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PART NO.
TTJAE-EN-00
ZX470-5A • 470LC-5A • 490H-5A • 490LCH-5A • 530LCH-5A HYDRAULIC EXCAVATOR TECHNICAL MANUAL TROUBLESHOOTING
Technical Manual
Troubleshooting
ZX
470-5A
470LC-5A
490H-5A
490LCH-5A
530LCH-5A
URL:http://www.hitachi-c-m.com
Hydraulic Excavator
Service Manual consists of the following separate Part No.

TTJAE-EN-00
Technical Manual (Operational Principle) : Vol. No.TOJAE-EN

Technical Manual (Troubleshooting) : Vol. No.TTJAE-EN
Workshop Manual : Vol. No.WJAE-EN
PRINTED IN JAPAN (K) 2016, 03 Engine Manual : Vol. No.ETJAE-EN, EWJAE-EN
INTRODUCTION
To The Reader
This manual is written for an experienced technician to  If you have any questions or comments, at if you found
provide technical information needed to maintain and any errors regarding the contents of this manual,
repair this machine. please contact using “Service Manual Revision Request
The machine specification and description according to Form” at the end of this manual. (Note: Do not tear off
destination may be explained on this manual. the form. Copy it for usage.):
 Technical Information Center Hitachi Construction
 Be sure to thoroughly read this manual for correct Machinery Co., Ltd.
product information and service procedures.  TEL: 81-29-832-7084
 FAX: 81-29-831-1162
 E-mail: HCM-TIC-GES@hitachi-kenki.com
Additional References
Please refer to the other materials (operator’s manual,
parts catalog, engine technical material and Hitachi
training material etc.) in addition to this manual.
Manual Composition
This manual consists the Technical Manual, the Workshop  Information included in the Workshop Manual:
Manual and the Engine Manual. Technical information needed for maintenance and
repair of the machine, tools and devices needed for
 Information included in the Technical Manual: maintenance and repair, maintenance standards, and
Technical information needed for redelivery and delivery, removal / installation and assemble / disassemble
operation and activation of all devices and systems, procedures.
operational performance tests, and troubleshooting
procedures.  Information included in the Engine Manual:
Technical information needed for redelivery and delivery
and maintenance and repair of the machine, operation
and activation of all devices and systems, troubleshooting
and assemble / disassemble procedures.
Page Number
Each page has a number, located on the center lower part
of the page, and each number contains the following
information:
Example:
 Technical Manual: T 1-3-5  Workshop Manual: W 1-3-2-5
T Technical Manual W Workshop Manual
1 Section Number 1 Section Number
3 Group Number 3 Group Number
5 Consecutive Page Number for Each Group 2 Sub Group Number
5 Consecutive Page Number for Each Group
IN-01
INTRODUCTION
Safety Alert Symbol and Headline Notations
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the potential dCAUTION:
for personal injury of machine damage. Indicates potentially hazardous situation which could, if
not avoided, result in personal injury or death.
d This is the safety alert symbol. When you see this IMPORTANT:
symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention to
component/part weights.
To avoid injury and damage, be sure to use appropriate
fNOTE:
Indicates supplementary technical information or know-
lifting techniques and equipment when lifting heavy
how.
parts.
Units Used
SI Units (International System of Units) are used in this Example: 24.5 MPa (250 kgf/cm2, 3560 psi)
manual. MKSA system units and English units are also
indicated in parentheses just behind SI units. A table for conversion from SI units to other system units
is shown below for reference purposes.
Quantity To Convert From Into Multiply By

Length mm in 0.03937
mm ft 0.003281
Volume L US gal 0.2642
L US qt 1.057
m3 yd3 1.308
Weight kg lb 2.205
Force N kgf 0.10197
N lbf 0.2248
Torque N·m kgf·m 0.10197
Pressure MPa kgf/cm 2
10.197
MPa psi 145.0
Power kW PS 1.360
kW HP 1.341
Temperature °C °F °C×1.8+32
Velocity km/h mph 0.6214
min -1
rpm 1.0
Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0
fNOTE: The numerical value in this manual might be

different from the above-mentioned table.
IN-02
SYMBOL AND ABBREVIATION
Symbol/ Name Explanation

Abbreviation
TO Technical manual (Operational principle)Technical manual (Operational Principle).
TT Technical manual (Troubleshooting) Technical manual (Troubleshooting).
T/M Technical manual Technical manual.
W, W/M Workshop manual Workshop manual (Removal and Installation, Disassembly
and Assembly).
MC Main Controller Main controller. MC controls the engine, pump, and valve
according to the machine operating condition.
ECM Engine Control Module Engine controller. ECM controls fuel injection amount
according to the machine operating condition.
GSM Global System for Mobile communications Communication controller. GSM is a type of wireless
controller communication system, is used in more than on 100
countries around Europe and Asia, and becomes the factual
global standards of the mobile telephone.
GPS Global Positioning System Global positioning system.
CAN Controller Area Network CAN communication. CAN is a serial communications
protocol internationally-standardized by ISO (International
Organization for Standardization).
A/C Air Conditioner Air conditioner.
OP, OPT Option Optional component.
MPDr. Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and
adjustment.
A/I Auto-Idle Auto-idle.
WU Warming-Up Warming-up.
Li Low (Slow) Idle Slow idle engine speed.
ATT Attachment Attachment. Attachment is optional parts such as breaker,
crusher, and pulverizer in this manual.
HI, Hi High Travel fast position.
LO, Lo Low Travel slow position.
EGR Exhaust Gas Recirculation The EGR control re-circulates a part of exhaust gas in the
intake manifold and combines it with intake-air. Therefore,
combustion temperature is lowered and generation of oxide
of nitrogen (NOx) is controlled.
ML Moment Limiter ML clane.
SPN-FMI Service Principal Name - Failure Mode ECM fault code(Hitachi Construction Machinery Co.).
Identifier
DTC Diagnostic Trouble Code ECM fault code(Engine Manufacturer).
SY-1
SYMBOL AND ABBREVIATION
(Blank)
SY-2
SAFETY
Recognize Safety Information

 These are the SAFETY ALERT SYMBOLS.
 When you see these symbols on your machine or in this
manual, be alert to the potential for personal injury.
 Follow recommended precautions and safe operating
practices.
SA-688
Understand Signal Words

 On machine safety signs, signal words designating the
degree or level of hazard - DANGER, WARNING, or CAUTION
- are used with the safety alert symbol.
 DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
 WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
 CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
 DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs.
 Some safety signs do not use any of the designated signal
words above after the safety alert symbol are occasionally
used on this machine.
 CAUTION also calls attention to safety message in this

manual.
SA-1223
 To avoid confusing machine protection with personal
safety messages, a signal word IMPORTANT indicates a
situation which, if not avoided, could result in damage to
the machine.
 NOTE: indicates an additional explanation for an

element of information.
SA-1
SAFETY
Follow Safety Instructions

 Carefully read and follow all safety signs on the machine
and all safety messages in this manual.
 Safety signs should be installed, maintained and replaced
when necessary.
 If a safety sign or this manual is damaged or missing,
order a replacement from your authorized dealer in the
same way you order other replacement parts (be sure to
state machine model and serial number when ordering).
 Learn how to operate the machine and its controls correctly
and safely.
 Allow only trained, qualified, authorized personnel to
operate the machine.
 Keep your machine in proper working condition. SA-003
 Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
 Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, function,
and/or service life. In addition, personal accident,
machine trouble, and/or damage to material caused by
unauthorized modifications will void Hitachi Warranty
Policy.
 Do not use attachments and/or optional parts or
equipment not authorized by Hitachi. Failure to do so
may deteriorate the safety, function, and/or service life
of the machine. In addition, personal accident, machine
trouble, and/or damage to material caused by using
unauthorized attachments and/or optional parts or
equipment will void Hitachi Warranty Policy.
 The safety messages in this SAFETY chapter are intended
to illustrate basic safety procedures of machines. However
it is impossible for these safety messages to cover every
hazardous situation you may encounter. If you have any
questions, you should first consult your supervisor and/
or your authorized dealer before operating or performing
maintenance work on the machine.
SA-2
SAFETY
Prepare for Emergencies

 Be prepared if a fire starts or if an accident occurs.
 Keep a first aid kit and fire extinguisher on hand.
 Thoroughly read and understand the label attached on
the fire extinguisher to use it properly.
 To ensure that a fire extinguisher can be always used
when necessary, check and service the fire extinguisher
at the recommended intervals as specified in the fire
extinguisher manual.
 Establish emergency procedure guidelines to cope with
fires and accidents.
 Keep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near your
telephone. SA-437
Wear Protective Clothing

 Wear close fitting clothing and safety equipment
appropriate to the job.
You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing SA-438
Wet weather gear
Respirator or filter mask
Be sure to wear the correct equipment and clothing for the
job. Do not take any chances.
 Avoid wearing loose clothing, jewelry, or other items that
can catch on control levers or other parts of the machine.
 Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones while
operating the machine.
SA-3
SAFETY
Protect Against Noise

 Prolonged exposure to loud noise can cause impairment or
loss of hearing.
 Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortably loud noises.
SA-434
Inspect Machine
 Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
 In the walk-around inspection be sure to cover all points
described in the "Inspect Machine Daily Before Starting"
section in the operator’s manual.
SA-435
SA-4
SAFETY
General Precautions for Cab
 Before entering the cab, thoroughly remove all dirt and/or
oil such as mud, grease, soil or stones that may mess up
the cab from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots, the operator’s foot
may slip off the pedal, possibly resulting in a personal
accident.
 Do not mess up around the operator’s seat with parts,
tools, soil, stones, obstacles that may fold up or turn
over, cans or lunch box. The levers or pedals become
inoperable if obstacle jams in operation stroke of the
travel levers/pedals, pilot control shut-off lever or control
levers, which may result in serious injury or death.
 Avoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.
 Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
 Keep all flammable objects and/or explosives away from
the machine.
 After using the ashtray, always cover it to extinguish the
match and/or tobacco.
 Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.
 Use proper floor mat dedicated to the machine. If another
floor mat is used, it may be displaced and contact with
the travel pedals during operation, resulting in serious
injury or death.
SA-5
SAFETY
Use Handholds and Steps

 Falling is one of the major causes of personal injury.
 When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
 Do not use any controls as hand-holds.
 Never jump on or off the machine. Never mount or
dismount a moving machine.
 Before getting on or off the machine, check the condition
of the steps and handrails for sticking of slippery material
like grease or mud. Thoroughly remove such material if
stuck. In addition, repair the damage to the steps and/or
SA-439
handrails. Retighten loose bolts.
 Never get on and off the machine with tools in your
hands.
Adjust the Operator's Seat

 A poorly adjusted seat for either the operator or the
work at hand may quickly fatigue the operator leading to
misoperations.
 The seat should be adjusted whenever changing the
operator for the machine.
 The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
 If not, move the seat forward or backward, and check
again.
 Adjust the rear view mirror position so that the best rear
visibility is obtained from the operator’s seat. If the mirror SA-378
is broken, immediately replace it with a new one.
SA-6
SAFETY
Ensure Safety Before Rising from or Leaving
Operator’s Seat
 Before rising from the operator’s seat to open/close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the pilot control shut-off lever to the LOCK position. Failure
to do so may allow the machine to unexpectedly move
when a body part unintentionally comes in contact with
a control lever and/or pedal, possibly resulting in serious
personal injury or death.
 Before leaving the machine, be sure to first lower the front
attachment to the ground and then move the pilot control
shut-off lever to the LOCK position. Turn the key switch OFF
to stop the engine.
 Before leaving the machine, close all windows, doors, and
access covers and lock them up.
Fasten Your Seat Belt

 If the machine should overturn, the operator may become
injured and/or thrown from the cab. Additionally the
operator may be crushed by the overturning machine,
resulting in serious injury or death.
 Prior to operating the machine, thoroughly examine
webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine.
 Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation to SA-237
minimize the chance of injury from an accident.
 We recommend that the seat belt is replaced every three
years regardless of its apparent condition.
SA-7
SAFETY
Move and Operate Machine Safely

 Bystanders can be run over.
 Take extra care not to run over bystanders. Confirm the
location of bystanders before moving, swinging, or
 Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
 Use a signal person when moving, swinging, or operating
the machine in congested areas. Coordinate hand signals
before starting the machine.
 Use appropriate illumination. Check that all lights are SA-426
operable before operating the machine. If any faulty
illumination is present, immediately repair it.
 Ensure the cab door, windows, doors and covers are
securely locked.
 Check the mirrors and the monitor in the cab for
problems.
If there is, replace the problem part(s) or clean the mirror,
camera lens and the monitor display.
Refer to "Rear View Monitor" section on the cleaning of
the camera lens and the monitor display in the operator’s
manual.
Operate Only from Operator's Seat

 Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury or
death.
 Start the engine only when seated in the operator's seat.
 NEVER start the engine while standing on the track or the
ground.
 Do not start engine by shorting across starter terminals.
 Before starting the engine, confirm that all control levers
are in neutral.
 Before starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders. SA-444
SA-8
SAFETY
Jump Starting
 Battery gas can explode, resulting in serious injury.
 If the engine must be jump started, be sure to follow
the instructions shown in the “OPERATING THE ENGINE”
chapter in the operator’s manual.
 The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
 Never use a frozen battery.
 Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
SA-032
Keep Riders off Machine

 Riders on machine are subject to injury such as being struck
by foreign objects and being thrown off the machine.
 Only the operator should be on the machine. Keep riders
off.
 Riders also obstruct the operator’s view, resulting in the
machine being operated in an unsafe manner.
SA-379
SA-9
SAFETY
Precautions for Operations

 Investigate the work site before starting operations.
 Be sure to wear close fitting clothing and safety
equipment appropriate for the job, such as a hard hat,
etc. when operating the machine.
 Clear all persons and obstacles from the area of operation
and machine movement. Do not permit persons
other than the operator to enter areas where there is
danger such as flying objects. Always beware of the
surroundings while operating. When working in a small
area surrounded by obstacles, take care not to hit the
upperstructure against obstacles.
 When loading onto trucks, bring the bucket over the truck
beds from the rear side. Take care not to swing the bucket
over the cab or over any person.
M178-05-007
SA-10
SAFETY
Investigate Job Site Beforehand

 When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
serious injury or death.
 Investigate the configuration and ground conditions of
the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles or banks
from collapsing.
 Make a work plan. Use machines appropriate to the work
and job site.
 Reinforce ground, edges and road shoulders as
necessary. Keep the machine well back from the edges of
excavations and road shoulders.
 When working on an incline or on a road shoulder, SA-380
employ a signal person as required.
 Confirm that your machine is equipped with a FOPS cab
before working in areas where the possibility of falling
stones or debris exist.
 When the footing is weak, reinforce the ground before
starting work.
 When working on frozen ground, be extremely alert. As
ambient temperatures rise, footing becomes loose and
slippery.
 Beware the possibility of fire when operating the machine
near flammable objects such as dry grass.
SA-11
SAFETY
 Make sure the worksite has sufficient strength to firmly
support the machine.
When working close to an excavation or at road
shoulders, operate the machine with the tracks positioned
perpendicular to the cliff face with travel motors at the rear,
so that the machine can more easily evacuate if the cliff face
collapses.
 If working on the bottom of a cliff or a high bank is required,
be sure to investigate the area first and confirm that no
danger of the cliff or bank collapsing exists. If any possibility
of cliff or bank collapsing exists, do not work on the area.
 Soft ground may collapse when operating the machine on
it, possibly causing the machine to tip over. When working
on soft ground is required, be sure to reinforce the ground
first using large pieces of steel plates strong and firm
enough to easily support the machine.
 Note that there is always a possibility of machine tipping
over when working on rough terrain or on slopes. Prevent M104-05-016
machine tipping over from occurring. When operating on
rough terrain or on slopes:
 Reduce the engine speed.
 Select slow travel speed mode.
 Operate the machine slowly and be cautious with
machine movements.
Install OPG Guard

In case the machine is operated in areas where the possibilities
of falling stones or debris exist, install the Hitachi OPG guard.
Consult your authorized dealer for installing the OPG guard.
In order not to impair operator protective structure:
Replace damaged OPG guard. Never attempt to repair or
modify the guard.
OPG: Operator Protective Guard
SA-490
SA-12
SAFETY
Restriction of Attachment Installation

 Do not install an attachment which exceeds specified
weight for the machine structure.
Provide Signals for Jobs Involving Multiple

Machines
 For jobs involving multiple machines, provide signals
commonly known by all personnel involved. Also, appoint
a signal person to coordinate the job site. Make sure that all
personnel obey the signal person’s directions.
SA-481
Confirm Direction of Machine to Be Driven

 Incorrect travel pedal/lever operation may result in serious
injury or death.
 Before driving the machine, confirm the position of the
undercarriage in relation to the operator’s position. If the
travel motors are located in front of the cab, the machine
will move in reverse when travel pedals/levers are
operated to the front.
SA-491
SA-13
SAFETY
Drive Machine Safely

 Before driving the machine, always confirm that the travel
levers/pedals direction corresponds to the direction you
wish to drive.
 Be sure to detour around any obstructions.
 Avoid traveling over obstructions. Soil, fragments of rocks,
and/or metal pieces may scatter around the machine. Do A
not allow personnel to stay around the machine while
traveling.
 Driving on a slope may cause the machine to slip or SA-657

overturn, possibly resulting in serious injury or death.
 Never attempt to ascend or descend 35 degrees or
steeper slopes.
 Be sure to fasten the seat belt.
 When driving up or down a slope, keep the bucket facing
the direction of travel, approximately 0.2 to 0.3 m (A)
above the ground.
 If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and stop.
 Driving across the face of a slope or steering on a
slope may cause the machine to skid or turnover. If A SA-658
the direction must be changed, move the machine to
level ground, then, change the direction to ensure safe
operation.
SA-441
WRONG
SA-590
SA-14
SAFETY
 Avoid swinging the upperstructure on slopes. Never
attempt to swing the upperstructure downhill. The
machine may tip over. If swinging uphill is unavoidable,
carefully operate the upperstructure and boom at slow
speed.
 If the engine stalls on a slope, immediately lower the
bucket to the ground. Return the control levers to neutral.
Then, restart the engine.
 Be sure to thoroughly warm up the machine before
ascending steep slopes. If hydraulic oil has not warmed
up sufficiently, sufficient performance may not be Travel Motor
obtained.
 Use a signal person when moving, swinging or operating M104-05-008
the machine in congested areas. Coordinate hand signals
before starting the machine.
 Before moving machine, determine which way to move
travel pedals/levers for the direction you want to go.
When the travel motors are in the rear, pushing down
on the front of the travel pedals or pushing the levers
forward moves the machine forward, towards the idlers.
An arrow-mark seal is stuck on the inside surface of the
side frame to indicate the machine front direction.
 Select a travel route that is as flat as possible. Steer the
Arrow -mark
machine as straight as possible, making small gradual
changes in direction. M178-03-001
 Before traveling on them, check the strengths of bridges
and road shoulders, and reinforce if necessary.
 Use wood plates in order not to damage the road surface.
Be careful of steering when operating on asphalt roads in
summer.
 When crossing train tracks, use wood plates in order not
to damage them.
 Do not make contact with electric wires or bridges.
 When crossing a river, measure the depth of the river
using the bucket, and cross slowly. Do not cross the river
when the depth of the river is deeper than the upper
edge of the upper roller.
SA-011
 When traveling on rough terrain, reduce engine speed.
Select slow travel speed. Slower speed will reduce
possible damage to the machine.
 Avoid operations that may damage the track and
undercarriage components.
 During freezing weather, always clean snow and ice from
track shoes before loading and unloading machine, to
prevent the machine from slipping.
SA-15
SAFETY
Avoid Injury from Rollaway Accidents

 Death or serious injury may result if you attempt to mount
or stop a moving machine.
To avoid rollaways:
 Select level ground when possible to park the machine.
 Do not park the machine on a grade.
 Lower the bucket and/or other work tools to the ground.
 Turn the auto-idle switch OFF.
 Run the engine at slow idle speed without load for 5
minutes to cool down the engine.
 Stop the engine and remove the key from the key switch.
 Pull the pilot control shut-off lever to LOCK position.
SA-391
 Block both tracks and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must park
on a grade.
 Position the machine to prevent rolling.
 Park at a reasonable distance from other machines.
SA-2273
SA-16
SAFETY
Avoid Injury from Back-Over and Swing

Accidents
 If any person is present near the machine when backing or
swinging the upperstructure, the machine may hit or run
over that person, resulting in serious injury or death.
To avoid back-over and swing accidents:
 Always look around BEFORE YOU BACK UP AND SWING
THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE
CLEAR.
 Keep the travel alarm in working condition (if equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE
WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
 USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW
IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN
VIEW. SA-383
Use hand signals, which conform to your local regulations,
when work conditions require a signal person.
 No machine motions shall be made unless signals are
clearly understood by both signal person and operator.
 Learn the meanings of all flags, signs, and markings used
on the job and confirm who has the responsibility for
signaling.
 Keep windows, mirrors, and lights clean and in good
condition.
 Dust, heavy rain, fog, etc., can reduce visibility. As visibility
decreases, reduce speed and use proper lighting.
 Read and understand all operating instructions in the SA-384
operator’s manual.
SA-17
SAFETY
Keep Person Clear from Working Area

 A person around the operating machine may be hit severely
by the swinging front attachment or counterweight, be
caught in other objects, and/or be struck by flying objects,
 Set up barriers and/or put a NO ADMISSION sign at the
machine operating site and areas exposed by flying
objects to prevent anyone from entering the work area.
 Before operating the machine, confirm that there are
no obstacles or person other than signal person from
working area.
SA-386
Never Position Bucket Over Anyone

 Never lift, move, or swing bucket above anyone or a truck
cab.
Serious injury or machine damage may result due to bucket
load spill or due to collision with the bucket.
SA-487
SA-18
SAFETY
Avoid Undercutting
 In order to retreat from the edge of an excavation if the
footing should collapse, always position the undercarriage
perpendicular to the edge of the excavation with the travel
motors at the rear.
 If the footing starts to collapse and if retreat is not
possible, do not panic. Often, the machine can be secured
by lowering the front attachment, in such cases.
SA-488
Avoid Tipping
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE
--- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP
FREE
FASTEN YOUR SEAT BELT
 The danger of tipping is always present when operating on
a grade, possibly resulting in serious injury or death.
To avoid tipping:
 Be extra careful before operating on a grade.
 Prepare machine operating area flat.
 Keep the bucket low to the ground and close to the SA-012
machine.
 Reduce operating speeds to avoid tipping or slipping.
 Avoid changing direction when traveling on grades.
 NEVER attempt to travel across a grade steeper than 15
degrees if crossing the grade is unavoidable.
 Reduce swing speed as necessary when swinging loads.
 Be careful when working on frozen ground.

 Temperature increases will cause the ground to become
soft and make ground travel unstable.
SA-440
SA-19
SAFETY
Never Undercut a High Bank

 The edges could collapse or a land slide could occur causing
SA-489
Dig with Caution

 Accidental severing of underground cables or gas lines may
cause an explosion and/or fire, possibly resulting in serious
injury or death.
 Before digging check the location of cables, gas lines, and
water lines.
 Keep the minimum distance required, by law, from cables,
gas lines, and water lines.
 If a fiber optic cable should be accidentally severed, do
not look into the end. Doing so may result in serious eye
injury.
 Contact your local “diggers hot line” if available in your
area , and/or the utility companies directly.
SA-382
Have them mark all underground utilities.
Operate with Caution

 If the front attachment or any other part of the machine hits
against an overhead obstacle, such as a bridge, both the
machine and the overhead obstacle will be damaged, and
personal injury may result as well.
 Take care to avoid hitting overhead obstacles with the
boom or arm.
SA-389
SA-20
SAFETY
Avoid Power Lines

 Serious injury or death can result if the machine or front
attachments are not kept a safe distance from electric lines.
 When operating near an electric line, NEVER move any
part of the machine or load closer than 3 m plus twice the
line insulator length.
 Check and comply with any local regulations that may
apply.
 Wet ground will expand the area that could cause any
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site.
SA-381
Precautions for Lightning

 Lightning may strike the machine.
If lightning comes close, immediately stop the operation,

and take the following action.
 When you are around the machine or operating cab-
less machine, evacuate to a safe place far away from the
machine.
 When you are in the cab, stay in the cab until lightning
has passed and safety is secured. Close the cab doors and
windows. Lower the bucket to the ground, and stop the
engine. Put your hands on your lap to avoid contact with
any metal surfaces. Never go out of the cab.
SA-1088
If lightning strikes the machine or near the machine, check
all of the machine safety devices for any failure after
lightning has passed and safety is secured. If any trouble is
found, operate the machine only after repairing it.
SA-21
SAFETY
Object Handling
 If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed underneath it,
 When using the machine for craning operations, be sure
to comply with all local regulations.
 Do not use damaged chains or frayed cables, sables,
slings, or ropes.
 Before craning, position the upperstructure with the
travel motors at the rear.
 Move the load slowly and carefully. Never move it
suddenly.
 Keep all persons well away from the load.
 Never move a load over a person’s head.
 Do not allow anyone to approach the load until it is safely
and securely situated on supporting blocks or on the
ground.
 Never attach a sling or chain to the bucket teeth. They
may come off, causing the load to fall.
SA-014
Protect Against Flying Debris

 If flying debris hit eyes or any other part of the body, serious
injury may result.
 Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
 Keep bystanders away from the working area before
striking any object.
 Always close the front windows, doors, door windows and
the overhead window when operating the machine.
SA-432
SA-22
SAFETY
Park Machine Safely

To avoid accidents:
 Park machine on a firm, level surface.
 Lower bucket to the ground.
 Turn auto-idle switch OFF.
 Run engine at slow idle speed without load for 5 minutes.
 Turn key switch to OFF to stop engine.
 Remove the key from the key switch.
 Pull the pilot control shut-off lever to the LOCK position.
 Close windows, roof vent, and cab door.
 Lock all access doors and compartments.
SA-390
Handle Fluids Safely−Avoid Fires

 Handle fuel with care; it is highly flammable. If fuel ignites,
an explosion and/or a fire may occur, possibly resulting in
 Do not refuel the machine while smoking or when near
open flame or sparks.
 Always stop the engine before refueling the machine.
 Fill the fuel tank outdoors.
 All fuels, most lubricants, and some coolants are flammable.

 Store flammable fluids well away from fire hazards.
 Do not incinerate or puncture pressurized containers.
 Do not store oily rags; they can ignite and burn SA-018
spontaneously.
 Securely tighten the fuel and oil filler caps.
SA-019
SA-23
SAFETY
Transport Safely
 Take care, the machine may turn over when loading or
unloading the machine onto or off of a truck or trailer.
 Observe the related regulations and rules for safe
transportation.
 Select an appropriate truck or trailer for the machine to
be transported.
 Be sure to use a signal person.
 Always follow the following precautions for loading or
unloading:
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to support the
machine weight. SA-395
3. Turn auto-idle switch OFF.

4. Always select the slow speed mode with the travel mode
switch.
5. Never load or unload the machine onto or off a truck
or trailer using the front attachment functions when
driving up or down the ramp.
6. Never steer the machine while on the ramp. If the
traveling direction must be changed while the ramp,
unload the machine from the ramp, reposition the
machine on the ground, then try loading again.
7. The top end of the ramp where it meets the flatbed is a
sudden bump. Take care when traveling over it.
8. Place blocks in front of and behind the tires. Securely
hold the machine to the truck or trailer deck with wire
ropes.
Be sure to further follow the details described in the

"TRANSPORTING" chapter in the operator’s manual.
SA-24
SAFETY
Practice Safe Maintenance

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

1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load for 5
minutes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by moving
the control levers several times. SA-028
7. Remove the key from the key switch.

8. Attach a “Do Not Operate” tag on the control lever.
9. Pull the pilot control shut-off lever to the LOCK position.
10. Allow the engine to cool.
 If a maintenance procedure must be performed with the

engine running, do not leave the machine unattended.
 If the machine must be raised, maintain a 90 to 110˚
angle between the boom and arm. Securely support any
machine elements that must be raised for service work.
 Inspect certain parts periodically and repair or replace as
necessary. Refer to the section discussing that part in the
“MAINTENANCE” chapter in the operator’s manual. SA-527
 Keep all parts in good condition and properly installed.
 Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
 When cleaning parts, always use nonflammable
detergent oil. Never use highly flammable oil such as fuel
oil and gasoline to clean parts or surfaces.
 Disconnect battery ground cable (−) before making
adjustments to electrical systems or before performing
welding on the machine.
SA-25
SAFETY
 Sufficiently illuminate the work site. Use a maintenance
work light when working under or inside the machine.
 Always use a work light protected with a guard. In case
the light bulb is broken, spilled fuel, oil, antifreeze fluid, or
window washer fluid may catch fire.
SA-037
Warn Others of Service Work

 Unexpected machine movement can cause serious injury.
 Before performing any work on the machine, attach a “Do
Not Operate” tag on the control lever.
This tag is available from your authorized dealer.
SS2045102
Support Machine Properly

 Never attempt to work on the machine without securing
the machine first.
 Always lower the attachment to the ground before you
work on the machine.
 If you must work on a lifted machine or attachment,
securely support the machine or attachment. Do not
support the machine on cinder blocks, hollow tires, or
props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
SA-527
SA-26
SAFETY
Stay Clear of Moving Parts

 Entanglement in moving parts can cause serious injury.
 To prevent accidents, care should be taken to ensure that
hands, feet, clothing, jewelry and hair do not become
entangled when working around rotating parts.
SA-026
SA-2294
Prevent Parts from Flying

 Grease in the track adjuster is under high pressure.
Failure to follow the precautions below may result in serious
injury, blindness, or death.
 Do not attempt to remove GREASE FITTING or VALVE
ASSEMBLY.
 Do not attempt to remove grease fitting securing cover.
 As pieces may fly off, be sure to keep body and face away
from valve.
 Never attempt to disassemble the track adjuster.
Inadvertent disassembling of the track adjuster may
cause the parts such as a spring to fly off, possibly SA-344
resulting in severe personal injury or death.
 Travel reduction gears are under pressure.

 As pieces may fly off, be sure to keep body and face away
from AIR RELEASE PLUG to avoid injury.
 GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually
loosen AIR RELEASE PLUG to release pressure.
SA-27
SAFETY
Avoid Injury from Attachment Falling Accident

 Stored attachments such as buckets, hydraulic hammers,
and blades can fall and cause serious injury or death.
 To avoid possible personal injury from attachment falling
accident, use a platform when replacing an attachment.
 Securely store attachments and implements to prevent
falling. Keep children and bystanders away from storage
areas.
SA-034
Prevent Burns
Hot spraying fluids:
 After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, radiator and
heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.
 Avoid possible injury from hot spraying water. DO NOT
remove the expansion tank cap until the engine is cool.
When opening, turn the cap slowly to the stop. Allow all
pressure to be released before removing the cap.
 The hydraulic oil tank is pressurized. Again, be sure to SA-039
release all pressure before removing the cap.
Hot fluids and surfaces:
 Engine oil, gear oil and hydraulic oil also become hot during
operation.
The engine, hoses, lines and other parts become hot as well.
 Wait for the oil and components to cool before starting
any maintenance or inspection work.
SA-225
SA-28
SAFETY
Replace Rubber Hoses Periodically

 Rubber hoses that contain flammable fluids under pressure
may break due to aging, fatigue, and abrasion. It is very
difficult to gauge the extent of deterioration due to aging,
fatigue, and abrasion of rubber hoses by inspection alone.
 Periodically replace the rubber hoses. (See the page of
“Periodic replacement of parts” in the operator’s manual.)
 Failure to periodically replace rubber hoses may cause a fire,

fluid injection into skin, or the front attachment to fall on a
SA-019
person nearby, which may result in severe burns, gangrene,
or otherwise serious injury or death.
Avoid High-Pressure Fluids

 Fluids such as diesel fuel or hydraulic oil under pressure can
penetrate the skin or eyes causing serious injury, blindness
or death.
 Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
 Tighten all connections before applying pressure.
 Search for leaks with a piece of cardboard; take care to
protect hands and body from high-pressure fluids. Wear a
face shield or goggles for eye protection.
 If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the SA-031
skin must be surgically removed within a few hours or
gangrene may result.
SA-292
SA-044
SA-29
SAFETY
Prevent Fires
Check for Oil Leaks:
 Fuel, hydraulic oil and lubricant leaks can lead to fires.
 Check for oil leaks due to missing or loose clamps, kinked
hoses, lines or hoses that rub against each other, damage
to the oil cooler, and loose oil cooler flange bolts.
 Tighten, repair or replace any missing, loose or damaged
clamps, lines, hoses, oil cooler and oil cooler flange bolts.
 Do not bend or strike high-pressure lines.
 Never install bent or damaged lines, pipes, or hoses.
 Replace fuel hoses and hydraulic hoses periodically even
if there is no abnormality in their external appearance.
SA-019
Check for Shorts:
 Short circuits can cause fires.
 Clean and tighten all electrical connections.
 Check before each shift or after eight (8) to ten (10) hours
operation for loose, kinked, hardened or frayed electrical
cables and wires.
 Check before each shift or after eight (8) to ten (10) hours
operation for missing or damaged terminal caps.
 DO NOT OPERATE MACHINE if cable or wires are loose,
kinked, etc.
 Never attempt to modify electric wirings.
SA-30
SAFETY
Clean up Flammable Materials:
 Spilled fuel and oil, and trash, grease, debris, accumulated
coal dust, and other flammable materials may cause fires.
 Prevent fires by inspecting and cleaning the machine
daily, and by removing adhered oil or accumulated
flammable materials immediately. Check and clean high
temperature parts such as the exhaust outlet and muffler
earlier than the normal interval.
 Do not wrap high temperature parts such as a muffler or
exhaust pipe with oil absorbents.
 Do not store oily cloths as they are vulnerable to catching
fire.
 Keep flammable materials away from open flames.
 Do not ignite or crush a pressurized or sealed container.
 Wire screens may be provided on openings on the engine
compartment covers to prevent flammable materials
such as dead leaves from entering. However, flammable
materials which have passed through the wire screen
may cause fires. Check and clean the machine every
day and immediately remove accumulated flammable
materials.
Check Key Switch:

 If a fire breaks out, failure to stop the engine will escalate
the fire, hampering fire fighting.
Always check key switch function before operating the
machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key switch to the OFF position to confirm that
the engine stops.
 If any abnormalities are found, be sure to repair them
Check Heat Shields:

 Damaged or missing heat shields may lead to fires.
 Damaged or missing heat shields must be repaired or

replaced before operating the machine.
 If hydraulic hoses are broken while the engine cover is
open, splattered oil on the high temperature parts such
as muffler may cause fire. Always close the engine cover
while operating the machine.
SA-31
SAFETY
Evacuating in Case of Fire

 If a fire breaks out, evacuate the machine in the following
way:
 Stop the engine by turning the key switch to the OFF
position if there is time.
 Use a fire extinguisher if there is time.
 Exit the machine.
 In an emergency, if the cab door or front window can not
be opened, break the front or rear window pane with
the emergency evacuation hammer to escape from the
cab. Refer to the explanation pages on the Emergency SA-393
Evacuation Method in the operator’s manual.
SS-1510
Beware of Exhaust Fumes

 Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
 If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open doors
and windows to bring enough outside air into the area.
SA-016
SA-32
SAFETY
Precautions for Welding and Grinding
 Welding may generate gas and/or small fires.
 Be sure to perform welding in a well ventilated and
prepared area. Store flammable materials in a safe place
before starting welding.
 Only qualified personnel should perform welding. Never
allow an unqualified person to perform welding.
 Turn the battery disconnect switch to the OFF position
 Grinding on the machine may create fire hazards. Store
flammable objects in a safe place before starting grinding.
 After finishing welding and grinding, recheck that there are SA-818
no abnormalities such as the area surrounding the welded
area still smoldering.
SA-33
SAFETY
Avoid Heating Near Pressurized Fluid Lines

 Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to yourself
and bystanders.
 Do not heat by welding, soldering, or using a torch near
pressurized fluid lines or other flammable materials.
 Pressurized lines can be accidentally cut when heat goes
beyond the immediate flame area. Install temporary
fire-resistant guards to protect hoses or other materials
before engaging in welding, soldering, etc.
SA-030
Avoid Applying Heat to Lines Containing

Flammable Fluids
 Do not weld or flame cut pipes or tubes that contain
flammable fluids.
 Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.
Precautions for Handling Accumulator and Gas

Damper
High-pressure nitrogen gas is sealed in the accumulator and
the gas damper. Inappropriate handling may cause explosion,
possibly resulting in serious injury or death.
Strictly comply with the following items:

 Do not disassemble the unit.
 Keep the units away from open flames and fire.
 Do not bore a hole, do not cut by torch.
 Avoid giving shocks by hitting or rolling the unit.
 Before disposing the unit, sealed gas must be released.
Consult your authorized dealer.
SA-34
SAFETY
Remove Paint Before Welding or Heating

 Hazardous fumes can be generated when paint is heated by
welding, soldering, or using a torch. If inhaled, these fumes
may cause sickness.
 Avoid potentially toxic fumes and dust.
 Do all such work outside or in a well-ventilated area.
Dispose of paint and solvent properly.
 Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper with SA-029
soap and water before welding. Remove solvent or paint
stripper containers and other flammable materials from
area. Allow fumes to disperse at least 15 minutes before
welding or heating.
Beware of Asbestos and Silicon Dust and Other

Contamination
 Take care not to inhale dust produced in the work site.
Inhalation of asbestos fibers may be the cause of lung
cancer. Inhalation of silicon dust or other contaminations
may cause sickness.
 Depending on the work site conditions, the risk
of inhaling asbestos fiber, silicon dust or other
contaminations may exist. Spray water to prevent
asbestos fibers, silicon dust or other contaminations from
becoming airborne. Do not use compressed air.
 When operating the machine in a work site where
asbestos fibers, silicon dust or other contaminations SA-029
might be present, be sure to operate the machine
from the upwind side and wear a mask rated to
prevent the inhalation of asbestos, silicon dust or other
contaminations.
 Keep bystanders out of the work site during operation.
 Asbestos fibers might be present in imitation parts. Use
only genuine Hitachi Parts.
SA-35
SAFETY
Prevent Battery Explosions

 Battery gas can explode.
 Keep sparks, lighted matches, and flame away from the
top of battery.
 Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
 Do not charge a frozen battery; it may explode. Warm the
battery to 16 ˚C ( 60 ˚F ) first.
 Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion of the
battery may result.
 Loose terminals may produce sparks. Securely tighten all
terminals. SA-032
 Connect terminals to the correct electrical poles. Failure
to do so may cause damage to the electrical parts or fire.
 Battery electrolyte is poisonous. If the battery should

explode, battery electrolyte may be splashed into eyes,
possibly resulting in blindness.
 Be sure to wear eye protection when checking electrolyte
specific gravity.
Service Air Conditioning System Safely

 If spilled onto skin, refrigerant may cause a cold contact
burn.
 Refer to the instructions described on the container for
proper use when handling the refrigerant.
 Use a recovery and recycling system to avoid leaking
refrigerant into the atmosphere.
 Never touch the refrigerant.
SA-405
SA-36
SAFETY
Handle Chemical Products Safely

 Direct exposure to hazardous chemicals can cause serious
injury. Potentially hazardous chemicals used with your
machine include such items as lubricants, coolants, paints,
and adhesives.
 A Safety Data Sheet (SDS) provides specific details on
chemical products: physical and health hazards, safety
procedures, and emergency response techniques.
 Check the SDS before you start any job using a hazardous
chemical. That way you will know exactly what the risks
are and how to do the job safely. Then follow procedures
and use recommended equipment.
 See your authorized dealer for SDS’s (available only in SA-2579
English) on chemical products used with your machine.
Dispose of Waste Properly

 Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with HITACHI equipment includes such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
 Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
 Do not pour waste onto the ground, down a drain, or into
any water source.
 Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations SA-226
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
 Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your authorized dealer.
SA-37
SAFETY
Never Ride Attachment

Never allow anyone to ride attachments or load. This is an
extremely dangerous practice.
Precautions for Communication Terminal

Electrical wave transmitted from the communication terminal
may cause malfunction of other electronic devices.
Inquire the device manufacturer for electrical wave
disturbance upon using an electronic device near the
communication terminal.
SA-38
SAFETY
Precautions for Communication Terminal
Equipment
This machine has a communication terminal equipment
emitting electrical waves installed inside a rear tray which
is situated at the back of the operator's seat. There is a
possibility that a medical device, including an implantable
device such as a cardiac pacemaker, would be affected and
would malfunction by the electrical waves emitted from the
communication terminal equipment.
Any person affixed with a medical device such as the above SA-2302
should not use this machine, unless the medical device and
the rear tray are at least 22 centimeters (8.7 inches) apart at
all times. If such condition cannot be met, please contact
your authorized dealer and have the person in charge stop
the communication terminal equipment from functioning
completely and confirm that it is not emitting electrical waves.
Specific Absorption Rate ("SAR") (measured by 10 g per unit) of

communication terminal equipments:
E-GSM900 0.573 W/Kg (914.80 MHz)
DCS-1800 0.130 W/Kg (1710.20 MHz)
WCDMA Band I 0.271 W/Kg (1950.00 MHz)
*This data was measured by having each type of

communication terminal equipment, such as the
communication terminal equipment used with this machine,
and a human body set apart by 3 cm (1.2 inches).
* SAR is a measure of the amount of radio frequency energy
absorbed by the body when using a wireless application such
as a mobile phone.
In Japan: *Under the Japanese Radio Act and other relevant

Japanese regulations, the maximum SAR value is 2 W/kg (as of
March 2010).
In EU Member nation: *Under the "Council Recommendation

1999/519/EC 12 July 1999'; the maximum SAR value is 2 W/kg
(as of March 2010).
SA-39
SAFETY
 Do not attempt to disassemble, repair, modify and displace
of the communication terminal, antenna and cables. Failure
to do so may cause damage or fire on the machine and the
communication terminal. (Before removing or installing the
communication terminal, consult your authorized dealer.)
 Do not pinch or forcibly pull cables, cords and connectors.

