5-5-55
TROUBLSHOOTING / Troubleshooting B
F-8 Boom mode selection function does not
operate.

B connector B. Disconnect connector A and
boom mode selection
solenoid valve SC.
Connect boom mode
selection solenoid valve
SC harness end connector terminals #1 and
#2 with a clip.
Check for continuity between harness end connector A terminals #A4
and #A3.
YES
Check if output to
boom mode selection
solenoid valve is
normal.
Boom mode selection
switch: ON
Built-in diagnosing system: Main controller B
Monitor item: Proportional valve ON/OFF
output: bit 7: Boom
mode selection solenoid valve output
NO
Interchange boom
mode selection
switch with heavy lift
switch and check if
system operates
properly.
Boom mode selection switch: ON
Disconnect boom
mode selection switch
and main controller B
connector B.
NO between boom mode
selection switch harness end connector
terminal #3 and connector B harness end
connector terminal
#B12.
YES
NO
YES
Connector
Boom Mode Selection
Switch
Main Controller B
Connector A A3
A4
Connector B
B12
Boom Mode Selection

Solenoid Valve SC
T183-05-04-010
T183-05-04-005
T183-05-04-101
T5-5-56

main controller B and
boom mode selection
solenoid valve SC.
NO

B connector A and
boom mode selection
YES solenoid valve SC. Install tee and pressure
gauge at boom mode
selection solenoid valve
SC output port.
Check if pressure is 3.9
MPa (40 kgf/cm2).
Boom mode selection
switch: ON
Faulty boom mode selection solenoid valve SC.
NO
Faulty overload relief

change valve in main
control valve, or faulty
YES

boom mode selection
switch and main controller B.
Faulty boom mode selection switch.
Output Port
Boom Mode
Selection Solenoid
Valve SC
Front
T183-05-04-015
T5-5-57
SWING SYSTEM TROUBLESHOOTING
S-1 Swing is unmoving, slow or weak in power.
Check whether the pilot system is faulty or the

main circuit is faulty.
In case other functions (front attachment and

travel) operate normally, the pilot pump is considered to be normal. If the pilot system is displaying a problem, the cause of the trouble may
exist in the circuit after the pilot valve.
The brake chatter is heard if a problem exists in
the swing parking brake system.
NO
Check if swing
YES motor relief
pressure is
normal.
Check if secondary pilot

pressure is
normal.
controller A
Monitor item:
Front attachment
operation pressure
Built-in diagnosing
Monitor item: Main
pump pressure
Measurement:
Refer to the OPERATIONAL
PERFORMANCE
TEST section.
Faulty swing
control valve
spool.

NO (swing brake release) is
bound or scored.
Check if single
YES boom, bucket,
arm and swing
operations are
slower than
specification.
Install tee and

pressure gauge
at main pump 3
port Pi.
Check if swing
YES pump control
pressure varies
smoothly, and
pump control
pressure becomes 0 MPa (0
kgf/cm2) with
swing lever in full
stroke.
Specification: Refer to the OPERATIONAL

PERFORMANCE
TEST section.
YES
Check if shuttle
valve (pilot selection) or shuttle
valve (pump 3
control valve selection) is bound or
scored.
NO Clean or replace shuttle

NO
Check if shuttle
valve (pilot selection) is bound
or scored.
Faulty swing control

YES valve.
Faulty pilot valve.
NO
Port Pi
T183-01-02-006
T5-5-58
YES

(swing brake release).
Faulty swing parking

brake release valve.
YES
Check if swing parking
brake release valve is
NO bound or scored.
Faulty swing motor.
NO
When brake shows a

trouble after disassembling, also check
brake release pressure
selection valve.
valve (pilot valve selection) or shuttle valve
(pump 3 control valve
selection).
YES

valve (swing make-up).
YES
NO Check if shuttle valve
(swing make-up) is
bound or scored.
Check if main
NO pump 2 delivery
pressure is normal.
Built-in diagnosing
Monitor item: Main
pump 2 pressure
YES
Faulty shockless valve.
NO

2).
Check if shockless
valve plunger is
NO bound.
YES
Check if pump 3 conYES trol valve is bound.
NO
T5-5-59
Faulty pump 3 control

valve.
3).
S-2 Swing drift is large when stopping
In case the upperstructure drifts and shakes,

valve related parts may be faulty. In case the
upperstructure drifts smoothly, spool related parts
may be faulty.
Check if secondary
pilot pressure is 0
2
YES MPa (0 kgf/cm )
when swing lever is in
neutral.
Check if swing relief

pressure is normal.
Monitor item: Main
pump 3 pressure
the OPERATIONAL
PERFORMANCE TEST
section.

Monitor item: Front attachment operation pressure
the OPERATIONAL
PERFORMANCE TEST
section.
Check if symptom appears after switching
swing overload relief
valve in swing control
NO valve with other overload relief valve except
boom mode selection in
main control valve.
YES Check if swing control

valve swing spool
operates normally.
Disassemble / Visual inspection

(pilot selection) is
NO bound or scored.
YES Faulty swing spool (replace spool or swing

control valve).
Faulty swing motor or

NO reduction gear box.
YES Clean or replace shuttle
NO
YES
NO
T5-5-60
Faulty pilot valve.
Faulty swing relief

valve
Faulty swing overload

relief valve.
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Both right and left tracks do not rotate or
rotate slowly.
Both right and left pilot valves, travel motors,

and/or control valve spools are unlikely to be
faulty at the same time.
In case both travel systems do not operate, the
pilot system, which is applied to both side travel
motors, may be faulty. If the primary pilot pressure is lower than specification, not only travel
but also all operations are affected. As this section describes the troubleshooting of faulty both
left and right tracks, refer to T-4 for the trouble on
only one track.
Faulty travel parking

brake.
YES
Install tee to line of
travel parking brake release pressure port,
gauge.
Check if travel parking
brake release pressure
is normal.
Specification: 1.8 MPa (18
kgf/cm2) or over.
Measure pressure in jacking
up either side of track.
YES

(swing brake release).

(swing brake release) is
NO faulty.
Faulty reducing valve.
NO
Brake Release Pressure Port
T183-05-04-100
T5-5-61
T-2 Fast travel is inoperable.
If the other solenoid valves are also not activating,

check the fuse.

Disconnect line
from reducing
3.9 MPa
valve output port,
(40 kgf/cm2) then install pressure gauge on the
port.
Disconnect line
from travel mode
control solenoid
valve output port,
YES then install pressure gauge on
the port.
Measure reducing valve selection pressure.
Check if output to
travel mode control
solenoid valve is
normal.
Travel mode
switch: ON
Faulty reducing
valve.
1.8 MPa (18 kgf/cm2)
Measure pressure.
Faulty travel motor

switch selection
mechanism.
3.9 MPa (40 kgf/cm )
Travel mode switch:

ON
Faulty travel mode

control solenoid
valve, or broken harness between travel
mode control solenoid valve and main
controller B.
0 MPa
(0 kgf/cm2)
Disconnect switch
box and main controller B connector B.
between switch box
harness end connector terminal #5
and connector B
harness end connector terminal #B13.
Travel mode switch:

ON
Built-in diagnosing
system: Main controller B
Monitor item: Propor- NO
tional valve ON/OFF
output: bit 6: Travel
mode control solenoid
valve output
YES Faulty main controller B.
NO
Faulty switch box, or

broken harness between switch box
and main controller
B
Connector
Side)
Travel Mode Control
Solenoid Valve
(Lower Side)
Reducing Valve
Output Port
Main Controller B
Connector B B13
Travel Mode Control Solenoid

Valve
T183-05-04-021
T183-05-04-022
T183-05-04-020
Switch Box
Output Port
T183-05-04-019
T183-05-04-004
T5-5-62
T-3 Slow travel is inoperable.
YES
NO
Check if output to travel

mode control
solenoid
valve is normal.
Disconnect main
controller B connector B.
between connector B
harness end connector terminal #B13
and vehicle frame.
Faulty switch box, or

short-circuited harness
between switch box and
main controller B.

NO
3.9 MPa
(40 kgf/cm2)

Travel mode
travel mode control
switch: ON
solenoid valve output
Built-in diagnosing
port, then install
YES pressure gauge on
system: Main
controller B
the port.
Monitor item: ProMeasure reducing
portional valve
valve selection pres0 MPa
ON/OFF output:
sure.
(0 kgf/cm2)
bit 6: Travel mode
Travel mode
control solenoid
switch: OFF
valve output
Faulty travel mode control solenoid valve.
1.8 MPa
(18 kgf/cm2)
reducing valve output
port, then install pressure gauge on the port.
Measure pressure.
Travel mode switch:
OFF
Faulty travel motor

switch selection
mechanism.
Faulty reducing valve.
3.9 MPa
(40 kgf/cm2)
Connector
Side)
Travel Mode Control
Solenoid Valve
(Lower Side)
Reducing Valve
(Travel Parking Brake)
Main Controller B
Connector B
Output Port
T183-05-04-021
Output Port
T183-05-04-020
T183-05-04-019
T5-5-63
T-4 One side track does not move, moves
slowly or mistracks.
If only one side of the track does not move, the

pilot valve, main control valve, travel motor or
center joint may be faulty.
If travel left and bucket open/close (LD) are also
slow, the main pump 1 or main pump 1 regulator
may be faulty.
If travel right is slow and boom, arm and bucket
are slightly slow, the main pump 2 or main pump
2 regulator may be faulty.
NOTE: LD: Loading Shovel
Check if secondary
travel pressure is normal.
Monitor item: Travel
operation pressure
the OPERATIONAL
PERFORMANCE
TEST section.
YES Check if travel motor

drain oil amount is normal.
Check if travel relief

NO pressure of slow
speed side is normal.
Monitor item: Main pump
1 pressure, main pump 2
pressure
the OPERATIONAL
PERFORMANCE TEST
section.
Check if symptom is
YES reversed when right
and left travel line
hoses are switched
each other at the top
of center joint.
YES
Faulty pilot valve.
NO
External Oil Leak
NO
Check if symptom is
reversed after switching
forward travel relief
valve with reverse travel
one, or right travel relief
valve with left one.
Bound main control

valve spool, or oil leak
in main control valve.
Relationship between Faulty Seal Location and Mistrack Direction

Seal
When traveling
When pivot turn is
No.
straight
performed
1
the OPERATIONAL
PERFORMANCE
TEST section.
Seal Location
2
2
Left Travel
(Forward)
4
Right Travel
(Reverse)
Left Travel
(Reverse)
6
7
Right Travel
(Forward)
External Oil Leak
T5-5-64
W183-03-08-001
NO
Faulty travel motor.

When travel parking
brake shows a trouble
after disassembling, also
check brake release
pressure selection valve.
YES
Disassemble travel
NO motor servo piston.
Check for faulty parts.
Disassemble travel
motor counterbalance
valve.
YES Check for faulty parts.
NO
Faulty travel motor

servo piston.
Faulty travel reduction

gear.
Faulty counterbalance
valve.
YES
YES
Faulty travel relief valve.
Faulty center joint.
NO
Arrangement of Pipe Line

1
2
3
1 - Right Travel Reverse

2 - Left Travel Reverse
3 - Left Travel Forward
W142-03-03-002
Machine Front Side
T5-5-65
4 - Right Travel Forward

5 - Drain Hose
6 - Pilot Hose
(Travel Mode Selection)
T-5 Travel motor runs excessively fast when
combined left travel and front attachment
operation is performed with left track off the
ground.
If the priority valve (travel motor overrun protection) in the signal control valve is stuck, the flow
combiner valve switches without right travel operating.
Same phenomenon can be observed when the
flow combiner valve is bound.
T5-5-66
T-6 Machine mistracks during combined travel
and front attachment operation.
Faulty flow combiner

valve.
YES
Check if flow combiner valve in main

control valve is abnormal.
Faulty flow combiner

valve selection spool
in signal control valve.
YES
NO
Disconnect hose (G)

from signal control
valve connecting to
flow combiner valve,
gauge.
Measure and check if
selection pressure is
approx. 3.9 MPa (40
kgf/cm2).
NO
YES
Faulty load check

valve in main control
valve.
NO
Find out cause of

trouble by tracing
other trouble symptoms.
Check if load check

valve in main control
valve is abnormal.

Control Valve
Side
Hose (G)
T183-05-04-025
T5-5-67
OTHER SYSTEM TROUBLESHOOTING
0-1 Auto-lubrication indicator comes ON.
(Grease pump does not operate.)
(Empty grease in pump)
If the Auto-lubrication indicator light comes ON,

damaged lubrication hose or clogged distribution
valve is suspected.
If the auto-lubrication selection switch is faulty,
the auto-lubrication indicator does not come ON.
In case of manual lubrication, the auto-lubrication
indicator always comes ON.
YES
Grease pump does not

operate (both auto and
manual).
Disconnect grease
pump.
Check if voltage at harness end connector terminal #1 is 24 V.
Key switch: ON
During grease pump
operation
YES Faulty auto-lubrication relay.

Connect disconnected
connector.
Check if grease pump
operates after switching
NO auto-lubrication relay
and other general-purpose relay.
YES
Empty grease in pump.
Faulty grease pump.
Disconnect
auto-lubrication relay.
NO harness end connector
terminals #1 and #3 is 24
V.
Reposition follow plate.
Disconnect grease pump air
lubrication hose at quick coupler.
Screw in and position follow
plate.
Check if grease still exists.
NO
T5-5-68
Replace with new grease

tin.
NO
Connect connector.
Check if grease
pump operates afYES
ter switching power
transistor 3 with
power transistor 1
or power transistor
2.
Disconnect power
transistor 3.
Check if voltage at
harness end connector terminal #5 is 24 V.
Disconnect main controller B connector A.

YES
between power transistor 3 harness end
and connector A harness end terminal
#A26.
YES
NO

B.
Broken harness between main controller
B and power transistor 3.
Blown fuse #14, or
broken harness between power transistor 3 and fuse #14.
NO
YES
Blown fuse #14, or

broken harness between auto-lubrication
relay and fuse #14.
NO
Connector
Auto-Lubrication Relay
Power Transistor 3
Main Controller B
Connector A
T183-05-04-011
T183-05-04-003
A26
T5-5-69
T183-05-04-008
O-2 Grease pump operates excessively slow.
Grease pump operates

excessively slow.
YES
Reinstall or replace exhaust hose.
NO
Check if coefficient of
grease viscosity becomes high due to winter or cold environment.

exhaust hose is kinked
or destroyed.
O-3 Grease pump does not stop operating.
If the proximity switch is not correctly adjusted,

the grease pump does not stop operating.
Change to AUTO position.
YES
YES
Check if manual/auto
selection valve near
grease pump is in
MANUAL position.
End
Adjust proximity switch.

NO
stops.
Disconnect proximity
switch.
Check if voltage at proxNO imity switch harness end
connector terminal #1 is
24 V.
Key switch: ON
T5-5-70
Push both ends of main

controller B connector B
YES to securely connect the
connector.
stops.
Broken harness beNO tween proximity switch

and fuse.
Connector
Side)
Proximity Switch
Auto-Lubrication Solenoid Valve Relay
Power Transistor 3
#2
T183-05-04-011
T183-05-04-003
Main Controller B
Connector A
A26
Connector B
T183-05-04-005
B10
YES
Overhaul grease pump.

NOTE: This trouble is caused
by the follow plate packing
pinched with the grease pump
when changing the grease.
When exchanging grease, remove quick coupler from air delivery hose.
NO Check if follow plate

packing is damaged.
Find out cause of trouble

by tracing other trouble
symptoms.
NO
Change grease to EP1.

