TROUBLESHOOTING OF HYDRAULIC AND

MECHANICAL SYSTEM
(H MODE)

Failure mode
Work equipment, travel, swing system
H- 1 Speeds of work equipment, travel, swing are all slow ................... . 20-182
H- 2 There is excessive drop in engine speed, or engine stalls ................ 20-184
H- 3 Work equipment, travel, swing do not move, or speed is extremely slow . 20-186
H- 4 Work equipment, travel, swing lack power ............................. 20-188
H- 5 Power mode selection system does not switch ........................ . 20-188
H- 6 Abnormal noise generated (from around pump) ........................ 20-189
H- 7 Auto-deceleration does not work ..................................... 20-189
Work equipment system
H- 8 Boom, arm speed is extremely slow ................................... 20- 190
H- 9 Work equipment (boom, arm, bucket) speed is slow .................... .. 20- 192
H-l 0 When boom and arm are operated simultaneously, boom is slow ........ . 20- 194
H-l 1 Work equipment (boom, arm, bucket) lacks power ..................... . 20- 194
H-l 2 Excessive hydraul,ic drift ............................................. .. 20- 194
H-13 Excessivetimelag .................................................. . 20-I 96
H-l 4 Does not enter finishing operation mode .............................. 20-I 96
H-l 5 When arm and swing are operated simultaneously, arm is slow .......... 20- 196
Travel system
H-16 When machine is traveling, it deviates naturally to one side
al Deviates in same direction both in forward and reverse . .. 20-I 98
b1 Deviates in different direction in forward and reverse . . 20-200
H-17 Excessive deviation during compound operations .. .... . 20-20 1
H-18 Excessive deviation when starting ...... .... ... .... . 20-202
H-19 Travel lacks power or speed is slow ... .. . ....... . 20-204
H-20 Travel speed does not switch .. . .... . .... ... .... . 20-204
H-21 Machine does not move (one side only) ... ........ .. . 20-205
Swing system
H-22 Doesnotswing ............................................ ....... . . 20-206
H-23 Swing speed is slow or acceleration is poor. .................. ...... 20-208
H-24 Excessive overrun when stopping swing ..................... ...... . 20-209
H-25 Excessive shock when stopping swing ....................... ...... . 20-209
H-26 Excessive abnormal noise when stopping swing .............. ...... . 20-210
H-27 Excessive hydraulic drift of swing ........................... ...... . 20-210
H-28 When operated simultaneously with arm, swing speed is slow . . ...... . 20-210
TABLE OF FAILURE MODES AND CAUSES ............................. ...... . 20-211

20-181
H-l Speeds of work equipment, travel, swing are all slow

* If there are other problems, such as travel deviation or low bucket or swing speed, go to H-l 6.

% 1. If the pressure is not at least 27 kg/cm2, the spool of the acceleration (Hi) end is not fully actuated.
x2. The discharge pressure of the pump has an effect on the TVC valve set pressure, so check it
before adjusting the TVC valve set pressure.

4 YES
v
Is engine speed . When normal relieved:
YES normal when PC200 2150 * 60 rpm
- pump is relieved - PC220 2300 * 60 rpm
with CO canceled?
3
. When CO canceled: NO
PC200 2050 ? 60 rpm PC220 2200 + 60 rpm
YES IS set pressure
* H.0 + H mode
- at Tvcvalve -
. Engine at high idling
normal?
. Arm relief
5 YES

. PC200: 16 ‘; Does condition

2 _ become normal
kg/cm’
+1 ND when TVC Valve
Yl Is relief pressure * pc220: 17_2 is adjusted?
. of F. R Pump - kg/& .,^
normal? NU
. H.0 + H mode
. l-pump relief
- At normal relief: * Engine at high idling
310 - 340 kg/cm’
1 - At 2-stage relief: 6 YES
335 - 365 kg/cm=
- H.0 + H mode DOS condition
Is relief pressure _ become nOrmal _
at charging pump * Engine at high
NO when main relief
normal? idling
valve is adjusted?
%2
* Engine at high NO
idling

. 30 TE kg/cm2

*1

20-182
0
 I CalKX Remedy

Leakage inside Replace pump

Pump assembly

21 See Engine shop manual

Adjust

fl/ Defective TVC valve Replace

4djus.t

Defective main relief Replace

valve

(Go to H-3, Item 3)