Failure to do so may cause damage or fire on the machine
and the communication terminal due to short/broken
circuit.
Before Returning the Machine to the Customer

 After maintenance or repair work is complete, confirm that:
 The machine is functioning properly, especially the safety
systems.
 Worn or damaged parts have been repaired or replaced.
SA-435
SA-40
SECTION AND GROUP SECTION 4 OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
TECHNICAL MANUAL Group 5 Component Test
Group 6 Adjustment
(Troubleshooting)
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Monitor
Group 3 e-Service
Group 4 Component Layout
Group 5 Troubleshooting A
Group 6 Troubleshooting B
Group 7 Air Conditioner
All information, illustrations and

specifications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.
COPYRIGHT(C)2016
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
TECHNICAL MANUAL (Operational Principle) WORKSHOP MANUAL
SECTION 1 GENERAL SECTION 1 GENERAL INFORMATION
Group 1 Specification Group 1 Precautions for Disassembling and Assembling
Group 2 Component Layout Group 2 Tightening Torque
Group 3 Component Specifications Group 3 Painting
SECTION 2 SYSTEM Group 4 Bleeding Air
Group 1 Controller Group 5 Pressure Release Procedure
Group 2 Control System Group 6 Preparation
Group 3 ECM System SECTION 2 MAINTENANCE STANDARD
Group 4 Hydraulic System Group 1 Upperstructure
Group 5 Electrical System Group 2 Undercarriage
SECTION 3 COMPONENT OPERATION Group 3 Attachment
Group 1 Pump Device SECTION 3 UPPERSTRUCTURE
Group 2 Swing Device Group 1 Cab
Group 3 Control Valve Group 2 Counterweight
Group 4 Pilot Valve Group 3 Main Frame
Group 5 Travel Device Group 8 Pump Device
Group 6 Signal Control Valve Group 9 Control Valve
Group 7 Others (Upperstructure) Group 10 Swing Device
Group 8 Others (Undercarriage) Group 11 Pilot Valve
Group 12 Solenoid Valve
Group 13 Signal Control Valve
Group 14 Shockless Valve
Group 15 Fan Valve
Group 16 Fan Moter
SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track
SECTION 5 ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
SECTION 4
OPERATIONAL PERFORMANCE TEST

CONTENTS
Group 1 Introduction Group 6 Adjustment
Operational Performance Tests....................................... T4-1-1 PUMP LEARNING.................................................................. T4-6-1
Preparation for Performance Tests................................ T4-1-2 TORQUE ADJUSTMENT...................................................... T4-6-2
CONNECTION........................................................................ T4-6-3
Group 2 Standard
Operational Performance Standard Table.................. T4-2-1
Main Pump P-Q Diagram.................................................. T4-2-5
Fan Pump P-Q Diagram..................................................... T4-2-6
Sensor Activating Range................................................... T4-2-7
Monitor Indicating Values (MC)...................................... T4-2-8
Monitor Indicating Values (ECM)..................................T4-2-14
Group 3 Engine Test
Engine Speed........................................................................ T4-3-1
Lubricant Consumption.................................................... T4-3-4
Group 4 Machine Performance Test
Travel Speed.......................................................................... T4-4-1
Track Revolution Speed..................................................... T4-4-2
Mistrack Check...................................................................... T4-4-3
Travel Parking Leakage...................................................... T4-4-4
Swing Speed.......................................................................... T4-4-5
Swing Function Drift Check............................................. T4-4-6
Swing Motor Leakage........................................................ T4-4-8
Maximum Swingable Slant Angle................................T4-4-10
Swing Bearing Play............................................................T4-4-12
Hydraulic Cylinder Cycle Time.......................................T4-4-14
Dig Function Drift Check.................................................T4-4-16
Control Lever Operating Force......................................T4-4-19
Control Lever Stroke.........................................................T4-4-20
Combined Operation of Boom Raise and
Swing Function Check................................................T4-4-21
Group 5 Component Test
Primary Pilot Pressure......................................................... T4-5-1
Secondary Pilot Pressure................................................... T4-5-3
4-Spool Solenoid Valve Set Pressure............................. T4-5-4
2-Spool Solenoid Valve Set Pressure............................. T4-5-5
Main Pump Delivery Pressure......................................... T4-5-7
Fan Pump Delivery Pressure............................................ T4-5-8
Main Relief Set Pressure.................................................... T4-5-9
Overload Relief Set Pressure..........................................T4-5-15
Main Pump Flow Rate Measurement.........................T4-5-18
Fan Pump Flow Rate Measurement............................T4-5-20
Swing Motor Drainage.....................................................T4-5-24
Travel Motor Drainage.....................................................T4-5-26
JAET-4-1
(Blank)
JAET-4-2
SECTION 4 OPERATIONAL PERFORMANCE TEST
Operational Performance Tests

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

1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.
T4-1-1
Preparation for Performance Tests

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

1. Accurately calibrate test instruments in advance to
obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test data
obtained can be produced repeatedly. Use mean
values of measurements if necessary.
T105-06-01-004
T4-1-2
Group 2 Standard
Operational Performance Standard Table The standard measurement conditions are as followings
unless instructed in each performance test procedure:
The standard Performance values are listed in the table  Engine Control Dial : Fast Idle
below.  Power Mode : HP
The detailed measurement procedures are explained in  Auto-Idle Switch: OFF
T4-3, T4-4, and T4-5. Refer to the reference page.  Work Mode: Digging Mode
Values indicated in parentheses [ ] are reference values.  Coolant Temperature: 80 °C or more
 Hydraulic Oil Temperature : 50±5 °C
Performance Test Unite Performance Remarks Reference

Standard Page
ENGINE SPEED min-1
Slow Idle Speed 900±50 Control Lever: Neutral
Fast Idle Speed (HP mode) 1900±50 Control Lever: Neutral
Fast Idle Speed (PWR mode) 1750±50 Control Lever: Neutral
Fast Idle Speed (ECO mode) 1730±50 Control Lever: Neutral
Fast Idle Speed 2030±50 Boom raise and arm roll-in
(HP mode) relief operation
With relief flow rate decrease
control disabled
Auto-Idle Speed 1380±50 Control Lever: Neutral
ENGINE COMPRESSION PRESSURE 2.75 Engine speed: 200 min-1
MPa
or more
VALVE CLEARANCE mm
Intake 0.2 With the engine cold
Exhaust 0.5 With the engine cold
LUBRICANT CONSUMPTION 43 or less At new machine
(At rated operation)
TRAVEL SPEED sec/20 m T4-4-1
Fast Speed 13.0±2.0 530LCH: 16.4±2.0
Slow Speed 18.0±2.0 530LCH: 21.2±2.0
TRACK REVOLUTION SPEED sec/3 rev T4-4-2
20.5±2.0 470LC/490LCH: 22.0±2.0,
Fast Speed
530LCH: 27.2±2.0
28.5±2.0 470LC/490LCH: 30.5±2.0,
Slow Speed
530LCH: 35.4±2.0
MISTRACK CHECK 200 or less T4-4-3
mm/20 m
(With fast and slow travel speed modes)
TRAVEL MOTOR LEAKAGE mm/5 min 0 T4-4-4
SWING SPEED sec/3 rev 18.0±1.5 Bucket: empty T4-4-5
SWING FUNCTION DRIFT CHECK mm/180° 1300 or less Bucket: empty T4-4-6
SWING MOTOR LEAKAGE 0 Bucket: loaded, Weight: 2550 T4-4-7
mm/5 min
kg
MAXIMUM SWINGABLE SLANT ANGLE 18.5 or more Bucket: loaded, Weight: 2550 T4-4-8
deg.
kg
SWING BEARING PLAY mm 0.6 to 1.85 Bucket: empty T4-4-10
T4-2-1
Group 2 Standard
Performance Test Unit Performance Remarks Reference

Standard Page
HYDRAULIC CYLINDER CYCLE TIME sec T4-4-12
Backhoe 3.4 m Arm 1.9 m3 (PCSA heaped)
Bucket, Bucket empty
Boom Raise 3.5±0.3
Boom Lower 2.5±0.3
Arm Roll-In 3.9±0.3
Arm Roll-Out 3.1±0.3
Bucket Roll-In 2.9±0.3
Bucket Roll-Out 2.2±0.3
DIG FUNCTION DRIFT CHECK mm/5 min T4-4-14
Backhoe 3.4 m Arm 1.9 m (PCSA heaped)
3
Bucket, Bucket loaded

Boom Cylinder 5 or less
Arm Cylinder 10 or less
Bucket Cylinder 15 or less
Bucket Bottom 100 or less
T4-2-2
Group 2 Standard

Standard Page
FAN MOTOR SPEED min-1 1260±50 With ECO control
deactivated, Control Lever:
Neutral
CONTROL LEVER OPERATING FORCE N T4-4-15
Front and Rear at Right Side 16.0 or less
Right and left at Left Side 13.0 or less
Right and left at Right Side 13.0 or less
Front and Rear at Left Side 16.0 or less
Travel Lever 28.0 or less
CONTROL LEVER STROKE mm T4-4-16
Front and Rear at Right Side 97±10
Right and left at Left Side 82±10
Right and left at Right Side 82±10
Front and Rear at Left Side 97±10
Travel Lever 120±10
COMBINED OPERATION OF BOOM RAISE sec 5.0 or less Backhoe: 3.4 m Arm1.9 T4-4-17
AND SWING FUNCTION CHECK m3 (PCSA heaped) Bucket,
(The time required to swing the Bucket empty
upperstructure 90 degrees)
Bucket Teeth Height: H mm 7400 or more
COMPONENT TEST
PRIMARY PILOT PRESSURE MPa T4-5-1
Engine: Fast Idle Speed 3.9±0.5
Engine: Slow Idle Speed 3.9±0.5
SECONDARY PILOT PRESSURE MPa T4-5-2
(Engine: Fast Idle Speed (normal) and Slow 3.4 to 4.0 (Control Lever: Full Stroke)
Idle Speed)
SOLENOID VALVE SET PRESSURE MPa Value indicated T4-5-4
on MPDr.±0.2
T4-2-3
Group 2 Standard

Standard Page
MAIN RELIEF SET PRESSURE MPa T4-5-9
When each Boom Lower, Arm, Bucket 31.9+2.0−0.5
Relief Operation
When Boom Raise, Power Digging 35.3+2.0−0.5
Operation
RELIEF PRESSURE MPa T4-5-13
When relieving swing 28.4 +2.0
−0.5
When relieving travel 35.3+2.0−0.5
OVERLOAD RELIEF SET PRESSURE MPa T4-5-15

Boom, Arm, and Bucket 36.3 +1.0
0 Reference values at 110
L/min
Boom (Lower) 11.8+1.00 Reference values at 215
(When operating boom mode selector) L/min
MAIN PUMP FLOW RATE MEASUREMENT L/min – Refer to page T4-2-5 T4-5-18
FAN PUMP FLOW RATE MEASUREMENT L/min – Refer to page T4-2-6 T4-5-20
SWING MOTOR DRAINAGE L/min T4-5-24
With constant speed 0.2 to 0.5
TRAVEL MOTOR DRAINAGE L/min T4-5-26
With the track raised off the ground less than 5 Allowable limit: 10
T4-2-4
Group 2 Standard
Main Pump P-Q Diagram

 Hydraulic P-Q Control
Delivery Pressure (P) Flow Rate (Q)
(REFERENCE: Measured at Test Stand) MPa L/min
 Rated Pump Speed: 2030 min-1 A 20 Approx. 259
 Hydraulic Oil Temperature: 50±5 °C B 25 Approx. 202
 Relief Flow Rate Decrease Control: Disabled C 30 Approx. 163
f NOTE: Refer to T4-5-18.
L/min
450
400
350
300
A
Q 250
B
200
C
150
100
50
0
0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 MPa
(51) (102) (153) (204) (255) (306) (357) (kgf/cm2)
P TJAE-04-02-001
P- Delivery Pressure Q- Flow Rate
T4-2-5
Group 2 Standard
Fan Pump P-Q Diagram

 Hydraulic P-Q Control
Delivery Pressure (P) Flow Rate (Q)
(REFERENCE: Measured at Test Stand) MPa L/min
 Rated Pump Speed: 2100 min-1 A 9.8 Approx. 66
 Hydraulic Oil Temperature: 50±5 °C B 22.6 Approx. 64
f NOTE: Refer to T4-5-20.
L/min
75
A
B
50
25
0
0 5.0 10.0 15.0 20.0 25.0 MPa
(51) (102) (153) (204) (255) (kgf/cm2)
P TJAA-04-02-002
P- Delivery Pressure Q- Flow Rate
T4-2-6
Group 2 Standard
Sensor Activating Range

1. Checking Method
 Hydraulic Oil Temperature: 50±5 °C

 Unless specified:
Engine Power Work Mode Auto-Idle

Control Dial Mode Switch
Maximum HP Digging OFF
Speed Mode
 Monitor each sensor using MPDr.
2. Sensor Activating Range
Sensor Operation Specification

Engine Control Dial Slow Idle Speed 0.3 to 1.0 V
Fast Idle Speed 4.0 to 4.7 V
Pilot Operation Pressure Sensor Control Lever: Neutral 0 to 0.5 MPa
Pilot Shut-Off Lever: LOCK
Control Lever: Full Stroke 2.45 to 3.9 MPa
Pilot Shut-Off Lever: UNLOCK
Pump Regulator Pressure Sensor Control Lever: Neutral Pump 1: *0.5 MPa
Pump 2: *0.5 MPa
Jack-up, Travel Lever: Full Stroke (The *2.55 MPa
side of track raised off the ground)
Pump Delivery Pressure Sensor Control Lever: Neutral *0.3 to 0.7 MPa
Boom Raise Relief 35.3+2-0.5 MPa
*: Reference Value
T4-2-7
Group 2 Standard
Monitor Indicating Values (MC)

Unless specified, test under the following conditions.
 Engine Control Dial: Fast Idle
 Power Mode Switch: HP mode
 Auto-Idle Switch: OFF
 Work Mode: Digging Mode
 Relief Flow Rate Decrease Control: Disabled (MPDr.)
Item Unit Reference Measured Value Remarks

Value First Second Third Average
DEMAND ENGINE SPEED min -1
Fast Idle Speed (HP Mode) 1800

Fast Idle Speed 1900
(When operating a control lever)
2000 When boom
Fast Idle Speed (HP Mode)
raise relieving
Fast Idle Speed (PWR mode) 1650
Fast Idle Speed (ECO mode) 1630
Auto-Idle Speed 1230
Slow Idle Speed 750
ACTUAL ENGINE SPEED min-1
(When operating a control lever)
Fast Idle Speed (HP Mode) 2030 When boom
raise relieving
Fast Idle Speed (ECO mode) 1730
Auto-Idle Speed 1380
Slow Idle Speed 900 Pilot shut-
off lever:
UNLOCK
position
ENGINE SPEED DEVIATION min-1
Fast Idle Speed 100
Fast Idle Speed 32 When boom
(When operating a control lever) raise relieving
Fast Idle Speed (HP Mode) 32
Fast Idle Speed (ECO mode) 60 When boom
raise relieving
Auto-Idle Speed 150
Slow Idle Speed 150 Pilot shut-off
lever: LOCK
position
EC DIAL V
Minimum 0.56
Maximum 4.42
T4-2-8
Group 2 Standard
Reference Measured Value

Item Unit Remarks
PUMP 1 DELIVERY
MPa
PRESSURE
Control Lever in Neutral 0.7
Boom Raise 35.3 When relieving
Boom Lower -
Arm Roll-In 31.9 When relieving
Arm Roll-Out 31.9 When relieving
Bucket Roll-Out 31.9 When relieving
Bucket Roll-In 31.9 When relieving
Combined Operation of
Boom Raise, Arm Roll-In, 31.9 When relieving
and Bucket Roll-In
PUMP 2 DELIVERY
MPa
PRESSURE
Boom Lower -
and Bucket Roll-In
T4-2-9
Group 2 Standard

Item Unit Remarks
PUMP 1 S/A Cont Pressure
MPa
PRESSURE
Boom Lower -
and Bucket Roll-In
PUMP 2 S/A Cont Pressure
MPa
PRESSURE
Boom Lower -
and Bucket Roll-In
T4-2-10
Group 2 Standard

Item Unit Remarks
FRONT ATT PILOT When boom raise
MPa 3.6
PRESSURE relieving
TRAVEL PILOT PRESSURE MPa 3.7 When relieving
BOOM RAISE PILOT
MPa 3.6 When relieving
PRESSURE
BOOM LOWER PILOT
PRESSURE
ARM ROLL-IN PILOT
PRESSURE
ARM ROLL-OUT PILOT
PRESSURE
BUCKET ROLL-OUT PILOT
PRESSURE
BUCKET ROLL-IN PILOT
PRESSURE
SWING PILOT PRESSURE MPa 3.7 When relieving
TRAVEL PILOT PRESSURE MPa 3.7 When relieving
T4-2-11
Group 2 Standard

Item Unit Remarks
MAIN RELIEF BOOST
MPa
PRESS OUTPUT
Power Digging Switch:
3.9
ON, Lever in Neutral
When Boom Raise
3.9
Relieving
TRAVEL MODE C/V When fast speed
MPa 3.7
OUTPUT traveling
BOOM MODE CONTROL Boom mode
MPa
PRESSURE selector switch: ON
Lever in Neutral 0.47
ARM 2 FLW CONT P/S
MPa
OUTPUT
When Arm Roll-In
3.25
Relieving
Lever in Neutral (HP
1.4
Mode)
Lever in Neutral (PWR
1.4
Mode)
Lever in Neutral (ECO
0.7
Mode)
SWING FLW CONT P/S
MPa
OUTPUT
When Boom Raise
3.0
Relieving and Swing
T4-2-12
Group 2 Standard

Item Unit Remarks
PUMP 1 (4 UNITS) P/S When boom raise
mA 380
OUTPUT relieving
PUMP 2 (5 UNITS) P/S When boom raise
mA 380
OUTPUT relieving
HYD FAN ROT P/S OUTPUT mA 280 to 500
ARM 2 FLW CONT P/S When arm roll-in
mA 507
OUTPUT relieving
When boom raise
SWING FLW CONT P/S
mA 490 relieving and
OUTPUT
swing
FAN DIR CONT P/S 1 O/P
mA -
FB
T4-2-13
Group 2 Standard
Monitor Indicating Values (ECM)

Unless specified, test under the following conditions.
 Engine Control Dial: Fast Idle
 Power Mode Switch: HP mode
 Work Mode: Digging Mode
 Relief Flow Rate Decrease Control: Disabled (MPDr.)

Item Unit Remarks
When boom raise
ENGINE TORQUE % 86
relieving
When boom raise
ACTUAL ENGINE SPEED min-1 2030
relieving
When boom raise
TARGET ENGINE SPEED min-1 2000
relieving
When boom raise
BOOST PRESSURE kPa 230
relieving
When boom raise
ENGINE OIL PRESSURE kPa 450 relieving, When
Neutral: 324 kPa
When boom raise
BATTERY VOLTAGE V 28.2
relieving
T4-2-14
Group 3 Engine Test
Engine Speed
Summary:
1. Measure the engine speed by using the monitor
unit or MPDr..
2. Measure the engine speeds in each mode.
fNOTE: Measure the engine speed before performing all

other tests. If the engine speed is not adjusted correctly,
all other performance data will be unreliable.
Preparation:
1. Select the service menu of the monitor or MPDr.. In
case of MPDr., install MPDr. first.
2. Warm up the machine until the coolant temperature
reaches 70 °C or more and the hydraulic oil
temperature is 50±5 °C.
T4-3-1
Group 3 Engine Test
Measurement: Remedy:
1. Measure the items as shown in the table below. Refer to Troubleshooting B.
2. When measuring, set the switch and test condition
as shown in the table below in response to the
engine speed to be measured.
Evaluation:
Refer to Operational Performance Standard.
Item Engine Control Power Mode Auto-Idle Work Test Conditions

Dial Switch Mode
Slow Idle Speed Min. Speed HP OFF Digging Pilot shut-off lever: LOCK position
Mode
Slow Idle Speed Min. Speed HP OFF Digging Pilot shut-off lever: UNLOCK position,
Mode Control lever in neutral
Fast Idle Speed Max. Speed HP OFF Digging Deactivate ECO by MPDr., Control lever
(With ECO Mode in neutral
deactivated)
Fast Idle Speed Max. Speed PWR OFF Digging Boom raise (Relief operation)
(Relief operation) Mode
Fast Idle Speed Max. Speed ECO OFF Digging
(ECO mode) Mode
Fast Idle Speed Max. Speed HP OFF Digging Boom raise (Relief operation)
(HP mode) Mode
Auto-Idle Speed Max. Speed HP ON Digging 3.5 seconds passed after returning the
Mode control levers to neutral
T4-3-2
Group 3 Engine Test
Switch Panel: Monitor:
TDAA-05-02-032 TDAA-05-02-060
3
1- Engine Control Dial 3- Power Mode Switch

2- Auto-Idle Switch 4- Digging Mode
T4-3-3
Group 3 Engine Test
Lubricant Consumption
Measuring Method
1. Place the machine on the level, firm ground and
leave the machine for at least one hour in order to
return the lubricant to the oil pan after the engine
stops.
At this time, confirm that the machine is level by
using a leveler.
2. Record read-out A (unit: hour) of the hour meter.
3. Replenish the lubricant up to the high-level gauge.
4. Operate the machine for at least 100 hours or until
the oil level lowers to the low-level gauge.
5. Place the machine on the level, firm ground and
leave the machine for at least one hour in order to
return the lubricant to the oil pan after the engine
stops.
At this time, confirm that the machine is level by
using a leveler.
6. Record read-out B (unit: hour) of the hour meter.
7. Replenish the lubricant up to the high-level gauge
while measuring the oil-replenishing volume C.
fNOTE: When measuring, use a high-precision

measuring cylinder or the like.
8. Determine the lubricant consumption from the
following equation:
Oil replenishing volume (C) [mL]/Operating hours
(B-A) [hr]
Evaluation:
T4-3-4
Travel Speed
Summary:
1. Measure the time required for the machine to travel
a test track and check the performance of the travel
systems (from main pump to travel motor).
c
Preparation: a
1. Adjust track sag of both tracks to the nominal b

e d
dimension.
2. Provide a flat, solid test yard 10 m in length, with
extra length of 3 to 5 m on both ends for machine d
acceleration and deceleration.
3. With the arm and the bucket cylinders fully
extended, hold the bucket 0.3 to 0.5 m above the
TDBC-04-04-001
ground.
4. Maintain the hydraulic oil temperature at 50±5 °C.
a- Bucket Height: 0.3 to 0.5 m d- Acceleration/Deceleration
b- Start Zone: 3 to 5 m
Measurement: c- End e- 10 m
1. Measure in both fast and slow travel modes.

2. Select the following conditions.
Travel Mode Engine Control Power Mode Auto-Idle Work Mode

Switch Dial Switch
Slow Mode Fast Idle HP OFF Digging Mode

Fast Mode Fast Idle HP OFF Digging Mode
3. Start traveling the machine in the acceleration zone

with the travel levers to full stroke.
4. Measure the time required to travel between the
start and end.
5. After measuring the time when going, swing the
upperstructure 180 degrees, and measure the time
when coming back in the same way.
6. Repeat the measurement three times and calculate
the mean values.
Evaluation:
Remedy:
Refer to Troubleshooting B.
T4-4-1
Track Revolution Speed

Summary:
1. Measure the track revolution cycle time with the
track raised off ground and check the performance
of the travel systems (from main pump to travel
motor).
a
Preparation:
1. Adjust track sag of both tracks to the nominal
dimension.
2. On the track to be measured, put a mark on one M104-07-067
shoe by using a piece of chalk or cloth.
a- 90 to 110 Degrees
3. Raise the track to be measured off the ground as
illustrated.
dCAUTION: Securely support the raised machine

off the ground by using blocks.
Measurement:
1. Measure on both tracks at slow and fast travel
modes with forward and reverse travel.

Switch Dial Switch
3. Operate the travel control lever of the track to be

measured to full stroke.
4. Measure the time required for 3 revolutions after a
constant track revolution speed is obtained.
the mean values.
Evaluation:
f NOTE: When the measurement data obtained through
the track revolution test with the track raised off the
ground has wide variations, the evaluation based on
the results obtained from the 10 m travel speed check
described before is more recommendable.
Remedy:
T4-4-2
Mistrack Check
Summary:
1. Allow the machine to travel 20 m. Measure the
maximum tread deviation from the tread chord
drawn between the travel start and end points and
check the performance of the travel system (from
main pump to travel motor).
2. If measured on a pavement surface, the tread
deviation has a trend to decrease.
Preparation: a
1. Adjust track sag of both tracks to the nominal
dimension.
2. Provide a flat, solid test yard 20 m in length, with b
extra length of 3 to 5 m on both ends for machine
acceleration and deceleration. c
3. With the arm and bucket cylinders fully extended,

hold the bucket 0.3 to 0.5 m above the ground.
T105-06-03-022
Measurement: a- Maximum Distance c- 20 m
b- Acceleration/Deceleration
1. Measure in both fast and slow travel modes. Zone: 3 to 5 m

Switch Dial Switch
3. Start traveling the machine in the acceleration zone

with the travel levers to full stroke.
4. Measure maximum distance (a) between a straight
20 m tread chord and the tread made by the
machine.
5. After measuring maximum distance (a) when going,
swing the upperstructure 180 degrees, and measure
maximum distance (a) when coming back in the
same way.
the mean values.
Evaluation:
Remedy:
T4-4-3
Travel Parking Leakage

Summary:
1. Measure the parking brake function on a specified
slope.
2. Measure on a flat slope with a gradient of 20 %
(11.31 degrees).
a
Preparation:
1. Measure on a flat slope with a gradient of 20 %
(11.31 degrees).
2. With the arm and bucket cylinders fully extended,
hold the bucket 0.2 to 0.3 m above the ground.
T105-06-03-004
a- 0.2 to 0.3 m
Measurement:
1. Climb the slope and set the travel control lever in
neutral.
2. Stop the engine.
3. After the machine stops, put marks onto the track
link or the shoe, and the track side frame.
4. When five minutes passed, measure the distance
between marks on the track link or the shoe, and
the track frame.
Evaluation:
TDAA-04-04-001
b- Distance measured when five

minutes passed
T4-4-4
Swing Speed
Summary:
1. Measure the time required to swing three complete
turns and check the performance of the swing
system (from main pump to swing motor).
Preparation:
1. Check lubrication of the swing gear and the swing
bearing.
2. Place the machine on a flat and solid ground with
ample space for swinging. Do not conduct this test
on a slope. a
3. Fully retract the arm cylinder. Fully extend the
bucket cylinder. Adjust and hold the boom so that
the arm end pin height is the same as the boom T105-06-03-013
foot pin height. (Empty the bucket.) a- The same height as boom foot pin
fNOTE: In case a sufficient space for the measurement

is difficult to find, carry out the measurement with the
boom fully raised and the arm fully rolled-in.
dCAUTION: 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:
Engine Power Mode Auto-Idle Work Mode

Control Dial Switch
Fast Idle HP OFF Digging
Mode
T178-04-03-001
2. Operate the swing control lever to full stroke and
swing the upperstructure.
3. Measure the time required to swing 3 turns when
the swing speed is a constant speed.
4. Check the time in both clockwise and
counterclockwise directions.
the mean values.
Evaluation:
Remedy:
T4-4-5
Swing Function Drift Check

Summary:
1. Measure the swing drift on the swing bearing outer
circumference when stopping after a 180 degrees
full-speed swing and check the performance of the
swing brake valve.
2. The mechanical brake for the swing parking brake is
equipped for the swing motor.
Preparation: a
1. Check lubrication of the swing gear and the swing T105-06-03-008
bearing. a- Put the marks on swing
bearing outer circumference
2. Place the machine on a flat and solid ground with and track frame.
ample space for swinging. Do not conduct this test
on a slope.
the arm end pin height is the same as the boom
foot pin height. (Empty the bucket.)
4. Put marks onto the swing bearing outer
circumference (upperstructure side) and the track
frame.
5. Swing the upperstructure 180 degrees.
b
T105-06-03-009

b- Before start the
measurement, swing the
upperstructure 180 degrees.
measurement.
T4-4-6
Measurement:

Control Dial Switch
a

Mode
2. Operate the swing control lever to full stroke and
swing the upperstructure 180 degrees. When the
mark on upperstructure aligns with that on track b
frame, return the swing control lever to the neutral
position. c
3. After stopping the upperstructure, measure the arc
T105-06-03-010
length (swing bearing circumference) between the
two marks on the swing bearing and track frame. a- Measure arc length (swing c- Mark on Swing Bearing
bearing circumference).
4. Check the arc length in both clockwise and b- Mark on Track Frame
the mean values.
Evaluation:
Remedy:
T4-4-7
Swing Motor Leakage
Summary:
1. Set the machine on a specified slope and swing the
upperstructure 90 degrees to the slope. Measure
the upperstructure drift while suspending a load on
a specified slope and check the performance of the
swing parking brake.
(The mechanical brake for the swing parking brake
is equipped for the swing device.)
Preparation:
bearing.
2. Load the bucket. (Refer to the Operational
performance Standard about the loading weight.) T105-06-03-011

foot pin height. (Empty the bucket.)
4. Park the machine on a smooth slope with a gradient
of 15±1 degrees.
5. Climb a slope and swing the upperstructure to
position it 90 degrees to the slope. Put the marks
onto the swing bearing outer circumference
(upperstructure side) and the track frame.
T4-4-8
Measurement:
Power Mode Auto-Idle Switch Work Mode a
HP OFF Digging Mode
2. Start the engine. When 5 minutes passed at idle

speed, measure the arc length (swing bearing
circumference) between the two marks on the
swing bearing and track frame. b
3. Check the arc length in both clockwise and

counterclockwise directions. c
4. Repeat the measurement three times and calculate T105-06-03-010

the mean values. a- Measure arc length (swing c- Mark on Swing Bearing
bearing circumference).
b- Mark on Track Frame
Evaluation:
Remedy:
T4-4-9
Maximum Swingable Slant Angle
Summary:
1. With the upperstructure swung 90 degrees to the
slope, check the maximum slant angle on which the
upperstructure can swing to the uphill side.
Preparation:
bearing.
performance Standard about the loading weight.)
foot pin height. (Empty the bucket.) T105-06-03-011
4. Climb a slope and swing the upperstructure 90
degrees to the slope.
5. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
T4-4-10
Measurement:

Control Dial Switch

Mode
2. Operate the swing control lever to full stroke to
swing the upperstructure to a uphill side.
3. If the machine can swing, measure the cab floor
slant angle.
4. When the machine can swing, increase the slant
angle. Check the slant angle in both clockwise and
Evaluation:
Remedy:
T4-4-11
Swing Bearing Play

Summary:
1. Measure the swing bearing play and check the wear
of the swing bearing races and the balls.
Preparation:
1. Check the swing bearing mounting bolts for 1 2
looseness. T105-06-03-014
1- Magnetic Base 2- Dial Gauge
2. Check lubrication of the swing bearing. Confirm
that bearing rotation is smooth without noise.
3. Secure dial gauge (2) on the round trunk (3) side of
the track frame by using magnetic base (1).
4. Position the upperstructure so that the boom aligns
with the tracks facing towards the front idlers.
5. Position dial gauge (2) so that its needle point
comes in contact with the bottom surface of the
swing bearing outer race. 3
6. Empty the bucket.
fNOTE: The measured value will vary depending on

1
where magnetic base (1) is secured. Secure magnet base T105-06-03-015
(1) on the round trunk as close to the swing bearing as 1- Magnetic Base 3- Round Trunk
possible.
T4-4-12
Measurement:
bucket cylinder. Adjust the boom so that the arm
end pin height is same as the boom foot pin height.
Record dial gauge reading (h1) of dial gauge (2).
a
T105-06-03-013
a - The arm end pin height is the

same as boom foot pin.
2. Lower the bucket onto the ground and raise the

front idler 0.5 m off the ground by using the front
attachment. Record reading (h2) of dial gauge (2).
3. Calculate bearing play (H) from these data (h1 and
h2) as follows:
H=h2-h1
T105-06-03-017
Evaluation:
T4-4-13
Hydraulic Cylinder Cycle Time
Summary:
1. Measure the cycle time of boom, arm, and bucket
cylinders, and check the performance of the front
attachment system (from main pump to each
cylinder).
Preparation:
1. Measurement is made for the following positions.
 Measurement of the cycle time of the boom cylinder:
With the bucket cylinder fully extended and the arm
cylinder fully retracted, lower the bucket onto the
ground.
T105-06-03-018
 Measurement of the cycle time of the arm cylinder:
Retract or extend the bucket cylinder so that the arm
and the bucket teeth are vertical to the ground.
Set the arm so that the center of arm operation
is vertical. The bucket teeth clearance above the
ground is 0.5 m.
 Measurement of the cycle time of the bucket

a
cylinder:
Adjust the boom and arm cylinders so that the
bucket oscillation center faces vertically to the
ground.
T1V1-04-05-005
2. Maintain the hydraulic oil temperature at 50±5 °C. a- 0.5 m
T105-06-03-020
T4-4-14
Measurement:

Control Dial Switch
Mode
2. Measure the cylinder cycle times as follows:
(Cylinder full stroke includes cylinder cushioning
zone.)
 Measurement of the cycle time of the boom cylinder:
Operate the boom control lever to full stroke.
Measure the time to raise and lower the boom.
 Measurement of the cycle time of the arm cylinder:
Operate the arm control lever to full stroke. Measure
the time to roll in and roll out the arm.
 Measurement of the cycle time of the bucket
cylinder:
Operate the bucket control lever to full stroke.
Measure the time to roll in and roll out the bucket.

the mean values.
Evaluation:
Remedy:
T4-4-15
Dig Function Drift Check
 Maximum Reach Position

Summary:
1. Measure dig function drift, which can be caused by
oil leakage in the control valve and boom, arm and
a b
bucket cylinders, with the bucket loaded.
2. When measuring the drift just after cylinder a
replacement, slowly operate the cylinder for ten
minutes and bleed air from the cylinder.
d
Preparation:
c
performance Standard about the loading weight.)
T105-06-03-021
bucket cylinder. Adjust and hold the boom so that a- Retracted Distance d- The arm end pin height is the
the arm end pin height is the same as the boom b- Extended Distance same as boom foot pin.
foot pin height. (Empty the bucket.) c- Dig Function Drift Amount
3. Position the arm cylinder and the bucket cylinder

with the rod 50 mm away from the full stroke end
position.
T4-4-16
Measurement:
1. Stop the engine. a
b b
2. When 5 minutes passed, measure the change in
position of bottom of the bucket, as well as the
boom, arm, and bucket cylinders.
Boom and Bucket Cylinders: Retracted
Distance: a
a=A-B
Arm Cylinder: Extended Distance: c
c=B-A T110-06-03-002
a- Boom and Bucket Cylinders: b- Mark
3. Repeat the measurement three times and calculate Retracted Distance
the mean values.
Evaluation: c
d d
Remedy:
TDCY-04-04-001
c- Arm Cylinder: Extended d- Mark

Distance
T4-4-17
 Arm Roll-In Position

Summary:
1. Measure dig function drift, which can be caused by
oil leakage in the control valve and boom, arm, and
bucket cylinders.
2. When measuring the drift just after cylinder
replacement, slowly operate the cylinder for 10
minutes and bleed air from the cylinder.
Preparation:
2. With the arm fully extended and the bucket fully
extended, hold the arm end 1 m above the ground.
3. Position the arm cylinder and the bucket cylinder
with the rod 50 mm away from the full stroke end
position.
a
Measurement:
1. Stop the engine. T173-04-03-001
a- 1m
2. When 5 minutes passed, measure the change in
position of bottom of the arm tip, as well as the
boom, arm and bucket cylinders.
Cylinder: Retracted Distance: b
b=A-B b
3. Repeat the measurement three times and calculate c c

the mean values.
Evaluation:
Remedy:
T110-06-03-002
b- Cylinder: Retracted Distance c- Mark
T4-4-18
Control Lever Operating Force
Summary:
1. Check a play and operating condition and measure
the operating force.
2. Measure the maximum operating force of the front
attachment control lever.
3. Measure the lever stroke along the control lever
operation from the grip center of each control lever.
Preparation:
TABA50-04-04-001
measurement.
Measurement:
1. Measure the operating force of each control lever.

Control Dial Switch
Mode
3. In case of boom (raise), arm, and bucket control
levers, measure the maximum operating force for
each with each actuator relieved. TABA50-04-04-003
4. In case of boom (lower) control lever, measure the

maximum operating force with the boom (lower)
relieved by raising the machine in a stable area.
5. In case of swing control lever, engage the
bucket teeth with the ground and secure the
upperstructure in order to prevent the machine
from swinging. Operate the swing control lever and
measure the maximum operating force with the
swing relieved.
6. In case of travel control lever, raise the track to be
measured off the ground. Measure the maximum
operating force to be required.
the mean values.
Evaluation:
T4-4-19
Control Lever Stroke
Summary:
1. Check a play and operating condition and measure
each control lever stroke.
2. Measure the control lever stroke at the grip center
of each control lever.
3. In case the lever stroke play is present in the neutral
position, add half (1/2) the play present to both side
lever strokes.
Preparation:
1. Maintain the hydraulic oil temperature at 50±5 °C. T107-06-03-005
Measurement:
1. Stop the engine.
2. Measure each control lever stroke from neutral to
the stroke end of each control lever of boom, arm,
bucket, swing, and travel.
3. Measure the chord length from neutral to the stroke
end.
the mean values.
Evaluation:
T4-4-20
Combined Operation of Boom Raise and

Swing Function Check
Summary:
1. Check the boom raise and swing movement
and speed while operating both functions
simultaneously.
2. Check if the cylinders do not hesitate while
operating the cylinder with the engine running at T107-06-03-009
fast idle.
Preparation:
1. With the arm cylinder fully retracted and the bucket
cylinder fully extended, lower the bucket onto the
ground. Lower the bucket onto the ground. (Empty
the bucket.)

measurement.
T107-06-03-010
Measurement:

Control Dial Switch

Mode
H
2. Raise the boom and swing the upperstructure in
full stroke at the same time. 90 Measure the time
required to swing the upperstructure 90 degrees
and height (H) of the bucket teeth. (The bucket
should be empty.)
T107-06-03-011
the mean values.
Evaluation:
Remedy:
T4-4-21
(Blank)
T4-4-22
Primary Pilot Pressure

Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
tank and bleed air.
3. Remove plug (1) from the pilot filter. Install adapter
(ST 6069) and pressure gauge (ST 6942) to the
pressure check port.
j : 19 mm
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
Measurement:
1

Control Dial Switch
Mode
Slow Idle HP OFF Digging
Mode T178-03-07-001
1- Plug
2. Measure the pilot pressure without load by using
the pressure gauge under each condition above.
the mean values.
Evaluation:
T4-5-1
Primary Pilot Pressure Adjustment Procedure
Adjustment:
Adjust the relief valve (1) set pressure if necessary.
1. Remove plug (2) from relief valve (1).

1
j : 22 mm
2. Install the estimated number of shims (3).
3. After the adjustment, tighten plug (2). T178-03-07-001
m : 25+2 N·m (2.5+0.2 kgf·m) 2

3
4. After the adjustment, check the set pressure.
fNOTE: Standard Change in Pressure (Reference)

Shim (3) Thickness Change in Pressure
(mm) kPa (kgf·m)
0.25 78 (0.8)
0.5 157 (1.6)
1.0 304 (3.1)
T111-06-04-004
1- Relief Valve 3- Shim

2- Plug
T4-5-2
Secondary Pilot Pressure

Preparation:
1
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil 8
tank and bleed air. 2
3. Measure the pilot pressure between pilot valve (1) 7
and signal control valve (2). Disconnect the signal
control valve (2) side of pilot hose (3) of the circuit 6
to be measured. Install hose (8), tee (5), adapter (4),
adapter (7), and pressure gauge (6) between signal
control valve (2) and pilot hose (3).
j : 19 mm, 22 mm
5
4. Start the engine. Confirm that no oil leakage is 4
observed at the pressure gauge (6) connection.
3
Measurement:

TJAA-04-05-001
Control Dial Switch
1- Pilot Valve 6- Pressure Gauge (ST 6942)
Mode
2- Signal Control Valve 7- Adapter (ST 6069)
Slow Idle HP OFF Digging 3- Pilot Hose 8- Hose (9/16-18UNF, Length:
Mode 4- Adapter (ST 6460) approx. 400 mm)
5- Tee (4351843)
2. Operate the control lever to be measured. Measure
the pilot pressure by using pressure gauge (6) with
the control lever set to the full stroke.
the mean values.
Evaluation:
Remedy:
T4-5-3
4-Spool Solenoid Valve Set Pressure

Use MPDr. and a pressure gauge at the same time.
1
Preparation:
1. Stop the engine. 2

tank and bleed air.
6
3. Disconnect the hose from the solenoid valve to
be measured. Install tee (4), hose (5), adapter (3),
adapter (6), and pressure gauge (2) between the
disconnected hose and the solenoid valve unit (1).
5 4 3
j : 17 mm, 19 mm
Connect MPDr. and select the monitoring function. T157-05-04-002
1- Solenoid Valve Unit 4- Tee (ST 6451)
4. Start the engine. Confirm that no oil leakage is 2- Pressure Gauge (ST 6942) 5- Hose (4216453)
observed at the pressure gauge (2) connection. 3- Adapter (ST 6461) 6- Adapter (ST 6069)
Measurement:

Control Dial Switch SC SF SI SG
Mode
Slow Idle HP OFF Digging
Mode
2. Operate as instructed below for each measuring
solenoid valve:
Solenoid Valve SG: Single operation of arm roll-in or
arm roll-out.
Solenoid Valve SI: Turn ON and OFF the power TJAA-01-02-102
digging switch.
Solenoid Valve SF: Single operation of bucket roll-in
or bucket roll-out.
Solenoid Valve SC: Set the travel mode switch fast
speed mode and slow speed mode.
3. Read the values on both MPDr. and the pressure
gauge.
the mean values.
Evaluation:
T4-5-4
2-Spool Solenoid Valve Set Pressure

Use MPDr. and a pressure gauge at the same time.
1
Preparation:
1. Stop the engine. 2

tank and bleed air.
6
3. Disconnect the hose from the solenoid valve to
be measured. Install tee (4), hose (5), adapter (3),
adapter (6), and pressure gauge (2) between the
disconnected hose and the solenoid valve unit (1).
5 4 3
j : 17 mm, 19 mm
Connect MPDr. and select the monitoring function. T157-05-04-002
1- Solenoid Valve Unit 4- Tee (ST 6451)
4. Start the engine. Confirm that no oil leakage is 2- Pressure Gauge (ST 6942) 5- Hose (4216453)
observed at the pressure gauge (2) connection. 3- Adapter (ST 6461) 6- Adapter (ST 6069)
Measurement:
Engine Power Auto-Idle Work Mode

Mode
Slow Idle HP OFF Digging SC SI
Mode
2. Operate as instructed below for each measuring
solenoid valve:
 Solenoid Valve SI: Combined operation of swing and
boom raise, or swing and arm roll-out.
 Solenoid Valve SC: Turn ON the boom mode selector
switch. Operate boom raise, boom lower, arm roll-in,
arm roll-out, bucket roll-in bucket roll-out or swing.
3. Read the values on both MPDr. and the pressure
gauge.
4. Repeat the measurement three times and calculate TJAA-01-02-103
the average values.
Evaluation:
Refer to the Operational Performance Standard.
T4-5-5
Solenoid Valve Adjustment Procedure

8 7 9
IMPORTANT: If loosening adjusting screw (8)
excessively, O-ring (9) is damaged and oil leakage
may cause. Do not loosen adjusting screw (8)
excessively. Do not loosen adjusting screw (8)
more than 2 turns from fully tightened position.
1. Loosen lock nut (7). Turn adjusting screw (8) in order

to adjust the set pressure.
2. After the adjustment, tighten lock nut (7). a
T1V1-04-05-004
j : 13 mm
m : 5 N·m (0.5 kgf·m)
l : 3 mm 8 7
3. After the adjustment, check the set pressure.

Adjusting Screw (8) 1/4 1/2 3/4 1
Turns
Change in kPa 69 137 206 275
Pressure (kgf/cm2) (0.7) (1.4) (2.1) (2.8)
T1V1-04-05-003
7 8
b c
W107-02-05-129
a- 2.0 mm c- Pressure Decrease

b- Pressure Increase
7- Lock Nut 9- O-Ring

8- Adjusting Screw
T4-5-6
Main Pump Delivery Pressure

The main pump delivery pressure can be also
measured by using MPDr..
Preparation:
1. Stop the engine.
tank and bleed air.
3. Remove the plug from the delivery pressure check
port of the main pump to be measured. Install
the adapter (ST 6069), the hose (ST 6943), and the
pressure gauge (ST 6941) to the delivery pressure
check port of the main pump to be measured.
j : 19 mm
l : 6 mm
Connect MPDr. and select the monitoring function.
2 1
Measurement: TJAA-04-05-002

1- Pump 1 Delivery Pressure 2- Pump 2 Delivery Pressure
Engine Power Mode Auto-Idle Work Mode Check Port Check Port
Control Dial Switch
Mode
2. Measure the pressure with the control lever set in
neutral without load.
the mean values.
Evaluation:
Remedy:
T4-5-7
Fan Pump Delivery Pressure

Preparation:
1. Stop the engine.
tank and bleed air.
3. Disconnect the delivery hose (1) from fun pump to
be measured. Install tee (ST6487), nipple (ST 6069),
hose (ST 6943) and pressure gauge (ST 6941).
j : 19 mm
1
l : 6 mm
Measurement:
1. Measurement Conditions are below.
Engine Power Auto-Idle

Work Mode
Digging
Fast Idle HP OFF
Mode TJAA-04-05-002
2. Measure pressure with the control levers in neutral

without load. 1- Delivery Hose

the average values.
Evaluation:
Refer to the Operational Performance Standard.
Remedy:
Refer to the Troubleshooting B.
T4-5-8
Main Relief Set Pressure

Summary:
Measure the main relief valve set pressure at the
delivery port in the main pump. The main relief set
pressure can be also measured by using MPDr..
Preparation:
1. Stop the engine.
tank and bleed air.
3. Remove the plug from the delivery pressure check
port of the main pump to be measured. Install
the adapter (ST 6069), the hose (ST 6943), and the
pressure gauge (ST 6941) to the delivery pressure
check port of the main pump to be measured.
j : 19 mm
l : 6 mm
Connect MPDr. and select the monitoring function.
observed at the pressure gauge connection. 2 1
TJAA-04-05-002
Check Port Check Port
T4-5-9
Measurement:
Engine Power Mode Auto-Idle Work Power Digging

Control Dial Switch Mode Switch
Fast Idle HP OFF Digging ON

Mode OFF
2. Main relief pressure:

Perform bucket, arm, boom, or travel operation.
Measure the set pressure of main relief valve (1).
When measuring the pressure of bucket, arm, and
boom, operate each control lever slowly. Operate
each cylinder to the stroke end (extend, retract) and
relieve the pressure.
3. Swing relief pressure:
When measuring the pressure of swing, secure the
upperstructure so that it does not swing. Slowly
operate the swing control lever and relieve the
swing function. In order to judge at which swing
device the swing relief pressure is detected, loosen
the adjustment plug of the swing device (right).
 When the swing relief pressure decreases, the swing
relief pressure at the swing device (right) is detected.
Further loosen the adjustment plug of the swing
device (right). When the swing relief pressure stops
decreasing, the pressure is the swing relief pressure
at the swing device (left). Return the adjustment
plug of the swing device (right) to the original
position.
 When the swing relief pressure does not decrease,
the swing relief pressure at the swing device (left) is
detected. Return the adjustment plug of the swing
device (right) to the original position. Slowly loosen
the adjustment plug of the swing device (left).
When the swing relief pressure stops decreasing,
the pressure is the swing relief pressure at the swing
device (right). Return the adjustment plug of the
swing device (left) to the original position.
4. Travel relief pressure:
When measuring the pressure of travel, secure the
tracks against an immovable object. Slowly operate
the travel control lever and relieve the pressure.
5. When measuring the pressure during power
digging operation, measure the pressure within 8
seconds after pushing the switch.
Evaluation:
T4-5-10
fNOTE: If pressures of all circuits are low, the pressure of 1

the main relief valve may decrease.
Main Relief Valve (1) Setting Adjustment Procedure

When adjusting the pressure during the power digging
operation, adjust the high-pressure side of main relief
pressure.
When adjusting the normal main relief pressure, adjust
the low-pressure side of main relief pressure.
When adjusting the high-pressure side of main relief
pressure, the low-pressure side of main relief pressure
setting is changed accordingly. Therefore, be sure to
adjust the low-pressure side of main relief pressure
after adjusting the high-pressure side of main relief
pressure.
High-pressure side of relief pressure adjustment TJAA-04-05-003

procedure.
2
1. Loosen lock nut (3). Lightly tighten plug (2) until 3
plug (2) comes into contact with the end of sleeve
(4). 4
Tighten lock nut (3). 5
j : 22 mm, 30 mm 6
(Lock Nut (3))
m : 50 to 60 N·m (5 to 6 kgf·m)
2. Loosen lock nut (5). Turn sleeve (4) and adjust the
pressure until the specified pressure is obtained.
j : 27 mm, 41 mm
(Lock Nut (5))
m : 90 to 100 N·m (9 to 10 kgf·m)

3. After the adjustment has been completed, tighten
lock nut (5).
4. After the adjustment, check the set pressure. T16J-04-04-003
1- Main Relief Valve 4- Sleeve
2- Plug 5- Lock Nut
3- Lock Nut 6- Cap
2, 4
a b
W107-02-05-127
a- Pressure Increase b- Pressure Decrease
T4-5-11
Low-pressure side of relief pressure adjustment 2

procedure.
3
3. Loosen lock nut (3). Turn plug (2) and adjust the
pressure until the specified pressure is obtained. 4
After the adjustment has been completed, tighten
5
lock nut (3).
j : 22 mm, 30 mm 6
(Lock Nut (3))
m : 50 to 60 N·m (5 to 6 kgf·m)
4. After adjustment, check the set pressure.
fNOTE: Standard chang in Pressure (Reference)

Plug (2), Sleeve (4) 1/4 1/2 3/4 1
Turns
Change MPa 4.4 8.8 13.2 17.7
in Relief
Pressure (kgf/cm2) (45) (90) (135) (180)
T16J-04-04-003
2- Plug 5- Lock Nut
3- Lock Nut 6- Cap
4- Sleeve
2, 4
b
a
W107-02-05-127
T4-5-12
Swing Relief Valve Set-Pressure Adjustment

Procedure 1
Adjust the set pressure of swing relief valve (1) using
adjusting plug (2) after loosening lock nut (3).
1. Loosen lock nut (3).
j : 38 mm
2. Turn adjusting plug (2) to adjust.
j : 30 mm
3. Tighten lock nut (3).
j : 38 mm
m : 118 N·m (12.0 kgf·m) 1 M1J1-07-053

4. After adjustment, check the set pressure.

Adjusting Plug Turns (2) 1
3 2
Change in MPa 10.0
Pressure (kgf/cm2) (102)
T16J-04-05-001
1- Swing Relief Valve 3- Lock Nut

2- Adjusting Plug
b
a
T157-05-04-023
T4-5-13
Travel Relief Valve Set-Pressure Adjustment

Procedure (Reference)
Adjust the set pressure of travel relief valve (1) using
adjusting screw (3) after loosening lock nut (2).
j : 19 mm
2. Turn adjusting screw (3) to adjust the pressure
setting, referring to the table below.
j : 6 mm
3. Retighten lock nut (2).
j : 19 mm
m : 34.3 to 44.1 N·m

1
T183-01-02-012
(3.5 to 4.5 kgf·m)
4. After adjustment check the set pressure by the
special test device. 2

Turns
Change in MPa 1.96 3.92 5.88 7.85
Pressure (kgf/cm2) (20) (40) (60) (80)
3
T142-05-04-007
1- Travel Relief Valve 3- Adjusting Screw

2- Lock Nut
2 3
b
a
W107-02-05-129
T4-5-14
Overload Relief Set Pressure

Summary:
1. When measure the overlaad relif set pressure, the Measurement:
circuit pressure must be increased by applying an
external force while blocking the return circuit of
the control valve. However, this measuring method Engine Power Mode Auto-Idle Work Mode
is hazardous and the results obtained with this Control Dial Switch
method are unreliable.
2. Accordingly, the overload relief valve assembly Fast Idle HP OFF Digging
should be removed from the machine and checked Mode
on a specified test stand at a correct oil flow rate.
2. Slowly operate the bucket, arm, or boom control
3. Measure the pressure on the machine is not
levers. Operate each cylinder to the stroke end
recommended because of above mentioned
(extend, retract) and relieve the main relief valve.
reasons. If the measurement on the machine is
required, please substitute the measurement of the 3. Read the pressure on the pressure gauge at this
main relief set pressure. The main relief set pressure time.
can be also measured by using MPDr..
4. Perform the measurement for the bucket, arm, and
boom in sequence.
Preparation:
1. Stop the engine. the mean values.
tank and bleed air. Evaluation:
3. Remove the plug from the delivery pressure check The overload relief valves are normal when each main
port of the main pump to be measured. Install relief set pressure in the measured circuits (bucket, arm,
adapter (ST 6069), hose (ST 6943), the pressure boom) is within the specified value range. Refer to the
gauge (ST 6941) to the delivery pressure check port Operational Performance Standard.
of the main pump to be measured.
j : 19 mm
l : 6 mm
4. Connect MPDr. and select the monitoring function.
Start the engine. Confirm that no oil leakage is
5. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
2 1
TJAA-04-05-002

Check Port Check Port
T4-5-15
Overload Relief Pressure Adjustment Procedure

(Reference) 1
IMPORTANT: Adjust the overload relief valve

pressure on a test stand.
Loosen lock nut (1) and adjust the set pressure of the
overload relief valve by using adjusting screw (2).
j : 19 mm 2
2. Turn adjusting screw (2) and adjust the set pressure. T162-04-04-004
l : 6 mm 1- Lock Nut 2- Adjusting Screw
3. Tighten lock nut (1).
j : 19 mm 1 2
m : 31.5 N·m (3.2 kgf·m)
4. After adjustment check the set pressure by the b

special test device. a

W107-02-05-129
Turns a- Pressure Increase b- Pressure Decrease
Change in MPa 4.9 9.8 14.7 19.6
Pressure (kgf/cm2) (50) (100) (150) (200)
T4-5-16
(Blank)
T4-5-17
Main Pump Flow Rate Measurement

