Ex2500-5 Performance Check and Troubleshooting PDF

SECTION 1
OPERATIONAL
PERFORMANCE TEST
CONTENTS

Group 1 Introduction Group 4 Component Test
Operational Performance Tests.........................1 Pilot Primary Pressure ....................................23
Preparation for Performance Tests ...................2 Pilot Secondary Pressure................................24
Main Relief Pressure ......................................26
Group 2 Engine Test Overload Relief Pressure ................................30
Engine Speed ...................................................3 Main Pump Flow Rate Measurement ..............32
Oil Cooler Fan Pump Flow Rate
Group 3 Excavator Test Measurement................................................40
Travel Speed ....................................................5 Swing Motor Drainage.....................................46
Track Revolution Speed ....................................6 Travel Motor Drainage ....................................48
Mistrack............................................................7
Travel Motor Drift Check ...................................8 Group 5 Standard
Swing Speed.....................................................9 Operational Performance
Standard Table ..............................................51
Swing Function Drift........................................ 10
Swing Motor Leakage ..................................... 11
Maximum Swingable Slant Angle .................... 12
Swing Bearing Play......................................... 14
Hydraulic Cylinder Cycle Time ........................ 16
Cylinder Drift................................................... 18
Control Lever Operating Force........................ 19
Control Lever Stroke ....................................... 20
Boom Raise/Swing Combined
Operation Check ........................................... 21
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TEST
Use operational performance test procedure to quan-

titatively check all system and functions on the ma-
chine.
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 machine’s performance to the desired
standard.
3. To economically operate the machine under opti-
mal 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 op-
erational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
“Performance Standard” is shown in tables to evalu-
ate the performance test data.
Precautions for Evaluation of Test Data

1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.
The machine performance does not always deteriorate

as the working hours increase. However, the machine
performance is normally considered to reduce in pro-
portion to the increase of the operation hours. Accord-
ingly, restoring the machine performance by repair,
adjustment, or replacement shall consider the number
of the machine’s working hours.
Definition of “Performance Standard”

1. Operation speed values and dimensions of the
new machine.
2. Operational performance of new components ad-
justed to specifications. Allowable errors will be
indicated as necessary.
1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out

performance tests accurately and safely.
THE MACHINE
1. Repair any defects and damage found, such as oil
or water leaks, loose bolts, cracks and so on, be-
fore starting to test.
TEST AREA AND MEASURING EQUIPMENT

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.
4. Prepare measuring instruments and apparatus
suitable to test requirements.
5. Arrange a test weight or an equivalent heavy ma-
terial.
T105-06-01-003
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among cowork-
ers. Once the test is started, be sure to communi-
cate 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 T105-06-01-004

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.
2
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Performance Test Conditions:

Oil Temperature :50±5 °C
Ground Conditions :Solid, level ground
Measurement:
1. Turn the key switch to the OFF position to stop the
engine.
2. Disconnect the engine speed sensor connector

(Lower side: For EC and MC). Connect the pulse
Engine Speed Sensor
counter harness to engine speed sensor harness.
3. Start the engine, run it at the specified speeds,

and read the pulse counter.
Calculate the engine speed using the following
formula:
-1
Engine speed (min ) = Pulse Number×60/142
Evaluation:
Refer to T4-5 Operational Performance Standard.
T141-04-02-001
3
OPERATIONAL PERFORMANCE TEST / Engine Test
(Blank)
4
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 2 to 3 m (6.5 to 9.8 ft) on both
ends for machine acceleration and deceleration. Track Sag:
3. Empty the bucket and roll in the arm. 465 to 535 mm
(18 to 21 in)
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
T145-05-03-001
Backhoe
Deceleration Zone: Travel Test Distance: Acceleration Zone:

2 to 3 m Finish 20.0 m Start 2 to 3 m T142-05-03-001
(6.5 to 9.8 ft) (65.5 ft) (6.5 to 9.8 ft)
Measurement:
1. Measure travel time at both fast and slow travel Loading Shovel
speeds.
2. Engine Control Lever: Maximum Position
Auto Idle Switch: OFF
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 T145-05-03-006
reverse travel time on the way back to the starting
position in the same method.
6. Repeat steps (3) and (5) three times and calculate
the average values.
Evaluation:
Solution:
Refer to T5-4 Troubleshooting B.
5
TRACK REVOLUTION SPEED
Summary:
Check the overall operational performance of the
travel power system(between the hydraulic pumps
and travel motors) by measuring the track revolution 90 to 110°
cycle time.
Preparation:
1. Equally adjust the track sag on both right and left T142-05-03-011
undercarriages.
Track sag : 465 to 535 mm (18 to 21 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. 90 to 110°
CAUTION: Never work under a machine

raised and solely supported by the boom. T142-05-03-012
Place blocks under the machine frame to

support the machine.
4. Maintain the hydraulic oil temperature at 50±5

°C(122±9 °F).
Measurement:
1. Measure the track rotation time at both fast and
slow travel speeds.
2. Engine Control Lever : Maximum Position
3. Operate the travel control lever of the raised track
Forward
in full forward and reverse.
4. After the track revolution attains to constant speed, Reverse
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 Travel Device T145-05-03-001
procedure.
the average values.
Evaluation:
Solution:
6
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.
T145-05-03-005
Preparation:
1. Equally adjust the track sag on both right and left
undercarriages.
Track sag : 465 to 535 mm (18 to 21 in)
2. Prepare a flat and firm travel test yard 20 m (65.5
ft) long with fringes 2 to 3 m (6.5 to 9.8 ft) on both
ends for machine acceleration and deceleration.
3. Empty the bucket and set the front attachment in
the driving position as illustrated.
(122±9 °F).
T145-05-03-006
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
Deceleration Zone:
stroke. 2 to 3 m
4. Draw a 20 m (65.5 ft) straight line from the travel (6.5 to 9.8 ft)
test start point to the end point as illustrated.
Measure the maximum distance (A) between the
rut and the straight line. Maximum Distance (A)
5. Conduct the measurement in both forward and
20 m (65.5 ft)
reverse travel operation in the same method.
the average values.
Evaluation: Acceleration Zone:

Refer to T4-5 Operational Performance Standard. 2 to 3 m
(6.5 to 9.8 ft)
T115-07-03-005
Solution:
7
TRAVEL MOTOR DRIFT CHECK
Summary:
The travel motor parking brake function and drift are
0.5 to 1.0 m
measured on a specified slope. (20 to 40 in)
Preparation
1. The test slope surface shall be flat with the gradi-
ent of 26.8 % (15°)
2. Put a white line mark on the drive tumbler.
T142-05-03-002
3. With the bucket empty, position the front attach-
ment as follows:
Backhoe: Hold the bucket 0.5 to 1.0 m (20 to 40
in) above the ground with the arm and bucket fully 0.5 to 1.0 m
(20 to 40 in)
rolled in .
Loading Shovel: With the arm and bucket cyl-
inders fully extended, hold the bucket 0.5 to 1.0 m
(20 to 40 in) above the ground.
(122±9 °C). T118-04-03-001
Measurement
1. Climb the slope and return the travel lever to neu-
tral.
2. Stop the engine.
3. After the machine stops, put alignment marks on
the track link or shoe, and the track side frame.
4. After five minutes have passed, measure the dif- Alignment
ference between the marks on the track link or Marks Put on Track
shoe, and the track side frame. Side Frame and Shoe
When Machine Stops.
Difference after 5
Evaluation Minutes.
T105-06-03-006
8
SWING SPEED
Summary:
swing power system (between the hydraulic
pumps and swing motors) by measuring time
required for the machine upperstructure to make
three complete turns.
Preparation:
T145-05-03-007
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: T145-05-03-008
With the arm cylinder fully extended and the
(122±9 °F).
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: 3 Revolutions
2. Operate the swing control lever at full stroke.
3. After the swing attains to constant speed,
measure the time required for the upperstructure
to rotate three times.
4. Measure in both directions (clockwise and
counterclockwise).
the average values.
Evaluation: T145-05-03-009
Solution:
9
SWING FUNCTION DRIFT
Summary
1. Use the swing drift (measured on the circumfer-
ence of the swing bearing) when stopping after a
180° full-speed swing, to evaluate the swing brake
valve performance.
NOTE: The swing motor is equipped with a swing
parking mechanical brake.
Preparation: T145-05-03-007
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
Loading shovel:
With the arm cylinder fully extended and the T145-05-03-008

4. Put aligning marks on the outer circumference of
the swing bearing and the track frame.
5. Swing the upperstructure 180°.
(122±9 °F).
Return the
make sure that the area is clear and that swing control
coworkers are out of the swing area before lever to the
starting the measurement. neutral position.
Measurement:
Drift
Auto Idle Switch: OFF Amount
2. Operate the swing lever full stroke. When the up-
perstructure rotates 180° back to the original po-
sition (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 Rotate 180 °
the average values.
Evaluation:
Solution: T142-05-03-003
10
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. Load bucket fully. In lieu of loading the bucket,
weight (W) of the follwing specification can be
used.
W = 21800 kg (48060 lb): Backhoe
21000 kg (46300 lb): Loading Shovel
3. Position the front attachment as described in the
following.
Loading shovel: With the arm cylinder fully T142-05-03-004
extended and the bucket cylinders fully extended,
position the arm top pin height flush with the boom
foot pin height.
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.
4. Park the machine on a smooth slope with a
gradient of 26.8 % (15°),
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.
(122±9 °F).
Measurement:
1. Stop the engine. After five minutes, measure the
difference between the marks along the swing Measure Difference Between Marks
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: Marking on the Track Frame

Marking on the Swing Bearing
Solution: T105-06-03-010
11
MAXIMUM SWINGABLE SLANT ANGLE
Summary:
1. With the upperstructure swung 90° to the slope,
check the maximum slant angle on which the
upperstructure can swing to the uphill side.
Preparation:
1. Check that the swing gear and bearing are well
lubricated.
2. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
W = 21800 kg (48060 lb): Backhoe
21000 kg (46300 lb): Loading Shovel
following.
Loading shovel: With the arm cylinder fully
extended and the bucket cylinders fully extended, T142-05-03-004
position the arm top pin height flush with the boom
foot pin height.
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.
4. Climb a slope and swing the upperstructure 90° to
the slope.
(122±9 °F).
Measurement:
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 slant
angle. Then, repeat the test until the maximum
swingable angle is obtained. Check in both clock-
wise and counterclockwise directions.
5. Perform the measurement three times in each
direction and calculate the average values.
Evaluation:
Solution:
12
(Blank)
13
SWING BEARING PLAY
Summary:
1. Measure the play between the outer and inner
races of the swing bearing to check wear on the
bearing races and balls.
Preparation:
1. Confirm that the swing bearing mounting bolts are
securely tightened.
2. Confirm that the swing bearing is well lubricated
Dial Gauge
and rotates smoothly with no noise.
3. Attach a dial gauge on the track frame using a
magnetic base.
Magnet
4. Position the upperstructure so that the boom and Base
bucket center line aligns with that of the track and
face toward the front idlers. T105-06-03-015
5. Position the dial gauge so that its needle point

comes into contact with the bottom face of the
swing bearing outer race.
6. Empty the bucket.
14
Measurement:
1. Take measurements of the play at positions A, B,
C, and D.
following. A
Backhoe: D B
With the arm cylinders fully retracted and the Measure the plays at
bucket cylinders fully extended, position the arm positions A, B, C and
C D.
top pin height is flush with the boom foot pin
height.
Loading shovel:
With the arm cylinder fully extended and the
top pin height is flush with the boom foot pin
height.
3. 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
T145-05-03-023
Evaluation:
Refer to the Performance Standard Table in Group
T4-5.
Backhoe Front
Measurement : (h1 ) Measurement : (h2 )
T142-05-03-006
Loading Shovel Front

Measurement : (h1 ) Measurement : (h2 )
T142-05-03-005
15
HYDRAULIC CYLINDER CYCLE TIME
Summary:
front attachment hydraulic system (between the Backhoe
hydraulic pumps and each cylinder) by measuring
the cycle time of the boom, arm, bucket, and
bucket dump (open/close) cylinders with the Boom Cylinder
bucket emptied.
Preparation:
(122±9 °F). T145-05-03-012

following.
• Backhoe
Boom Cylinder:
With the bucket cylinder fully extended and the Arm Cylinder
arm cylinder fully retracted, lower the bucket to
the ground. T118-04-03-003
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
Bucket Cylinder:
Adjust the boom and arm cylinder so that the T145-05-03-014
center of full stroke movement of the bucket is

Loading Shovel
positioned vertically.
• Loading Shovel
Boom Cylinder:
With the bucket cylinder and the arm cylinder fully Boom Cylinder
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 T145-05-03-015
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
Arm Cylinder
position, adjust the boom cylinder stroke so that
bucket bottom height is approx. 1 m (39 in) above T145-05-03-016
the ground.
Bucket Dump (Open-Close) Cylinder:
With the bucket cylinder and arm cylinder fully
extended, adjust the boom cylinder stroke so that
Bucket Cylinder
the bucket bottom height approx. 1 m (39 in)
above the ground. T145-05-03-017
Dump Cylinder
T145-05-03-018
16
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.)
(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) 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
(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
(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
calculate the average values.
Evaluation:
Remedy:
Refer to the T5-4 Troubleshooting B.
17
CYLINDER DRIFT
Summary:
1. Evaluate the internal oil leakage in the control
valve, boom, arm, and bucket cylinders by
measuring cylinder (dig function) drift with the
bucket loaded.
NOTE: When checking soon after cylinder T145-05-03-020

replacement, move to full stroke each
cylinder to purge air trapped in the
cylinders.
Preparation:
Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
W = 21800 kg (48060 lb): Backhoe
21000 kg (46300 lb): Loading Shovel T145-05-03-021

following. BH: Boom and Bucket Cylinders Retraction
LD: Boom, Arm and Bucket Cylinders Retraction
Backhoe:
With the arm cylinder with rod approx.50 mm (2 Mark Mark
in) extended from the fully retracted position, and
bucket cylinder with the rod approx. 50 mm (2 in)
retracted from the fully extended position.
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.
3. Maintain the hydraulic oil temperature at 50±5 °C T110-06-03-002
(122±9 °F).
BH: Arm Cylinder Extension
Measurement:
1. Stop the engine.
2. After five minutes have passed, measure the re-
tractions of the boom, arm, and bucket cylinders
as illustrated
Mark
3. Repeat step (2) three times and calculate the
average values.
Evaluation:
Solution:
Refer to T5-4 Troubleshooting B. T110-06-03-001
NOTE: BH: Backhoe

LD: Loading Shovel
18
CONTROL LEVER OPERATING FORCE
Summary:
1. Measure each control lever stroke play and op-
erating force, and check if it can be moved
smoothly.
2. Measure the maximum operating force for the
front attachment control levers.
3. Measure operating force at each lever grip center.
Preparation:
1. Maintain the hydraulic oil temperature at 50 ± 5 °C
(122 ± 9 °C).
Measurement:
1. Measure all control levers.
2. Run the engine at the maximum speed with the
T107-06-03-003
auto-idle switch OFF.

make sure that the area is clear and that co-
workers are out of the swing area before
3. Operate the boom, arm, bucket, and swing levers

full stroke and measure the required maximum
operating force.
4. When measuring the travel lever, raise the side
track to be measured off the ground by lowering
the bucket. Then, measure the required maximum
operating force. T107-06-03-004
5. Repeat each measurement three times and cal-
culate the average values.
Evaluation:
19
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:
(122 ± 9 °F).
Measurement:
1. Stop the engine.
2. Measure the boom, arm, bucket, swing travel T107-06-03-005
levers full stroke from the neutral position at the

lever grip top center.
3. Measure the stroke straight from the neutral posi-
tion to the stroke end.
Evaluation:
20
BOOM RAISE/SWING COMBINED OP-
ERATION CHECK
Summary:
1. Check the combined operation performance while
operating the boom raise and swing simultane-
ously.
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.
(122 ± 9 °F).
CAUTION: Prevent personal injury. Always 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:
T142-05-03-010
21
(Blank)
22
OPERATIONAL PERFORMANCE TEST / Component Test
PILOT PRIMARY PRESSURE
Preparation
1. Stop the engine.
CAUTION: The breather cap may pop off if

turned quickly. Slowly turn it to release
internal pressure before removing it.
2. Release air from the hydraulic oil tank by loosen

the air breather cap.
: 4 mm
Pilot Filter
3. Disconnect the output hose (1⋅1/16-12 UNF-2B)
from the pilot filter, then install the pressure gauge
at the disconncted port in the pilot filter.
: 36 mm
4. Start the engine and check for oil leakage from

the connections.