20-183
 H-2 There is excessive drop in engine speed, or engine stalls

YES
I
2
When pump is
I
Y, relieved, is Y,
OUtpUt pressure Of
co valve normal?
3
a At normal relief: Does output f Output pres-
Max. 5.5 kg/cm’ pres$ure become sure becomes
a When CO canceled: _ normal when CO normal
Same pressure at NO valve is * Condition also -
TVC press”re adjusted? becomes
* Engine at high idling normal J
. H.0 + H mode * output pres-
suredoes not -
become
normal I

* PCZOO: 16
+1
-2
. set pressure
becomes
YES

.r
kg/cm’ normal

. PC220: 17
+1
_2
. Problem does
4 I L not cnange
kg/cm2
Does condition . Set pressure
* l-pump relief becomes
become normal
* H.0 + H mode
“orma’
* Engine at high 1v”L when TVCvalve --
. Condition also

.
set pressure is
idling adjusted? becomes
i normal 1

Set pressure
does not
become
normal

20-184
0
 Cause Remedy

See Engine shop manual -

Defective adjustment of Adjust

co valve

( Defective CD valve Replace

Defective adjustment of
Adjust
TVC valve

. Defective TVC valve ReplXe

M-3 Work equipment, travel, swing do not move, or speed
is extremely slow

* When there is a big difference from the permissible value.

* Auto-deceleration is normal.
* Mode selection is H.0 and H mode.

YES
3-
Block circuit (1) -
YES (6) in Fig. 1. Is
-charging pump -
relief pressure 4 YES

I
n normal?
_ Is any foreign
material found in
* 30 ‘E kg/cm2 _ oil drained from -
NO charging pump
* Engine at high outlet strainer?
idling
NO

motor.
- Disconnect
gcwernor “lOtOr
Do not move, or connector, and set h
speed is extremely governor lever
to NO INJECTION.

YES
L To I tern 3 above
5

Speed is IS set pressure of

extremely slow - TVCvalve 6 YES
3
normal?
Does condition
become normal ::
. 14 - 17 kg/cm* NO_ when TVC valve
. H.0 + H mode is adjusted? ::
. Engine at high idling
z
NO

Fig. 1 Control circuit

Travel PPC valve

Solenoid valve 4

_Y 9tJ+

R.H. PPC valve

Charging pump
Safety lock valve 5

L.H. PPC valve

205FO5300

20-186
0
 Remedy

Defective charging

Wplace relief
ralve

. Defectwe damper
iPT0)
_ - Defective mm pump
(broken shaft, etc 1

Defective set pressure

Idj ust
of TVC valve

20-187
0
 H-4 Work equipment, travel, swing lack power

* Mode selection is H.0 and H mode.

CaUSe Remedy

3 YE
Defective CO valve
correct or
reDlace

YI Outlet Port Of

solenoid valve’

When digging
2 * See conditions for N
Defective
solenoid
CO cancel
valve
ReplaCe

Y ES Item 4 below.
force is
maximized
4 YE Drop in set pressure of Adjust or
* At travel relief: main relief valve ,ep1ace
335 - 365 kg/cm*
1 . Engine at high ,
idling solenoid valve
Does the problem
cxcur when Defective 2.stage
digging force is Replace
- At travel relief and N relief solenoid valve
maximized, or when digging force
during normal is maximized:
25 - 35 kg/cm’
. During normal
operation: 0 kg/cm’

* It is also possible to hold the solenoid

During normal valve outlet hose by hand to judge. 4djust or
Drop in set pressure
operation 3 of main relief valve .ep1ace
NO

H-5 Power set selection system does not switch

Cause Remedy

1
When TVC valve 1 YES
solenoid is remov- Defective TVC valve ReplaCe

ed, and mode

selection switch is
operated with con-
nector still conne-
cted, does spool . Defective TVC solenoid RePlaCe
of solenoid move? NO

I) Turn starting
switch ON.