 P-Q Control (Torque Control)
Summary:
Install hydraulic tester (5) to the delivery port of the
main pump to be measured. Main pump performance 6. Disconnect the hose from the port Psv (11). Install
is checked by measuring the pump flow rate. Use MPDr. the plug (ST 6427) (13) to the port Psv.
and a pressure gauge at the same time. 7. Remove the vacuum pump. Loosen plug (12) on top
of the pump casing. Bleed air from the casing until
IMPORTANT: This measurement procedure is a oil comes out.
simple method. In order to measure accurately,
8. Fully open the loading valve of hydraulic tester (5).
disconnect the return circuit from the control
valve and connect it to the hydraulic oil tank. 9. Start the engine. Confirm that no oil leakage is
obserbed at the hydraulic tester and pressure
gauge connection. Connect MPDr. and select the
Preparation:
monitoring function.
1. Stop the engine. Push the air bleed valve on top
of the hydraulic oil tank and bleed air. Connect a
Measurement:
vacuum pump to the oil filler port.
fNOTE: Operate the vacuum pump while connecting the
2. Measure the maximum flow rate.
pump flow rate test line.
2. Disconnect the delivery hose from the main pump 3. Measurement conditions are below.
to be measured. Connect pipe (1 or 2) to the
delivery port of the main pump with the split flange Engine Power Auto-Idle
Work Mode
and bolt of the disconnected hose. Control Dial Mode Switch
Digging
j : 41 mm Fast Idle HP OFF
Mode
l : 10 mm 4. Adjust the relief set pressure of main relief valve in
control valve to each pressure point specified along
3. Install pipe (1 or 2) to hydraulic tester (5) with test
the main pump P-Q curve. (Refer to T4-2-5) Slowly
hose (3) and adapter (4). Install adapter (6), joint (7),
restrict the loading valve of hydraulic tester while
test hose (8), and flange (9) to hydraulic tester (5).
relieving pressure in the arm roll-in circuit. Measure
j : 41 mm the flow rates and engine speeds at each pressure
point specified in the P-Q curve.
l : 10 mm
4. Install flange (9) and the disconnected delivery hose the average values.
with split flange (10) and bolt (11).
l : 10 mm
5. Install a pressure gauge to the main pump to be
measured. (Refer to Main Relief Set Pressure.)
l : 6 mm
T4-5-18
Evaluation:
1. Convert the measured flow rates to those at the 2. Standard Flow Rate
specified pump speed by using the following
formula.
fNOTE: When actually measuring, install pipe (1 or 2)
Qc = Q × Ns / Ne only to the pump to be measured.
Qc : Converted Flow Rate

Q : Measured Flow Rate
Ns : Specified Engine Speed:
2000 min-1
Ne : Measured Engine Speed:
Values indicated on MPDr.
1, 2 3 4 5 6 7 8 9 10
Delivery Hose
(To Control
Valve)
TJAA-04-05-004
11
12
13
TJAA-04-05-010
1- Pipe F (ST 6138) 5- Hydraulic Tester (ST 6299) 9- Split Flange (4075853)
2- Pipe D (ST 6132) 6- Adapter G1 × UNF1-7/8 10- Bolt (J271245) (4 Used)
3- Test Hose (ST 6145) (ST 6146) 11- Port Psv
4- Adapter G1 × UNF1-7/8 7- Test Hose (ST 6145) 12- Plug
(ST 6146) 8- Flange (ST 6140) 13- Plug (ST 6247)
T4-5-19
Fan Pump Flow Rate Measurement

 P-Q Control (Torque Control) Measurement:
Summary: 1. Maintain the hydraulic oil temperature at 50±5 °C.
Fan pump performance is checked by measuring the 2. Measure the maximum flow rate.
pump flow rate by using a hydraulic tester (3) installed
at the fan pump delivery port to be measured. Use a 3. Select the following conditions.
hydraulic tester.
Engine Power Auto-Idle
Work Mode
IMPORTANT: This measurement procedure is a Control Dial Mode Switch
simple method. Digging
Fast Idle HP OFF
Mode
Preparation: 4. Adjust the set pressure of relief valve in fan valve
1. Stop the engine. Push the air bleed valve and bleed to each pressure point specified along the fan
air. Connect a vacuum pump to the oil filler port. pump P-Q curve. (Refer to T4-2-6) Slowly restrict the
loading valve of hydraulic tester (3). Measure the
fNOTE: Operate the vacuum pump while connecting the flow rates and engine speeds at each pressure point
specified in the P-Q curve.
pump flow rate test piping.
2. Disconnect the delivery hose (8) from fan pump. 5. Repeat the measurement three times and calculate
Install the adapter (1) (ST 6686) to the delivery port. the average values.
j : 36 mm, 41 mm
3. Connect test hose (2) to adapter (1) (ST 6686) and
hydraulic tester (4) with adapter (3). Install adapter
(5), test hose (6) and nipple (7) to hydraulic tester
(4).
j : 41 mm
4. Connect the delivery hose (8) to nipple (7).
j : 36 mm
5. Disconnect the hose from the port Pp (9). Install
plug (ST 6204) to the port Pp (9).
j : 19 mm
6. Remove the vacuum pump. Loosen plug (10) on top
of the pump casing. Bleed air from the casing until
oil only comes out.
l : 6 mm
7. Fully open the loading valve of hydraulic tester (4).
observed at the hydraulic tester (4) connection.
T4-5-20
Evaluation: 2. Standard Flow Rate

1. Convert the measured flow rates to those at the Refer to Operational Performance Standard.
specified pump speed by using the following
formula.
Qc = Q × Ns / Ne
Qc : Converted Flow Rate

Q : Measured Flow Rate
Ns : Specified Engine Speed:2000 min-1
Ne : Measured Engine Speed:
Values indicated on MPDr.
1 2 3 4 5 6 7
Delivery Hose
(To Control Valve)
11 TJAA-04-05-005
10
11 TJAA-04-05-006
1- Adapter (ST 6147) 4- Hydraulic Tester (ST 6299) 7- Nipple (ST 6025) 11- Adapter
2- Test Hose (ST 6145) 5- Adapter G1 × UNF1-7/8 8- Delivery Hose
3- Adapter G1 × UNF1-7/8 (ST 6146) 9- Port Pp
(ST 6146) 6- Test Hose (ST 6145) 10- Plug
T4-5-21
Adjustment of Main Pump Flow Rate Control

The flow rate control is performed by pump control j : 13 mm : Lock Nut (2)
solenoid valve signal current (I) of pump control
solenoid valve. The flow rate control is adjusted by l : 6 mm : Adjusting Screw (3)
changing the set-force of spring (1).
Adjustment: Loosen lock nut (2) and turn adjusting
screw (3).
1 2 3
T16J-04-04-006
1- Spring 2- Lock Nut 3- Adjusting Screw
Q
Adjusting Screw (3) Turn 1/4
Flow Rate Change 55 L/min
Main Pump Speed 1900 min-1
I
TJAA-04-05-009
I- Pump Control Solenoid Valve Q- Pump Delivery Flow Rate

Signal Current
b
a
W107-02-05-129
a- Flow Rate Decrease b- Flow Rate Increase
T4-5-22
(Blank)
T4-5-23
Swing Motor Drainage

Summary:
1. Measure amount of oil draining from the swing
motor while swinging the upperstructure and check
the swing motor performance.
2. Secure absolute safety for the measuring persons as
well as for the surrounding while measuring.
1
3. The amount of drain oil from the swing motor will
change depending on hydraulic oil temperature.
A
Preparation: B
1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F). Rotate the swing motor in order to warm
inside of the motor.
2. Stop the engine. Push air bleed valve (1) on top of
the hydraulic oil tank and release any remaining
pressure.
3. Disconnect right drain hose (1) at right side of tee
(A). Install plug (ST 6491) on the tee side. The drain 2
oil at the swing device (right) comes out from the
drain hose (1).
Disconnect drain hose (2) at left side of tee (B).
Machine
Connect a test drain hose (3/4-16UN) to the motor Front Side
side and plug (ST 6637) to drain hose (2). The drain
oil at the swing device (left) comes out from the test
drain hose.
j : 27 mm
m : 93 N·m (9.5 kgf·m)
Preconditions for Measurement:

T16J-04-04-007
1. Select the following conditions. 1- Drain Hose (Between Swing 2- Drain Hose (Return Hydraulic
Motor) Oil Tank)
Control Dial Mode Switch A- Right Side Tee B- Left Side Tee
Mode
T4-5-24
Measurement:

measurement. Also, take care not to fall off from
the machine while measuring.

bucket cylinder. Hold the boom so that the arm tip
pin height is the same as the boom foot pin height.
Empty the bucket.
2. Start the engine. Operate and hold the swing
control lever in the full stroke. After the swing
speed reaches a constant maximum speed, start the
a
draining oil measurement when the drain oil starts
coming out of the drain hose end.
T105-06-03-013
3. Repeat the measurement at least three times in
both clockwise and counterclockwise directions, a- The same height as boom
and calculate the mean values. foot pin
4. The measuring time should be more than 45
seconds.
Evaluation:
* Conversion of amount of measured drain oil into
the per-minute value
First measure the amount of drain oil by using a
calibrated container. Then, convert the measured
drain oil into the per-minute value by using the
following formula.
Q =60×q/t
Q : Amount of drain oil per minute (L/min)
t : Measured time (seconds)
q : Total amount of drain oil (L)
T107-06-05-008
T4-5-25
Travel Motor Drainage

Summary:
1. While rotating the travel motor with the track to be
measured raised off the ground, measure amount of 1
oil draining from the travel motor and check travel
motor performance.
2. Secure absolute safety for the measuring persons as
well as for the surrounding while measuring.
3. Judge travel motor performance from the results
including travel speed, mistrack and so on overall.
4. The amount of drain oil from the travel motor will
change depending on hydraulic oil temperature.
Keep the hydraulic oil temperature.
M183-01-001
Preparation:
1. Adjust track sag.
Track sag specification: 390 to 430 mm
2. Main hydraulic oil temperature at 50±5 °C (122±9
°F). Rotate the travel motor and warm inside of the
motor. 2
3. Stop the engine. Push air bleed valve on top of

the hydraulic oil tank and release any remaining
pressure.
4. Disconnect the drain hose (1) in the travel motor at
the travel motor end. Install plug (3) (ST 6637) to the
disconnected end. Connect test drain hose (2) (3/4-
16UN) to the travel motor.
j : 27 mm
T157-05-04-019
m : 93 N·m (9.5 kgf·m)
Preconditions for Measurement: 1


Mode 3
T183-04-04-011
1- Drain Hose 3- Plug

2- Test Drain Hose
T4-5-26
Measurement:
dCAUTION: When the working around moving

parts is unavoidable, pay special attention to
ensure that hands, feet, and clothing do not
become entangled. Securely support the raised
a
track off the ground by using the blocks.
1. Start the engine. Raise the track to be measured off

the ground.
2. Rotate the track to be measured. Start drain oil M104-07-067
measurement when drain oil starts coming out of a- 90 to 110°
the connected drain hose end.
3. Repeat the measurement at least three times in
both clockwise and counterclockwise directions,
and calculate the mean values.
4. The measuring time should be more than 45
seconds.
Evaluation:
* Conversion of the amount of drain oil measured into

the per-minute value
First measure the amount of drain oil by using a
calibrated container. Then, convert the measured
drain oil into the per-minute value by using the
following formula.
Q =60×q/t
Q : Amount of drain oil per minute (L/min)
t : Measured time (seconds) T157-05-04-019
q : Total amount of drain oil (L)
T4-5-27
(Blank)
T4-5-28
Group 6 Adjustment
PUMP LEARNING
(Pump Regulator Pressure Learning)
Detects electrical current and pressure, which control the

pump regulator, of the pump control solenoid valve, and
memorize in MC. (Refer to the T/M (SYSTEM) section.)
Therefore, as difference between the signal to pump
control solenoid valve from MC and the regulator
pressure controlled by the pump control solenoid valve is
adjusted, the pump swash angle is controlled correctly.
MPDr. displays the pump status during the pump learning
and can check if the learning has been done correctly.
IMPORTANT: Perform the pump learning if the
following work is done.
 Replace the pump, pump regulator and pump
control solenoid valve
 Replace MC
 When executing all parameter initialize of MC
IMPORTANT: After the learning, turn the learning
switch to the OFF position. If the pump learning
fails, the adjustment is not done. If the adjustment
succeeds and the learning switch is turned by
mistake, the learning may fail.
Learning Start Condition

 MC, ECM: No breakdown, no failure
 Engine Control Dial: Fast idle
 Power Mode Switch: HP Mode
 Pressure Sensor: Output zero. (The control lever is in
neutral.)
 Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
 Pilot Shut-Off Lever: LOCK Position
 Learning Switch: OFF
f NOTE: Cancellation during learning:
When the learning switch is turned to the OFF position
before finishing the learning, the adjustment is done
according to the former learning result.
T4-6-1
Group 6 Adjustment
TORQUE ADJUSTMENT
Adjust pump drive torque, sum of main pumps 1, 2, by
using MPDr. (Refer to the T/M (SYSTEM) section.)
IMPORTANT: These procedures are for only
adjustment without repair. When main pump
drive torque need to increase or decrease, do
these procedures.
Adjustment Start Condition:
 MC, ECM: No breakdown and No malfunction (by
using MPDr.)
 Engine output horsepower: Normal
 Hydraulic oil temperature: 50±5 °C (122±9 °F)
T4-6-2
Group 6 Adjustment
CONNECTION
1. Connect MPDr. to the MPDr. connector by using the
USB serial cable, the inter link cross cable, and the MPDr. Connector 1
connecting harness.
2. Turn the key switch ON or start the engine.
Personal Computer (MPDr.)
Inter Link
Cross cable
TJAA-01-02-018
USB Serial
Cable
Connecting
Harness
T1T1-06-01-001
1- MPDr. Connector
T4-6-3
Group 6 Adjustment
(Blank)
T4-6-4
MEMO
MEMO
SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 Diagnosing Procedure Pilot Port (Signal Control Valve)....................................T5-4-32
Introduction........................................................................... T5-1-1
Diagnosis Procedure........................................................... T5-1-2
Troubleshooting A (Base Machine Diagnosis
Electrical System Inspection............................................ T5-1-5
By Using Fault Codes) Procedure.............................. T5-5-1
Precautions for Inspection and Maintenance............ T5-1-6
MC Fault Code List............................................................... T5-5-3
Instructions for Disconnecting Connectors............... T5-1-8
ECM Fault Code List...........................................................T5-5-22
Fuse Inspection...................................................................T5-1-10
Monitor Controller (Monitor) Fault Code List..........T5-5-27
Fusible Link Inspection....................................................T5-1-13
Monitor Controller (Information)
Battery Voltage Check......................................................T5-1-14
Fault Code List...............................................................T5-5-28
Alternator Check................................................................T5-1-15
Air Conditioner Controller Fault Code List................T5-5-31
Continuity Check...............................................................T5-1-16
Communication Terminal Fault Code List.................T5-5-32
Voltage and Current Measurement.............................T5-1-18
MC Fault Codes 11000 to 11002...................................T5-5-33
Check by False Signal.......................................................T5-1-25
MC Fault Code 11003.......................................................T5-5-34
Test Wire Harness...............................................................T5-1-26
MC Fault Codes 11006, 11007,11009..........................T5-5-37
Group 2 Monitor Monitor Controller (Monitor) Fault Codes
Outline..................................................................................... T5-2-1 13002, 13003, 13005...................................................T5-5-37
Operating Procedures of Service Menu....................... T5-2-2 CAN0 Harness Check........................................................T5-5-38
Setting Menu.......................................................................T5-2-39 MC Fault Codes 11008, 11010.......................................T5-5-41
Inspection of Engine Oil Level, Coolant Level, Hour Monitor Controller (Monitor) Fault Codes
Meter, and Fuel Gauge...............................................T5-2-41 13004, 13006, 13007...................................................T5-5-41
Fuel Gauge and Coolant Temperature Gauge.........T5-2-42 CAN1 Harness Check........................................................T5-5-42
MC Fault Code 11100.......................................................T5-5-45
Group 3 e-Service MC Fault Code 11101.......................................................T5-5-46
Outline..................................................................................... T5-3-1 MC Fault Codes 11200, 11202.......................................T5-5-47
List of Operation Data........................................................ T5-3-2 MC Fault Codes 11301, 11302.......................................T5-5-48
Snapshot Data....................................................................... T5-3-6 MC Fault Code 11303.......................................................T5-5-49
Communication System.................................................... T5-3-7 MC Fault Codes 11304, 11325.......................................T5-5-50
Group 4 Component Layout MC Fault Code 11405.......................................................T5-5-51
Main Component................................................................. T5-4-1 MC Fault Code 11408.......................................................T5-5-52
Electrical System (Overview)........................................... T5-4-3 MC Fault Code 11412.......................................................T5-5-53
Electrical System (Rear Tray)............................................. T5-4-4 MC Fault Code 11428.......................................................T5-5-54
Electrical System (Switch Panel)..................................... T5-4-5 MC Fault Code 11802.......................................................T5-5-55
Electrical System (Utility Space)..................................... T5-4-6 MC Fault Code 11901.......................................................T5-5-56
Engine...................................................................................... T5-4-8 MC Fault Codes 11942, 11944.......................................T5-5-57
Pump Device......................................................................... T5-4-9 MC Fault Codes 11945......................................................T5-5-58
Around Pump Device.......................................................T5-4-10 MC Fault Code 11948.......................................................T5-5-59
Control Valve.......................................................................T5-4-11 MC Fault Code 11950.......................................................T5-5-60
Check Valve/Accumlator.................................................T5-4-12 MC Fault Code 11951.......................................................T5-5-61
Signal Control Valve..........................................................T5-4-12 MC Fault Code 11953.......................................................T5-5-62
Swing Device.......................................................................T5-4-14 MC Fault Codes 11978, 11979.......................................T5-5-63
Travel Device.......................................................................T5-4-14 MC Fault Code 11982.......................................................T5-5-64
4-Spool Solenoid Valve Unit...........................................T5-4-15 MC Fault Codes 11985, 11986.......................................T5-5-65
2-Spool Solenoid Valve Unit...........................................T5-4-15 MC Fault Code 11989.......................................................T5-5-66
Fan Valve (Option).............................................................T5-4-15 MC Fault Codes 11992, 11994.......................................T5-5-67
Layout of Control Valve....................................................T5-4-16 MC Fault Codes 11995, 11997.......................................T5-5-68
JAET-5-1
MC Fault Code 11998.......................................................T5-5-69
MC Fault Codes 20062......................................................T5-5-70
Monitor Controller (Information) Fault Codes
13304, 13310..................................................................T5-5-71
Monitor Controller (Information) Fault Code
13311................................................................................T5-5-72
20100 to 20104, 20106...............................................T5-5-73
20107, 20109, 20110, 20114, 20146, 20149........T5-5-74
Air Conditioner Controller Fault Codes 11 to 22.....T5-5-75
Troubleshooting B (Machine Diagnosis
by Using Trouble Symptom) Procedure................. T5-6-1
Relationship between Machine Trouble
Symptoms and Related Parts..................................... T5-6-3
Correlation Between Trouble Symptoms
and Part Failures...........................................................T5-6-29
Engine System Troubleshooting..................................T5-6-47
All Actuator System Troubleshooting.........................T5-6-54
Front Attachment System Troubleshooting.............T5-6-62
Swing System Troubleshooting....................................T5-6-75
Travel System Troubleshooting....................................T5-6-78
Other System Troubleshooting.....................................T5-6-82
Exchange Inspection........................................................T5-6-89
How to Lowering Boom When Emergency
and When Engine Stops.............................................T5-6-92
Outline..................................................................................... T5-7-1
Functions of Main Parts..................................................... T5-7-4
Troubleshooting................................................................... T5-7-9
Air Conditioner Controller Fault Code List................T5-7-10
Work after Replacing Components.............................T5-7-34
Refill Compressor Oil........................................................T5-7-35
Charge Air Conditioner with Refrigerant..................T5-7-36
Hose and Pipe Tightening Torque................................T5-7-44
JAET-5-2
Introduction
Refer to the inspection and troubleshooting procedures
after any machine trouble has occurred. The inspection
and troubleshooting procedures are presented in an
orderly fashion in this section to quickly find the cause of
the machine trouble and solution.
The troubleshooting section in this manual consists of

seven groups as follows.
1. Diagnosing Procedure 5. Troubleshooting A (Base Machine Diagnosis By

Using Fault Codes)
This group explains procedures of troubleshooting
and precautions and/or information for the Refer to these procedures if any fault codes are
electrical system inspection. displayed when each controller is diagnosed by
using MPDr. (or the service menu of monitor).
Example: Fuse Inspection
IMPORTANT: The monitor controller receives and
records the electrical signal system malfunction of
2. Monitor
each controller in the form of fault codes by using
This group contains the display screen of monitor the CAN communication. The monitor controller
and the operating procedures of service menu. records the electrical signal system malfunction
in the form of fault codes by the self-diagnosing
function.
3. e-Service
This group contains as follows. Procedures Example: Fault Code 11000-2: Abnormal EEPROM
of downloading and uploading data from
the monitor controller. Procedures when 6. Troubleshooting B (Machine Diagnosis by Using
starting communication, when installing the Trouble Symptom)
communication controller and when replacing
the monitor controller. Explanation for the Refer to troubleshooting B for diagnosis by using
communication system. trouble symptom.
Refer to these procedures when no fault codes are
4. Component Layout displayed after diagnosing the machine by using
MPDr. (or the service menu of monitor).
Example: Even if engine control dial is rotated,

engine speed does not change.
7. Air Conditioner
This group explains air conditioner system,
troubleshooting, and procedure of charging
refrigerant to the air conditioner.
T5-1-1
Diagnosis Procedure
These six basic steps are essential for efficient
troubleshooting:
1. Study the system

 Study the machine's technical manuals.
 Know the system and how it works, and what the
construction, functions and specifications of the
system components are.
(Construction and functions)
2. Ask the operator
Before inspecting, get the full story of malfunctions
T107-07-01-001
from the operator below.
 Operating condition: How is the machine being
used? Find out if the machine is being operated
correctly.
 Trouble identification: When was the trouble noticed,
and what type of work was the machine doing at
that time?
 Trouble symptom: What are the details of the
trouble? Did the trouble slowly get worse, or did it
appear suddenly?
 Trouble history: Did the machine have any other
troubles previously? If so, which parts were repaired
before?
3. Inspect the machine
Before starting the troubleshooting procedure,
check the machine's daily maintenance points, as
shown in the operator's manual.
Troubles in the electrical system such as low
battery voltage, loose connections and blown fuses
will result in malfunction of the controllers. Also, T107-07-01-002
troubles in the electrical system will cause total
operational failure of the machine.
If troubleshooting is started without checking
for blown fuses, a wrong diagnosis may result
in wasting time. Check for blown fuses before
troubleshooting.
Even if a fuse looks normal by visual inspection, a
fine crack may exist and it is difficult to find. Always
use a circuit tester when checking the fuses.
4. Operate the machine yourself
Reproduce the trouble on the machine and make
sure the actual phenomenon.
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 corresponding to
the trouble.
T107-07-01-003
T5-1-2
5. Perform troubleshooting
dCAUTION: Do not disconnect wire harnesses

or hydraulic lines while the engine is running.
The machine may malfunction or pressurized
oil may spout out, possibly resulting in personal
injury. Stop the engine before disconnecting wire
harnesses or hydraulic lines.
Perform diagnosis by connecting MPDr. to the
machine or by using the service menu of monitor.
In case any fault code has been displayed by
diagnosis by using MPDr. (or the service menu of
monitor), write the fault code. Then, delete the
fault code once and retry self-diagnosis again. If
the fault code is displayed again, check the cause
of the trouble by referring to Troubleshooting A in
this section. After the machine trouble has been
corrected, the fault code (displayed by the service TDCD-05-01-002
menu of monitor) will be deleted. Therefore, if there
are problems that are not easily re-predicable, check
the fault code by using MPDr..
If the fault code is not displayed, check operating
condition of each component by referring to
Troubleshooting B in this section and by using MPDr.
(or the service menu of monitor).
f NOTE: The controller stores even temporary electrical
malfunctions, such as a drop in battery output voltage
or disconnection of the switches, sensors, etc., for
inspections.
T5-1-3
6. Trace possible causes

Before reaching a conclusion, check the most
suspect causes again.
Try to identify the actual cause of the trouble.
Based on your conclusion, make a plan for
appropriate repairs to avoid secondary
malfunctions.
7. Maintenance mode
Before checking the electrical system such
T107-07-01-007
as disconnecting the connector, select the
maintenance mode on the monitor. (Refer to
Monitor.)
T5-1-4
Electrical System Inspection

The precautions and information for the electrical system
inspection are explained here. The electrical system
inspection contains as follows.
 Precautions for Inspection and Maintenance

 Instructions for Disconnecting Connectors
 Fuse Inspection
 Fusible Link Inspection
 Battery Voltage Check
 Alternator Check
 Continuity Check
 Voltage and Current Measurement
 Check by False Signal
 Test Wire Harness
T5-1-5
Precautions for Inspection and Maintenance

IMPORTANT: Do not turn OFF battery disconnect
switch (1) while the engine is running and the key
1
switch is in the position other than OFF. And do
not turn OFF battery disconnect switch until more
than five minutes past after setting the key switch
to the OFF position. Failure to do so may damage
the electrical system.
1. Disconnect the power source.
Turn OFF battery disconnect switch (1) first when
taking off wire harnesses and connectors for repair
or replacement work. Failure to do so can result in
damage to the wire harnesses, fuses and fusible
links and, in some cases, cause fire due to short
circuiting. In addition, even when the key switch
is set to the OFF position, the controller may be
operated for a specified time. Therefore, turn OFF MJAC-01-050
battery disconnect switch (1) after setting the key
switch to the OFF position and waiting five minutes
or more.
2. Color coding of wire harnesses.
As for the color codes of wire harnesses in the
electrical system, refer to the table. If one wire
consists of two colors, two or more codes are
indicated. The left code stands for base color and
the right code stands for marking color.
Code R W L G Y B
Color Red White Blue Green Yellow Black
Code Or Lg Br P Gr V
Color Orange Light Brown Pink Gray Violet
green
fNOTE:
 Code BW indicates a black base wire harness with

white fine-line marking.
 Initials "O" and "Or" both stand for the color orange.

 Longitudinal stripes printed on wires are not color

code and indicate the kinds of wires.
T5-1-6
3. Precautions for connecting and disconnecting

terminal connectors
 Disconnect the connectors by grasping. Do not
pull on the wire harness itself. Release the lock
first before attempting to separate the connectors,
if a lock is provided. (Refer to Instructions for
Disconnecting Connector on T5-1-8.)
 The water-resistant connectors keep water out.
If water enters them, water will not easily drain TDAA-05-08-002
from them. When checking the water-resistant
connectors, take extra care not to allow water to
enter the connectors. In case water should enter the
connectors, reconnect only after the connectors are 1
thoroughly dried.
 Before connecting the connectors, check that no 2
terminals are bent (3) or coming off (4). In addition,
as most terminals are made of brass, check that no 3
terminals are rusting (2).
 When connecting connectors provided with a lock,
insert them together until the lock "clicks." 4
 Pull lightly the wire harness near the connector in TDAA-05-08-003
order to check if it is correctly connected.
1- Normal 3- Bent
2- Rusting 4- Coming Off
4. Precautions for using a circuit tester

 Before using a circuit tester, refer to the instructions
in the circuit tester manual. Then, set the circuit TDAA-05-08-004
tester to meet the object to be measured, voltage
range and current polarity.
 Before starting the connector test, always check
the connector terminal numbers by referring to the
circuit diagram. When the connector size is very
small, and the standard probe size is too large to be
used for testing, wind a fine piece of sharpened wire
or a pin around the probe to make the test easier.
 When checking the connector by using a circuit
tester, do not damage the terminal inside the
connector. Insert a tester probe from the wire
harness end of the connector.
T5-1-7
Instructions for Disconnecting Connectors
 Push, Unlock, and Separate Type

(Most connectors are this type.)
 The connectors will not be easily separated even if

the lock is pushed while being pulled. At first push
the lock and pull the connectors.
 The lock is located on female side connector (wire
harness end side).
T107-04-05-002
 Raise Lock, Pull, and Separate Type
T107-04-05-003
T5-1-8
 Pull Lock and Switch the Lever Type
TDAA-05-08-005
 Remove Bolt (1) and Remove Type: (A)

 Push Lock and Switch Lever (2) Type: (B)
A
B TDAA-05-08-006
1- Bolt (M8) 2- Lever
T5-1-9
Fuse Inspection
Cracks in a fuse are so fine that it is very difficult or
impossible to find by visual inspection. Use a circuit tester
fNOTE: Check the starter circuit fuse with the key switch
set in the START position and follow the procedure in step
in order to correctly inspect fuse continuity by following 3.
the instructions described below.
b a b
1. Set the key switch to the ON position. When the
key switch is in the ON position, current from key
switch terminal M turns ON the battery relay so that
electric power is supplied to all circuits except the
starter circuit. (Refer to the circuit diagram.)
2. Remove the fuse box cover. Set a circuit tester.
(Measurement Range: 0 to 30 V)
3. Ground the negative probe of circuit tester to the
body. Touch the terminals located (b) away from
center of the fuse box with the positive probe of
circuit tester one at a time. When the circuit tester
indicates 20 to 25 V (battery voltage), the fuse is
normal.
M178-07-034
a- Terminals connected to the b- Terminals connected to loads

power source (accessories)
Fuse Box 1 Fuse Box 2
10 20 30 40
9 19 29 39
8 18 28 38
7 17 27 37
6 16 26 36
5 15 25 35
4 14 24 34
3 13 23 33
2 12 22 32
1 11 21 31
M178-07-034 M178-07-034
T5-1-10
Fuse No. Capacity Connected to

1 20 A Work Light Relay 1
2 10 A Washer Relay, Wiper Motor
3 20 A Air Conditioner Unit
4 20 A Pilot Shut-Off Relay, Pilot Shut-Off Solenoid Valve, Security Relay, MC (Solenoid Valve Power)
5 5A Option 1, Travel Alarm (Optional), Option 2, ATT
6 20 A Option 2, OPT-Wiper
7 5A Monitor Controller, ECM
8 30 A ECM Main Relay (Power)
9 10 A Monitor Controller (Backup Power), Switch Panel, Cab Light, Radio (Backup Power), Security Horn
(Power), Security Horn Relay (Power), GSM (Power)
10 5A MC (Power), GSM (Power), Wiper/Light Controller (Power)
11 5A Fuel Pump Relay
12 5A Wiper/Light Controller, Radio (Power)
13 10 A Cigar Lighter
14 5A Monitor Controller (Power)
15 10 A Auxiliary (Power)
16 5A Glow Plug Relay
17 5A Buzzer, Engine Stop Switch, Air Conditioner Unit, Work Light Relay 1, Washer Relay, Wiper Relay,
GSM, Monitor Controller, ECM, MC, OPT-Wiper
18 5A ACC Cut Relay, Key Switch ON Cut Relay, Auto Shut-Down Relay, Starter Cut Relay
19 10 A Horn Relay (Power)
20 5A Option 3
T5-1-11
Fuse No. Capacity Connected to

21 10 A Seat Heater (Optional)
23 10 A Cab Light Rear Side (Optional)
24 10 A -
25 5A Immobilizer (Optional)
26 5A Quick Hitch (Optional)
27 5A -
28 10 A -
30 10 A Auto Lubrication Relay
31 10 A Seat Compressor (Optional)
32 10 A Cab Light Front Side (Optional)
33 10 A Indicator (Optional)
34 10 A -
35 20 A -
36 15 A Suction Control Valve 1, Suction Control Valve 2
37 10 A Grease Pump
38 - -
39 - -
40 - -
T5-1-12
Fusible Link Inspection

Inspection
1. Visually inspect fusible link (2, 3).
1
Replacement 2
1. Turn OFF the battery disconnect switch.

3
2. Pull out fusible link (2, 3). Replace fusible link (2, 3).
3. Turn ON the battery disconnect switch.
MJAA-07-055
2, 3
T111-04-05-015
1- Battery Relay 3- Fusible Link (75A)

2- Fusible Link (45A)
T5-1-13
Battery Voltage Check

1. Turn OFF the key switch. Check the voltage
between the battery positive terminal and the body
(ground).
Specification: 24 V
fNOTE: If the voltage is not within the specification,

recharge or replace the battery.
2. Start the engine. Check the voltage between the
battery positive terminal and the body (ground).
Specification: 26 to 28 V
fNOTE: If the voltage is not within the specification,

check the charging system.
T162-05-06-005
T5-1-14
Alternator Check
Generally, if the alternator has generated electricity,
alternator alarm (1) will disappear. If alternator alarm (1)
is displayed while the engine is running, the alternator
might be defective.
How to Check Alternator

1. Set the key switch to the ON position. Confirm that
alternator alarm (1) is displayed.
1
2. Measure voltage between terminals B and E of the
alternator. If the measured voltage is around 24 V,
the alternator circuit can be considered normal. If
the measured voltage is low, a shortage in battery
capacity or looseness of the wire connectors MDAA-01-043
between battery and alternator might be the cause
of the malfunction. When voltage is 0 V, the ground
line of the alternator might be disconnected.
3. Next, start the engine and measure voltage
generated while the alternator rotates. As described
above, measure voltage between terminals B and E
on the alternator side. If voltage is around 28 V, the
alternator is operating normally. If the measured B Connector (L, R)
voltage is same as the battery voltage (around 24

V), there is some trouble with the alternator or the
regulator.
T16J-05-06-001
T5-1-15
Continuity Check
IMPORTANT: Before continuity check, set the key
switch to the OFF position. A a
 Single line continuity check

Disconnect both end connectors of the wire harness and
check continuity (measure the resistance) between both
end terminals:
 ∞ Ω = Open circuit
 0 Ω = Normal
A a
 When the one end connector is far apart from the

other
Connect one end of connector (A) to the body by using a
clip. Then, check continuity of the wire harness between
terminal (a) and the body.
 ∞ Ω = Open circuit
 0 Ω = Normal A a
 Single line short circuit check

Disconnect both end connectors of the wire harness and
check continuity between one end connector terminal of
the wire harness and the body:
 0 Ω = Short circuit
T107-07-05-003
 ∞ Ω = Normal
 Multi line continuity check

Disconnect both end connectors of the wire harness,
and short circuit two terminals, (A) and (B), at one end A a
B b
connector. Then, check continuity between terminals (a) C c
and (b) at the other connector.
If the ohm meter reading is ∞ Ω, either line (A) - (a), or (B)
- (b) is in discontinuity, or both lines (A) - (a) and (B) - (b)
are in discontinuity. Discontinuity is not limited at only
one place. Check discontinuity of the single line for all
uncertain wire harnesses.
T107-07-05-004
 Multi line short circuit check
Disconnect both end connectors of the wire harness, and
check continuity between terminals (A) and (B) or (C).
 0 Ω = Short circuit exists between the lines.
 ∞ Ω = Normal
A a
B b
C c
T107-07-05-005
T5-1-16
(Blank)
T5-1-17
Voltage and Current Measurement

Turn on the switches so that the specified voltage (current) is supplied to the location to be measured. Judge if the circuit
is normal by evaluating whether the measured voltage (current) matches the specification.
24-Volt Circuit
Start checking the circuit in order up to the location to be measured from either power source or actuator side.
Thereby, the faulty location in the circuit will be found.
 Black (negative) probe terminal of circuit tester: To the body (to ground)
 Red (Positive) probe terminal of circuit tester: To touch the location to be measured
Engine Key Switch Location to be Measured Specification

Electric Power Circuit
Stopped OFF Between (2) and (1): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (2): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (1): Two Batteries 20 to 25 V
Stopped OFF Between (4) and Ground: Battery Power 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link 20 to 25 V
Stopped OFF Between (1) and Ground: Backup Current *1 20 mA or less
Preheating Circuit
Stopped ON or START Between (11) and Ground: Key Switch 20 to 25 V
Stopped ON or START Between (7) and Ground: Glow Plug *2 20 to 25 V
Charging Circuit
Fast Speed ON Between (9) and Ground: Alternator (B), Generating Voltage 26 to 30 V
Fast Speed ON Between (8) and Ground: Battery Relay, Generating Voltage 26 to 30 V
Fast Speed ON Between (17) and Ground: Fuse Box 1, Generating Voltage 26 to 30 V
Fast Speed ON Between (14) and Ground: Monitor Controller (A15) 13 to 30 V
Surge Voltage
Prevention Circuit
Slow Idle Speed ON Between (9) and Ground: Alternator (B) 26 to 30 V
Slow Idle Speed ON Between (13) and Ground: Key Switch ON Cut Relay 26 to 30 V
Slow Idle Speed ON Between (10) and Ground: Load Dump Relay 26 to 30 V
Slow Idle Speed ON Between (6) and Ground: Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (12) and Ground: ACC Cut Relay 20 to 25 V
Stopped ON Between (15) and Ground: Monitor Controller 20 to 25 V
Stopped ON Between (16) and Ground: Wiper/Light Controller, Radio 20 to 25 V
Stopped ON Between (18) and Ground: Auxiliary 20 to 25 V
Stopped ON Between (19) and Ground: Cigar Lighter 20 to 25 V
Stopped ON Between (6) and Ground: Battery Relay 20 to 25 V
*1
Before measurement, turn OFF the battery disconnect switch.
*2
The preheating circuit is operated for the preheating time according to the coolant temperature.
T5-1-18
g
h 12 13 i
11
1 2 3 4 5 6
c j
d e f
14
n
10
a k
7
8
19 18 17 16 15
9
b
TJAE-05-01-001
a- Battery e- Glow Plug i- Key Switch ON Cut Relay m- MC

b- Alternator f- Load Dump Relay j- Fuse Box 1 n- Fuse Box 2
c- Fusible Link g- Key Switch k- Monitor Controller
d- Battery Relay h- ACC Cut Relay l- ECM
T5-1-19

Starting Circuit
Started START Between (20) and Ground: Battery Relay (Coil) 20 to 25 V
Started START Between (21) and Ground: Battery Relay (Switch) 20 to 25 V
Started START Between (22) and Ground: Starter (B) 20 to 25 V
Started START Between (23) and Ground: Starter (C) 20 to 25 V
Started START Between (24) and Ground: Starter Relay 1 (B) 20 to 25 V
Started START Between (25) and Ground: Starter Cut Relay 20 to 25 V
Started START Between (26) and Ground: Fuse Box 1 20 to 25 V
Started START Between (27) and Ground: Key Switch 20 to 25 V
Started START Between (28) and Ground: Fuse Box 1 20 to 25 V
Started START Between (29) and Ground: Monitor Controller (A16) 20 to 25 V
Started START Between (30) and Ground: MC (E4) 20 to 25 V
Started START Between (31) and Ground: ECM (134) 20 to 25 V
Started START Between (32) and Ground: ECM Main Relay 20 to 25 V
Started START Between (33) and Ground: ECM Main Relay 20 to 25 V
T5-1-20
27
20 26
c d 28
k g
a 25 f
21 A16
22
23 29
24
b 30
33
h
32
31 E4
j
134
i
TJAE-05-01-001
a- Starter d- Starter Cut Relay g- Monitor Controller j- MC

b- Starter Relay 1 e- Key Switch h- ECM Main Relay k- Fuse Box 2
c- Battery Relay f- Fuse Box1 i- ECM
T5-1-21

Pilot Shut-Off
Circuit*
Stopped ON Between (34) and Ground: Pilot Shut-Off Solenoid Valve 20 to 25 V
Stopped ON Between (35) and Ground: Pilot Shut-Off Relay (Coil) 20 to 25 V
Stopped ON Between (36) and Ground: Pilot Shut-Off Relay (Switch) 20 to 25 V
Stopped ON Between (37) and Ground: Security Relay 20 to 25 V
Stopped ON Between (38) and Ground: Fuse Box 1 20 to 25 V
* Before measurement, set the pilot shut-off lever to the UNLOCK position.
T5-1-22
34 a b c d
38
35
36
37
TJAE-05-01-001
a- Pilot Shut-Off Solenoid Valve c- Security Relay e- Fuse Box 2

b- Pilot Shut-Off Relay d- Fuse Box 1
T5-1-23
5-Volt Circuit
 Voltage between terminal #1 and the body Two Polarities
Disconnect the connector with the key switch OFF.
Measure voltage between terminal #1 (5 V power supply) 1 2
on the body harness end connector and the body
(ground).
 Key Switch: ON
 Black (negative) probe terminal of circuit tester: To
the body (to ground)
 Red (positive) probe terminal of circuit tester:
Terminal #1
T107-07-05-006
If the measuring voltage is within 5 ± 0.5 volts, the circuit
up to terminal #1 is normal. Three Polarities
1 2 3
 Voltage between terminal #1 and the ground terminal

Turn OFF the key switch, and disconnect the sensor T107-07-05-007
connector. Measure the voltage between terminal #1
(5 V power supply) on the body harness end connector
and the ground terminal (terminal #2 for two-polarities Two Polarities
or terminal #3 for three-polarities connector) under the
1 2
following conditions.
 Key Switch: ON
 Black (negative) probe terminal of circuit tester: To
ground terminal (Terminal #2 or #3)
 Red (positive) probe terminal of circuit tester:
Terminal #1
If the measuring voltage is within 5 ± 0.5 volts, the circuit T107-07-05-008

up to terminal #1 and the ground terminal (terminal #2 or
#3) is normal.
Three Polarities
1 2 3
T107-07-05-009
T5-1-24
Check by False Signal

Two Polarities
Turn OFF the key switch. Disconnect the sensor
1 2
connector. Turn ON the key switch. Connect terminal
#1 (power source) of the body harness end connector
to terminal #2 (signal). (Power voltage is used as a false
signal.)
Check this state by using the monitor function of MPDr..
When the maximum value is displayed, MC and the circuit
up to the body harness end connector are normal. In case
of a pressure switch, it displays "ON" status.
T107-07-05-010
IMPORTANT: Do not connect terminal #1 or #2
to terminal #3 or to the body (ground) when
Three Polarities
checking a three-polarity connector.
fNOTE: Some kinds of sensors can be monitored by the 1 2 3
service menu of the monitor.
T107-07-05-011
T5-1-25
Test Wire Harness Parts Number 4283594 (ST 7126)
Install a test wire harness between connectors. Check

the circuit condition depending on whether the test wire
harness lamp lights or extinguishes during operation.
 Parts Number 4283594 (ST 7126)

Use in order to check a single-line (open circuit and/or
voltage).
T107-07-05-012
 During Operation: Light is ON.
Parts Number (ST 7226)
4
 Parts Number (ST 7226) 3 50
Use in order to check the solenoid valve unit circuits.
150 50 50
1 2 2 1
 When the corresponding control lever or switch is
operated: Light is ON. T107-07-06-015
Connect a test wire harness to the wire harness end

connector of pressure sensor. Check the state of pressure
sensor circuit.
 ST 6701 for high-pressure sensor
 ST 6703 for low-pressure sensor
TDAA-05-06-003
T5-1-26
Connecting Procedure of Test Wire Harness

1
fNOTE: The connecting procedures of test wire harness
of pump 2 delivery pressure sensor (1) are explained.
1. Disconnect the connector of pump 2 delivery
pressure sensor (1).
2. Connect the male end connector of test wire TJAA-05-01-002

harness (3) (ST 6701) to wire harness end connector
(4) of pump 2 delivery pressure sensor (1).
3. Connect dummy sensor (2) equivalent to #4703324

to the female end connector of test wire harness (3)
(ST 6701).
2 3 TDAA-05-06-002
2 3 4
TDAA-05-06-003
T5-1-27
(Blank)
T5-1-28
Group 2 Monitor
Outline
Basic Screen
1 2 3 4
5
6
7
8
19
18
9
17
16
15
10
14
11
13 12
MJAE-01-012
1- Work Mode Display 6- Fan Reverse Display (Option) 11- Logo Display/ Operation 15- Auxiliary
2- Auto-Idle Display 7- Glow Signal Display Display/ No Display/ Rear View 16- Auxiliary
3- Power Mode Display 8- Seat Belt Display Monitor Display 17- Travel Mode Display
4- Clock, Hour Meter 9- Fuel Gauge 12- Radio Display 18- Auto Shut-Down Display
5- Auto-Lubrication Display 10- Sub Meter 13- Air Conditioner Display 19- Auxiliary
(Option) 14- Coolant Temperature Gauge
T5-2-1
Group 2 Monitor
Operating Procedures of Service Menu

IMPORTANT: The service menu is provided only for
service activity. Do not explain this function to
your customers.
The following items can be displayed on the monitor

without using MPDr..
 Troubleshooting:
Fault code is displayed.
 Monitoring:
A part of monitor items for MPDr. is displayed.
 Controller Version:
The controller version is displayed.
 Issued Warning Record:
Ten alarms which were issued recently are displayed.
 Operation:
Total operating hours of various hour meters are
displayed.
 Communication Terminal Status:
Information of the communication terminal is
displayed.
 Machine Setting:
The settings are adjusted.
 Monitor Setting:
All item operations displayed on the monitor are set
to enable/disable.
 Engine Setting:
Fault Code Clear is set.
 Maintenance Mode:
ON/OFF of the maintenance mode is set.
f NOTE: Machine Setting and Monitor Setting are not
displayed in initialization. When displaying Machine
Setting and Monitor Setting, make enable by function
settings of MPDr..
T5-2-2
Group 2 Monitor
How to display service menu 1 2
1. Push select/set switch (3) while pushing 9 on

numeric keypad (4) when the basic screen is
displayed with the key switch set in the ON position 3
or the engine running. Service Menu (5) is added to
the Main Menu screen. (Figure A)
2. Turn select/set switch (3) and select Service Menu
(5). When pushing select/set switch (3), the Service
Menu screen appears. (Figure B)
3. When pushing back switch (1), the previous screen
appears.
4. When pushing return to basic screen switch (2), the
basic screen appears.
4
fNOTE: Once the basic screen appears, Service Menu (5) TDAA-05-02-032
on the Main Menu screen is deleted. If Service Menu (5) is
required to display, perform step 1 again. A B
TDC1-05-02-014EN TDC1-05-02-010EN
T5-2-3
Group 2 Monitor
Troubleshooting
1 2
1. Turn select/set switch (3) and select
Troubleshooting (4) on Service Menu. When
pushing select/set switch (3), the Troubleshooting
screen appears. (Figure A)
3
2. Turn select/set switch (3) and select the controller.
When pushing select/set switch (3), the self-
diagnostic result of selected controller (fault code) is
displayed. (Figure B)
TDAA-05-02-030
fNOTE: Main (MC) (5) is selected as an example here.
A
3. The past fault codes as well as the current ones are
displayed at this time.
4. Turn select/set switch (3), select CLEAR (6), and push
select/set switch (3). 4
5
5. The past fault codes are deleted and only the
current fault codes which have been generated
newly can be displayed. (Figure C)
appears.
basic screen appears. TDC1-05-02-010EN TDC1-05-02-024EN
B C
TDC1-05-02-025EN TDC1-05-02-031EN
T5-2-4
Group 2 Monitor
(Blank)
T5-2-5
Group 2 Monitor
Monitoring 1 2
1. Turn select/set switch (3) and select Monitoring (4)

on Service Menu. When pushing select/set switch 3
(3), the Monitoring screen appears. (Figure A)
2. Turn select/set switch (3) and select the controller
for monitoring. When pushing select/set switch
(3), the monitoring items for selected controller are TDAA-05-02-030
displayed. (Figure B) (Refer to List of Monitoring
Item.) A
3. Turn select/set switch (3), select the item for

monitoring, and push select/set switch (3). (Up to 12
items can be selected.)
4. Push back switch (1) and the Monitoring screen
4
appears. (Figure C)
5. Turn select/set switch (3), select START (5), and push
select/set switch (3). (Figure C)
fNOTE: START (5) and CLEAR (HOLD) (6) are displayed

only when one or more monitoring items are selected.
START (5) and CLEAR (HOLD) (6) are not displayed when
no monitoring item is selected. TDC1-05-02-010EN TDC1-05-02-015EN
B C
5
6
TDAA-05-02-016EN TDC1-05-02-017EN
T5-2-6
Group 2 Monitor
6. The selected monitoring item is started monitoring. 1 2

(Figure D)
7. When pushing select/set switch (3) while 3
monitoring, PAUSE (7) is displayed and the
monitoring value can pause (be held). (Figure E)
8. When pushing select/set switch (3) again, pause is
stopped. TDAA-05-02-030
D E
fNOTE: Even if the key switch is set to OFF position, the
selected monitoring item has been stored. If the selected
monitoring item is required to release, select CLEAR 7
(HOLD) (6) on the Monitoring screen and push select/set
switch (3) for a while until START (5) and CLEAR (HOLD)
(6) disappear.

appears.
TDC1-05-02-019EN TDC1-05-02-018EN
5
6
TDC1-05-02-017EN
T5-2-7
Group 2 Monitor
List of Monitoring Item

