SECTION 6 TROUBLESHOOTING

GROUP 1 HYDRAULIC AND MECHANICAL SYSTEM

1. INTRODUCTION
1) MACHINE IN GENERAL
(1) If even a minor fault is left intact and operation is continued, a fatal failure may be caused,
entailing a large sum of expenses and long hours of restoration.
Therefore when even a small trouble occurs, do not rely on your intuition and experience, but
look for the cause based on the troubleshooting principle and perform maintenance and
adjustment to prevent major failure from occurring. Keep in mind that a fault results from a
combination of different causes.
(2) The following lists up commonly occurring faults and possible causes with this machine. For the
troubleshooting of the engine, refer to the coming troubleshooting and repair.
(3) When carrying out troubleshooting, do not hurry to disassemble the components.
It will become impossible to find the cause of the problem.
(4) Ask user or operator the following.
‫ ڸ‬Was there any strange thing about machine before failure occurred?
‫ ڹ‬Under what conditions did the failure occur?
‫ ں‬Have any repairs been carried out before the failure?
(5) Check before troubleshooting.
‫ ڸ‬Check oil and fuel level.
‫ ڹ‬Check for any external leakage of oil from components.
‫ ں‬Check for loose or damage of wiring and connections.

6-1
2. DRIVE SYSTEM
1) UNUSUAL NOISE COMES OUT OF PUMP CONNECTION

Cause Remedy
YES
Coupling element Disassemble and
is broken. repair.
Remove dust plug
under engine
flywheel and check YES
if rubber pieces or Replace hub or
particles are not retighten
present. Coupling hub setscrew.
spline is worn or
NO hub fastening
setscrew is slack.
If hydraulic pump or engine is suspected as
NO
a culprit, refer also to shop manuals
"hydraulic components" and"engine"

6-2
 2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL

Cause Remedy
NO
Replenish
specified oil to the
Is oil level in Abnormal noise standard level.
YES YES
hydraulic oil tank comes out of Hydraulic pump is Disassemble and
within standard hydraulic pump broken. repair.
level?
Do not hydraulic
Abnormal noise
pump and pump YES YES
comes out of See item 1).
YES connections make
pump connection
abnormal noise?

Is primary pilot
pressure within ‫ڞ‬
NO standard level?

YES
Clean pilot piping
Is not pilot piping interior or repair
YES clogged or is not
piping.
oil leakage present
on pilot piping?
Pilot valve is faulty. Disassemble and
NO
‫ڞ‬ repair.

YES
Pilot relief valve is Repair of replace.
Is gear pump faulty.
NO delivering oil?
Gear pump is Disassemble and
NO
broken. repair.

6-3
3. HYDRAULIC SYSTEM
1) HYDRAULIC OIL IS CLOUDY

Cause Remedy
YES
Water is mixed. Put hydraulic oil
still, separate
Drop hydraulic oil water and
sample on hot
dispose it or
plate and check if
foams come up. replace hydraulic
oil.
Air is intruded. Check suction
NO
line and return
line and eliminate
the air intruding
source.

2) HYDRAULIC OIL TEMPERATURE HAS RISEN ABNORMALLY

Cause Remedy
NO Replenish
specified oil to the
standard level.
Is hydraulic oil
volume proper? YES
Clean oil cooler.
In not oil cooler Secure air
clogged and is circulation route.
YES anything blocking YES ‫ڞ‬
air circulation?
Is fan belt tension
NO proper?
Adjust belt
NO
tension or replace
belt.

Is not the set YES Readjust set

pressure of main
relief,port relief and pressure.
‫ڞ‬
travel relief valve
lower than the Is main relief valve YES Reduce load.
standard level? NO used very often?

6-4
 3) CAVITATION OCCURS WITH PUMP

Cause Remedy
NO
Replenish
specified oil to the
standard level.
Is hydraulic oil
YES
volume proper? Replace oil with
one of proper
Is not viscosity of viscosity.
YES hydraulic oil too YES
high? Clean suction
strainer.
Is not suction
NO Is not air intruding
strainer clogged?
Check for air
NO from pump suction
line? intrusion in
suction line and
retighten or
replace parts.

4) HYDRAULIC OIL IS CONTAMINATED

Cause Remedy
YES
Replace
Has not hydraulic hydraulic oil to be
oil passed specified.
specified replace-
ment hours? Has return filter
NO
been replaced at Flush with
NO
proper intervals? hydraulic oil and
replace return
filter.