Output Hose
(122±9 °F).
Measurement
1. Measure the primary pilot pressure in both the fast T117-05-04-001
idle and the slow idle.
2. Repeat step (1) three times and calculate the

average values.
Evaluation
23
PILOT SECONDARY PRESSURE
Preparation Measurement
1. Stop the engine.
CAUTION: Before measuring, check that the-
re are no obstacles or personnel within the
CAUTION: The breather cap may pop off if swing radius. When measuring the boom
turned quickly. Slowly turn it to release lower pilot pressure, raise the machine off
internal pressure before removing it. the ground while paying attention not to al-
low the base machine (counterweight) to con-
2. Release air from the hydraulic oil tank by loosen tact with the ground. Be careful not to tip
the air breather cap. over due to a loss of balance.
: 4 mm 1. Select the following switch / lever positions:

Engine speed control lever: Fast and slow Idle
3. Install the tee (ST 6450) between the pilot piping Auto-idle switch: OFF
and the shuttle valve of the function to be tested.
Install the pressure gauge on the tee. 2. Slowly operate the lever to be tested full stroke.
: 22 mm 3. Repeat step (2) three times and calculate the

average values.
the connections. Evaluation
(122±9 °F). Reference
If not OK, measure the pilot primary pressure. If
primary pressure is OK, the pilot valve is faulty.
Shuttle Valve 1 Shuttle Valve 4 T141-05-02-001
Shuttle Valve 2 Shuttle Valve 3
24
Shuttle Valve 1
Loading Shovel: Backhoe:
T117-06-02-021
1 2
1 2 3 4
T117-06-02-013
Shuttle Valve 2
Backhoe:
Loading Shovel:
T117-06-02-015
5 6 3 4 5 6
T117-06-02-014
Shuttle Valve 3
Loading Shovel
1 - Bucket Tilt-In 8 - Left Travel Forward
2 - Bucket Tilt-Out 9 - Right Travel Reverse
3 - Boom Raise 10 - Right Travel Forward
4 - Boom Lower 11 - Bucket Close
5 - Arm Retract 12 - Bucket Open
6 - Arm Extend 13 - Right Swing
7 - Left Travel Reverse 14 - Left Swing
7 8 9 10 T117-06-02-015 Backhoe
1 - Arm Roll-Out 8- Left Travel Forward
2 - Bucket Roll-Out 9- Right Travel Reverse
3 - Boom Raise 10 - Right Travel Forward
Shuttle Valve 4 4 - Boom Lower 11 - Auxiliary
5 - Arm Roll-In 12 - Auxiliary
6 - Bucket Roll-In 13 - Right Swing
7 - Left Travel Reverse 14 - Left Swing
11 12 13 14 T117-06-02-015
25
MAIN RELIEF PRESSURE
Preparation
1. Stop the engine.

2. Release air from the hydraulic oil tank by loosen 2

the air breather cap. 1
: 4 mm
3. Install the pressure gauge in the gauge port 4

located on top of the high pressure strainer, as
3
illustrated .
: 6 mm 6
5
the connections.

(122±9 °F).
Measurement
1. Select the following switch / lever positions:
Engine speed control lever : Fast Idle
Auto-idle switch : OFF
T117-05-04-007
Connection of the high pressure strainer
2. Slowly operate each control lever of boom, arm
and bucket functions at full stroke end over relief High Pressure
and measure the pressure. Main Ponp Control Valve
Strainer
3. Repeat step (2) three times and calculate the 1 1

Center
average value. 2 2
3 3
Evaluation Right
Refer to T4-5 Operational Performance Standard. 4 4
5 5
Reference Left
If any one of the measured pressures is lower than 6 6
the others, it indicates that the overload relief valve
of that circuit is lower than the main relief pressure
setting.
26
Main Relief Valve Adjustment
1. Loosen the lock nut .

Lock Nut
: 17 mm
2. Adjust main relief pressure by turning the

adjusting screw. The table below shows changes
in pressure obtained by turning the screw. Refer to
it when adjusting the pressure.
: 6 mm
Adjusting
Screw
3. Retighten the lock nut.
T145-02-03-001
: 17 mm
: 27.5 to 31.4 N⋅m
(2.8 to 3.2 kgf⋅m, 20 to23 lbf⋅ft)
4. Recheck the relief pressure settings.

Lock Nut
Adjusting Screw
NOTE: Change in pressure setting
Adjusting Screw Turns 1/4 1/2 3/4 1
Set MPa 4.5 8.9 13.4 17.8
2
Pressure kgf/cm 45.3 90.5 135.8 181
Change psi 645 1285 1930 2535
Pressure Pressure
Increase Decrease
W107-02-05-129
27
Swing Relief Valve Set Pressure Adjustment
Procedure Swing Relief Valve
1. Loosen the lock nut.

: 41 mm
2. Turn the adjusting screw to adjust the pressure

setting.
: 27 mm
M144-07-012

Lock Nut Adjusting
: 41 mm Screw
: 19.5 to 29.5 N⋅m
(2 to 3 kgf⋅m, 15 to 22 lbf⋅ft)
4. Recheck the relief pressure setting.
T117-02-02-004

Adjusting Screw
Set MPa 2.5 5.0 7.5 10.0
2
Pressure kgf/cm 25.5 51 76.5 102
Change psi 363 725 1088 1450
Pressure Pressure
Increase Decrease
T157-05-04-023
28
Travel Relief Valve Adjustment
2. Adjust travel relief pressure by turning the

adjusting screw.
: 6 mm
3. Tighten the lock nut.
: 17 mm Travel Relief Valve

: 33 to 44 N⋅m
(35 to 45 kgf⋅m, 25 to 33 lbf⋅ft)
T115-03-02-006
4. Recheck the travel relief pressure. Lock Nut
Adjusting
Screw
T145-05-04-004

Adjusting Screw Turns 1/4 1/2 3/4 1 Lock Nut
Set MPa 1.96 3.92 5.88 7.85 Adjusting Screw
2
Pressure kgf/cm 20 40 60 80
Change psi 280 570 850 1140
Pressure Pressure
Increase Decrease
W107-02-05-129
29
OVERLOAD RELIEF PRESSURE
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 over-
load 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 ad-
dition, 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 al-
ways increased more than the overload relief
valve set-pressure as the adjustable upper limit of
the main relief valve set-pressure is provided. Ac-
cordingly, the overload relief valve assembly
should be removed from the machine and check-
ed 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 pas-
sage. 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:
Refer to the Measurement Main Relief Valve.
30
Overload Relief Valve Adjustment
If necessary, loosen the lock nut and adjust pressure

with the adjusting screw. Lock Nut
NOTE: In principle, use the test equipment to

adjust the overload relief valve.
: 17 mm
Adjusting
2. Adjust main relief pressure by turning the Screw
adjusting screw. The table below shows changes
in pressure obtained by turning the screw. Refer to T145-02-03-001
it when adjusting the pressure.
: 6 mm
: 17 mm
: 27.5 to 31.4 N⋅m
(2.8 to 3.2 kgf⋅m, 20 to23 lbf⋅ft)
Lock Nut
Adjusting Screw
4. Recheck the travel relief pressure.

Pressure Pressure
Set MPa 5.3 10.6 15.9 21.2 Increase Decrease
2
Pressure kgf/cm 54 108 162 216
Change psi 770 1535 2305 3070 W107-02-05-129
31
MAIN PUMP FLOW RATE MEASUREMENT
• P-Q Line (Torque Adjustment) 4. Purge air from the main pump.
5. Disconnect pipe from ports (Psv and Pi). Install
Summary: tee (2) on port Psv of the regulator, then install
In order to check performance of the main pump, hose (1) and hose (3) of Psv circuit to tee (2).
measure the main pump flow rate by connecting a Connect additional hose (1) to the tee (2).
hydraulic tester to the delivery hose of the main Connect the hose (1) and elbow (4) to port (Pi).
pump. Install plug to the disconnected end of hose (Pi).
Connecting pump servo assist pressure (Psv) cir-
Measurement Preparation: cuit to port Pi allows the pump to be operated by
1. Stop the engine. supplying the maximum Pi pressure with the con-
2. Release air from the hydraulic oil tank by trol lever operated full stroke.
loosening the air breather cap at the oil supply 6. Disconnect connectors from EHC valve and pow-
port on the hydraulic oil tank. er reduction solenoid valve.
7. Connect the pulse meter to the engine speed
: 4 mm sensor.
8. Fully open the loading valve of the hydraulic
tester.
CAUTION: CAUTION:The air breather cap
9. Start the engine and check the line connection for
may pop off if turned quickly. Slowly turn it to
leakage.
release internal pressure before removing it.
3. Connect a hydraulic tester and pressure gauge to
the delivery hose. Necessary components and
parts are as follows:
• Pressure gauge
• Hydraulic tester
• Pressure gauge assembly (ST 6934)
• Test hose (Inlet)
• Test hose (Outlet)
• Pipe
• Flange
• Split flange
Psv
(Port Size: PF1/4) 1 2 3
Pi Psv
Pi
Psv 4 (Port Size: PF1/4)
T118-04-04-009
32
Measurement:
1. Measure the maximum flow rate.
2. Auto-idle switch : OFF
Engine speed control lever : Fast Idle
3. Measure the pump flow rate and engine speed at
the pressure (referring to the table below) while
gradually throttling the loading valve of the
hydraulic tester.
4. Measure each pressure three times and take the
average as the measured figure.
Evolution:
Connect the measurement results to the date of the
pump with the specked speed.
QC : Converted Flow Rate
Q : Measured Flow Rate
I : Pump Speed Ratio (0.86)
-1
Np : Pump Specified Speed (1547 min )
Ne : Measured Engine Speed
Pulse Number Np
Ne= 2.36 QC= i×Ne ×Q
33
Main Pump (1 to 4) P-Q Diagram (Standard) Main Pump (1 and 3) P-Q Diagram (Power Decrease)
P (Pressure) Q (Flow Rate) P (Pressure) Q (Flow Rate)
2 2
4.9 Mpa (50 kgf/cm ) 376 L/min 9.8 Mpa (100 kgf/cm ) 363 L/min
2 2
2 2
2 2
2 2
2
29.4 Mpa (300 kgf/cm ) 213 L/min
Main Pump (1 to 4) P-Q Diagram (Power Increase)
P (Pressure) Q (Flow Rate)
2
2 24.5 Mpa (250 kgf/cm ) 307 L/min
NOTE: 1 kgf/cm =14,220 psi 2
29.4 Mpa (300 kgf/cm ) 247 L/min
(Flow Rate)
(Pressure)
T141-04-04-005
34
Main Pump (5 to 6) P-Q Diagram (Standard) Main Pump (5) P-Q Diagram (Power Decrease)
P (Pressure) Q (Flow Rate) P (Pressure) Q (Flow Rate)
2 2
2 2
2 2
2 2
2 2
2
29.4 Mpa (300 kgf/cm ) 213 L/min
Main Pump (5 to 6) P-Q Diagram (Power Increase)
P (Pressure) Q (Flow Rate)
2
2 24.5 Mpa (250 kgf/cm ) 308 L/min
NOTE: 1 kgf/cm =14,220 psi 2
29.4 Mpa (300 kgf/cm ) 247 L/min
(Flow Rate)
(Pressure)
T141-04-04-006
35
• Pi-Q Control by Pump Pilot Pressure Signal
(Pilot Pressure Characteristics)
Summary: Measurement:
In order to check performance of the main pump, 1. Measure the main pump flow rate controlled by
measure the main pump flow rate by connecting a the pump control pilot pressure signal.
hydraulic tester to the delivery hose of the main
pump. 2. Turn the auto-idle switch is OFF position. Operate
the engine control lever to fast idle position.
Preparation:
1. Refer to steps 1 to 3 on page T4-4-10, connect a 3. Adjust the reducing valve (8) set pressure to the
portable tester to the main pump to be measured. specified pressure shown on the P-Q diagram of
the main pump (Pilot Pressure Characteristics).
2. Disconnect hose from regulator port Pi, and at- Measure the flow rate and engine speed at each
tach plug in the disconnected hose. specified pressure shown on the P-Q diagram.
Connect hose (5) on regulator port Pi.
4. Repeat the measurement three times and calcu-
3. Connect adapters (6)(2 used) and adapter (10) to late the average values.
reducing valve (8).
Remove plug (1) located on the manifold. Con- Evolution:
nect adapter (4) to the removed plug port. Con- Convert the measurement results to the flow rate at
nect hose (7) between adapter (4) and adapter (6) the specified pump speed by the following formulas:
to port P1 on reducing valve (8). Ne = Pulse Number (Hz) × 60/149
: 19 mm : 6 mm QC = (Np × Q)/(i × Ne)
Where:
4. Connect tee (9) to port P2 on reducing valve (8). QC : Converted Flow Rate
Connect pressure gauge (3) and hose (5) to tee Q : Measured Flow Rate
-1
(9). Np : Specified Pump Speed (1547 min )
: 19 mm i : Pump Drive Gear Speed Ratio (0.86)
Ne : Measure Engine Speed
5. Connect hose (5) to port T on reducing valve (8).
Remove Plug (2) from hydraulic oil tank, and con- Pi-Q Diagram
nect adapter (10) and hose (11) to the removed Flow Rate Control
Flow Rate Remarks
plug (2) hole. Pressure
: 19 mm. 22 mm 1.3 MPa 100 L/min Main Pump
A 2
(13.4 kgf/cm ) (26 US gal/min) 1 to 6
6. Purge air from the main pump. 2.6 MPa 375 L/min Main Pump
B 2
(27 kgf/cm ) (99 US gal/min) 1 to 4
7. Fully open the loading valve on the portable tester. 2.9 MPa 425 L/min Main Pump
B’ 2
(29.5 kgf/cm ) (112 US gal/min) 5 and 6
8. Start the engine. Check the pressure gauge con-
2
nection for any oil leakage. NOTE: 1 kgf/cm =14,220 psi
B’
400
B
300
Q(Flow Rate)
L/min
200
A
100
0 10 20 30
Pi (Flow Rate Control Pressure)
kgf/cm 2
36
Main Pump: Pump Control Panel:
Regulator Pi
Manifold
Pi T141-04-04-004
Hydraulic Oil Tank: 2
T141-04-04-003
T117-05-04-010
Reducing Valve
Port Position To Hydraulic Oil Tank
Reducing Plug (2) Hole
Valve (8)
10
3
P1 P2 11
10
5
To Regulator To Manifold
Port Pi Plug (1) Hole
9 6 8 6 7 4
T118-04-04-014
1 - Plug PF1/4 4 - Adapter UNF7/16×PF1/4 7 - Hose UNF7/16×UNF7/16 10 - Adapter PF3/8×PF3/8

(4042037) (4042031)
2 - Plug PF3/8 5 - Hose UNF7/16×UNF7/16 8 - Reducing Valve (4325439) 11 - Hose PF3/8×PF3/8
(ST6961)
3 - Pressure Gauge 6 - Adapter PF3/8×UNF7/16 9 - Tee UNF7/16×UNF7/16
(ST 6931) (4200465) ×PF1/4 (ST 6451)
37
Adjustment of Maximum and Minimum Flow Rate
The pump flow rate can be adjusted by changing the : 30 mm : Nut (1), Nut (3)
maximum servo piston stroke. When adjusting the : 13 mm : Screw (2)
maximum flow rate, loosen nut (1) and adjust screw : 10 mm : Screw (4)
(2) on the servo piston large chamber side. When
adjusting the minimum flow rate, loosen nut (3) and
adjust screw (4) on the servo piston small chamber.
NOTE: Turning screw (2) clockwise decreases the

maximum flow rate, and turning counter-
clockwise increase. 1/4 turn of screw (2)
changes the flow rate approx. 7.9 L/min.
Turning screw (4) clockwise increase the
minimum flow rate, and turning counter-
clockwise decreases. 1/4 turn of screw (4)
4 3 1 2 2 1 3 4
T141-04-04-004
(Pump Flow Maximum Flow Rate Adjustment (Pump Flow

Minimum Flow Rate Adjustment
Rate) Rate)
Q Q
Pi (Flow Rate Pi (Flow Rate

Contrl Pressure) Contrl Pressure)
38
Adjustment for Torque Constant Control
The torque constant control is performed by pump NOTE: When adjusting screw (4) is turned, inner
delivery pressure Pd . Therefore, the torque constant spring (2) set-force varies. Therefore, when
control is adjusted by changing the set-force of inner adjusting screw (4) is turned, turn adjusting
spring (2) and outer spring (1). screw (6) 2.17 times the turns of adjusting
(Before adjust the screws (4) and (6), mark the end of screw (4) in the opposite direction to keep
the adjusting screw with a white marker for the record inner spring (2) set-force unchanged.
of the original position.)
When resetting inner spring (2), loosen nut (5) and : 36 mm : Nut (3)
adjust screw (6). : 24 mm : Screw (4)
When resetting outer spring (1), loosen nut (3) and : 13 mm : Nut (5)
adjust screw (4). : 4 mm : Screw (6)
1 2
3
4
5
6
T117-05-04-005
Outer Spring Adjustment Date Inner Spring Adjustment Date

Adjusting Screw Turn 1/4 Adjusting Screw Turn 1/4
Flow Rate Change 35.4 L/min Flow Rate Change 16.3 L/min
(9.35 US gal/min) (3.59 US gal/min)
Pressure Change 1.7 Mpa Pressure Change 1.8 Mpa
(17.8 kgf/cm2, 253 psi) (18.4 kgf/cm 2, 262 psi)
Engine Torque Change 74.5 N⋅m Engine Torque Change 49.8 N⋅m
(7.6 kgf⋅m, 55 lbf⋅ft) (5.08 kgf⋅m, 36.7 lbf⋅ft)
(Pump Flow (Pump Flow
Rate) Q Rate) Q
Pd (Pump Delivery Pd (Pump Delivery