Engine Controller (ECM)
Item Unit Data
Target Engine Speed min-1 Target engine speed signal to ECM
Engine Torque % Input signal from ECM
Actual Engine Speed min-1 Input signal from crank speed sensor and cam angle sensor
Boost Pressure kPa Input signal from boost pressure sensor
Target Fuel Injection Qty mm3/st Input signal from ECM
Starter Switch OFF/ON Key switch ON/OFF status
Air Cleaner Restriction SW OFF/ON Clogged air filter status
Engine Stop Switch OFF/ON Engine stop switch ON/OFF status
Common Rail Pressure MPa Input signal from common rail pressure sensor
Directed Engine Speed min-1 Input signal from engine control dial
Starter Cutoff Relay Signal OFF/ON Starter cutoff relay ON/OFF status
Common Rail Pressure DP MPa Input signal from common rail pressure sensor
Coolant Temperature ºC Input signal from coolant temperature sensor
Fuel Temperature ºC Input signal from fuel temperature sensor
Supply Pump Inlet Press kPa Input signal from suction control valve
Engine Oil Pressure kPa Input signal from engine oil pressure sensor
Atmospheric Pressure kPa Input signal from atmospheric pressure sensor
Intake Air Temperature ºC Input signal from intake-air temperature sensor
Boost Temperature ºC Input signal from boost temperature sensor
Battery Voltage V Input signal from ECM
EGR Opening Amount 1 % Input signal from ECM
Coolant Temp (Meter) ºC Input signal from coolant temperature sensor (Coolant
Temperature Gauge)
T5-2-8
Group 2 Monitor
Main Controller (MC)

Item Unit Data
Demand Engine Speed min-1 Input signal from engine control dial
Actual Engine Speed min-1 Input signal from ECM
Engine Speed Deviation min-1 Difference between actual engine speed and requested engine
speed
EC Dial V Input signal from engine control dial
Hydraulic Oil Temperature ºC Input signal from hydraulic oil temperature sensor
Tgt Pump 1 Flow Rate L Command signal to maximum pump 1 flow rate limit control
solenoid valve
Tgt Pump 2 Flow Rate L Command signal to maximum pump 2 flow rate limit control
solenoid valve
Tgt Pump 1 Displacement cm3 Calculated value from engine speed and input signal from
pump 1 delivery pressure sensor
Tgt Pump 2 Displacement cm3 Calculated value from engine speed and input signal from
Pump 1 Load Factor % Calculated value from engine speed and input signal from
Pump 2 Load Factor % Calculated value from engine speed and input signal from
Pump 1 Delivery Pressure MPa Input signal from pump 1 delivery pressure sensor
Pump 2 Delivery Pressure MPa Input signal from pump 2 delivery pressure sensor
Boom Cyl Bottom Press*1 MPa Input signal from boom cylinder bottom pressure sensor
Boom Raise Pilot Pressure MPa Input signal from pressure sensor (boom raise)
Arm Roll-In Pilot Pressure MPa Input signal from pressure sensor (arm roll-in)
Bucket Roll-In Pilot Press MPa Input signal from pressure sensor (bucket roll-in)
Travel Pilot Pressure MPa Input signal from pressure sensor (travel)
Front ATT Pilot Pressure MPa Input signal from pressure sensor (front attachment)
Swing Pilot Pressure MPa Input signal from pressure sensor (swing)
fNOTE: *1: Option

*2: Unused (The item is only displayed)
T5-2-9
Group 2 Monitor
Item Unit Data

ATT 1 Pilot Pressure*1 MPa Input signal from pressure sensor (auxiliary 1)
Arm Roll-Out Pilot Pressure*1 MPa Input signal from pressure sensor (arm roll-out)
Arm 2 Flw Cont P/S Output MPa Control signal to 4-spool solenoid valve unit (SG)
Arm 2 Flw Cont P/S O/P FB mA Feedback from 4-spool solenoid valve unit (SG) output
Digital Input 7 OFF/ON -
PCSL Lever Switch OFF/ON Pilot shut-off switch ON/OFF status
Power Boost Switch OFF/ON Power digging switch ON/OFF status
Engine Oil Level Switch OFF/ON Engine oil level switch ON/OFF status
Power Mode Switch OFF/ON Power mode switch operating status
Travel Mode SW LO/HI Travel mode switch selection status
Auto-Idle Switch OFF/ON Auto-idle switch ON/OFF status
O/L Warning Buzzer SW*1 OFF/ON Overload alarm switch ON/OFF status
Auto Shut-Down Relay OFF/ON Auto shut-down relay ON/OFF status
Tgt Clg Fan Pump 1 Flw L Command signal to fan pump control solenoid valve
Tgt Clg Fan Pump 2 Flw L Command signal to fan pump control solenoid valve
fNOTE: *1: Option

T5-2-10
Group 2 Monitor
Item Unit Data

Pump 1 S/A Cont Press MPa Command signal to pump 1control solenoid valve
Pump 2 S/A Cont Press MPa Command signal to pump 2control solenoid valve
Pump 1 S/A Cont Press Learning Cond - Pump 1 learning condition
Pump 2 S/A Cont Press Learning Cond - Pump 2 learning condition
Pump 1 S/A Cont Press Learning Stat - Pump 1 learning status
Pump 2 S/A Cont Press Learning Stat - Pump 2 learning status
Torque Learning Condition - Torque learning condition
Torque Learning Status - Torque learning status
Bm Lower Pilot Pressure MPa Input signal from pressure sensor (boom lower)
Bucket Roll-Out Pilot Press MPa Input signal from pressure sensor (bucket roll-out)
Low Pressure Monitor Sensor MPa -
Auxil 2 Cont Press Snsr (5P) MPa -
Auxil 1 Cont Press Snsr (4P) MPa -
Signal C/V SA Port Pressure MPa Input signal from pressure sensor (4-spool side)
Signal C/V SB Port Pressure MPa Input signal from pressure sensor (5-spool side)
Pump 1 (4 Units) P/S Output MPa Control signal to pump 1control solenoid valve
Pump 2 (5 units) P/S Output MPa Control signal to pump 2control solenoid valve
Analog Output 2 MPa -
Travel Mode C/V Output MPa Control signal to 4-spool solenoid valve unit (SC)
Bypass Cut Cont P/S MPa Control signal to 4-spool solenoid valve unit (SF)
Swing Flw Cont P/S Output MPa Control signal to 2-spool solenoid valve unit (SI)
4-unit bypass P/S (2Sp)*2 MPa Control signal to 3-spool solenoid valve unit (SA)
3-Port Valve Control*2 MPa Control signal to 3-spool solenoid valve unit (SC)
ATT O/L Cont P/S Output*2 MPa Control signal to 3-spool solenoid valve unit (SB)
Main Relief Boost Press Output MPa Control signal to 4-spool solenoid valve unit (SI)
Boom Mode Cont P/S O/P MPa Control signal to 2-spool solenoid valve unit (SC)
fNOTE: *1: Option

T5-2-11
Group 2 Monitor
Item Unit Data

Brk Rel Cont P/S O/P* MPa Control signal to 3-spool solenoid valve unit (SB)
Pump 1 (4 Units) P/S O/P FB mA Feedback from pump 1 control solenoid valve
Pump 2 (5 units) P/S O/P FB mA Feedback from pump 2 control solenoid valve
Analog Output FB 2 mA -
Travel Mode C/V Output FB mA Feedback from 4-spool solenoid valve unit (SC)
Fan Sp Cont P/S 1 O/P FB mA Feedback from fan pump control solenoid valve
Bypass Cut Cont P/S FB mA Feedback from 4-spool solenoid valve unit (SF)
Fan Dir Cont P/S 1 O/P FB mA Feedback from reverse rotation control solenoid valve
Fan Dir Cont P/S 2 O/P FB mA Feedback from reverse rotation control solenoid valve
Swing Flw Cont P/S O/P FB mA Feedback from 2-spool solenoid valve unit (SI)
4-unit bypass P/S (2Sp) FB*2 mA Feedback from 3-spool solenoid valve unit (SA)
3-Port Valve Control FB*2 mA Feedback from 3-spool solenoid valve unit (SC)
ATT O/L Cont P/S O/P FB*2 mA Feedback from 3-spool solenoid valve unit (SB)
Main Relief Boost Press O/P FB mA Feedback from 4-spool solenoid valve unit (SI)
Bm Mode Cont P/S O/P FB mA Feedback from 2-spool solenoid valve unit (SC)
Fan Sp Cont P/S 2 O/P FB mA Feedback from fan pump control solenoid valve
Brk Rel Cont P/S O/P FB*2 mA Feedback from 3-spool solenoid valve unit (SB)
Arm 2 Flw Cont Disable SW OFF/ON Arm 2 flow rate disable switch status
AG Detn Time Adj Switch OFF/ON Auto lubrication error time change switch ON/OFF
status
AG Manual Switch OFF/ON Auto-lubrication manual switch ON/OFF status
AG Main Switch OFF/ON Auto-lubrication main switch ON/OFF status
AG Limit Switch OFF/ON Auto-lubrication limit switch ON/OFF status
Boom Mode Switch OFF/ON Boom mode selector switch ON/OFF status
F/M Rotation Dir Cont SW OFF/ON Reverse switch ON/OFF status
Max Fan Speed Switch OFF/ON Max fan speed switch ON/OFF status
Loader Selection Switch OFF/ON Loader selection switch ON/OFF status
Fan Rotation Test Switch OFF/ON Fan rotation test switch ON/OFF status
Engine Torque Learning OFF/ON Engine torque learning switch ON/OFF status
fNOTE: *1: Option

T5-2-12
Group 2 Monitor
Item Unit Data

Pump Reg Press Learning SW OFF/ON Pump regulator pressure learning switch ON/OFF
status
Coolant Level Switch OFF/ON Coolant level switch ON/OFF status
Warning Buzzer*1 OFF/ON Warning Buzzer ON/OFF status
Swing Alarm*1 OFF/ON Swing alarm ON/OFF status
Travel Alarm*1 OFF/ON Travel alarm ON/OFF status
ON/OFF Valve Output 4 OFF/ON -
ON/OFF Valve Output1 OFF/ON -
AG Output OFF/ON Grease pump ON/OFF status
fNOTE: *1: Option

T5-2-13
Group 2 Monitor
Wiper/Light Controller
Item Unit Data
Wiper 1 Input V Input signal from wiper switch
Wiper 2 Input V Input signal from overhead window wiper switch
Washer 1 Switch OFF/ON Washer switch ON/OFF status
Washer 2 Switch OFF/ON Washer switch ON/OFF status
Work Light 1 Switch OFF/ON Work light switch 1 ON/OFF status
Work Light 2 Switch OFF/ON Work light switch 2 ON/OFF status
Cab Light Switch OFF/ON Cab light switch ON/OFF status
Wiper 1 Output OFF/ON Wiper relay ON/OFF status
Wiper 2 Output OFF/ON Overhead window wiper relay ON/OFF status
Washer 1 Output OFF/ON Washer relay ON/OFF status
Washer 2 Output OFF/ON Washer relay ON/OFF status
Work Light 1 Output OFF/ON Work light relay 1 ON/OFF status
Work Light 2 Output OFF/ON Work light relay 2 ON/OFF status
Cab Light 1 Output OFF/ON Cab light ON/OFF status
Cab Light 2 Output OFF/ON Cab light ON/OFF status
Air Conditioner Unit

Item Unit Data
Compressor Operation OFF/ON Compressor operating status
Outdoor Air Temperature ºC Input signal from ambient temperature sensor
Indoor Air Temperature ºC Input signal from re-circulated air temperature sensor
Amount of Insolation W/m2 Input signal from solar radiation sensor
T5-2-14
Group 2 Monitor
Controller Version
1 2
1. Turn select/set switch (3) and select Controller
Version (4) on Service Menu.
2. When pushing select/set switch (3), the version of
each controller appears. (Figure A)
3
appears.
basic screen appears. TDAA-05-02-030
TDC1-05-02-010EN TDC1-05-02-009EN
T5-2-15
Group 2 Monitor
Issued Warning Record

1 2
1. Turn select/set switch (3) and select Issued Warning
Record (4) on Service Menu. When pushing select/
set switch (3), the Issued Warning Record screen
appears. (Figure A)
3
2. The logo and trouble of maximum ten alarms which
were issued recently are displayed. (Refer To List of
Alarm.)
3. Turn select/set switch (3) and select the displayed
TDAA-05-02-030
alarm. When pushing select/set switch (3), the time
(ON/OFF) when the selected alarm has occurred/ A
solved are displayed. (Figure B)
4. In case of current alarms, the time (---) when the
selected alarm has solved is displayed. (Figure C)
fNOTE: The display of date and time depends on the

setting. (Refer to the operator’s manual.)
4
appears.
TDC1-05-02-010EN TDC1-05-02-021EN
B C
TDC1-05-02-022EN TDC1-05-02-023EN
T5-2-16
Group 2 Monitor
List of Alarm
Logo Alarm Trouble Screen Remedy

Engine Oil Level Alarm Check Engine Oil Level And Add Oil If Required. Follow Trouble
Screen on the
monitor.
M183-01-075
Overheat Alarm Coolant Temperature Is Abnormally High. Stop Refer to
Operation. Run The Engine At Slow Idle To Cool Coolant Troubleshooting
Temperature. A.
MDAA-01-067
Coolant Level Alarm Check Coolant Level And Add Coolant If Required. Follow Trouble
Screen on the
monitor.
MDAA-01-065
Overheat Alarm Coolant Temperature Is Abnormally High. Stop Refer to
Operation. Run The Engine At Slow Idle To Cool Coolant Troubleshooting
Temperature. A.
MDAA-01-067
Hydraulic Oil Overheat Hydraulic Oil Temperature Is Abnormally High. Stop Refer to
Alarm Operation, Check Hydraulic Oil Level And Any Oil Leaks Troubleshooting
From Hydraulic Circuit. A.
MDAA-01-068
Engine Trouble Alarm Engine Or Accessory Are Abnormal. Contact Your Refer to Engine
Nearest Authorized Dealer. Troubleshooting
Manual.
MDAA-01-069
T5-2-17
Group 2 Monitor

*Engine Oil Pressure Alarm Engine Oil Pressure Is Low. Immediately Stop Engine. Refer to
Check Engine Oil System And Oil Level. Troubleshooting
A.
M178-01-037
*Engine Start Disabled Engine Cannot Start If Pilot Shut-Off Lever Is UNLOCK Set the pilot
Position. shut-off lever
to the LOCK
position.
MDAA-01-028
*Engine Start Disabled Engine Cannot Start If Engine Shut-Off Switch Is In The Set the engine
OFF Position. stop switch to
the ON position.
MDAA-01-028
Alternator Alarm Electrical System Is Abnormal. Check Alternator And Refer to
Battery Systems. Troubleshooting
A.
M183-01-071
*Fuel Level Alarm Fuel Level Is Low. Refer to
Troubleshooting
A.
M178-01-034
fNOTE: *: These alarms are not displayed on the Issued

Warning Record screen.
T5-2-18
Group 2 Monitor

Fuel Temperature Alarm Fuel Temperature Is Abnormally High. Stop Operation Refer to
And Check For Any Abnormality Such As Clogged Fuel Troubleshooting
Cooler. A.
MDAA-01-032
Auto-Lubrication Indicator This indicator will light when any trouble occurs in the Refer to
auto-lubrication system. Troubleshooting
Replace the grease container or check the piping. A.
T1J1-05-01-005
Air Cleaner Restriction Air Cleaner Is Clogged. Clean Or Replace Air Cleaner Refer to
Alarm Element. Troubleshooting
A.
M183-01-067
Fuel Filter Restriction Fuel Filter Is Clogged. Replace Fuel Filter Element. Refer to
Alarm Troubleshooting
A.
M1U1-01-116
System Failure Alarm Machine Network System Is Abnormal. Contact Your Refer to
Nearest Authorized Dealer. Troubleshooting
A.
MDAA-01-034
Pilot Control Shut-Off Pilot Control Shut-Off Lever System Is Abnormal. Refer to
Lever Alarm Contact Your Nearest Authorized Dealer. Troubleshooting
A.
MDAA-01-036
T5-2-19
Group 2 Monitor
Operation
1 2
1. Turn select/set switch (3) and select Operation (4)
on Service Menu. When pushing select/set switch
(3), the Operation screen appears. (Figure A)
2. The hour meters are displayed.
3
appears.
basic screen appears. TDAA-05-02-030
TDC1-05-02-010EN TDC1-05-02-020EN
T5-2-20
Group 2 Monitor
Communication Terminal Status

1 2
1. Turn select/set switch (3) and select Communication
Terminal Status (4) on Service Menu. When pushing
select/set switch (3), the Communication Terminal
Status screen appears. (Figure A)
3
2. Each data of the communication terminals is
displayed. (Refer To List of Communication Terminal
Status.)
TDAA-05-02-030
appears.
basic screen appears. A
TDC1-05-02-011EN TDC1-05-02-034EN
T5-2-21
Group 2 Monitor
List of Communication Terminal Status

Item Unit Data
GSM Terminal Satellite Terminal (Optional)
GPS Status 0 to 2 0: Uncoupled Connection 0: Uncoupled Connection/
Incomplete Positioning
1: Incomplete Positioning 1: Incomplete Positioning
2: Positioning State 2: Positioning State
Radio Wave Intensity 0 to 3, 250 0: GSM Antenna: 0 0: Communication not
available
1: GSM Antenna: 1 1: Communication available
2: GSM Antenna: 2
3: GSM Antenna: 3
250: Out of service
Data Transmission Status 0, 1 0: Uncoupled Connection -
1: Connection
Comm Module Status 0, 1 0: Correct -
1: Incorrect
Potable Antenna Signal 0 to 31, 99 0 to 1: Out of service -
(GSM Antenna Signal) 2 to 8: GSM Antenna: 0
9 to 12: GSM Antenna: 1
99: Not detected
GPRS Ntwk Conn Status 0, 1 0: Failure -
1: Success
Frequency Band 0 to 3 0 to 3 -
fNOTE: The detail data of radio wave intensity are

displayed for GSM Antenna Signal.
fNOTE: If “--------” is displayed on Radio Wave Intensity,
the communication data is abnormal.
T5-2-22
Group 2 Monitor
Machine Setting
1 2
fNOTE: Machine Setting is not displayed in initialization.
When displaying Machine Setting, make Machine
Setting enable with MPDr..
3
 Constant Change
1. Turn select/set switch (3) and select Machine
Setting (4) on Service Menu. When pushing select/
set switch (3), the Machine Setting screen appears.
(Figure A) TDAA-05-02-030
2. Turn select/set switch (3) and select the item to A

be adjusted. When pushing select/set switch (3),
the adjustment screen for selected item appears.
(Figure B) (Refer to List of Setting Item.)
fNOTE: Li Speed (5) is selected as an example here.
3. When pushing select/set switch (3), the color of 5

selected adjustment item data is changed. Turn
4
select/set switch (3), change the data, and push
select/set switch (3). (Figure C)
4. Turn select/set switch (3) and select a check mark.
When pushing select/set switch (3), the setting has
been completed. TDCD-05-02-011EN TDC1-05-02-061EN
B C
appears.
TDC1-05-02-071EN TDC1-05-02-072EN
T5-2-23
Group 2 Monitor
List of Machine Setting Item (Constant Change)
Item Unit Data

ECO Control Suspend 0, 1 Setting of ECO control (casual deactivation)
0: Enable
1: Casual Deactivation
Li Speed min-1 Adjustment of slow idle engine speed
AI Speed min-1 Adjustment of auto-idle engine speed
PWR Mode Speed min-1 Adjustment of PWR mode fast idle engine speed
ECO Mode Selection 0, 1 ON/OFF of ECO control
0: OFF
1: ON
Power Mode Memory Selection 0, 1 Setting of power mode with the key switch ON
0: OFF (Power mode is ECO mode when turning the key
switch ON. )
1: ON (The power mode when turning the key switch OFF
is kept.)
Work Mode Memory Selection 0, 1 Setting of attachment mode with the key switch ON
0: OFF (Setting of attachment mode is bucket (digging)
mode when turning the key switch ON.)
1: ON (Setting of the attachment mode when turning the
key switch OFF is kept.)
Power Mode Selection 0 to 4 Setting of power mode selection
0: ECO, PWR mode: Selected
1: ECO mode: Fixed
2: PWR mode: Fixed
3: ECO, PWR, HP mode: Selected
4: HP mode: Fixed
T5-2-24
Group 2 Monitor
Item Unit Data

Auto Shut-Down Control 0 to 2 Setting of auto shut-down control with the key switch ON
0: OFF when starting
1: ON when starting
2: Previous setting is held.
Auto Shut-Down Set Time Holding 0, 1 The time until starting auto shut-down control is held.
0: Settable
1: Un-settable
Air Conditioner Control Mode 0 to10 Selection of air conditioner specification
0: Unused (without an air conditioner)
1: STD cab (middle) (with an air conditioner)
2: STD cab (middle) (without an air conditioner)
3: STD cab (large) (with an air conditioner)
4: STD cab (large) (without an air conditioner)
5: US cab (75US class) (with an air conditioner)
6: US cab (75US class) (without an air conditioner)
ATT Speed Deceleration Waiting Time ms The time when the increased engine speed is held at
attachment operation speed increase control
T5-2-25
Group 2 Monitor
 List of Adjustment (Constant Change)

Minimum
Item Unit Adjustable Range Initial Value
Adjustment
ECO Control Suspend 0, 1 - 0, 1 0
Li Speed min -1
10 0 to 150 0
AI Speed min-1 10 -180 to 500 0
PWR Mode Speed min-1 10 -100 to 0 0
ECO Control Selection 0, 1 - 0, 1 1
Power Mode Memory Selection 0, 1 - 0, 1 0
Work Mode Memory Selection 0, 1 - 0, 1 1
Power Mode Selection 0 to 4 - 0 to 4 0
Auto Shut-Down Control 0 to 2 - 0 to 2 0
Auto Shut-Down Set Time Holding 0, 1 - 0, 1 0
Air Conditioner Control Mode 0 to 10 - 0 to 10 3
ATT Speed Deceleration Waiting Time ms 40 0 to 9600 9600
T5-2-26
Group 2 Monitor
 Attachment Constant Change 1 2

1. Turn select/set switch (3) and select Machine
set switch (3), the Machine Setting screen appears. 3
(Figure A)
2. Turn select/set switch (3) and select the item to
be adjusted. When pushing select/set switch (3),
the adjustment screen for selected item appears. TDAA-05-02-030
(Figure B) (Refer to List of Setting Item.) A
fNOTE: ATT 1 Type (5) is changed as an example here.

(Initial setting: Breaker 1)
5
3. When pushing select/set switch (3), the color of
selected adjustment item data is changed. Turn
select/set switch (3), change the data, and push
select/set switch (3). (Figure C) 4

been completed.
5. When pushing back switch (1), the previous screen TDCD-05-02-011EN TDCD-05-02-073EN
appears.
B C
TDAA-05-02-074EN TDAA-05-02-075EN
TDAA-05-02-026EN TDAA-05-02-076EN
T5-2-27
Group 2 Monitor
List of Setting Item (Attachment Constant Change)
Item Unit Data

ATT1 Type 0 to 7 Kinds of attachment
0: Unset
1: Breaker
2: Pulverizer
3: Crusher
4: Vibrating Hammer
5: Others
6: Grapple
7: Clamshell
ATT1 No. 1 to 5 Selection of attachment setting No.
1: 1
2: 2
3: 3
4: 4
5: 5
ATT1 Pump 1 Maximum Flow Rate L/min Adjustment of maximum pump 1 flow rate when using
attachment
ATT1 Pump 2 Maximum Flow Rate L/min Adjustment of maximum pump 2 flow rate when using
attachment
ATT1 Engine Speed min-1 Adjustment of engine speed when using attachment
ATT1 Relief Valve 0 to 2 Selection of breaker relief solenoid valve, auxiliary overload
relief solenoid valve
0: Both are disabled.
1: ATT relief is enabled.
2: Breaker relief is enabled.
ATT1 Selector Valve*2 0, 1 Selection of return circuit connection of selector valve
0: C/V
1: O/T
ATT1 Auxiliary Flow Combiner Valve*1 0, 1 Setting of auxiliary flow combiner valve selection
0: OFF
1: ON
fNOTE: *1: Option

T5-2-28
Group 2 Monitor
 List of Adjustment (Attachment Constant Change)
ATT1
Item Unit Minimum Adjustable Initial Value
Adjustment Range
ATT1 Type 0 to 7 - 0 to 7 1
ATT1 No. 1 to 5 - 1 to 5 1
ATT1 Pump 1 Maximum Flow Rate L/min 0.5 100 to 367 367
ATT1 Engine Speed min-1 10 -700 to 100 100
ATT1 Relief Valve 0 to 2 - 0 to 2 2
ATT1 Selector Valve*2 0, 1 - 0, 1 1
ATT1 Auxiliary Flow Combiner Valve*1 0, 1 - 0, 1 0
ATT2
Adjustment Range
ATT2 No. 1 to 5 - 1 to 5 2
fNOTE: *1: Option

*2: Unused (The item is only displayed.)
T5-2-29
Group 2 Monitor
ATT3
Adjustment Range
ATT3 No. 1 to 5 - 1 to 5 3
ATT4
Adjustment Range
ATT4 No. 1 to 5 - 1 to 5 4
fNOTE: *1: Option

T5-2-30
Group 2 Monitor
ATT5 to 11
Adjustment Range
ATT5 No. 1 to 5 - 1 to 5 1
fNOTE: *1: Option
T5-2-31
Group 2 Monitor
Monitor Setting 1 2
fNOTE: Monitor Setting is not displayed in initialization.

When displaying Monitor Setting, make Monitor Setting 3
enable with MPDr..
 Operation Permission
1. Turn select/set switch (3) and select Monitor TDAA-05-02-030
set switch (3), the Monitor Setting screen appears. A
(Figure A)
2. Turn select/set switch (3) and select Operation
Permission. When pushing select/set switch (3), the
setting screen for selected item appears. (Figure B)
(Refer to List of Monitor Setting Item.)
selected item data is changed. Turn select/set
switch (3), change the data, and push select/set
switch (3). (Figure C) 4
fNOTE: Setting Value:

1: Operation/Change: Possible
TDCD-05-02-011EN TDC1-05-02-048EN
0: Operation/Change: Impossible
B C
When Operation Permission is set to "0" and
each item is selected on Maintenance of
Information Menu, RESET (5) of Remains and
Maintenance Interval (6) of the maintenance
items are not displayed.
fNOTE: Engine Oil is selected as an example here.
been completed.
appears.
6. When pushing return to basic screen switch (2), the TDC1-05-02-077EN TDC1-05-02-078EN
5
6
TDC1-05-02-052EN TDC1-05-02-051EN
T5-2-32
Group 2 Monitor
 Maintenance Items 1 2
1. Turn select/set switch (3) and select Monitor
set switch (3), the Monitor Setting screen appears. 3
(Figure A)
change the setting. When pushing select/set switch
(3), the setting screen for selected item appears. TDAA-05-02-030
A
(Figure B) (Refer to List of Monitor Setting Item.)
fNOTE: Engine Oil is selected as an example here.

selected item data is changed. Turn select/set
switch (3). (Figure C)
fNOTE: Setting Value: 4

1: Operation/Change: Possible
0: Operation/Change: Impossible
When Engine Oil is set to "0", the item of Engine TDCD-05-02-011EN TDC1-05-02-048EN
Oil is deleted on Maintenance of Information
B C
Menu.
been completed.
appears.
TDC1-05-02-049EN TDC1-05-02-050EN
TDC1-05-02-079EN TDC1-05-02-080EN
T5-2-33
Group 2 Monitor
List of Monitor Setting Item

Item Unit Details Initial Value
Startup Screen Image 0: System Starting - 1
1: HITACHI
2: John Deere
3: System Starting (Fixed)
4: REC
Startup Screen Control 0: Auto-Control: OFF - 1
1: Auto-Control: ON
Work Mode 0: Void with or without 1
1: Exist function
Crane Switch Memory 0: Non-storable - 1
1: Store
Mail 0: Void with or without 0
1: Exist function
Setting Menu 0: Void with or without 1
1: Exist function
Time Setting 0: Void with or without 1
1: Exist function
Breaker Alarm 0: Void with or without 1
1: Exist function
Auto Shut-down 0: Void with or without 1
1: Exist function
Auto-Lubrication 0:Void with or without 1
1:Exist function
Sub Meter Selection 0: Void with or without 1
1: Exist function
Crane 0: Void with or without *0
1: ML Crane function
2: Overload Alarm
3: Grapple Load Meter
Crane Switch Memory 0: Non-storable - 0
1: Store
Fuel Gauge 0:Void with or without 0
1:Exist function
Breaker Hour Meter 0:Void with or without 0
1:Exist function
Rear View Camera Monitor 0: Void with or without 0
1: Exist function
fNOTE: *: Initial values are different according to the

factory default specification.
T5-2-34
Group 2 Monitor

Display Item Selection 0: Void with or without 1
1: Exist function
Brightness Adjustment 0: Void with or without 1
1: Exist function
Language 0: Void with or without 1
1: Exist function
Unit Selection 0: Void with or without 1
1: Exist function
Main Menu Sequence Change 0: Void with or without 1
1: Exist function
Information Menu 0: Void with or without 1
1: Exist function
Operation 0: Void with or without 1
1: Exist function
Maintenance 0: Void with or without 1
1: Exist function
Operation Permission 0: Inhibited - 1
1: Permission
Engine Oil 0: Un-displayed Display 1
1: Display
Engine Oil Filter 0: Un-displayed Display 1
1: Display
Hydraulic Oil 0: Un-displayed Display 1
1: Display
Pilot Hydraulic Oil Filter 0: Un-displayed Display 1
1: Display
Hydraulic Oil Full-Flow Filter 0: Un-displayed Display 1
1: Display
Pump Drain Filter 0: Un-displayed Display 1
1: Display
Pump Transmission Oil 0: Un-displayed Display 1
1: Display
Travel Reduction Gear Oil 0: Un-displayed Display 1
1: Display
Swing Reduction Gear Oil 0: Un-displayed Display 1
1: Display
Swing Motor Drain Filter 0: Un-displayed Display 0
1: Display
T5-2-35
Group 2 Monitor

Swing Bearing Grease 0: Un-displayed Display 1
1: Display
Air Cleaner Element 0: Un-displayed Display 1
1: Display
Fuel Filter 0: Un-displayed Display 1
1: Display
Air Conditioner Filter 0: Un-displayed Display 1
1: Display
Line Filter 0: Un-displayed Display 1
1: Display
Water Separator Filter 0: Un-displayed Display 1
1: Display
User Setting 1 0: Un-displayed Display 1
1: Display
User Setting 2 0: Un-displayed Display 1
1: Display
Troubleshooting (Information Menu) 0: Void with or without 1
1: Exist function
Monitoring (Information Menu) 0: Void with or without 1
1: Exist function
T5-2-36
Group 2 Monitor
Engine Setting
1 2
1. Turn select/set switch (3) and select Engine Setting
(4) on Service Menu. When pushing select/set
switch (3), the Engine Setting screen appears.
(Figure A)
3
change the setting. When pushing select/set switch
(3), the setting screen for selected item appears.
(Figure B)
TDAA-05-02-030
fNOTE: Fault Code Clear (5) is selected as an example
here. A

been completed.
5
appears.
5. When pushing return to basic screen switch (2), the 4
fNOTE: When delete ECM fault codes and the engine

trouble alarm, operate Fault Code Clear (5).
TDBL-05-02-001EN TDBL-05-02-002EN
TDAA-05-02-054EN
T5-2-37
Group 2 Monitor
Maintenance Mode 1 2
1. Turn select/set switch (3) and select Maintenance

Mode (4) on Service Menu. When pushing select/set 3
switch (3), the Maintenance Mode screen appears.
(Figure A)
selected item data is changed. Turn select/set TDAA-05-02-030
switch (3).
fNOTE: Setting Value:

1: Maintenance Mode: ON
0: Maintenance Mode: OFF
4
been completed.
4. When Maintenance Mode is ON, maintenance mode
alarm (5) is displayed on the basic screen.
TDBL-05-02-003EN
appears. A
TDC1-05-02-205EN
TDBL-05-02-004
T5-2-38
Group 2 Monitor
Setting Menu
When logging on the service menu, The following items
are added to the setting menu.
Setting Menu Item During Normal Operation When logging on Data

service menu
Breaker Alarm Un-displayed Display Setting of breaker alarm ON/ OFF and the time
until the alarm is operated
Attachment Adjust Pump Flow Rate  Adjustment of pump flow rate
fNOTE: Attachment Adjustment is displayed only when

the work mode is attachment mode. (Attachment
Adjustment is not displayed when the work mode is
digging mode.)
T5-2-39
Group 2 Monitor
Breaker Alarm(Option)
1 2
1. Turn select/set switch (3) and select Breaker Alarm
(4) on the setting menu. When pushing select/set
switch (3), the Breaker Alarm screen appears. (Figure
A)
3
2. Push select/set switch (3) and turn Breaker Alarm
ON.
3. Turn select/set switch (3) and select Setting Time (5).
Push select/set switch (3).
TDAA-05-02-030
4. Turn select/set switch (3) and set the setting time
until Breaker Alarm is activated. When pushing A
select/set switch (3), the setting is completed.
fNOTE: When ON is selected on the setting screen of

Breaker Alarm and the breaker is operated for the setting
time continuously, the buzzer sounds. (Refer to SYSTEM/
Control System.) 5
5. When pushing back switch (1), the previous screen 4

appears.
TDAA-05-02-029EN TDAA-05-02-013EN
T5-2-40
Group 2 Monitor
Inspection of Engine Oil Level, Coolant Level,

1
Hour Meter, and Fuel Gauge
Inspection of Engine Oil Level
1. If pushing return to basic screen switch (1) for a
while with the key switch set in the ON position,
engine oil level and coolant level can be checked.
2. If engine oil level alarm (2) and coolant level alarm
(5) are green, oil level and coolant level are normal.
TDAA-05-02-030
3. If engine oil level alarm (2) and coolant level alarm
(5) are red, oil level and coolant level are abnormal.
Add or replace engine oil and coolant.
MJAA-03-001
Inspection of Hour Meter and Fuel Gauge

1. If pushing return to basic screen switch (1) for a 3
while with the key switch set in the OFF position,
hour meter (3) and fuel gauge (4) can be checked.
TDAA-05-02-081EN
T5-2-41
Group 2 Monitor
Fuel Gauge and Coolant Temperature Gauge
Fuel Gauge No. Fuel Level (%) Fuel Sensor (Ω)

A
A 100 (FULL) 100-4
B
B 75 19
C
C 50 32±5
D D 25 49.3
E - -
E
F 0 (EMPTY) 80+12+2
TDAA-05-02-082
Coolant Temperature Gauge No. Coolant Temperature (ºC) Coolant Temperature Sensor (kΩ)
E
A 25 7.6±0.76
F B 40 4.0±0.35
C 50 2.7±0.22
D 80 0.92±0.07
D 95 0.56±0.04
E 105 0.42±0.03
D F 120 0.28±0.01
B
A
TJBG-05-02-084
T5-2-42
Group 3 e-Service
Outline
Controller saves the input signals from various sensors
and switches of the machine as data. Various input signals
are recorded as Operation Data in monitor controller.
The recorded data can be downloaded to the personal

computer. The downloaded data can be uploaded to the
center server via LAN, and can be used as “e-Service”. The
machine equipped with the communication terminal
(optional) sends the data to the center server by using
the communication terminal. (As for the communication
system, refer to T5-3-7.)
T5-3-1
Group 3 e-Service
List of Operation Data

List of Daily Report Data
Item Details
Date Date of daily report data.
Time Final time when the engine is operated during a day.
Fuel Level The value of the final remained fuel during a day. (Value is recorded by fuel
sensor data from monitor controller.)
Fuel Usage Amount The value of fuel used during a day. (Value is calculated and recorded by
accumulated fuel usage amount from ECM.)
Machine Hour Meter Hour meter cumulative hours. (Hours are recorded by hour meter from monitor
controller.)
Engine HP Mode Hours Total engine operating hours selecting HP mode during a day. (Hours are
Operating recorded by power mode switch information from MC.)
Hours PWR Mode Hours Total engine operating hours selecting PWR mode during a day. (Hours are
recorded by power mode switch information from MC.)
ECO Mode Hours Total engine operating hours selecting ECO mode during a day. (Hours are
recorded by power mode switch information from MC.)
Auto-Idle Switch ON Time Hours when auto-idle switch is turned ON during a day. (Hours are recorded by
switch from MC.)
Travel Fast (Hi) Traveling Total operating hours of travel mode Fast (Hi) during a day. (Hours are recorded
Operating Hours by travel mode switch information from MC.)
Hours Slow (Lo) Traveling Total operating hours of travel mode Slow (Lo) during a day. (Hours are recorded
Hours by travel mode switch information from MC.)
Swing Operating Hours Total swing operating hours during a day. (Hours are recorded by swing pressure
sensor information from MC.)
Digging Operating Hours Total front attachment operating hours during a day. (Hours are recorded by
front attachment pressure sensor information from MC.)
T5-3-2
Group 3 e-Service
Item Details
Attachment Breaker Operating Total operating hours selecting breaker during a day. (Hours are recorded by
Operating Hours Hours attachment information from MC.)
Pulverizer Total operating hours selecting pulverizer during a day. (Hours are recorded by
Operating Hours attachment information from MC.)
Crusher Operating Total operating hours selecting hydraulic crusher during a day. (Hours are
Hours recorded by attachment information from MC.)
Vibrating Hammer Total operating hours selecting vibrating hammer during a day. (Hours are
Operating Hours recorded by attachment information from MC.)
Bucket Operating Total operating hours selecting bucket during a day. (Hours are recorded by
Hours or Others attachment information from MC.)
No Load Time Total machine’s waiting hours during a day. (Hours are recorded by each
pressure sensor information from MC.)
Engine Operating Hour Distribution Engine operating hour distribution during a day. (Operating hours are recorded
Data when the condition that the engine is operated continues over 5 minutes.)
Loaded Time Distribution Data Machine operating hour distribution during a day. (Operating hours are
recorded only when operating pressure is continuously detected for more than
5 minutes while the engine runs.)
Latitude Final position during a day. (Signal from GPS antenna.)
Longitude Final position during a day. (Signal from GPS antenna.)
fNOTE: The daily operation in this table is equivalent

to the hours between 0:00 and 23:59:59 counted by the
monitor controller built-in clock. In case the engine is
kept operated beyond 0:00, such data are recorded as
those for the following day.
T5-3-3
Group 3 e-Service
List of Frequency Distribution Data
Item Details
Pump Load Frequency distribution of average pump delivery pressure of pumps 1 and 2
Average Pump Delivery Pressure in Frequency distribution of average delivery pressure from pumps during digging
Digging Operation operation
Average Pump Delivery Pressure in Frequency distribution of average delivery pressure from pumps during travel
Travel Operation operation
Radiator Coolant Temperature (79 °C Total hours when coolant temperature is less than 80 °C during a day.
or less)
Radiator Coolant Temperature (80 to Total hours when coolant temperature is 80 °C or more and less than 94 °C
93 °C) during a day.
Radiator Coolant Temperature (94 to Total hours when coolant temperature is 94 °C or more and less than 105 °C
104 °C) during a day.
Radiator Coolant Temperature (105 °C Total hours when coolant temperature is 105 °C or more during a day.
or more)
Hydraulic Oil Temperature (49 °C or Total hours when hydraulic oil temperature is less than 50 °C during a day.
less)
Hydraulic Oil Temperature (50 to 89 Total hours when hydraulic oil temperature is 50 °C or more and less than 90 °C
°C) during a day.
Hydraulic Oil Temperature (90 to 99 Total hours when hydraulic oil temperature is 90 °C or more and less than 100 °C
°C) during a day.
Hydraulic Oil Temperature (100 °C or Total hours when hydraulic oil temperature is 100 °C or more during a day.
more)
T5-3-4
Group 3 e-Service
List of Total Operating Hours
Item Details
Hour Meter End Machine hour meter’s value
Engine HP Mode Hours Total engine operating hours selecting HP mode
Operating
Hour PWR Mode Hours Total engine operating hours selecting PWR mode
ECO Mode Hours Total engine operating hours selecting ECO mode
Auto-Idle Switch ON Time Total hours when auto-idle switch is turned ON
Travel Fast (Hi) Traveling Total operating hours of travel mode Fast (Hi)
Operating Hours
Hour Slow (Lo) Traveling Total operating hours of travel mode Slow (Lo)
Hours
Swing Operating Hour Total swing operating hours
Front Attachment Operating Hour Total front attachment operating hours
Attachment Breaker Operating Total operating hours selecting breaker during daily operation
Operating Hours
Hour Pulverizer Operating Total operating hours selecting pulverizer during daily operation
Hours
Hydraulic Crusher Total operating hours selecting hydraulic crusher during daily operation
Operating Hours
Vibrating Hammer Total operating hours selecting vibrating hammer during daily operation
Operating Hours
Bucket Operating Total operating hours selecting bucket during daily operation
Hours or Others
No Load Time Total machine’s waiting hours
MC Communication Error Time Total hours of MC communication error
ECM Communication Time Out Time Total hours of ECM communication time out
T5-3-5
Group 3 e-Service
Snapshot Data
Item Details
Serial No. - Machine serial no.
Snapshot Model 1 Difference of large-sized crawler, middle-sized crawler, wheeled excavator, and
wheel loader
Model 2 Detail difference on model 1
DTC Code Fault code and frequency of occurrence
Priority -
Hour Meter Machine hour meter at a time when trouble occurred
Occurrence: Year Year at a time when trouble occurred
Occurrence: Date Date at a time when trouble occurred
Occurrence: Time Time at a time when trouble occurred
SA -
SPN Version 001: Version 1
010: Version 2
011: Version 3
100: Version 4
111: Missing version
fNOTE: The data on machine body system including

MC are downloaded as for Snapshot Data Download
(Hitachi). The data on engine system including ECM are
downloaded as for Snapshot Data Download (Isuzu).
T5-3-6
Group 3 e-Service
Communication System
The communication system is used for maintenance of
the machine: “e-Service” by transmitting various data of
the machine regularly via the communication terminal.
fNOTE: The communication system transmits digital

data through the radio wave. Depending on the
circumstances of the machine (ex. in a building, in a
tunnel, affected by surrounding buildings, and affected
of noise), the data transfer rate may become slower, or
the communication might not be established. If there is
excessively noise or use of electrical equipment which
causes noise near the machine, they cause reduces data
transfer rate or communication might not be established
at worst.
The communication terminal, GPS antenna, and

communication antenna are installed to the machine
equipped with the communication system.
The functions of each equipment are:
 Communication Terminal:
Receives the data from monitor controller and GPS
antenna, and sends the data to the communication
antenna.
 GPS Antenna:
Receives location information of the machine.
 Communication Antenna:
Communicates the data.
T5-3-7
Group 3 e-Service
(Blank)
T5-3-8
SECTION 5 TROUBLE SHOOTING
Main Component
36
35 1
34
2
3
33 5
6
30 7
29 8 38
31 9
32 28 11
37
12
27 13
26
25 14
24 15
2322 16
21 17
20 19
18 MJAG-07-048
1- Arm Cylinder 13- Shoe, Track Link 23- Swing Bearing 35- Bucket Cylinder
2- Boom 14- Engine 24- Lower Roller 36- Arm
3- Washer Tank 15- Muffler 25- Hydraulic Oil Tank 37- Components Related with
5- Battery 16- Engine Oil Filter 26- Track Adjuster Radiator/Oil Cooler/Inter
6- Components Related with 17- Main Pump 27- Front Idler Cooler (Refer to T5-4-2.)
Swing Device (Refer to T5-4- 18- Components Related with 28- Cab 38- Components Related with
14.) Travel Device (Refer to T5-4- 29- Boom Cylinder Shock Less Valve/Signal
7- Fuel Tank 14.) 30- Side Cutter Control Valve (Refer to T5-4-
8- Control Valve 19- Fan Pump 31- Tooth 2.)
9- Air Cleaner 20- Pilot Filter 32- Bucket
11- Expansion Tank 21- Drain Filter 33- Link A
12- Counterweight 22- Upper Roller 34- Link B
T5-4-1
Radiator/Oil Cooler/Inter Cooler
5
4
2 3 TJAA-01-02-006
Shock less Valve/Signal Control Valve