20-188
0
H-6 Abnormal noise generated (from around pump)

CaUSe Remedy

Clogged strainer Clean

2

Loose piping clamp Tighten

3
Is problem
removed when
piping between
tank and pump is 4 YE
Defective pump Replace
Is oil level in
hydraulic tank oil is drained, are
any metal wear
particles found? Inspect again
Operate for a time
and watch any Depending on
changes in symptoms changes
in symptoms)

Add hydraulic
Lack of oil
oil

H-7 Auto-deceleration does not work

CaUSe Remedy

t-
1 YES Defective travel shuttle Repair or
Valve reDlaCe
Is hydraulic
pressure at inlet
port of travel -
shuttle valve
normal? Defective PPC shuttle Repair or
valve replace
- 25 - 35 kg/cm’ ND

20-189
 H-8 Boom, arm speed is extremely slow

l Mode selection is H.0 and H mode.

* When the travel, swing, and bucket speeds are normal.

C.WSl2 Remedy

1 YES Defective operation Repair or

of straight-travel valve replaCe

Does travel shuttle

valve spool move -
smoothly?
Defective operation of Repair or
*Valve on top of NO travel shuttle valve replace
control valve

20- 190
0
 H-9 Work equipment (boom, arm, bucket) speed is slow

* When the travel and swing speeds are normal

(However, if there is any travel deviation and the bucket or boom speed is slow when operated indi-
vidually, go first to “H-l 4 When machine is traveling, it deviates naturally to one side”.)
l Mode selection is H.0 and H mode.

3 YES

Is operation of
- boom holding -
valve normal?
NO
. Check movement of
valve with your hand.

4 YES
Is hydraulic
pressure at Outlet
Arm only ] - port of arm half -
I
flow solenoid
valve normal? NO
. F.0 or L.0 mode: 0 kg/cm2
. Normal operation: 25 - 36 kg/cm2
l It is also possible to hold the solenoid valve outlet
hose by hand to judge.
[ Bucket only
J

1
* ;li~b/c-’ 1
* Engine at high

Is hydraulic drift NO
of slow cylinder _
within standard
ValUe?

5
Does hydraulic
drift become
faster when YES
lever is
operated? NO 6

* See TESTING AND

ADJUSTING.
r[ Arm, bucket ]

* For details of the

* 20 cc/min
type of safety
* When relieved NO
valve, see 7 YES
* Engine at high idling
Table 1. 4
II
L[ BoomonlY 1
Is boom holding
valve normal?
H
* Check movement NO
of valve with your
hand.

Table 1 Table of locations and types of safety valves used for

each cylinder
( ) : Setpressure
Cylinder Bottom end (kg/cm2) Head end (kg/cm 2)
Boom Safen/ -suction valve (355) Safety -suction valve (290)

Arm Safety - suction valve (355) Safety valve (355)

Bucket Safety - suction valve (355) Safetv -suction valve (3551

20-192
0
 I Cause Remedy

Repair or
Defective operation of replaCe
control valve spool control valve
(boom) assembly

Defective operation Repair or

of boom holding valve replaCe

Repair or
Defective operation of
replace
control valve spool (arm)
Control valve
assembly

Defective arm half flow

solenoid valve

)I Defective PPC valve

Defective safety (suction)

valve

Defective oil-tightness
of control valve spool

20-193
H-10 When boom and arm are operated simultaneously,
boom is slow.

l When usual operation is normal.

F-i-i
Defective
valve
arm throttle Repair
replaCe
or

H-l 1 Work equipment (boom, arm, bucket) lacks power.

* When the travel and swing speeds are normal.

* Mode selection is H.0 and H mode.

2 YES

H
i I I

YES Is main relief

pressure normal
at travel relief?
i

1
r
-w I
NO

I-
. Engine at high idling
Does this problem
occur when digging
force is maximized, 4 YES
or during normal I 1 I
operation?
YES
3r
power at both
j_ ( During normal head end and
~0 i operation bottom end, or

One end only ]

NO

Table 1 mm

H-l 2 Excessive hydraulic drift

+I Go to H-9, Item 5.

20-l 94
a
 Cause Remedy

Defective operation of
1 CO cancel solenoid ReplaCe

valve

Defective OperatiOn Of
*-stage relief solenoid ReplaCe

Valve

- (Go to H-9, Item 2)

(Go to H-9, Item 5)

Defective safety
Replace
(suction) valve

20-195
H-13 Excessive time lag

* If the work equipment speed is normal (if the speed is slow, go first to H-9, Item 2).