YES
YES Faulty auto-lubrication
relay.
Disconnect power
transistor 3 and main
controller B connector
Connect proximity
YES A.
switch harness end
between connector A
and vehicle frame with
a clip.
#A26 and power tranNO
Disconnect main consistor 3 harness end
troller B connector B.
connector terminal #2.
between main controller B harness conNO
nector terminal #B10
and vehicle frame.
YES connector.
Disconnect
auto-lubrication relay.
between
auto-lubrication relay
terminals #3 and #5.
NO
Check if grease
pump stops after
switching power
transistor 3 with
NO
power transistor 1 or
power transistor 2.

power transistor 3 and
main controller B.
proximity switch and
main controller B.
End
(Faulty connector connection)
YES
T5-5-71
(1)
Proximity Switch Adjustment Procedure
1. Loosen the nut.
: 17 mm
2. Slowly tighten the proximity switch by hand until
the end of the proximity switch touches the protrusion.
3. Loosen the proximity switch 1/2 to 1 turn. Be sure
that the indicator faces in the direction of as the
figure on the right.
Indictor
Proximity Switch
Nut
IMPORTANT: The proximity switch may break.

Do not excessively tighten the nuts.
4. Tighten the nut to secure the proximity switch.
: 17 mm
: 0.78 Nm (0.08 kgfm, 0.57lbfft)
T142-06-04-024
Proximity Switch
Nut
Adapter
Protrusion
T142-06-04-025
Pin
YES
(1)
NO
T5-5-72
(Blank)
T5-5-73
O-4 Fan motor does not rotate at speed corresponding to hydraulic oil temperature or
fuel temperature. Fan motor does not rotate
at all.
If the oil cooler fan motor speed control operates

normally, the oil cooler fan motor rotates at the
corresponding speed to the hydraulic oil temperature.
Install pressure gauge

on fan control solenoid
valve delivery port.
YES Check if pilot pressure
is normal by hydraulic
oil temperature and
fuel temperature (refer
to Table 2).
Measure hydraulic oil
temperature.
Disconnect hydraulic oil
temperature sensor,
then measure sensor
resistance.
Check if relationship
between hydraulic oil
temperature and resistance value are correctly. (Refer to Table
1.)
Disconnect fan control

solenoid valve wire on
one side.
Connect tester (amNO meter) between disconnected wire.
Check if power is normal by each hydraulic
oil temperature (refer
to Table 2).
(If polot pressure to

hydraulic oil temperature is different
from that to fuel temperature, lower pilot
pressure is selected.) YES
Measure oil cooler fan

motor drive pump flow
rate.
Check if flow rate is
normal.
Faulty fan motor drive pump.
Faulty hydraulic oil sensor or

fuel temperature sensor (fan
motor speed control).
Connector
Main Controller A
B
Fan Control Solenoid Valve
T146-05-04-012

T183-05-04-021
C10
T146-05-04-012
C23
Faulty fan motor.
NO
NO
C
C1
Disconnect fan control solenoid valve. Connect harness

end connector terminals #1
and #2.
NO Disconnect main controller A
connector A.
harness end connector terminals A6 and A7.
YES
Check fuel temperature sensor in the

same procedures.
B22
YES Faulty fan control solenoid

valve.
C31
C24
T5-5-74
YES
NO
Broken harness between oil cooler fan control solenoid valve and
main controller A.
Fan Control Solenoid Valve
Table 1: Relationship of Sensor (Fan Motor Speed

Control) Resistance (Hydraulic oil temperature sensor and fuel temperature sensor are
same.)
Temperature
Resistance (k)
(C)
(F)
-30
-22
28.6
-20
-4
16.21.6
-10
14
9.56
0
32
5.88
10
50
3.73
20
68
2.450.24
30
86
1.65
40
104
1.14
50
122
0.808
60
140
0.534
70
158
0.430
80
176
0.3220.032
90
194
0.245
100
212
0.189
110
230
0.148
120
248
0.117
Tester
A
Delivery Port
T183-05-04-023
Table 2: Relationship between Temperature and Fan Motor Speed

Fuel
Fan Motor Speed
Hydraulic Oil
Pilot Pressure from Fan Control
Temperature
Temperature
Solenoid Valve [Current from MC]
66 C (151 F) 8001100 min-1
70 C (157 F) 0.99 Mpa (10 kgf/cm2, 142 psi)
[285 mA]
69 C (156 F) 1100140050
80 C (176 F) 0 MPa (0 kgf/cm2, 0 psi)
min-1
[200 mA]
63 C (145 F) 1100800 min-1
65 C (149 F) 1.36 Mpa (14 kgf/cm2, 199 psi)
[309 mA]
66 C (151 F) 1400501100
75 C (167 F) 0.99 Mpa (10 kgf/cm2, 142 psi)
min-1
[285 mA]
NOTE: The above fan motor speed shows the
motor speed at rated engine speed (1650
min-1).
T5-5-75
Fan Motor
Speed Mode
LowMiddle
MiddleHigh
MiddleLow
High Middle
O-5 Step light does not come ON.
YES
Faulty step light relay.
YES
Check if step light
comes ON after switching step light relay with
other general-purpose
relay.
NO
Check if step light comes

ON when connecting
main controller B connector B terminal #B11
and vehicle frame.
Measure voltage at the
terminals from the rear
of connector using a
piece of clip with connector connected.
Disconnect step light.

ON when connecting
NO
harness end terminal to
vehicle frame.
Step Light
NO

main controller B and step
light switch.
Disconnect main controller

B connectors A and B.
Connect connector A harness end terminal #A27
and connector B harness
end terminal #B11 with a
clip.
ON.
Faulty step light switch.

YES
M183-01-036
Connector
Step Light Relay
Step Light Switch
Main Controller B
Connector A
Connector B
T183-05-04-003
A27
B11
T183-05-04-024
T5-5-76
T183-05-04-005
YES
NO

B.
Disconnect step light

relay.
Connect harness end
and terminal #3 with a
clip.
Check if step light
comes ON.
Check if voltage at
NO
step light relay harness end connector
terminal #3 is 24 V.
Connect connector.
YES
terminal.
Check if voltage at
is 24 V.
NO
YES
NO
Faulty step light.
Broken harness between step light and

step light relay.
Broken harness between step light relay

and fuse box 1 fuse #8,
or blown fuse #8.
Broken harness between step light relay
and main controller B.
YES
T5-5-77
O-6 Even if step light switch is turned OFF, step
light does not come OFF after 60 seconds.
YES
Check if step light

comes OFF after
switching step light relay with other general-purpose relay.
Faulty step light relay.
NO
YES

main controller B and step
light switch.
NO
Faulty main controller B, or

between step light relay
Disconnect main controller B connector B.

OFF.

switch.
NO Check if step light comes
OFF.
Faulty step light switch.

YES
T5-5-78
(Blank)
T5-5-79
O-7 Malfunction of Air Conditioner
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 conditioner control panel at the same time for more
than 3 seconds with the key switch ON.
NOTE: After operation has been performed, the
buzzer will sound.
Temperature
Control Switch
Fan OFF Switch
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
first.
LCD
M178-01-017
Fault Code List

Location in Trouble
Abnormal circulation
air sensor
Fault
Code
E11
E12
Cause
Broken circuit in air circulation
sensor
Short-circuited circulation air
sensor
Broken circuit in fresh air sensor
Short-circuited fresh air sensor
Abnormal fresh air

sensor
E13
E14
Abnormal solar
radiation sensor
E18
Short-circuited solar radiation

sensor
Abnormal evaporator sensor
E21
Broken circuit in evaporator sensor

Short-circuited evaporator sensor
Abnormal air vent damper
Abnormal air mix damper
Abnormal circulation/fresh air
damper
Broken circuit in water temperature sensor
Short-circuited water temperature sensor
Abnormal high/low refrigerant
pressure
E22
Abnormal damper
E43
E44
E45
Water temperature
sensor
E15
E16
Abnormal refrigerant
E51
T5-5-80
Symptom
Y value (air flow-in temperature) cannot
be adjusted in response to the
set-temperature.
Operation is controlled under such circumstance as no fresh air sensor is provided.
Operation is controlled under such circumstance as no solar radiation sensor is
provided.
Operation is controlled under such circumstance as the evaporator temperature
is set to 10 C (50 F).
Corresponding damper servo becomes
inoperable.
Operation is controlled under such circumstance as the water temperature is

set to 60 C (140 F). (Warm-up control is
not performed.)
The compressor clutch is disengaged.
(The compressor stops.)
Change Displayed Fault Code
1. When displaying more than one fault code, press

either the upper or bottom side of the temperature 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.
Temperature
Control Switch
LCD
Delete Fault Code
LCD
1. Press and hold both the circulation air switch and

the fresh air 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
Air Switch
Fresh Air
Switch
M178-01-017
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.
Fan Switch
T5-5-81
M178-01-017
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 machines 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
Air Induction
Re-Circulation
Fresh Air Circulation
Control
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
<Check Result>
Symptom
Not turned ON
(1) Is problem reproducible ?
Not turned OFF
Reproducible
Others
Not
reproducible
Uncontrollable air temperature
(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
Before replacing the control amplifier, be sure to
Uncontrollable vent hole
check that the connectors are correctly connected
Symptom
Vent hole isnt 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
T5-5-82
(Blank)
T5-5-83
Cooling Circuit
Refrigerant pressure
in both high and low
pressure sides is low.
Bubbles can be seen in sight

glass.
No bubbles are seen in sight

glass.
Piping and/or parts are stained with

oil, respond to gas detector.
No oil stain is found or gas detector
doesnt respond. Refrigerant has not
been refilled for longer than one season.
After cooling at fast speed continuously, cooling power is reduced. Air

flow volume remains unchanged.
Air flow volume is reduced.
Refrigerant pressure in low pressure
side is high.
Insufficient
Cooling
Power

glass.
Refrigerant pressure in high

pressure side is low.
Compressor cylinder is extremely

hot, emitting a smell.
Compressor cylinder is extremely

hot, emitting a smell.
Heater unit emits hot air.
Refrigerant pressure in high pressure side is high.

glass.
Refrigerant pressure in low pressure

side is low.
Condenser is stained and clogged.

Even if condenser is sprayed with water, few bubbles appear. Receiver dryer temperature is low.
After cooling at fast speed continuously, cooling power is reduced. Air

flow volume is reduced.
Frost
forms.
Thermistor doesnt cool.

Thermistor cools.
T5-5-84
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 valve.
Readjust or replace expansion 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

receiver 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 type).
Clogged high pressure circuit before receiver
dryer.
Repair.
Remove clog, or replace parts.

Clean Condenser.
Excessive refrigerant.
Remove excessive refrigerant to proper level.
Air is mixed in system.
After evacuation, refill refrigerant and/or replace

receiver dryer.
Incorrect thermistor location.
Correct thermister location.
Gas leaks from case.
Seal gaps using vinyl tape or packing compound.
Faulty thermistor (stays ON).
Disconnected thermister cord.
Even if function and performance are normal,

when air-conditioner is kept operated for a long
time with thermistor in max. cooling position and
air flow in M or L mode, frost may form.
Instruct user on correct air-conditioner operation.

(Reset thermistor to either minimum or middle
cooling position or increase air flow.)
T5-5-85
Cooling Circuit
Case connection.
Louver resonance.
Fan contacts case, or foreign matter enters case.
Blower fan connection.
Noise
Brush friction noise, metal and/or thrust washer contact noise.
Gas blowing sound (roaring).
Gas vibration noise (compressor discharge and/or

suction gas noise).
Expansion valve connection, whistle

sound, gas blowing sound.
Abnormal noise from expansion valve (Expansion

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.
T5-5-86
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.
T5-5-87
Compressor
Compressor doesnt rotate.
Clutch terminal voltage is normal 24 V.
Inoperable
cooling
system.
Clutch terminal voltage is low.

Clutch terminal voltage is 0 V.
Bubbles exist even after refrigerant is refilled.
Both high and low side
pressures are low.
Both compressor
and blower
motor rotate.
Check for oil and refrigerant leaks from parts other than
compressor and pipe joints using gas detector.
Check for oil and

refrigerant leaks
from compressor
(no leaks from
parts other than
compressor) using
gas detector.
Refer to NOTE 1 and 2 on page T5-5-95.

Refrigerant has not been refilled for longer
than one season.
Stain
on
exterior.
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.
High pressure side is

slightly low and low pressure side is high.
Compressor cylinder is not hot. (Refrigerant returns to compressor in liquid form.)

No refrigerant returns in liquid form. High pressure side is low.
Bubbles can be seen through

sight glass.
Others
High pressure side is high.

Temperature is not cooled when compressor is
operated at fast speed continuously.
Refer to the Cooling Circuit Troubleshooting Table on page T5-5-84.
Air flow from blower is insufficient.
Compressor rotation is abnormally draggy.

Overheating
is susceptible
to occur.
Trouble other than compressor.
Refer to the Cooling Circuit Troubleshooting Table on page

T5-5-84.
T5-5-88
Seized clutch.
Replace.
Improper gap between amature and rotor (improper air gap).

Replace.
Broken or short-circuited core cable.
Shaft doesnt rotate (internally locked).
Replace.
Faulty Electrical System.
Faulty Electrical System.
Faulty 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.
Normal leaks from hoses.
Replace.
Charge
refrigerant.
No leaks (normal).
Refer to the Cooling Circuit Troubleshooting Table on page T5-5-84.

Broken valve (See NOTE 3 on page T5-5-95.)
Replace.
Blown gasket (See NOTE 3 on page T5-5-95.)
Check and
adjust oil level.
Excessive oil.
Broken clutch bearing due to overly tightened belt.
Replace.
Shaft doesnt rotate.

Replace.
Shaft rotates draggy.
T5-5-89
Compressor
Noise is heard when clutch is OFF.
Abnormal
noise
Noise is heard when clutch is ON.
T5-5-90
Broken clutch bearing.

Replace.
Contact or slip due to poor air gap.
Faulty idle pulley bearing.
Refer to the Cooling Circuit
Troubleshooting Table on
page T5-5-84.
Saggy belt.
Loose screws.
Broken valve.
Replace.
Blown gasket.
Abnormal internal noise.
Replace.
Vibration due to saggy belt.