6
TJAA-01-02-008
1- Inter Cooler 3- Air Conditioner Condenser 5- Oil Cooler 7- Control Valve

2- Fuel Cooler 4- Radiator 6- Signal Control Valve 8- Shockless Valve
T5-4-2
Electrical System (Overview)
4 5 6
2 3
1 8, 16
9
10
11
7, 23
21
20 12
24
19
13
14
18 15
17, 25 TJAG-01-02-017
1- Monitor 8- Components Related with 13- Rear View Camera 20- Hydraulic Oil Temperature
2- GPS Aerial Control Valve (Refer to T5-4- 14- Air Cleaner Restriction Switch Sensor
3- Horn 11.) 15- Components Related with 21- Electrical System (Utility
4- Boom Bottom Pressure Sensor 9- Components Related with Engine (Refer to T5-4-8.) Space) (Refer to T5-4-6.)
(Option) (Refer to T5-4-7.) Signal Control Valve (Refer to 16- Components Related with 23- Expansion Tank (Refer to T5-4-
5- Around Battery (Refer to T5-4-12, 13.) 2-Spool Solenoid Valve Unit 13.)
T5-4-7.) 10- Fuel Sensor (Refer to T5-4-16.) 24- Components Related with Fan
6- Components Related with 11- Components Related with 17- Components Related with Valve (Refer to T5-4-15.)
Check Valve/Accumulator 4-Spool Solenoid Valve Unit Pump Device (Refer to T5-4-9.) 25- Components Related with
(Refer to T5-4-12.) (Refer to T5-4-15.) 18- Fan Pump Control Solenoid Pump Device (Refer to T5-4-
7- Coolant Level Switch 12- Around Radiator (Refer to Valve 10.)
T5-4-7.) 19- Fuel Pump
T5-4-3
Electrical System (Rear Tray)
22 23 24 25
2
1
3
4
5
TJAA-01-02-004
7
10 11 12 13
9
14
8
15
16
21 20 19 18 17
T1V1-01-02-009
1- Monitor Controller 6- Fuse Box 2 13- Washer Relay (R9) 20- Pilot Shut-Off Relay (R2)
2- GSM (Option)/Satellite 7- Wiper/Light Controller 14- Horn Relay (R10) 21- Load Damp Relay (R1)
Communication Unit (Option) 8- Wiper Relay (R6) 15- Security Relay (R5) 22- Auto Lubrication Relay (R15)
3- MC (Main Controller) 9- Work Light Relay 1 (R7) 16- Starter Cut Relay (R4) 23- Fuel Pump Relay (R16)
4- MPDr. Connector (Download 10- ACC Cut Relay (R12) 17- Key Switch ON Cut Relay (R13) 24- Work Light Relay 3 (R17)
Connector Using Conbinedly) 11- Work Light Relay 2 (R8) 18- Security Horn Relay (R3) 25- Pump Regulator Pressure
5- Fuse Box 1 12- Auto Shut-Down Relay (R11) 19- ECM Main Relay (R14) Learning Switch
T5-4-4
Electrical System (Switch Panel)
1 2
16
4
15
13 14 7
24
23
22
21
12 11 10
20
19
17 18
TJAA-01-02-003 TDAA-05-02-059
1- Return to Previous Screen 7- Auto-Idle Switch 15- AUTO/OFF Switch/Blower 21- Overload Alarm Switch
Switch (Monitor) 8- Travel Mode Switch Switch (Option)
2- Return to Basic Screen Switch 9- Work Light Switch 16- Temperature Control Switch/ 22- Swing Alarm Cancel Switch
(Monitor) 10- Power Mode Switch MODE Switch (Option)
3- Selector/Set Switch 11- Key Switch 17- Travel Alarm Cancel Switch 23- Rear Work Light Switch
4- AM·FM Switch/Tuning Switch 12- Numerical Keypad (Option) (Option)
(Radio) 13- Overhead Window Wiper/ 18- Seat Heater Switch (Option) 24- Beacon Light Switch (Option)
5- Power Switch/Volume Control Overhead Window Washer 19- Boom Mode Selector Switch
Switch (Radio) Switch (Option) 20- Auto-Lubrication Switch
6- Engine Control Dial 14- Wiper/Washer Switch (Option)
T5-4-5
Electrical System (Utility Space)
TJAE-01-02-001
1- ECM (Engine Controller)
T5-4-6
Boom Bottom Pressure Sensor (Option) Around Radiator
3 2
TJAA-01-02-104
TJAA-01-02-006
Around Battery Section A
5 7
6
12
A
TJAG-01-02-001
9 10 TJAG-01-02-100 8
11
4 MJAA-07-055
1- Boom Bottom Pressure Sensor 5- Glow Plug Relay 9- Electric Grease Gun 12- Battery Disconnect Switch
2- Receiver Tank 6- Starter Relay 1 10- Fuel Filter System Switch
3- Fresh Air Temperature Sensor 7- Battery Relay (Option)
4- Battery 8- Fusible Link (45A) 11- Fusible Link (75A)
T5-4-7
Engine
2 15 5 6
9 8 18
17
TJAE-01-02-002 TJAE-01-02-003
3
TJAE-01-02-004
13 11
1- Overheat Switch 6- Fuel Temperature Sensor 11- EGR Valve 18- Cam Angle Sensor
2- Coolant Temperature Sensor 7- Crank Speed Sensor 13- Boost Pressure Sensor
3- Glow Plug 8- Supply Pump 15- Boost Temperature Sensor
5- Common Rail Pressure Sensor 9- Engine Oil Pressure Sensor 17- Engine Oil Level Switch
T5-4-8
Pump Device
12 1 2 3 4 5
11
10 9 8 7 6
TJAG-01-02-014A
A
A- Machine Front
1- Pump 2 Control Pressure 4- Pump 1 Control Solenoid Valve 8- Pump 2 12- Fuel Filter Differential Pressure
Sensor 5- Pump 1 9- Fan Pump Sensor
2- Pump 2 Control Solenoid Valve 6- Pump 1 Delivery Pressure 10- Pump 2 Delivery Pressure
3- Pump 1 Control Pressure Sensor Sensor
Sensor 7- Pilot Pump 11- Fuel Main Filter
T5-4-9
Around Pump Device
TJAE-01-02-006
2
1- Water Separater 2- Fuel Pre-Filter 3- Fuel Main Filter
T5-4-10
Control Valve
1
5 TJAG-01-02-015
2 3 4
7
TJAG-01-02-101 TJAG-01-02-016
1- Main Relief valve 4- Pressure Sensor (Arm Roll-out) 6- Pressure Sensor (Bucket
2- Pressure Sensor (Bucket Roll- 5- 2-Spool Solenoid Valve Unit Roll-In)
Out) (Refer to T5-4-17.) 7- Pressure Sensor (Boom Lower)
3- Pressure Sensor (Boom Raise) 8- Pressure Sensor (Arm Roll-In)
T5-4-11
Check Valve/Accumlator
7 1
TJAA-01-02-017
Signal Control Valve
TJAA-03-06-003
1- Pressure Sensor (4-Spool Side) 3- Pressure Sensor port (Swing) 5- Pressure Sensor port 6- Check Valve
2- Pressure Sensor (5-Spool Side) 4- Pressure Sensor port (Travel) (Attachment) 7- Accumlator
T5-4-12
TJAA-03-06-004
Section A-A
7 2
6 3
5 4
T178-03-06-002
a- Pilot Valve Side
1- Shockless Valve 3- Pump 1 Flow Rate Control 5- Swing Parking Brake Release 7- Auxiliary
2- Arm Flow Rate Control Valve Valve Spool
Control Spool 4- Flow Combiner Valve Control 6- Pump 2 Flow Rate Control
Spool Valve
T5-4-13
Swing Device Travel Device
1 2
1
M1J1-07-048
M1J1-07-053
1- Swing Relief Valve 2- Counterbalance Valve 3- Travel Relief Valve
T5-4-14
4-Spool Solenoid Valve Unit 2-Spool Solenoid Valve Unit
1 2 3 4 5 6
TJAA-01-02-102 TJAA-01-02-103
Fan Valve (Option)
8 7
9
TJAG-01-02-021
1- 4-Spool Solenoid Valve Unit 3- 4-Spool Solenoid Valve Unit 5- 2-Spool Solenoid Valve Unit 7- Fan Valve (Option)
(SC) (SI) (SC) 8- Reverse Rotation Control
2- 4-Spool Solenoid Valve Unit 4- 4-Spool Solenoid Valve Unit 6- 2-Spool Solenoid Valve Unit Solenoid Valve
(SF) (SG) (SI) 9- Relief Valve
T5-4-15
Layout of Control Valve
c a a c
1 2 3 4 5 6 7 8 9
52
10
11
51
12
50
49 13
48 14
47
46 15
45 16
17
44
43
18
42 19
41 20
40
21
39
38 22
37
23
36
24
35
25
26
31 30
34 33 32 29 28 27
TJAG-03-03-001
54 53
T5-4-16
A Side
23 21 24, 25 27 15, 16, 17, 18, 19 20 26 29
g c a
14
13
11
7
d 6 10 8 9 TJAG-03-03-002
b
a- Machine Upper Side c- Machine Lower Side d- Arm Roll-In Pressure Sensor g- Bucket Roll-In Pressure Sensor
b- Machine Front Side Connecting Position Connecting Position
1- Load Check Valve (Travel (Left) 16- Boom Flow Rate Control Valve 30- Check Valve (Auxiliary Flow 42- Arm Rod Anti-Drift Valve
Parallel Circuit) (Poppet Valve) Combiner Circuit) (Check Valve)
2- Bypass Shut-Out Valve (B side) 17- Boom Lower Meter-In Cut 31- Auxiliary Flow Combiner Valve 43- Overload Relief Valve (Arm:
3- Check Valve (Bucket Flow Valve (Selector Valve) Rod Side)
Combiner Circuit) 18- Boom 1 Anti-Drift Valve 32- Auxiliary Flow Combiner Valve 44- Boost Check Valve (Boom
4- Check Valve (Bucket Flow (Selector Valve) (Poppet Valve) Regenerative Back Pressure
Combiner Circuit) 19- Boom 1 Anti-Drift Valve (Check 33- Swing Flow Rate Control Valve Valve)
5- Check Valve (Main Relief Valve) (Selector Valve) 45- Overload Relief Valve (Boom 2:
Circuit) 20- Overload Relief Valve (Boom 1: 34- Swing Flow Rate Control Valve Rod Side)
6- Flow Combiner Valve Bottom Side) (Poppet Valve) 46- Boom 2 Anti-Drift Valve
7- Check Valve (Flow Combiner 21- Overload Relief Valve (Low 35- Arm 1 Flow Rate Control Valve (Selector Valve)
Circuit) Pressure) (Boom 1: Rod Side) (Selector Valve) 47- Boom 2 Anti-Drift Valve (Check
8- Check Valve (Main Relief 22- Boom Overload Relief Selector 36- Arm 1 Flow Rate Control Valve Valve)
Circuit) Valve (Poppet Valve) 48- Overload Relief Valve
9- Main Relief valve 23- Load Check Valve (Arm 2 37- Load Check Valve (Arm 1 (Auxiliary)
10- Load Check Valve (Bucket Tandem Circuit) Tandem Circuit) 49- Load Check Valve (Auxiliary
Parallel Circuit) 24- Arm 2 Flow Rate Control Valve 38- Load Check Valve (Boom 2 Tandem Circuit)
11- Bucket Regeneration Cut Valve (Selector Valve) Parallel Circuit) 50- Overload Relief Valve
12- Bucket Regenerative Valve 25- Arm 2 Flow Rate Control Valve 39- Check Valve (Boom 2 (Auxiliary)
13- Overload Relief Valve (Bucket: (Poppet Valve) Regenerative Circuit) 51- Load Check Valve (Auxiliary
Rod Side) 26- Check Valve (Arm Make-Up) 40- Overload Relief Valve (Arm: Parallel Circuit)
14- Overload Relief Valve (Bucket: 27- Bypass Shut-Out Valve (A side) Bottom Side) 52- Load Check Valve (Travel (Left)
Bottom Side) 28- Arm Regenerative Valve 41- Arm Rod Anti-Drift Valve Tandem Circuit)
15- Boom Flow Rate Control Valve 29- Arm Regenerative Cut Valve (Selector Valve) 53- Pump 1
(Selector Valve) 54- Pump 2
T5-4-17
c a a c
1 2 3 4 5 6 7 8 9
52
10
11
51
12
50
49 13
48 14
47
46 15
45 16
17
44
43
18
42 19
41 20
40
21
39
38 22
37
23
36
24
35
25
26
31 30
34 33 32 29 28 27
TJAG-03-03-001
54 53
T5-4-18
B Side
37 40 41, 42 33, 34 35, 36 40 31
a c
44 1 50 46, 47 49 52 2 39 45 48
TJAA-03-03-007
b
a- Machine Upper Side c- Machine Lower Side e- Boom Lower Pressure Sensor
b- Machine Front Side Connecting Position
T5-4-19
c a a c
1 2 3 4 5 6 7 8 9
52
10
11
51
12
50
49 13
48 14
47
46 15
45 16
17
44
43
18
42 19
41 20
40
21
39
38 22
37
23
36
24
35
25
26
31 30
34 33 32 29 28 27
TJAG-03-03-001
54 53
T5-4-20
A B Section A-A
28
C
C
D
D
E c a
E
F
F
G 12
G
H
H
6 9
b
A B
J TJAA-03-03-008 TJAA-03-03-041
a- Machine Upper Side b- Machine Front Side c- Machine Lower Side
T5-4-21
c a a c
1 2 3 4 5 6 7 8 9
52
10
11
51
12
50
49 13
48 14
47
46 15
45 16
17
44
43
18
42 19
41 20
40
21
39
38 22
37
23
36
24
35
25
26
31 30
34 33 32 29 28 27
TJAG-03-03-001
54 53
T5-4-22
Section B-B Section C-C
i
26 37 40
33
a c
27 34
TJAA-03-03-010 TJAA-03-03-011
b
a- Machine Upper Side b- Machine Front Side c- Machine Lower Side i- Swing
T5-4-23
c a a c
1 2 3 4 5 6 7 8 9
52
10
11
51
12
50
49 13
48 14
47
46 15
45 16
17
44
43
18
42 19
41 20
40
21
39
38 22
37
23
36
24
35
25
26
31 30
34 33 32 29 28 27
TJAG-03-03-001
54 53
T5-4-24
Section D-D Section E-E
j 29 k 42 41 18 19 l 44 m 46
20
47
24 38
25
28
23 32 40 36 35 17 16 21 39 45
TJAA-03-03-042 TJAA-03-03-013
a- Machine Upper Side j- Arm 2 l- Boom 1

c- Machine Lower Side k- Arm 1 m- Boom 2
T5-4-25
c a a c
1 2 3 4 5 6 7 8 9
52
10
11
51
12
50
49 13
48 14
47
46 15
45 16
17
44
43
18
42 19
41 20
40
21
39
38 22
37
23
36
24
35
25
26
31 30
34 33 32 29 28 27
TJAG-03-03-001
54 53
T5-4-26
Section F-F Section G-G
n 11 o 50 p 1 q
13
10 52
12
14 48 49
TJAA-03-03-014 TJAA-03-03-015
a- Machine Upper Side n- Bucket p- Travel (Right)

c- Machine Lower Side o- Auxiliary q- Travel (Left)
T5-4-27
c a a c
1 2 3 4 5 6 7 8 9
52
10
11
51
12
50
49 13
48 14
47
46 15
45 16
17
44
43
18
42 19
41 20
40
21
39
38 22
37
23
36
24
35
25
26
31 30
34 33 32 29 28 27
TJAG-03-03-001
54 53
T5-4-28
Section H-H
7 6 2
TJAA-03-03-016
a- Machine Upper Side c- Machine Lower Side
T5-4-29
c a a c
1 2 3 4 5 6 7 8 9
52
10
11
51
12
50
49 13
48 14
47
46 15
45 16
17
44
43
18
42 19
41 20
40
21
39
38 22
37
23
36
24
35
25
26
31 30
34 33 32 29 28 27
TJAG-03-03-001
54 53
T5-4-30
View J Section I-I
TJAA-03-03-017 T450-03-03-008
a- Machine Upper Side c- Machine Lower Side
T5-4-31
Pilot Port (Signal Control Valve)

Pilot Valve Side
Port Name Connected to Remark
Port A Right Pilot Valve Boom Raise Pilot Pressure
Port B Right Pilot Valve Boom Lower Pilot Pressure
Port C Left Pilot Valve Arm Roll-Out Pilot Pressure
Port D Left Pilot Valve Arm Roll-In Pilot Pressure
Port E Left Pilot Valve Swing (Left) Pilot Pressure
Port F Left Pilot Valve Swing (Right) Pilot Pressure
Port G Right Pilot Valve Bucket Roll-In Pilot Pressure
Port H Right Pilot Valve Bucket Roll-Out Pilot Pressure
Port I Travel Pilot Valve Travel (Left Forward) Pilot Pressure
Port J Travel Pilot Valve Travel (Left Reverse) Pilot Pressure
Port K Travel Pilot Valve Travel (Right Forward) Pilot Pressure
Port L Travel Pilot Valve Travel (Right Reverse) Pilot Pressure
Port M - Plug
Port N - Plug
Port SA 4-Spool Side Pressure Sensor Pump 1 Control Pressure
Port SB 5-Spool Side Pressure Sensor Pump 2 Control Pressure
Port PI Pilot Shut-Off Solenoid Valve Primary Pilot Pressure
Port PH Pilot Shut-Off Solenoid Valve Primary Pilot Pressure (Heater Circuit)
Port SH Swing Parking Brake Brake Release Pressure
Port DF Hydraulic Oil Tank Returning to Hydraulic Oil Tank
T5-4-32
Pilot Valve Side
PH
C A
D M
H
B
F SB
G
PI
N
K
I
J
SH
DF
SA L TJAA-03-06-002
Control Valve Side
SM 3
1 5
13 4
2 SE
SK 8
S3
14
6
7
9 SN
11
10
SL
TJAA-03-06-003
TR 12 SP
T5-4-33
Control Valve Side

Port Name Connected to Remark
Port 1 Control Valve Boom Raise Pilot Pressure
Port 2 Control Valve Boom Lower Pilot Pressure
Port 3 Control Valve Arm Roll-Out Pilot Pressure
Port 4 Control Valve Arm Roll-In Pilot Pressure
Port 5 Control Valve Swing (Left) Pilot Pressure
Port 6 Control Valve Swing (Right) Pilot Pressure
Port 7 Control Valve Bucket Roll-In Pilot Pressure
Port 8 Control Valve Bucket Roll-Out Pilot Pressure
Port 9 Control Valve Travel (Left Forward) Pilot Pressure
Port 10 Control Valve Travel (Left Reverse) Pilot Pressure
Port 11 Control Valve Travel (Right Forward) Pilot Pressure
Port 12 Control Valve Travel (Right Reverse) Pilot Pressure
Port 13 - Plug
Port 14 - Plug
Port S3 Pressure Sensor (Swing) -
Port SE Control Valve Arm 1 Flow Rate Control Valve Control Pressure
Port SM Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port SN - Plug
Port SP Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port SL Control Valve Flow Combiner Valve Control Pressure
Port SK - Plug
Port TR Pressure Sensor (Travel) -
T5-4-34
Pilot Valve Side
PH
C A
D M
H
B
F SB
G
PI
N
K
I
J
SH
DF
SA L TJAA-03-06-002
Control Valve Side
SM 3
1 5
13 4
2 SE
SK 8
S3
14
6
7
9 SN
11
10
SL
TJAA-03-06-003
TR 12 SP
T5-4-35
(Blank)
T5-4-36
Troubleshooting A (Base Machine Diagnosis

By Using Fault Codes) Procedure
Refer to troubleshooting A procedure in case any fault

codes are displayed after diagnosing by using MPDr. or fNOTE: The engine controller (ECM) judges the engine
the service menu of the monitor. malfunction. After the engine is repaired, select Fault
Code Clear on Engine Setting. Then, delete the fault code
 Diagnosis Procedure of engine controller (ECM) on Troubleshooting. (Refer to
 Check the symptoms in machine operation for each TROUBLESHOOTING/Monitor.)
fault code. When the symptoms match the machine
operation when trouble occurs, perform the remedy.
 In case more than one fault code are displayed at the
same time, MC may be faulty or the power/ground
of the sensor system may be faulty.
 When the MC fault code is displayed with other fault
code, replace MC.
 When fault code 11003-3 (Abnormal Sensor Voltage)
is displayed with other fault code, diagnose for fault
code 11003-3 first.
 In case more than one fault code other than those
described above are displayed at the same time,
diagnose for each fault code.
 It may be required that the machine is operated or
the test harness is connected at inspection.
Check the items of preparation and perform
inspection according to the procedures when
diagnosing.
fNOTE: All connector images in this section are viewed

from the open end side of wire harness end.
1
2
T6L4-05-03-001
1- Wire Harness End Connector 2- Wire Harness
T5-5-1
Contents of Diagnosis
Fault Code
Preparation
Tools for a diagnosis and contents

needing inspection beforehand are
explained.
How to Read Table

Inspection
Fault Code Trouble Evaluation Cause
Method
(C) (D) (E)
(A) (B)
(F) (G) (H)
 A: Fault code
 B: Trouble details
 C, F: Inspection method for trouble cause
 D, G: Evaluation specification of check results
 E, H: Trouble cause for the fault code
Procedure:
1. Check an applicable line depending on displayed fault cord (A).
2. After checking or measuring on Inspection Method (C), refer to
Evaluation (D) and judge the results.
3. In case the results are satisfied with Evaluation (D), the trouble cause is
Cause (E).
In case the results are not satisfied with Evaluation (D), go to the next
procedure, Inspection Method (F).
Circuit Diagram of Test Harness
A connection point of the test harness and a point to check are explained.
(Only Pressure Sensor System Troubleshooting)
T5-5-2
MC Fault Code List
Controller Hardware Failure

Fault Code Trouble Cause Symptoms in Machine Remedy
Operation When Trouble
Occurs
11000-2 Abnormal EEPROM Faulty MC. - Replace MC.
11001-2 Abnormal RAM Faulty MC. - Replace MC.
11002-2 Abnormal A/D Faulty MC. - Replace MC.
Converter
11003-3 Abnormal Sensor Faulty MC. Although the engine control Check the sensor connected
Voltage Faulty sensor. dial is operated, the engine to MC.
Faulty wire harness. speed does not change. Check the wire harness.
Replace MC.
T5-5-3
CAN Data Reception Failure

Fault Code Trouble Cause Symptoms in Machine Operation Remedy
When Trouble Occurs
11006-2 (MC) EC Faulty harness. The machine movement is slow. Check the wire
Communication Error (The torque is reduced by the speed harness.
sensing.)
11007-2 (MC) IC Faulty MC. The machine movement is slow. Check the CAN0
Communication Error Faulty CAN0 harness.
1 harness. Check MC.
11008-2 (MC) IC Faulty MC. Auto shut-down is not activated. Check the CAN1
Communication Error Faulty CAN1 harness.
2 harness. Check MC.
11009-2 (MC) Monitor Faulty MC. The machine movement is slow. Check the CAN0
Controller Faulty CAN0 harness.
Communication Error harness. Check MC.
1
11010-2 (MC) Monitor Faulty MC. Auto shut-down is not activated. Check the CAN1
Controller Faulty CAN1 harness.
Communication Error harness. Check MC.
2
fNOTE: IC is the Information Control Unit of Monitor Controller.
T5-5-4
Engine Failure
Occurs
11100-2 Abnormal Engine Engine speed: 4000 The machine operation Check the crank speed
Speed min-1 or more speed is slow. (During sensor.
speed sensing, the torque is Check the cam angle sensor.
decreased.) (Refer to the engine manual.)
11101-3 Abnormal Engine Voltage: more than Trouble condition with the Check the wire harness.
Control Angle 4.75 V key switch ON: The engine Replace the engine control
Sensor High Input speed is kept at slow idle dial.
speed.
Trouble condition during
operation: The engine speed
is kept at the speed just
before trouble occurs.
11101-4 Abnormal Engine Voltage: less than Trouble condition with the Check the wire harness.
Control Angle 0.25 V key switch ON: The engine Replace the engine control
Sensor Low Input speed is kept at slow idle dial.
speed.
Trouble condition during
operation: The engine speed
is kept at the speed just
before trouble occurs.
T5-5-5
Pump Failure
When Trouble Occurs
11200-3 Pump 1 Delivery Voltage: more Combined operation of arm roll- Check the wire harness.
Pressure Sensor than 4.75 V in and boom raise or combined Replace the pump 1 delivery
Circuit High Input operation of arm roll-in and swing: pressure sensor.
Arm roll-in speed becomes slow.
Single operation of boom raise:
Lifting force is weak.
Machine is kept to travel at slow
speed.
11200-4 Pump 1 Delivery Voltage: less Combined operation of arm roll- Check the wire harness.
Circuit Low Input operation of arm roll-in and swing: pressure sensor.
speed.
11202-3 Pump 2 Delivery Voltage: more Combined operation of arm roll- Check the wire harness.
Circuit High Input operation of arm roll-in and swing: pressure sensor.
speed.
11202-4 Pump 2 Delivery Voltage: less Combined operation of arm roll- Check the wire harness.
Circuit Low Input operation of arm roll-in and swing: pressure sensor.
speed.
T5-5-6
Pilot Failure
When Trouble Occurs
11301-3 Swing Pilot Pressure Voltage: more Swing speed becomes slow. Check the wire harness.
Sensor Circuit High than 4.75 V Combined operation of swing, arm Replace the swing pilot
Input roll-in, and boom raise: Boom does pressure sensor.
not raise easily and arm speed
becomes fast.
Swing alarm (optional) continues
to sound.
11301-4 Swing Pilot Pressure Voltage: less Swing speed becomes slow. Check the wire harness.
Sensor Circuit Low than 0.1 V Combined operation of swing, arm Replace the swing pilot
Input roll-in, and boom raise: Boom does pressure sensor.
not raise easily and arm speed
becomes fast.
Swing alarm (optional) continues
to sound.
11302-3 Boom Raise Pilot Voltage: more When operating boom raise, Check the wire harness.
Pressure Sensor than 4.75 V engine speed does not increase. Replace the boom raise pilot
Circuit High Input Combined operation of swing, arm pressure sensor.
roll-in, and boom raise: Boom does
not raise easily.
11302-4 Boom Raise Pilot Voltage: less When operating boom raise, Check the wire harness.
Pressure Sensor than 0.1 V engine speed does not increase. Replace the boom raise pilot
Circuit Low Input Combined operation of swing, arm pressure sensor.
roll-in, and boom raise: Boom does
not raise easily.
11303-3 Arm Roll-in Pilot Voltage: more When operating arm roll-in, Check the wire harness.
Pressure Sensor than 4.75 V engine speed does not increase. Replace the arm roll-in pilot
Circuit High Input Arm speed becomes fast. pressure sensor.
11303-4 Arm Roll-in Pilot Voltage: less When operating arm roll-in, Check the wire harness.
Pressure Sensor than 0.1 V engine speed does not increase. Replace the arm roll-in pilot
Circuit Low Input Arm speed becomes fast. pressure sensor.
T5-5-7

When Trouble Occurs
11304-3 Travel Pilot Pressure Voltage: more Machine travel speed is slow. Check the wire harness.
Sensor Circuit High than 4.75 V When traveling, engine speed Replace the travel pilot
Input does not increase to the pressure sensor.
specification.
When traveling, engine speed
does not return from auto-idle
speed.
does not return from ECO speed.
Travel alarm (optional) continues
to sound.
11304-4 Travel Pilot Pressure Voltage: less Machine travel speed is slow. Check the wire harness.
Sensor Circuit Low than 0.1 V When traveling, engine speed Replace the travel pilot
Input does not increase to the pressure sensor.
specification.
does not return from auto-idle
speed.
does not return from ECO speed.
Travel alarm (optional) continues
to sound.
11325-3 Bucket Roll-In Pilot Voltage: more When operating light digging, Check the wire harness.
Pressure Sensor than 4.75 V bucket speed becomes slow. Replace the bucket roll-in
Circuit High Input pilot pressure sensor.
11325-4 Bucket Roll-In Pilot Voltage: less When operating light digging, Check the wire harness.
Pressure Sensor than 0.1 V bucket speed becomes slow. Replace the bucket roll-in
Circuit Low Input pilot pressure sensor.
T5-5-8
Proportional Solenoid Valve Failure

When Trouble Occurs
11405-3 Travel Swash Angle Current: more Machine is kept travel at fast speed. Check the wire
P/S Valve FB High than 920 mA harness
Current (4-spool
solenoid valve unit
(SC))
11405-4 Travel Swash Angle Current: less than Machine is kept travel at slow speed. Check the wire
P/S Valve FB Low 56 mA harness
Current (4-spool
solenoid valve unit
(SC))
T5-5-9

When Trouble Occurs
11408-3 Center Bypass Cut P/S Current: more Machine mistracks. Check the wire
Valve FB High Current than 920 mA Precise control cannot be performed. harness
11408-4 Center Bypass Cut P/S Current: less than Bucket operation speed is slow. Check the wire
Valve FB Low Current 56 mA During single operation of pulverizer/ harness
crusher: Attachment operation speed
is slow.
11412-3 Hyd. Fan P/S Valve FB Current: more Fan rotation speed is kept at the Check the wire
High Current than 920 mA minimum speed. harness
11412-4 Hyd. Fan P/S Valve FB Current: less than Fan rotation speed is kept at the Check the wire
Low Current 56 mA maximum speed. harness
fNOTE: The fault codes 11408-3 and 11408-4 are

displayed on MPDr. as follows.
11408-3: Muffler Filter Regenerative (Center Bypass
Cut) P/S Valve FB High Current.
Cut) P/S Valve FB Low Current.
T5-5-10

When Trouble Occurs
11428-3 Arm 2 Flow Rate Current: more Arm operation speed becomes slow. Check the wire
Control P/S Valve FB than 920 mA harness
High Current
11428-4 Arm 2 Flow Rate Current: less than Combined operation of arm roll-in Check the wire
Control P/S Valve FB 56 mA and bucket roll-in: Bucket roll-in harness
Low Current operation speed is slow.
T5-5-11
Other Failures
Occurs
11802-3 Boom Bottom Voltage: more than 4.75 V The buzzer sounds. Check the wire
Pressure Sensor Circuit harness
High Input (Option) Replace the boom
bottom pressure
sensor
11802-4 Boom Bottom Voltage: less than 0.25 V The buzzer sounds. Check the wire
Pressure Sensor Circuit harness
High Input (Option) Replace the boom
bottom pressure
sensor
11901-3 Hyd. Oil Temp Sensor Voltage: more than 4.35 V Fan rotation speed is Check the wire
Circuit High Input kept at the maximum harness
speed. Pump driving
torque is reduced.
11901-4 Hyd. Oil Temp Sensor Voltage: less than 0.1 V Fan rotation speed is Check the wire
Circuit Low Input kept at the maximum harness
speed. Pump driving
torque is reduced.
T5-5-12

Occurs
11942-3 Attachment Pilot Voltage: more than 4.75 V When operating Check the wire
Pressure Sensor Circuit attachment, engine harness
High Input (Option) speed does not increase. Replace the
Attachment speed attachment pilot
becomes slow. pressure sensor
11942-4 Attachment Pilot Voltage: less than 0.1 V When operating Check the wire
Pressure Sensor Circuit attachment, engine harness
Low Input (Option) speed does not increase. Replace the
Attachment speed attachment pilot
becomes slow. pressure sensor
11944-3 Signal Control Valve Voltage: more than 4.75 V Boom operation speed Check the wire
SB-port Pressure becomes slow. harness
Sensor Circuit High Arm operation speed Replace the signal
Input (5-spool side becomes slow. control valve
pilot pressure sensor) Swing speed becomes SB-port pressure
slow. sensor
Machine mistracks.
11944-4 Signal Control Valve Voltage: less than 0.25 V Boom operation speed Check the wire
SB-port Pressure becomes slow. harness
Sensor Circuit Low Arm operation speed Replace the signal
pilot pressure sensor) Swing speed becomes SB-port pressure
slow. sensor
Machine mistracks.
T5-5-13

Occurs
11945-3 Signal Control Valve Voltage: more than 4.75 V Boom operation speed Check the wire
SA-port Pressure becomes slow. harness
Sensor Circuit High Arm operation speed Replace the signal
pilot pressure sensor) Bucket operation speed SA-port pressure
becomes slow. sensor
Machine mistracks.
11945-4 Signal Control Valve Voltage: less than 0.25 V Boom operation speed Check the wire
SA-port Pressure becomes slow. harness
Sensor Circuit Low Arm operation speed Replace the signal
pilot pressure sensor) Bucket operation speed SA-port pressure
becomes slow. sensor
Machine mistracks.
11948-3 Main Relief Pressure Current: more than 920 mA Pressure always Check the wire
Control P/S Valve FB increases. harness
High Current (4-spool Machine is kept travel at
solenoid valve unit fast speed.
(SI))
11948-4 Main Relief Pressure Current: less than 56 mA Pressure increasing is Check the wire
Control P/S Valve FB impossible. harness
Low Current (4-spool Machine is kept travel at
solenoid valve unit slow speed.
(SI))
11950-3 Pump 2 P/S Valve FB Current: more than 920 mA Pump 2 torque is always Check the wire
High Current maximum. harness
The engine stalls is
remarkable at high
loaded. The engine lug-
down is remarkable at
high loaded.
11950-4 Pump 2 P/S Valve FB Current: less than 56 mA Pump 2 torque is always Check the wire
Low Current minimum. harness
Machine overall
operation is slow.
T5-5-14

Occurs
11951-3 Pump 1 P/S Valve FB Current: more than 920 mA Pump 1 torque is always Check the wire
High Current maximum. The engine harness
stalls is remarkable at
high loaded. The engine
lug-down is remarkable
at high loaded.
11951-4 Pump 1 P/S Valve FB Current: less than 56 mA Pump 1 torque is always Check the wire
Low Current minimum. Machine harness
overall operation is slow.
T5-5-15

Occurs
11953-3 Swing Flow Rate Current: more than 920 mA Swing speed becomes Check the wire
Control P/S Valve FB slow. harness
High Current (2-spool
solenoid valve unit
(SI))
11953-4 Swing Flow Rate Current: less than 56 mA Combined operation of Check the wire
Control P/S Valve FB swing and arm roll-out: harness
Low Current (2-spool Arm operation speed
solenoid valve unit becomes slow.
(SI)) Combined operation of
swing and boom raise:
Boom operation speed
becomes slow.
T5-5-16

Occurs
11978-3 Auxiliary 2 Pilot Voltage: more than 4.75 V - Check the wire
Pressure Sensor harness
Circuit High Input
(Option)
11978-4 Auxiliary 2 Pilot Voltage: less than 0.1 V - Check the wire
Circuit Low Input
(Option)
11979-3 Auxiliary 1 Pilot Voltage: more than 4.75 V - Check the wire
Circuit High Input
(Option)
11979-4 Auxiliary 1 Pilot Voltage: less than 0.1 V - Check the wire
Circuit Low Input
(Option)
T5-5-17

Occurs
11982-3 Fan Reverse Rotation Current: more than 920 mA Fan does not rotate in Check the wire
P/S Valve 1 FB High reverse. harness
Current
11982-4 Fan Reverse Rotation Current: less than 56 mA Fan does not rotate in Check the wire
P/S Valve 1 FB Low reverse. harness
Current
T5-5-18

Occurs
11985-2 Pump 2 Regulator Faulty pump 2 control Machine overall Check the wire
Pressure Calibration solenoid valve operation is slow. harness
Abort Replace the pump
2 control solenoid
valve
11986-2 Pump 1 Regulator Faulty pump 1 control Machine overall Check the wire
Pressure Calibration solenoid valve operation is slow. harness
Abort Replace the pump
1 control solenoid
valve
11989-3 Boom Mode Control Current: more than 920 mA Boom mode selector Check the wire
P/S Valve FB High control is impossible. harness
Current (2-spool
solenoid valve unit
(SC))
11989-4 Boom Mode Control Current: less than 56 mA Boom mode selector Check the wire
P/S Valve FB Low control is impossible. harness
Current (2-spool
solenoid valve unit
(SC))
T5-5-19

When Trouble Occurs
11992-3 Pump 2 Reg- Voltage: more Fast travel cannot be selected Check the wire harness
Pressure Sensor than 4.75 V easily. Replace the pump 2 reg-
Pressure Sensor pressure sensor
Circuit High Input
(Pump 2 control
pressure sensor)
11992-4 Pump 2 Reg- Voltage: less Fast travel cannot be selected Check the wire harness
Circuit Low Input
(Pump 2 control
pressure sensor)
11994-3 Pump 1 Reg- Voltage: more Fast travel cannot be selected Check the wire harness
Circuit High Input
(Pump 1 control
pressure sensor)
11994-4 Pump 1 Reg- Voltage: less Fast travel cannot be selected Check the wire harness
Circuit Low Input
(Pump 1 control
pressure sensor)
T5-5-20

Occurs
11995-3 Arm Roll-Out Pilot Voltage: more than 4.75 V When Operating arm Check the wire
Pressure Sensor Circuit roll-out, engine speed harness
High Input does not increase. Replace the arm
Arm speed becomes roll-out pilot
fast. pressure sensor
11995-4 Arm Roll-Out Pilot Voltage: less than 0.1 V When Operating arm Check the wire
Pressure Sensor Circuit roll-out, engine speed harness
Low Input does not increase. Replace the arm
Arm speed becomes roll-out pilot
fast. pressure sensor
11997-3 Bucket Roll-Out Pilot Voltage: more than 4.75 V When Operating light Check the wire
Pressure Sensor Circuit digging: Bucket speed harness
High Input becomes slow. Replace the bucket
roll-out pilot
pressure sensor
11997-4 Bucket Roll-Out Pilot Voltage: less than 0.1 V When Operating light Check the wire
Pressure Sensor Circuit digging: Bucket speed harness
Low Input becomes slow. Replace the bucket
roll-out pilot
pressure sensor
11998-3 Boom Lower Pilot Voltage: more than 4.75 V When Operating boom Check the wire
Pressure Sensor Circuit lower, engine speed harness
High Input does not increase. Replace the
Combined operation of boom lower pilot
swing, arm roll-in, and pressure sensor
boom lower: Boom does
not lower easily.
11998-4 Boom Lower Pilot Voltage: less than 0.1 V When Operating boom Check the wire
Pressure Sensor Circuit lower, engine speed harness
Low Input does not increase. Replace the
Combined operation of boom lower pilot
swing, arm roll-in, and pressure sensor
boom lower: Boom does
not lower easily.
20062-0 Hydraulic Oil Overheat Hydraulic oil temperature is The alarm is displayed Check the wire
Alarm high on the monitor. harness. Replace
the hydraulic
oil temperature
sensor.
T5-5-21
ECM Fault Code List

(Refer to the Engine Manual for ECM Fault Codes.)
Fault Code Trouble Cause Symptoms in Machine Operating
SPN- DTC Operation When Trouble Rank
FMI Occurs A B C D
91-2 P2138 Accelerator Pedal Opening amount difference One of the sensor is abnormal:
Position Sensor 1-2 between accelerator sensors 1 Operating normally
Correlation and 2 is 45 % or more Both of the sensors are 
abnormal: Accelerator opening
amount is limited to 0 %
91-3 P2123 Accelerator Pedal Voltage at accelerator sensor 1 is One of the sensor is abnormal:
Position Sensor 1 High more than 4.9 V Operating normally
Input Both of the sensors are 
Position Sensor 2 High more than 4.9 V Operating normally
Position Sensor 1 Low less than 0.2 V Operating normally
Position Sensor 2 Low less than 0.2 V Operating normally
100-3 P0523 Engine Oil Pressure Voltage at the engine oil pressure Nothing special.

Sensor Circuit High Input sensor is more than 4.9 V
100-4 P0522 Engine Oil Pressure Voltage at the engine oil pressure Nothing special.

Sensor Circuit Low Input sensor is less than 0.1 V
102-3 P0238 Boost Pressure Sensor Voltage at the boost pressure The output power decreases.

Circuit High Input sensor is more than 4.9 V
102-4 P0237 Boost Pressure Sensor Voltage at the boost pressure The output power decreases.

Circuit Low Input sensor is less than 0.1 V
105-3 P1113 Boost Temperature Voltage at the boost temperature The rotation speed does not

Sensor Circuit High Input sensor is more than 4.94 V increase.
105-4 P1112 Boost Temperature Voltage at the boost temperature The rotation speed does not

Sensor Circuit Low Input sensor is less than 0.1 V increase.
108-3 P2229 Atmospheric Pressure Voltage at the atmospheric The output power decreases.

Sensor Circuit High Input pressure sensor is more than 4 V
108-4 P2228 Atmospheric Pressure Voltage at the atmospheric The output power decreases.

Sensor Circuit Low Input pressure sensor is less than 0.5 V
110-0 P0217 Overheat Coolant temperature is more There is no influence when

than 101 °C operating the machine.
Operating Rank
A: Digging is operable.
B: Machine can travel with the boom raised.
C: The engine only runs. (Only operation with light load is possible.)
D: The engine cannot stop/start.
T5-5-22

Operation When Trouble Rank
SPN-FMI DTC Occurs A B C D
110-3 P0118 Engine Coolant Voltage at the coolant The output power decreases.
Temperature Circuit temperature sensor is more 
High Input than 4.9 V
110-4 P0117 Engine Coolant Voltage at the coolant The output power decreases.
Temperature Circuit temperature sensor is less 
Low Input than 0.1 V
157-3 P0193 Common Rail Pressure Voltage at the common The engine may be stalled. The
Sensor Circuit High rail pressure sensor is more output power decreases. 
Input than 4.8 V
157-4 P0192 Common Rail Pressure Voltage at the common rail The engine speed increases
Sensor Circuit Low pressure sensor is less than automatically and abnormally. 
Input 0.7 V
157-15 P0089 Abnormal Common Actual rail pressure is more Vibration of the engine may be
Rail Pressure (Over than 40 MPa higher than large, rough idle, output power
Pumping) the target rail pressure decrease may occur, faulty

increasing of rotation speed,
dark smoke may occur, output
power may be too large.
158-3 P0563 Abnormally High Voltage is more than 32 V The battery may be faulty.

Battery System Voltage
172-3 P0113 Intake Air Temperature
Voltage at the intake-air The output power decreases.
Sensor Circuit High temperature sensor is more 
Input than 4.9 V
172-4 P0112 Intake Air Temperature
Voltage at the intake-air The output power decreases.
Sensor Circuit Low temperature sensor is less 
Input than 0.1 V
174-3 P0183 Combustion Voltage at the fuel Nothing special.
Temperature Sensor temperature sensor is more 
Circuit High Input than 4.9 V
174-4 P0182 Combustion Voltage at the fuel Nothing special.
Temperature Sensor temperature sensor is less 
Circuit Low Input than 0.1 V
190-0 P0219 Engine Overrun Engine speed is more than Engine speed may not increase

specification (2500 min-1) 2500 min-1 or more.
628-2 P0601 Abnormal ROM Check sum is NG The engine cannot start. 
633-7 P0087 Common Rail Pressure It is judged by rail pressure The output power decreases.

Limiter Open change pattern
636-2 P0340 Abnormal Cam Angle The signal from cam sensor While the engine runs, there
Sensor (No Signal) is not present. is nothing abnormal with
machine operation.  
After the engine is stalled, the
re-start is impossible.
636-7 P0016 Phase Difference The correct cam pulse is not While the engine runs, there
between Cam and present at the gap in the is nothing abnormal with
Sensor crank machine operation.  
After the engine is stalled, the
re-start is impossible.
639-2 U0101 Abnormal CAN Time- TSC1 message from SA=228 The engine runs at idle speed.

out is not received
639-19 U0073 Abnormal CAN Bus The bus line OFF is detected The engine runs at idle speed. 
T5-5-23
Fault Code Trouble Cause Symptoms in Machine Operation When Operating

Trouble Occurs Rank
SPN-FMI DTC A B C D
651-5 P0201 Cylinder 1 No input signal of Vibration of the engine is large, rough idle,
Injector Circuit injector 1 monitor output power decrease, faulty increasing of 
Open rotation speed, exhaust gas becomes bad.
723-2 P0335 Crank Position Even if the cam signal The output power may decrease, white
Sensor Failure is present, the crank smoke may occur and vibration may occur,

(No Signal) signal is not present the engine may be stalled (If the cam senor
is normal, the engine can re-start).
723-8 P0336 Crank Position The pulse of crank The output power may decrease, white
Sensor Failure signal is not matched smoke may occur and vibration may occur,

(Abnormal the engine may be stalled (If the cam senor
Signal) is normal, the engine can re-start).
1077-2 P0606 Abnormal CPU Failure of main CPU is The output power decreases.
detected by sub CPU 
(Sub CPU resets CPU)
1079-2 P0641 Abnormal Voltage of 5 V power 
5V-Electric source circuit 1 or 5 is

Power Circuit #1 over 5.5 V or less than
4.5 V
1080-2 P0651 Abnormal Voltage of 5 V power 
5V-Electric source circuit 2 or 5 is

Power Circuit #2 over 5.5 V or less than
4.5 V
1239-1 P1093 Pressure Actual rail pressure is Vibration of the engine may be large, rough
Decline in 50 MPa or more lower idle, output power decrease may occur,
Common Rail than the target rail faulty increasing of rotation speed, dark 
(No Pumping pressure smoke may occur, output power may be
Pressure) too large.
1239-31 P1093 Pressure Actual rail pressure is Vibration of the engine may be large, rough
Decline in 50 MPa or more lower idle, output power decrease may occur,
Common Rail than the target rail faulty increasing of rotation speed, dark
(No Pumping pressure smoke may occur, output power may be 
Pressure) too large.
- low fuel
temperature.
T5-5-24

Operation When Trouble Rank
SPN-FMI DTC Occurs A B C D
1240-1 P0093 Pressure Decline in Actual rail pressure is 50 Vibration of the engine may
Common Rail (Lack of MPa or more lower than the be large, rough idle, output
Pumping Pressure 2) target rail pressure power decrease may occur,
faulty increasing of rotation 
speed, dark smoke may
occur, output power may be
too large.
1240-31 P0093 Pressure Decline in Actual rail pressure is 50 Vibration of the engine may
Common Rail (Lack of MPa or more lower than the be large, rough idle, output
Pumping Pressure 2) target rail pressure power decrease may occur,
(Low Fuel Temperature) faulty increasing of rotation 
speed, dark smoke may
occur, output power may be
too large.
1347-3 P0092 PCV 1 Drive Circuit + PCV 1 current is 2400 mA or The output power
Short Circuit B more, or difference between decreases, there is influence

PCV 1 current and target to exhaust gas.
current is 1000 mA or more
1347-4 P0091 PCV 1 Drive Circuit PCV 1 current is 50 mA or The output power
Open or Short Circuited less, or difference between decreases, there is influence
to GND PCV 1 current and target to exhaust gas, the supply
current is 1000 mA or more pump can not be controlled, 
the engine may increase the
rotation speed automatically
and abnormally.
1348-3 P2296 PCV2 Drive Circuit + PCV2 current is 2400 mA or The output power
Short Circuit B more, or difference between decreases, there is influence

PCV2 current and target to exhaust gas.
current is 1000 mA or more
1348-4 P2295 PCV2 Drive Circuit Open PCV2 current is 50 mA or The output power
or Short Circuited to less, or difference between decreases, there is influence
GND PCV2 current and target to exhaust gas, the supply
current is 1000 mA or more pump can not be controlled, 
the engine may increase the
rotation speed automatically
and abnormally.
1381-3 P1294 Fuel Filter Restriction Voltage at the restriction Nothing special.
Sensor Circuit High sensor is more than 4.9 V 
Input
1381-4 P1293 Fuel Filter Restriction Voltage at the restriction Nothing special.