Pressure) Pressure)
39
OIL COOLER FAN PUMP FLOW RATE
MEASUREMENT
• Hydraulic P-Q Control (Torque Adjustment)
Summary
A hydraulic tester to measure the oil cooler pump flow
rate is installed on the oil cooler fan pump delivery
hose to check pump performance.
Preparation
1. Stop the engine. 4. Purge air from the oil cooler fan pump.
5. Disconnect fan motor solenoid valve both side
CAUTION: Do not quickly loosen the cap on
connectors.
the hydraulic oil tank. The cap may fly off due
to internal pressure. Always turn the cap NOTE: Both connectors on the fan motor solenoid
slowly to release any remaining pressure be- valve are the same in form Mark them be-
fore removing it. fore disconnecting to help when reassem-
2. Release air pressure from the hydraulic oil tank. bling.
: 4 mm 6. Connect a pulse meter to the engine speed sen-
3. Connect a hydraulic tester and pressure gauge to sor.
the delivery hose. Necessary components and 7. Fully open the loading valve of the hydraulic
parts are as follows: tester.
• Pressure Gauge 8. Start engine and check for oil leaks.
• Hydraulic Tester
• Pressure Gauge Assembly (ST 6934)
• Test Hose (Inlet)
• Test Hose (Outlet)
• Pipe
• Flange
• Split Flange
Pump Control Valve
Fan Motor Solenoid Valve
T117-05-04-010
40
Measurement:
1. Measure the maximum flow rate.
2. Auto-Idle Switch: OFF
3. Engine Control Lever: Fast Idle Position
4. Referring to the table and diagram, measure the
pump flow rate and engine speed while gradually
throttling the loading valve of the hydraulic tester.
Evaluation:
Convert the measurement results to the flow rate at
the specified pump speed by the following formulas:
Ne = Pulse Number (Hz) × 60/149
QC = (Np × Q)/(i × Ne)
Where:
QC : Converted Flow Rate
Q : Measured Flow Rate
-1
Np : Specified Pump Speed (2232 min )
i : Pump Drive Gear Speed Ratio (1.089)
Ne : Measure Engine Speed
P-Q Diagram Data for Oil Cooler Fan Pump

Position Q P
A 196 L/min 18.4 Mpa
(51.9 US gal/min) (188 kgf/cm 2, 2670 psi)
B 173 L/min 18.4 20.6 Mpa
(45.7 US gal/min) (210 kgf/cm 2, 2990 psi)
Q(Flow Rate)
L/min
300
A
200
B
100
0
100 200 300 P(Pressure)
kgf/cm 2
T118-04-04-012
41
• Pi-Q Control by Pump Control Pilot Pressure Signal
(Pilot Pressure Characteristics)
Summary: Measurement:
In order to check performance of the oil cooler fan 1. Measure the oil cooler fan pump flow rate con-
pump, measure the main pump flow rate by connect- trolled by the pump control pilot pressure signal.
ing a hydraulic tester to the delivery hose of the oil
cooler fan pump. 2. Turn the auto-idle switch is OFF position. Operate
the engine control lever to fast idle position.
Preparation:
1. Refer to steps 1 to 3 on page T4-4-18, connect a 3. Adjust the reducing valve (8) set pressure to the
portable tester to the oil cooler fan pump to be specified pressure shown on the P-Q diagram of
measured. the oil cooler fan pump (Pilot Pressure Charac-
teristics).
2. Disconnect hose from regulator port Pi, and at- Measure the flow rate and engine speed at each
tach plug in the disconnected hose. specified pressure shown on the P-Q diagram.
Connect hose (5) on regulator port Pi.
4. Repeat the measurement three times and calcu-
3. Connect adapters (6) (2 used) and adapter (10) to late the average values.
reducing valve (8).
Remove plug located on the manifold. Connect Evolution:
adapter (4) to the removed plug port. Connect Convert the measurement results to the flow rate at
hose (7) between adapter (4) and adapter (6) to the specified pump speed by the following formulas:
port P1 on reducing valve (8). Ne = Pulse Number (Hz) × 60/149
: 19 mm : 6 mm QC = (Np × Q)/(i × Ne)
4. Connect tee (9) to port P2 on reducing valve (8). Where:

Connect pressure gauge (3) and hose (5) to tee QC : Converted Flow Rate
(9). Q : Measured Flow Rate
-1
: 19 mm Np : Specified Pump Speed (2232 min )
i : Pump Drive Gear Speed Ratio (1.089)
5. Connect hose (5) to port T on reducing valve (8). Ne : Measure Engine Speed
Remove plug (2) from hydraulic oil tank, and con-
nect adapter (10) and hose (11) to the removed Pi-Q Diagram
plug (2) hole. Flow Rate Control
Flow Rate
: 19 mm, 22 mm Pressure
0.9±0.2 Mpa 25±3 L/min
A 2
6. Purge air from the main pump. (9±2 kgf/cm , 128±28 psi) (6.6±0.8 US gal/min)
2.46±0.2 MPa 202±3 L/min
B 2
7. Fully open the loading valve on the portable tester. (25.1±2 kgf/cm , 357±28 psi) (53.4±0.8 US gal/min)
8. Start the engine. Check the pressure gauge con-

nection for any oil leakage. B
200
Q (Flow Rate) 150

L/min
100
50 A
0 10 20 30
Pi(Flow Rate Control Pressure)
kgf/cm 2
42
Oil Cooler Fan Pump: Pump Control Panel:
Manifold
Regulator
Pi
T118-05-02-026
Hydraulic Oil Tank: 2

1
T141-04-04-003
T117-05-04-010
Reducing Valve
Port Position To hydraulic oil
tank plug (2) hole
Reducing Valve (8)
10
3
P1 P2 11
10
5
To regulator To manifold
port Pi plug (1) hole
9 6 8 6 7 4
T118-04-04-014
1 - Plug PF1/4 4 - Adapter UNF7/16×PF1/4 7 - Hose UNF7/16×UNF7/16 10 - Adapter PF3/8×PF3/8

(4042037) (4042031)
2 - Plug PF3/8 5 - Hose UNF7/16×UNF7/16 8 - Reducing (4325439) 11 - Hose PF3/8×PF3/8
(ST 6961)
3 - Pressure Gauge 6 - Adapter PF3/8×UNF7/16 9 - Tee UNF7/16×UNF7/16
(ST 6931) (4200465) ×PF1/4 (ST 6451)
43
Adjustment of Maximum and Minimum Flow Rate
(Oil Cooler Fan Drive Pump)
The pump flow rate can be adjusted by changing the NOTE: Turning screw (2) clockwise decreases the
maximum servo piston stroke. When adjusting the maximum flow rate, and turning counter-
maximum flow rate, loosen nut (1) and adjust screw clockwise increases. 1/4 turn of screw (2)
(2) on the servo piston large chamber side. When changes the flow rate approx. 6.3 L/min.
adjusting the minimum flow rate, loosen nut (3) and Turning screw (4) clockwise increases the
adjust screw (4) on the servo piston small chamber minimum flow rate, and turning counter-
side. clockwise decreases. 1/4 turn of screw (4)
: 30 mm : Nut (1)
: 24 mm : Nut (3)
: 13 mm : Screw (2)
: 8 mm : Screw (4)
4 3 1 2
T118-04-04-007
(Pump Flow Maximum Flow Rate Adjustment (Pump Flow Minimum Flow Rate Adjustment
Rate) Q Rate) Q
Pi (Flow Rate Pi (Flow Rate

Control Pres- Control Pres-
sure) sure)
44
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 screw (3) to reset the set-
force of spring (1).
: 13 mm : Nut (2)
: 4 mm : Screw (3)
2 3
T117-05-04-006
Spring Adjustment Data

Adjusting Screw Turn 1/4
Pressure Change (Pi) Mpa (1.8 kgf/cm 2, 25.6 psi) Flow Rate Control
Flow Rate Change 20 L/min (5.3 US gal/min) (Pump Flow
Rate) Q
Pi (Flow Rate
Control
Pressure)
45
SWING MOTOR DRAINAGE
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.
Preparation:
1. Rotate the swing motor to warm the inside of the
motor.

2. Properly shut down the engine. Slowly loosen air

breather cap to release air from the hydraulic oil
tank.
3. Disconnect the swing motor drain hose at the

1
hydraulic oil tank end. Install plug (1 /16-12UN) to
the disconnected end.
: 30 mm, 36 mm M117-07-082
Drain Hose
: 176 N⋅m (18 kgf⋅m, 130 lbf⋅ft)

make sure that the area is clear and that
coworkers are out of the swing area before
starting machine operation.
Also, take care not to fall off the machine
while the measurement.
Preconditions for Measurement:

1. Engine Control Lever : Fast Idle Position
Auto-idle Switch : OFF
46
Measurement:
1. Amount of Oil Drained While Swinging the
Upperstructure
(1) Fully roll out (extend) the arm. Fully roll in (tilt-
in) the bucket. 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.
(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.
(3) Repeat the measurement at least three times T145-05-03-008
in both clockwise and counterclockwise

directions, and calculate the average values.
2. Amount of Oil Drained While Relieving Swing

Motor Circuit
(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) Start the engine. Operate and hold the swing
T145-05-03-007
lever full stroke. Start drain oil measurement
when drain oil starts coming out of the drain
hose end. The measuring time should be more
than 20 seconds.
(3) Repeat the measurement at least three times
in both clockwise and counterclockwise
directions, and calculate the average values.
Evaluation:
* 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 / t) × q
Where:
∆Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
47
TRAVEL MOTOR DRAINAGE
Summary:
To check travel motor performance, measure the
amount of oil draining from the travel motor, while
rotating the travel motor with the measuring 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.

starting machine operation.
Preparation:
1. Rotate the travel motor to warm the inside of the
motor.

2. Properly shut down the engine. Slowly loosen the

air breather cap to release air from the hydraulic
oil tank.
Drain Hose
3. Disconnect the travel motor drain hose at the

1
hydraulic oil tank end. Install plug (1 /16-12UN) to
the disconnected end.
: 30 mm, 36 mm
: 176 N⋅m (18 kgf⋅m, 130 lbf⋅ft)

1. Engine Control Lever : Fast Idle Position
Auto-idle Switch : OFF
M117-07-087
48
Engine Control Lever : Fast Idle
Auto-Idle : OFF
Measurement:
(1) Start the engine. Jack up the measuring side
track using the front attachment, as illustrated.
CAUTION: When working around moving

90 to 110°
parts is unamoidable, pay special attention to
ensure that hands, feet, and clothing do not
become entangled. 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
90 to 110°
calculate the average values.
Evaluation:
Refer to T4-5 Operational Performance Standard. 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 / t) × q
Where:
∆Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
49
(Blank)
50
OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE STAN-
DARD TABLE
The standard performance values are listed in the Engine Control Lever : Fast Idle Position
table below. Hydraulic Oil Temperature : 50±5 °C ( 122±9 °F )
Refer to the Groups 2 to 4 for performance test
procedures. Values indicated in parentheses are
reference values.
The following switch positions shall be selected and

the hydraulic oil temperature shall be maintained as
indicated below as the preconditions of performance
tests unless otherwise instructed in each performance
test procedure:
EX2500-5
Performance Test Designation (Performance Remarks
Standard)
ENGINE SPEED ( min-1)
Fast Idle Speed 2 050±50
Slow Idle Speed 780±20
Auto-Idle Speed 1 400±50
TRAVEL SPEED (sec/20 m)
Fast Speed Mode 31
Slow Speed Mode 45
TRACK REVOLUTION SPEED (sec/3 rev)
Fast Speed Mode 77±4
Slow Speed Mode 109±5
MISTRACK (mm/20 m) 100 or less
(With fast and slow travel speed modes)
TRAVEL MOTOR LEAK (mm/5 min) 0
SWING SPEED (sec/3 rev) 47±0.5
SWING FUNCTION DRIFT CHECK (mm/180) 740 or less
SWING PARKING FUNCTION CHECK (mm/5 min) 0
MAXIMUM SWINGABLE SLANT ANGLE (deg.) 20 or possibly more
SWING BEARING PLAY (mm) 0.5 or less
NOTE: BH : Backhoe (9.0 m Boom, 4.2 m Arm,

3
13.8 m (PCSA heaped) Bucket)
LD : Loading Shovel
51
EX2500-5
Standard)
HYDRAULIC CYLINDER CYCLE TIME (sec)
Backhoe
Boom Raise 7.7±0.7
Boom Lower 4.7±0.5
Arm Roll-In 7.1±0.5
Arm Roll-Out 6.0±0.5
Bucket Roll-In 5.3±0.5
Bucket Roll-Out 3.9±0.5
Loading Shovel
Boom Raise 8.2±0.7
Boom Lower 5.0±0.5
Arm Extend 3.4±0.5
Arm Retract 4.2±0.5
Bucket Tilt-In 4.0±0.5
Bucket Tilt-Out 2.9±0.4
Bucket Open 2.1±0.4
Bucket Close 2.5±0.4
DIG FUNCTION DRIFT CHECK (mm/5 min)
Backhoe
Boom Cylinder 25 or less
Arm Cylinder 40 or less
Bucket Cylinder 20 or less
Bucket Bottom 200 or less
Loading Shovel
Boom Cylinder 25 or less
Arm Cylinder 25 or less
Bucket Cylinder 20 or less
Bucket Bottom 300 or less
CONTROL LEVER OPERATING FORCE (N)
(Hitachi Lever Pattern)
Boom Lever 11.8 or less (1.2 or less kgf)
Arm Lever 11.8 or less (1.2 or less kgf)
ISO Lever Patterm: Swing
Bucket Lever (Roll In / Out) 11.8 / 6.9 or less (1.2 / 0.7 or less kgf)
Swing Lever (Right / Left) 11.8 / 6.9 or less (1.2 / 0.7 or less kgf)
ISO Lever Patterm: Arm
Travel Lever 19.6 or less (2.0 or less kgf)
Bucket Open-Close Pedal 49 or less (5.0 or less kgf)
52
EX2500-5
Standard)
CONTROL LEVER STROKE (mm)
Boom Lever 90±10
Arm Lever 90±10
Bucket Lever 90±10
Swing Lever 90±10
Travel Lever 110±10
Bucket Open-Close Pedal 25±5
BOOM RAISE/SWING (Bucket Empty) (sec) 5.6 or less
Bucket Teeth Height: H (mm) 4600 or less
COMPONENT TEST
PRIMARY PILOT PRESSURE (MPa)
2
Engine Fast Idle 4.4±0.5 (45±5 kgf/cm , 640±70 psi)
2
Engine Slow Idle 3.9±0.5 (40±5 kgf/cm , 569±70 psi)
2
SECONDARY PILOT PRESSURE (MPa) 3.6±0.5 (37±5 kgf/cm , 526±70 psi)
+1.5 +15 2 +210
MAIN PUMP DELIVERY PRESSURE (MPa) 29.4 -0 (300 -0 kgf/cm , 4270 -0)
MAIN RELIEF PRESSURE (MPa)
+1.5 +15 2 +210
Boom, Arm, Bucket, Bucket Open 29.4 -0 (300 -0 kgf/cm , 4270 -0)
+2.5 +25 2 +350
Travel 29.4 -0 (300 -0 kgf/cm , 4270 -0)
+2 +20 2 +285
Swing 27.4 +5 (280 +5 kgf/cm , 3980 -70)
+1 +10 2 +355
Bucket Close 16.7 -0 (170 -0 kgf/cm , 2420 -0)
+1 +10 2 +355
OVERLOAD RELIEF PRESSURE (MPa) 31.4 -0 (320 -0 kgf/cm , 4550 -0)
+1 +10 2 +355
Bucket Close 16.7 -0 (170 -0 kgf/cm , 2420 -0)
MAIN PUMP FLOW TEST (L/min) − Refer to T4-4-10
Swing Motor Drainage
29 or less (7.66 or less US gal)
(With constant Max. speed) (L/min)
Travel Motor Drainage
28 or less (7.4 or less US gal)
(Slow speed : With the track jacked up) (L/min)
NOTE: BH : Backhoe (9.0 m Boom, 4.2 m Arm,

3
13.8 m (PCSA heaped) Bucket)
LD : Loading Shovel
53
(Blank)
54
SECTION 2
TROUBLESHOOTING
CONTENTS