Refer to the Cooling Circuit
Troubleshooting Table on
page T5-5-84.
Loose screws.
NOTE:
1. Dont 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 surface 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.
T5-5-91
WORK AFTER
NENTS
REPLACING
COMPO-
The following work is required after replacing

compressor, high pressure hose, low pressure hose,
condenser, receiver tank, liquid hose, and air
conditioner unit.
The same work is required when gas leakage is
found.
1. Add compressor oil
2. Charge air conditioner with refrigerant
Purging
Charge air conditioner with refrigerant
Warm up operation
Inspection
ADD COMPRESSOR OIL

Compressor oil quantity to be added after component
replacement: 180 cm3 (0.19 qt)
T5-5-92
CHARGE AIR
REFRIGERANT
CONDITIONER
WITH
Necessity of Purging
Be sure to purge the air conditioner circuit with a
vacuum before charging with refrigerant (R134a)
because the following problems can arise if air or
other gases remain in the A/C circuit.
1. Pressure rise in the high pressure side
Air
If air remains in the air conditioner circuit, this

disturbs the heat exchange between refrigerant
and air in the condenser, causing pressure to rise
in the high pressure side (compressor side).
Usually, refrigerant gas is easily liquefied;
however, air cannot be liquefied and remains as
a gas in the condenser because the temperature
at which air liquefies is extremely low. That is,
liquidation of the refrigerant gas in the condenser
decreases by the amount of air in the circuit, and
the gas pressure in the high pressure side
increases accordingly.
Pressure increases if air

remains in the air
conditioner circuit
W115-02-10-001
2. Metal corrosion
If air remains in the air conditioner circuit, a
chemical reaction between refrigerant and
moisture in the air takes place, and as a result,
hydrochloric acid, that corrodes metals such as
aluminum, copper and iron, is produced.
Hydrochloric acid
corrodes metals if
moisture exists
Hydrochloric acid
W115-02-10-002
Metal corrosion
3. Plugging of the expansion valve by moisture

When high pressure refrigerant gas passes
through the expansion valve, gas pressure
decreases and temperature drops. Moisture
included in high pressure refrigerant gas in the
air conditioner circuit freezes at the expansion
valve orifice, plugging refrigerant flow. Operation
of the air conditioner becomes unstable and
cooling efficiency lowers.
Ice produced at the

expansion valve disturbs
refrigerant flow, lowering
cooling efficiency
Plugged refrigerant
flow
W115-02-10-003
Low cooling
efficiency
T5-5-93
Purging Procedure
Gauge Manifold
IMPORTANT: Never mistake the charge hose

connections.
1. Close the high and low pressure valves on the
gauge manifold (Parts Number 4360564).
Connect the high-pressure-side charge hose and
the low-pressure-side charge hoses to the
high-pressure-side charge valve (D marked)
and to the low-pressure-side charge valve (S
marked) located on the compressor, respectively.
Connect the charge hose located on the center of
the manifold bottom to the vacuum pump (Parts
Number 4360565).
NOTE: Vacuum Pump Joint
Number 4360566).
Adapter
Low Pressure
Valve
Low Pressure
Charge Hose
High Pressure
Valve
High Pressure
Charge Hose
Center Pressure
Charge Hose
Vacuum Pump
(Parts
W115-02-10-005
Low Pressure
Side
S
Compressor
D
High Pressure
Side
T142-02-05-018
Fully Open
2. Open the high pressure and low pressure valves

in the gauge manifold. Perform purging for 10
minutes or more by operating the vacuum pump.
Fully Open
In Operation
W115-02-10-005
T5-5-94
IMPORTANT: If the pointer returns to 0, retighten
the line connections and perform
purging again.
3. When the low pressure gauge reading falls
below-755 mmHg, stop the vacuum pump and
close the high and low pressure valves. Wait for
approximately five minutes and confirm that the
pointer does not return to 0.
Close
Close
In Operation
W115-02-10-005
4. With the high pressure and low pressure valves

of the gauge manifold closed, connect the charge
hose to the refrigerant container (Parts Number
4347644).
Refrigerant Container
W115-02-10-007
5. Loosen the charge hose connection to the gauge

manifold and open the refrigerant container valve
to purge air in the charge hose with the
refrigerant pressure.
Loosen
Open
W115-02-10-007
T5-5-95
IMPORTANT: Always stop the engine when
charging the air conditioner with
refrigerant. Never position the
refrigerant container upside down
during charging operation. When
changing the refrigerant container
during charging operation, be sure
to purge air from the charge hose,
as shown in step 10.
6. Fully tighten the charge hose connection to the
gauge manifold. Open the high pressure valve
and refrigerant container valve to charge with
refrigerant (R134a).
Close the high pressure valve and refrigerant
container valve when the high pressure gauge
reading reaches 98 kPa (1 kgf/cm2, 14 psi).
NOTE: Use warm water of 40 C (104 F) or less
to warm the refrigerant container to aid in
charging operation.
IMPORTANT: Use the leak tester for R134a.

7. After charging, check the line connections for gas
leaks using leak tester (Parts Number 4360567).
T5-5-96
High
Pressure
Gauge
Tighten
Open
Open
W115-02-10-007
W115-02-10-008
8. Confirm that the
high pressure and low
pressure valves in the gauge manifold and the
refrigerant container valve are closed.
Start the engine and operate the air conditioner.
Operating Conditions of the Air Conditioner:
Engine Speed : Slow Idle
Cab Window : Fully Open
Cooler Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum
IMPORTANT: Never open the high pressure valve
in the gauge manifold.
9. Open the low pressure valve in the gauge
manifold and the refrigerant container valve to
charge with refrigerant until the bubbles seen in
the receiver/drier sight glass disappear.
Open
NOTE: The required refrigerant quantity is 1250

g50 g (30.01 lb).
Open
10. If the refrigerant container becomes empty during

the charging work, replace it with a new
refrigerant container as follows:
(1) Close the high pressure and low pressure
valves on the manifold gauge.
(2) Replace the empty container with a new
one.
(3) Tighten, then slightly loosen the refrigerant
container joint.
(4) Slightly open the low pressure valve on the
manifold gauge.
(5) When the refrigerant container joint starts to
leak, immediately tighten the refrigerant
container joint and close the low pressure
valve on the manifold gauge.
W115-02-10-007
Close
Close
11. After charging, close the low pressure valve in

the gauge manifold and the refrigerant container
valve, and stop the engine.
W115-02-10-007
T5-5-97
IMPORTANT: If the air conditioner is operated
with very low refrigerant, a bad load
will be exerted on the compressor. If
the air conditioner is overcharged
with refrigerant, cooling efficiency
will lower and abnormal high
pressure will arise in the air
conditioner circuit, causing danger.
12. Start the engine and operate the air-conditioner
again.
Observe the sight glass of the receiver/drier to
check refrigerant quantity.
Operating Conditions of the Air Conditioner:
Cab Window : Fully Open
Cooler Switch : ON
NOTE: As the bubbles in the sight glass vary
depending on the ambient temperature,
check refrigerant quantity confirming the
changes in pressure .
Sight Glass
Receiver/Drier
W115-02-10-009
Checking procedures: Stop the air conditioner and

wait until refrigerant returns to the balanced pressure.
Then, start the air conditioner again.
Relation
between
Refrigerant
Quantity
and
Refrigerant Flow in Sight Glass:
Refrigerant Flow in Sight Glass
Refrigerant
(approx. 1 min. after air conditioner
Quantity
switch is turned ON)
(immediately after)
(approx. 1 mm after)
Adequate
Explanation for Refrigerant Flow in Sight Glass

Immediately after the air conditioner is turned ON,
few bubbles are seen. Then the flow becomes transparent and shows thin milk white color.
W115-02-10-016
No bubbles are seen after the air conditioner is

turned ON.
Overcharged
W115-02-10-017
Bubbles are seen continuously after the air conditioner is turned ON.
Not Enough
W115-02-10-018
CAUTION: Wait until the high-pressure-side

pressure drops to less than 980 kPa (10
kgf/cm2, 142 psi) before attempting to disconnect the high-pressure-side charge hose.
Otherwise, refrigerant and compressor oil
may spout.
W115-02-10-019
Bubbles exist: Bubbles are seen in refrigerant flow

as both liquid refrigerant and refrigerant gas exist,
being mixed.
W115-02-10-020
Transparent: Refrigerant flow is transparent as only

liquid refrigerant exists.
115-02-10-021
Milk white:
Refrigerant flow shows thin milk white
as oil and refrigerant are separated.
10. After checking refrigerant quantity, disconnect the

low-pressure-side charge hose first. Wait for the
high-pressure-side pressure to drop to less than
980 kPa (10 kgf/cm2, 142 psi). Disconnect the
high-pressure-side charge hose.
T5-5-98
Warm-up Operation
After charting the air conditioner, carry out warm-up
operation five minute to lubricate system with
compressor oil.
Operating Conditions of the Air Conditioner
Cab Window
: Fully Open
Cooler Switch : ON
Inspection
After warm-up operation, carry out gas leak check
and performance check.
CAUTION: Refrigerant
will
produce
poisonous material if exposed to heat of
1000 C (1800 F) or more. Never bring
refrigerant close to a fire.
1. Check the air conditioner for gas leaks using a
leak tester.
(1) Perform checking under well-ventilated
conditions.
(2) Thoroughly wipe off dust from the charge
hose connections of the compressor.
(3) Pay special attention to check the line
connections.
(4) If any gas leaks are found, retighten the line
connections.
2. Performance Check
Carry out performance check of the air
conditioner after checking each air conditioner
component.
(1) Check each component for abnormalities.
(2) Carry out ON-OFF check of the compressor
clutch.
(3) Check compressor fan belt tension.
(4) Check the coolant level in the radiator.
(5) Operate the air conditioner and check the
performance.
T5-5-99
Leak Tester
W115-02-10-013
Retighten Line
Connection
W115-02-10-014
3. The checklist before the summer season is as
follows:
(1) Check each air conditioner component for
abnormalities.
(2) Check the line connections for oil leaks.
(3) Check refrigerant quantity.
(4) Check the engine cooling circuit.
(5) Check belts for wear. Replace if necessary.
4. Off-Season Maintenance
(1) During off-season, operate the idler pulley
and compressor at least once a month for a
short time to check for any abnormal
sounds.
(2) Do not remove the compressor belts during
off-season.
Operate
the
compressor
occasionally at slow speed for 5 to 10
minutes with the belt slightly loosened in
order to lubricate the machine parts.
T5-5-100
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C (TROUBLESHOOTING FOR MONITOR) PROCEDURE
Use troubleshooting C when any monitors, such as
gauges or indicators, malfunction.

YES(OK)
(2)
After completing the checking and/or measuring procedures in box (1),

select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
(1)
NO(NOT OK)
Key switch: ON
(3)
Instructions, reference, and/or inspection methods and/or measurements are occasionally

described under the box. If incorrectly checked or measured, not only will troubleshooting
be unsuccessful but also damage to the components may result.
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.

the open end side.
Harness

Open End Side
T158-05-03-001
T5-6-1
MALFUNCTION OF
PERATURE GAUGE
COOLANT
TEM-
This troubleshooting procedures should be performed after checking that the other instruments
are performing correctly.
Gauge Pointer Does Not Move At All
YES
Disconnect coolant temperature sensor terminal (white).

Ground harness end terminal to
vehicle frame. Check if pointer
swings to the right side.
Connect disconnected terminal.

Ground monitor controller
connector B terminal #B18 to
Key switch: ON
NO
Key switch: ON
Connect terminal from the
rear of connector using a
piece of clip with connector
connected.
Gauge Pointer Swings Over Scale

YES

Check if pointer returns to zero.
YES
Key switch: ON
NO
terminal. Disconnect
monitor controller connector B. Check if
pointer returns to zero.
NO
Gauge Pointer Keeps Moving Unstably

YES
Ground harness end terminal to
swings and is stabilized to the
right side.
Key switch: ON
NO
T5-6-2
Coolant Temperature Gauge
Faulty coolant temperature sensor .
NO
Faulty coolant temperature gauge.

M183-01-010
YES
Broken harness between coolant temperature gauge and

coolant temperature
sensor .
Coolant Sensor Resistance

Coolant Temperature
C (F)
25 (77)
40 (104)
50 (122)
80 (176)
95 (203)
105 (221)
120 (248)
Faulty coolant temperate sensor .

Short-circuited harness between coolant temperature
gauge and sensor .
Resistance (k)
7.6
4.00.32
2.70.22
0.98
0.6
0.45
0.30.02
Connector
Monitor Controller
Connector B
T183-05-04-013
B18
Faulty coolant temperature sensor .
T5-6-3
MALFUNCTION OF FUEL GAUGE
Connector
This troubleshooting procedures should be per-
Monitor Controller
Connector B
Fuel Sensor
formed after checking that the other instruments

are performing correctly.
T183-05-04-010
Fuel Gauge Pointer Does Not Move At All
T183-05-04-013
B19
YES
Disconnect fuel sensor from
connector. Ground harness
end connector terminal #2 to
Connect disconnected connector.

connector B terminal #B19 to
vehicle frame.
Check if pointer swings to the
right side.
Key switch: ON
NO
Key switch: ON
piece of clip with connector
connected.
Fuel Gauge Pointer Swings Over Scale

YES

connector. Check if pointer
returns to zero.
YES
Key switch: ON
NO
connector.
Disconnect monitor controller connector B.
Check if pointer returns
to zero.
NO
Fuel Gauge Pointer Keeps Moving Unstably
YES
connector. Ground harness
end connector terminal #2 to
vehicle frame.
Check if pointer swings and is
stabilized to the right side.
Key switch: ON
NO
T5-6-4
Fuel Gauge
Upper Limit
1/2
Lower Limit
Faulty fuel sensor.
NO
Faulty fuel gauge.
M183-01-011
Fuel Sensor
Float
FULL
YES
Broken harness between fuel gauge

and sensor.
3/4
257 mm
138.5 mm
R370
22
33
70.5 mm
Faulty fuel sensor.
228 mm
1/2
27
28
338 mm
Electric Resistance
1/4
Short-circuited harness between fuel

gauge and sensor.
EMPTY
T107-04-03-020
Faulty fuel gauge.
Faulty fuel sensor.
Faulty fuel gauge.
T5-6-5
Float Position
Resistance ()
Upper Limit (FULL)
10+1.0-0.5
3/4
(19)
1/2
323
1/4
(49.5)
Lower Limit (EMPTY)
80+12+2
MALFUNCTION OF INDICATOR LIGHT
CHECK SYSTEM
YES
Indicator does not
come ON when
indicator light
check operation is
performed.
Check power line.

Fuse
Disconnect monitor controller connector C. Check for
continuity between harness
end terminal #C1 and fuse
terminal #7 (fuse box 1).
Check if all indicators

do not come ON.
NO
Connector
Monitor Controller
Connector C
C1
T183-05-04-014
T5-6-6
Go to individual troubleshooting according to malfunctioning indicator.
(Blank)
T5-6-7
MALFUNCTION OF OVERHEAT INDICATOR
NOTE: Overheat Switch Operating Temperature:
100 C (212 F) or more
Indicator Does Not Come ON Even If Engine
Overheats
Faulty monitor controller
or burnt indicator light.
NO
Turn indicator light

check switch ON.
Check if indicator
comes ON.
Key switch: ON

DLU and monitor.
NO
Disconnect DLU connector
D.
Check for continuity beYES tween DLU connector D
terminal #66 and monitor
controller terminal #B6.
Disconnect ECM connector 9 poles and

DLU connector C.
between ECM terminal
#C and DLU terminal
#52.
YES Check for continuity
between ECM terminal
#D and DLU terminal
#51.
YES Faulty DLU or faulty engine.
NO

ECM and DLU.
Connector
DLU Connector D
DLU Connector C

#C
#D
T18E-05-06-002
#66
#51
#52
T5-6-8
T18E-05-06-004
T18E-05-06-003
Indicator Comes ON Even If Coolant Temperature
Is Low
YES
Faulty engine.
Disconnect ECM
connector 9 poles.
Check if indicator
goes OFF.
YES
NO
Disconnect the removed

terminal. Disconnect DLU
connector D.
Check if indicator goes
OFF.
Disconnect the removed terminal. Disconnect monitor connector B.

NO Check for continuity
between harness end
and vehicle frame.
Faulty DLU.
YES Short-circuited harness

between DLU and monitor.
Broken monitor.
NO
Monitor Connector
#6
T183-05-04-013
T5-6-9
MALFUNCTION OF AIR CLEANER RESTRICTION INDICATOR
YES
YES
Disconnect air cleaner

restriction switch.
Ground harness end
connector (Yellow) side
to vehicle frame. Check if
indicator comes ON.
Key switch: ON
Even if air cleaner is

clogged, indicator
does not come ON.
Check if indicator
comes ON when key
switch is turned ON.
NO
NO
YES
Although air cleaner

is not clogged, indicator comes ON.
Disassemble / Visual
Inspection
Verify that air cleaner
is not moist.
Check if indicator
goes OFF when air
cleaner restriction
switch is disconnected.
YES
Key switch: ON
NO
Disconnect air cleaner

restriction switch and
monitor controller connector B.
Check for continuity between monitor controller
terminal #B7 and vehicle
frame.
NO
T5-6-10
Disconnect monitor controller connector B. Keep

air cleaner restriction
switch connector connected to vehicle frame.
terminal #B7 and vehicle
frame.
Faulty air cleaner restriction switch.
YES
NO
Air Cleaner Restriction Switch
Pressure
5.0 kPa
(50848 mmH2O) or lower
5.0 kPa
(50848 mmH2O) or more
Operation
OFF
ON

monitor controller and air
cleaner restriction
switch.
Burned indicator light, or
faulty monitor.
Connector
Monitor Controller
Connector B
B7
T183-05-04-013
Faulty air cleaner restriction switch.
Short-circuited harness
between monitor controller and air cleaner
restriction switch.
T5-6-11
MALFUNCTION OF FUEL LEVEL INDICATOR
YES
YES
Indicator does not

come ON even if fuel
gauge pointer
reaches "E".
Disconnect fuel sensor

from connector. Ground
terminal #2 to vehicle
frame. Check if indicator
comes ON.
Turn key switch to

ON position.
Check if indicator
comes ON.
NO
NO
YES
Indicator comes ON
even if fuel still remains.
Disconnect fuel
sensor from connector. Check if
indicator goes
OFF.
Key switch: ON
YES
Disconnect fuel level sensor
and monitor controller connector B.
Check for continuity beNO tween monitor controller
harness end connector terminal #B19 and vehicle
frame.
NO
T5-6-12

connecting fuel sensor
connected to vehicle
frame.
terminal #B19 and vehicle frame.
Faulty fuel sensor.
YES
NO

monitor controller and
fuel sensor.
faulty monitor controller.
Connector
Faulty fuel sensor.
Fuel Sensor
between monitor controller and fuel sensor.
T183-05-04-010
Monitor Controller
Connector B
T183-05-04-013
B19
T5-6-13
MALFUNCTION OF PREHEAT INDICATOR
Check that all other indicators work correctly.
Indicator Does Not Come ON Even If Air Heater Is
Operating
Faulty preheat indicator
relay.
YES
Check if indicator
comes ON after
switching preheat
indicator relay and
other general-purpose relay.
Disconnect preheat indicator relay from connector.
NO Check if voltage at harness end connector terminal #1 is 24 V.
connector.
Disconnect monitor
YES controller connector B.
between harness end
connector terminal #B20
and vehicle frame.
YES Faulty monitor controller,

or burned indicator light.