CaUSi? Remedy

Defective operation
Replace
of suction valve
Time lag set

H-14 Does not enter F.0 mode (Half flow functiuon)

CaUSe Remedy

Defective operation
of arm half flow ReplaCe
solenoid valve

H-15 When arm and swing are operated simultaneously, arm

is slow
* If the operation of the auto-deceleration is normal (if the auto-deceleration is defective, go first to
H-7).

C.NSe Remedy

Defective OperatiOn of Repair or

swing priority valve repl.3Ce

20-196
0
H-l 6 When machine is traveling, it deviates naturally to one
side

* When the travel speed is normal.

* Mode selection is H.0 and H mode.

a) Deviates in same direction both in forward and reverse

“I ES

Direction of 41L
YES
deviation . For details, see NO
changes TESTING AND
YES Is OUtpUt preSS”re
ADJUSTING.
- of NC valve
* Fordetails, see normal?
YES
TESTING AND
ADJUSTING. 6-
* When track is rota-
ted freely or during
normal travel, Is differential
-
sensor norma!?

Is main relief the TVC output

pressurenormal? pressure.
* Lever at neutral:
* Lever at neutral:
13 - 19 kg/cm’ No
Max. 5.5 kg/cm’
* Engine at high idling . SeeNore.

1
When pump outle t
hoses are changed
between F and R,
does direction of
deviation change?

10
Are metal particles
YES found in oil
_ drained from final _ YES
drive on side
which deviates? 11 r
p DoesdirectionOf
deviario"
change when
_ leftand
rigil*tmres _
9 NO betwee"
C0"tr.d "he
andIWi".I
joint are
i”tsrchsnged7
YES Does control valve
spool move
smoothly? NO
I I

Direction of
Is output preswre
L deviation does
of PPC valve
NO not change

NO

. 30 ‘g kg/cm2

Note: When the track is rotated freely, if the output pressure of the NC valve is the same as the
output pressure of the TVC valve, both the jet sensor and NC valve are normal.

20-:98
 CCV_lSC? Remedy

Defective adjustment See TESTING

of pump AND
ADJUSTING

Leakage of inside
ReplaCe
pump

Defective operation
Replace
of servo valve

Defective operation Adjust or

of NC valve replace

7 YES Drop in set pressure

Adjust
Does condition of jet sensor relief valve
becc~me normal
when relief valve
of jet sensor is
interchanged or
adjusted? Defective jet sensor Clean or
orifice replaCe
. never operated: NO
Max. 2 kg/cm’
* Engine at high idling

Drop in set pressure Of Adjust or

main relief valve replace

- ’ Defective final Repair or

drive replace

Defective control
Replace
valve body

Defective swivel
Replace
joint

Defective travel Replace motor

rncltor assembly

Defective Operation Of
Replace
COntrOl valve spool

Defective PPC valve Replace

20- 199
 b) Deviates in different direction in forward and reverse (See Fig. 1 I

2 YES Defective swivel

joint packing replace
YES lS OUfpUt pWss”W
, - of PPC valve
__ normal?
Repair or
Is relief pressure - - Defective PPC valve
replace
normal at travel - . 30 ‘E kg/,-+ NO
relief?
a Engine at high idling

. 335 - 365 kg/cm2 ND Drop in set pressure Replace safetv

. Engine at high idlint of travel motor Safety
valve assembly
valve

Location of defective swivel

Fig. 1 joint packing and direction
of deviation in travel

20-200
0
H-l 7 Excessive deviation during compound operations

* If individual travel is normal.

CS_lSC? Remedy

2 YES Defective operation Repair or

of straight-travel valve replaCe

Does spool of
YES travel shuttle
1 - valve mclve
smoothly?
Defective operation of Repair or
Is oil pressure at
- travel shuttle valve repIS
inlet port of travel NO
shuttle valve
normal?

.25 - 36 kg/cm* Defective operation of

NO PPC shuttle valve

* If the pressure in Item 1 is lost, the auto-deceleration also will not work.