Group 1 General Group 4 Troubleshooting B
Introduction .................................................... 55 Troubleshooting B Procedure........................ 113
Diagnostic Procedure ..................................... 56 Machine Malfunctions and
Possible Cases ........................................... 114
Group 2 Component Layout Engine System..............................................120
Main Component Layout ................................. 59 Actuator System ...........................................132
Pilot Panel ...................................................... 61 Front Attachment System ..............................140
Pump and Components .................................. 62 Swing System ...............................................146
Electrical Component Layout .......................... 63 Travel System ...............................................149
Engine and Components................................. 64 Auto-Lubrication System ...............................156
Battery Component ......................................... 65 Wiper Operating System ...............................162
Electrical Component Layout in the Cab ......... 66 Air Conditioner ..............................................170
Electrical Equipment Box ................................ 68
Control Valve .................................................. 70
Swing Device.................................................. 72
Pilot Piping ..................................................... 74
Group 3 Troubleshooting A
Troubleshooting A Procedure ........................ 105
Fault Code Indication by Indicator
Blonking Pattern ......................................... 106
Commins Engine Fault Code
Information ................................................. 108
Group 5 Troubleshooting C Malfunction of Engine Oil Level
Troubleshooting C Procedure ....................... 185 Indication ....................................................216
Tachometer does not Work Correctly ............ 186 Malfunction of Coolant Level Warning
Coolant Temperature Gauge does not Indicator......................................................218
Work Correctly............................................ 188 Malfunction of Hydraulic Oil Level
Hydraulic Oil Temperature Gauge Indicator......................................................220
does not Work Correctly ............................. 190 Malfunction of Auto-Idle Indicator ..................221
Fuel Gauge does not Work Correctly ............ 192 Malfunction of Fast Speed Travel
Malfunction of Alternator Warning Indicator......................................................222
Indicator ..................................................... 194 Malfunction of Slow Speed Travel
Malfunction of Air Filter Restriction Indicator......................................................223
Warning Indicator ....................................... 195 Malfunction of Entrance Light Indicator .........224
Malfunction of Engine Oil Pressure Malfunction of Maintenance Work Light
Warning Indicator ....................................... 196 Indicator......................................................225
Malfunction of Overheat Warning Malfunction of Indicator Light
Indicator ..................................................... 198 Check System.............................................226
Malfunction of Fuel Level Warning Hour Meter does not Work Correctly .............227
Indicator ....................................................... 200 Malfunction does not Work Correctly ............228
Malfunction of Engine Stop Warning
Indicator 1................................................... 202 Group 6 Electrical System Inspection
Malfunction of Engine Stop Warning Procedure
Indicator 2................................................... 203 Precautions for Inspection and
Malfunction of Engine Warning Maintenance ...............................................229
Indicator 1, 2............................................... 203 Disconnection of Connector ..........................231
Malfunction of Engine Protection Battery Voltage Check ..................................232
Warning Indicator ....................................... 203 Fusible Link Inspection .................................233
Malfunction of Emergency Engine Stop Fuse Continuity Check ..................................234
Indicator ..................................................... 204 Alternator Check ...........................................237
Malfunction of Hydraulic Oil Level Continuity Check...........................................238
Warning Indicator ....................................... 206 Voltage Check ..............................................239
Malfunction of Pump Transmission Oil 5 Volt Circuit .................................................240
Pressure Warning Indicator .......................... 208 Check Using False Signal .............................241
Malfunction of Pump Contamination Circuit Check by Lamp Harness ....................242
Warning Indicator ......................................... 210
Malfunction of Stop Valve Warning
Indicator ..................................................... 212
Malfunction of Ladder Warning
Indicator ..................................................... 213
Malfunction of Auto-Lubrication
Warning Indicator ....................................... 214
Malfunction of Fast-Filling Panel
Warning Indicator (Option) .......................... 215
TROUBLESHOOTING / General
INTRODUCTION
Each group of the troubleshooting section is presented

in orderly fashion so as to make inspection and
troubleshooting procedures easy to follow.
Use the troubleshooting section to guide you in
locating the source of any problems that may arise.
This troubleshooting section consists of 6 groups;

Diagnosing Procedure, Component Layout Drawings,
Troubleshooting A (Diagnosis of engine control sys-
tem), Troubleshooting B (Diagnosis in accordance with
the trouble symptom), Troubleshooting C (Diagnosis
related to monitor trouble), and Electrical System
Check.
• Diagnosing Procedure
Diagnosing procedure are shown.
• Component layout drawing

Main components and parts position are shown.
• Troubleshooting A (Diagnosis of engine control

system in accordance with indicated fault codes)
Apply this procedure if any fault code is indicated
by the blinking of the indicator on the engine fault
code indicator panel.
(ECM memorizes malfunctions that have oc-
curred in the electrical signal sending system in
the form of fault codes by the self-diagnosis func-
tion.)
Example:Fault code 346: ECM Power Failure
• Troubleshooting B (starting with phenomenons)

Use these charts when the machine is exhibiting
trouble.
Example:Using the engine speed control lever,

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

Use these charts when any gauges or indicators
malfunction.
Example:The fuel gauge does not operate.
• Electrical system inspection procedure

Refer to this group for precautions and inspection
procedures of the electrical system when or
before performing inspections on the electrical
system.
55
DIAGNOSING PROCEDURE
These six basic steps are essential for efficient

troubleshooting:
1. Study the system.

2. Ask the operator.
3. Inspect the machine.
4. Operate the machine yourself.
5. Perform troubleshooting.
6. Trace possible causes.
1. Study the system

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

Before inspecting, get the full story of
malfunctions as specifically as possible 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 machine’s daily maintenance points, as
shown in the operator’s manual.
Also, check the electrical system, including the

batteries, as troubles in the electrical system such
as low battery voltage, loose connections and
blown fuses will result in malfunction of the
controllers, causing total operational failure of the
machine.
T107-07-01-003
56
4. Operate the machine yourself
Try to identify the trouble by operating the
machine yourself.
If the trouble cannot be confirmed, stop the
engine and obtain further details of the
malfunction from the operator.
Also, check for any incomplete connections of the
wire harnesses.
T107-07-01-004
5. Perform troubleshooting
CAUTION: 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.
If any fault code is indicated on the engine fault

code indicator panel, perform troubleshooting A,
record the fault code and contact CUMMINS CO.
for advise.
If no fault code is displayed on the panel, despite
the fact that the machine has a malfunction, T107-07-01-006
check functions of components by referring to
troubleshooting B and C.
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
57
(Blank)
58
TROUBLESHOOTING / Component Layout
MAIN COMPONENT LAYOUT 7
8
Loding shovel 9
1
6
11
5 1
1
1
1
1
1
1
1
1
2
19
2
4 3 4
4
2
4 21
3 2
3 2
2
2
2
3 2
3
3 2 Pirot Panel
3 2
3 3
3 3
T141-01-03-005
1 - Arm Cylinder 12 - Compressor 23 - Auxiliary Hydraulic Oil Tank 34 - Accumulator

(For Air Conditioner) (For Adjuster)
2 - Level Cylinder 13 - Auto-Lubrication Device 24 - Bypass Filter 35 - Relief Valve
(Lubricator) (For Accumulator)
3 - Bucket Cylinder 14 - Swing Device 25 - Lift Cylinder 36 - Pressure Reducing Valve
(Fast Filling Device: Option) (For Accumulator)
4 - Dump Cylinder 15 - Air Breather Solenoid Valve 26 - Fast Filling Solenoid Valve 37 - Accumulator
(Fast Filling Device: Option) (For Adjuster)
5 - Bucket 16 - Control Valve (Right, Center, 27 - Boom Priority Valve 38 - Center Joint
Left)
6 - Arm 17 - Main Hydraulic Oil Tank 28 - Travel Pilot Pressure Cut- 39 - Swing Bearing
Off Valve
7 - Boom 18 - High Pressure Strainer 29 - Accumulator 40 - Adjuster Cylinder
(For Pilot Circuit)
8 - Boom Cylinder 19 - Fuel Cooler 30 - Shuttle Valve 41 - Compressor Motor
9 - Pilot Valve (Travel) 20 - Oil Cooler 31 - Travel Device 42 - Swing Stop Solenoid
Valve
10 - Pilot Valve (Front/Swing) 21 - Pump Transmission Oil 32 - Pilot Pressure Selector 43 - Pilot Shut-Off Valve
Cooler Valve
11 - Pilot Valve 22 - Oil Cooler Fan Motor 32 - Travel Brake Valve
(Bucket Open/Close)
59
Backhoe
5
4
6
3 7
8
9
10
11
12
13
14
2 15
16
17
1
39
38
37
18
36
19
35
20
34
21
33
22
32
23 T141-01-03-006
31
30
29 Pirot Panel
28 26 25 24
27
1 - Bucket 11 - Swing Device 21 - Bypass Filter 31 - Relief Valve

(For Accumulator)
2 - Arm 12 - Air Breather Solenoid Valve 22 - Compressor Motor 32 - Pressure Reducing
Valve(For Accumulator)
3 - Bucket Cylinder 13 - Control Valve 23 - Swing Stop Solenoid 33 - Accumulator
Valve (For Adjuster)
4 - Arm Cylinder 14 - Main Hydraulic Oil Tank 24 - Travel Pilot Pressure 34 - Center Joint
Cut-Off Valve
5 - Boom Cylinder 15 - High Pressure Strainer 25 - Accumulator 35 - Swing Bearing
(For Pilot Circuit)
6 - Boom 16 - Fuel Cooler 26 - Shuttle Valve 36 - Adjuster Cylinder
7 - Pilot Valve (Travel) 17 - Oil Cooler 27 - Travel Device 37 - Compressor Motor
8 - Pilot Valve 18 - Pump Transmission Oil 28 - Pilot Pressure Selector 38 - Swing Interlock Solenoid
(Front/Swing) Cooler Valve Valve
9 - Compressor 19 - Oil Cooler Fan Motor 29 - Travel Brake Valve 39 - Pilot Shut-Off Valve
(For Air Conditioner)
10 - Auto-Lubrication Device 20 - Auxiliary Hydraulic Oil Tank 30 - Accumulator
(Lubricator) (For Ajiuster)
60
PILOT PANEL
1 2 3 4 5 6 7
T141-01-03-008
11 10
1 - Shuttle Valve 4 - Pressure Reducing Valve 7 - Slow Return Valve 10 - Relief Valve
(Compressor Driving)
2 - Pressure Sensor (Travel 5 - Shuttle Valve 8 - Manifold 11 - Pressure Sensor (Fast
Alarm) Filling)
3 - Shuttle Valve 6 - Travel Mode Solenoid 9 - Pressure Sensor (Auto-
Valve Idle)
61
PUMP AND COMPONENTS
15
14
13
12
11
10
7 2
9
3
4
8
5
6
T117-01-02-004
1 - Contamination Sensor 5 - Quadruplicate Pump 9 - Pilot Filter 13 - EHC Valve

(Power Increasing)
2 - Main Pump 3 (Transmis- 6 - Transmission Oil Pressure 10 - Pressure Reducing Valve 14 - Horsepower Reducing
sion Side) Switch (For Oil Cooler Fan Motor Solenoid Valve
Main Pump 4 Speed Control)
(Pump End Side)
3 - Main Pump 5 (Transmis- 7 - Transmission Oil Filter 11 - Directional Valve 1 15 - Fan Motor Solenoid Valve
sion Side) (For Pump Flow Rate
Main Pump 6 Control)
(Pump End Side)
4 - Main Pump 1 (Transmis- 8 - Pilot Relief Valve 12 - Directional Valve 2
sion Side) (For Pump Flow Rate
Main Pump 2 Control)
(Pump End Side)
62
ELECTRICAL COMPONENT LAYOUT
2
1
3
4
5
6
8
7 9
10
11
30
12
13
29
28
14
15
16
27 17
26
25 18
24 19
23
22 T141-01-03-007
21
20
1 - Work Light (on the Cab) 9 - Hydraulic Oil Level Switch 17 - Proximity Switch 24 - Fuel Temperature Sensor
2 (For Hydraulic Oil Level (Fast-Filling System: Option)
Indicator)
2 - Entrance Light 10 - Engine Room Light 18 - Fast Filling Solenoid Valve 25 - Room Light
(Fast-Filling System: Option) (The Room Under the
Cab)
3 - Air Conditioner 11 - Valve Limit Switch 19 - Work Light (On the Left Side 26 - Electrical Equipment Box
of the Base Machine)
4 - Swing Stop Solenoid Valve 12 - Pump Room Light 20 - Valve Limit Switch 27 - Receiver-Dryer
(Deliver Circuit) (Suction Circuit) Condenser Fan Motor
Control Pressure Switch
5 - Work Light (Front Right) 13 - Work Light 21 - Fuel Level Switch 28 - Work Light (On the Left
(Rear Right) Side of the Base Machine)
6 - Battery 14 - Hydraulic Oil Temperature 22 - Ladder Limit Switch 29 - Condenser
Sensor 1 (For Hydraulic Oil Condenser Fan Motor
Temperature Gauge)
7 - Air Dump Solenoid 15 - Hydraulic Oil Temperature 23 - Low Fuel Level Switch 30 - Horn
Sensor 2 (For Oil Cooler
Fan Motor Speed Control)
8 - Hydraulic Oil Level Switch 16 - Travel Alarm
1 (For Hydraulic Oil Level
Indicator)
63
ENGINE AND COMPONENTS
1
Radiator
3 (Aftercooler)
Reservoir
(On Engine Room)
Radiator
12
4
11
5
10
Engine Oil Filter
Coolant Filter
6
7
Fuel Filter
9 T141-01-03-002
1 - Coolant Level Switch 4 - Alternator 7 - Lower Starter 10 - PRELUB Oil Pressure

(Level Warning Indicator) Switch
2 - Starting Aid Solenoid Valve 5 - Engine Oil Level Switch 8 - ECM 11 - Engine Oil Pressure Switch
3 - Air Cleaner Restriction 6 - Upper Starter 9 - Coolant Level Switch 12 - Engine Speed Sensor
Switch
64
BATTERY COMPARTMENT
1 2 3 4 5 6 7 8
10
11
17
12
16
13
15
14
T141-01-02-004
1 - PRELUB Timer 6 - Fusible Link 6 10 - Fusible Link 1 to 5 and 14 - Battery

8
2 - Safety Relay 7 - Auto-Lubrication Grease 11 - Fusible Link 7 15 - PRELUB Relay
Pressure Switch 2
3 - Battery Relay 2 8 - Auto-Lubrication Grease 12 - Battery Relay 1 16 - Battery Relay 3
Pressure Switch 1
4 - Starter Relay 1 (Upper) 9 - Auto-Lubrication Mode 13 - Circuit Breaker 17 - Cover Switch
Switch
5 - Starter Relay 2 (Lower)
65
ELECTRICAL COMPONENT LAYOUT IN
THE CAB
1 2
4
5
3 Front of Cab M146-01-010
Front Side in Cab M146-01-039

6
M146-07-048 M144-01-033
Upper Front of Cab

7
9 13
10
12
11
Power Source Terminal Layout

M117-07-172
T141-01-02-003
Rear Left Side in Cab
1- Switch Panel 5 - Key Switch 8 - Power Source Terminal 11 - Code Display Light
2- Monitor Panel 6 - Hour Meter 9 - Buzzer 12 - DC-DC Converter
3- Radio 7 - Fuse Box (Cab) 10 - Data Link Connector 13 - Engine Diagnostic Switch
4- Emergency Engine Stop
Switch
66
Monitor Panel
1 2 3 4 5 6 7 8 9 10 11 12 13 14
34
33
32 21
22
23
31
30 29 28 27 26 25 24 20 19 18 17 16 15 T141-01-02-002
Switch Panel
39
35 36 37 38
49
48
T141-01-02-001
47 46 45 44 43 42 41 40
1 - Download Indicator 14 - Tachometer 26 - Pump Contamination Indicator 38 - Side Air Conditioner Con-
troller
2 - Engine Oil Level Indicator 15 - Alternator Indicator 27 - Air Cleaner Restriction Indi- 39 - Front Air Conditioner Con-
cator troller
3 - Coolant Level Indicator 16 - Pump Transmission Oil 28 - Stop Valve Indicator 40 - Throttle Lever
Pressure Indicator
4 - Hydraulic Oil Level 17 - Engine Oil Pressure 29 - Emergency Engine Stop Indi- 41 - Work Light Switch
Indicator Indicator cator
5 - Travel Mode Indicator 18 - Coolant Temperature 30 - Ladder Position Indicator 42 - Dome Light Switch
(Slow Speed) (Overheat) Indicator
6 - Auto-Idle Indicator 19 - Hydraulic Oil Level 31 - Dimmer Switch 43 - Maintenance Light Switch
Indicator (Engine Room)
7 - Engine Room Light 20 - Fuel Level Indicator 32 - Buzzer Stop Switch 44 - Entrance Light Switch
Indicator
8 - Entrance Light Indicator 21 - Coolant Level Indicator 33 - Level Check Switch 45 - Travel Mode Switch
9 - PRELUB Indicator 22 - Auto-Lubrication Indicator 34 - Indicator Light Check Switch 46 - Auto-Idle Switch
10 - Travel Mode Indicator 23 - Engine Stop Indicator 35 - Cigar Lighter 47 - Fast Filling System Switch
(Fast Speed) (Option)
11 - Fuel Gauge 24 - Engine Waning Indicator 36 - Wiper Switch 48 - Washer Switch
12 - Hydraulic Oil Temperature 25 - Fast Filling System Indi- 37 - Rear Air Conditioner Controller 49 - Wiper Delay Selector
Gauge cator (Option) Switch
13 - Coolant Temperature
Gauge
67
ELECTRICAL EQUIPMENT BOX
17
3
4
5
6
10
11
(Refer to the
following page)
12 13 14 15 16
T141-01-02-005
1 - Diode Cover 6 - ECU 10 - Resister (27 Ω) 14 - Fuse Box 2