NO preheat indicator relay.

preheat indicator relay
and preheat relay 1 or
blown fuse (5A).
NO
Indicator Comes ON Even If Air Heater Is Not

Operating
YES
Disconnect monitor
controller connector B.
Check if indicator
comes ON.
between monitor controller and preheat indicator relay.
YES
Disconnect preheat indicator relay.
Check for continuity beNO tween harness end connector terminal #3 and
vehicle frame.
Connect connector.
Check if indicator
comes ON after switchNO ing preheat indicator
relay and other general-purpose relay.
Connector
NO Faulty preheat indicator

relay.
between preheat indicator relay and preheat
YES relay 2 or faulty preheat
relay 2.
Monitor Controller
Connector B
Preheat Indicator Relay
B20
T183-05-04-003
T5-6-14
T183-05-04-014
MALFUNCTION OF DOWNLOAD INDICATOR
Indicator Does Not Come ON Even If DLU Data
Memory Is Full
YES
Disconnect monitor
C.
between terminal
#C20 and vehicle
frame.
Burnt indicator bulb, or

YES
Faulty DLU.
NO

DLU and monitor controller.
Disconnect DLU connector D.

Check for continuity beNO tween terminals #56 and
#C20.
Indicator Comes ON Even If Download Is Completed

Faulty DLU.
YES
Disconnect DLU
connector D.
Check if indicator
goes OFF.
Disconnect monitor controller connector C.

Check for continuity between DLU harness end
NO
and connector C harness
end terminal #C20.
between DLU and
monitor controller.
YES

NO
Connector
Monitor Controller
Connector C
DLU Connector D
#56
T183-05-04-014
T18E-05-06-002
T5-6-15
C20
MALFUNCTION OF ALTERNATOR INDICATOR
Check for loose harness connections before-
Connector
hand.
Monitor Controller
Connector A
A2
T183-05-05-001
Alternator indicator
stays ON after engine is started.
Engine: Running
Disconnect alternator
terminal R, then ground
the terminal to vehicle
frame.
Disconnect connector A
of monitor controller.
Check for continuity between alternator relay
terminal #A2 and vehicle
frame.
YES
Faulty alternator.

alternator terminal R and
monitor controller or
NO
Less than 10 V
Faulty monitor controller,

or broken harness between monitor controller
and alternator.
YES Measure voltage at alternator terminal R.

Key switch: ON
Engine: Stop
Although alternator
output is low, alternator indicator does
not come ON.
Faulty alternator.
Turn key switch
ON. Check if indicator comes ON.
10 V or more
Burned alternator indicator light, or faulty

monitor controller.
NO
T5-6-16
(Blank)
T5-6-17
MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR
Check for restricted oil filter.
Even if the key switch is ON with the engine

stopped, the engine oil pressure indicator does
not come ON.
Even If Engine Oil Pressure Becomes Low With
Engine Running, Indicator Does Not Come ON
Check if the engine has trouble by using the fault
code monitor at engine side beforehand.

check switch ON.
Check if indicator
comes ON.
Connect the connector.

Disconnect DLU connector 76C and ECM
connector 9 poles.
YES Check for continuity
between terminals #52
and C.
and D.
Disconnect monitor controller connector C and

YES DLU connector 76D.
Check for continuity between terminals #55 and
#C18.
NO
Key switch: ON
YES Faulty DLU.
Broken CAN harness.

NO
DLU and monitor.
Faulty monitor controller,
or burnt indicator bulb.
NO
Indicator Stays ON After Engine Is Started

(Oil Level and Oil Pressure are Normal)
Check if the engine has trouble by using the fault
code monitor at engine side beforehand.
YES
Faulty DLU.
NO
Broken or short-circuited
CAN harness.
Check for continuity of

YES CAN harness.
Check for
shorted-circuited CAN
harness.
Disconnect DLU
connector 76D.
Check if indicator
goes OFF.
YES
NO
Disconnect harness between DLU and monitor.

Check for continuity between terminals #55 and
vehicle frame.
between monitor and
DLU.
Broken monitor.
NO
T5-6-18
Connector
DLU Connector 76D
DLU Connector 76C

#C
#55
T18E-05-06-002
#51
#52
#5
T18E-05-06-004
T18E-05-06-003
T5-6-19
MALFUNCTION OF PUMP TRANSMISSION
OIL PRESSURE INDICATOR
Indicator does not come ON even if pump transmission oil pressure is insufficient.
YES
YES
Disconnect pump
transmission oil pressure switch. Ground
#M4 to vehicle frame.
Check if indicator
comes ON.
Key switch: ON
Turn key switch to

ON position.
Check if indicator
comes ON.
NO
terminal.
connector A terminal #A13
to vehicle frame.
Check if indicator comes
ON.
Key switch: ON
piece of clip with connector connected.
Key switch: ON
NO
Indicator stays ON even if engine is started.

YES
Disconnect pump
transmission oil
pressure switch.
Check if indicator
goes OFF.
Key switch: ON
Engine: Stop
Disconnect monitor controller connector A. Keep

cab connector disconnected.
Check for continuity between monitor harness
end connector terminal
#A13 and vehicle frame.
NO
T5-6-20
Pump Transmission Oil Pressure Switch

Pressure
Operation
less than 39 to 59 kPa
ON
(0.4 to 0.6 kgf/cm2)
Indication pressure 39 to 59 kPa
OFF
(0.4 to 0.6 kgf/cm2) or more
Faulty pump transmission oil pressure switch.
YES

pump transmission oil
pressure switch.

NO
Connector
Monitor Controller
Connector A

T183-05-05-001
A13
Faulty pump transmission oil pressure switch,

faulty oil pressure system or restricted oil filter.
YES
between monitor controller and pump transmission oil pressure
switch.

NO
T5-6-21
MALFUNCTION OF ENGINE OIL LEVEL
INDICATOR
Check that machine is parked on level surface.
Indicator Does Not Come ON Even If Oil Level is
Normal
YES
NO
Disconnect engine oil

level switch. Ground
terminal #1 to vehicle
frame.
Check if indicator
comes ON.
Turn key switch to ON

position.
ON.
Connect engine oil level

switch.
Check for continuity between harness end connector terminal #B8 and
vehicle frame.
YES
NO
Indicator Does Not Come ON Even If Oil Level Is

Lower Than Low
YES
NO
Disconnect engine oil

level switch.
Check if indicator
comes ON.
Check oil level with an oil

level gauge.
Check if oil level is higher
than low limit.
NO
YES
T5-6-22

engine oil level switch
disconnected.
Check for continuity between connector B harness end terminal #B8
and vehicle frame.
YES
Connector
Monitor Controller
Connector B
NO
B8

engine oil level switch.
T183-05-04-013
Faulty engine oil level

switch.
Engine Oil Level Switch

YES
between monitor controller and engine oil
level switch.

NO
Faulty engine oil level

switch.
Normal.
T5-6-23
T18E-05-06-006
MALFUNCTION OF COOLANT LEVEL INDICATOR
Indicator Does Not Come ON Even If Coolant
Level Is Lower than Low
Check if fault cod 235 is displayed on the engine
fault code monitor beforehand.
If fault code 235 is displayed, the following troubles may occur.
Faulty engine (coolant level sensor or ECM)
Broken or short -circuited harness between ECM
and coolant level sensor.
NO
Turn key switch ON.

Check if indicator
comes ON.
Burnt indicator bulb, or faulty

monitor controller.
YES
YES
Disconnect monitor
Disconnect DLU connector 76D.
between DLU terminals #76 to 57D and
vehicle frame.
YES Faulty DLU.
NO
Indicator Comes ON Even If Coolant Level Is

YES
Normal
YES
Disconnect DLU
connector 76D.
between DLU end
terminal 76-57D and
vehicle frame.
NO

connector 9 poles.
between terminals
#76 to 52 and C.
between terminals
#76 to 51 and D.
Disconnect monitor
Check for
between DLU terminals #76 to 57 and
monitor controller terminal B9.

DLU and monitor controller.
NO

connector 9 poles.
to 52 and C.
to 51 and D.
Disconnect coolant
level sensor connector
and ECM connector
21 poles. Check for
broken or
between terminals below.
NO
Faulty harness between

ECM and DLU.
harness between DLU and
ECM.
NO
YES
harness between ECM and
coolant level sensor.
Faulty engine. (coolant level
sensor or ECM)
Coolant level sensor

Terminals #A and ECM #T
Terminals #B and ECM #V
Terminals #C and ECM #U
Terminals #D and ECM #S
YES
NO
T5-6-24
harness between DLU and
monitor controller.
DLU Connector 76D
Monitor Controller
DLU Connector 76C
Connector B
#57
B9
T18E-05-06-002
T183-05-04-013
Coolant Level Sensor Connector

#D
#C
T18E-05-06-007
T18E-05-06-003
T5-6-25
#51
#52
T18E-05-06-004
MALFUNCTION OF
LEVEL INDICATOR
HYDRAULIC
OIL

Indicator Does Not Come ON Even If Hydraulic
Oil Level Is Lowered Below Lower Limit
YES

level switch 1. Ground
YES
terminal to vehicle frame.
ON after 5 seconds.
Key switch: ON
Faulty hydraulic oil

level switch 1.
connector.
Disconnect hydraulic
oil level switch 2.
NO Ground harness end
connector terminal to
vehicle frame. Check if
indicator comes ON
after 5 seconds.
Key switch: ON

check switch ON.
Check if indicator
comes ON.
Key switch: ON
NO

main controller B connector B.
Check for continuity between connector C harness end terminal #C14
and connector B harness
end terminal #B23.
YES Faulty hydraulic oil

level switch 2.
NO
connector.
Disconnect main controller B connector B.
between harness end
connector terminal
#B15 and vehicle
frame.
NO
Burned indicator light,

faulty monitor controller, or broken harness
between monitor controller and main controller B.
YES
Connect monitor controller connector C.

Connect main controller B terminal #B15
and harness end connector #B15 with a
clip.
Check if indicator
comes ON.
T5-6-26
Connector
Monitor Controller
Connector C
Main Controller B
Connector B
Hydraulic Oil Level Switch 1, 2
T183-05-04-010
T183-05-04-014
C14
B23
B15
T183-05-04-021
YES
YES between harness end
connector terminal
#B16 and vehicle
frame.
Broken harness between hydraulic oil level

switch 2 and main controller B.
NO
Broken harness between hydraulic oil level

switch 1 and main controller B.
NO
Broken harness between main controller B

and hydraulic oil level
switch 2.
YES
Check if indicator
comes ON after
YES switching hydraulic oil
level switch 1 and hydraulic oil level switch
2.
NO
oil level switch 1.
between main controller B harness end
connector terminal
#B15 and hydraulic oil
level switch 2 harness
end connector terminal #1.
Faulty hydraulic oil level

switch 2.
NO
YES
oil level switch 1.
Ground harness end
connector terminal to
vehicle frame.
Check if indicator
comes ON after 5
seconds.
YES
Faulty hydraulic oil level

switch 1.

NO
Broken harness between main controller B

and hydraulic oil level
switch 1.
NO
T5-6-27
Indicator Comes ON Even If Hydraulic Oil Level
Is Normal
YES

level switch 1.
oil level switch 1.
Check if indicator
goes OFF.
NO
connectors.
Disconnect main conNO troller B connector B.
between harness end
connector terminals
#B15, B16 and vehicle
frame.

level switch 2. Check if
indicator goes OFF.
NO
Disconnect monitor
controller connector C.
between connector C
#C14 and connector B
#B23.
between hydraulic oil
YES level switch 1, 2 and
main controller B.

level switch 2.
YES
Connector
Monitor Controller
Connector C
Main Controller B
Connector B
Hydraulic Oil Level Switch 1, 2

B16
T183-05-04-010
T183-05-04-014
C14
B23
B15
T183-05-04-021
T5-6-28
YES
NO
between monitor controller
Faulty monitor controller or

main controller B.
T5-6-29
MALFUNCTION OF AUTO-LUBRICATION
INDICATOR
Indicator Comes ON Even If Auto-lubrication

System Operates Normally.
NOTE: Indicator comes ON when lubrication
mode switch is turned to "Manual" position.
24 V
Disconnect monitor controller

connector C.
Check for voltage at harness
end connector terminal #C15.
Disconnect main controller B

connector A.
monitor controller connector C
harness end terminal #C15
and connector A harness end
terminal #A29.

0V
Indicator Does Not Come ON Even If

Auto-lubrication System is Abnormal or Lubrication Mode Switch is Turned to "Manual" Position.
YES
Disconnect monitor controller

connector C.
Check for voltage at harness
end connector terminal #C15.
Key switch: ON
Turn key switch to ON position.

Check if indicator comes ON.

NO
T5-6-30
Connector
Monitor Controller
Connector C
Main Controller B
Connector A
T183-05-04-014
C15
YES
A29
Short-circuited harness between monitor controller and

main controller B.

NO
0V
Faulty main controller B, or

monitor controller and main
controller B.

24 V
T5-6-31
T183-05-04-008
MALFUNCTION OF ENGINE STOP INDICATOR
Even If Engine is Normal, Indicator comes ON.
Check if fault code corresponding to ECM is not
displayed beforehand.
NO
Faulty engine stop indicator relay.
Switch stop indicator

Check if indicator
comes ON.
Key switch: ON
YES
Disconnect DLU connector 76D.
YES DLU terminals #76 to #64
and vehicle frame is 24V.
Disconnect DLU connector 76D and monitor connector C.

Check for
NO short-circuited harness
and vehicle frame.
Faulty DLU.
YES Short-circuited harness

between DLU and
monitor.
Faulty monitor.
NO
Indicator does not come ON even if engine has

troubles.
Burnt indicator bulb, or
NO
Turn key switch

ON.
YES
Faulty engine stop indicator relay.
Switch stop indicator

YES Check if indicator
comes ON.
Disconnect DLU
connector 76D.
Check if voltage beNO tween DLU terminals
#76 to #64 and vehicle frame is 24V.
NO DLU
Disconnect
connector 76D.
NO Check if voltage between terminals #8
and #9 is 24V.
NO Faulty DLU.