Sensor Circuit Low Input sensor is less than 0.1 V
1485-5 P0685 Abnormal Main Relay Voltage in the main relay The engine cannot start.
Circuit (Inactivation) circuit is 1 V or less with the 
main relay coil output ON
1485-6 P0687 Abnormal Main Relay Even if the main relay coil Electrical power is kept
Circuit (Kept closed) output is turned OFF, the supplying to the machine. 
main relay is kept ON
T5-5-25
Fault Code Trouble Cause Symptoms in Machine Operation Operating

When Trouble Occurs Rank
SPN-FMI DTC A B C D
10001-2 P0409 EGR Position Error The output signal of EGR The output power decreases.
(Brushless Type) position sensor is stuck in

a low or high condition
for 5 second or more.
10001-13 P1404 Abnormal EGR Zero- EGR opening amount The output power decreases.
point calibration change is abnormal

during Zero-point
calibration
10002-2 P0404 Abnormal EGR Valve Difference between The output power decreases.
Control Circuit the target valve lift and

actual position is more
than 20 %
10003-2 P2146 Abnormal Injector Abnormal charge voltage Vibration of the engine may be
Common 1 Circuit circuit of injectors 1, 2, 3, large, rough idle, output power
or short circuit in injector decrease may occur, faulty 
solenoid control circuit of increasing of rotation speed may
injectors 1, 2, 3. occur, the engine may be stalled
10004-2 P2149 Abnormal Injector Abnormal charge voltage Vibration of the engine may be
Common 2 Circuit circuit of injectors 4, 5, 6, large, rough idle, output power
or short circuit in injector decrease may occur, faulty 
solenoid control circuit of increasing of rotation speed may
injectors 4, 5, 6. occur, the engine may be stalled
10005-2 P1261 Abnormal Charge Voltage at bank 1 of Vibration of the engine may be
Circuit (Bank 1) charge circuit in ECM is large, rough idle, output power
low decrease may occur, faulty 
increasing of rotation speed may
occur, the engine may be stalled
10006-2 P1262 Abnormal Charge Voltage at bank 2 of Vibration of the engine may be
Circuit (Bank 2) charge circuit in ECM is large, rough idle, output power
low decrease may occur, faulty 
increasing of rotation speed may
occur, the engine may be stalled
10007-2 P0606 Abnormal CPU No change of RUN-SUB The output power decreases

Monitor IC pulse in 20 msec
10008-2 P060B Abnormal A/D A/D conversion cannot Output power decrease, dark

Converter be done smoke occurs
10009-2 P0697 Abnormal 5V-Electric Voltage of 5 V power 
Power Circuit #3 source circuit 3 or 7 is 5.5 
V or more or 4.5 V or less
10010-2 P1655 Abnormal 5V-Electric Voltage of 5 V power 
Power Circuit #4 source circuit 4 is 5.5 V or 
more or 4.5 V or less
10013-2 P1621 Abnormal EEPROM/ Abnormal EEPROM is 

Abnormal HDEEPROM detected
10032-2 P0602 QR Code Error QR code and Q adjust Combustion sound may change

have not been written
10033-2 P0604 Abnormal RAM Abnormal RAM is The engine cannot start

detected
T5-5-26
Monitor Controller (Monitor) Fault Code List
Fault Code Trouble Cause Remedy

13002-2 (Monitor Controller) Faulty monitor controller Check the CAN0 harness.
Engine Controller Faulty CAN0 harness Replace the monitor controller.
Communication
Error
Main Controller Faulty CAN0 harness Replace the monitor controller.
Communication
Error 1
Main Controller Faulty CAN1 harness Replace the monitor controller.
Communication
Error 2
ICF Communication Faulty CAN0 harness Replace the monitor controller.
Error 1
ICF Communication Faulty CAN1 harness Replace the monitor controller.
Error 2
Body Controller Faulty CAN1 harness Replace the monitor controller.
Communication
Error
20113-2 System Failure Faulty CAN communication line. Check the CAN harness.
Alarm
T5-5-27
Monitor Controller (Information) Fault Code List

14001-2 ICF: Flash Memory The internal After initializing the monitor controller (information) by
Read/Write Error memory of monitor
using MPDr., retry the troubleshooting. If the fault code is
controller is displayed after retry, the monitor controller may be broken.
abnormal Replace the monitor controller.
When initializing the monitor controller (information), all
stored data is deleted.
14002-2 ICF: External RAM The internal After initializing the monitor controller (information) by
Read/Write Error memory of monitor using MPDr., retry the troubleshooting. If the fault code is
controller is displayed after retry, the monitor controller may be broken.
abnormal Replace the monitor controller.
When initializing the monitor controller (information), all
stored data is deleted.
14003-2 Abnormal EEPROM The internal Retry the troubleshooting by using MPDr.. If the fault code
memory of monitor is displayed after retry, the monitor controller may be
controller is broken. Replace the monitor controller.
abnormal
14006-2 ICF: Communication Communication Check the communication line, power line for
Terminal: error with communication terminal, and fuses. Then, retry the
Communication communication troubleshooting by using MPDr.. If the fault code is
Error equipment displayed after retry, the communication equipment may
be broken. Replace the communication equipment.
14008-2 ICF: Abnormal The internal Retry the troubleshooting by using MPDr.. If the fault code
Internal RAM memory of monitor is displayed after retry, the monitor controller may be
controller is broken. Replace the monitor controller.
abnormal
14021-2 Communication Security failure Check the communication line. Check the GPS antenna. In
Terminal Security of mobile case the communication equipment has been replaced,
Error communication it may be considered faulty. After disable the checking
equipment function for mobile phone number by security setting
of MPDr., enable it again. Retry the troubleshooting by
using MPDr.. If the fault code is displayed after retry, the
communication equipment may be broken. Replace the
communication equipment.
14022-2 SIM Card Error Abnormal SIM Retry the troubleshooting by using MPDr.. If the fault code
card in mobile is displayed after retry, the communication equipment may
communication be broken. Replace the communication equipment.
equipment
14023-2 Security Error Communication Check the CAN1 harness. Retry the troubleshooting by
error with MC using MPDr.. If the fault code is displayed after retry, MC
may be broken. Replace MC.
T5-5-28

Operation When
Trouble Occurs
13303-2 Abnormal Thermistor Thermistor The screen of the Cool the monitor
Temperature (Monitor temperature: 85 °C or monitor becomes and so on until the
Inside Temperature) more dark. temperature inside the
monitor is less than
85 °C
Replace monitor
13304-2 Abnormal REG Input Alternator generating The alternator alarm Check the wire
H Level voltage: 33.5 V or more is displayed on the harness
monitor. Check the battery
Check the alternator
13310-3 Coolant Temperature 50 Ω or less continues The coolant Check the wire
Sensor Short Circuit for 60 seconds temperature gauge harness
(pointer) on the Replace the coolant
monitor disappears. temperature sensor
The logo becomes to
red.
13311-3 Fuel Level Sensor High 1.14±1 Ω or less The fuel gauge Check the wire
Input continues for 60 (pointer) on the harness
seconds monitor disappears. Replace the fuel
The logo becomes to sensor
red.
13311-4 Fuel Level Sensor Low 500±20 Ω or less The fuel gauge Check the wire
Input continues for 60 (pointer) on the harness
seconds monitor disappears. Replace the fuel
The logo becomes to sensor
red.
T5-5-29

20100-2 Overheat Alarm Coolant temperature is high while Check the wire harness.
the engine runs. Replace the overheat switch.
20101-2 Engine Warning Faulty engine system. Refer to Engine Troubleshooting Manual.
Alarm
20102-2 Engine Oil Pressure Engine oil pressure decreases. Check the wire harness.
Alarm Replace the engine oil pressure sensor.
20103-2 Alternator Alarm Regulator voltage is high. During Check the wire harness.
the engine stop state, the Check the batteries.
regulator voltage is high. Check the alternator.
20104-2 Fuel Level Alarm Fuel level is low. Check the wire harness.
Replace the fuel level sensor.
20106-2 Air Cleaner Clogged air cleaner. Check the wire harness.
Restriction Alarm Replace the air cleaner restriction switch.
20107-2 Water Separator The water separator is full. Check the wire harness.
Alarm Replace the water separator alarm switch.
20109-2 Pilot Control Shut- Faulty pilot shut-off switch. Check the wire harness.
Off Lever Alarm Replace the pilot shut-off switch restriction
switch.
20110-2 Fuel Filter Clogged fuel filter. Check the wire harness.
Restriction Alarm Replace the fuel filter.
20114-2 Overheat Alarm Coolant temperature is high Check the wire harness.
(Immediately after within ten seconds after the Replace the overheat switch.
the key is turned engine starts.
ON)
20146-2 Fuel Temperature Fuel temperature increases. Check the wire harness.
Increase Alarm Replace the fuel temperature sensor.
20149-2 EGR Gas EGR gas temperature increases. Check the wire harness.
Temperature Alarm Replace the intake manifold temperature
sensor.
T5-5-30
Air Conditioner Controller Fault Code List

Occurs.
11 Open circuit in Voltage: more than Operation is controlled Check the wire harness.
re-circulated air 4.95 V under such circumstance Replace the re-circulated
temperature sensor as no re-circulated air air temperature sensor.
temperature sensor is
provided.
12 Short circuit in Voltage: less than 0.3 V Operation is controlled Check the wire harness.
re-circulated air under such circumstance Replace the re-circulated
temperature sensor as no re-circulated air air temperature sensor.
temperature sensor is
provided.
13 Open circuit in Voltage: more than Operation is controlled Check the wire harness.
ambient temperature 4.88 V under such circumstance Replace the ambient
sensor as no ambient temperature temperature sensor.
sensor is provided.
14 Short circuit in Voltage: less than Operation is controlled Check the wire harness.
ambient temperature 0.096 V under such circumstance Replace the ambient
sensor as no ambient temperature temperature sensor.
sensor is provided.
18 Short circuit in solar Voltage: more than Operation is controlled Check the wire harness.
radiation sensor 5.04 V under such circumstance as Replace the solar
no solar radiation sensor is radiation sensor.
provided.
21 Open circuit in frost Voltage: more than The compressor clutch Check the wire harness.
sensor 4.79 V is disengaged. (The Replace the frost sensor.
compressor stops.)
22 Short circuit in frost Voltage: less than The compressor clutch Check the wire harness.
sensor 0.096 V is disengaged. (The Replace the frost sensor.
compressor stops.)
43 Abnormal air vent Short circuit: Voltage: Air vent damper servo Check the wire harness.
damper servo motor 0V motor becomes inoperable. Replace the air vent
Open circuit: Voltage: damper servo motor.
more than 5 V
44 Abnormal air mix Short circuit: Voltage: Air mix damper servo motor Check the wire harness.
damper servo motor less than 0.2 V becomes inoperable. Replace the air mix
Open circuit: Voltage: damper servo motor.
more than 4.8 V
51 Abnormal high/low Voltage: 0 V The compressor clutch Check the wire harness.
refrigerant pressure is disengaged. (The Replace the high/low
compressor stops.) pressure switch.
91 CAN communication Faulty CAN1 harness Air conditioner stops. Check the CAN1 harness.
error between monitor Replace the air
controller and air conditioner controller.
conditioner controller.
92 CAN bus off error Faulty air conditioner Air conditioner stops. Check the CAN1 harness.
controller. Replace the air
Faulty CAN1 harness. conditioner controller.
T5-5-31
Communication Terminal Fault Code List

14100-2 Communication Terminal: The internal memory of satellite Replace the controller (satellite
Abnormal EEPROM communication terminal communication terminal).
(optional) is abnormal.
14101-2 Communication Terminal: The internal memory of satellite Replace the controller (satellite
Abnormal IB/OB Queue communication terminal communication terminal).
(optional) is abnormal.
14102-2 Communication Terminal: The results of communication test Check the communication
Abnormal Local Loop Back with the satellite is abnormal. antenna for satellite.
14103-2 Communication Terminal: No Satellite can not be caught. Check the communication
Satellite Found antenna for satellite.
14104-2 Communication Terminal: The results of communication test Replace the controller (satellite
Remote Loop Back Error 1 with the satellite and base station communication terminal).
are abnormal.
14105-2 Communication Terminal: The results of communication test Replace the controller (satellite
Remote Loop Back Error 2 with the satellite and base station communication terminal).
are abnormal.
14106-2 Communication Terminal: Transmission/receiving data with Replace the controller (satellite
Transmission/Receiving Data the satellite is unmatched. communication terminal).
Unmatched
14107-2 Communication Terminal: Abnormal mobile communication Replace the controller (mobile
Abnormal GSM Module equipment. communication terminal).
fNOTE: Fault codes 14100-2 to 14106-2 are for satellite

communication terminal. Fault code 14107-2 is for
mobile communication terminal.
T5-5-32
MC Fault Codes 11000 to 11002
Fault Code Trouble Cause

11000-2 Abnormal EEPROM Faulty MC.
11001-2 Abnormal RAM Faulty MC.
11002-2 Abnormal A/D Converter Faulty MC.
fNOTE: When the engine and the machine is operated

normally with the fault code displayed after retrial, the
machine can be operated as it is.
T5-5-33
MC Fault Code 11003

IMPORTANT: When fault code 11003-3 (Abnormal
Sensor Voltage) is displayed with other fault code,
diagnose on fault code 11003-3 first.
Fault Code Trouble Inspection Method Evaluation Cause

11003-3 Abnormal Sensor Disconnect connectors from all Fault code 11003-3 is Faulty sensor
Voltage sensors and switch panel Retry not displayed
the troubleshooting by using
MPDr.
Measure voltage between 0V Open circuit in wire
sensor harness end #1 and harness #1
body.
Check short circuit in wire 0Ω Short circuit in wire
harness between sensor harness harness #1 and #3
end #1 and #3.
- Normal in above check Faulty MC
2
3
4
5
18
6
17 7
8
9
16 10
11
15
12
13 TJBG-05-05-001
1- MC 7- Pressure Sensor (Bucket Roll- 12- Pressure Sensor (Attachment) 16- Pump 1 Control Pressure
2- Pressure Sensor (Boom Raise) Out) (Option) Sensor
3- Pressure Sensor (Boom Lower) 8- Pressure Sensor (Swing) 13- Bottom Pressure Sensor 17- Pump 2 Delivery Pressure
4- Pressure Sensor (Arm Roll-In) 9- Pressure Sensor (Travel) (Option) Sensor
5- Pressure Sensor (Arm Roll-Out) 10- Pressure Sensor (4-Spool Side) 15- Pump 1 Delivery Pressure 14- Pump 2 Control Pressure
6- Pressure Sensor (Bucket 11- Pressure Sensor (5-Spool Side) Sensor Sensor
Roll-In)
T5-5-34
Connector (Wire harness end of connector viewed from

the open end side)
 Pressure Sensor (Boom Raise)
 Pressure Sensor (Boom Lower)
 Pressure Sensor (Arm Roll-In)
 Pressure Sensor (Arm Roll-Out)
 Pressure Sensor (Bucket Roll-In)
 Pressure Sensor (Bucket Roll-Out)
 Pressure Sensor (Swing)
 Pressure Sensor (Travel)
 Pressure Sensor (4-Spool Side)
 Pressure Sensor (5-Spool Side)
 Pressure Sensor (Attachment) (Option)
 Pump 1 Control Pressure Sensor
 Pump 2 Control Pressure Sensor
TJBG-05-05-011
 Pump 1 Delivery Pressure Sensor

 Pump 2 Delivery Pressure Sensor
 Boom Bottom Pressure Sensor (Option)
TJBG-05-05-010
 Switch Panel
(Engine Control Dial)
TJBG-05-05-016
T5-5-35
(Blank)
T5-5-36
MC Fault Codes 11006, 11007,11009

Monitor Controller (Monitor) Fault Codes
13002, 13003, 13005
Preparation
 Check the wiring connections first.
 Check the CAN0 harness between the controllers.
(Refer to CAN0 Harness Check.)
Fault Code Trouble Inspection Method Cause

11006-2 (MC) EC Continuity check (open circuit) Open circuit in wire
Communication harness.
Error Discontinuity check Short circuit in wire
harness.
11007-2 (MC) IC Continuity check (open circuit) Open circuit in wire
Error 1 Discontinuity check Short circuit in wire
harness.
11009-2 (MC) Monitor Continuity check (open circuit) Open circuit in wire
Controller harness.
Communication Discontinuity check Short circuit in wire
Error 1 harness.
13002-2 (Monitor Controller) Continuity check (open circuit) Open circuit in wire
Engine Controller harness.
Error harness.
Main Controller harness.
Error 1 harness.
ICF Communication harness.
harness.
fNOTE: IC and ICF are the Information Control Unit of Monitor Controller.
T5-5-37
CAN0 Harness Check

Preparation
 Before continuity check, set the key switch to the
OFF position.
Evaluation
Continuity (0 Ω) Discontinuity (∞ Ω)
Continuity check Correct Incorrect (open
(open circuit) circuit)
Discontinuity check Incorrect (short Correct
(short circuit) circuit)
Inspection CAN Harness MC ECM Monitor Controller

Continuity check High side #D2 #154 #A24
between MC and Low side #D3 #132 #A23
each controller
Discontinuity High side #D2-#E1 #154-#61 #A24-#A22
check between #D2-#E2 #154-#62 #A24-#B35
CAN circuit and
#D2-#F4 #154-#63 #A24-#B36
ground circuit in
each controller #D2-#F5 #154-#64 -
#D2-#F6 #154-#65 -
- #154-#66 -
- #154-#97 -
- #154-#119 -
- #154-#137 -
Low side #D3-#E1 #132-#61 #A23-#A22
#D3-#E2 #132-#62 #A23-#B35
#D3-#F4 #132-#63 #A23-#B36
#D3-#F5 #132-#64 -
#D3-#F6 #132-#65 -
- #132-#66 -
- #132-#97 -
- #132-#119 -
- #132-#137 -
T5-5-38
Inspection CAN Harness MC ECM Monitor Controller

Discontinuity High side #D2-#E5 #154-#67 #A24-#B17
check between #D2-#E6 #154-#89 #A24-#B18
CAN circuit and
#D2-#F1 #154-#111 -
power circuit in
each controller #D2-#F2 #154-#133 -
#D2-#F3 - -
Low side #D3-#E5 #132-#67 #A23-#B17
#D3-#E6 #132-#89 #A23-#B18
#D3-#F1 #132-#111 -
#D3-#F2 #132-#133 -
#D3-#F3 - -
Discontinuity High side #D2-#E4 #154-#134 #A24-#A16
check between
CAN circuit and
Low side #D3-#E4 #132-#134 #A23-#A16
key signal circuit
in each controller
Discontinuity - #D2-#D3 #154-#132 #A24-#A23
check between
CAN (High side)
circuit and CAN
(Low side) circuit
in each controller
T5-5-39
Connector (Wire harness end)
 MC-D Connector  Monitor Controller-A Connector
TDAB-05-06-011
TJBG-05-05-005
 MC-E Connector  Monitor Controller-B Connector
TJBG-05-05-006 TJBG-05-05-012
 MC-F Connector
TJBG-05-05-007
 ECM-2 Connector
TJBG-05-05-021
T5-5-40
MC Fault Codes 11008, 11010

Monitor Controller (Monitor) Fault Codes
13004, 13006, 13007
Preparation
 Check the CAN1 harness between the controllers.
(Refer to CAN1 Harness Check.)
Fault Code Trouble Inspection Method Cause

11008-2 (MC) IC Continuity check (open circuit) Open circuit in wire
harness.
11010-2 (MC) Monitor Continuity check (open circuit) Open circuit in wire
Controller harness.
Error 2 harness.
Main Controller harness.
Error 2 harness.
ICF Communication harness.
harness.
Body Controller harness.
Error harness.
fNOTE: IC and ICF are the Information Control Unit of Monitor Controller.
T5-5-41
CAN1 Harness Check

Preparation
 Before continuity check, set the key switch to the
OFF position.
Evaluation
Continuity (0 Ω) Discontinuity (∞ Ω)
Continuity check Correct Incorrect (open
(open circuit) circuit)
Discontinuity check Incorrect (short Correct
(shorted circuit) circuit)
Inspection CAN Harness MC Monitor Wiper/ Radio A/C

Controller Light
Controller
Continuity check High side #D4 #A26 #B1 #4 #9(A/C2)
between MC and Low side #D5 #A25 #B11 #12 #10(A/C2)
each controller
Discontinuity check High side #D4-#E1 #A26-#A22 #B1-#A8 #4-#15 #9(A/C2)-#1(A/C1)
between CAN circuit #D4-#E2 #A26-#B35 - - -
and ground circuit
#D4-#F4 #A26-#B36 - - -
in each controller
#D4-#F5 - - - -
#D4-#F6 - - - -
Low side #D5-#E1 #A25-#A22 #B11-#A8 #12-#15 #10(A/C2)-#1(A/C1)
#D5-#E2 #A25-#B35 - - -
#D5-#F4 #A25-#B36 - - -
#D5-#F5 - - - -
#D5-#F6 - - - -
T5-5-42
Inspection CAN Harness MC Monitor Wiper/ Radio A/C

Controller Light
Controller
Discontinuity check High side #D4-#E5 #A26-#B17 #B1-#A4 #4-#8 #9(A/C2)-#2(A/C1)
between CAN circuit #D4-#E6 #A26-#B18 - - #9(A/C2)-#3(A/C1)
and power circuit in
#D4-#F1 - - - -
each controller
#D4-#F2 - - - -
#D4-#F3 - - - -
Low side #D5-#E5 #A25-#B17 #B11-#A4 #12-#8 #10(A/C2)-#2(A/C1)
#D5-#E6 #A25-#B18 - - #10(A/C2)-#3(A/C1)
#D5-#F1 - - - -
#D5-#F2 - - - -
#D5-#F3 - - - -
Discontinuity High side #D4-#E4 #A26-#A16 #B1-#B19 #4-#16 #9(A/C2)-#4(A/C1)
check between
CAN circuit and key Low side #D5-#E4 #A25-#A16 #B11-#B19 #12-#16 #10(A/C2)-#4(A/C1)
signal circuit in each
controller
Discontinuity check - #D4-#D5 #A26-#A25 #B1-#B11 #4-#12 #9(A/C2)-#10(A/C2)
between CAN (High
side) circuit and CAN
(Low side) circuit in
each controller
T5-5-43
 MC-D Connector  Wiper/ Light Controller-A Connector
TDAB-05-06-018
TJBG-05-05-005
 MC-E Connector  Wiper/ Light Controller-B Connector
TDAB-05-06-019
TJBG-05-05-006
 MC-F Connector  Radio Connector
TDAB-05-06-010
TJBG-05-05-007
 Monitor Controller-A Connector  A/C1 Connector
TDAB-05-06-011 TDAB-05-06-008
 Monitor Controller-B Connector  A/C2 Connector
TDAB-05-06-009
TJBG-05-05-012
T5-5-44
MC Fault Code 11100

Preparation
 The actual engine speed which ECM sends by using
the CAN bus line is abnormal.
Diagnose ECM.
Fault Code Trouble Cause

11100-2 Abnormal Engine Speed Engine speed: 4000 min-1 or more
T5-5-45
MC Fault Code 11101

Preparation

11101-3 Engine Control Dial Measure resistance 0Ω Faulty engine control dial
Sensor Circuit High between switch panel end
Input #4 and #5.
- Normal in above Short circuit in wire
check harness #4 and #5
11101-4 Engine Control Dial Measure resistance ∞Ω Faulty engine control dial
Sensor Circuit Low Input between switch panel end
#4 and #5.
switch panel harness end harness #4
#4 and body.
switch panel harness end harness #6
#4 and #6.
- Normal in above Open circuit in wire
check harness #5
Connector (Wire harness end of connector viewed from

the open end side).
Switch Panel (Engine control dial)
TJBG-05-05-016
T5-5-46

Preparation
 Connect the test harness (ST 6701) and dummy
sensor equivalent to #4703324.
 Before inspection, set the key switch to the ON
position.

11200-3 Pump 1 Delivery Retry by using MPDr.. Un-displayed fault Faulty sensor
Pressure Sensor Circuit code
High Input Measure voltage between Voltage: more than Short circuit in wire
B and body. 4.5 V harness #1 and #2
Low Input Measure voltage between 0V Open circuit in wire
A and body. harness #1
A and C (GND). harness #3
check harness #2
check harness #2
C B A
TDAA-05-06-003
T5-5-47

Preparation
position.

11301-3 Swing Pilot Pressure Retry by using MPDr.. Un-displayed fault Faulty sensor
Sensor Circuit High code
Input Measure voltage between Voltage: more than Short circuit in wire
11301-4 Swing Pilot Pressure Retry by using MPDr.. Un-displayed fault Faulty sensor
Sensor Circuit Low Input code
check harness #2
11302-3 Boom Raise Pilot Retry by using MPDr.. Un-displayed fault Faulty sensor
11302-4 Boom Raise Pilot Retry by using MPDr.. Un-displayed fault Faulty sensor
check harness #2
C B A
TDAA-05-06-003
T5-5-48
MC Fault Code 11303

Preparation
position.

11303-3 Arm Roll-In Pilot Retry by using MPDr.. Un-displayed fault Faulty sensor
11303-4 Arm Roll-In Pilot Retry by using MPDr.. Un-displayed fault Faulty sensor
check harness #2
C B A
TDAA-05-06-003
T5-5-49

Preparation
position.

11304-3 Travel Pilot Pressure Retry by using MPDr.. Un-displayed fault Faulty sensor
11304-4 Travel Pilot Pressure Retry by using MPDr.. Un-displayed fault Faulty sensor
check harness #2
11325-3 Bucket Roll-In Pilot Retry by using MPDr.. Un-displayed fault Faulty sensor
11325-4 Bucket Roll-In Pilot Retry by using MPDr.. Un-displayed fault Faulty sensor
check harness #2
C B A
TDAA-05-06-003
T5-5-50
MC Fault Code 11405

Preparation

11405-3 Travel Swash Angle P/S Measure resistance 0Ω Faulty solenoid valve
Valve FB High Current between solenoid valve #1 (Specification: 22
(4-spool solenoid valve and #2. Ω)
unit (SC)) - Normal in above Short circuit in wire
check. harness #1 and #2
11405-4 Travel Swash Angle P/S Measure resistance ∞Ω Faulty solenoid valve
Valve FB Low Current between solenoid valve #1 (Specification: 22
unit (SC)) Measure voltage between 0V Open circuit in wire
solenoid valve harness end harness #1
#1 and body.
Monitor Travel Mode C/V 0 mA Open circuit in wire
Output FB. harness #2

 Solenoid Valve Connector
TJBG-05-05-003
T5-5-51
MC Fault Code 11408

Preparation

11408-3 Center Bypass Cut P/S Measure resistance 0Ω Faulty solenoid valve
and #2. Ω)
11408-4 Center Bypass Cut P/S Measure resistance ∞Ω Faulty solenoid valve
and #2. Ω)
#1 and body.
Monitor Muf/Filtr Regen 0 mA Open circuit in wire
P/S O/P FB. harness #2
fNOTE: The fault codes 11408-3 and 11408-4 are

displayed on MPDr. as follows.
Cut) P/S Valve FB High Current.
Cut) P/S Valve FB Low Current.

TJBG-05-05-003
T5-5-52
MC Fault Code 11412

Preparation

11412-3 Hyd. Fan P/S Valve FB Measure resistance 0Ω Faulty solenoid valve
High Current between solenoid valve #1 (Specification: 22
and #2. Ω)
11412-4 Hyd. Fan P/S Valve FB Measure resistance ∞Ω Faulty solenoid valve
Low Current between solenoid valve #1 (Specification: 22
and #2. Ω)
#1 and body.
Monitor Hyd Fan Rot P/S 0 mA Open circuit in wire
O/P FB. harness #2

TJBG-05-05-003
T5-5-53
MC Fault Code 11428

Preparation

11428-3 Arm 2 Flow Rate Control Measure resistance 0Ω Faulty solenoid valve
P/S Valve FB High between solenoid valve #1 (Specification: 22
Current and #2. Ω)
11428-4 Arm 2 Flow Rate Control Measure resistance ∞Ω Faulty solenoid valve
P/S Valve FB Low Current between solenoid valve #1 (Specification: 22
and #2. Ω)
#1 and body.
Monitor Arm 2 Flw Cont P/S 0 mA Open circuit in wire
O/P FB. harness #2

TJBG-05-05-003
T5-5-54
MC Fault Code 11802

Preparation
position.

11802-3 Boom Bottom Pressure Retry by using MPDr.. Un-displayed fault Faulty sensor
(Option) B and body. 4.5 V harness #1 and #2
11802-4 Boom Bottom Pressure Retry by using MPDr.. Un-displayed fault Faulty sensor
(Option) Measure voltage between 0V Open circuit in wire
check harness #2
C B A
TDAA-05-06-003
T5-5-55
MC Fault Code 11901

Preparation

11901-3 Hyd. Oil Temp Sensor Measure resistance 0Ω Faulty sensor
Circuit High Input between sensor #1 and #2.
check harness #1
11901-4 Hyd. Oil Temp Sensor Measure resistance ∞Ω Faulty sensor
Circuit Low Input between sensor #1 and #2.
body.
check harness #2
fNOTE: Specification of Hydraulic Oil Temperature

Sensor. ( ) is a reference value.
Hydraulic Oil Resistance (kΩ)

Temperature (°C)
-30 (24.5)
-20 15.04+1.29-1.20
-10 (9.16)
0 (5.74)
10 (3.70)
20 2.45+0.14-0.13
30 (1.66)
40 (1.15)
50 (0.811)
60 (0.584)
70 (0.428)
80 0.318±0.008
90 (0.240)
100 (0.1836)
110 0.1417±0.0018
120 (0.1108)

 Hydraulic Oil Temperature Sensor
TDAB-05-06-023
T5-5-56

Preparation
position.

11942-3 Attachment Pilot Retry by using MPDr.. Un-displayed fault Faulty sensor
High Input (Option) Measure voltage between Voltage: more than Short circuit in wire
11942-4 Attachment Pilot Retry by using MPDr.. Un-displayed fault Faulty sensor
Low Input (Option) Measure voltage between 0V Open circuit in wire
check harness #2
11944-3 Signal Control Valve Retry by using MPDr.. Un-displayed fault Faulty sensor
SB-port Pressure Sensor code
Circuit High Input Measure voltage between Voltage: more than Short circuit in wire
(5-spool side pilot B and body. 4.75 V harness #1 and #2
pressure sensor)
SB-port Pressure Sensor code
Circuit Low Input Measure voltage between 0V Open circuit in wire
(5-spool side pilot A and body. harness #1
pressure sensor)
check harness #2
C B A
TDAA-05-06-003
T5-5-57
MC Fault Codes 11945

Preparation
position.

SA-Port Pressure Sensor code
Circuit High Input Measure voltage between Voltage: more than Short circuit in wire
(4-spool side pressure B and body. 4.5 V harness #1 and #2
sensor)
SA-Port Pressure Sensor code
Circuit Low Input Measure voltage between 0V Open circuit in wire
(4-spool side pressure A and body. harness #1
sensor)
check harness #2
C B A
TDAA-05-06-003
T5-5-58
MC Fault Code 11948

Preparation

11948-3 Main Relief Pressure Measure resistance 0Ω Faulty solenoid valve
Control P/S Valve FB between solenoid valve #1 (Specification: 22
High Current (4-spool and #2. Ω)
solenoid valve unit (SI)) - Normal in above Short circuit in wire
11948-4 Main Relief Pressure Measure resistance ∞Ω Faulty solenoid valve
Low Current (4-spool and #2. Ω)
solenoid valve unit (SI)) Measure voltage between 0V Open circuit in wire
#1 and body.
Monitor Pressure Boost P/S 0 mA Open circuit in wire
Output FB. harness #2

TJBG-05-05-003
T5-5-59
MC Fault Code 11950

Preparation

11950-3 Pump 2 P/S Valve FB Measure resistance 0Ω Faulty solenoid valve
and #2. Ω)
11950-4 Pump 2 P/S Valve FB Measure resistance ∞Ω Faulty solenoid valve
and #2. Ω)
#1 and body.
Monitor Pump 2 (5 units) 0 mA Open circuit in wire

TJBG-05-05-003
T5-5-60
MC Fault Code 11951

Preparation

11951-3 Pump 1 P/S Valve FB Measure resistance 0Ω Faulty solenoid valve
and #2. Ω)
11951-4 Pump 1 P/S Valve FB Measure resistance ∞Ω Faulty solenoid valve
and #2. Ω)
#1 and body.
Monitor Pump 1 (4 Units) 0 mA Open circuit in wire

TJBG-05-05-003
T5-5-61
MC Fault Code 11953

Preparation

11953-3 Swing Flow Rate Measure resistance 0Ω Faulty solenoid valve
High Current (2-spool and #2. Ω)
solenoid valve unit (SI)) - Normal in above Short circuit in wire
11953-4 Swing Flow Rate Control Measure resistance ∞Ω Faulty solenoid valve
P/S Valve FB Low Current between solenoid valve #1 (Specification: 22
unit (SI)) Measure voltage between 0V Open circuit in wire
#1 and body.
Monitor Swing Flw Cont 0 mA Open circuit in wire

TJBG-05-05-003
T5-5-62

Preparation
position.

11978-3 Auxiliary 2 Pilot Pressure Retry by using MPDr.. Un-displayed fault Faulty sensor
Input (Option) Measure voltage between Voltage: more than Short circuit in wire
check harness #2
Input (Option) Measure voltage between Voltage: more than Short circuit in wire
check harness #2
C B A
TDAA-05-06-003
T5-5-63
MC Fault Code 11982

Preparation

11982-3 Fan Reverse Rotation P/S Measure resistance 0Ω Faulty solenoid valve
Valve 1 FB High Current between solenoid valve #1 (Specification: 22
and #2. Ω)
11982-4 Fan Reverse Rotation P/S Measure resistance ∞Ω Faulty solenoid valve
Valve 1 FB Low Current between solenoid valve #1 (Specification: 22
and #2. Ω)
#1 and body.
Monitor Fan Dir Cont P/S 2 0 mA Open circuit in wire
O/P FB. harness #2

TJBG-05-05-003
T5-5-64

Preparation

11985-2 Pump 2 Regulator Measure resistance 0/∞ Ω Faulty solenoid valve
Pressure Calibration between solenoid valve #1 (Specification: 22
Abort and #2. Ω)
#1 and body.
Monitor Pump 2 (5 units) 0 mA Open circuit in wire
11986-2 Pump 1 Regulator Measure resistance 0/∞ Ω Faulty solenoid valve
Pressure Calibration between solenoid valve #1 (Specification: 22
Abort and #2. Ω)
#1 and body.
Monitor Pump 1 (4 Units) 0 mA Open circuit in wire

TJBG-05-05-003
T5-5-65
MC Fault Code 11989

Preparation

11989-3 Boom Mode Control P/S Measure resistance 0Ω Faulty solenoid valve
unit (SC)) - Normal in above Short circuit in wire
11989-4 Boom Mode Control P/S Measure resistance ∞Ω Faulty solenoid valve
unit (SC)) Measure voltage between 0V Open circuit in wire
#1 and body.
Monitor Bm Mode Cont P/S 0 mA Open circuit in wire
O/P FB. harness #2

TJBG-05-05-003
T5-5-66

Preparation
position.

11992-3 Pump 2 Reg-Pressure Retry by using MPDr.. Un-displayed fault Faulty sensor
Input (Pump 2 control Measure voltage between Voltage: more than Short circuit in wire
pressure sensor) B and body. 4.5 V harness #1 and #2
Sensor Circuit Low code
Input (Pump 2 control Measure voltage between 0V Open circuit in wire
pressure sensor) A and body. harness #1
check harness #2
Input (Pump 1 control Measure voltage between Voltage: more than Short circuit in wire
pressure sensor) B and body. 4.5 V harness #1 and #2
Sensor Circuit Low code
Input (Pump 1 control Measure voltage between 0V Open circuit in wire
pressure sensor) A and body. harness #1
check harness #2
C B A
TDAA-05-06-003
T5-5-67

Preparation
position.

11995-3 Arm Roll-Out Pilot Retry by using MPDr.. Un-displayed fault Faulty sensor
11995-4 Arm Roll-Out Pilot Retry by using MPDr.. Un-displayed fault Faulty sensor
check harness #2
11997-3 Bucket Roll-Out Pilot Retry by using MPDr.. Un-displayed fault Faulty sensor
11997-4 Bucket Roll-Out Pilot Retry by using MPDr.. Un-displayed fault Faulty sensor
check harness #2
C B A
TDAA-05-06-003
T5-5-68
MC Fault Code 11998

Preparation
position.

11998-3 Boom Lowering Pilot Retry by using MPDr.. Un-displayed fault Faulty sensor
11998-4 Boom Lowering Pilot Retry by using MPDr.. Un-displayed fault Faulty sensor
check. harness #2
C B A
TDAA-05-06-003
T5-5-69
MC Fault Codes 20062

20062-0 Hydraulic Oil Overheat Perform troubleshooting - -
Alarm from other fault code.
T5-5-70
Monitor Controller (Information) Fault Codes 13304, 13310

13304-2 Abnormal REG Input H Measure voltage between 13 to 33.5 V Faulty monitor
Level monitor controller harness controller
end #A15 and body.
Measure voltage at 13 to 33.5 V Open circuit in wire
alternator terminal L. harness
- Normal in above Faulty alternator.
check.
13310-3 Coolant Temperature Measure resistance 0Ω Faulty sensor
Sensor Short Circuit between sensor and body.
check. harness

 Monitor Controller-A Connector
TDAB-05-06-011
fNOTE:
Coolant Temperature Gauge No. Coolant Temperature (ºC) Coolant Temperature Sensor (kΩ)
E
A 25 7.6±0.76
F
B 40 4.0±0.35
C 50 2.7±0.22
D 80 0.92±0.07
D 95 0.56±0.04
E 105 0.42±0.03
D F 120 0.28±0.01
B
A
TJBG-05-02-084
T5-5-71
Monitor Controller (Information) Fault Code 13311

13311-3 Fuel Level Sensor Circuit Measure resistance 0Ω Faulty sensor
High Input between sensor #1 and #2.
body.
- Normal in above Open circuit in
check harness #2
13311-4 Fuel Level Sensor Circuit Measure resistance ∞Ω Faulty sensor
Low Input between sensor #1 and #2.
fNOTE:
Fuel Gauge No. Fuel Level (%) Fuel Sensor (Ω)
A A 100 (FULL) 100-4
B
B 75 19
C
C 50 32±5
D
D 25 49.3
E 6 -
E
F 0 (EMPTY) 80+12+2
TDAA-05-02-082

 Fuel Sensor
TDCD-05-06-010
T5-5-72
Monitor Controller (Information) Fault Codes 20100 to 20104, 20106

20100-2 Overheat Alarm Disconnect a connector Displayed fault code Faulty monitor
from the overheat switch controller or short
and retry by using MPDr.. circuit in wire harness
Un-displayed fault Faulty overheat
code switch
20101-2 Engine warning Alarm Diagnose on fault codes - -
of ECM.
20102-2 Engine Oil Pressure Alarm Diagnose on fault codes - -
of ECM.
20103-2 Alternator Alarm Measure voltage between 13 V to 33.5 V Faulty monitor
monitor controller harness controller
end #A15 and body.
Measure voltage at 13 V to 33.5 V Open circuit in wire
alternator terminal L. harness
- Normal in above Faulty alternator
check
20104-2 Fuel Level Alarm Disconnect a connector Displayed fault code Faulty monitor
from the fuel level sensor controller or short
and retry by using MPDr.. circuit in wire harness
Un-displayed fault Faulty fuel level
code sensor
20106-2 Air Cleaner Restriction Disconnect a connector Displayed fault code Faulty monitor
Alarm from air cleaner restriction controller or short
switch and retry by using circuit in wire harness
MPDr.. Un-displayed fault Faulty air cleaner
code restriction switch

 Monitor Controller-A Connector
TDAB-05-06-011
T5-5-73
Monitor Controller (Information) Fault Codes 20107, 20109, 20110, 20114, 20146, 20149

20107-2 Water Separator Alarm Disconnect a connector Displayed fault code Faulty monitor
from the water separator controller or shorted
alarm switch. Retry by circuit in wire harness
using MPDr.. Un-displayed fault Faulty water separator
code alarm switch
20109-2 Pilot Control Shut-Off Check the pilot shut-off Normal Faulty wire harness
Lever Alarm switch. Abnormal Faulty pilot shut-off
switch
20110-2 Fuel Filter Restriction Check fuel filter restriction Normal Fanlty wire harness,
Alarm sensor Diagnose on fault
codes of ECM.
Abnormal Faulty fuel filter
restriction sensor
20114-2 Overheat Alarm Disconnect a connector Displayed fault code Faulty monitor
(Immediately after the key from the coolant overheat controller or short
is turned ON) switch and retry by using circuit in wire harness
MPDr.. Un-displayed fault Faulty coolant
code overheat switch
20146-2 Fuel Temperature Increase Diagnose on fault codes - -
Alarm of ECM.
20149-2 EGR Gas Temperature Diagnose on fault codes - -
Alarm of ECM.
T5-5-74
Air Conditioner Controller Fault Codes 11 to

22
Preparation
position.

11 Open Circuit in Measure resistance ∞ Ω (Normal value: Faulty sensor
Re-circulated Air between sensor #25H and 300 to 430 kΩ)
Temperature Sensor #6B.
sensor harness end #25H harness #25H
and body.
check. harness #6B
12 Short Circuit in Measure resistance 0 Ω (Normal value: Faulty sensor
Re-circulated Air between sensor #25H and 300 to 430 kΩ)
Temperature Sensor #6B.
check. harness #25H and #6B
13 Open Circuit in Ambient Measure resistance ∞ Ω (Normal value: Faulty sensor
Temperature Sensor between sensor #25H and 100 to 210 kΩ)
#6B.
and body.
check. harness #6B
14 Short Circuit in Ambient Measure resistance 0 Ω (Normal value: Faulty sensor
Temperature Sensor between sensor #25H and 100 to 210 kΩ)
#6B.
18 Short Circuit in Solar Continuity check between 0Ω Short circuit in wire
Radiation Sensor sensor harness end #25H harness #25H and #6B
and #6B.
- Normal in above Faulty sensor
check.
21 Open Circuit in Frost Measure resistance ∞ Ω (Normal value: Faulty sensor
Sensor between sensor #25H and 100 to 115 kΩ)
#6B.
and body.
check. harness #6B
22 Short Circuit in Frost Measure resistance 0 Ω (Normal value: Faulty sensor
Sensor between sensor #25H and 100 to 115 kΩ)
#6B.
T5-5-75
Air Conditioner Controller Fault Codes 43 to

92
Preparation
position.

43 Abnormal Air Vent Measure voltage between servo 0V Faulty controller or open
Damper Servo motor harness end 7C and body. circuit in wire harness between
Motor (AUTO/OFF switch/blower controller and air vent damper
switch: ON) servo motor
Measure voltage between 0V Faulty controller or open
servo motor harness end 7C and circuit in wire harness between
25D. (AUTO/OFF switch/blower controller and air vent damper
- Normal in Faulty air vent damper servo
above check. motor
44 Abnormal Air Mix Measure voltage between servo 0 V Faulty controller or open
Damper Servo motor harness end 7D and body. circuit in wire harness between
Motor (AUTO/OFF switch/blower controller and air mix damper
Measure voltage between servo 0 V Faulty controller or open
motor harness end 7D and 25E. circuit in wire harness between
(AUTO/OFF switch/blower controller and air mix damper
- Normal in Faulty air mix damper servo
above check. motor
51 Abnormal High/ Measure voltage between high/ 0 V Faulty controller or open
Low Refrigerant low pressure switch harness circuit in wire harness between
Pressure end A211 and A052. (AUTO/OFF controller and high/low pressure
switch/blower switch: ON) switch
- Normal in Faulty high/low pressure switch
above check.
91 CAN Continuity check in CAN1 Normal Faulty controller
Communication harness. Abnormal Faulty CAN1 harness
Error
92 CAN Bus Off Error Continuity check in CAN1 Normal Faulty controller
harness. Abnormal Faulty CAN1 harness
T5-5-76
Troubleshooting B (Machine Diagnosis by

Using Trouble Symptom) Procedure
Refer to troubleshooting B procedures for diagnosis

by using trouble symptom when no fault codes are
displayed.
 Diagnosis Procedure
 Perform diagnosis by using MPDr. or the service
menu of monitor first.
 When the fault code is displayed, refer to the
troubleshooting A group and diagnose.
 In case any fault code has not been displayed by
diagnosis, perform inspection according to the
procedures in this group when diagnosing.
 On the front section pages of this group, there are
the tables indicating the relationship between
machine trouble symptoms and related parts
which may cause such trouble if failed. Start the
troubleshooting with more probable causes selected
by referring to these tables.
f NOTE: All connector images in this section are viewed
from the open end side of wire harness end.
1
2
T6L4-05-03-001
1- Wire Harness End Connector 2- Wire Harness
T5-6-1
Contents of Diagnosis
Trouble Symptom
Preparation
Viewpoints for a diagnosis and contents

needing inspection beforehand are
explained.
How to Read Table
Inspection
Procedure Condition Evaluation Cause
Method
(A) (B) (C) (D) (E)
(F) (G) (H) (I) (J)
 A, F: Inspection order
 B, G: Inspection method for trouble cause
 C, H: Conditions for inspection
 D, I: Evaluation specification of check results
 E, J: Trouble cause for trouble symptom
Procedure:
1. Perform inspection according to Inspection Method (B) and Condition (C) of
Procedure (A).
2. In case the results are applied to Evaluation (D), the trouble cause is Cause (E).
In case the results are not applied to Evaluation (D), go to the next, Procedure (F).
T5-6-2
Relationship between Machine Trouble

Symptoms and Related Parts
This table indicates the relationship between machine
trouble symptoms and the potential problem parts, which
may cause trouble if failed, and the evaluation methods of
these components.
Parts MC (Main Controller) Engine Control Dial Auto-Idle Switch
Item
Function MC controls the engine, pump, Engine control dial instructs target This switch activates auto-idle
and valve. engine speed. control.
ON: 0 VAuto-idle control is
activated.
OFF: 5 VAuto-idle control is
not activated.
Symptoms Depending on trouble situations, Even if engine control dial is Open circuit: Auto-idle is not
in control control system malfunction may operated, engine speed does not activated.
system when differ. (The following symptoms in change. Short circuit: Even if auto-idle
machine operation indicate that
trouble occurs switch is in OFF position, auto-
MC logic circuit has failed.) idle control is always activated.
Symptoms Even if engine starts, engine Engine speed is fixed at 1200 min . Same as shown above
-1
in machine speed remains in slow idle speed. (Auto-idle is operated.)

operation As pump displacement is held at In case of open circuit or shorted
when trouble minimum, all actuator speeds are circuit, target engine speed is fixed
occurs slow. at 1200 min-1.
Engine can stop by using the key
switch.
Evaluation by 11000, 11001, 11002, 11003 11101 -
Fault Code
Evaluation by - MC: Demand Engine Speed, Engine MC: Auto-Idle Switch
Monitoring Control Dial
ECM: Target Engine Speed
Evaluation - - -
by using Test
Harness
Note - - -
Descriptions T2-2 T2-2 T2-2
of Control
(Operational
Principle
Section in
T/M)
T5-6-3
Parts Power Mode Switch (ECO Mode) Travel Mode Switch Boom Mode Selector Switch
Item
Function This switch shifts power mode This switch shifts 4-spool This switch reduces overload
switch to ECO mode. solenoid valve unit (SC) and relief pressure at the boom
ON: 0 VECO mode control is changes travel speed. cylinder rod side.
operated.
OFF: 5 VNormal.
Symptoms Open circuit: Even if ECO mode is Open circuit: Travel speed Open circuit: Boom mode
in control selected, engine speed does not remains unchanged in slow selector control is not performed.
system when decrease with the control lever in speed. Short circuit: Overload relief
trouble occurs neutral. Short circuit: Even if travel mode pressure at the boom cylinder
Short circuit: Even if power mode switch is in slow idle position, rod side remains low constantly
is set to PWR mode or HP mode machine travels at fast speed. and machine cannot be raised
from ECO mode with the control off the ground with front
lever in neutral and the engine attachment.
control dial in fast idle position,
engine speed does not increase.
Symptoms Same as shown above Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by - - -
Fault Code
Evaluation by MC: Power Mode Switch MC: Travel Mode SW MC: Boom Mode Switch
Monitoring
Evaluation - - -
by using Test
Harness
Note - - -
of Control
(Operational
Principle
Section in
T/M)
T5-6-4
Parts Digging Regenerative Control Pump Regulator Pressure

Learning Switch
Item
Function This switch shifts 4-spool This switch starts pump learning.
solenoid valve unit (SI) and ON: 0 VPerform pump learning
activates power digging. OFF: 5 VNormal Control
ON: 0 VPressure increases.
OFF: 5 VPressure does not
increase.
Symptoms Open circuit: Pressure does not Pump learning cannot be
in control increase. performed.
system when Short circuit: Pressure increase
trouble occurs only for 8 seconds after the key
switch is turned ON.
Symptoms Same as shown above Open circuit or the switch
in machine continuity failure: The machine
operation is operated normally. (Only the
when trouble learning cannot be done.)
occurs Short circuit: The pump learning
cannot be done even if pushing
the learning switch after turning
the key switch ON.
Evaluation by - -
Fault Code
Evaluation by MC: Power Boost Switch MC: Pump Regulator Pressure,
Monitoring Learning SW
Evaluation - -
by using Test
Harness
Note - -
Descriptions T2-2 T2-2
of Control
(Operational
Principle
Section in
T/M)
T5-6-5
Parts Pilot Shut-Off Switch (Pilot Shut-

Off Lever)
Item
Function This switch shifts pilot shut-off
solenoid valve.
Symptoms Open circuit: Pilot shout-off
in control switch is always OFF. Pilot shut-
system when off solenoid valve is not shifted.
trouble occurs Even if lever is operated with
pilot shut-off lever in UNLOCK
position, all actuator are not
operated.
Short circuit: Pilot shout-off
switch is always ON. Engine does
not start. If short circuit occurs
while engine running and a
lever is operated with pilot shut-
off lever in the LOCK position,
actuator is operated.
Symptoms Same as shown above
in machine
operation
when trouble
occurs
Evaluation by -
Fault Code
Evaluation by MC: Pilot Control Shut-Off Lever
Monitoring Switch
Evaluation -
by using Test
Harness
Note -
Descriptions T2-5
of Control
(Operational
Principle
Section in
T/M)
T5-6-6
Parts Auto-Lubrication ON/OFF Switch Proximity Switch (Auto-