(D1 to D3, D9 to D42)
2 - MC(A) 7 - A/C Controller 11 - Resister (5.6 Ω) 15 - Diode Cover
(D43 to D49, R1C, R2C)
3 - Contamination Sensor 8 - Resister (27 Ω) 12 - Diode Cover (D4 to D8) 16 - Fuse Box 3
Unite
4 - MC(B) 9 - Auto-Lubrication Interval 13 - Fuse Box 1 17 - Fluorescent Illumination
Switch Light
5 - DLU
68
Location of Relay
1 2 3 4 5 6 7
8 9 10 11 12 13
14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29
30 31 32 33 34 35 36 37
38 39 40 41 42 43 44 45
1 - Air Condenser Fan Motor 13 - Auto-Lubrication Solenoid 24 - Work Light Relay 35 - Indicator Check Relay
Relay Valve Relay 1 (On the Cab)
(Front)
2 - Air Condenser Fan Motor 14 - Auto-Lubrication Solenoid 25 - Work Light Relay 36 - Washer Motor Relay
Relay Valve Relay 2 (Base Machine Right)
(Side)
3 - Air Condenser Fan Motor 15 - Power Decrease Control 26 - Work Light Relay 37 - Wiper Relay
Relay Solenoid Valve Relay (Rear) (Upper Side Fast-Speed)
(Rear)
4 - A/C Relay (Rear) 16 - Valve Limit Switch Relay 1 27 - Cab Room Light Relay 38 - Wiper Relay
(Upper Side Slow-Speed)
5 - A/C Relay (Side) 17 - Valve Limit Switch Relay 2 28 - Entrance Light Relay 39 - Main Wiper Relay
(Upper Side)
6 - A/C Relay (Front) 18 - Emergency Relay 1 29 - Horn Relay 40 - Wiper Relay
(Lower Side Fast-Speed)
7 - Ether Relay 19 - Emergency Relay 2 30 - Buzzer Relay 41 - Wiper Relay
(Lower Side Slow-Speed)
8 - Auto-Lubrication Relay 1 20 - Maintenance Light Relay 31 - PRELUB Indicator Relay 42 - Main Wiper Relay
(Engine Room) (Lower Side)
9 - Auto-Lubrication Relay 2 21 - Maintenance Light Relay 32 - Travel Mode Relay 43 - Load Damp Relay
(Pump Room)
10 - Auto-Lubrication Relay 3 22 - Maintenance Light Relay 33 - Illumination Relay 44 - Work Light Signal Relay
(The Room Under the Cab)
11 - Hour Meter Relay 23 - Work Light Relay 34 - Level Check Indicator Re- 45 - Entrance Light Signal Re-
(Base Machine Left) lay lay
12 - Swing Pilot Shut-Off
Relay
69
CONTROL VALVE
5 6 7 8
Overload Relief Valve
Make-up Valve
Main Relief Valve
Make-up Valve
Overload Relief Valve
T117-02-03-002
Center Control Valve
1 2 3 4 Overload 9 10 11 12
Overload
Relief Valve
Relief Valve
Make-up Make-up
Valve Valve
Main Relief
Valve
Main Relief
Valve
Make-up Make-up
Valve Valve
Overload Overload
Relief Valve Relief Valve
T117-02-03-003 T117-02-03-001
Right Control Valve Left Control Valve
NOTE: This figure is front view of Loading Shovel. NOTE: LD:Loading Shovel
BH:Backhoe
1 - Boom 4 - Swing 7 - Bucket Open/Close (LD) 10 - Arm

Bucket (BH)
2 - Bucket 5 - Right Travel 8 - Arm 11 - Boom
3 - Arm Extend (LD) 6 - Boom Raise/Bucket Tilt-in (LD) 9 - Left Travel 12 - Bucket
Arm (BH) Boom (BH)
70
Pilot Port Position 9 10 11 12
16 15 14 13
Center Control Valve T117-02-03-002

1 2 3 4 17 18 19 20
8 7 6 5 24 23 22 21
Right Control Valve T117-02-03-003

Left Control Valve
T117-02-03-001
NOTE: This figure is front view of Loading Shovel. NOTE: LD:Loading Shovel
BH:Backhoe
1 - Boom raise 7 - Bucket Tilt-out 13 - Arm Retract (LD) 19 - Boom raise

Arm Extend (BH)
2 - Bucket Tilt-in 8 - Boom Lower 14 - Bucket Close (LD) 20 - Bucket Tilt-in
Bucket Tilt-out (BH)
3 - Arm Extend (LD) 9 - Right Travel Forward 15 - Bucket Tilt-in (LD) 21 - Bucket Tilt-out
Arm Retract (BH) Boom raise (BH)
4 - Right Swing 10 - Boom Raise 16 - Right Travel Reverse 22 - Boom Lower
5 - Left Swing 11 - Bucket Open (LD) 17 - Left Travel Reverse 23 - Arm Retract(LD)
Bucket Tilt-in (BH) Arm Extend (BH)
6 - Arm Extend (BH) 12 - Arm Extend (LD) 18 - Arm Extend (LD) 24 - Left Travel Forward
Arm Retract (BH) Arm Retract (BH)
71
SWING DEVICE
Valve Unite
Make-up Valve
Relief Valve
Swing Motor
Swing Reduction Gear
T144-03-02-001
72
(Blank)
73
PILOT PIPING 1
2
3
4 5
6
7
8 Pump Control
Panel
19
18 9
17
16 10
11 Pilot Panel
15
12
14 13
T141-04-02-002
Pilot Panel:
20 21 22 23 24 25 26 27
30
28
29
T141-04-02-003
74
Pump Control Panel:
38
37
36
35
34 39
33
32
40
31
41
T141-04-02-004
1 - Travel Pilot Valve 12 - Shuttle Valve 22 - Shuttle Valve 5 32 - Pilot Filter

2 - Left Pilot Valve 13 - Travel Motor 23 - Reducing Valve 33 - Reducing Valve (Fan Motor
Revolution Control)
3 - Right Pilot Valve 14 - Pilot Pressure Selector 24 - Shuttle Valve 6 34 - Changeover Valve 1
Valve (Pump Flow Control)
4 - Bucket Open and Close 15 - Shuttle Valve 1 25 - Travel Mode Change 35 - Changeover Valve 2
Pilot Valve Solenoid Valve (Pump Flow Control)
5 - Swing Motor 16 - Center Joint 26 - Slow Return Valve 36 - EHC Valve
(Power Increasing)
6 - Left Control Valve 17 - Adjustment Cylinder 27 - Manifold 7 37 - Power Reducing Solenoid
Valve
7 - Center Control Valve 18 - Swing Stop Solenoid Valve 28 - Pressure Sensor 38 - Fan Motor Solenoid Valve
(Auto Idle)
8 - Right Control Valve 19 - Pilot Shut-off Valve 29 - Manifold 6 39 - Manifold 7
9 - Boom Priority Valve 20 - Manifold 4 30 - Manifold 5 40 - Manifold 9
(Loading shovel only)
10 - Travel Pilot Pressure 21 - Pressure Sensor (Travel 31 - Pilot Relief Valve 41 - 4 Units Pump
Cut-Off Valve Alarm)
11 - Accumulator (for Pilot Line)
75
Pilot Shut-Off Valve
This valve opens and closes the pilot pressure oil
circuit to each pilot valve.
No. Connecting Point Remarks
1 Left Pilot Valve (5) Pilot Pressure
2 Travel Pilot Valve (2) Pilot Pressure
3 Right Pilot Valve (6) Pilot Pressure
4 Right Pilot Valve (3) Return oil to hydraulic oil tank
5 Manifold 8 (4) Pilot Pressure
6 Hydraulic oil tank Return oil to hydraulic oil tank
7 Travel Pilot Valve (5) Return oil to hydraulic oil tank

8 Left Pilot Valve (2) Return oil to hydraulic oil tank
3 2 1
Front Side
4
Right Side Left Side
8
7
Rear Side
6 5
T118-05-02-027
Left Pilot Valve

This valve controls the pilot pressure to the arm and
swing control valve
1 Manifold 1 (14) Pilot pressure for left swing
2 Pilot Shut-Off Valve (8) Return oil to hydraulic oil tank
3 Manifold 1 (13) Pilot pressure for arm retract (Loading shovel)
Pilot pressure for arm roll-out (Backhoe)
4 Manifold 1 (15) Pilot pressure for right swing
5 Pilot Shut-Off Valve (1) Pilot Pressure
6 Manifold 1 (12) Pilot pressure for arm extend (Loading shovel)
Pilot pressure for arm roll-in (Backhoe)
2 4 NOTE: The illustration shows position in the HITA-

CHI lever type.
Front Side HITACHI Standard ISO Standard
3 Arm retract Left swing
Arm extend Right swing
6 LD
Right Side Left Side Right swing Arm extend
Left swing Arm retract
Arm roll-in Right swing
5
1 Rear Side Arm roll-out Left swing
BH
T118-05-02-028
Right swing Arm roll-out
Left swing Arm roll-in
76
Right Pilot Valve
This valve controls the pilot pressure to the boom
and bucket control valve.
1 Manifold 1 (2) Pilot pressure for bucket roll-in (Backhoe)
Pilot pressure for bucket tilt-in (Loading shovel)
2 Manifold 1 (4) Pilot pressure for boom raise
4 Manifold 1 (3) Pilot pressure for bucket roll-out (Backhoe)
Pilot pressure for bucket tilt-out (Loading shovel)
5 Manifold 1 (5) Pilot pressure for boom lower
6 5
Front Side
4
3
2 Rear Side
T118-05-02-028
Travel Pilot Valve

This valve controls the pilot pressure to the travel
control valve.
1 Manifold 1 (7) Pilot pressure for travel forward left
Bucket Open/Close Pilot Valve (2) Parking brake release pressure
3 Manifold 1 (6) Pilot pressure for travel reverse left
4 Manifold 1 (8) Pilot pressure for travel reverse right
Bucket Open/Close Pilot Valve (3) Return oil to hydraulic oil tank (Loading shovel only)
6 Manifold 1 (9) Pilot pressure for travel forward right
Front Side
6 1
5 2
4 3
Rear Side
T118-05-02-029
77
Bucket Open/Close Pilot Valve
(Loading shovel only)
This valve controls the pilot pressure to the bucket
open/close control valve.
1 Manifold 1 (10) Pilot pressure for bucket close
2 Travel Pilot Valve (2) Pilot Pressure
Manifold 1 (1) Pilot pressure for swing parking brake release
3 Travel Pilot Valve (5) Return oil to hydraulic oil tank
4 Manifold 1 (11) Pilot pressure for bucket open
Front Side
4 1
3 2
Rear Side
T118-05-02-030
Swing Stop Solenoid Valve

Blocks the swing pilot pressure to deactivate the
swing function when either the ladder or the fast fill-
ing panel (Option) is lowered.
Upper Side
2 1
4 3
Lower Side
T117-06-02-006
78
Manifold 1
This manifold is a pilot line connection block from pi-
lot valve to manifold 2 and swing stop solenoid valve.
1 Bucket Open / Close Pilot Valve (2): Upper Pilot pressure for swing parking brake release
Manifold 2 (1): Lower
2 Right Pilot Valve (1): Upper Pilot pressure for bucket roll-in (Backhoe)
Manifold 2 (2): Lower Pilot pressure for bucket tilt-in (Loading shovel)
3 Right Pilot Valve (4): Upper Pilot pressure for bucket roll-out (Backhoe)
Manifold 2 (3): Lower Pilot pressure for bucket tilt-out (Loading shovel)
4 Right Pilot Valve (2): Upper Pilot pressure for boom raise
Manifold 2(4): Lower
5 Right Pilot Valve (5): Upper Pilot pressure for boom lower
6 Travel Pilot Valve (3): Upper Pilot pressure for travel reverse left
7 Travel Pilot Valve (1): Upper Pilot pressure for travel forward left
8 Travel Pilot Valve (4): Upper Pilot pressure for travel reverse right
9 Travel Pilot Valve (6): Upper Pilot pressure for travel forward right
10 Bucket Open / Close Pilot Valve (1): Upper Pilot pressure for bucket close (Loading shovel)
Manifold 2 (10): Lower Auxiliary (Backhoe)
11 Bucket Open / Close Pilot Valve (4): Upper Pilot pressure for bucket open (Loading shovel)
Manifold 2 (11): Lower Auxiliary (Backhoe)
12 Left Pilot Valve (6): Upper Pilot pressure for arm extend (Loading shovel)
Manifold 2 (12): Lower Pilot pressure for arm roll-in (Backhoe)
13 Left Pilot Valve (3): Upper Pilot pressure for arm retract (Loading shovel)
Manifold 2 (13): Lower Pilot pressure for arm roll-out (Backhoe)
14 Left Pilot Valve (1): Upper Pilot pressure for left swing
Swing Interlock Solenoid Valve (2): Lower
15 Left Pilot Valve (4): Upper Pilot pressure for right swing
Swing Interlock Solenoid Valve (1): Lower
1 2 4 6 8 10 12 14
Rear Side
Front Side
3 5 7 9 11 13 15
T117-06-02-005
79
Manifold 2
This manifold is a pilot line connection block from
manifold 1 and swing stop solenoid valve to shuttle
valves (1, 2, 3, 4) and manifold 5.
1 Manifold 1 (1): Upper Plot pressure for swing parking brake release
2 Manifold 1 (2): Upper Pilot pressure for bucket roll-in (Backhoe)
Shuttle Valve 1 (9): Lower (Loading shovel) Pilot pressure for bucket tilt-in
Shuttle Valve 2 (6): Lower (Backhoe) (Loading shovel)
3 Manifold 1 (3): Upper Pilot pressure for bucket roll-out (Backhoe)
Shuttle Valve 1 (8): Lower (Loading shovel) Pilot pressure for bucket tilt-out
Shuttle Valve 1 (4): Lower (Backhoe) (Loading shovel)
4 Manifold 1 (4): Upper Pilot pressure for boom raise
Shuttle Valve 1 (7): Lower (Loading shovel)
Shuttle Valve 2 (9): Lower (Backhoe)
5 Manifold 1 (5) :Upper Pilot pressure for boom lower
Shuttle Valve 2 (8): Lower (Backhoe)
6 Manifold 1 (6): Upper Pilot pressure for travel reverse left
Travel Pilot Cut-Off Valve (9): Lower
7 Manifold 1 (7): Upper Pilot pressure for travel forward left
8 Manifold 1 (8): Upper Pilot pressure for travel reverse right
9 Manifold 1 (9): Upper Pilot pressure for travel forward right
10 Manifold 1 (10): Upper Pilot pressure for bucket close
Auxiliary (Backhoe)
11 Manifold 1 (11): Upper Pilot pressure for bucket open
Auxiliary (Backhoe)
12 Manifold 1 (12): Upper Pilot pressure for arm extend
Shuttle Valve 2 (5): Lower (Loading shovel) (Loading shovel)
Shuttle Valve 2 (7): Lower (Backhoe) Pilot pressure for arm roll-in (Backhoe)
13 Manifold 1 (13): Upper Pilot pressure for arm retract
Shuttle Valve 2 (4): Lower (Loading shovel) (Loading shovel)
Shuttle Valve 1 (5): Lower (Backhoe) Pilot pressure for arm roll-out (Backhoe)
14 Swing Interlock Solenoid Valve (3): Upper Pilot pressure for left swing
Shuttle Valve 4 (6): Lower
15 Swing Interlock Solenoid Valve (4): Upper Pilot pressure for right swing
Shuttle Valve 4 (7): Lower
1 2 4 6 8 10 12 14 Rear Side
T117-06-02-007
Front Side
3 5 7 9 11 13 15
80
Manifold 3
shuttle valve 1 and 2 to control valves (Right, Center
Left).
1 Left Control Valve (1) Pilot pressure for bucket tilt-in (Loading shovel)
Pilot pressure for bucket roll-in (Backhoe)
2 Right Control Valve (11) Pilot pressure for bucket tilt-in (Loading shovel)
Pilot pressure for bucket roll-in (Backhoe)
3 Left Control Valve (3) Pilot pressure for boom raise
4 Center Control Valve (7) Pilot pressure for boom raise
5 Right Control Valve (12) Pilot pressure for boom raise
6 Center Control Valve (5) Pilot pressure for arm extend (Loading shovel)
7 Right Control Valve (10) Pilot pressure for arm extend (Loading shovel)
8 Left Control Valve (3) Pilot pressure for arm extend (Loading shovel)
9 Shuttle Valve 2 (1): Loading shovel Pilot pressure for arm extend (Loading shovel)
Shuttle Valve 2 (3): Backhoe
10 Shuttle Valve 1 (3): Loading shovel Pilot pressure for boom raise
Shuttle Valve 2 (1): Backhoe
11 Shuttle Valve 1 (1): Loading shovel Pilot pressure for bucket tilt-in (Loading shovel)
Shuttle Valve 2 (4): Backhoe Pilot pressure for bucket roll-in (Backhoe)
12 Center Control Valve (6):Backhoe only Pilot pressure for bucket roll-in (Backhoe)
X
Upper Side
2 3 4 5
6 Left Side Right Side

1
7
12 Lower Side
8
11 10 9
T117-06-02-008
View X
Cross Section A Cross Section B Cross Section C

2 5 7
1 4 6
11 10 9 T141-05-02-006
12 3 8 T141-05-02-014
81
Manifold 4
shuttle valves (1, 2, 3, 4) and shuttle valves (5, 6).
1 Shuttle Valve 1 (5): Loading shovel Pilot pressure for boom or bucket operation (Loading
Shuttle Valve 2 (5): Backhoe shovel)
Pilot pressure for boom or arm operation (Backhoe)
2 Shuttle Valve 2 (3): Loading shovel Pilot pressure for arm operation (Loading shovel)
Shuttle Valve 1 (3): Backhoe Pilot pressure for bucket operation (Backhoe)
3 Shuttle Valve 3 (5) Pilot pressure for travel operation
4 Shuttle Valve 4 (5) Pilot pressure for swing or bucket open/close
(Loading shovel only) operation
5 Shuttle Valve 5 (2) Pilot pressure for swing or bucket open/close
6 Shuttle Valve 5 (1) Pilot pressure for travel operation
7 Shuttle Valve 6 (1) Pilot pressure for arm operation (Loading shovel)
Pilot pressure for bucket operation (Backhoe)
8 Shuttle Valve 5 (6) Pilot pressure for boom or bucket operation (Loading
shovel)
Upper Side
1 2 3 4
Left Side Right
Lower Side
T117-06-02-009
8 7 6 5
View X
Cross
Section A
1, 2, 3, 4
5, 6, 7, 8
T141-01-03-008
T117-06-02-025
82
Manifold 5
manifold 2 to manifold 7.
1 Manifold 2 (1) Pilot pressure for swing parking brake release
1 2 Upper Side
Left Side Right Side