DLU and relay. (termiYES nals #5 to #64)
YES
Faulty DLU.

between monitor C19
YES and terminals #67.
NO monitor and DLU.
T5-6-32
Connector
DLU Connector D
DLU Connector A
#64
Monitor Connector C
#8
#9
T18E-05-06-008
T18E-05-06-002
#67
T5-6-33
T18E-05-06-009
#19
MALFUNCTION OF ENGINE WARNING
INDICATOR
Indicator comes ON even if engine has no trouble.

between ECM and monitor
controller.
YES
Disconnect monitor controller connector C.
Check for continuity for
vehicle frame and terminal
#16.

NO
Indicator does not come ON even if engine has

troubles.
YES
Turn key switch to ON position.

ON.

ECM connector 31 poles.
Check for continuity between terminals #C16 and
#17.
Key switch: ON
YES Broken harness between

ECM.
Faulty ECM.
NO

NO
T5-6-34
Connector
Engine Warning Indicator Relay
Monitor Controller
Connector C
#17
T183-05-04-014
T183-05-04-003
C16
T18E-05-04-004
T5-6-35
MALFUNCTION OF QUICK-IDLE INDICATOR
Connector
Monitor Controller
Connector B
T183-05-04-013
Connector C
C3
T183-05-04-014
Indicator comes ON even if quick-idle system is

not operating.
Disconnect monitor conYES troller connector B.

ON.
Disconnect quick-idle
switch.
ON.
Disconnect monitor conYES troller connector C.

Check if voltage at harness end connector
terminal #C3 is 24 V.
NO
between quick-idle
switch and monitor controller.
Faulty quick-idle switch.

NO
Indicator does not come ON even if quick-idle

system is operating.
Burned indicator light, or faulty monitor controller.
T5-6-36
Faulty quick-idle relay, or

short-circuited harness between monitor controller and
quick-idle relay.
YES

NO
T5-6-37
MALFUNCTION OF AUTO-IDLE INDICATOR
Connector
Switch Box
T183-05-04-004
Monitor Controller
Connector B
B10
Indicator does not come ON even if auto-idle

system is operating.
T183-05-04-013

YES
Check if voltage at harness end connector terminal #B10 is 24 V.

switch box and monitor
controller.
NO
Indicator comes ON even if auto-idle system is

not operating.
YES

ON.
YES
NO
between switch box and
monitor controller.
Disconnect monitor
Check if indicator
comes ON.
Faulty switch box.

NO
T5-6-38
(Blank)
T5-6-39
MALFUNCTION OF HOURMETER
Hourmeter Does Not Operate When Engine Is
Running
Less than 13 V
or 33.5 V or more
13 V or more
less than
33.5 V
NO Measure voltage at
alternator terminal L.
Engine speed:
900 min-1 (rpm)
or more.
Connect alternator relay.

Disconnect monitor
controller connector A.
13 V or more
Measure voltage at
less than 33.5 V harness end connector
terminal #A2.
Check if alternator indicator comes ON.

Engine: Running
0V

monitor controller and alternator.
Refer to "MALFUNCTION
OF ALTERNATOR INDICATOR" (Alternator
indicator stays ON after
engine is started).
YES
Connector
Monitor Controller
Connector A
Faulty alternator.
A2
T183-05-05-001
T5-6-40
(Blank)
T5-6-41
MALFUNCTION OF BUZZER
Buzzer sounds continuously key switch is turned
ON without starting engine.
10 V or more
Measure voltage at
monitor controller
connector A terminal
#A2.
Key switch: ON
without starting engine
Faulty alternator.
Faulty monitor
controller.
Less than
10 V
Buzzer sounds continuously when engine is

started.
YES
Check if pump
transmission oil
pressure indicator
comes ON.
Faulty pump
transmission oil
pressure system.
YES
NO
Check if engine
stop indicator
comes ON.
NO
Buzzer does not sound even if pump transmission oil pressure indicator or engine stop indicator comes ON.
Faulty engine system.
Check if buzzer
stops by pressing
buzzer cancel
switch.
Normal (Engine
speed is too slow).
NO
Check if alternator
indicator comes ON.
Measure voltage at
regulator terminal
R.
YES
Engine: Running
T5-6-42
Connector
Starter Relay 2
(Harness End)
Monitor Controller
Connector A (Harness End)
A2
1
2
T183-05-05-001
YES
Normal.

NO
less than
13 V
Disconnect alternator
terminal R and monitor
controller connector A.
Check for continuity between terminals R and
#A2.
YES
Faulty alternator.
NO

alternator terminal R and
monitor panel.

13 V or
more
T5-6-43
MALFUNCTION
DISPLAY (LCD)
OF
LIQUID
CRYSTAL
This section describes the following items:

1 to 7: Displayed in normal condition.
8 to 23: Displayed when switched to the build-in
diagnosing system.
Check that the machine control is not malfunctioning.
Main Controller A Side
Display
Description
Order
1
Hourmeter
2
Trip1
3
Trip2
Engine Actual Speed
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Fault Code
Front Attachment Operation Pressure
Travel Operation Pressure
Engine Exhaust Gas
Temperature
EC Angle
Digital Input 0
Digital Input 1
Digital Input 2
Digital Input 3
Digital Output
Proportional Valve
ON/OFF Output
Hydraulic Oil Cooling
Output Current
Power Increase Output
Current
Causes
Refer to T5-6-40
Faulty monitor.
Faulty sensor system detecting corresponding signal. (There should be
some abnormality with the machine control. Refer to Troubleshooting
B).

B).
T5-6-44
This section describes the following items:

1 to 7: Displayed in normal condition.
8 to 23: Displayed when switched to the build-in
diagnosing system.
Check that the machine control is not malfunctioning.
Main Controller B Side
Display
Description
Order
1
Hourmeter
2
Trip1
3
Trip2
Engine Actual Speed
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Fault Code
Digital Input 0
Digital Input 1
Digital Input 2
Digital Input 3
Digital Output
Proportional
Valve
ON/OFF Output
Auto-Lubrication Status
1
2
(upper 4 bits)
2
(lower 4 bits)
Auto-Lubrication Interval
Selection
Digital Output 2
(upper 4 bits)
Digital Output 2
(lower 4 bits)
Causes
Refer to T5-6-40.
Faulty monitor.
B).
Faulty monitor, or faulty communication between monitor and MC.

B).
T5-6-45
MALFUNCTION OF ENGINE TROUBLESHOOTING OPERATION
Fault code is not displayed when engine has

some trouble even if engine diagnostic switch is
turned to ON position.

engine fault diagnosing
switch A and ground.
NO
Check for continuity beYES tween harness end terminal #2 and vehicle
frame.
YES Faulty ECM.
Disconnect ECM connector 31 poles.

YES Check for continuity between harness end terminals #1 and #18.
Disconnect engine fault

diagnosing switch A
connector.
Check for continuity between terminals.

ECM and engine fault
NO diagnosing switch A.
Engine fault diagnostic

switch: ON
Faulty engine fault diagnosing switch A.
NO
Connector
Fault Diagnostic Switch B
Fault Diagnostic Switch A
#18
1
2
3
T18E-05-06-010
#12
T18E-05-04-004
#13
T5-6-46
Even if some troubles occur in the engine and
engine fault diagnosing switch B is switched, the
previous or following fault code is not displayed.
NOTE: If only one trouble occurs in the engine
and engine fault diagnosing switch B is
switched, the fault code does not change.
Faulty engine fault diagnosing switch B.
YES
Disconnect engine fault

diagnosing switch B
connector. Connect
#1 to #3 and #2 to #3.
Check if fault code
switches.
YES
Key switch: ON
Engine fault diagnosing
switch A: ON
NO
Disconnect ECM connector 31 poles. Check

for continuity between
#1 and #13, #2 and #12.
NO
T5-6-47
Faulty ECM.

engine fault diagnosing
switch B and ECM.
(Blank)
T5-6-48
TROUBLESHOOTING / Troubleshooting D
TROUBLESHOOTING D PROCEDURES
Refer to Troubleshooting D if the engine stop indicator
and the engine warning indicator in the cab start flashing by the ECM diagnosis system. Refer to the System section in the Technical Manual (Operational
Principle).
T5-7-1
Inspection Method
When any trouble occurs in the engine control system,
one of the following indicators come ON:
Monitor Panel
Overheat Indicator
Engine Oil Pressure Indicator
Coolant Level Indicator
Engine Warning Indicator 1
Engine Stop Indicator 1
4
In addition, the following indicators on the engine fault

code indicator panel blink or come ON to indicate the
fault code or fault level.
Engine Warning Indicator 2

Engine Stop Indicator 2
Engine Protection Indicator
ECM (Electronic Control Module) memorizes malfunctions of the engine in the form of fault codes. This fault
code can be displayed in two forms:
2
Indicated by the blinking pattern of the engine

warning indicator and engine stop indicator.
Displayed by INSITE (diagnostic tool by CUMMINS CO.)
T183-01-02-013
Engine Fault Code Indicator Panel
When the fault code is displayed, record the fault

code (3 digit number), and contact CUMMINS CO. for
advise.
NOTE: The fault level indicates the seriousness of
the trouble which is preset in ECM.
The engine warning indicator, engine stop
indicator or engine protection indicator
comes ON according to the seriousness of
the trouble.
T141-05-03-002
M18E-01-009
1 - Engine Warning Indicator 1

2 - Engine Stop Indicator 1
3 - Coolant Level Indicator
4 - Overheat Indicator
T5-7-2
5 - Engine Oil Pressure Indicator

6 - Engine Warning Indicator 2
7 - Engine Stop Indicator 2
8 - Engine Protection Indicator
FAULT CODE INDICATION BY INDICATOR
BLINKING PATTERN
The fault code is indicated by the blinking pattern of
the engine warning indicator 2 and engine stop indicator 2 if the engine fault diagnosing switch A and/or B
is operated.
NOTE: The engine warning indicator 1 and engine
stop indicator 1 on the monitor panel may
blink when the fault diagnosing switch A
and/or B is operated. This does not indicate the fault code.
Fault Diagnosing Switch
There are two diagnostic switches: A and B. These
switches are used to indicate the fault codes.
Both diagnostic switches are self-return type, so a
fault code is indicated while switches are pressed up
or down.
Switch A: The fault code is indicated by pressing the
switch upward.
Switch B: This is used when more than one fault code
is memorized. The next fault code is displayed when
pressing the switch up once, and previous fault code
is displayed when pressing the switch down once.
Troubleshooting Procedure
1. Turn key switch to ON position. (Engine: Stop)
When Fault Code is Not Memorized:
The engine warning indicator 2, engine stop indicator 2 and engine protection indicator come
ON in sequence. Then, all three indicators go
OFF.
When Faulty Code is Memorized:
The engine warning indicator 2, engine stop indicator 2 and engine protection indicator come
ON in sequence. Then, all three indicators go
OFF. After that, the indicator corresponding to the
fault level stays ON.
T5-7-3
Fault Diagnosing
Switch B
Fault Diagnosing
Switch A
M18E-01-009
2. Turn the engine fault diagnosing switch A ON
(press upward). The engine warning indicator 2
and engine stop indicator 2 blink in the following
sequence. (Three indicators stay ON when no
fault code is memorized).
The engine warning indicator 2 blinks once.
After approx. one seconds, the engine stop indicator 2 blinks. The blinking number indicates the
hundredth digit.
tenth digit.
first digit.
Finally, the engine warning indicator 2 blinks
once.
3. The fault code is indicated repeatedly in the
above sequence.
Example: in case of Fault Code 132

(Fault code is indicated in three digit number)
hundredth
number
tenth
number
first
number
ON
OFF
NOTE: When wires of the engine control system

has been disconnected for service, ECM
recognizes it as malfunction and stores it
in the history. This record remains even if it
is reconnected.
The diagnostic tool INSITE is required to
erase this record.
NOTE: The code indicated on the fault code indicator panel shows the trouble occurring
currently.
The diagnostic tool INSITE is required to
indicate the past history.
T5-7-4
one
second
one
second
T141-05-03-004
FAULT CODES FOR QUANTUM ENGINES
S020
3
114
Yellow
QSK60
113
Yellow
QSK45
635
7
QST30
S020
7
QSK23
112
Red
QSK19
Engine Control Module Critical

internal failure
QSX15
629
12
QSM11
S254
12
DESCRIPTION
QSL9
111
Red
FMI
QSC
SID(S)
PID(P)
FMI
QSB
SPN
FAULT
CODE/
LAMP
Engine Timing Actuator is not

responding to ECM commands
635
3
Engine Timing Actuator Circuit shorted high
S020
4
635
4
Engine Timing Actuator Circuit shorted low
115
Red
P190
2
190
2
116
Red
P156
3
156
3
Engine Speed/Position Sensor Circuit lost both of two signals from the
magnetic pickup sensor
Fuel Timing Pressure Sensor Circuit shorted high
117
Red
P156
4
156
4
118
Yellow
P135
3
119
Yellow
X
X
Fuel Timing Pressure Sensor Circuit shorted low
135
3
Fuel Pump Delivery Pressure Sensor

Circuit - shorted high
P135
4
135
4
Fuel Pump Delivery Pressure Sensor

Circuit - shorted low
121
Yellow
P190
10
190
10
122
Yellow
P102
3
102
3
Engine Speed/Position Sensor Circuit lost one of two signals from the
magnetic pickup sensor
Intake Manifold Pressure Sensor #1
123
Yellow
P102
4
102
4
Intake Manifold Pressure Sensor #1

124*
Yellow
102
16
125*
None
High Intake Manifold Pressure Left

Bank
102
18
Low Intake Manifold Pressure Left

Bank
126*
Yellow
1129
16
High Intake Manifold Pressure Right

Bank
127*
None
1129
18
Low Intake Manifold Pressure Right

Bank
NOTE: *Denotes Cense Fault codes.
T5-7-5
QSK45
QSK60
129*
None
1129
4
Right Bank Intake Manifold Pressure

Sensor Circuit Failed Low
QSX15
Right Bank Intake Manifold Pressure

Sensor Circuit Failed High
QSL9
1129
3
QSC
128*
None
DESCRIPTION
QSB
QST30
FMI
QSK23
SPN
QSK19
SID(S)
PID(P)
FMI
QSM11
FAULT
CODE/
LAMP
131
Red
P091
3
091
3
Accelerator Pedal Position Sensor

132
Red
P091
4
091
4

133
Red
P029
3
974
3
Remote Accelerator Pedal Position

Sensor Circuit - shorted high
133
Red
P029
3
29
3

134
Red
P029
4
974
4

Sensor Circuit - shorted low
134
Red
P029
4
29
4

135
Yellow
P100
3
100
3
Engine Oil Pressure Sensor Circuit shorted high
136*
None
1208
3
Pre Filter Oil Pressure Sensor Circuit

Failed High
137*
None
1208
4
Pre Filter Oil Pressure Sensor Circuit

Failed Low
X
X
P100
4
100
4
Engine Oil Pressure Sensor Circuit shorted low
143
Yellow
P100
1
100
18
Engine Oil Pressure Low - Warning
143
White
P100
1
100
1
Engine Oil Pressure Low - Warning
144
Yellow
P110
3
110
3
Engine Coolant Temperature Sensor

145
Yellow
P110
4
110
4
Engine Coolant Temperature Sensor

146
Yellow
P110
0
110
16
Engine Coolant Temperature High

Warning
T5-7-6
141
Yellow
X
X
X
X
SID(S)
PID(P)
FMI
QSB
QSC
QSL9
QSM11
QSX15
QSK19
QSK23
QST30
QSK45
QSK60
SPN
FAULT
CODE/
LAMP
147
Red
P091
8
091
8

Circuit - low frequency
148
Red
P091
8
091
8

Circuit - high frequency
151
Red
P110
0
110
0

Critical
151
White
P110
0
110
0

Critical
153
Yellow
P105
3
105
3
Intake Manifold Temperature Sensor

#1 Circuit - shorted high
154
Yellow
P105
4
105
4
Intake Manifold Temperature Sensor