6-5
4. SWING SYSTEM
1) BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE

Cause Remedy
NO
Replenish
YES specified oil to the
‫ڞ‬
Is safety valve
YES standard level.
pressure within
standard?
Gear is gear pump Safety valve faulty Repair or replace.
pressure within NO
Is oil in hydraulic or not operated.
YES standard level?
tank within
standard level? Gear pump faulty Repair or replace.
NO
YES
Main relief valve Disassemble and
YES Is not main relief faulty repair.
valve faulty?
Is swing brake
Are attachment Swing motor is out Disassemble and
‫ڞ‬ release valve NO
and travel motions pressure within of order. repair.
impossible at all? standard? Is not pilot relief
valve faulty? Swing brake release Disassemble and
NO NO
valve is out of order. repair.
NO
Swing control valve Disassemble and
YES Does swing control
valve spool move spool is stuck. repair.
Is MCV pilot
YES ‫ڟ‬
pressure within YES
standard level?
Does RH travel ‫ڠ‬
NO
NO function? Does not symptom
change when front YES
and rear pump Hydraulic pump is Disassemble and
NO
discharge hoses broken. repair.
are exchanged?
YES
Swing brake release Disassemble and
valve is broken. repair.
Is swing brake
‫ڟ‬ release valve YES
faulty? Swing reduction Disassemble and
Does swing motor unit is broken. repair.
NO rotate?
Swing motor is Disassemble and
NO
broken. repair.
YES
Pilot relief valve is Disassemble and
NO Is gear pump faulty. repair or replace.
delivering oil?
Gear pump is out of Disassemble and
Is gear pump pilot NO
order. repair.
‫ڠ‬ pressure within
standard level? YES
Is not there oil Clean pilot piping
leakage from pilot interior or repair
YES piping or is not it piping.
clogged? Pilot valve is Disassemble and
NO
broken. repair.

6-6
 2) SWING SPEED IS LOW

Cause Remedy
YES
Swing port relief Disassemble and
Does swing control
YES valve is faulty. repair or replace.
valve spool move
smoothly by hand?
Swing control valve Disassemble and
NO
Is secondary pilot spool is stuck. repair.
pressure same on
LH and RH sides? YES
Clogged or oil leak. Clean pilot piping
Is not pilot piping
interior or repair
Single direction clogged or is not it
NO piping.
leaking oil?
Is the trouble in NO Pilot valve or main Disassemble and
one direction or in control valve is repair.
both direction? faulty.
YES ‫ڞ‬
Does swing control
YES
Both directions valve spool move
Is MCV pilot lightly by hand?
YES pressure within Swing control valve Disassemble and
NO
Is Arm speed standard level? spool is stuck. repair.
within standard ‫ڟ‬
value? NO
‫ڠ‬
NO
Is swing motor's
‫ڞ‬ NO Swing motor is Disassemble and
drain rate within
standard value? broken. repair.
Check that pilot
YES piping is not NO
Pilot valve or swing Disassemble and
clogged or oil is
not leaking from it? motor is faulty. repair.

Is gear pump pilot Clogged or oil leak. Clean pilot piping

‫ڟ‬ pressure within interior or repair
standard level?
piping.

YES
Pilot relief valve is Disassemble and
Is gear pump
defective. repair or replace.
NO delivering oil?
NO
Gear pump is Disassemble and
broken. repair.
NO
Main relief valve Main relief valve
faulty. pressure resetting
or repair.
Is main relief valve Does the symptom YES Hydraulic pump is Disassemble and
‫ڠ‬ setting pressure change when front
YES broken. repair.
normal and rear pump
discharge hoses
Is safety valve pilot are exchanged? Swing motor faulty. Repair or replace.
NO
pressure within
YES YES
standard level? Pilot relief faulty. Repair or replace.
Is gear pump
output pressure
NO within standard
level Gear pump faulty. Repair or replace.
NO

6-7
 3) SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION

Cause Remedy
YES
Does symptom Swing port relief Disassemble and
change when LH valve is faulty. repair.
YES
and RH port relief
valves are
Does swing exchanged Swing control valve Disassemble and
NO
YES control valve spool or swing motor is repair.
move smoothly by faulty
hand?
Is MCV pilot
pressure same for Swing control valve Disassemble and
NO
LH and RH? spool is stuck. repair.
Check if pilot piping
is not clogged or YES
Pilot valve is Disassemble and
NO does not have oil
leakage. broken. repair.

Clogged or oil
leak. Clean pilot piping
interior or repair
piping.