X
Lower Side
T141-05-02-009
View X 1
Cross Section A
T117-06-02-026
T141-04-02-003
Manifold 6
shuttle valves (5, 6) to changeover valves (1, 2).
1 Shuttle Valve 5 (5) Control pressure of switch valve 1
2 Shuttle Valve 6 (2) Control pressure of switch valve 2
3 Changeover Valve 2 (4) Control pressure of switch valve 2
4 Changeover Valve 1 (2) Control pressure of switch valve 1
3
Upper Side
2 4
X
Lower Side
1
T141-05-02-010
1
4
Cross
Section A
2
3
Cross Cross
Section X Section B
T141-05-02-011 T141-01-03-008
83
Manifold 7
manifold 5 to swing motor and travel mode change
solenoid valve.
1 Swing Motor Pilot pressure for swing parking brake release
3 Travel Mode Change Solenoid Valve (3) Travel parking brake release pressure / Travel speed
change pressure
Upper Side
1 2
X
Lower Side
3
T117-06-02-012
View X
3
1 Cross
Section B
T141-01-03-008
Cross T117-06-02-028
Section A
84
Manifold 8
This manifold is a pilot line connection block from pi-
lot shut-off valve and manifold 9 to manifold of fan
motor solenoid valve, horsepower reducing solenoid
valve, EHC valve, changeover valves (1, 2).
1 Manifold 9 Pilot pressure
2 Manifold of fan motor solenoid valve, Pilot pressure
horsepower reducing solenoid valve, EHC
valve,
changeover valves (1, 2) (P)
3 Pilot Filter Pilot pressure
4 Pilot Shut-off Valve (5) Pilot pressure
Upper Side
2
Rear Side Front Side

1
Lower Side
3
4
T117-06-02-037
Cross
Section A
2
Cross
4 T117-06-02-034
Section B
T117-06-02-031
85
Manifold 9
This manifold is a pilot line connection block of pump
control pressure.
1 Changeover Valve 1 (1) Flow rate control pressure Pi for main pump
2 Horspower Reducing Solenoid Valve (6) Horspower reducing pressure Pf for main pump
3 Changeover Valve 2 (3) Flow rate control pressure Pi for main pump
4 EHC Valve (5) Hosepower Increase pressure Pz for main pump
5 Reducing Valve (6) Flow rate control pressure Pi for fan motor pump
6 Manifold 8 (1) Pilot pressure
7 Main Pump 3 (1): Loading Shovel Flow rate control pressure Pi for main pump
Main Pump 3 (1), 5 (1), 6 (5): Backhoe
8 Main Pump 1 (2), 3 (2), 5 (2) Horspower reducing pressure Pf for main pump
9 Main Pump 1 (1), 2 (5), 4 (5), 5 (1), 6 (5) Flow rate control pressure Pi for main pump
: Loading Shovel
Main Pump 1 (5), 2 (5), 4 (1): Backhoe
10 Main Pump 1 (7), 2 (4), 3 (7), 4 (4), 5 (7), 6 (4) Hosepower Increase pressure Pz for main pump
11 Fan Motor Pump (2) Flow rate control pressure Pi for main pump
12 Main Pump 1 (6), 2 (2), 3 (6), 4 (2), 5 (6), 6 (2) Pump servo assist pressure Psv for main pump
13 Fan Motor Pump (1) Pump servo assist pressure Psv for fan motor pump
1 7 Upper Side
2
8 Rear Side Front Side
3
9
4
10 Lower Side
5
11
6
12
13
T117-06-02-038
11
Cross
Section A
13
∼ 12
7∼
∼6
1∼
Cross
Section B T141-05-02-007
T117-06-02-031
Pump Control Panel
86
Shuttle Valve 1
Loading Shovel:
1 Manifold 3 (11) Pilot pressure for bucket tilt-in
2 Left Control Valve (28) Pilot pressure for bucket tilt-out
4 Left Control Valve (26) Pilot pressure for boom lower
5 Manifold 4 (1) Pilot pressure for boom or bucket operation
8 Manifold 2 (3) Pilot pressure for bucket tilt-out
10 Boom Priority Switch Valve (4) Pilot pressure for bucket tilt-in
11 Boom Priority Switch Valve (3) Pilot pressure for boom raise
Backhoe:
1 Left Control Valve (24) Pilot pressure for arm roll-out
2 Left Control Valve (28) Pilot pressure for bucket roll-out
3 Manifold 4 (2) Pilot pressure for bucket operation
4 Manifold 2 (3) Pilot pressure for bucket roll-out
5 Manifold 2 (13) Pilot pressure for arm roll-out
Loading Shovel Backhoe
1 2 3 4 Upper Side 1 2
10 Lower Side
5
3
9
5 4
T117-06-02-021
8 7 6 T117-06-02-013
Shuttle Valve 1 T141-05-02-008
87
Shuttle Valve2
Loading Shovel:
1 Manifold 3 (9) Pilot pressure for arm extend
2 Left Control Valve (24) Pilot pressure for arm retract
3 Manifold 4 (2) Pilot pressure for arm operation
4 Manifold 2 (13) Pilot pressure for arm retract
Backhoe:
3 Manifold 3 (9) Pilot pressure for arm roll-in
4 Left Control Valve (24) Pilot pressure for bucket roll-in
5 Manifold 4 (1) Pilot pressure for boom or arm operation
6 Manifold 2 (2) Pilot pressure for bucket roll-in
Loading Shovel Backhoe
1 2
1 2 3 4
Upper Side
Lower Side
3 9 5
5 4 T117-06-02-014
T117-06-02-015
8 7 6
T141-05-02-008
Shuttle Valve 2
88
Shuttle Valve 3
1 Left Control Valve (1) Pilot pressure for travel reverse left
2 Left Control Valve (22) Pilot pressure for travel forward left
3 Right Control Valve (17) Pilot pressure for travel reverse right
4 Right Control Valve (8) Pilot pressure for travel forward right
5 Manifold 4 (3) Pilot pressure for travel operation
6 Pilot Pressure Cut-Off Valve (4) Pilot pressure for travel forward right
7 Pilot Pressure Cut-Off Valve (6) Pilot pressure for travel reverse right
8 Pilot Pressure Cut-Off Valve (3) Pilot pressure for travel forward left
9 Pilot Pressure Cut-Off Valve (5) Pilot pressure for travel reverse left
1 2 3 4
Upper Side
Lower Side
9 5
T117-06-02-015
8 7 6
T141-05-02-008
Shuttle Valve 3
89
Shuttle Valve 4
1 Center Control Valve (19) Pilot pressure for bucket close (Loading shovel)
Auxiliary (Backhoe)
2 Center Control Valve (6) Pilot pressure for bucket open (Loading shovel)
Auxiliary (Backhoe)
3 Right Control Valve (9) Pilot pressure for right swing
4 Right Control Valve (16) Pilot pressure for left swing
5 Manifold 4 (4) Pilot pressure for swing or bucket open/close
8 Manifold 2 (11) Pilot pressure for bucket open (Loading shovel)
Auxiliary (Backhoe)
9 Manifold 2 (10) Pilot pressure for bucket close (Loading shovel)
Auxiliary (Backhoe)
1 2 3 4
Upper Side
Lower Side
9 5
T117-06-02-015
8 7 6
T141-05-02-008
Shuttle Valve 4
90
Shuttle Valve 5
1 Manifold 4 (6) Pilot pressure for travel operation
2 Manifold 4 (5) Pilot pressure for swing or bucket open / close
3 Shuttle Valve 6 (3) Pilot pressure shuttle valve 6
5 Manifold 6 (1) Control pressure of switch valve 1
6 Manifold 4 (8) Pilot pressure for boom or bucket operation
(Loading shovel)
Upper Side
2 3
1
Lower Side
6 5 T117-06-02-016
T141-01-03-008
Shuttle Valve 6

1 Manifold 4 (7) Pilot pressure for arm operation (Loading shovel)
Pilot pressure for bucket operation (Backhoe)
2 Manifold 6 (2) Control pressure of switch valve 2
3 Shuttle Valve 5 (3) Pilot pressure
1 2
T117-06-02-017
3
Upper Side
Left Side Right Side T141-01-03-008
Lower Side
91
Travel Mode Change Solenoid Valve
1 Reducing Valve (2) Control pressure of reducing valve
3 Manifold 7 (3) Travel parking brake release pressure / Travel speed
change pressure
4 Reducing Valve (3) Travel parking brake release pressure / Travel speed
change pressure
Upper Side
Lower Side
T117-06-02-018
3
T141-01-03-008
Reducing Valve (For travel mode change)

1 Center Joint to Travel Motor Travel parking brake release pressure / Travel speed
change pressure
2 Travel Mode Change Solenoid Valve (2) Control pressure of reducing valve
3 Travel Mode Change Solenoid Valve (4) Travel parking brake release pressure / Travel speed
change pressure
Upper Side

2
Lower Side
3
1
T141-05-02-012
4
T141-01-03-008
92
Boom Priority Switch Valve (Loading shovel only)
2 Center Control Valve (18) Pilot pressure for bucket tilt-in
3 Shuttle Valve 1 (11) Pilot pressure for boom raise
4 Shuttle Valve 1 (10) Pilot pressure for bucket tilt-in
Upper Side

2
1 3
Lower Side
5 4
T117-06-02-020
T141-05-02-002
93
Control Valve
Loading Shovel:
4 Shuttle Valve 3 (1) Pilot pressure for travel reverse left
6 Shuttle Valve 4 (2) Pilot pressure for bucket open
8 Shuttle Valve 3 (4) Pilot pressure for travel forward right
9 Shuttle Valve 4 (3) Pilot pressure for right swing
14 Left Control Valve (27) Pilot pressure for bucket tilt-out
16 Shuttle Valve 4 (4) Pilot pressure for left swing
17 Shuttle Valve 3 (3) Pilot pressure for travel reverse right
18 Boom Priority Switch Valve (2) Pilot pressure for bucket roll-in
19 Shuttle Valve 4 (1) Pilot pressure for bucket close
20 Left Control Valve (23) Pilot pressure for arm retract
22 Shuttle Valve 3 (2) Pilot pressure for travel forward left
23 Center Control Valve (20) Pilot pressure for arm retract
24 Shuttle Valve 2 (2) Pilot pressure for arm retract
25 Right Control Valve (12) Pilot pressure for boom lower
26 Shuttle Valve 1 (4) Pilot pressure for boom lower
27 Right Control Valve (14) Pilot pressure for bucket tilt-out
28 Shuttle Valve 1 (2) Pilot pressure for bucket tilt-out
94
1 2 3 4 5 6 7 8 9 10 11 12
28 27 26 25
16 15 14 13
T141-05-02-002
24 23 22 20 19 18 17
Upper Side
Lower Side
95
Backhoe:
9 Shuttle Valve 4 (3) Pilot pressure for right swing
14 Left Control Valve (27) Pilot pressure for bucket roll-out
15 Center Control Valve (21) Pilot pressure for arm roll-out
16 Shuttle Valve 4 (4) Pilot pressure for left swing
19 Right Control Valve (29) Pilot pressure for bucket roll-out
20 Left Control Valve (23) Pilot pressure for arm roll-out
21 Right Control Valve (15) Pilot pressure for arm roll-out
23 Center Control Valve (20) Pilot pressure for arm roll-out
24 Shuttle Valve 1 (1) Pilot pressure for arm roll-out
26 Shuttle Valve 2 (2) Pilot pressure for boom lower
27 Right Control Valve (14) Pilot pressure for bucket roll-out
28 Shuttle Valve 1 (2) Pilot pressure for bucket roll-out
29 Center Control Valve (19) Pilot pressure for bucket roll-out
30 Center Control Valve (18) Pilot pressure for boom lower
96
1 2 3 4 5 6 7 8 9 10 11 12
20
21
28 27 26 25
15 16 29 14 30 13
T141-05-02-001
24 23 22 19 18 17
Upper Side
Lower Side
97
Changeover Valve 1
This valve controls flow rate control pressure Pi to
main pump 3.(Loading shovel)
main pump 3, 5, and 6.(Backhoe)
1 Manifold 9 (1) Flow rate control pressure Pi for main pump
2 Manifold 6 (4) Changeover pressure
Changeover Valve 2
main pump 1, 2, 4, 5, and 6.(Loading shovel)
main pump 1, 2, and 4.(Backhoe)
3 Manifold 9 (3) Flow rate control pressure Pi for main pump
4 Manifold 6 (3) Changeover pressure
EHC Valve
This valve controls horsepower increase pressure Pz
to main pump 1to 6
5 Manifold 9 (4) Horsepower increase pressure Pz for main pump
Horsepower Reducing Solenoid Valve

This valve controls horsepower reducing pressure Pf
to main pump 1, 3, and 5
6 Manifold 9 (2) Horsepower reducing pressure Pf for main pump
98
Horsepower Reducing
Solenoid Valve
6
EHC Valve
Changeover 2
5
3
4
1
2
Changeover 1
T117-06-02-031
Upper Side
Lower Side
99
Flow rate control pressure Pi to fan motor pump is
controlled by the combination with the reducing valve.
1 Reducing Valve (3) Changeover pressure
2 Reducing Valve (4) Flow rate control pressure Pi for fan motor pump
P Manifold 8 (2) Pilot Pressure
T Reducing Valve (5) Return to hydraulic oil tank
Reducing Valve (For fan motor pump control)

Flow rate control pressure Pi to fan motor pump is
controlled by the combination with the fan motor so-
lenoid valve.
3 Fan Motor Solenoid Valve Changeover pressure solenoid valve
4 Fan Motor Solenoid Valve Flow rate control pressure Pi for fan motor pump
5 Pilot Filter Return to hydraulic oil tank
6 Manifold 9 (5) Flow rate control pressure Pi for fan motor pump
100
T
3 4
5
Reducing Valve
(For fan motor
pump control)
T117-06-02-031
Upper Side
Lower Side
101
Main Pump
1 Manifold 9 (7), (9) Flow rate control pressure Pi
2 Manifold 9 (8) Horsepower reducing pressure Pf
3 Manifold 9 (12) Pump servo assist pressure Psv
4 Manifold 9 (10) Horsepower increase pressure Pz
5 Manifold 9 (7), (9) Flow rate control pressure Pi
6 Manifold 9 (12) Pump servo assist pressure Psv
7 Manifold 9 (10) Horsepower increase pressure Pz
1 2 3 4
Front Side
Rear Side
T141-05-02-013
7 6 5
Fan Motor Pump

1 Manifold 9 (7), (9) Pump servo assist pressure Psv
2 Manifold 9 (8) Flow rate control pressure Pi
1
Upper Side
2 Lower Side
T118-05-02-026
102
Travel Pilot Pressure Cut-Off Valve
Travel pilot pressure cut-off valve is activated by the
pilot pressure from pilot pressure selector valve,
blocking the travel pilot pressure to stop machine
traveling.
1 Center Joint → Pilot Pressure Selector Valve Travel pilot pressure cut-off valve changeover pressure
2 Return to hydraulic oil tank
7 Manifold 2 (7) Pilot pressure for travel forward left
8 Manifold 2 (9) Pilot pressure for travel forward right
9 Manifold 2 (6) Pilot pressure for travel reverse left
10 Manifold 2 (8) Pilot pressure for travel reverse right
1
2
3
4 Rear Side Left Side
5
6
Right Side Front Side
10 7
9 8
T117-06-02-039
Upper Side
Lower Side
T141-05-02-005
103
Pilot Pressure Selector Valve
Pilot pressure selector valve is activated by the
pressure from the adjuster cylinder, supplying
changeover pressure to the travel pilot pressure cut-
off valve.
1 Adjuster Cylinder (L) Pilot pressure selector valve changeover pressure
2 Center Joint Return to hydraulic oil tank
3 Center Joint → Travel Pilot Pressure Cut-Off Travel pilot pressure cut-off valve changeover
Valve (1)
4 Adjuster Cylinder (R) Pilot pressure selector valve changeover pressure
5 Center Joint Return to hydraulic oil tank
1 2 3 4
Front Side
Rear Side
T117-06-02-040
T141-05-02-004
104
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURES
Apply troubleshooting A when diagnosing the engine Monitor Panel

control system.
When any trouble occurs in the engine control system,
one of the following indicators come ON:
• Overheat Indicator
• Engine Oil Pressure Indicator
• Coolant Level Indicator
• Engine Warning Indicator 1
• Engine Stop Indicator 1
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 T141-05-03-001
• Engine Stop Indicator 2 1 2 3 4 5

• Engine Protection Indicator
ECM (Electronic Control Module) memorizes malfunc- Engine Fault Code Indicator Panel
tions of the engine in the form of fault codes. This fault
code can be displayed in two forms:
• Indicated by the blinking pattern of the engine

warning indicator and engine stop indicator.
TM
• Displayed by Echek (diagnostic tool by CUM-
MINS CO.)
When the fault code is displayed, record the fault code