#1 Circuit - shorted low
155
Red
P105
0
105
0
Intake Manifold Temperature #1 High Critical
155
White
P105
0
105
0
Intake Manifold Temperature #1 High Critical
156*
Yellow
1131
3
157*
Yellow
FMI
DESCRIPTION
X
X
1131
4
Left Bank Rear Intake Manifold

Temperature Sensor Circuit Failed
High
Left Bank Rear Intake Manifold
Temperature Sensor Circuit Failed Low
158*
White
1131
0
High Intake Manifold Temperature Left Bank Rear
159*
Yellow
1132
3
161*
Yellow
1132
4
Right Bank Front Intake Manifold

High
Right Bank Front Intake Manifold
162*
White
1132
0
High Intake Manifold Temperature Right Bank Front
163*
Yellow
1133
3
164*
Yellow
1133
4
Right Bank Rear Intake Manifold

High
Right Bank Rear Intake Manifold
165*
White
1133
0
High Intake Manifold Temperature Right Bank Rear
T5-7-7
X
X
Rack Position Sensor #1 Circuit shorted Low
172
Red
S023
6
638
6
Rack Actuator Position #1 Circuit grounded circuit
173
Yellow
S023
7
638
7
Rack Actuator - mechanically stuck

open
184
Yellow
S233
2
609
2
Engine Control Module Identification

Input State Error
185
Yellow
S231
2
639
2
Engine Control Module Network

Communication Error
187
Yellow
S232
4
620
4
Sensor Supply Voltage #2 Circuit shorted low
211
None
S216
11
1484
31
Additional OEM/Vehicle Diagnostic

Codes have been logged. Check other
ECM's for DTC's.
OEM Component Failure
175
3
Engine Oil Temperature Sensor Circuit

- shorted high
175
3

- shorted high
175
4

- shorted low
175
4

- shorted low
175
0
Engine Oil Temperature High - Critical
175
0
Engine Oil Temperature High - Critical
211*
None
212
Yellow
613
14
P175
3
212*
Yellow
213
Yellow
P175
4
213*
Yellow
214
Red
P175
0
214*
White
219
Maint
P17
1
1380
17
Low Oil Level in the Centinel makeup

oil tank
219
White
P17
1
1380
1
Low Oil Level in the Centinel makeup

oil tank
221
Yellow
P108
3
108
3
Ambient Air Pressure Sensor Circuit

shorted high
T5-7-8
QSK60
733
4
QST30
S024
4
QSK23
167
Yellow
QSK19
QSX15
Rack Position Sensor #1 Circuit shorted high
QSM11
733
3
QSL9
S024
3
DESCRIPTION
QSC
166
Yellow
FMI
QSB
SID(S)
PID(P)
FMI
QSK45
SPN
FAULT
CODE/
LAMP
X
X
SPN
Engine Oil Burn Valve Solenoid Circuit

shorted low
225
Yellow
S086
4
1266
4
Engine Oil Replacement Valve

Solenoid Circuit - shorted low
227
Yellow
S232
3
620
3
Sensor Supply Voltage #2 Circuit shorted high
231
Yellow
P109
3
109
3
Engine Coolant Pressure Sensor

232
Yellow
P109
4
109
4
Engine Coolant Pressure Sensor

233
Yellow
P109
1
109
18
Engine Coolant Pressure Low Warning
233
White
P109
1
109
1
Engine Coolant Pressure Low Warning
234
Red
P190
0
190
0
Engine Speed High - Cricital
235
Red
P111
1
111
1
Engine Coolant Level Low - Critical
235
White
P111
1
111
1
Engine Coolant Level Low - Critical
237
Yellow
S030
2
644
2
External Speed Input (Multiple Unit

Sychronization) - data incorrect
241
Yellow
P084
2
084
2
Vehicle Speed Sensor Circuit - data

incorrect
242
Yellow
P084
10
084
10
Vehicle Speed Sensor Circuit tampering has been detected
243
Yellow
P121
4
513
4
Engine Brake Driver #1 Circuit shorted low
245
Yellow
S033
4
647
4
Fan Clutch Circuit - shorted low
252
Yellow
P098
2
098
2
Engine Oil Level #1 Sensor Circuit data incorrect
T5-7-9
QSK60
1265
4
QSK45
S085
4
QST30
223
Yellow
QSK19
Ambient Air Pressure Sensor Circuit

shorted low
QSX15
108
4
QSM11
P108
4
DESCRIPTION
QSL9
222
Yellow
FMI
QSC
SID(S)
PID(P)
FMI
QSB
FAULT
CODE/
LAMP
X
X
X
X
X
X
Fuel Shutoff Valve Circuit - shorted low
254
None
S017
4
632
4
Fuel Shutoff Valve Circuit - shorted low
255
Yellow
S017
3
632
3
Fuel Shutoff Valve Circuit - shorted

high
259
Red
S017
7
632
7
Fuel Shutoff Valve - stuck open
261
Yellow
P174
0
174
16
Fuel Temperature High - Warning
261
White
P174
0
174
0
Fuel Temperature High - Warning
263
Yellow
P174
3
174
3
Fuel Temperature Sensor Circuit shorted high
264
Yellow
P174
11
174
11
Fuel Temperature Sensor Circuit - data

out-of-range
265
Yellow
P174
4
174
4
268
Yellow
P094
2
271
Yellow
X
X
QSK60
632
4
QSK45
S017
4
QST30
254
Red
QSK19
Engine Oil Level #1 Low - Critical
QSX15
098
1
QSM11
P098
1
DESCRIPTION
QSL9
253
White
FMI
QSC
SID(S)
PID(P)
FMI
QSB
SPN
FAULT
CODE/
LAMP
X
X
X
X
X
X
Fuel Temperature Sensor Circuit shorted low
94
2
Fuel Pressure Sensor Circuit - data

incorrect
S126
4
1347
4
High Fuel Pressure Solenoid Valve #1

272
Yellow
S126
3
1347
3

273
Yellow
S127
4
1348
4

274
Yellow
S127
3
1348
3

275
Yellow
S126
7
1347
7
Fuel Pumping Element #1 (Front) mechanically stuck
276
Yellow
S018
3
633
3
Fuel Injection Control Valve Circuit shorted high
T5-7-10
278
Yellow
P073
11
1075
11
Fuel Priming Pump Control Circuit shorted high/low
279
Yellow
S018
4
633
4
281
Yellow
S126
7
282
Yellow
QSC
QSL9
X
Fuel Injection Control Valve Circuit shorted low
1347
7

- mechanically stuck
S127
7
1348
7

- mechanically stuck
283
Yellow
S221
3
1043
3
284
Yellow
S221
4
1043
4
285
Yellow
S231
9
639
9
Engine Speed/Position Sensor #1

(Crankshaft) Supply Voltage Circuit shorted high
(Crankshaft) Supply Voltage Circuit shorted low
SAE J1939 Multiplexing PGN Timeout
Error
286
Yellow
S231
13
639
13
SAE J1939 Multiplexing Configuration

Error
287
Red
P091
2
91
19
SAE J1939 Multiplexing Accelerator

Pedal Sensor System Error
288
Red
P029
2
974
19
SAE J1939 Multiplexing Remote

Throttle Data Error
292
White
P223
14
1083
14
Auxiliary Temperature Sensor Input # 1

Engine Protection - Critical
293
Yellow
S441
3
441
3

Circuit shorted high
293
Yellow
P223
3
1083
3

293
Yellow
S154
3
1083
3

294
Yellow
S441
4
441
4

Circuit shorted low
294
Yellow
P223
4
1083
4

Circuit shorted low
T5-7-11
QSB
X
X
QSK60
Fuel Injection Control Valve mechanically stuck
QSK45
633
7
QST30
S018
7
DESCRIPTION
QSK19
277
Yellow
FMI
QSX15
SID(S)
PID(P)
FMI
QSM11
SPN
FAULT
CODE/
LAMP
295
Yellow
P108
2
108
2
Ambient Air Pressure Sensor Circuit data incorrect
296
Red
P223
14
1387
14
Auxiliary Pressure Sensor Input # 2

296
White
P223
14
1084
14

297
Yellow
P223
3
1387
3

297
Yellow
P223
3
1084
3

298
Yellow
P223
4
1387
4

Circuit shorted low
298
Yellow
P223
4
1084
4

Circuit shorted low
299
None
S117
14
1384
31
Engine Shutdown Commanded by

J1939
299
Yellow
S117
11
1384
31
Engine Shutdown Commanded by

J1939
311
Yellow
S001
6
651
6
Injector Solenoid Valve Cylinder #1

Circuit grounded circuit
312
Yellow
S005
6
655
6

313
Yellow
S003
6
653
6

314
Yellow
S006
6
656
6

Circuit - grounded circuit
315
Yellow
S002
6
652
6

316
Yellow
S078
3
931
3
318
Yellow
S078
7
931
7
QSK60
QSK45
QST30

Circuit shorted low
QSK19
QSX15
1083
4
QSL9
S154
4
DESCRIPTION
QSC
294
Yellow
FMI
QSB
SID(S)
PID(P)
FMI
QSM11
SPN
FAULT
CODE/
LAMP
X
X
Fuel Supply Pump Actuator Circuit shorted high
Fuel Supply Pump Actuator

mechanically stuck
T5-7-12

Circuit - grounded circuit
322
Yellow
S001
5
651
5

Circuit - open circuit
323
Yellow
S005
5
655
5

Circuit open circuit
324
Yellow
S003
5
653
5

325
Yellow
S006
5
656
5

328
Yellow
S152
7
1348
7
Fuel Pumping Element #2 (Rear) mechanically stuck
329
Yellow
S233
14
1077
14
Fuel System Leakage error
331
Yellow
S002
5
652
5

332
Yellow
S004
5
654
5

341
Yellow
S253
2
630
2
Engine Control Module data lost
342
Red
S253
13
630
13
Engine Control Module out of

calibration
343
Yellow
S254
12
629
12
Engine Control Module - Warning

internal hardware failure
346
Yellow
S253
12
630
12
Engine Control Module - Warning

Software error
349
Yellow
P191
0
191
16
Transmission Output Shaft (Tailshaft)

Speed High Warning
349
Yellow
P191
0
191
0

Speed High Warning
352
Yellow
S232
4
1079
4
Sensor Supply Voltage #1 Circuit shorted low
T5-7-13
QSK60
654
6
QSK45
S004
6
QST30
321
Yellow
QSX15
Real Time Clock - Power Interrupt
QSM11
251
2
QSL9
P251
2
DESCRIPTION
QSC
319
Maint
FMI
QSB
SID(S)
PID(P)
FMI
QSK19
SPN
FAULT
CODE/
LAMP
X
X
X
X
1076
4
Fuel Pump Control Module, Fuel

Control Valve Circuit - shorted low
363
Yellow
S251
7
1076
7

Control Valve - mechanically stuck
364
Yellow
S233
9
1077
9
365
Yellow
S233
4
1077
4
Fuel Pump Control Module, CAN

Communication Error - abnormal
update rate
Fuel Pump Control Module, Supply
Voltage Circuit - shorted low
366
Yellow
S233
2
1077
2
Fuel Pump Control Module, Supply

Voltage Circuit - data incorrect
367
Yellow
P190
11
1078
11
Fuel Pump Control Module, Increment

Angle Time Sensor Error
368
Yellow
S254
8
1078
8
Fuel Pump Control Module, Timing

Error
369
Yellow
P190
2
1078
2
Fuel Pump Control Module, Engine

Synchronization Error
372
Yellow
S233
11
1077
11
Fuel Pump Control Module, Idle

Validation Error
373
Red
S233
3
1077
3

Shutoff Error
374
Yellow
S233
12
1077
12
Fuel Pump Control Module, Self-Test

Error
375
Yellow
S254
2
629
2
Fuel Pump Control Module, Electronic

Calibration Code Error
376
Yellow
S233
13
1077
13
Fuel Pump Control Module, Fueling or

Engine Speed Mismatch
377
Yellow
S233
7
1077
7
Fuel Pump Control Module, Stuck

Relay Error
378
Yellow
S018
5
633
5
Fueling Actuator #1 Circuit - open

circuit
379
Yellow
S018
6
633
6
Fueling Actuator #1 Circuit - grounded

circuit
T5-7-14
QSK60
S251
4
QSK45
362
Yellow
QST30
QSX15

Control Valve Circuit - shorted high
QSM11
1076
3
QSL9
S251
3
DESCRIPTION
QSC
361
Red
FMI
QSB
SID(S)
PID(P)
FMI
QSK19
SPN
FAULT
CODE/
LAMP
382
Yellow
S237
11
626
11
Intake Air Heater (Relay Enable) #2

Circuit - data incorrect
384
Yellow
S237
11
626
11
Start Assist Device Control Circuit

Error (Ether Injection)
385
Yellow
S232
3
620
3
OEM Sensor Supply Voltage Circuit shorted high
386
Yellow
S232
3
1079
3
Sensor Supply Voltage #1 Circuit shorted high
387
Yellow
S221
3
1043
3

Supply Voltage Circuit - shorted high
389
Yellow
S033
11
647
11
Fan Clutch Circuit Error
391
Yellow
S017
11
632
11
Fuel Shutoff Valve Supply Voltage

error
394
Yellow
S020
5
635
5
Timing Actuator #1 Circuit - open

circuit
395
Yellow
S020
6
635
6
Timing Actuator #1 Circuit - grounded

circuit
396
Yellow
S083
5
1244
5
Fueling Actuator #2 Circuit - open

circuit
397
Yellow
S083
6
1244
6
Fueling Actuator #2 Circuit - grounded

circuit
398
Yellow
S084
5
1245
5
Timing Actuator #2 Circuit - open

circuit
399
Yellow
S084
6
1245
6
Timing Actuator #2 Circuit - grounded

circuit
414*
Yellow
S250
9
608
9
Data Communication error over the

J1587 data link Circuit
415
Red
P100
1
100
1
Engine Oil Pressure Low Critical
415
White
P100
1
100
1
Engine Oil Pressure Low Critical
T5-7-15
QSK60
QSK45
Intake Air Heater (Relay Enable) #1

QST30
626
11
QSK19
QSL9
S237
11
DESCRIPTION
QSX15
QSC
381
Yellow
FMI
QSM11
SID(S)
PID(P)
FMI
QSB
SPN
FAULT
CODE/
LAMP
X
X
X
X
1319
2
Intake Manifold Boost Pressure

Imbalance
P111
2
111
2
Engine Coolant Level Sensor Circuit data incorrect
423
Yellow
P156
2
156
2
Fuel Timing Pressure or Timing

Actuator Stuck
426
None
S231
2
639
2
SAE J1939 datalink - cannot transmit
426
Yellow
S231
2
639
2
639
2
426*
None
X
X
X
S231
639
9
SAE J1939 not fast enough
428
Yellow
P097
3
97
3
Water in Fuel Sensor Circuit - shorted

high
429
Yellow
P097
4
097
4
Water in Fuel Sensor Circuit - shorted

low
431
Yellow
S230
2
558
2
Accelerator Pedal Idle Validation

431
Yellow
P091
2
91
2

432
Red
S230
13
558
13

Circuit - out of calibration
432
Red
P091
13
91
13

Circuit - out of calibration
433
Yellow
P102
2
102
2
Intake Manifold Pressure Sensor

434
Yellow
S251
2
627
2
Power Lost without Ignition Off
435
Yellow
P100
2
100
2
Engine Oil Pressure Sensor Circuit data incorrect
T5-7-16
427
None
QST30
QSK19
QSK60
Water in Fuel Indicator High

Maintenance
QSK45
097
15
QSX15
422
Yellow
DESCRIPTION
QSM11
P097
0
FMI
QSL9
418
WIF /
Maint.
419
Yellow
SPN
QSC
SID(S)
PID(P)
FMI
QSB
FAULT
CODE/
LAMP
X
X
X
X
X
X
441
None
P168
1
168
1
Battery #1 Voltage Low - Warning
442
Yellow
P168
0
168
16
Battery #1 Voltage High - Warning
442
Yellow
P168
0
168
0
Battery #1 Voltage High - Warning
443
Yellow
S221
4
1043
4