4) MACHINE SWINGS BUT DOES NOT STOP

Cause Remedy
YES
Swing brake Disassemble and
release valve line is repair or replace.
YES Is MCV pilot YES Is gear pump pilot
pressure within pressure within faulty.
standard value? standard level?
Gear pump is Disassemble and
NO
Does swing broken. repair.
YES control valve spool
move smoothly by
hand? Pilot valve is faulty. Disassemble and
NO
repair.
Is swing control
valve's return
spring normal? Swing control valve Disassemble and
NO
spool is stuck. repair.

NO Return spring is Disassemble and

faulty. replace.

6-8
 5) THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE

Cause Remedy
YES
Swing brake Disassemble and
release valve or replace.
YES Is brake spring swing brake is
normal? abnormal.
YES Is brake spring
normal? NO ‫ڞ‬
Is return spring of
swing control Brake spring is Disassemble and
valve normal? NO
faulty replace.
NO Return spring of Disassemble and
swing control valve replace.
is faulty.

YES
Swing relief valve Disassemble and
YES Is drain rate of is faulty. repair or replace.
swing motor within
standard value?
Is swing relief Swing motor is Disassemble and
NO
‫ڞ‬ pressure within broken. repair.
standard level?

NO Adjust swing relief

valve pressure or
replace swing
relief valve.

6-9
5. TRAVEL SYSTEM
1) TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE

Cause Remedy
YES ‫ڞ‬
Does counterbalance
YES spool in travel brake
valve move lightly by
Is travel brake hand?
YES valve pressure Counter spool in
NO
Disassemble and
within standard Does the symptom travel brake valve repair or replace.
Has travel control level? change when relief is stuck.
YES valve spool valves in travel YES
Relief valve built in Disassemble and
changed over NO motor are
exchanged? travel motor is repair.
positively?
faulty.
YES
Does spool move Control system is Disassemble
lightly when hand defective. inspect and
NO is let free from repair.
control lever?
Is bucket or arm NO
Travel control valve Disassemble and
operation spool is stuck. repair.
possible?
YES
Travel reduction Disassemble and
Do not metallic
particles come out unit is faulty. repair.
‫ڞ‬ of drain port in
travel reduction
unit?
NO Travel motor is out Disassemble and
of order. repair.
Does the symptom
change when front
and rear pump YES
Hydraulic pump is Disassemble and
NO discharge hoses
broken. repair.
are exchanged?

6 - 10
 2) SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES

Cause Remedy
YES
Brake valve is Disassemble and
Do LH and RH travel defective. repair or replace.
speeds change
YES when LH and RH
YES
travel brake valves Does the symptom Relief valve built in Disassemble and
are exchanged? change when relief travel motor is repair.
valves in LH and
NO faulty.
Has control valve RH travel motors
YES ‫ڞ‬
spool changed are exchanged? NO
over positively?
YES
Control system is Disassemble,
Does spool move faulty . inspect and
lightly when it is repair.
Is the lower speed
NO cut off from control
(bucket or arm) spool?
within standard Control valve spool Disassemble and
level? NO
is stuck. repair.

YES
Travel relief valve is Disassemble and
Do LH and RH
faulty. repair or replace.
travel speeds Does the symptom
change over when YES
change when front YES
NO travel relief valves and rear pump Hydraulic pump is Disassemble and
are exchanged? Is external pilot discharge hoses broken. repair.
pressure within are exchanged?
NO
standard level?
NO External pilot piping Disassemble and
is clogged or oil is clean.
leaking from it.
Does travel speed
change when
YES parking brake YES Travel motor's Disassemble and
Is leak rate of spring in the slower parking brake is not clean pilot piping.
‫ڞ‬ travel motor within travel motor is
released properly.
standard level?
Travel motor is Disassemble and
NO
faulty. repair.

6 - 11
 3) MACHINE DOES NOT STOP ON A SLOPE
Machine is pulled forward as sprocket rotates during digging operation.

Cause Remedy
None Is parking brake YES
Friction plate is Disassemble and
Check if parking friction plate worn?
YES faulty. repair.
brake pilot line is
not clogged.
clogged Disassemble and
clean pilot piping.
Is travel brake Is drain rate of NO
pressure within travel motor within Travel motor is Disassemble and
standard level? standard value? defective or drain repair.
line is clogged.

Brake release Disassemble and

NO
valve is faulty or repair or replace.
pilot relief valve is
abnormal.

4) LH AND RH TRAVEL MOTIONS ARE IMPOSSIBLE

Cause Remedy
YES
Inspect according
to the procedure
"Travel does not
function at all on
one side."
However, a case
where both LH
and RH travel
motions are
disabled is
extremely
seldom
Is bucket or arm
statistically.
operation
possible? OK Hydraulic pump is Disassemble and
Disassemble both
travel relief valves faulty. repair.
OK and inspect for
Remove dust plug any fault or check
under engine main relief valve.
OK flywheel and Travel relief valve Disassemble and
Faulty
check that there is is faulty. repair or replace.
no coupling
Check oil volume element particles.
Particles present. Coupling at pump Disassemble and
in hydraulic oil
NO connection is repair.
tank.
broken.
Short Replenish
hydraulic oil.