(3 digit number), and contact CUMMINS CO. for ad- T141-05-03-002
vise.
6 7 8
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 co-
mes ON according to the seriousness of
the trouble.
Rear Left Side in Cab T141-01-02-003
1 - Engine Warning Indica- 5 - Engine Oil Pressure

tor 1 Indicator
2 - Engine Stop Indicator 1 6 - Engine Warning Indica-
tor 2
3 - Coolant Level Indicator 7 - Engine Stop Indicator 2
4 - Overheat Indicator 8 - Engine Protection Indi-
cator
105
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 diagnostic 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 diagnostic switch A and/or B
is operated. This does not indicate the fault
code.
Diagnostic Switch
There are two diagnostic switches: A and B. These
switches are used to indicate the fault codes. Switch A
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 B
switch down.
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 T141-05-03-003
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 indi-
cator corresponding to the fault level stays ON.
106
2. Turn the engine diagnostic switch A ON (press
down). 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 indi-
cator 2 blinks. The blinking number indicates the Example: in case of Fault Code 132
hundredth digit. (Fault code is indicated in three digit number)
• After approx. one seconds, the engine stop indi-
hundredth tenth first
cator 2 blinks. The blinking number indicates the number number
number
tenth digit.
• After approx. one seconds, the engine stop indi- ON
cator 2 blinks. The blinking number indicates the
first digit.
• Finally, the engine warning indicator 2 blinks once.
3. The fault code is indicated repeatedly in the above
sequence.
OFF
NOTE: When wires of the engine control system

one one
has been disconnected for service, ECM second
T141-05-03-004
second
recognizes it as malfunction and stores it in
the history. This record remains even if it is
reconnected.
TM
The diagnostic tool Echek is required to
erase this record.
NOTE: The code indicated on the fault code indi-

cator panel shows the trouble occurring
currently.
TM
The diagnostic tool Echek is required to
indicate the past history.
107
CUMMINS ENGINE FAULT CODE INFOR-
MATION
FAULT
CODE REASON EFFECT (Only when fault code is active)
INDICATOR
* 112 The error between estimated timing fueling and Depending on the calibration the engine will shut
Red desired timing fueling is outside of acceptable down or speed derate or no action by the ECM is
limits. taken.
* 113 High voltage detected at pin 20 of the engine No action by the ECM is taken. Actuator is open or
Yellow harness connector. closed, or partially closed. Engine power output
will vary. Fault code 112 will be logged.
114 Short Circuit: bitween pin No.1 of the timing No action by the ECM is taken. Actuator is open or
Yellow actuator circuit and the battery partially open. The engine power output varies
power and the burning sound is louder.
or
at the engine harness side ground
of pin No.20
115 No engine speed signal detected at pin No.27, 28, The engine shuts down.
Red 37 and 38 of the engine harness.
116 More than 4.78 volts DC detected at the timing Depending on the calibration the engine will shut
Red pressure sensor signal pin No.33 of the engine down or speed derate or no action by the ECM is
harness. taken.
117 Less than 0.15 volts DC detected at the timing Depending on the calibration the engine will shut
Red pressure sensor signal pin No.33 of the engine down or speed derate or no action by the ECM is
harness. taken.
118 More than 4.78 volts DC detected at the fuel pump No action by the ECM is taken.
Yellow output pressure sensor signal pin No.32 of the
engine harness.
119 Lass than 0.30 volts DC detected at the fuel pump No action by the ECM is taken.
Yellow output pressure sensor signal pin No.32 of the
engine harness.
* 121 No engine speed signal detected at one pair of No action by the ECM is taken.
Yellow pins, either pins No.27, 28 or pins No.37, 38 of the
engine harness.
* 122 More than 4.72 volts DC detected at the intake Engine power derate to no-air setting.
Off manifold air pressure sensor signal pin No.35 of
the engine harness.
* 123 Less than 0.33 volts DC detected at the intake Engine power derate to no-air setting.
Off manifold air pressure sensor signal pin No.35 of
the engine harness.
131 More than 4.20 volts DC detected at the throttle Calibration dependent power and speed derate.
Red position signal pin No.29 of the OEM interface
harness.
132 Less than 0.13 volts DC detected at throttle Calibration dependent power and speed derate.
Red position signal pin No.29 of the OEM interface
harness.
133 More than 4.82 volts DC detected at the remote The engine power output and the engine speed
Red throttle position sensor signal pin No.30 of the become low.
OEM interface harness.
134 Less than 0.12 volts DC detected at the remote The engine power output and the engine speed
Red throttle position sensor signal pin No.30 of the become low.
OEM interface harness.
135 More than 4.88 volts DC detected at oil pressure No engine protection for oil pressure.
Yellow sensor signal pin No.24 of the engine harness.
141 Less than 0.31 volts DC detected at the oil No engine protection for oil pressure.
Yellow pressure sensor signal pin No.24 of the engine
harness.
TM
NOTE: * Can be detected by Echek only.
108
FAULT
INDICATOR
* 143 Low oil pressure has been detected. Voltage Calibration dependent progressive power derate
Orange signal at oil pressure signal pin No.24 of the and engine shutdown with increasing time after
engine harness indicates oil pressure lower than alert.
-1
103 kPa [15 psi] at 600 min (rpm); 131 kPa [19
-1
psi] at 800 min (rpm); 165 kPa [24 psi] at 1500
-1
min (rpm); and 207 kPa [30 psi] above 2100
-1
min (rpm).
144 More than 4.95 volts DC detected at the coolant Possible white smoke. No engine protection for
Yellow temperature signal pin No.22 of the engine coolant temperature.
harness.
145 Less than 0.21 volts DC detected at the coolant Possible white smoke. No engine protection for
Yellow temperature signal pin No.22 of the engine coolant temperature.
harness.
151 High coolant temperature has been detected. Calibration dependent progressive power and
Orange Voltage signal at coolant temperature signal pin speed derate and engine shut down as
No.22 indicates coolant temperature above 100 temperature increases over thresholds.
°C [212 °F].
153 More than 4.88 volts DC detected at intake No engine protection for intake manifold air
Yellow manifold air temperature signal pin No.23 of the temperature.
engine harness.
154 Less than 0.08 volts DC detected at intake No engine protection for intake manifold air
Yellow manifold air temperature signal pin No.23 of the temperature.
engine harness.
* 155 High intake air manifold temperature has been Calibration dependent progressive power and
Orange detected. Voltage signal at intake manifold sir speed derate and engine shutdown as
temperature signal pin No.23 indicates intake temperature increases over thresholds.
manifold air temperature above 104 °C [220 °F].
221 More than 4.78 volts DC detected at the ambient No action by the ECM is taken.
Yellow air temperature signal pin No.34 of the engine
harness.
222 Less than 0.20 volts DC detected at the ambient No action by the ECM is taken.
Yellow air temperature signal pin No.34 of the engine
harness.
231 More than 4.72 volts DC detected at the coolant No engine protection for the coolant pressure.
Yellow pressur sensor signal pin No.16 of the engine
harness.
232 Less than 0.33 volts DC detected at the coolant No engine protection for the coolant pressure.
Yellow pressur sensor signal pin No.16 of the engine
harness.
233 Low coolant level has been detected. The signal The engine power output and the engine speed
Orange from the coolant pressure sensor signal pin No.16 become low. After warning, the engine shuts
of the engine harness indicates lower than 28 kPa down.
-1
[4.1 psi] at 800 min (rpm); 41 kPa [5.9 psi] at
-1 -1
1300 min (rpm); 76 kPa [11 psi] at 1800 min
-1
(rpm); and 96 kPa [14 psi] at 2000 min (rpm);
-1
and 103 kPa [15 psi] above 2100 min (rpm).
* 234 Engine speed signals on No.27 and 28 and/or 37 Fuel shutoff valve de-energizes ( valve closes).
Red and 38 of engine harness indicate an engine Re-energizes (FSO valve opens) when engine
-1 -1
speed greater than 2650 min (rpm). speed falls below 2130 min (rpm).
235 Low coolant level has been detected. Voltage Calibration dependent progressive power and
Orange signal on the coolant level signal pin No.23 of the speed derate and engine shut down with
OEM interface harness indicates low radiator increasing time after alert.
coolant level on the vehicle.
254 Less than 17 volts DC detected at the fuel shutoff ECM doesn’t provide a voltage to the fuel shutoff
Off valve signal pin No.30 of the engine harness. valve. The engine shuts down.
TM
109
FAULT
INDICATOR
259 The fuel shutoff valve is always open. No action by the ECM is taken.
Red
261 The fuel temperature rises. The signal from the The engine power output and the engine speed
Orange fuel temperature signal pin No.26 indicates that it become low. When the fuel temperature rises
is more than 71 °C [160 °F]. beyond the set valve, the engine shuts down.
263 More than 4.95 volts DC detected at the fuel No engine protection for the fuel temperature.
Yellow temperature sensor signal pin No.26 of the engine
harness.
265 Less than 0.21 volts DC detected at the fuel No engine protection for the fuel temperature.
Yellow temperature sensor signal pin No.26 of the engine
harness.
316 Broken Circuit: at the fuel pump actuator circuit. No action by the ECM and the actuator is taken.
Yellow or
Short Circuit: between pin No.11 and the battery
power or the ground in the engine
harness.
or
Short Circuit: between pin No.40 and the battery
power or the ground in the engine
harness.
318 The difference between the desired pressure and No function by the ECM is taken.
Yellow the estimated one of the fuel pump pressure is
beyond the allowable limit.
343 Microprocessor communication error internal to Variable; Performance will or will not be affected.
Yellow the ECM.
* 346 ECM Powerdown internal data store error. Powerdown data (which includes maintenance
Off monitoring, current ECM/engine delta times, past
fault data) are lost.
* 415 Very low oil pressure has been detected. Voltage Calibration dependent progressive power and
Orange signal at oil pressure signal pin No.24 of the speed derate and engine shutdown with
engine harness indicates oil pressure lower than increasing time after alert.
-1
83 kPa [12 psi] at 600 min (rpm); 110 kPa [16
-1
psi] at 800 min (rpm); 138 kPa [20 psi] at 1500
-1
min (rpm); and 172 kPa [25 psi] above 2100
-1
min (rpm).
422 Voltage detected simultaneously on both the No engine protection for coolant level.
Yellow coolant level high and low signal pin No.14 and 23
of the OEM interface harness - or - no voltage
detected on either pin.
431 Voltage detected simultaneously on both the No action for the operational performance.
Yellow idling position switch signal pin No.12 and 13 of
the OEM interface harness.
432 Voltage detected at the idling ON swich of the idle The engine power outout and the engine speed
Red position switch signal pin No.13 of the OEM become low or the ECM doesn’t work.
harness when the voltage of the throttle position
sensor signal pin No.29 of the OEM harness
indicates that the pedal moves.
or
Voltage detected at the idling OFF swich of the
idle position switch signal pin No.12 of the OEM
harness when the voltage of the throttle position
sensor signal pin No.29 of the OEM harness
indicates that the pedal stops.
TM
110
FAULT
INDICATOR
* 441 Less than 12.0 volts DC battery voltage detected ECM voltage supply approaching level at which
Off at ECM. unpredictable operation will occur.
442 More than 38.0 volts DC battery voltage detected
ECM damage will occur.
Yellow at ECM.
451 More than 4.78 volts DC detected at the rail Depending on the calibration the engine will
Red pressure sensor signal pin No.31 of the engine shutdown or power derate or no action by the
harness. ECM is taken.
452 Less than 0.15 volts DC detected at the rail Depending on the calibration the engine signal
Red pressure sensor signal pin No.31 of the engine will shutdown or power derate or no action by the
harness. ECM is taken.
455 Rail Actuator circuit is open, or supply pin No.3 is No action by the ECM is taken. Actuator is closed,
Red shorted to battery voltage or ground, or return pin or partially closed. Engine will not run, or runs at
No.10 is shorted to battery voltage or ground in one speed. Fault code 514 will also be logged.
the engine harness.
457 The difference between the desired timing fuel The engine speed becomes low and the ECM
Yellow and the actualy supplied timing fuel is beyond the doesn’t work.
allowable limit.
468 The difference between the desired rail fuel and The engine speed becomes low and the ECM
Yellow the actualy supplied rail fuel is beyond the doesn’t work.
allowable limit.
514 The error between estimated rail fueling and Depending on the calibration the engine will
Red desired rail fueling is outside of acceptable limits. speed derate or no action by the ECM is taken.
Engine will overspeed, or run at one speed, or not
run.
551 At the same time shut down the voltage detected The engine doesn’t turn into 0% throttle.
Red at the idling position switch signal pin No.12 and
13 of the OEM interface harness.
553 Fuel rail pressure exceeds a normal limit. Fuel shutoff valve de-energized (valve closes).
Red Reenergizes (FSO valve opens) when fuel rail
pressure falls below acceptable limit for current
engine speed.
554 More than 1.83 volts DC or less than 0.50 volts Engine power derate of 25 percent.
Yellow DC detected at the rail pressure signal pin No.31
of the engine harness at engine key on.
555 The blowby pressure is high. The signal from the The engine power output and the engine speed
Orange blowby pressure is more than 368 mm H2O (14.5 become low. When the blowby pressure, the
In H2O). engine shuts down.
719 More than 4.94 volts DC detected at the blowby No engine protection for the blowby pressure.
harness.
729 Less than 0.29 volts DC detected at the blowby No engine protection for the blowby pressure.
harness.
753 The signals of pin No.27 and 28 in the engine No action by the ECM is taken.
Off position sensor and the signals of pin No.37 and
38 of the ECM are different.
TM
111
(Blank)
112
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
In this section, troubleshooting starts with a description

of the machine malfunction.
On the next page, malfunctions and possible causes

are shown on charts. Refer to the charts to find the
flow chart applicable for your problem.
• How to Read the Troubleshooting Flow Charts
YES (OK)
(2)
• • After checking or measuring item (1), select either Yes
(1)
(OK) or No (NOT OK) and proceed to item (2) or (3), as
appropriate.
(3)
NO (NOT OK)
• Special instructions or reference item are indicated in the spaces under the box.
•
Incorrect measuring or checking methods will render troubleshooting impossible,
and may damage components as well.
⋅ Key switch: ON
• Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
•
causes can be seen without going through the flow chart.
NOTE: If “Contact CUMMINS.” is indicated, be

sure to inform them of the fault codes if any
are indicated. (Refer to “Troubleshooting A”
for how to read fault codes.)
NOTE: For all connector drawings illustrated in this

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

Harness End Connector
T158-05-03-001
113
MACHINE MALFUNCTIONS AND POSSI-
BLE CASES
Engine System
Hydraulic
Controller Pump Engine Control
Possible Cause Component
MC(B) ECM Main Pump Shuttle Valve CUMMINS Throttle Auto-Idle Pilot
Regulator System Sensor Switch Pressure
Sensor
Malfunction
Engine speed doesn’t decrease

after all control levers are returned
to neutral. (Auto-Idle: ON)
• • • •
Engine speed doesn’t increase
when any of control lever is oper-
ated. (Auto-Idle: ON)
•
Engine doesn’t increase only when
a particular control lever is oper-
ated. (Auto-Idle: ON)
•
Engine speed doesn’t change even
though engine control lever is op-
erated.
• •
Engine stalls when operated under
severe conditions such as at high
altitude.
• • •
Starting aid doesn’t function.
•
PRELUB doesn’t function.
PRELUB gear pump rotates but

both top and bottom starters do not
rotate.
Actuator System
Pump Engine
Pump Hydraulic Component
Possible Cause Control Control
Main Pump Pilot Pump Pilot Valve Pilot Relief Control EHC Valve Engine
Malfunction Regulator Valve Valve Speed
Sensor
All actuators don’t move or move slowly.
• • •
Actuator doesn’t stop after control lever is
returned to neutral. • •
Speed sensing is inoperable.
• • •
Front Attachment System
Pump Control Valve Hydraulic Component
Possible Cause
Main Spool Spring Overload Load Check Make-Up Pilot Valve Cylinder
Malfunction Pump Relief Valve Valve Valve
Regulator
One or more front cylinders move
slowly. • • • •
Front attachment drifts exces-
sively. • • • • • •
Front attachment slightly moves
downward before beginning to
move.
• •
When boom raise and bucket are
simultaneously operated boom
raise speed is slow (loading shovel
only).
Single bucket operation speed is
slow (loading shovel only).
114
Engine Control Pump Control

Starting Starting Engine PRELUB Gear PRELUB Key Battery Starter Starter Safety Horse- Horse-
Aid Aid Speed Oil Pump Timer Switch Relay Relay power power
Solenoid (Ether) Sensor Pressure Reducing Reducing
Valve Relay Switch Solenoid Solenoid
Valve Valve
•
• •
• • • • • • •
• • • • • •
Hydraulic Component
NOTE: The above table shows the correlation be-
tween a machine operation trouble and the
Selector Boom Slow Return
Valve Priority Valve
related parts that may cause trouble if fail.
Valve However, the correlation described in this
table is based on the condition supposing
• • that a specific trouble only occurs. In case
any other troubles occur at the same time,
trace the causes of the troubles by check-
• ing all other parts that may cause these
troubles if fail at the same time.
115
Swing System
Hydraulic
Pump Control Valve Swing Device
Possible Cause Component
Swing Spool Main Relief Overload Pilot Valve Swing Swing Swing
Malfunction Pump/ Valve Relief Motor Relief Parking
Regulator Valve Valve Brake
Swing function is inoperable, slow,
or has no power. • • • • • •
Swing drifts excessively when
stopping. • • • • •
Travel System
Control Hydraulic
Travel Speed Travel Control
Possible Cause Valve Component
Spool Center Joint Travel Parking Reduction Swash Travel Travel Pilot
Motor Brake Gear Angle Stop Pressure
Malfunction Mechanism Valve Control
Valve
Travel function is inoperable or
slow. • • •
Fast travel mode is inoperable.
•
Slow travel mode is inoperable.
•
Machine mistracks.
• • • • • •
Auto-Lubrication System
Auto-
Possible Cause Controller Auto-Lubrication Device Lubrication
Control
MC (A) Grease Orifice Vent Valve Injector Auto- Auto-
Pump/Motor Lubrication Lubrication
Malfunction Solenoid Solenoid
Valve 1 Valve Relay 1
Grease Pump does not operate
both automatically and manually • • • •
Lubrication mode doesn’t change.
•
When auto lubrication mode is
selected, indicator comes ON. • • • • • • •