*O-$O’
H-l 8 Excessive deviation when starting

* When the travel speed is normal

* If there is also deviation during normal travel, go to “H-l 6 When machine is traveling, it deviates
naturally to one side.”
For deviation during simultaneous operations with the work equipment, go first to “H-l 7 Excessive
deviation during compound operations.”
* Bleed all air completely from the circuit.

\IES 4 YES
Deviates at
full stroke

NO

El
Does machine
deviate at lever
full stroke, or
during fine
control?
. 220mm/20m 6 YES
7
is OUtpUt
YES_ pressure at NC
valve at fast end
normal?
5
Machine deviates Is differential - Control lever at NO
when starting, pressure of jet neutral: Max.5.5 kg/cm=
I regardless of N - - sensor at fast - * Traqk rotating freely: Min. 18 kg/cm*
NO fine control, or side (outside of a Engine at high idling
_ N - Full stroke turn) normal? 7 YES
- ,s”,::99’ lever at

13 - 19 kg/cm2
- Control lever at
full stroke problem reversed?
Max. 2 kg/cm= NO
a Engine at high idling

20-202
0
 Remedy

Defective OperatiOn
of servo valve

Defective control
valve

Defective swivel joint

Defective travel motor

Defective operation of
servo valve

Defective adjustment of
NC valve

Defective jet sensor

relief valve

Defective jet SenSOr

orifice

20-203
H-19 Travel lacks power (or speed is slow)

Ir The mode selection is H.0 and H mode.

* When there is no travel deviation.
* If the main relief pressure has dropped, the work equipment lacks power even for normal work. If
the CO cancel and 2-stage relief valve systems are defective, the work equipment lacks power for
work using the power maximizing function.

Cause Remedy

2 YES Repair or
Defective CO valve
Is hydraulic replace
YES preSS”re at Outlet
- port of co cancel -
solenoid valve
1 Il0rlllal? Defective CO cancel Replace
* See conditions for NO solenoid valve
Is main relief Item 3 below.
pressure at travel -
relief normal?
3 YES Drop in set pressure of 4djust or
At travel relief: Is hydraulic main relief valve replace
335 - 365 kg/cm* pressure at Outlet
Engine at high N& port of 2.stage -
idling relief solenoid
valve normal?
I I I Defective 2.stage relief

1:
replace
. At travel relief and NO solenoid valve
with power
maximized:
25 - 35 kg/cm’
. During normal
operation: 0 kg/cm’

H-20 Travel speed does not switch

* When the travel speed is normal at Hi or Lo.

Remedy

Defective travel motor

1 YES
.Speed change servo Replace motor
Is hydraulic valve ass’v
pressure at
outlet port of -
travel weed
solenoih normal? Defective travel speed
solenoid valve Replace
* At Hi: NO
25 - 35 kg/cm’
At Lo: 0 kg/cm’

20-204
0
H-21 Machine does not move (one side only)

CaUSe
I Remedy

2 YES Repair 0,
Defective final drive
replace
Is any foreign
YES material found in _

I
oil drained from
final drive?
I Travel motcar brake Replace motor
dragging assern b I y
NO
Is main relief
pressure at motor -’
relief normal? .
3 YES Defective travel I Replace safety
. At travel relief: mtxclr safety valve valve
Is hydraulic pressure
325 - 365 kg/cm’ normal at motor
* Engine at high - relief when safety -
idling NO va,ves are
interchanged?
Defective travel Replace motor
. For standard value, NO motor assembly
see Item 1.
 H-22 Does not swing

l When other work equipment and travel speeds are normal

l Mode selection is H.0 and H mode.
* Turn swing lock switch OFF.

YES
4

Is any foreign
YES material found in
oil drained from
swing machinery? 5 YES
3-
Does control
Is hydraulic L valve spool move
NO
YES_ pressure et left smoothly?
and right relief
normal?
2 _ NO

-1Is hydraulic
* .285 - 300 kg/cm2

r H
Does not swing pressure et swing Engine at high
YES
in either brake solenoid NO
idling
direction valve Outlet port
normal?
I
. Lever operated:
25 - 36 kg/cm2 NO
Does not swing in
- Lever at neutral:
either direction, or 0 ka/cm’
in one direction l It is a?so possible to hold the solenoid valve outlet hose by hand to judge.