Lubrication Device)
Item
Function This switch activates the auto- This switch detects operation
lubrication function. (Auto- number of times of the
Lubrication Control) distribution valve to set
ON: 0 VOperate. the lubrication time. (Auto-
OFF: 5 VDoes not operate. Lubrication Control)
Symptoms No signal is input to MC. No signal is input to MC.
in control
system when
trouble occurs
Symptoms The auto-lubrication does not As the pump keeps operating
in machine operate both for open and short until generation of the auto-
operation circuit. lubrication error, grease is
when trouble discharged a lot. When the
occurs error judgment time is reached,
the auto-lubrication alarm is
displayed on the monitor unit.
Evaluation by - -
Fault Code
Evaluation by MC: Auto-Lubrication Main SW MC: Auto-Lubrication Limit SW
Monitoring
Evaluation - -
by using Test
Harness
Note - -
of Control
(Operational
Principle
Section in
T/M)
T5-6-7
Parts Pilot Shut-Off Solenoid Valve Hydraulic Oil Temperature Sensor
Item
Function This valve opens and closes pilot This sensor monitors hydraulic oil
circuit. temperature.
Symptoms When close: All actuators are not MC recognizes that hydraulic oil
in control activated. (Pilot pressure oil is not temperature is 120 °C when an
system when supplied to pilot valve.) open circuit occurs. (Hydraulic
trouble occurs When open: Pilot pressure oil is oil temperature: 120 °C is not
always supplied to pilot valve. displayed on monitoring.)
Symptoms Same as shown above The fan speed is fixed to the
in machine maximum value.
operation
when trouble
occurs
Evaluation by - 11901
Fault Code
Evaluation by - MC: Hydraulic Oil Temperature
Monitoring
Evaluation - -
by using Test
Harness
Note - -
of Control
(Operational
Principle
Section in
T/M)
T5-6-8
Parts Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor
Item
Function This sensor detects pump 1 This sensor detects pump 2
delivery pressure. delivery pressure.
Symptoms When output is 0 V or 5 V, the When output is 0 V or 5 V, the
in control following symptoms occur. following symptoms occur.
system when
trouble occurs
Symptoms HP Mode cannot be set. HP Mode cannot be set.
in machine As the pump 1 delivery flow rate As the pump 2 delivery flow rate
operation is restricted, operation speed is restricted, operation speed
when trouble of the boom, arm, and bucket of the boom, arm, and swing
occurs becomes slower. becomes slower.
The engine becomes easily The engine becomes easily
stalled. stalled.
As the machine is kept to travel As the machine is kept to travel
at slow speed, speed does not at slow speed, speed does not
change into fast. change into fast.
Evaluation by 11200 11202
Fault Code
Evaluation by MC: Pump 1 Delivery Pressure MC: Pump 2 Delivery Pressure
Monitoring
Evaluation - -
by using Test
Harness
Note Possible to judge if sensor or Possible to judge if sensor or
harness is faulty by switching harness is faulty by switching
pressure sensor with other pressure sensor with other
delivery pressure sensor. delivery pressure sensor.
of Control
(Operational
Principle
Section in
T/M)
T5-6-9
Parts Pump 1 Control Pressure Sensor Pump 2 Control Pressure Sensor
Item
Function This sensor detects pump control This sensor detects pump control
pressure of pump 1. pressure of pump 2.
system when
trouble occurs
Symptoms Engine speed does not decrease Engine speed does not decrease
in machine when operating bucket and when operating travel (left) at
operation travel (right) at ECO mode. ECO mode.
when trouble Fast travel cannot be selected Fast travel cannot be selected
occurs easily when travering. easily when travering.
Fault Code
Evaluation by MC: Pump 1 Control Pressure MC: Pump 2 Control Pressure
Monitoring
Evaluation - -
by using Test
Harness
Note Possible to judge if sensor or wire Possible to judge if sensor or wire
harness is faulty by switching harness is faulty by switching
pressure sensor with other pump pressure sensor with other pump
control pressure sensor. control pressure sensor.
of Control
(Operational
Principle
Section in
T/M)
T5-6-10
Parts Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Pressure Sensor (Arm Roll-In)
Item
Function This sensor monitors boom raise This sensor monitors Boom Lower This sensor monitors arm roll-in
pilot pressure. pilot pressure. pilot pressure.
Symptoms When output is 0 V or 5 V, the When output is 0 V or 5 V, the When output is 0 V or 5 V, the
in control following symtoms occur. following symtoms occur. following symtoms occur.
system when
trouble occurs
Symptoms Engine speed is difficult to Engine speed is difficult to Engine speed is difficult to
in machine increase when performing increase when performing increase when performing
operation digging operation. digging operation. digging operation.
when trouble Arm roll-in speed is slow during Boom lower speed is slow when Arm roll-in speed is slow during
occurs combined operation of arm roll- performing combined operation combined operation of arm roll-
in and boom raise. of swing, arm roll-in, and boom in and boom raise.
During boom raise single lower. Arm roll-in speed is fast during
operation, power is weak. arm level crowding operation.
Boom raise speed is slow during Attachment and boom raise
combined operation of swing, speed are slow when performing
arm roll-in, and boom raise. combined operation of arm roll-
in, boom raise, and attachment.
Evaluation by 11302 11998 11303
Fault Code
Evaluation by MC: Boom Raise Pilot Pressure MC: Bm Lower Pilot Pressure MC: Arm Roll-In Pilot Pressure
Monitoring
Evaluation - - -
by using Test
Harness
Note Possible to judge if pressure Possible to judge if pressure Possible to judge if pressure
sensor is faulty or port is clogged sensor is faulty or port is clogged sensor is faulty or port is clogged
by switching pressure sensor with by switching pressure sensor with by switching pressure sensor with
other pressure sensor. other pressure sensor. other pressure sensor.
of Control
(Operational
Principle
Section in
T/M)
T5-6-11
Parts Pressure Sensor (Arm Roll-Out) Pressure Sensor (Bucket Roll-In) Pressure Sensor (Bucket Roll-Out)
Item
Function This sensor monitors arm roll-out This sensor monitors bucket roll- This sensor monitors bucket roll-
pilot pressure. in pilot pressure. out pilot pressure.
Symptoms When output is 0 V or 5 V, the When output is 0 V or 5 V, the When output is 0 V or 5 V, the
in control following symtoms occur. following symtoms occur. following symtoms occur.
system when
trouble occurs
Symptoms Engine speed is difficult to Engine Speed is difficult to Bucket speed is slow when
in machine increase when performing arm increase when performing performing light digging
operation roll-out operation. digging operation. operation.
when trouble Arm roll-out speed is slow. Bucket speed is slow when
occurs performing light digging
operation.
Evaluation by 11995 11325 11997
Fault Code
Evaluation by MC: Arm Roll-Out Pilot Pressure MC: Bucket Roll-In Pilot Pressure MC: Bucket Roll-Out Pilot Pressure
Monitoring
Evaluation - - -
by using Test
Harness
Note Possible to judge if pressure Possible to judge if pressure Possible to judge if pressure
sensor is faulty or port is clogged sensor is faulty or port is clogged sensor is faulty or port is clogged
by switching pressure sensor with by switching pressure sensor with by switching pressure sensor with
other pressure sensor. other pressure sensor. other pressure sensor.
of Control
(Operational
Principle
Section in
T/M)
T5-6-12
Parts Pressure Sensor (Travel) Pressure Sensor (Swing)
Item
Function This sensor monitors travel pilot This sensor monitors swing pilot
pressure. pressure.
in control following symtoms occur. following symtoms occur.
system when
trouble occurs
Symptoms Even if the machine travels, When performing combined
in machine engine speed is kept at auto-idle operation of swing and boom
operation speed. raise, engine speed does not
when trouble Even if the machine travels with increase.
occurs the engine running at slow idle Boom raise speed is slow and
speed, engine speed does not arm roll-in speed is fast when
increase. performing combined operation
As the machine is kept to travel of swing, arm roll-in, and boom
at slow speed, speed does not raise.
change into fast. Swing speed acceleration
When performing combined becomes bad and swing
operation of attachment and operation at constant speed is
travel, the machine mistracks. slow.
Travel alarm (option) continues to Swing alarm (option) continues
sound. to sound.
Fault Code
Evaluation by MC: Travel Pilot Pressure MC: Swing Pilot Pressure
Monitoring
Evaluation - -
by using Test
Harness
Note Possible to judge if pressure Possible to judge if pressure
sensor is faulty or port is clogged sensor is faulty or port is clogged
by switching pressure sensor with by switching pressure sensor
other pressure sensor. with other pressure sensor.
of Control
(Operational
Principle
Section in
T/M)
T5-6-13
Parts Pressure Sensor (4-spool Side) Pressure Sensor (5-spool Side)
Item
Function This sensor monitors control This sensor monitors control valve
valve 4-spool side pilot pressure. 5-spool side pilot pressure.
Symptoms When output is 0 V ro 5 V, the When output is 0 V ro 5 V, the
system when
trouble occurs
Symptoms Boom operation speed is slow. Boom operation speed is slow.
in machine Arm operation speed is slow. Arm operation speed is slow.
operation Bucket operation speed is slow. Swing speed is slow. The machine
when trouble The machine mistracks. mistracks.
occurs
Evaluation by - -
Fault Code
Evaluation by MC: Signal C/V SA Port Pressure MC: Signal C/V SB Port Pressure
Monitoring
Evaluation 11945 11944
by using Test
Harness
Note Possible to judge if pressure Possible to judge if pressure
sensor is faulty or port is clogged sensor is faulty or port is clogged
by switching pressure sensor by switching pressure sensor with
with other pressure sensor. other pressure sensor.
of Control
(Operational
Principle
Section in
T/M)
T5-6-14
Parts Pressure Sensor (Attachment)

(Option)
Item
Function This sensor monitors attachment
pilot pressure.
Symptoms When output is 0 V or 5 V, the
in control following symptoms occur.
system when
trouble occurs
Symptoms Even if engine speed of
in machine attachment is set to faster (+)
operation speed and the attachment is
when trouble operated, engine speed does not
occurs increase.
Attachment speed is slow.
Evaluation by 11942
Fault Code
Evaluation by MC: ATT 1 Pilot Pressure
Monitoring
Evaluation -
by using Test
Harness
Note Possible to judge if pressure
sensor is faulty or port is clogged
by switching pressure sensor with
other pressure sensor.
Descriptions T2-2
of Control
(Operational
Principle
Section in
T/M)
T5-6-15
Parts Pump 1 Control Solenoid Valve Pump 2 Control Solenoid Valve
Item
Function This valve changes pump 1 This valve changes pump 2
displacement angle displacement angle
Symptoms High current: Pump 1 High current: Pump 2
in control displacement angle is held at displacement angle is held at
system when maximum. The engine stalls or maximum. The engine stalls or
trouble occurs engine lug-down is remarkable engine lug-down is remarkable at
at high loaded. high loaded.
Low current: Pump 1 Low current: Pump 2
displacement angle is held displacement angle is held
at minimum. Machine overall at minimum. Machine overall
operation is slow operation is slow.
Symptoms Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Fault Code
Evaluation by MC: Pump 1 (4 Units) P/S Output, MC: Pump 2 (5 Units) P/S Output,
Monitoring Pump 1 (4 Units) P/S O/P FB Pump 2 (5 Units) P/S O/P FB
Evaluation - -
by using Test
Harness
Note - -
of Control
(Operational
Principle
Section in
T/M)
T5-6-16
Parts Fan Speed Control Solenoid Valve Reverse Rotation Control

Solenoid Valve (Option)
Item
Function This fan controls fan rotation This fan controls fan rotation
speed. direction.
Symptoms High current: The fan speed is High current: The fan rotation
in control fixed to the minimum value. direction is fixed to the normal
system when Low current: The fan speed is direction.
trouble occurs fixed to the maximum value. Low current: The fan rotation
direction is fixed to the normal
direction.
in machine
operation
when trouble
occurs
Fault Code
Evaluation by MC: Fan Sp Cont P/S 2 O/P, Fan Sp MC: Fan Dir Cont P/S 1 O/P, Fan
Monitoring Cont P/S 2 O/P FB Dir Cont P/S 1 O/P FB
Evaluation - -
by using Test
Harness
Note - -
of Control
(Operational
Principle
Section in
T/M)
T5-6-17
Parts 4-Spool Solenoid Valve Unit (SI) 4-Spool Solenoid Valve Unit (SG)
Item
Function This valve temporally increase This valve shifts selector valve of
main relief valve relief pressure. arm 2 flow rate control valve.
Symptoms High current: Pressure increases High current: As arm 2 flow rate
in control constantly. control valve (selector valve) is
system when Low current: Pressure does not restricted constantly, the arm
trouble occurs increase constantly. speed becomes slow.
Low current: As arm 2 flow rate
control valve (selector valve) is
opened constantly, operability
of arm combined operation
becomes worse.
in machine
operation
when trouble
occurs
Fault Code
Evaluation by MC: Main Relief Boost Press MC: Arm 2 Flw Cont P/S Output,
Monitoring Output, Main Relief Boost Press Arm 2 Flw Cont P/S O/P FB
O/P FB
Evaluation Install light harness (ST 7226). Install light harness (ST 7226).
by using Test Check output signals from MC Check output signals from MC
Harness and wire harness condition. and wire harness condition.
Note - -
of Control
(Operational
Principle
Section in
T/M)
T5-6-18
Parts 4-Spool Solenoid Valve Unit (SC) 2-Spool Solenoid Valve Unit (SC) 2-Spool Solenoid Valve Unit (SI)
Item
Function This valve decreases angle of This valve shifts boom overload This valve shifts swing flow rate
travel motor to the minimum and relief valve. control valve.
increases travel speed.
Symptoms High current: Machine is kept to High current: Shifts boom High current: Shifts swing flow
in control travel at fast speed. overload relief selector valve rate control valve constantly.
system when Low current: Machine is kept to constantly. Machine cannot raise Swing speed becomes slow.
trouble occurs travel at slow speed. the track off the ground. Low current: As swing flow rate
Low current: Since boom control valve does not shift,
overload relief selector does not boom raise speed is slow when
shift, Machine may be able to performing combined operation
raise the track off the ground. of swing and boom raise.
in machine
operation
when trouble
occurs
Evaluation by 11405 11989 11953
Fault Code
Evaluation by MC: Travel Mode C/V Output, MC: Boom Mode Cont P/S O/P, MC: Swing Flw Cont P/S Output,
Monitoring Travel Mode C/V Output FB Boom Mode Cont P/S O/P FB Swing Flw Cont P/S O/P FB
Evaluation Install light harness (ST 7226). Install light harness (ST 7226). Install light harness (ST 7226).
by using Test Check output signals from MC Check output signals from MC Check output signals from MC
Harness and wire harness condition. and wire harness condition. and wire harness condition.
Note - - -
of Control
(Operational
Principle
Section in
T/M)
T5-6-19
Parts 4-Spool Solenoid Valve Unit (SF) Main Relief Valve
Item
Function This valve shifts bypass shut-out This valve prevent pressure
valve. in pump 1 and 2 circuits from
exceeding the set pressure when
the control lever is operated.
Symptoms High current: Machine mistracks If valve is stuck in fully
in control to the right when performing closed position, hose of front
system when travel operation. attachment may be damaged.
trouble occurs Low current: Bucket speed is If valve is stuck in fully open
slow when performing bucket position, power is weak when
single operation. performing digging and climbing
operation.
in machine
operation
when trouble
occurs
Evaluation by 11408 -
Fault Code
Evaluation by Bypass Cut Cout P/S, Bypass Cut -
Monitoring cout P/S FB
Evaluation Install light harness (ST 7226). -
by using Test Check output signals from MC
Harness and wire harness condition.
Note - -
of Control
(Operational
Principle
Section in
T/M)
T5-6-20
Parts Overload Relief Valve Boom Anti-Drift Valve Arm Anti-Drift Valve (Rod Side)
Item
Function This valve prevents actuator This valve forcibly opens the This valve forcibly opens check
circuit pressure generated by check valve in boom lower return valve in arm roll-in return circuit
external force from exceeding circuit and lowers boom, only and rolls arm in only when
the set pressure with the control when performing boom lower performing arm roll-in operation.
lever set in neutral. operation. The valve prevents The valve prevents arm from
boom from drifting due to oil drifting due to oil leaks in control
leaks in control valve. valve.
Symptoms If valve is stuck in fully If check valve is kept closed, If check valve is kept closed, arm
in control closed position, hose of front boom does not lower smoothly. roll-in speed becomes slow.
system when attachment may be damaged by If check valve is kept open, If check valve is kept open, front
trouble occurs external force. machine cannot be raised off the attachment drift increases due to
If valve is stuck in fully open ground. oil leaks in control valve.
position, power is weak when
performing digging operation.
in machine
operation
when trouble
occurs
Evaluation by - - -
Fault Code
Evaluation by - - -
Monitoring
Evaluation - - -
by using Test
Harness
Note - - -
of Control
(Operational
Principle
Section in
T/M)
T5-6-21
Parts Flow Combiner Valve
Item
Function This valve supplies pressure oil to
both right and left travel spools
from pump 1 when performing
combined operation of travel and
front attachment/swing.
Symptoms If valve is stuck in fully closed
in control position, machine mistracks
system when to the left when performing
trouble occurs combined operation of travel and
If valve is stuck in fully open
position, machine mistracks to
the right when performing travel
single operation.
in machine
operation
when trouble
occurs
Evaluation by -
Fault Code
Evaluation by -
Monitoring
Evaluation -
by using Test
Harness
Note -
Descriptions T3-3
of Control
(Operational
Principle
Section in
T/M)
T5-6-22
Parts Arm Regenerative Valve Bucket Regenerative Valve Bucket Regeneration Cut Valve
Item
Function This valve supplies returning This valve supplies returning oilThis valve decreases pressure
oil from arm cylinder rod side from bucket cylinder rod side in bucket cylinder rod side
to bottom side and prevents to bottom side and prevents and improves digging force
cylinder hesitation. cylinder hesitation. when performing bucket roll-in
operation at heavy load.
Symptoms If valve is kept closed, arm If check valve is kept closed, If valve is stuck in fully closed
in control regeneration is not done and arm bucket digging speed becomes position, power is weak when
system when roll-in speed becomes slow. slow, or bucket cylinder performing bucket digging
trouble occurs If valve is kept open, oil from hesitation occurs. operation.
pump 2 flow back through arm If check valve is kept open, power If valve is stuck in fully open
2 spool, and arm roll-in speed is weak. position, bucket digging speed
becomes slow. becomes slow.
in machine
operation
when trouble
occurs
Evaluation by - - -
Fault Code
Evaluation by - - -
Monitoring
Evaluation - - -
by using Test
Harness
Note - - -
of Control
(Operational
Principle
Section in
T/M)
T5-6-23
Parts Arm 1 Flow Rate Control Valve Arm 2 Flow Rate Control Valve Swing Flow Rate Control Valve
Item
Function This valve is shifted by swing pilot This valve is shifted by pilot This valve is shifted by pilot
pressure. The valve restricts arm pressure from 4-spool solenoid pressure from 2-spool solenoid
1 circuit and secures swing speed valve unit (SG). The valve valve unit (SI). The valve restricts
when performing combined restricts arm 2 circuit and keepsswig circuit and secures boom
operation of swing and arm roll- bucket speed when performing or arm speed when performing
in. combined operation of arm roll- combined operation of swing
in and bucket. and boom raise or swing and arm
roll-out.
Symptoms If poppet valve or selector valve is If poppet valve or selector valve is If poppet valve or selector valve
in control stuck in fully closed position, arm stuck in fully closed position, arm is stuck in fully closed position,
system when roll-in speed becomes slow. roll-in speed becomes slow. swing speed becomes slow.
trouble occurs If poppet valve or selector valve If poppet valve or selector valve If poppet valve or selector valve
is stuck in fully open position, is stuck in fully open position, is stuck in fully closed position,
swing speed becomes slow when bucket roll-in speed becomes boom raise or arm roll-out speed
performing combined operation slow when performing combined becomes slow when performing
of swing and arm roll-in. operation of arm roll-in and combined operation of swing
bucket roll-in. and boom raise or swing and arm
roll-out.
in machine
operation
when trouble
occurs
Evaluation by - - -
Fault Code
Evaluation by - - -
Monitoring
Evaluation - - -
by using Test
Harness
Note - - -
of Control
(Operational
Principle
Section in
T/M)
T5-6-24
Parts Boom Flow Rate Control Valve Auxiliary Flow Combiner Valve Bypass Shut-Out Valve
(Option)
Item
Function This valve is shifted by boom This valve is shifted by pilot This valve is shifted by pilot
lower pilot pressure. It restricts pressure from auxiliary flow pressure from 4-spool solenoid
boom 1 circuit to prioritize other combiner solenoid valve (option). valve unit (SF) and increases
actuators. Supplies pressure oil from pump pressure of pump 2 circuit.
to auxiliary spool.
Symptoms If poppet valve or selector valve If valve is stuck in fully closed If valve is stuck in fully closed
in control is stuck in fully closed position, position, attachment speed does position, main relief valve (P2)
system when boom lower speed becomes not increase when performing continues to be relieved with all
trouble occurs fast when performing combined combined operation of control levers set in neutral.
operation. attachment.
If poppet valve or selector valve If valve is stuck in fully open
is stuck in fully open position, the position, travel speed becomes
track can not be raised off the slow when performing combined
ground. operation of attachment and
travel.
in machine
operation
when trouble
occurs
Evaluation by - - -
Fault Code
Evaluation by - - -
Monitoring
Evaluation - - -
by using Test
Harness
Note - - -
of Control
(Operational
Principle
Section in
T/M)
T5-6-25
Parts Boom Lower Meter-In Cut Valve Travel Motor Displacement Angle Pump 1 Flow Rate Control Valve
Control Valve
Item
Function This valve is shifted by returning This valve is shifted by pilot This valve supplies flow rate
oil from boom cylinder bottom pressure from 5-spool solenoid control pressure Pi according to
side. The valve lowers boom valve unit (SC). The valve shifts lever stroke to pump 1 regulator
due to own weight by the travel speed. when operating boom, arm,
boom regenerative circuit bucket , travel (right).
when performing boom lower
operation above ground, and
gives priority to operate other
actuators. When machine is
raised off the ground, the valve
gives priority to operate boom
and increses the force to raise the
machine.
Symptoms If valve is stuck in fully closed If valve is stuck in fully closed If valve is stuck in fully closed
in control position, boom lower speed position, machine is kept to travel position, pump 1 displacement
system when becomes fast when performing at slow speed. angle is held at minimum
trouble occurs combined operation. If valve is stuck in fully open when operating control lever.
If valve is stuck in fully open position, machine travels at fast Travel (right) is not operated
position, machine cannot be speed with travel mode switch when performing travel single
raised off ground. set in slow speed position. operation. Bucket speed
becomes extremely slow.
position, pump 1 displacement
angle is held at maximum with
control lever in neutral. Machine
mistracks to the left when travel
control lever is operated at half
stroke. Pump 1 control pressure
sensor detects maximum
pressure.
in machine
operation
when trouble
occurs
Evaluation by - - -
Fault Code
Evaluation by - - -
Monitoring
Evaluation - - -
by using Test
Harness
Note - - -
of Control
(Operational
Principle
Section in
T/M)
T5-6-26
Parts Pump 2 Flow Rate Control Valve Arm Flow Rate Control Valve Swing Parking Brake Release
Control Spool Spool
Item
Function This valve supplies flow rate This valve is shifted by arm roll-in This spool is shifted by pilot
control pressure according to pilot pressure. The valve supplies pressure of boom, arm, bucket or
pilot pressure to pressure sensor swing pilot pressure to arm 1 swing. The spool supplies release
when operating boom, arm, flow rate control valve in control pressure to swing parking brake.
swing and travel (left). valve.
Symptoms If valve is stuck in fully closed If valve is stuck in fully closed If spool is stuck in fully closed
in control position, pump 2 displacement position, swing speed is slow position, swing parking brake is
system when angle is held at minimum when performing combined kept applied. (Dragging is felt.)
trouble occurs when operating control lever. operation of swing and arm roll- Even if control lever is operated
Travel (left) is not operated in. at auto-idle control, engine speed
when performing travel single If valve is stuck in fully open does not increase as pressure
operation. position, swing speed is slow sensors (boom, arm, and bucket)
If valve is stuck in fully open when performing combined are always OFF.
position, pump 2 displacement operation of swing and arm roll- If spool is stuck in fully open
angle is held at maximum with out position, swing parking brake is
control lever in neutral. Machine kept released. (Machine vibrates
mistracks to the right when travel when traveling.) Even if control
control lever is operated at half lever is set to neutral with auto-
stroke. Pump 2 control pressure idle switch ON, engine speed
sensor detects maximum does not decrease as pressure
pressure. sensors (boom, arm, and bucket)
are always ON.
in machine
operation
when trouble
occurs
Evaluation by - - -
Fault Code
Evaluation by - - -
Monitoring
Evaluation - - -
by using Test
Harness
Note - - -
of Control
(Operational
Principle
Section in
T/M)
T5-6-27
Parts Flow Combiner Valve Control

Spool
Item
Function This spool is shifted by travel
(right) pilot pressure. The spool
supplies selection pressure to
flow combiner valve in control
valve.
Symptoms If valve is stuck in fully closed
in control position, machine mistracks
system when to the left when performing
trouble occurs combined operation of travel and
front attachment/swing. Travel
(left) speed becomes slow.
position, flow combiner valve
is shifted when performing
combined operation of travel and
in machine
operation
when trouble
occurs
Evaluation by -
Fault Code
Evaluation by -
Monitoring
Evaluation -
by using Test
Harness
Note -
Descriptions T3-6
of Control
(Operational
Principle
Section in
T/M)
T5-6-28
Correlation Between Trouble Symptoms and

Part Failures
This table indicates the relationship between machine
troubles and parts contributing to the cause of the
trouble if failed.
The trouble symptoms in this table are described based
on the conditions that other operations are normal and
only one particular trouble symptom occures. In case
more than one trouble occurs at the same time, find
out all faulty components while checking all suspected
components in each trouble symptom.
The marks / in this table indicate the influence to

trouble symptom.
: Related, required to check
: Related. However, in case this component fails, fault
code is displayed, or other trouble symptom will be more
noticeable. Thus, this component will not be the direct
cause of the trouble concerned.
T5-6-29
Engine System Troubleshooting

Trouble Symptom E-1 E-2 E-3
Starter does not rotate. Even if starter rotates, Even if power mode
engine does not start. switch is operated, power
Parts mode is not shifted.
MC 
ECM  
Monitor Controller 
Monitor 
Key Switch  
Engine Control Dial
Auto-Idle Switch
Power Mode Switch 
Travel Mode Switch
Pilot Shut-Off Relay 
Starter Cut Relay 
Security Relay 
Auto Shut-Down Relay
ACC Cut Relay
Key Switch ON Cut Relay  
ECM Main Relay  
Engine Stop Switch  
Fuse Box 1 (#8, #17) (#17)
Pilot Shut-Off Switch 
MPDr. 
Battery 
Starter Relay 1 
Battery Relay 
Engine Unit 
Starter 
Overheat Switch
Coolant Temperature Sensor
Pump 1 Delivery Pressure Sensor
Pump 1 Control Pressure Sensor
Pressure Sensor (Boom Raise)
Pressure Sensor (Boom Lower)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Arm Roll-Out)
Pressure Sensor (Bucket Roll-In)
Pressure Sensor (Bucket Roll-Out)
Pressure Sensor (Swing)
Pressure Sensor (Travel)
Pressure Sensor (4-spool side)
Pressure Sensor (Attachment) (OP)
Remark
T5-6-30

Trouble Symptom E-4 E-5
ECO mode is faulty. Travel HP mode is faulty.
Parts
MC  
ECM  
Monitor Controller
Monitor
Key Switch
Engine Control Dial  
Auto-Idle Switch
Power Mode Switch (ECO)
Travel Mode Switch
Pilot Shut-Off Relay
Starter Cut Relay
Security Relay
Auto Shut-Down Relay
ACC Cut Relay
Key Switch ON Cut Relay
ECM Main Relay
Engine Stop Switch
Fuse Box 1
Pilot Shut-Off Switch
MPDr.
Battery
Starter Relay 1
Battery Relay
Engine Unit
Starter
Overheat Switch
Pump 1 Delivery Pressure Sensor  
Pump 1 Control Pressure Sensor 
Pressure Sensor (Travel) 
Pressure Sensor (Attachment) (OP)
Remark
T5-6-31
Trouble Symptom E-6 E-7

Auto-idle system is faulty. Auto shut-down is not
activated
Parts
MC  
ECM  
Monitor 
Key Switch 
Engine Control Dial  
Auto-Idle Switch 
Power Mode Switch 
Travel Mode Switch
Starter Cut Relay
Security Relay
Auto Shut-Down Relay 
ACC Cut Relay 
Key Switch ON Cut Relay 
ECM Main Relay 
Engine Stop Switch
Fuse Box 1 (#17, #18)
Pilot Shut-Off Switch 
MPDr. 
Battery 
Starter Relay 1
Battery Relay 
Engine Unit
Starter
Overheat Switch 
Coolant Temperature Sensor 
Pressure Sensor (Boom Raise) 
Pressure Sensor (Boom Lower) 
Pressure Sensor (Arm Roll-In) 
Pressure Sensor (Arm Roll-Out) 
Pressure Sensor (Bucket Roll-In) 
Pressure Sensor (Bucket Roll-Out) 
Pressure Sensor (Swing) 
Pressure Sensor (Attachment) (OP) 
Remark
T5-6-32
All Actuator System Troubleshooting

Trouble Symptom A-1 A-2 A-3
All actuators do not work. All actuator speed is slow. Travel (right) operation speed
is slow when performing travel
single operation. Bucket single
Parts operation speed is slow.
MC 
ECM
Key Switch 
Engine Control Dial
Pilot Shut-Off Relay 
Security Horn Relay 
Starter Cut Relay 
Security Relay 
Key Switch ON Cut Relay 
Fuse Box 1  (#4)
Pilot Shut-Off Switch 
Pilot Shut-Off Solenoid Valve  
Hydraulic Oil Temperature Sensor
Battery 
Starter Relay 1 
Main Pump 1  
Main Pump 2 
Pilot Pump 
Pump 1 Regulator  
Pump 2 Regulator 
Pump 1 Control Solenoid Valve  
Pump 2 Control Solenoid Valve 
Spool
Pilot Valve 
Pump 1 Flow Rate Control Valve  
Pump 2 Flow Rate Control Valve 
Shuttle Valve (Signal Control Valve) 
Pilot Filter 
Pilot Relief Valve 
Remark
T5-6-33
A-4 A-5
Trouble Symptom
Travel (left) operation speed is slow Actuator does not stop even if
when performing travel single control lever is set to neutral.
Parts
operation.
MC
ECM
Monitor Controller
Key Switch
Engine Control Dial
Security Horn Relay
Starter Cut Relay
Security Relay
Fuse Box 1
Pilot Shut-Off Solenoid Valve
Hydraulic Oil Temperature Sensor
Battery
Starter Relay 1
Main Pump 1
Main Pump 2 
Pilot Pump
Pump 1 Regulator
Pump 2 Regulator 
Pump 1 Control Solenoid Valve
Spool 
Pilot Valve 
Pump 1 Flow Rate Control Valve
Pump 2 Flow Rate Control Valve 
Shuttle Valve (Signal Control Valve)
Pilot Filter
Pilot Relief Valve
Remark
T5-6-34
Trouble Symptom A-6 A-7

Fan rotation speed does not Fan rotation reverse does not
Parts change. change.
MC 
ECM 
Monitor Controller
Monitor
Key Switch
Engine Control Dial
Security Relay
Fuse Box 1
Hydraulic Oil Temperature Sensor 
Battery
Air Conditioner
Reverse Rotation Control Solenoid Valve 
Main Pump 1
Main Pump 2
Pilot Pump
Fan Pump 
Pump 1 Regulator
Pump 2 Regulator
Fan Pump Regulator 
Fan Reverse Switch 
Fan Motor 
Fan Pump Control Solenoid Valve 
Bypass Shut-Out Valve
Spool
Pilot Valve
4-Spool Solenoid Valve Unit (SF)
Pilot Filter
Pilot Relief Valve
Remark
T5-6-35
Front Attachment System Troubleshooting

Trouble Symptom F-1 F-2 F-3
All front attachment actuator Even if power digging switch is pushed, power Some cylinders are not
power is weak. does not increase. Boom raise power is weak operated or speeds are slow.
Parts when performing digging operation.
MC  
Power Mode Switch
Power Digging Switch 
Main Pump 1  
Main Pump 2  
Pilot Pump   
Pump 1 Regulator
Pump 2 Regulator
Main Relief Valve  
Boom Anti-Drift Valve 
Arm Anti-Drift Valve (Rod Side) 
Arm Regenerative Valve
Bucket Regenerative Valve
Bucket Regeneration Cut Valve
Arm 1 Flow Rate Control Valve
Boom Lower Meter-In Cut Valve
Boom Overload Relief Selection Valve
Load Check Valve 
Spool 
Pressure Sensor (Boom Raise) 
Pressure Sensor (Arm Roll-In)  
Pressure Sensor (Arm Roll-Out) 
Cylinder 
Pilot Valve 
Shockless Valve (Signal Control Valve) (Only Boom)
Pressure Sensor (4-Spool Side)
Swing Flow Rate Control Valve
4-Spool Solenoid Valve Unit (SG)
4-Spool Solenoid Valve Unit (SI)  
4-Spool Solenoid Valve Unit (SC)
2-Spool Solenoid Valve Unit (SI)
Pilot Filter   
Pilot Relief Valve   
Remark
T5-6-36
F-4 F-5 F-6

Trouble Symptom Bucket roll-in speed is slow and Even if the boom mode selector Boom raise speed is slow when
power is weak when performing switch is pushed, machine is raised performing combined operation of
digging operation. off the ground. swing and boom raise. Arm roll-out
speed is slow when performing
Parts
combined operation of swing and
arm roll-out.
MC   
Power Mode Switch  
Power Digging Switch
Boom Mode Selector Switch 
Main Pump 1 
Main Pump 2
Pilot Pump  
Pump 1 Regulator  
Pump 2 Regulator 
Pump 1 Delivery Pressure Sensor 
Main Relief Valve 
Boom Anti-Drift Valve
Arm Anti-Drift Valve (Rod Side)
Arm Anti-Drift Valve (Bottom Side)
Bucket Regenerative Valve 
Bucket Regeneration Cut Valve 
Boom Overload Relief Selection Valve 
Load Check Valve
Spool 
Pressure Sensor (Boom Raise)  
Pressure Sensor (Arm Roll-In)  
Pressure Sensor (Arm Roll-Out)  
Pressure Sensor (Bucket Roll-In)  
Cylinder
Pilot Valve
Shockless Valve (Signal Control Valve)
Pressure Sensor (Swing)  
Swing Flow Rate Control Valve 
4-Spool Solenoid Valve Unit (SD)
2-Spool Solenoid Valve Unit (SC) 
2-Spool Solenoid Valve Unit (SI) 
Pilot Filter 
Pilot Relief Valve 
Remark
T5-6-37
Trouble Symptom F-7 F-8 F-9

When performing combined operation, When performing combined When boom raise or arm roll-out
arm does not start to move smoothly. operation, boom does not start is operated, boom or arm starts to
Arm starts to move slightly slow when to move smoothly. Boom starts to move after moving slightly down.
performing arm single operation. These move slightly slow during boom
troubles often occur when temperature lower single operation.
Parts is low.
MC
Power Mode Switch
Main Pump 1
Main Pump 2
Pilot Pump
Pump 1 Regulator
Pump 2 Regulator
Main Relief Valve
Boom Anti-Drift Valve  
Arm Anti-Drift Valve (Rod Side)  
Arm Regenerative Valve 
Boom Lower Meter-In Cut Valve 
Load Check Valve 
Spool
Cylinder
Pilot Valve
Pilot Filter
Pilot Relief Valve
Remark
T5-6-38
F-11 F-12
Trouble Symptom F-10
Front attachment drifts remarkably. Boom lower speed above ground Arm speed is slow when performing
is faster than other actuators when arm level crowding operation. Arm
performing combined operation. power is weak when performing
Machine cannot be raised off the digging operation.
Parts
ground.
MC 
Power Mode Switch
Main Pump 1  
Main Pump 2  
Pilot Pump 
Pump 1 Regulator
Pump 2 Regulator
Main Relief Valve
Boom Anti-Drift Valve 
Arm Anti-Drift Valve (Rod Side) 
Arm Regenerative Cut Valve 
Bypass Shut-Out Valve 
Boom Lower Meter-In Cut Valve 
Load Check Valve 
Spool  
Cylinder   
Pilot Valve  
Pilot Filter   
Pilot Relief Valve   
Remark
T5-6-39
Trouble Symptom F-13

Bucket roll-in speed is slow when
performing combined operation of arm
Parts roll-in and bucket roll-in.
MC 
Power Mode Switch
Main Pump 1 
Main Pump 2 
Pilot Pump
Pump 1 Regulator
Pump 2 Regulator
Main Relief Valve
Boom Anti-Drift Valve
Arm Anti-Drift Valve (Rod Side)
Arm Regenerative Cut Valve
Arm 2 Flow Rate Control Valve 
Load Check Valve
Spool 
Cylinder
Pilot Valve
4-Spool Solenoid Valve Unit (SG) 
Pilot Filter 
Remark
T5-6-40
Swing System Troubleshooting
S-1 S-2 S-3

Trouble Symptom Swing is slow or unmoving. When starting swing Swing speed is slow when
operation, swing speed is performing combined
Parts fast. operation of swing and
arm roll-in.
MC 
Monitor Controller
Engine Control Dial
Pilot Shut-Off Solenoid Valve 
Main Pump 1
Main Pump 2  
Pilot Pump 
Pump 1 Regulator
Pump 2 Regulator  
Swing Motor  
Swing Parking Brake 
Pilot Valve   
Swing Parking Brake Release

Spool
Shuttle Valve (Signal Control

Valve)
Arm Flow Rate Control Valve

(Signal Control Valve)
Arm 1 Flow Rate Control Valve 
Pressure Sensor (Swing)  
2-Spool Solenoid Valve Unit (SI) 
Pilot Filter 
Remark
T5-6-41
Travel System Troubleshooting
Trouble Symptom T-1 T-2 T-3

Both of right and left One side travel is not Machine mistracks when
travels are not operated or operated or travel speed is performing combined
travel speed is slow. slow. Machine mistracks. operation of travel and
Parts front attachment.
MC
Monitor Controller
Monitor
Engine Control Dial
Travel Mode Switch
Main Pump 1  
Main Pump 2  
Pilot Pump  
Pump 1 Regulator
Pump 2 Regulator
Flow Combiner Valve 
Auxiliary Flow Combiner Valve
Spool  
Center Joint  
Travel Device  
Pilot Valve  
Flow Combiner Valve Control

Spool
 
Valve)
4-Spool Solenoid Valve Unit (SC) 
Pilot Filter 
Pilot Relief Valve  
Remark
T5-6-42
Trouble Symptom T-4

Fast travel is can not be
selected. Travel mode does
not change from slow
speed mode to fast speed
Parts mode.
MC 
Monitor Controller
Monitor
Engine Control Dial
Travel Mode Switch  (Fast Speed)
MPDr.
Main Pump 1 
Main Pump 2 
Pilot Pump 
Pump 1 Regulator
Pump 2 Regulator
Flow Combiner Valve
Auxiliary Flow Combiner Valve
Spool
Center Joint
Travel Device
Pilot Valve
Flow Combiner Valve Control
Spool
Valve)
4-Spool Solenoid Valve Unit (SC) 
Pilot Filter 
Remark
T5-6-43
Other System Troubleshooting
Trouble Symptom O-1 O-2 O-3

Work light does not light. Boom light does not light. Cab light does not light.
Parts
MC
Monitor Controller  
Wiper/Light Controller   
Monitor  
Work Light Switch  
Wiper/Washer Switch
Wiper Relay
Work Light Relay 1 
Work Light Relay 2 
Washer Relay
Wiper Motor
Fuse Box 1  (#1, #17)  (#1, #17)  (#9)
MPDr.
Door Open/Close Switch 
Cab Light Switch 
Washer Motor
Work Light 
Boom Light 
Cab Light 
Remark
T5-6-44
Trouble Symptom O-4 O-5

Parts Wiper does not operate. Washer does not operate.
MC
Wiper/Light Controller  
Monitor 
Work Light Switch
Wiper/Washer Switch  
Wiper Relay 
Work Light Relay 1
Work Light Relay 2
Washer Relay 
Wiper Motor 
Fuse Box 1  (#2, #17)  (#2, #17)
MPDr.
Door Open/Close Switch
Cab Light Switch
Washer Motor 
Work Light
Boom Light
Remark
T5-6-45
Trouble Symptom O-6

Parts Auto lubrication is faulty.
MC 
Auto-Lubrication Switch 
Auto-Lubrication Relay 
Distribution Valve 
Grease Pump 
Remark
T5-6-46

E-1 Starter does not rotate.
Preparation
 Check that the pilot shut-off lever is in the LOCK  In case the radio with the key switch set in the ACC
position. position and the horn with the key switch set in
 This trouble is not related to the electronic control the OFF position are operated normally, the wire
system such as MC. harness between battery and key switch terminal B
 Check the wiring connections first. is considered normal.
Procedure Inspection Method Condition Evaluation Cause

1 Measure battery voltage - The measured Faulty battery
and electrolyte density. values are out of the
specification.
(Specification: Voltage:
24 V or more, Electrolyte
density: 1.26 or more)
2 Switch the starter cut relay Set the key switch to The starter rotates. Faulty starter cut relay
with other general relay. START after switching
relays.
3 Measure voltage at starter Key Switch: START 0V Open circuit in wire harness
cut relay harness end #1 between key switch and
and #3. starter cut relay
4 Measure voltage at starter Key Switch: START 0V Open circuit in wire harness
relay 1 harness end between starter cut relay and
terminal S. starter relay 1
5 Measure voltage at starter Key Switch: ON 0V Short circuit in wire harness
cut relay harness end #2. between starter cut relay and
engine stop switch
6 Measure voltage at battery Key Switch: ON 0V Faulty battery relay
relay terminal A.
7 Measure voltage at starter Key Switch: START 0V Faulty starter relay 1
terminal S.
8 Check continuity between Key Switch: START ∞Ω Faulty key switch
key switch #1 and #6.
9 - - The check mentioned Faulty starter
above is normal.
 Starter Cut Relay  Starter Relay
b
TJAE-05-06-001
TJAE-05-06-002
b- Terminals
 Key Switch  Starter
TJAE-05-06-004
TJAE-05-06-003
T5-6-47
E-2 Even if starter rotates, engine does not start.
Preparation
 Check that the engine stop switch is in the OFF
position.
 Check that fuses #8 and #17 are normal.

1 Switch the ECM main relay Set the key switch to The engine starts. Faulty ECM main relay
with other general relay. START after switching
relays.
2 Monitor Engine Stop Engine Stop Switch: ON is displayed. Faulty engine stop switch
Switch. OFF
3 - - The check mentioned Faulty ECM or engine unit
above is normal. (Refer to Engine Manual)
T5-6-48
E-3 Even if power mode switch is operated, power

mode is not shifted.
Preparation

1 Monitor Power Mode Power Mode Switch: OFF is displayed. Faulty power mode switch or
Switch. ON open circuit in wire harness
between power mode switch
and MC
2 - - The check mentioned Faulty MC
above is normal.
T5-6-49
E-4 ECO mode is faulty.
Specification Remark
(min−1)
Fast Idle Speed 1730±50
(ECO mode)
Preparation
 In case other trouble symptoms occur, perform  Pump 1, 2 control pressure sensors, pump 1, 2
troubleshooting of these troubles first. delivery pressure sensors are also related to the ECO
 The sensors detect the conditions necessary to mode control. However, if these sensors fail, other
operate ECO mode. Therefore, if any of these sensors operating functions will be also affected.
fails, ECO mode becomes ineffective.  Refer to SYSTEM/Control System/ECO Mode Control.

1 Check continuity between Power Mode Switch: ∞Ω Open circuit in wire harness
MC harness end #F9 and ON between power mode switch
body. and MC
2 Monitor Power Mode Key Switch: ON OFF is displayed. Faulty power mode switch
Switch and operate the
power mode switch.
above is normal.
MC-F Connector
TJBG-05-05-007
T5-6-50
E-5 Travel HP mode is faulty.
(min-1)
Fast Idle 2100 When relieving
(Travel HP Mode) travel
 Even if the engine control dial is set to 1750 min-1 or

higher when performing travel single operation, travel
PWR mode is inoperable.
Preparation
 The sensors detect the conditions necessary to
operate travel HP mode. Therefore, if any of these  Refer to SYSTEM/Control System/Travel HP Mode
sensors fails, travel HP mode becomes ineffective. Control.
 Pressure sensor (travel) and pump 1 and 2 delivery  Check the wiring connections first.
pressure sensors are also engaged in the HP mode
control. However, if these sensors fails, other
operating functions will be also affected.
Procedure Inspection Method Condition Evaluation: Cause

1 Engine Control Dial Engine speed: Engine speed: Less Faulty engine control dial.
1750 min-1 or than 1750 min-1
higher
above is normal.
 Even if the engine control dial is not set 1750 min-1 or

higher, the travel speed becomes fast.
Procedure Inspection Method Condition Evaluation: Cause

1 Monitor the engine control Engine speed: Engine speed: 1750 Short circuit in wire harness
dial Less than 1750 min-1 or higher between MC and engine control
min-1 dial.
above is normal.
T5-6-51
E-6 Auto-idle system is faulty.
(min−1)
Auto-Idle Speed 1380±50
 Even if the control lever is set to neutral, auto-idle

system is not operated.
Preparation
 In case other trouble symptoms occur, perform  Refer to SYSTEM/Control System/Auto-Idle Control.
troubleshooting of these troubles first.  Check the wiring connections first.
 Failure in pressure sensors (boom raise, boom lower,
arm roll-in, arm roll-out, bucket roll-in, bucket
roll-out, swing, travel, 4-spool side, 5-spool side,
attachment (option)) may related to malfunction of
the auto-idle control. However, if these sensors fail,
other operating functions will be also affected.

1 Check continuity between Auto-Idle Switch: ON ∞ Ω Open circuit in wire harness
MC harness end #F7 and between auto-idle switch and
body. MC
2 Monitor Auto-Idle Switch Key Switch: ON OFF is displayed. Faulty auto-idle switch
and turn ON the auto-idle
switch.
above is normal.
 Even if the auto-idle switch is in the OFF position, auto-

idle system is operated.
Preparation

1 Check continuity between Auto-Idle Switch: OFF 0 Ω Short circuit in wire harness
MC harness end #F7 and between auto-idle switch and
body. MC
2 Monitor Auto-Idle Switch Key Switch: ON ON is displayed. Faulty auto-idle switch
and turn OFF the auto-idle
switch.
above is normal.
MC-F Connector
TJBG-05-05-007
T5-6-52
E-7 Auto shut-down is not activated.
Preparation
 Refer to SYSTEM/Control System and SYSTEM/
Electric System/Auto Shut-Down Control.

1 Switch auto shut-down - The symptom Faulty auto shut-down relay
relay with other general disappears.
relay.
2 Switch key switch ON cut - The symptom Faulty key switch ON cut relay
relay with other general disappears.
relay.
3 Switch ACC cut relay with - The symptom Faulty ACC cut relay
other general relay. disappears.
4 Monitor Pilot Control Shut- Pilot Shut-Off Lever: ON is displayed. Faulty pilot shut-off switch
OFF Lever Switch. UNLOCK Position
above is normal.
T5-6-53
All Actuator System Troubleshooting

A-1 All actuators do not work.
Preparation
 The pilot shut-off circuit may be faulty.  Refer to SYSTEM/Electric System.
 Even if the key switch is set to the START position  Check the wiring connections first.
with the pilot shut-off lever in the UNLOCK position,
the starter does not rotate.
 Even if the key switch is set to the START position
with the engine stop switch is in the ON position and
the pilot shut-off lever is in the UNLOCK position, the
starter rotates.

1 Monitor Pilot Control Shut- Pilot Shut-Off Lever: OFF is displayed. Faulty pilot shut-off switch
OFF Lever Switch. UNLOCK Position
2 Switch the pilot shut-off Pilot Shut-Off Lever: The symptom Faulty pilot shut-off relay
relay with other general UNLOCK Position disappears.
relay.
3 Switch the security relay Pilot Shut-Off Lever: The symptom Faulty security relay
with other general relay. UNLOCK Position disappears.
4 Measure resistance - 0/∞ Ω (Specification: Faulty pilot shut-off solenoid
between solenoid valves 49 Ω) valve
#1 and #2.
5 Measure voltage between Key Switch: ON 0V Open circuit in wire harness
pilot shut-off solenoid between pilot shut-off
valve harness end #1 and solenoid valve and battery
body. relay
pilot shut-off relay harness between pilot shut-off relay
end #1 and body. and battery relay
7 Check continuity between Connect pilot shut- ∞Ω Open circuit in wire harness
pilot shut-off relay harness off solenoid valve between pilot shut-off
end #3 and body. harness end terminal solenoid valve and pilot shut-
#2 to the body. off relay
8 Check continuity between Connect pilot shut- ∞Ω Open circuit in wire harness
security relay harness end off relay harness end between pilot shut-off relay
#4 and body. terminal #5 to the and security relay
body.
9 Check continuity between - ∞Ω Faulty ground in security
security relay harness end relay
#3 and body.
10 Check continuity between - 0Ω Short circuit in wire harness
security relay harness end between monitor controller
#2 and body. and security relay
11 - - The check mentioned Faulty monitor controller
above is normal.
T5-6-54
 Pilot Shut-Off Solenoid Valve  Security Relay
T1V1-05-04-003
 Pilot Shut-Off Relay

TDC1-05-06-001
TDC1-05-06-005
T5-6-55
A-2 All actuator speed is slow.
(MPa)
Primary Pilot 3.9+1.0-0 Engine Control
Pressure Dial: Fast Idle
Preparation
 Decrease of pump 1, 2 flow rate due to some reasons
or faulty pilot system (A-1) may cause this trouble.
 Even if speed is satisfactory, in case power is weak,
refer to the troubleshooting for faulty main relief
valve (F-1).

1 Monitor Boom Raise Pilot - The measured Faulty pilot relief valve or
Pressure and relieve the values are out of the clogged pilot filter
boom raise circuit. specification.
(Specification: 3.4-4.0
MPa)
2 - - The check mentioned Faulty pump device
above is normal.
T5-6-56
A-3 Travel (right) operation speed is slow when

performing travel single operation. Bucket
single operation speed is slow. (All problems
occur at the same time.)
Preparation
 The pump 1 flow rate is minimized due to some
reasons. Travel (right) and bucket, which are driven
by pressure oil from pump 1, move very slowly.
 Refer to SYSTEM /Control System, Hydraulic System.

1 Monitor Pump 1 S/A Cont Operate travel (right) Pressure does not Stuck pump 1 control
Pressure. control lever. increase according to solenoid valve
control lever stroke.
2 - - The check mentioned Faulty pump 1 regulator
above is normal.
T5-6-57
A-4 Travel (left) operation speed is slow when

performing travel single operation.
Preparation
 The pump 2 flow rate is minimized due to some
reasons. Travel (left) which is driven by pressure oil
from pump 2, move very slowly.
 Refer to SYSTEM/Control System, Hydraulic System.