6 - 12
 5) TRAVEL ACTION IS POWERLESS(travel only)

Cause Remedy
YES
‫ڞ‬
YES Is travel motor's
drain rate within
standard level?
YES Is travel brake NO
Travel motor is Disassemble and
pressure within faulty. repair.
standard level?
Is travel relief valve Travel brake valve Disassemble and
pressure within NO
is defective. repair or replace.
standard level?

Travel relief valve Disassemble and

NO
or main relief valve repair or replace.
is faulty.

YES
Hydraulic circuit Disassemble and
Does parking that releases travel clean.
Remove parking Increases brake piston move parking brake is
brake spring in lightly by hand? clogged with dirt.
travel motor, draw
out piston Parking brake Disassemble and
‫ڞ‬ NO
completely, refit piston in travel repair.
cover and check if motor is stuck.
travel power Remains
unchanged Travel reduction Disassemble and
changes.
unit is defective. repair.

6) MACHINE RUNS RECKLESSLY ON A SLOPE

Travel brake valve Cause Remedy

(counterbalance
valve) is faulty or Disassemble and
brake release valve repair or replace.
or line is abnormal.

6 - 13
 7) MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL AND
ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME

Cause Remedy
Is operation of all
YES
spools except arm2 Repair spool
YES Is RCV pilot spool normal? assembly.
pressure normal?

NO
Repair RCV pilot
YES Is T/S valve
normal? line.

Is pilot pressure for T/S valve is faulty. Repair or replace.

NO
travel straight(T/S)
valve within YES Remove dirt on
standard level? Is filter in pilot pilot line filter.
piping between
gear pump and YES Is pilot relief valve NO Pilot relief valve is
NO Disassemble and
control valve not
clogged? normal? defective. repair or replace.
Does gear pump
NO deliver oil?
Gear pump is Disassemble and
NO
broken. repair.

6 - 14
6. ATTACHMENT SYSTEM
1) BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL

Cause Remedy
Does the symptom YES Port relief valve is Disassemble and
change when port faulty. repair or replace.
YES
relief valve is
replaced with other
Is MCV pilot valve? ‫ڞ‬
YES NO
pressure within
standard level? Inspect if pilot
piping is not OK
YES Are other clogged or oil is not Pilot valve is faulty. Disassemble and
attachments NO
leaking from the repair.
operable? piping.
YES
Pilot relief valve is Disassemble and
Is gear pump pilot NO
Is gear pump faulty. repair or replace.
pressure within
NO delivering oil?
standard level?
Gear pump is Disassemble and
NO
Are LH/RH broken. repair.
operations
possible? OK Hydraulic pump is Disassemble and
Disassemble main broken. repair.
YES relief valve and
Remove dust plug check if it is not
under engine irregular.
OK flywheel and check Main relief valve is Disassemble and
Faulty
if coupling element defective. repair or replace.
particles are not
Inspect oil volume present. Particles present
NO
in hydraulic oil Coupling at pump Disassemble and
tank. connection is repair.
broken.
Short
Replenish
hydraulic oil
YES
Does control valve Cylinder interior is Disassemble and
‫ڞ‬ spool move lightly broken. repair.
by hand?
NO Control valve spool Disassemble and
is stuck. repair.

6 - 15
 2) BOOM, ARM OR BUCKET SPEED IS LOW
Cause Remedy
YES
Normal
YES ‫ڞ‬
Are other
YES attachment speeds
Is speed low only Is combination of within standard
oil streams normal levels? ‫ڟ‬
in composite YES NO
operation? at boom hoisting YES Summation spool
and at arm Repair or replace.
extrusion? Is summation is faulty.
(2 spools) spool
Are LH/RH travel NO
normal?
speeds within Replace spring.
NO NO
standard levels?
YES
Hydraulic pump is Disassemble and
Are both LH/RH faulty. repair.
YES ‫ڠ‬
NO travel speeds low?
Is MCV pilot
pressure within
NO
standard?
NO
‫ڡ‬
Does the symptom OK Port relief valve is Disassemble and
YES change when port faulty. repair or replace.
relief valve is
replaced with other
Does control valve valve? Cylinder is faulty. Disassemble and
YES spool move lightly NO
repair.
by hand?