Supply Voltage Circuit - shorted low
444
Yellow
S232
1
620
18
OEM Sensor Supply Voltage Low Warning
446*
None
N/A
GSP Communication Failure
447*
None
N/A
448*
None
RPC Number Not Supported
N/A
RPC Argument Mismatch
DESCRIPTION
QST30
QSK60
QSK45
QSX15
Battery #1 Voltage Low - Warning
QSM11
168
18
QSL9
P168
1
QSC
441
Yellow
FMI
QSB
SID(S)
PID(P)
FMI
QSK19
SPN
FAULT
CODE/
LAMP
X
X
X
X
449
Yellow
P094
0
094
16
Fuel Pressure High - Warning
451
Yellow
P157
3
157
3
Injector Metering Rail #1 Pressure

451
Red
P157
3
157
3

452
Yellow
P157
4
157
4

452
Red
P157
4
157
4

455
Red
S018
3
633
3
Fuel Control Valve Circuit - shorted

high
466
Yellow
S032
4
1188
4
Turbocharger #1 Wastegate Control

467
Yellow
S020
2
635
2
Timing Rail Actuator Circuit - data

incorrect
T5-7-17
Engine Oil Level Low - Maintenance
471
Maint.
P098
1
98
1
Engine Oil Level Low - Maintenance
472
Maint.
P017
2
1380
2
Engine Oil Level #2 Low

Maintenance
473
Yellow
P017
2
1380
2
Engine Oil Level #2 Low Warning
1318
9
Exhaust Port Temperature Bank

Imbalance
479*
None
094
18
Fuel Pressure Low - Warning
483
Yellow
P129
3
1349
3

484
Yellow
P129
4
1349
4

485
Yellow
P129
0
1349
16

High - Warning
486
Yellow
P129
1
1349
18
Injector Metering Rail #2 Pressure Low

- Warning
487
None
S237
1
626
1
Start Assist Device - Canister Empty

(Ether Injection)
488
Yellow
P105
0
105
16
Intake Manifold Temperature High

Warningl
489
Yellow
P191
1
191
18

Speed Low Warning
489
Yellow
P191
1
191
1

Speed Low Warning
493
S018
1076
Fuel Pump Calibration Trim Circuit
13
13
Error
S221
11
1043
11

(Camshaft) Supply Voltage
T5-7-18
P094
1
482
Yellow
496
Yellow
QSK60
98
17
QSK45
P098
1
QST30
471
Maint.
QSK19
Fuel Rail Actuator Circuit - data

incorrect
QSX15
633
2
QSM11
S018
2
DESCRIPTION
QSL9
468
Yellow
FMI
QSC
SID(S)
PID(P)
FMI
QSB
SPN
FAULT
CODE/
LAMP
X
X
497
Yellow
S114
2
1377
2
Multiple Unit Synchronization Switch

498
Yellow
P098
3
098
3
499
Yellow
P098
4
514
Red
QSK60
X
098
4
Engine Oil Level Sensor circuit

shorted low
S018
7
633
7
Fuel Control Valve - mechanically

stuck
515
Yellow
P091
3
091
3
Accelerator Pedal Frequency Position

Sensor Supply Circuit - shorted high
516
Yellow
P091
4
091
4
Accelerator Pedal Frequency Position

Sensor Supply Circuit - shorted low
517
Yellow
S251
12
1076
12
Fuel Metering Solenoid - bad device
524
Yellow
P113
2
113
2
OEM Alternate Droop Switch

Validation - data incorrect
527
Yellow
P154
3
702
3
Auxiliary Input/Output #2 Circuit shorted high
527
Yellow
S040
3
702
3
528
Yellow
P093
2
093
2
OEM Alternate torque validation switch

- data incorrect
529
Yellow
S051
3
703
3
539
Yellow
S018
11
633
11
Injector Control Valve Electronic Filter

(Transorb) Error
546
Yellow
P094
3
94
3
Fuel Delivery Pressure Sensor Circuit shorted high
547
Yellow
P094
4
94
4
Fuel Delivery Pressure Sensor Circuitshorted low
551
Yellow
S230
4
558
4

551
Red
P091
4
091
4

553
Yellow
P157
0
157
16

High - warning level
T5-7-19
QST30
QSX15
Engine Oil Level Sensor circuit

shorted high
QSL9
QSC
DESCRIPTION
QSB
QSK45
FMI
QSK19
SID(S)
PID(P)
FMI
QSM11
SPN
FAULT
CODE/
LAMP
X
X
X
X
X
X
X
X
QSK60
X
554
Yellow
P157
2
157
2
Fuel Pressure Sensor Error
555
Yellow
P022
0
1264
16
Engine Blowby - Warning Level
555
White
P022
0
1264
0
Engine Blowby - Warning Level
581
Yellow
P015
3
1381
3
Fuel Supply Pump Inlet Pressure

582
Yellow
P015
4
1381
4
Fuel Supply Pump Inlet Pressure

Sensor Circuit shorted low
583
Yellow
P015
1
1381
18
Fuel Supply Pump Inlet Pressure Low warning level
595
Yellow
P103
0
103
16
Turbocharger #1 Speed High - warning

level
596
Yellow
P167
0
167
16
Electrical Charging System Voltage

597
Yellow
P167
1
167
18

Low - Warning Level
598
Red
P167
1
167
1

Low - Critical Level
599
Red
S025
14
640
14
OEM Commanded Dual Output

Shutdown
611
None
S151
11
1383
31
Engine Hot Shutdown
611
None
S151
14
1383
31
Engine Hot Shutdown
612*
Red
99
1
High Lubricating Oil Filter Restriction
616*
None
1173
16
High Turbo Compressor Inlet Temp RB
617*
None
1172
0
High Turbo Compressor Inlet Temp LB
621*
Yellow
1137
18
Low #1 LB Cylinder Power
X
X
T5-7-20
QST30
QSK19
X
QSX15

QSM11
157
0
QSL9
P157
0
DESCRIPTION
QSC
553
Red
FMI
QSB
SID(S)
PID(P)
FMI
QSK45
SPN
FAULT
CODE/
LAMP
SPN
QSK45
QSK60
623*
Yellow
1139
18
624*
Yellow
1140
18
625*
Yellow
1141
18
626*
Yellow
1142
18
627*
Yellow
1143
18
628*
Yellow
1144
18
631*
Yellow
1143 (45)
1145 (60)
18
1329
1
Low #1 RB Cylinder Power
1144 (45)
1146 (60)
18
1329
1
1145 (45)
1147 (60)
18
1329
1
1146 (45)
1148 (60)
18
1329
1
631*
Yellow
632*
Yellow
632*
Yellow
633*
Yellow
633*
Yellow
634*
Yellow
634*
Yellow
T5-7-21
QSX15
QSL9
1138
18
QSC
622*
Yellow
DESCRIPTION
QSB
QST30
FMI
QSK19
SID(S)
PID(P)
FMI
QSM11
FAULT
CODE/
LAMP
QSK60
QST30
QSK19
QSX15
QSM11
DESCRIPTION
QSL9
FMI
QSK45
635*
Yellow
SPN
QSC
SID(S)
PID(P)
FMI
QSB
FAULT
CODE/
LAMP
1147 (45)
1149 (60)
18
1329
1
636*
Yellow
1148 (45)
1150 (60)
18
1329
1
637*
Yellow
1151
18
638*
Yellow
1152
18
641*
Red
1137
0
High #1 LB Cylinder Exhaust

Temperature
642*
Red
1138
0

Temperature
643*
Red
1139
0

Temperature
644*
Red
1140
0

Temperature
645*
Red
1141
0

Temperature
646*
Red
1142
0

Temperature
647*
Red
1143
0

Temperature
648*
Red
1144
0

Temperature
635*
Yellow
636*
Yellow
649
None
S153
0
1378
0
Change Lubricating Oil and Filter
649
White
S153
11
1378
31
T5-7-22
X
X
QST30
QSK45
QSK60
X
651*
Red
657*
Red
1143
1145
0
1144
1146
0
1145
1147
0
1146
1148
0
1147
1149
0
1148
1149
0
1150
0
(30,45)
(60)
High #1 RB Cylinder Exhaust

Temperature
658*
Red
1151
0
652*
Red
(30,45)
(60)

Temperature
653*
Red
(30,45)
(60)

Temperature
654*
Red
(30,45)
(60)

Temperature
655*
Red
(30,45)
(60)

Temperature
656*
Red
(30,45)
(60)

Temperature
659*
None
QSX15
QSL9
QSC
649*
None
DESCRIPTION
QSK19
FMI
QSM11
SPN
SID(S)
PID(P)
FMI
QSB
FAULT
CODE/
LAMP

Temperature

Temperature
Change fuel filter
661*
Yellow
1137
16
High #1 LB Cylinder Power
661*
Yellow
1323
0
662*
Yellow
1138
16
662*
Yellow
1324
0
663*
Yellow
1139
16
T5-7-23
QSK45
QSK60
QST30
QSK19
QSX15
DESCRIPTION
QSM11
FMI
QSL9
SPN
QSC
SID(S)
PID(P)
FMI
QSB
FAULT
CODE/
LAMP
663*
Yellow
1325
0
664*
Yellow
1140
16
664*
Yellow
1326
0
665*
Yellow
1141
16
665*
Yellow
1327
0
666*
Yellow
1142
16
666*
Yellow
1328
0
667*
Yellow
1143
16
668*
Yellow
1144
16
669*
None
Change coolant filter
671*
None
1137
4
Cyl #1 LB Exhaust Temp Sens Failed

Low
672*
None
1138
4

Low
673*
None
1139
4

Low
674*
None
1140
4

Low
675*
None
1141
4

Low
676*
None
1142
4

Low
677*
None
1143
4

Low
678*
None
1144
4

Low
T5-7-24
QSK60
QSK19
QSX15
QSK45
Change Coolant
QST30
679*
None
DESCRIPTION
QSM11
FMI
QSL9
SPN
QSC
SID(S)
PID(P)
FMI
QSB
FAULT
CODE/
LAMP
691*
None
1172
3
LBF Turbo Comp Inlet Temp Sens

Failed High
692*
None
1172
4
LBR Turbo Comp Inlet Temp Sens

Failed Low
694*
None
1173
3
RBF Turbo Comp Inlet Temp Sens

Failed High
695*
None
1174
4
RBR Turbo Comp Inlet Temp Sens

Failed Low
711*
Yellow
1143 (45)
1145 (60)
16
1329
0
High #1 RB Cylinder Power
1144 (45)
1146 (60)
16
1330
0
1145 (45)
1147 (60)
16
1331
0
1146 (45)
1148 (60)
16
1332
0
1147 (45)
1148 (60)
16
1333
0
1148 (45)
1149 (60)
16
711*
Yellow
712*
Yellow
712*
Yellow
713*
Yellow
713*
Yellow
714*
Yellow
714*
Yellow
715*
Yellow
715*
Yellow
716*
Yellow
T5-7-25
QSK60
QSK45
QST30
QSK19
QSX15
DESCRIPTION
QSM11
FMI
QSL9
SPN
QSC
SID(S)
PID(P)
FMI
QSB
FAULT
CODE/
LAMP
716*
Yellow
1334
0
717*
Yellow
1150
0
718*
Yellow
1151
0
1264
3
Crankcase Blowby Pressure

719
Yellow
P022
3
721*
None
727*
None
1143
1145
4
1144
1146
4
1145
1147
4
1146
1148
4
1147
1149
4
1148
1150
4
1151
4
728*
None
722*
None
723*
None
724*
None
725*
None
726*
None
729
Yellow
P022
4
(30,45)
(60)
Cyl #1 RB Exhaust Temp Sens

Failed Low
(30,45)
(60)

Failed Low
(30,45)
(60)

Failed Low
(30,45)
(60)

Failed Low
(30,45)
(60)

Failed Low
(30,45)
(60)

Failed Low

Failed Low
1152
4

Failed Low
1264
4
Crankcase Blowby Pressure

747*
None
Trend Data Memory Nearly Full
748*
None
Trend Data Memory Full
749*
None
Fault Log Snapshot Data Nearly Full
T5-7-26
755
Yellow
Fault Log Snapshot Data Full

P157
7
157
7

Malfunction
QSK60
QST30
QSK19
QSK45
754*
None
Engine Speed/Position #2 - Cam sync

error
QSX15
723
2
DESCRIPTION
QSM11
S064
2
FMI
QSL9
753
None
SPN
QSC
SID(S)
PID(P)
FMI
QSB
FAULT
CODE/
LAMP
756*
None
Change Lubricating Oil Filters
757*
None
Catastrophic Power Loss - ECM Data

Lost
758
Yellow
P129
7
1349
7

Malfunction
772
Yellow
S118
11
1657
11
Needle Movement Sensor Left Bank
773
Yellow
S119
11
1658
11
Needle Movement Sensor Right Bank
768
Yellow
S009
11
923
11
Output Device Driver (VGT or

Transmission shift PWM signal)
777
Yellow
P173
0
1180
0
Turbocharger #1 Turbine Inlet

Temperature High - warning level
779
Yellow
S051
11
703
11
Auxiliary Equipment Sensor Input # 3

(OEM Switch)
951
None
P166
2
166
2
Cylinder Power Imbalance between

cylinders
1000*
None
X
X
Vehicle Controller initiated fault log
2154*
None
611
3
Post-Filter Oil Pressure Sensor CircuitShorted high
2155*
None
611
4
Post-Filter Oil Pressure Sensor CircuitShorted Low

(OEM Pressure Sensor) Engine
Protection Warning
(OEM Switch) Engine Protection Critical
2194
Yellow
P223
11
1387
11
2195
Red
S051
14
703
14
T5-7-27
(Blank)
T5-7-28
TROUBLESHOOTING / Electrical System Inspection

PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect 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 circuit.
2. Color Coding of Wire Harnesses
The color codes of the wire harnesses in the
electrical system are shown in the table on the
light. In some cases, where two colors are indicated for one wire, the left initial stands for the
base color, while the right initial stands for the
marking color.
Code
Color
Red
White
Blue
Green
Yellow
Black
Code
Or
Lg
Br
Gr
Color
Orange
Brown
Pink
Gray
Violet
Light
Green
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.
T5-8-1

3. Precautions for Connecting and Disconnecting
Terminal Connectors
1) When disconnecting harnesses, grasp them by
their connectors. Do not pull on the wire itself. Be
sure to release the lock first before attempting to
separate connectors, if a lock is provided.
2) Water-resistant connectors keep water out so
that if water enters the connector, water will not
easily drain. When checking water-resistant
connectors, take extra care not to allow water to
enter these types of connectors. In case water
should enter this connector, reconnect only after
thoroughly drying the connector.
3) Before connecting terminal connectors, check
that no terminals are bent or missing. In addition,
as most connectors are made of brass, check
that no terminals are corroding.
4) When connecting terminal connectors provided
with a lock, be sure to insert them together until
the lock clicks.
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 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. When the connector size is very
small, and the standard probe size is too large to
be used for testing, wind a fine piece of sharpened wire or a pin around the probe to make the
test easier.
T5-8-2
Correct
Incorrect
T107-07-06-001
Correct
Rust
Bending
Separation
T107-07-06-002
Wind wire around the probe.
Probe
Sharpen the tip of wire.

T107-07-06-003

INSPECTIONS
CONNECTORS
FOR
DISCONNECTING
1. Push the lock to disconnect.