However, the correlation described in this
that a specific trouble only occurs. In case
ing all other parts that may cause these
116
Swing
Swing Control
Device
Swing Swing Stop Swing Stop Ladder
Reduction Solenoid Solenoid Limit
Gear Valve Valve Relay Switch
• • • •
Travel Control
Travel Reducing Travel Travel Travel Counter- Travel
Cut-Off Valve Mode Mode Mode balance Relief
Valve Solenoid Switch Control Valve Valve
Valve Relay
• •
• • •
• • • •
• •
Auto-Lubrication Control
Auto- Pressure
Lubrication Switch 1
Switch
•
•
• •
117
Wiper System
Controller Wiper Device Wiper Control
Possible Cause
MC (A) Top Side Bottom Fast Slow Wiper
Malfunction Wiper Side Wiper Wiper Wiper Switch
Motor Motor Relay Relay
Wiper doesn’t operate in fast
mode. • • •
Wiper doesn’t operate in slow
mode. • • • • •
Others
Oil Cooler Fan Fast Filling System
Possible Cause
MC (A) Fan Fan Reducing Fan Motor Fast Filling Check Fast Filling
Malfunction Pump motor Valve Solenoid Switch Valve Solenoid
Regulator Valve Valve
Oil cooler fan motor doesn’t rotate,
or doesn’t rotate at speed corre-
sponding to the hydraulic oil tem- • • • • •
perature.
Even if fast filling switch is turned
ON, fast filling paled doesn’t lower. • • •

However, the correlation described in this
that a specific trouble only occurs. In case
ing all other parts that may cause these
118
(Blank)
119
ENGINE SYSTEM
Engine speed does not decrease after control
levers are returned to neutral.
(With auto-idle switch turned on)
• Check for loose harness connections beforehand. No Broken harness be-

Con- tween pilot pressure
Disconnect pilot pres- tinuity sensor and MC (B), or
sure sensor. Connect broken ground circuit
harness end connector between pilot pressure
terminals #1 and #3. sensor and vehicle
Disconnect MC (B) con- frame.
NO
nector (A). Check for
continuity between har-
ness end connector ter- Faulty MC (B).
minal #A42 and vehicle Con-
frame. tinuity
⋅ Key Switch: OFF
Check if voltage be- Disconnect MC (A) and
MC (B).
YES tween pilot pressure
sensor connector ter- With pilot pressure sen-
minals #1 and #3 is NO sor disconnected, check
5±0.5 V. for continuity between
sensor end harness
⋅ Key Switch: ON connector terminal #2
⋅ Auto Idle Switch: ON and vehicle frame.
Check if voltage at pilot
pressure sensor con-
YES nector terminal #2 is less
than 0.74 V.
Disconnect pilot pres-
Using engine speed ⋅ Key Switch: ON sure sensor. Ground
control lever, engine ⋅ Auto-Idle Switch: ON harness end connector
speed varies normally. ⋅ Measure the voltage from terminal #2 to vehicle
the rear of connector with frame. Disconnect MC
⋅ Engine: Running connector connected. (B).
YES Check for continuity
between harness end
connector terminal #A31
and vehicle frame.
Faulty ECM.
Contact CUMMINS.
NO
Connector
Pilot Pressure Sensor
T141-05-005
120
Continuity Short-circuited harness be-

tween MC (A) or MC (B) and
pilot pressure sensor.
Faulty pilot pressure sensor.

No Continuity
Continuity Broken harness between MC

(B) and pilot pressure sensor.
YES Faulty auto-idle switch
Reconnect disconnected
connector. Disconnect MC (B) con-
No Check if auto-idle indicator Continuity Faulty MC (B).
Continuity comes ON. nector (A). Ground har-
ness end connector ter-
⋅ Key Switch: ON minal #A27 to vehicle
⋅ Auto-Idle Switch: ON frame.
NO
Check for continuity be-
tween auto-idle switch Broken harness between MC
line (brown) and vehicle No (B) and auto-idle switch.
frame. Continuity
⋅ Key Switch: ON
Connectors
MC(A) and MC(B)
T141-05-04-006
121
Engine stalls when operated under adverse con-
ditions such as operating on mountains.
• Check for loose harness connections beforehand.
Faulty ECM.
YES
Contact CUMMINS.
Check if voltage at pilot

pressure sensor con-
nector terminal #2 is 0.9
V or more.
⋅ Key Switch: ON
⋅ Measure the voltage Faulty pilot pressure sen-
from the rear of con- NO sor.
nector with connector
connected.
Connector
Pilot Pressure Sensor
T141-05-04-005
Engine speed does not increase only when a par-

ticular control lever is operated
(Auto-Idle Switch : ON)
Engine speed does not

increase only when a Faulty shuttle valve.
certain function is op-
erated.
122
Engine speed does not change even though en-
gine control lever is operated.
• Refer to Troubleshooting A when the engine stop

indicator 1 comes ON.
Faulty ECM .
YES
Contact CUMMINS.
YES
Faulty harness between

throttle sensor and ECM, or
Install measurement harness NO faulty engine unit.
at throttle sensor.
Operate fuel lever to full
stroke.
Check if voltage between ter-
minals #1 and #2 changes
within 0.4 to 4.4 V.
⋅ Measurement Harness
(Parts No. 3046248)
Faulty throttle sensor.
NO
Connector
Throttle Sensor
T141-05-04-004
123
Engine stalls when operated under severe condi-
tions such as at high altitude.
Faulty engine (consult

YES CUMMINS DIESEL Co.)
or faulty main pump
regulator.
Remove plug 1 from

manifold 9 and install Disconnect horsepower
pressure gauge. Check
YES
if pressure is 3.9±0.5 YES reducing solenoid valve
2 at plug connector. Check
Mpa (40±5 kgf/cm ) if voltage at harness end
when engine speed is terminal #1 is 26 V.
reduced to less than
1
⋅ Engine running
Remove plug 2 from
Check if resistance in
manifold 9 and install
engine speed sensor is
pressure gauge. Check if
pressure varies in the NO 200 to 300 Ω.
range of 0 to 0.78 Mpa (0
2
to 8 kgf/cm ) while op-
erating fuel lever from the
minimum speed position
to the maximum speed Faulty engine speed
position. sensor.
NO
⋅ Engine running
-1
(2050 min or slower)
Refer to the Malfunction of
Speed Sensing Control.
NO
Horsepower Reducing
Solenoid Valve
EHC Valve
Manifold 9
Plug 1 (PF1/4)
Plug 2 (PF1/4)
T117-06-02-031
124
YES Faulty horsepower reducing

valve.
YES
Faulty power decrease so-
lenoid valve relay.
Connect power decrease
solenoid valve.
Check if engine stalls after
NO switching power decrease
solenoid valve relay and Faulty MC (B), or broken
other normal relay. harness between MC (B)
NO terminal #B41 and power
decrease solenoid valve.
Connectors
Horsepower Reducing Valve
T141-05-04-012
MC(B) Connector B
T141-05-04-020
125
Starting aid does not function.
NOTE: When the coolant temperature is -6.7 °C

(20 °F) or higher, the starting aid solenoid
valve is not activated.
YES Faulty Starting

aid(ether) relay.
Check if ether is in- Faulty ECM, or broken

YES jected after switching 0V
wire between ECM and
ether relay and the ether relay.
relay next to it.
⋅ Key Switch: START
With ether relay discon-
nected, measure volt-
NO age at harness end ter-
minal #1.
Check if ether bottle With ether relay discon-
is securely installed. nected, measure voltage
⋅ Also, check if the at harness end terminal
24 V #4.
bottle contains suffi-
cient amount of ⋅ Key Switch: START
ether.
Incorrect ether bottle

installation, or empty
NO
ether bottle.
Connectors
Starting Aid Relay
T141-05-04-007
126
YES Blown fuse #24 or

fusible link #4.
0 V Check if fuse #24, fusi-

ble link #4 is blown.
Broken wire between

ether relay and ter-
NO minal 2.
0 V Broken wire between

ether solenoid valve
and ether relay.
Install ether relay.

Disconnect ether
solenoid valve con-
24 V nector (positive).
Measure voltage at
harness end.
Faulty ether solenoid
24 V valve.
127
PRELUB does not function.
• All hydraulic oil stop valves are open.

• The emergency engine stop switch and engine stop
switch are turned OFF.
Disconnect PRELUB
24 V timer. Measure voltage
at harness end con-
nector terminal #3.
⋅ Key switch: START
YES Measure voltage

at starter (lower) Harness breakage
terminal B. 24 V
between battery relay
and starter.
⋅ Key switch: ON
Measure voltage at
battery relay terminal
Check if battery voltage 0 V A.
and specific gravity of ⋅ Key switch: ON
battery electrolyte are
in normal ranges.
Measure voltage at key

switch terminal M
0V (terminal #4).
⋅ Key switch: ON
Faulty battery
NO
Battery Relay
T141-05-04-024
128
Continuity Faulty PRELUB pressure

Disconnect both side of switch.
24 V PRELUB pressure
switch terminal. Check
continuity between Faulty gear pump
switch terminals. No continuity
Measure voltage at
24 V starter (lower) terminal
Disconnect PRELUB
M. timer and PRELUB re- Faulty PRELUB timer or
lay. Continuity broken harness between
⋅ Key Switch: ON
Check for continuity PRELUB timer and starter.
between PRELUB timer
terminal #7 and PRE-
0V LUB relay terminal #2,
and between PRELUB Broken harness.
timer terminal #6 and No continuity
PRELUB relay terminal
#1.
24 V Broken harness between
valve switch relay 1 and
PRELUB timer.
Reconnect PRELUB
timer connector. Broken harness between
Measure voltage at key switch and valve switch
0V 24 V
valve switch relay 1 relay 1, or between valve
terminal #4. switch relay 1 and engine
⋅ Key Switch: START Measure voltage at key stop relay 1.
switch terminal
0V G2.(terminal #5)
⋅ Key Switch: START Faulty key switch
0V
24 V Harness breakage between

battery relay and key switch.
Disconnect battery relay
24 V line to terminal S.
Measure voltage at
harness side terminal.
Faulty battery relay
⋅ Key switch: ON 0V
Faulty key switch

0V
Connectors
PRELUB Timer PRELUB Relay Key Switch Valve Switch Relay 1
T141-05-04-013 T141-05-04-016
T141-05-04-007
T141-05-04-015
129
PRELUB gear pump operates but both top and
bottom starters do not rotate.
• Engine oil is sufficient.

Short-circuited har-
ness between PRE-
Continuity LUB oil pressure swit-
ch and PRELUB timer
solenoid.
Check for continuity With starter relay connec-
between harness end tors (2 used) disconnected,
connector terminal #4 disconnect PRELUB timer
and vehicle solenoid connector.
NO 0V
frame.Check for con- Check for continuity be-
tinuity between har- tween PRELUB timer har-
ness end connector ness end connector terminal
terminal #4 and vehi- #5 and starter relay con-
cle frame. Reconnect discon-
nector terminal #2.
nected connector.
⋅ Key Switch: ON Disconnect starter re-
lay (2 used).
Disconnect PRELUB Measure voltage at
No continuity
oil pressure switch harness end connector
line (black and white). terminal #2.
Check if starter ro- ⋅ Key Switch: ON
tates. Reconnect disconnected
⋅ Key Switch: START connector.
Disconnect safety relay.
Check for continuity be-
24 V tween contacting point end
connector terminals #3 and
Faulty PRELUB oil #4.
pressure switch or
YES gear pump.
130
Connectors
PRELUB timer
T141-05-04-013
Starter Relay, Safety Relay

continuity Faulty PRELUB timer.
T141-05-04-014
Broken harness be-

tween PRELUB timer
No continuity and starter relay.
No continuity Faulty safety relay.
24 V Faulty starter.
Reconnect disconnect-
ed connector.
continuity Measure voltage at
starter terminal C.
⋅ Key Switch: START Faulty starter relay, or
broken harness be-
0V tween starter relay and
starter.
131
ACTUATOR SYSTEM
All actuators do not move or move slowly.
Disconnect connector
from horsepower
YES
reducing solenoid
valve. Check if
problem disappears.
Check if primary pilot

YES pressure is in normal
range.
⋅ Primary pilot
pressure :
4.4±0.5 Mpa
Check if pilot control 2 Remove, disassemble,
(45±5 kgf/cm .)
shut-off lever is moved to clean, reassemble,
UNLOCK position. and reinstall pilot relief
NO valve. Check if
problem still appears.
Move pilot control

shut-off lever to
NO UNLOCK position.
Delivery Flow Rate of Main Pump Unit: L/min

MP1 MP2 MP3 MP4 MP5 MP6 Total
Travel Right 375 375 − − − − 750
Travel Left − − 375 375 − − 750
Swing − − − − 425 425 850
Boom Raise 375 375 375 375 425 425 2350
Boom Lower − − 375 375 425 425 1600
BH: Arm Roll-In BH:375 BH:2350
375 375 375 425 425
LD: Arm Roll-Out LD:100 LD:2075
BH: Arm Roll-Out BH:100 BH:100 BH:1425
375 375 100 375
LD: Arm Roll-In LD: − LD: − LD:1225
Bucket Roll-In 375 375 375 375 425 425 2350
BH:375 BH:375 BH:100 BH:100 BH:100 BH:1425
Bucket Roll-Out 375
LD: − LD: − LD:375 LD:425 LD:425 LD:1600
Bucket
375 375 − − − − 750
Open/Close (LD)
NOTE: BH: Backhoe, LD: Loading Shovel
132
NO Faulty MC.
Disconnect engine speed

YES sensor. Check if resis-
tance at sensor is 200 to
300 Ω.
Faulty engine speed

YES sensor.
Sticking of horsepower
reducing solenoid valve
NO spool.
YES Faulty pilot valve.
Faulty pilot relief valve

NO
Connector
Engine Speed Sensor
T141-05-04-008
133

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SECTION 1

Use operational performance test procedure to quan-

Purpose of Performance Tests

Precautions for Evaluation of Test Data

The machine performance does not always deteriorate

Definition of “Performance Standard”

Observe the following rules in order to carry out

TEST AREA AND MEASURING EQUIPMENT

MAKE PRECISE MEASUREMENT T105-06-01-004

Performance Test Conditions:

2. Disconnect the engine speed sensor connector

3. Start the engine, run it at the specified speeds,

Deceleration Zone: Travel Test Distance: Acceleration Zone:

CAUTION: Never work under a machine

Place blocks under the machine frame to

4. Maintain the hydraulic oil temperature at 50±5

NOTE: When tested on a concrete surface road,

Evaluation: Acceleration Zone:

CAUTION: Prevent personal injury. Always

1. Confirm that the swing gears and bearing are

bucket cylinders fully extended, position the arm

Evaluation: Marking on the Track Frame

5. Position the dial gauge so that its needle point

Loading Shovel Front

2. Position the front attachment as described in the

center of full stroke movement of the bucket is

stroke to position the bucket bottom 1 m (39 in)

NOTE: When checking soon after cylinder T145-05-03-020

2. Position the front attachment as described in the

NOTE: BH: Backhoe

CAUTION: Prevent personal injury. Always

3. Operate the boom, arm, bucket, and swing levers

levers full stroke from the neutral position at the

CAUTION: Prevent personal injury. Always T142-05-03-008

CAUTION: The breather cap may pop off if

2. Release air from the hydraulic oil tank by loosen

4. Start the engine and check for oil leakage from

5. Maintain the hydraulic oil temperature at 50±5 °C

2. Repeat step (1) three times and calculate the

: 4 mm 1. Select the following switch / lever positions:

: 22 mm 3. Repeat step (2) three times and calculate the

Shuttle Valve 1 Shuttle Valve 4 T141-05-02-001

Shuttle Valve 2 Shuttle Valve 3

Loading Shovel: Backhoe:

CAUTION: The breather cap may pop off if

2. Release air from the hydraulic oil tank by loosen 2

3. Install the pressure gauge in the gauge port 4

5. Maintain the hydraulic oil temperature at 50±5 °C

3. Repeat step (2) three times and calculate the 1 1

1. Loosen the lock nut .

2. Adjust main relief pressure by turning the

4. Recheck the relief pressure settings.

1. Loosen the lock nut.

2. Turn the adjusting screw to adjust the pressure

3. Retighten the lock nut.

4. Recheck the relief pressure setting.

NOTE: Change in pressure setting

1. Loosen the lock nut.

2. Adjust travel relief pressure by turning the

3. Tighten the lock nut.

: 17 mm Travel Relief Valve

4. Recheck the travel relief pressure. Lock Nut

NOTE: Change in pressure setting