NO
Control valve spool Disassemble and
Is MCV pilot
‫ڞ‬ pressure within is stuck. repair.
standard level?
YES
Is not secondary Clean pilot piping
pilot pressure interior or repair
piping clogged or
NO piping.
is not there oil
leakage? Pilot valve is Disassemble and
NO
defective. repair.
YES
Pilot relief valve is Disassemble and
Is primary pilot
NO Is gear pump faulty. repair or replace.
‫ڟ‬ pressure within
delivering oil?
standard level?
Gear pump is Disassemble and
NO
broken. repair.
Is engine
NO
‫ڠ‬ revolution within Adjust engine
standard level? revolution.

YES
Clean orifice in
control valve.
Is not orifice in
‫ڡ‬ control valve YES
clogged? Is pilot piping not Clean pilot piping
clogged or is oil interior or repair
NO not leaking from piping
the piping? Is pilot valve
Pilot valve is faulty. Disassemble and
NO normal? NO
repair.

6 - 16
 3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS

Cause Remedy
YES
Port relief valve is Disassemble and
Does the symptom
faulty repair or replace.
change when port
Normal
relief valve is
replaced with YES
‫ڞ‬
normal valve? Is control valve
YES Is not hydraulic oil NO return spring
normal?
temperature high? Control valves Disassemble and
NO
return spring is replace.
faulty.
Is genuine Abnormally high. Locate the cause
hydraulic oil or of hydraulic oil
equivalent being
used? temperature rise
and lower it to
proper level.

NO Replace with
genuine hydraulic
oil or equivalent.
OK
Disassemble and Pressure tightness Disassemble and
inspect check between control repair.
YES
valve in hydraulic valve casing and
circuit and check spool is poor.
Is cylinder internal for any fault.
Abnormal Contact surface Disassemble and
‫ڞ‬ leakage within
between poppet repair.
standard level?
and seat is poor.
NO
Cylinder is faulty. Disassemble and
repair.

6 - 17
 4) BOOM, ARM OR BUCKET POWER IS WEAK

Cause Remedy
YES
Check according
Is cylinder internal to the procedure
YES leakage within in Item "Speed is
standard level? low"
Is relief pressure in
YES port relief valve Cylinder is faulty. Disassemble and
NO
within standard repair.
level?

NO
Port relief valve is Adjust pressure,
YES faulty. repair or replace.
Is relief pressure in Is power boost in
main relief valve YES main relief valve YES
Cylinder is faulty. Disassembly and
within standard within standard Is the solenoid
level? repair.
level? valve of power
NO boost
normal(40K)?
Power boost Disassemble and
NO
solenoid valve is repair.
faulty.

Main relief valve is Adjust pressure,

NO
defective. repair or replace.

5) ONLY BUCKET OPERATION IS TOTALLY IMPOSSIBLE

Cause Remedy
YES
Port relief valve is Disassemble and
Does the symptom
defective. repair or replace.
change when port
YES relief valve is
replaced with YES
Cylinder interior is Disassemble and
other valve? Does control valve broken. repair.
Is secondary pilot NO spool move
YES smoothly by hand?
pressure within Control valve spool Disassemble and
standard level? NO
is stuck. repair.

Is RH travel Pilot valve is faulty. Disassemble and

NO
possible? repair.

YES
Does the symptom Main relief valve is Adjust pressure,
change when faulty. repair or replace.
LH/RH main relief Does the symptom
NO
valves are change when YES
exchanged? Hydraulic pump is Disassemble and
NO hydraulic pump's
discharge hoses broken. repair.
are exchanged?

6 - 18
 6) BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED

Cause Remedy
YES
Frictional noise
occurs between
the sliding faces
of boom
cylinder's oil seal
and boom
Is boom foot pin
greased proper.
sufficiently? Ɠ Frictional
noise will
disappear if
they are kept
used.

Boom foot pin has Supply grease to

NO
run out of grease. it.
Ɠ If seizure is in
an initial stage,
supply
sufficient
grease.
If seizure is in
a grown state,
correct it by
paper lapping
or with an oil
stone.

6 - 19
Ɠ HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE

1. Lower the bucket teeth to the ground with

bucket cylinder fully retracted and arm
cylinder rod retracted almost in full.

2. Disconnect hose(A) from rod side of boom

cylinder and drain oil from cylinders and
hose.(Put cups on piping and hose ends) A

3. Raise bucket OFF the ground by retracting

the arm cylinder rod.

If off leaks from piping side and boom cylinder

rod is retracted there is an internal leak in the
cylinder.
If no oil leaks from piping side and boom
cylinder rod is retracted, there is an internal
leak in the control valve.

6 - 20