6 YES
When left and
o”
Does not swing right safety valves
~0 are interchanged, -
I in one direction l- 0”
is problem
reVet?Xd? z
NO
l IS possible to measure
also

the hydraulic pressure to

judge.
* 285 - 300 kg/cm2
- Engine at high idling

20-206
0
 CaLI% Remedy

Repair or
Defective swing machinery rep,ace

Replace motor
Defective motor brake assembly

Defective operation of
control valve spool

Defective swing motor Replace motor

assembly

Defective operation Of
swing brake solenoid Replace

valve

- Defective safety valve Replace

. ‘Defective PPC valve Replace

20-207
H-23 Swing speed is slow or acceleration is poor

+ When other work equipment and travel speeds are normal. (If there is also deviation (to right)
during normal travel, go first to “H-l 6 When machine is traveling, it deviates naturally to one side”.)
* Mode selection is H.0 and H mode.

CaUSe Remedy

Excessive leakage inside

3 YES swing motor, or brake
7ep1ace motor
assembly
dragging
YE Does spool move
smoothly when

2 Defective operation of
NC control Valve spool

YI Both left and

right

4 YES Drop in set pressure of

Adjust
* Must be the same a! co valve
TVC valve outp”f
pressure become normal
I\ when CO valve is
* At relief:
Max. 5.5 kg/cm’
Defective operation Of
. Measure at NC valw
co valve
ReplaCe
For standard value, NC
both left and
see Item 2.
right, or in one
direction only?
6 YES Drop in set pressure of
- Time taken to start Adjust

F[
safety Valve
swing (set) (90’) :
PCZOO: Max. 3.4
sec.
PC220: Max. 3.8
* Time taken for
Defective safety valve qeplace
swing (secK5 turns)
One direction . For standard value, NC
Both PC200 and
only see Item 5.
220: Max. 30 NO
* Engine at high idling

* Is also possible to NO
Defective PPC valve GDlaCe
measure the hydraL c
pressure to judge.
.285- 300 kg/cm2
-Engine at high idling

20-208
0
 H-24 Excessive overrun when stopping swing

* If the speed is slow or the acceleration is poor, go first to H-23.

Cause Remedy

VES [ Both left and Replace motor

L right . Leakage inside motor
assemblv
excessive to both
left and right, or
in onidirection
r One direction Replace or
C Defective safety valve
* Overrun when NO I only adjust
sropp,ngswl~g:
* PC200: 120
* PC220:
-.
160’
- tnguneat nagllldllng

0”
t3 H-25 Excessive shock when stopping swing
S+
* When the swing speed is normal.

C&US= Remedy

Defective Swing
Repair
machinery

Defective swing motor Replace

brake

Is shock excessive . Lever operated: 25 - 36 kg/cm’ NO Defective swing brake Replace

on both left and a Lever et neutral: 0 kg/cm’ solenoid valve
right, or in one *When the swing is operated and the lever
direction only? is returned to neutral, the hydraulic
pressure becomes 0 after approx. 6 sec.

i One direction
OlllY
1 Defective safety valve ReDlaCe
NO J

20-209
0
H-26 Excessive abnormal noise when stopping swing

* When the swing speed is normal.

CaUSe Remedy

2 YES 3efective swing

3epair
nachinery
Is any foreign I

H
YES Both left and material found in
right

1
oil drained from
swing machinery?
1
NO
Defective
Valve
lift check 3ePlXe

on both left and

right, or in one
direction only?
3 YES
Defective safety valve 3ep1ace

L
One direction become normal 1

I
O”lV when safetv
NO
interchanged?
3efective suction valve 3eplace
NO

H-27 Excessive hydraulic drift of swing

CaUSe Remedy

1 YES Defective swing motor Replace motor

brake assem b I v
Is hydraulic
pressure et swing
brake solenoid -
valve Outlet port
normal? Defective swing brake Replace
solenoid valve
. never at neutral: NO
0 kg/cm’
* Lever operated:
25 - 36 kg/cm2

H-28 When operated simultaneously with arm, swing speed

is slow

l When the usual swing speed is normal.

CCdUSe Remedy

Defective operation of Repair or

swing priority valve ,ep1ace

20-210
0