NOTE: 1) Connectors may not be separated if the
lock is pushed while the connectors are
pulled. Be sure to push the lock first
before pulling the connectors.
2) The lock is provided on the female
connector (harness side).
T107-04-05-002
Locations of This Type Connector

Hydraulic Oil Level Switch
Proximity Switch
Washer
Air Conditioner Clutch
Governor Actuator
Monitor Controller
Work Light
Main Pump Delivery Pressure Sensor
Oil Level Switch
Diode
Front All Pressure Sensor
Starter Relay 2
Buzzer Cancel Switch
Air Conditioner
Pressure Switch
Air Conditioner Sensor
Air Compressor
Speaker
Boost Pressure Sensor
Wiper Motor
Travel Pressure Sensor
Heavy Lift Switch
Auto-Lubrication Timer Switch
Air Conditioner Controller
Air Conditioner Unit
Ambient Air Temperature Sensor
ECM Relay
Exhaust Gas Temperature Sensor
Coolant Level Sensor

Data Link
Engine Diagnostic Switch
Key Switch
DC-DC Controller
Room Light
ECM
Engine Speed Sensor
Fuel Sensor
2. Pull to disconnect.
Oil Pressure Sensor
Air Vent Select Servo Motor
Switch Box
Frash Memory
A/M Servo Motor
Radio
Fusible Link
Circulation Servo Motor

Preheat Switch
Power Transistor
Thermo-Guard Switch
Step Light Switch
Sun Exposure Sensor
T107-04-05-004
3. Connector to pull apart

Use a 10 mm wrench to tighten the screw until
the torque mark (convex) appears when
re-tightening.
Screw
Convex

DLU
T107-04-05-005
T5-8-3

FUSE INSPECTION
Fuse failure is often caused by a fine crack in the fuse,
and such fine cracks are very hard to detect by visual
inspection.
Checking fuse continuity with a tester is far superior to
sight inspection.
3. Connect the negative probe to the vehicle ground,

and touch the outside terminal of each fuse with
the positive probe of the tester.
When normal continuity of a fuse is intact, the
tester will indicate 20 to 25 volts.
1. Turn the key switch ON

In doing so, the battery relay is activated by the
current from terminal M of the key switch, and
electric power is supplied to all circuits except the
No.19 fuse circuit and the No.20 fuse circuit.
NOTE: (a) All the inside terminals of the fuses in

the fuse box are connected to the
power source, while the outside
terminals are connected to the
accessories.
Test all fuses using the same method,
except the fuses for the No.19 fuse
circuit and the No.20 fuse circuit.
(b) To check the fuse for the No.19 fuse
circuit and No.20 fuse circuit, turn the
key switch to the START position and
perform the test as described in (3).
2. Remove the fuse box cover and set the correct

voltage measurement range of the tester.
(Measurement range: 0 to 30 V)
No.20 Fuse Circuit
No.19 Fuse Circuit
Accessory (Outside)
Accessory (Outside)
Power Source
(Inside)
T142-06-06-004
T5-8-4

Connection in Fuse Box 1
Fuse No.
Description
Capacity
Connected to
Remarks
Backup
5A
Monitor Controller, DLU
Backup power source,
Controller
5A
Main Controller B
Main power source

Power source ON sig.
Power source
3
Power ON SIG.
5A
Main Controller A, Main Controller B
DC-DC Converter
20 A
DC-DC Converter
Power source
MCX SOL
10 A
Main Controller A, Main Controller B
Power source
Travel Alarm
5A
Travel Alarm (Optional)
Power source
Switch Box
5A
Monitor Controller, Main Controller A
Main power source
Step Light
5A
Step Light Relay
Power source
Power source
Air Conditioner
5A
Air Conditioner
10
BATT
5A
Battery Relay, Battery Relay 2
Power source
11
Light
20 A
Work Light Relay 1, Work Light Relay 2
Power source
12
Wiper
20 A
Washer Relay, Wiper Motor
Power source
13
Air Conditioner
20 A
Power source
14
Solenoid
15 A
Air Conditioner (Heater)

Flow Rate Decrease Solenoid Valve Relay, Power Transistor 1,
Power Transistor 2, Power Transistor 3, Auto-Lubrication Relay,
Solenoid Valve Relay
Power source
15
Radio
5A
Radio, Monitor Controller
Power source
16
Lighter
10 A
Lighter
Power source
17
Room Lamp
5A
Room Lamp
Power source
18
Horn
10 A
Horn Relay
Power source
19
Start Repeating Relay
5A
Starter Relay 1
Power source
20
ECM. ENG. Start, SIG
5A
T18E-01-02-003
20
19
18 17 16 15 14 13 12 11
T18E-05-08-002
10
T5-8-5

Fuse Box 2
T18E-01-02-003
T18E-05-08-001
Connection in Fuse Box 2

Fuse No.
1
Description
ECM Main Power Source
Capacity
20 A
Connected to
Remarks
ECM
Main power source
Preheat Switch
5A
Preheat Relay
5A
Preheat Relay 1
Power source
ECM
Power source
DOWN LOAD PC, Satellite Communication Controller
Power source
ECM
5A
DLU Main Power Source
5A
DOWN LOAD PC
5A
OPT5
20 A
OPT6
20 A
5A
T5-8-6

FUSIBLE LINK INSPECTION
Fusible Link 1 to 4
Pull off the fusible links to visually inspect.
Fusible Link 1 to 4
Fusible Link 5 to 8
Fusible Link 5 to 8
Check continuity between both ends of the fusible

link.
T183-01-02-015
T183-05-08-001
T5-8-7

BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between
the battery positive terminal and the vehicle.
V
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.
Normal Voltage: 26 to 28 V
NOTE: If voltage is abnormal, check the charging
system.
ALTERNATOR CHECK
T142-06-06-002
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.
Terminal R
Terminal B
Generating Voltage Measurement

1. Measure voltages at terminals R and B after
starting the engine.
Specification: Terminal R: More than 21 V
Terminal B: Approx. 28 V
T18E-05-08-004
T5-8-8

(Blank)
T5-8-9

VOLTAGE CHECK
Operate the key switch and the engine control dial as
specified to apply voltage to the point to be measured.
Check if the specified (standard) voltage is obtained at
each point.
Tester Probes:
Black (-) Probe :To vehicle (Grounding)
Red (+) Probe :To the point to be measured.
24 Voltage Circuits
For each 24 voltage circuit, start checking either
from the power source side or the actuator side.
Thereby, the failed part in each circuit can be
located, if any.
Engine
Power Source Circuit
Stopped
Stopped
Stopped
Stopped
Stopped
Starting Circuit
Cranking
Cranking
Cranking
Cranking
Cranking
Cranking
Accessory Circuit
Stopped
Stopped
Stopped
Stopped
Charging Circuit
Running
Running
Running
Running
Surge Voltage
Prevention Circuit
Running-Stopped
Running-Stopped
Key Switch
Check Point
Standard
OFF
OFF
OFF
OFF
OFF
Between (2) and (1): One Battery

Between (3) and (2): One Battery
Between (3) and (1): Two Battery
Between (4) and (E): Power Source
Between (5) and (E): Fusible Link
10 to 12.5 V
10 to 12.5 V
20 to 25 V
20 to 25 V
20 to 25 V
START
START
START
START
START
START
Between (6) and (E) : Key Switch

Between (7) and (E) : Fuse
Between (8) and (E) : Starter Relay 1 (Coil)
Between (9) and (E) : Starter Relay 1 (Switch)
Between (10) and (E): Starter Relay 2 (S)
Between (11) and (E): Starter Motor (C)
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
ACC
ACC
ACC
ACC
Between (12) and (E): Radio

Between (13) and (E): Cigar Lighter
Between (14) and (E): Room Light
Between (15) and (E): Horn
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
ON
ON
ON
ON
Between (16) and (E): Alternator (B)

Between (17) and (E): Battery Relay 1 (B)
Between (18) and (E): Alternator (R)
Between (19) and (E): Monitor Controller
26 to 30 V
20 to 25 V
20 to 25 V
20 to 25 V
ON-OFF
ON-OFF
Between (20) and (E): Load Dump Relay (Coil)

Between (21) and (E): Battery Relay (Coil)
20 to 25 V
20 to 25 V
T5-8-10

Power Circuit
Fuse Box 1
Key Switch
DLU
5
Fusible Link
Battery
Relay 2
Fuse Box 2
Load Damp
Relay
Battery
Battery
Relay 1
Monitor
Controller
3
ECM
Main
Controller B
T18E-02-03-007
T5-8-11

Starting Circuit
Key Switch
Fusible Link 1
Fuse
Box 1
1 Pole
Junction
Battery
Relay 2
Fusible Link 5
Fusible
Link 6
Fusible
Link 7
Battery
Relay 1
Fusible
Link 8
Battery
Fuse
Box 2
Alternator
Starter Relay
Starter Motor 2
Safety Relay 2
10
ECM
Starter Motor 1
Safety Relay 1
11
T5-8-12
T18E-02-03-010

Accessory Circuit
12
13
Fuse
Box 1
Radio
Key Switch
Fusible
Link #1
Cigar
Lighter
Cab
Light
Horn
14
15
Battery Relay 2
Battery Relay 1
Battery
T18E-02-03-009
T5-8-13

Charging Circuit
Key Switch
Fusible Link 1
Fuse Box 1
Fusible Link 2
17
1 pole
Junction
Battery Relay 2
Fusible Link 3
Fusible Link 4
Battery Relay 1
Fusible Link 5
Battery
Fusible
Link 6
Fuse Box 2
Fusible
Link 7
16
Alternator
Fusible Link 8
18
Starter Relay
Air Heater 2
Air Heater 1
19
Monitor
Controller
T18E-02-03-011
T5-8-14

Surge Voltage Prevention Circuit
Key Switch
Fuse
Box 1
Fusible link 1
1 Pole
Junction
Battery Relay 2
Fusible link 3
Battery Relay 1
20
Load
Damp
Relay
Power
Transistor 3
21
Fusible link 5
Battery
Fusible
link 6
Fusible
link 7
Alternator
Fusible link 8
Main
Controller B
Monitor
Controller
Safety Relay 2
Safety Relay 1
T18E-02-03-012
T5-8-15

5-Volt Circuit
Power
Source
1
Voltage between Terminal #1 and Vehicle Frame

Turn the key switch OFF. After disconnecting the
sensor connector, measure the voltage between
machine side harness end connector terminal #1
(5 V power) and the vehicle frame (ground) under
the following conditions.
Signal or Ground
2
Two Polarities
Key Switch: ON
Black Probe (Minus) of Tester: Vehicle Frame
(Ground)
Red Probe (Plus) of Tester:
Terminal #1
T107-07-05-006
When the voltage matches 5 0.5 V, the circuit

up to terminal #1 is normal.
Power
Source Signal Ground
1
3
2
Three Polarities
Voltage between Terminal #1 and Ground Terminal

Turn the key switch OFF. After disconnecting the
sensor connector, measure the voltage between
machine side harness end connector terminal #1
(5 V power) and the ground terminal (terminal #2
for two polarities, terminal #3 for three polarities)
under the following conditions.
T107-07-05-007
Two Polarities
Key Switch: ON
Black Probe (Minus) of Tester: Ground Terminal
(Terminal #2 or #3)
Red Probe (Plus) of Tester: Terminal #1
T107-07-05-008
When the voltage matches 5 0.5 V, the circuit

up to terminal #1 or the ground terminal is normal.
Three Polarities
T107-07-05-009
T5-8-16

CONTINUITY CHECK
Harness
Single-line continuity check

Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is: 0 = Continuity
= Discontinuity
NOTE: When the one end connector is far apart
from the other, connect one end of
connector (A) to the machine chassis
using a clip. Then, check continuity of the
harness through the vehicle frame as
illustrated.
Connect to
the vehicle
frame.
NOTE: By conducting the multi-line continuity

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 = Line (B) - (b) has discontinuity.
= Line (A) - (a) has discontinuity.
Multi-line short-circuit check
Disconnect both end connectors of the harness, and
check continuity between terminals (A) and (B) or
(C).
0 = Short-circuit exists between the lines.
= No short-circuit exists between the lines.
T5-8-17
Single-line short-circuit check

Disconnect both end connectors of the harness and
check continuity between one end connector of the
harness and the vehicle frame:
0 = Short circuit is present.
= No short circuit is present.
Multi-line continuity check
Disconnect both end connectors of the harness, and
short-circuit two terminals, (A) and (B), at one end
connector, as illustrated. Then, check continuity
between terminals (a) and (b) at the other connector.
If the ohm-meter reading is , either line (A) - (a),
or (B) - (b) is in discontinuity. To find out which line is
discontinued, conduct the single line continuity 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)
and (c).
Connect to
the vehicle
frame.
If the ohm-meter reading is: 0 = Continuity

= Discontinuity
Short-circuit
between the
harness and
the vehicle
frame
T107-07-05-003
First short-circuit
A
B
C
a
b
c
Second short-circuit
T107-07-05-004
Short-circuit between harnesses.

A
B
C
a
b
c
T107-07-05-005

(Blank)
T5-8-18
MEMO
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Hitachi Construction Machinery Co. Ltd

Attn: Publications, Marketing & Product Support
Fax: 81-29-831-1162
Hitachi Ref. No.
SERVICE MANUAL REVISION REQUEST FORM

NAME OF COMPANY:
MODEL:
PUBLICATION NO.:
YOUR NAME:
DATE:
FAX:
(Located at the right top corner in the cover page)
PAGE NO.:
(Located at the bottom center in the page. If two or more revisions 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.)
EX1200-5C ELECTRICAL CIRCUIT DIAGRAM (CUMMINS ENGINE SPECIFICATION)
EX1200-5C CONNECTORS
EX1200-5C BACKHOE HYDRAULIC CIRCUIT DIAGRAM
EX1200-5C LOADING SHOVEL HYDRAULIC CIRCUIT DIAGRAM

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INTRODUCTION

to provide technical information needed to maintain

If you have any questions or comments, at if you

The Operators Manual

Operation Manual of the Engine

Information included in the Technical Manual

Information included in the Technical Manual

Information included in the Workshop Manual:

cal Manual (Operational Principle), the Technical

lower part of the page, and each number contains

SAFETY ALERT SYMBOL AND HEADLINE

Indicates a situation which, if not conformed to the

SI Units (International System of Units) are used in

A table for conversion from SI units to other system

Follow recommended precautions and safe operating

UNDERSTAND SIGNAL WORDS

WARNING indicates a potentially hazardous situation

CAUTION indicates a potentially hazardous situation

DANGER or WARNING safety signs are located

Some safety signs dont use any of the designated

CAUTION also calls attention to safety messages in this

To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT indicates

NOTE indicates an additional explanation for an

Safety signs should be installed, maintained and replaced when necessary.

If a safety sign or this manual is damaged or missing,

Allow only trained, qualified, authorized personnel to

Keep your machine in proper working condition.

The safety messages in this SAFETY chapter are in-

tended to illustrate basic safety procedures of machines.

PREPARE FOR EMERGENCIES

To ensure that a fire-extinguisher can be always used

Establish emergency procedure guidelines to cope

Keep emergency numbers for doctors, ambulance

You may need:

Avoid wearing loose clothing, jewelry, or other items

Operating equipment safely requires the full attention of

PROTECT AGAINST NOISE

Wear a suitable hearing protective device such as

walking around it before you start it to avoid personal

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

Refrain from listening to the radio, or using music

Keep all flammable objects and/or explosives away

After using the ashtray, always cover it to extinguish

Dont leave cigarette lighters in the cab. When the

Do not use any controls as handholds.

Be careful of slippery conditions on platforms, steps,

and handrails when leaving the machine.

ADJUST THE OPERATORS SEAT

work at hand may quickly fatigue the operator leading to

The seat should be adjusted whenever changing the

If not, move the seat forward or backward, and check

come injured and/or thrown from the cab. Additionally

Prior to operating the machine, thoroughly examine

Be sure to remain seated with the seat belt securely

We recommend that the seat belt be replaced every

MOVE AND OPERATE MACHINE SAFELY

Always keep the travel alarm and horn in working

Start the engine only from the operators seat.

Do not start engine by shorting across starter terminals.

Before starting the engine, confirm that all control lev-

ers are in neutral.

The operator must be in the operators seat so that

Never use a frozen battery.