1 Monitor Pump 2 S/A Cont Operate travel (left) Pressure does not Stuck pump 2 control
Pressure. control lever. increase according to solenoid valve
2 - - The check mentioned Faulty pump 2 regulator
above is normal.
T5-6-58
A-5 Actuator does not stop even if control lever is

set to neutral.
Preparation
 Stuck spool in the pilot valve or stuck main spool in
the control valve is suspected.

1 Set the pilot shut-off lever - The actuator stops. Faulty pilot valve (stuck
to the LOCK position. spool)
2 - - The check mentioned Faulty control valve (stuck
above is normal. spool)
T5-6-59
A-6 Fan rotation speed does not change.
Preparation

1 Monitor Fan Sp Con P/S 1 Air conditioner Fan Speed Control P/S Faulty fan pump control
O/P FB. switch: ON 1 output FB does not solenoid valve or faulty MC
change according to the
engine control dial.
2 - - The check mentioned Faulty fan pump regulator
above is normal.
T5-6-60
A-7 Fan rotation reverse does not change.

Preparation
 Refer to SYS TEM/Control System/Oil Cooler Fan
Reverse Control.
 Refer to SYS TEM/Hydraulic System/Oil Cooler Fan
Reverse Control Circuit.

1 Monitor F/M Rotation Dir Fan Reverse Switch: OFF is displayed Faulty fan reverse switch
Cont Switch ON Open circuit in harness
between fan reverse switch
and MC
2 Monitor Fan Dir Cont P/S 1 Fan Reverse Switch: The reverse rotation Stuck reverse rotation control
O/P FB ON control solenoid valve solenoid valve
out put does not change
3 - - The check mentioned Faulty oil fan valve
above is normal
T5-6-61
Front Attachment System Troubleshooting

F-1 All front attachment actuator power is weak.
Main Relief Valve Specification (MPa) Remark

Set Pressure
Boom Raise, Arm, 31.9+2.0−0.5
Bucket (Relief
operation for
each)
Preparation
 If operating speeds are extremely slow, pump control
may be faulty (A-3, A-4). Faulty pilot system may also
cause this trouble.

1 Monitor Pump 1 Delivery When relieving arm The measured Faulty main relief valve
Pressure, and Pump 2 values are out of the (readjust)
Delivery Pressure. specification.
2 - - The check mentioned Find out cause of trouble
above is normal. by tracing other trouble
symptoms.
T5-6-62
F-2 Even if power digging switch is pushed, power

does not increase or boom raise power is
weak when performing digging operation.
Main Relief Valve Specification (MPa) Remark

Set Pressure
Power Digging 35.3+2.0−0.5
Preparation
 Refer to SYSTEM/Control System/Power Digging
Control and Auto-Power Lift Control.

1 Monitor Power Boost Power Digging OFF is displayed. Faulty power digging switch,
Switch. Switch: ON or open circuit in wire harness
between power digging
switch and MC
2 Monitor Pump 1 Delivery Relieve boom raise The measured Faulty main relief valve
Pressure, and Pump 2 circuit. values are out of the
Delivery Pressure. specification.
MPa)
above is normal.
T5-6-63
F-3 Some cylinders are not operated or speeds

are slow.
Overload Relief Specification Remark

Valve Set Pressure (MPa)
Boom, Arm, 36.3+1.0−0
Bucket
Boom Lower 11.8 Boom Mode
Selector Switch:
ON
Preparation
 When other actuators (travel and swing motors) are
operated normally, the pilot pump (primary pilot
pressure) is considered to be normal.

1 Monitor Boom Raise Pilot Fully operate boom The measured Faulty pilot valve or stuck
Pressure and Arm Roll-In raise and arm roll-in. values are out of the spool of shockless valve in
Pilot Pressure. specification. signal control valve (only
(Specification: 3.4-4.0 boom raise)
MPa)
2 Monitor Pump 1 S/A Cont Slowly operate the Pump displacement Faulty shuttle valve in signal
Pressure and Pump 2 S/A control lever. angle control pressure control valve
Cont Pressure. changes smoothly.
3 Switch overload relief - Symptom is reversed. Faulty overload relief valve
valves, of which the set
pressure are same.
4 - - The check mentioned Stuck control valve spool, or
above is normal. faulty cylinder (faulty seal kit)
T5-6-64
F-4 Bucket roll-in speed is slow and power is weak

when performing digging operation.
Preparation
 Refer to SYSTEM/Hydraulic System/Bucket
Regenerative Cut Circuit.

1 Disassemble and inspect - There is abnormality. Faulty bucket regeneration
the bucket regeneration cut valve
cut valve.
2 Disassemble and inspect - There is abnormality. Faulty bucket regenerative
the bucket regenerative valve
valve.
symptoms.
T5-6-65
F-5 Even if the boom mode selector switch is

pushed, machine is raised off the ground.
Preparation
 Refer to SYSTEM/Control System/Boom Mode
Selector Control

1 Monitor Boom Mode Boom Mode Selector OFF is displayed. Faulty boom mode selector
Switch. Switch: ON switch, or open circuit in wire
harness between boom mode
selector switch and MC
2 Disassemble and inspect - There is abnormality. Faulty boom overload relief
the boom overload relief selection valve
selection valve.
symptoms.
T5-6-66
F-6 Boom raise speed is slow when performing

combined operation of swing and boom raise.
Arm roll-out speed is slow when performing
combined operation of swing and arm roll-out
Preparation
 In case other trouble symptoms occur, perform
troubleshooting of these troubles first.
 Refer to SYSTEM/Hydraulic System/Swing Flow Rate
Control Circuit.

1 Disassemble and inspect - There is abnormality. Faulty digging swing flow
the swing flow rate control rate control valve
valve.
symptoms.
T5-6-67
F-7 When performing combined operation, arm

does not start to move smoothly. Arm starts
to move slightly slow when performing arm
single operation. These troubles often occur
when temperature is low.
Preparation
 Refer to COMPONENT OPERATION/Control Valve

1 Disassemble and inspect - There is abnormality. Faulty arm anti-drift valve
the arm anti-drift valve.
2 Disassemble and inspect - There is abnormality. Faulty arm regenerative valve
the arm regenerative valve.
symptoms.
T5-6-68
F-8 When performing combined operation, boom

does not start to move smoothly. Boom starts
to move slightly slow when performing boom
lower single operation.
Preparation
 Refer to COMPONENT OPERATION/Control Valve

1 Disassemble and inspect - There is abnormality. Faulty boom anti-drift valve
the boom anti-drift valve.
2 Disassemble and inspect - There is abnormality. Faulty boom lower meter-in
the boom lower meter-in cut valve
cut valve.
symptoms.
T5-6-69
F-9 When boom raise or arm roll-out is operated,

boom or arm starts to move after moving
slightly down.
When the load check valve is faulty:
Preparation
(B)
 When start to operate control lever, oil pressure
and flow rate from the pump is low. Therefore, if
the load check valve is faulty, the load on the boom (A)
cylinder is applied, the oil in the bottom side of the
boom cylinder flows back into the circuit through
the load check valve. Therefore, the boom cylinder is
temporarily retracted.
 As oil pressure and flow rate from the pump is
low, if oil leaks from bottom side (A) to rod side
(B) due to faulty boom cylinder piston or cylinder
tube, the boom cylinder is temporarily retracted
when performing the initial stage of operation. The
T105-07-04-012
cylinder becomes the lack of force. The cylinder drift
increases in this case.

1 Disassemble and inspect - There is abnormality. Faulty load check valve
the load check valve.
2 Disassemble and inspect - There is abnormality. Faulty anti-drift valve
the anti-drift valves (boom,
arm).
3 - - The check mentioned Faulty cylinder (seal kit)
above is normal.
T5-6-70
F-10 Front attachment drifts remarkably.
 Boom Cylinder Internal Leakage Check

1. With the bucket cylinder fully retracted and the arm
cylinder slightly extended from the fully retracted
position, lower the bucket tooth tips onto the
ground.
2. Disconnect the hoses from the boom cylinder rod
side. Drain oil from the hoses and cylinders. (Plug
the disconnected hose ends.)
3. Retract the arm cylinder and lift the bucket off the
ground. If oil flows out of the hose disconnected
piping ends and the boom cylinders are retracted
at this time, oil leaks in the boom cylinders. If no oil
flows out of the hose disconnected piping ends but T105-07-04-009
the boom cylinders are retracted, oil leaks in the
control valve.

1 Set the pilot shut-off lever - The symptom Faulty pilot valve
to the LOCK position. disappears.
2 Switch overload relief - The symptom Faulty overload relief valve
valves. disappears.
3 Disassemble and inspect - There is abnormality. Faulty anti-drift valve
the anti-drift valves (boom,
arm).
4 Disassemble and inspect - There is abnormality. Faulty emergency valve
the emergency valve.
5 Disassemble and inspect - There is abnormality. Faulty cylinder (seal kit)
the cylinder.
6 - - The check mentioned Scored control valve spool,
above is normal. broken spring, or loose spool
end
T5-6-71
F-11 Boom lower speed above ground is faster

than other actuators when performing
combined operation. Machine cannot be
raised off the ground.
Preparation
 The boom lower meter-in cut valve or boom flow
rate control valve may be faulty.
 Refer to SYSTEM/Hydraulic System and COMPONENT
OPERATION/Control Valve.
 In case boom lower single operation speed is slow,
also refer to F-8.
 In case machine cannot be raised off the ground, also
check boom mode selector control (F-5).

1 Disassemble and inspect - There is abnormality. Faulty boom lower meter-in
the boom lower meter-in cut valve
cut valve.
2 Disassemble and inspect - There is abnormality. Faulty bypass shut-out valve
the bypass shut-out valve.
symptoms.
T5-6-72
F-12 Arm speed is slow when performing arm level

crowding operation. Arm power is weak when
performing digging operation.
Preparation
 Refer to SYSTEM/Hydraulic System/Arm Regenerative
Cut Circuit.

1 Disassemble and inspect - There is abnormality. Faulty arm regenerative cut
the arm regenerative cut valve
valve.
symptoms.
T5-6-73
F-13 Bucket roll-in speed is slow when performing

combined operation of arm roll-in and bucket
roll-in.
Preparation
 Refer to SYSTEM/Control System/Arm 2 Flow
Rate Control.

1 Measure pressure at port Combined operation The measured Stuck spool in 4-spool
SG of 4-spool solenoid of arm roll-in and values are out of solenoid valve unit SG
valve unit. bucket roll-in the specification.
(Specification: approx.
4.0 MPa)
2 Disassemble and inspect - There is abnormality. Faulty arm 2 flow rate control
the arm 2 flow rate control valve
valve.
symptoms.
T5-6-74
Swing System Troubleshooting

S-1 Swing is slow or unmoving.
(sec/3 rev)
Swing Speed 18.0±1.5 The bucket
should be empty
Preparation
 Check whether the pilot system is faulty or the main
circuit is faulty.
 If other functions (front attachment and travel) are
operated normally, the pilot pump (primary pilot
pressure) and pump flow rate control are considered
to be normal. If the pilot system is faulty, the cause
of trouble may exist in the circuit downstream of the
pilot valve.

1 Monitor Swing Pilot Fully swing The measured Faulty pilot valve
Pressure. values are out of
the specification.
MPa)
2 Monitor Front ATT Pilot When relieving arm The measured Faulty swing parking brake
Pressure. values are out of release spool in signal control
the specification. valve
MPa)
3 Disassemble and inspect - There is abnormality. Faulty swing parking brake
the parking brake release release valve
valve in the swing motor.
4 Monitor Pump 2 Delivery When relieving swing The measured Faulty swing relief valve
the specification.
MPa)
5 Measure the swing motor With constant speed Refer to T4-5 Swing Faulty swing motor
drainage. Motor Drainage.
6 - - The check mentioned Faulty swing reduction gear
above is normal.
T5-6-75
S-2 When starting swing operation, swing speed

is fast.
Preparation
 Refer to SYSTEM/Control System/Swing High
Pressure Power Decrease Control.

1 Monitor Swing Pilot Combined operation The measured Faulty pilot valve
Pressure. of Fully swing and values are out of
boom lower. the specification.
Combined operation (Specification: 3.4-4.0
of Fully swing and MPa)
bucket.
2 Monitor Pump 1 Delivery When relieving The measured Faulty pump 1 regulator
Pressure. bucket. values are out of
the specification.
MPa)
3 Monitor Pump 2 Delivery When relieving The measured Faulty pump 2 regulator
Pressure. swing. values are out of
the specification.
MPa)
4 Measure pressure at port Combined operation The measured Stuck spool in 2-spool
SI of 2-spool solenoid valve of swing and arm values are out of solenoid valve unit (SI)
unit. roll-out. the specification.
MPa)
symptoms.
T5-6-76
S-3 Swing speed is slow when performing

combined operation of swing and arm roll-in.
Preparation
 In case other trouble symptoms occur, perform
troubleshooting of these troubles first.
 Refer to SYSTEM/Hydraulic System/Arm 1 Flow Rate
Control Circuit.

1 Monitor Swing Pilot Fully swing. The measured Faulty pilot valve
the specification.
MPa)
2 Measure pressure at port Fully swing. The measured Faulty arm flow rate control
SE of signal control Valve. values are out of valve control spool in signal
the specification. control valve
(Specification: 31.9 MPa)
3 Disassemble and inspect - There is abnormality. Faulty arm 1 flow rate control
the arm 1 flow rate control valve
valve.
symptoms.
TJAA-05-07-002
a- Control Valve Side b- Port SE
T5-6-77
Travel System Troubleshooting

T-1 Both of right and left travels are not operated
or travel speed is slow.
Travel Speed Specification Remark

(sec/20 m)
Fast Speed 13.0±2.0
Slow Speed 18.0±2.0
Preparation
 Both right and left pilot valves, travel motors, and/or
control valve spools are unlikely to be faulty at the
same time.
 If both travel systems are not operated, the pilot
system, which is applied to both side travel motors,
may be faulty. If the primary pilot pressure is lower
than specification, the front attachment operating
speed becomes slow as well. Refer to A-2.
 If the fast travel mode cannot be selected, refer to
T-4.
T5-6-78
T-2 One side travel is not operated or travel speed

is slow. Machine mistracks.
Track Revolution Specification Remark

Speed (sec/3 rev)
Fast Speed 20.5±2.0 470LC, 490LCH:
22.0±2.0
Slow Speed 28.5±2.0 470LC, 490LCH:
30.5±2.0
 In only one side track does not rotate, the pilot valve,
Preparation
the control valve, the travel motor, or the center joint
 Check that both side track sags are equally adjusted. may be faulty.
 Faulty pump control will cause the machine to
mistrack. Refer to A-3 or A-4.

1 Monitor Travel Pilot Operate the control The measured Faulty pilot valve
Pressure. lever alternately. values are out of
the specification.
MPa)
2 Switch right and left travel - Symptom is reversed. Stuck control valve spool
line hoses each other on
the top of center joint.
3 Monitor Pump 1 Delivery When relieving travel The measured Faulty travel relief valve
Pressure and Pump 2 values are out of
Delivery Pressure. the specification.
(Specification: approx.
32.3 MPa)
4 Switch forward travel relief - Symptom is reversed. Faulty center joint
valve with reverse travel
one, or right travel relief
valve with left one.
5 Measure the travel motor With the motor The measured Faulty travel motor
drainage. relieved values are out of
the specification.
(Specification: less than
5 L/min)
6 Disassemble and inspect - There is abnormality. Faulty counterbalance valve
the counterbalance valve.
7 Disassemble and inspect - There is abnormality. Faulty travel motor servo
the travel motor servo piston.
piston.
8 - - The check mentioned Faulty travel reduction gear
above is normal.
T5-6-79
T-3 Machine mistracks when performing

combined operation of travel and front
attachment.

1 Measure pressure at port Combined operation The measured Faulty flow combiner valve
SL of signal control valve. of travel and front values are out of control spool in signal control
attachment. the specification. valve
MPa)
2 Disassemble and inspect - There is abnormality. Faulty flow combiner valve
the flow combiner valve.
3 Disassemble and inspect - There is abnormality. Faulty load check valve
the load check valve.
symptoms.
TJAA-05-07-002
a- Control Valve Side b- Port SL
T5-6-80
T-4 Fast travel can not be selected. Travel mode

does not change from slow speed mode to
fast speed mode.
Preparation
 Refer to SYSTEM/Control System/Travel Motor
Displacement Angle Control.

1 Monitor Travel Mode Shift the travel mode HI/LO of travel mode are Faulty travel mode switch or
Switch. switch. not shifted. open circuit in wire harness
between travel mode switch
and MC
2 Monitor Travel Pilot Operate travel Pressure does not Faulty pressure sensor (travel)
Pressure. function. change according to
3 Measure pressure at port Travel Mode Switch: The measured Stuck spool in 4-spool valve
SC of 4-spool solenoid Fast Speed values are out of unit (SC)
valve the specification.
(Specification: approx
4.0 MPa)
4 Disassemble and - There is abnormality. Faulty travel motor
inspect the travel motor displacement angle control
displacement angle valve
control valve.
5 - - The check mentioned Faulty travel motor or travel
above is normal. reduction gear
T5-6-81
Other System Troubleshooting

O-1 Work light does not light.
Preparation
 Check that the work lights are not broken.
 Refer to SYSTEM/Electrical System.

1 Monitor Work Light 1 Work Light Switch: 1 OFF is displayed. Faulty work light relay 1 or
Output. position open circuit in wire harness
between work light relay 1
and wiper/light controller
2 Monitor Work Light 1 Work Light Switch: 1 OFF is displayed. Faulty work light switch or
Switch. position open circuit in wire harness
between work light switch
3 - - The check mentioned Faulty wiper/light controller
above is normal.
T5-6-82
O-2 Boom light does not light.
Preparation
 Check that the boom lights are not broken.

1 Monitor Work Light 2 Work Light Switch: 2 OFF is displayed. Faulty work light relay 2 or
Output. position open circuit in wire harness
between work light relay 2
2 Monitor Work Light 2 Work Light Switch: 2 OFF is displayed. Faulty work light switch or
Switch. position open circuit in wire harness
between work light switch
above is normal
T5-6-83
O-3 Cab light does not light.
Preparation

1 Monitor Cab Light Switch. Door Open/Close OFF is displayed. Faulty door open/close
Switch: ON switch or open circuit in wire
harness between door open/
close switch and wiper/light
controller
2 Monitor Cab Light 1 Cab Light Switch: OFF is displayed. Faulty cab light switch (Door
Output. Door Position Interlocking Position) or
open circuit in wire harness
between cab light switch and
wiper/light controller
3 Monitor Cab Light 2 Cab Light Switch: ON OFF is displayed. Faulty cab light switch (ON
Output. Position Position) or open circuit in
wire harness between cab
light switch and wiper/light
controller
above is normal.
T5-6-84
O-4 Wiper is not operated.
Preparation
 The wiper is driven by electric power routed via the
 When the front window is open, the wiper is not
relay circuit. The relay circuit is controlled by the
operated. Check that the front window is closed
wiper/light controller.
securely.
 When the wiper is not operated, first check if the
 When the washer is also not operated, check fuse #2.
wiper relay is activated. Next, check if electric power
is routed to the wiper motor.

1 Switch the wiper relay with Key Switch: ON The wiper is operated. Faulty wiper relay
other general relay.
2 Monitor Wiper 1 Input (or Wiper Switch: ON OFF is displayed. Faulty wiper switch or
Wiper 2 Input). Position open circuit in wire harness
(or Overhead between wiper switch and
Window Wiper wiper/light controller
Switch: ON Position)
3 Monitor Wiper 1 Output (or Wiper Switch: ON OFF is displayed. Open circuit in wire harness
Wiper 2 Output). Position between wiper relay and
(or Overhead wiper/light controller
Window Wiper
window contact (cab side) Wiper Switch: ON between wiper relay and
terminals B and L. window contact
window contact (wiper Wiper Switch: ON between window contact and
motor side) terminals B wiper motor
and L.
6 - - The check mentioned Faulty wiper motor
above is normal.
Wiper Driving Circuit

1
3 T1V1-05-07-004
1- Wiper Motor 2- Wiper Relay 3- Window Contact
T5-6-85
O-5 Washer is not operated.
Preparation

1 Switch the washer relay Key Switch: ON The washer is operated. Faulty washer relay
with other general relay.
2 Monitor Washer 1 Switch Washer Switch: ON OFF is displayed. Faulty washer switch or
(or Washer 2 Switch). Position (or Overhead open circuit in wire harness
Window Washer between washer switch and
Switch: ON Position) wiper/light controller
3 Monitor Washer 1 Output Washer Switch: ON OFF is displayed. Open circuit in wire harness
(or Washer 2 Output). Position (or Overhead between washer relay and
Window Washer wiper/light controller
4 - - The check mentioned Faulty washer motor
above is normal.
T5-6-86
O-6 Auto lubrication is faulty.
Preparation
 Refer to SYSTEM/Control System/Auto-Lubrication
Control.
 Even if the auto lubrication switch is ON, auto-

lubrication is inoperable.
 Interval: 90 minutes (variable between 10 and 90
minutes), Lubrication time: 5 minutes

1 Switch the auto-lubrication Auto-lubrication The grease pump is Faulty auto-lubrication relay
relay with other general Switch: ON operated.
relay.
2 Monitor AG Main Switch. Auto-lubrication OFF is displayed. Faulty auto-lubrication switch
Switch: ON or open circuit in wire harness
between auto-lubrication
switch and MC
3 Monitor AG Limit Switch. Auto-lubrication ON/OFF does not Faulty proximity switch
Switch: ON display alternately. Open circuit in wire harness
between proximity switch
and MC or open circuit in wire
harness between proximity
switch and auto-lubrication
relay
4 Monitor AG Output. Auto-lubrication OFF is displayed. Faulty grease pump or
Switch: ON open circuit in wire harness
between grease pump and
auto-lubrication relay
5 Check continuity between Auto-lubrication 0Ω Open circuit in wire harness
auto-lubrication relay #2 Switch: ON between auto-lubrication
and machine. relay and MC
6 - - The check mentioned Damaged lubrication pipings
above is normal. between grease pump and
distribution valve or faulty
distribution valve
T5-6-87
 Auto-lubrication does not start even lubrication time is

passed.
Even if auto-lubrication switch is OFF, auto-lubrication
does not stop.
 Interval: 60 minutes (variable between 10 to 90
minutes), lubrication time: 5 minutes.

1 Switch the auto-lubrication Auto-lubrication ON/ Grease pump operates. Faulty auto-lubrication relay
relay with other general OFF Switch: OFF
relay.
2 Monitor AG Main Switch. Auto-lubrication ON/ ON Faulty auto-lubrication switch
OFF Switch: OFF or short circuit in wire harness
between auto-lubrication
switch and MC
3 - - The check mentioned Short circuit in wire harness
above is normal. between auto-lubrication
relay and MC or faulty MC
 When auto-lubrication stops, auto-lubrication alarm is

generated.
 Shortage of grease or faulty proximity switch may be

the cause.
Inspect the following items.
1. Grease level in the cartridge
2. Air mixture in the circuit
3. Plug is installed to the grease cartridge
4. Faulty proximity switch
T5-6-88
Exchange Inspection
Exchange inspection method is a troubleshooting
method to find the trouble location by exchanging
the suspected part/component with another part /
component having identical characteristics.
Many sensors and solenoid valves used on this machine

are identical. Therefore, by using this switch-check
method, faulty part /component, and/or harness can be
easily found.
Ex.) Abnormal pump 1 delivery pressure high voltage (MC

fault code: 11200-3)
Check Method:
1. Switch connectors of pump 1 delivery pressure 2 1
sensor and pump 2 delivery pressure sensor. TJAA-04-05-006
2. Retry troubleshooting. 1- Pump 1 Delivery Pressure 2- Pump 2 Delivery Pressure

Sensor Sensor
Result:
In case abnormal pump 2 delivery pressure high voltage
(MC fault code 11202-3) is displayed, the pump 1 delivery
pressure sensor is considered to be faulty.
In case abnormal pump 1 delivery pressure high voltage

(MC fault code 11200-3) is displayed, the pump 1 delivery
pressure sensor harness is considered to be faulty.
T5-6-89
Applicability of Switch-Check Method

Fault Code Trouble Remedy
11200-3 Pump 1 Delivery Pressure Sensor Circuit High Input Applicable (Wire Harness/Sensor)
11200-4 Pump 1 Delivery Pressure Sensor Circuit Low Input
11202-3 Pump 2 Delivery Pressure Sensor Circuit High Input
11202-4 Pump 2 Delivery Pressure Sensor Circuit Low Input
11994-3 Pump 1 Reg-Pressure Sensor Circuit High Input Applicable (Wire Harness/Sensor)
11994-4 Pump 1 Reg-Pressure Sensor Circuit Low Input
11992-3 Pump 2 Reg-Pressure Sensor Circuit High Input
11992-4 Pump 2 Reg-Pressure Sensor Circuit Low Input
11301-3 Swing Pilot Pressure Sensor Circuit High Input Applicable (Wire Harness/Sensor)
11301-4 Swing Pilot Pressure Sensor Circuit Low Input
11302-3 Boom Raise Pilot Pressure Sensor Circuit High Input
11302-4 Boom Raise Pilot Pressure Sensor Circuit Low Input
11303-3 Arm Roll-In Pilot Pressure Sensor Circuit High Input
11303-4 Arm Roll-In Pilot Pressure Sensor Circuit Low Input
11304-3 Travel Pilot Pressure Sensor Circuit High Input
11304-4 Travel Pilot Pressure Sensor Circuit Low Input
11325-3 Bucket Roll-In Pilot Pressure Sensor Circuit High Input
11325-4 Bucket Roll-In Pilot Pressure Sensor Circuit Low Input
11942-3 Attachment Pilot Pressure Sensor Circuit Hign Input (Option)
11942-4 Attachment Pilot Pressure Sensor Circuit Low Input (Option)
11944-3 Signal Control Valve SB-Port Pressure Sensor Circuit High
Input (5-Spool Side Pilot Pressure Sensor)
11944-4 Signal Control Valve SB-Port Pressure Sensor Circuit Low
11945-3 Signal Control Valve SA-Port Pressure Sensor Circuit High
11945-4 Signal Control Valve SA-Port Pressure Sensor Circuit Low
11995-3 Arm Roll-Out Pilot Pressure Sensor Circuit High Input
11995-4 Arm Roll-Out Pilot Pressure Sensor Circuit Low Input
11997-3 Bucket Roll-Out Pilot Pressure Sensor Circuit High Input
11997-4 Bucket Roll-Out Pilot Pressure Sensor Circuit Low Input
11998-3 Boom Lowering Pilot Pressure Sensor Circuit High Input
11998-4 Boom Lowering Pilot Pressure Sensor Circuit Low Input
T5-6-90
Fault Code Trouble Remedy

11950-3 Pump 2 P/S Valve FB High Current Applicable (Wire Harness/ Solenoid
11950-4 Pump 2 P/S Valve FB Low Current Valve)
11951-3 Pump 1 P/S Valve FB High Current
11951-4 Pump 1 P/S Valve FB Low Current
11405-3 Travel Swash Angle P/S Valve FB High Current (4-Spool Applicable (Wire Harness/ Solenoid
Solenoid Valve Unit (SC)) Valve)
11405-4 Travel Swash Angle P/S Valve FB Low Current (4-Spool
Solenoid Valve Unit (SC))
11408-3 Center Bypass Cut P/S Valve FB High Current
11408-4 Center Bypass Cut P/S Valve FB Low Current
11428-3 Arm 2 Flow Rate Control P/S Valve FB High Current
11428-4 Arm 2 Flow Rate Control P/S Valve FB Low Current
11948-3 Main Relief Pressure Control P/S Valve FB High Current
(4-Spool Solenoid Valve Unit (SI))
11948-4 Main Relief Pressure Control P/S Valve FB Low Current
(4-Spool Solenoid Valve Unit (SI))
11953-3 Swing Flow Rate Control P/S Valve FB High Current (2-Spool Applicable (Wire Harness/ Solenoid
Solenoid Valve Unit (SI)) Valve)
11953-4 Swing Flow Rate Control P/S Valve FB Low Current (2-Spool
Solenoid Valve Unit (SI))
11989-3 Boom Mode Control P/S Valve FB High Current (2-Spool
11989-4 Boom Mode Control P/S Valve FB Low Current (2-Spool
T5-6-91
How to Lowering Boom When Emergency 3

and When Engine Stops
dCAUTION: Prevent personal injury. Confirm

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

boom to the ground referring to the following procedure.
1. Loosen lock nut (1) of emergency valve (3). Loosen

screw (2) 1/2 turn. The boom lowering speed can be
somewhat adjusted by loosening screw (2) more.
2. After the boom is lowered, tighten screw (2) and
tighten lock nut (1) to the specifications below.
TJAA-04-05-003
Lock Nut (1)
j : 10 mm 3- Emergency Valve
m : 15 N·m (1.5 kgf·m)

2
Screw (2) 1
l : 3 mm
m : 6.0 N·m (0.6 kgf·m)
fNOTE: Excessive leakage may result if the screw and

lock nut are tightened insufficiently. Tighten the screw
and lock nut with above-mentioned tightening torque.
TJAA-05-07-001
1- Lock Nut 2- Screw
T5-6-92
Outline
Configuration layout of the air conditioning system is The vents (operator’s front/rear vent, foot vent, and the
illustrated below. front window) can be simultaneously or independently
Either fresh or re-circulated air is induced into the air selected by air vent damper servo motor (1) in accordance
conditioner unit by operating fresh/re-circulated air with the set-ventilation mode.
damper servo motor (6). The front widow and operator’s front vents are manually
The induced air flows out of the vents through evaporator selectable. The air conditioning controller controls the
(5) or heater (15) by blower motor (11). Evaporator (5) is air conditioning system. The air conditioner controller
a device used to cool the air. Heater (15) is a device used controls the damper operation by corresponding to the
to warm the air. In the air conditioning system, after the job site conditions such as atmospheric and cab inside
refrigerant is compressed by the compressor, it is sent to air temperatures, coolant temperature, operator’s set-
evaporator (5) in which the refrigerant expands to cool temperature, and the set-ventilation mode. In addition,
the air. Heater (15) warms air by absorbing heat from the air conditioning controller displays the air conditioner
warmed engine coolant. The temperature is kept at the system operation status on the monitor.
set temperature by adjusting evaporator (5) and heater
(15).
8
7
1 5
10 9
2 3
16
TDAA-05-07-001
15 14 13 12 11
1- Air Vent Damper Servo Motor 6- Fresh/Re-circulated Air 9- Re-circulated Air Filter 13- Frost Sensor
2- Defroster Vent Damper Servo Motor 10- Re-circulated Air Induction 14- Air Mix Damper Servo Motor
3- Rear Vent 7- Re-circulated Air Temperature Port 15- Heater Core
4- Front Vent Sensor 11- Blower Motor 16- Foot Vent
5- Evaporator 8- Fresh Air Induction Port 12- Power Transistor
T5-7-1
Component Layout
1 2
3
4
5
6
7
10
8
TDAA-05-07-027
27
11
TJAA-01-02-006 TJAA-05-07-003
14 13 12
1- Solar Radiation Sensor 4- AUTO/OFF Switch / Blower 8- Air Conditioner Unit 13- Air Conditioner Condenser
2- Monitor Switch 9- Fresh Air Filter 14- Receiver Tank
3- Temperature Control Switch/ 5- Engine Control Dial 10- Air Conditioner Controller 27- Compressor
Mode Switch 6- Key Switch 11- Ambient Temperature Sensor
7- Monitor Controller 12- High/Low Pressure Switch
T5-7-2
19
18
17
16
15
20
21
22
23
24
25
TDAA-05-07-028
26
15- Re-circulated Air Filter 18- Fresh/Re-circulated Air 21- Heater Core 25- Power Transistor
16- Compressor Relay Damper Servo Motor 22- Air Mix Damper Servo Motor 26- Blower Motor
17- Re-circulated Air Temperature 19- Frost Sensor 23- Air Vent Damper Servo Motor
Sensor 20- Evaporator 24- Blower Motor Relay
T5-7-3
Functions of Main Parts

The functions of the main parts for the air conditioner are
described below. The connector number. is shown in the
parentheses after the part name.
 Controller
The controller controls the air conditioning system. The
controller has the following functions.
 The operator’s instructions are input by the switches.
 The air and coolant temperature are detected by the
sensors.
 Input the air conditioner unit conditions.
 The blower motor and compressor are controlled by
operating the relays.
 The air conditioner operating conditions are TDC1-05-07-002
displayed on the monitor panel.
 Power Transistor (CN7)

The power transistor is an electric switch to control
blower motor voltage.
TDC1-05-07-003
 Blower Motor Relay (CN3)

The blower motor relay supplies 24 volts power to the
blower motor when the air conditioner is operated. The
blower motor relay is turned ON when excited by the
current from terminal #30B in controller.
TDC1-05-07-004
 Compressor Relay (CN4)

The compressor relay supplies 24 volts power to the
compressor clutch when the air conditioner is operated.
The compressor relay is turned ON when excited by the
current from terminal #29B in controller.
TDC1-05-07-005
T5-7-4
 Frost Sensor (CN12)

When the air conditioner is operated the frost sensor
detects the fin temperature which is cooled by the
evaporator. When the temperature is higher than 3 °C
(approx. 4.2 kΩ), the controller turns ON the compressor
relay. When the temperature is 2 °C (approx. 4.5 kΩ) TDC1-05-07-006
or less, the controller turns OFF the compressor relay.
Therefore, the evaporator in the air conditioner unit is
prevented from freezing. The electrical resistance in the
frost sensor is 100 Ω to 115 kΩ.
 High/Low Pressure Switch (CN14)

The high/low pressure switch controls the compressor
clutch solenoid while detecting the compressor circuit
pressure. The high/low pressure switch consists of a TDC1-05-07-007
pressure gauge and a switch. The pressure gauge detects
the low pressure range (0.196 MPa to 0.216 MPa) and the
surge pressure range (2.55 MPa to 3.14 MPa). When the
circuit pressure decreases to the low pressure range or
increases to the surge pressure range, the pressure gauge
turns OFF the switch. Therefore, the compressor operation
stops. If the pressure decreases to the low range, a lack TDAA-05-07-014
of refrigerant is suspected. Therefore, damage to the
compressor due to a lack of refrigerant is prevented.
When the pressure increases to the surge range, damage
to the air conditioner circuit parts due to excessively high
circuit pressure is prevented.
 Re-circulated Air Temperature Sensor (CN11)

The re-circulated air temperature sensor detects the
temperatures (0 to 25 °C) around the re-circulated air inlet
as the interior air temperatures and converts them to the
TDC1-05-07-008
electrical resistance values. The temperatures 0 °C to 25 °C
corresponds to a resistance of 1.645 kΩ (0 °C) to 5 kΩ (25
°C) respectively.
The electrical resistance in the re-circulated air
temperature sensor is 300 Ω to 430 kΩ.
 Ambient Temperature Sensor (CN15)

The ambient temperature sensor detects the temperature
at the side of the air conditioner condenser as the
ambient temperature, and converts the temperature to TDC1-05-07-009
the electrical resistance value. The electrical resistance in
the ambient temperature sensor is 100 Ω to 210 kΩ.
T5-7-5
 Solar Radiation Sensor (CN16)

The solar radiation sensor converts the amount of solar
radiation (illumination intensity) at the cab front to the
current values.
TDC1-05-07-010
 Fresh/Re-circulated Air Damper Servo Motor (CN10)

The fresh/re-circulated air damper servo motor opens or
closes the fresh/re-circulated air selection door. This servo
motor consists of a motor, link mechanism, and position
sensing switch. The motor opens or closes the fresh/re-
circulated air selection door via the link mechanism.
TDC1-05-07-011
T5-7-6
 Air Mix Damper Servo Motor (CN9)

The air mix damper servo motor controls opening/closing
of the air mixing door in response to the set temperature.
This servo motor consists of a motor, link mechanism,
and potentiometer. The motor opens or closes the air
mixing door via the link mechanism. The potentiometer
converts the link movements (the mixing door strokes)
to the voltage. Both ends of the potentiometer are TDC1-05-07-012
energized by 5 V from terminals #7D (+) and #25E (-) in
controller. The voltage (0.5 to 4.5 V) corresponding to the
link movement is output from the center terminal of the
potentiometer, and is input to terminal #19B in controller.
The set temperature is determined by temperature UP/
DOWN signal from the controller. The controller calculates
voltage (Vr) corresponding the link position for the set
temperature. Then, the controller checks the air mixing
door position by voltage (Vf ) from the potentiometer. The
controller decides the motor rotational direction (polarity
of motor) based on the differential voltage between
Vr and VP. The controller sends out the current from
terminals #15B and #16B. The controller drives the motor
until voltage (Vf ) becomes equal to voltage (Vr).
T5-7-7
 Air Vent Damper Servo Motor (CN8)

The air vent damper servo motor opens or closes the front
and rear air vent, foot vent, and defroster vent doors. This
servo motor damper consists of a motor, link mechanism,
and potentiometer. The motor opens or closes vent
louvers via the link mechanism. The potentiometer
converts the link movements (vent doors strokes) to the
voltage. Both ends of the potentiometer are energized by TDC1-05-07-013
5 V from terminals #7C (+) and #25D (-) in controller. The
voltage (0.5 to 4.5 V) corresponding to the link movement
is output from the center terminal of the potentiometer,
and is input to terminal #20B in controller. Depending on
the MODE switch set position, vent doors are operated as
shown below:
 Front Air Vent: Open, Rear Air Vent: Close, Foot Air
Vent: Close
 Front Air Vent: Open, Rear Air Vent: Open, Foot Air
Vent: Close
 Front Air Vent: Open, Rear Air Vent: Open, Foot Air
Vent: Open
 Front Air Vent: Close, Rear Air Vent: Close, Foot Air
Vent: Open
The controller calculates the doors position of front
and rear vent that are corresponding to selected switch
position as the voltage (Vr) of potentiometer. Then, The
controller checks the vent louvers positions by receiving
voltage (Vf ) from the potentiometer. The controller
decides the motor rotational direction (polarity of motor)
based on the differential voltage between Vr and Vf. The
controller sends out the current from terminals #31B and
#32B. The controller drives the motor until voltage (Vf )
becomes equal to voltage (Vr).
T5-7-8
Troubleshooting
IMPORTANT:
When replacing the compressor due to the

breakage of compressor from internal lock,
sufficiently clean the air conditioner circuit or
replace all the parts.
When cleaning is insufficient or all the parts are

not replaced, the air conditioner may be broken
due to contaminants remaining in the circuit.
Using deteriorated LLC (coolant) or low-

concentration LLC, the heater core will receive
a bad influence and it may lead water leaks
and shorten the service life of machine.
Replace coolant and manage LLC concentration
according to the Operator's Manual.
fNOTE: The fault code of the air conditioner controller
is displayed only on the monitor. It is not displayed on
MPDr..
T5-7-9
Air Conditioner Controller Fault Code List

Operation When Trouble Occurs.
11 Open circuit in Voltage: more than Operation is controlled under Check the wire
re-circulated air 4.95 V such circumstances as no re- harness.
temperature sensor circulated air temperature Replace the re-
sensor is provided. circulated air
temperature sensor.
12 Short circuit in Voltage: less than 0.3 V Operation is controlled under Check the wire
re-circulated air such circumstances as no re- harness.
temperature sensor circulated air temperature Replace the re-
sensor is provided. circulated air
temperature sensor.
13 Open circuit in Voltage: more than Operation is controlled under Check the wire
ambient temperature 4.88 V such circumstance as no harness.
sensor ambient temperature sensor is Replace the ambient
provided. temperature sensor.
14 Short circuit in Voltage: less than Operation is controlled under Check the wire
ambient temperature 0.096 V such circumstance as no harness.
sensor ambient temperature sensor is Replace the ambient
provided. temperature sensor.
18 Short circuit in solar Voltage: more than Operation is controlled under Check the wire
radiation sensor 5.04 V such circumstance as no solar harness.
radiation sensor is provided. Replace the solar
radiation sensor.
21 Open circuit in frost Voltage: more than The compressor clutch is Check the wire
sensor 4.79 V disengaged. (The compressor harness.
stops.) Replace the frost
sensor.
22 Short circuit in frost Voltage: less than The compressor clutch is Check the wire
sensor 0.096 V disengaged. (The compressor harness.
stops.) Replace the frost
sensor.
43 Abnormal air vent Short circuit: Voltage: Air vent damper servo motor Check the wire
damper servo motor 0V stops. harness.
Open circuit: Voltage: Replace the air vent
more than 5 V damper servo motor.
44 Abnormal air mix Short circuit: Voltage: Air mix damper servo motor Check the wire
damper servo motor less than 0.2 V servo motor stops. harness.
Open circuit: Voltage: Replace the air mix
more than 4.8 V damper servo motor.
51 Abnormal high/low Voltage: 0 V The compressor clutch is Check the wire
refrigerant pressure disengaged. (The compressor harness.
stops.) Replace the high/low
pressure switch.
91 CAN communication Faulty CAN1 harness Air conditioner stops. Check the CAN1
error between monitor harness.
controller and air Replace the air
conditioner controller conditioner controller.
92 CAN bus off error Faulty air conditioner Air conditioner stops. Check the CAN1
controller harness.
Faulty CAN1 harness Replace the air
conditioner controller.
T5-7-10
Air Conditioner Controller Fault Codes 11 to 22

Preparation
 Check the wire harness connections first.
 Before inspection, set the key switch to the ON position.
Fault Code Trouble Procedure Inspection Method Evaluation Cause

11 Open circuit in 1 Measure resistance ∞ Ω (Normal value: YES: Faulty sensor
re-circulated between sensor #25H 300 to 430 kΩ) NO: Go to Procedure No. 2
air temperature and #6B
sensor 2 Measure voltage 0V YES: Open circuit in wire
between sensor harness harness #25H
end #25H and the body. NO: Open circuit in wire
harness #6B
12 Short circuit in 1 Measure resistance 0 Ω (Normal value: YES: Faulty sensor
re-circulated between sensor #25H 300 to 430 kΩ) NO: Short circuit in wire
air temperature and #6B harness #25H and #6B
sensor
13 Open circuit 1 Measure resistance ∞ Ω (Normal value: YES: Faulty sensor
in ambient between sensor #A251 100 to 210 kΩ) NO: Go to Procedure No. 2
temperature and #A41
sensor 2 Measure voltage 0V YES: Open circuit in wire
between sensor harness harness #A251
end #A251 and the body. NO: Open circuit in wire
harness #A41
14 Short circuit 1 Measure resistance 0 Ω (Normal value: YES: Faulty sensor
in ambient between sensor #A251 100 to 210 kΩ) NO: Short circuit in wire
temperature and #41 harness #A251 and #A41
sensor
18 Short circuit in 1 Check continuity 0Ω YES: Short circuit in wire
solar radiation between sensor harness harness #A71 and #31
sensor end #A71 and #A31. NO: Faulty sensor
21 Open circuit in 1 Measure resistance ∞ Ω (Normal value: YES: Faulty sensor
frost sensor between sensor #25C 100 to 115 kΩ) NO: Go to Procedure No. 2
and #5B
2 Measure voltage 0V YES: Open circuit in wire
between sensor harness harness #25C
end #25C and the body. NO: Open circuit in wire
harness #5B
22 Short circuit in 1 Measure resistance 0 Ω (Normal value: YES: Faulty sensor
frost sensor between sensor #25C 100 to 115 kΩ) NO: Short circuit in wire
and #5B harness #25C and #5B
T5-7-11
Air Conditioner Controller Fault Codes 43 to 92

Preparation
 Before inspection, set the key switch to the ON position.
Fault Code Trouble Procedure Inspection Method Evaluation Cause

43 Abnormal air vent 1 Measure voltage between 0 V YES: Faulty controller or
damper servo air vent damper servo open circuit in wire harness
motor motor harness end 7C between controller and air
and the body. (AUTO/OFF vent damper servo motor
switch / blower switch: NO: To Procedure No. 2
ON)
2 Measure voltage between 0 V YES: Faulty controller or
air vent damper servo open circuit in wire harness
motor harness end 7C and between controller and air
25D. (AUTO/OFF switch / vent damper servo motor
blower switch: ON) NO: Faulty air vent damper
servo motor
44 Abnormal air mix 1 Measure voltage 0V YES: Faulty controller or
damper servo between air mix damper open circuit in wire harness
motor servo motor harness end between controller and air
7D and the body. (AUTO/ mix damper servo motor
OFF switch / blower NO: To Procedure No. 2
switch: ON)
2 Measure voltage between 0 V YES: Faulty controller or
air mix damper servo open circuit in wire harness
motor harness end 7D and between controller and air
25E. (AUTO/OFF switch / mix damper servo motor
blower switch: ON) NO: Faulty air mix damper
servo motor
51 Abnormal high/ 1 Measure voltage between 0 V YES: Faulty controller or
low refrigerant high/low pressure switch open circuit in harness
pressure harness end A211 and between controller and
A052. (AUTO/OFF switch / high/low pressure switch
blower switch: ON) NO: Faulty high/low
pressure switch
91 CAN 1 Check continuity in CAN1 Normal YES: Faulty controller
communication harness. NO: Faulty CAN1 harness
error
92 CAN bus off error 1 Check continuity in CAN1 Normal YES: Faulty controller
harness. NO: Faulty CAN1 harness
T5-7-12
(Blank)
T5-7-13
Faulty cooling (1)
Condition:
 Fault code: Un-displayed
 Airflow volume: faulty
Blower motor Normal speed Clogged re-circulated air filter Filter cleaning
rotates Clogged fresh air filter Filter cleaning
Obstacles are found in inlet area Remove obstacles
Deformation or breakage of blower Replace the blower
Frosted evaporator Go to A
Adhered dirt on evaporator surface Evaporator surface cleaning
Slow speed Power source voltage decreases Check the battery charging
system
Poor battery terminal contact Repair
Faulty blower motor Replace
Faulty power transistor Replace
Blower motor Faulty blower motor relay Replace
does not rotate Faulty blower motor Replace
Blower interferes with case Repair
Faulty controller Replace the controller
Faulty ground in body Make sure to ground
Faulty wire harness, disconnection of connector Check the wire harness
Blowout of power transistor thermal fuse due to locked motor Replace the motor
Blowout of fuse Replace with the Blower motor is locked Replace the blower motor
same capacity fuse Faulty wire harness Refer to wire harness
diagram and check
Short circuit Check the wire harness
T5-7-14
A: Frosted evaporator
Frosted evaporator Stop air conditioner and melt ice
With voltage applied to Faulty magnet clutch Check of clutch circuit Replace the clutch relay
magnet clutch circuit
Faulty wire harness of Short circuit check Repair
frost sensor
Faulty frost sensor Characteristic check Replace the frost
characteristics sensor.
Frost sensor is out Reinsert (floating distance from evaporator is 3
of evaporator (faulty mm or less)
sensitivity)
No voltage applied to magnet clutch Faulty magnet clutch Replace the magnet
clutch
T5-7-15
Faulty cooling (2)
Condition:
 Fault Code: Un-displayed
 Airflow volume: Normal
 Compressor: Compressor rotates normally
 Compressor pressure: Normal
Fresh air enters Close the window and door.
Readjust the fresh/re-circulated
air selection damper.
Disconnection of Air Set the link again.
Mix link
T5-7-16
(Blank)
T5-7-17
Faulty cooling (3)
Condition:
 Compressor: Compressor rotates normally
 Compressor pressure: Abnormal
Pressure on low- Overcharge of air Remove refrigerant thoroughly and recharge refrigerant to proper
pressure side is too conditioner with refrigerant level after purging
high (approx. 0.29 Faulty compressor Breakage of head gasket Replace the compressor.
MPa or more) Breakage of inlet valve Replace the compressor.
Foreign matter is caught in inlet Replace the compressor.
valve
Excessive open of Faulty valve Replace the valve.
expansion valve
Pressure on high- Abnormally low ambient temperature
pressure side is too Lack of refrigerant To B
low (pressure is not Faulty compressor Swash plate shoe is locked Replace the compressor.
approx. 0.98 MPa or Piston is locked Replace the compressor.
more) Faulty suction discharge valve Replace the compressor.
Faulty expansion valve Clogged valve (foreign matter) Replace the valve
Temporary clogged due to freezing Thoroughly perform purging
valve (moisture in the system) after replacing valve and
receiver.
Pressure on low- Abnormally low ambient temperature
pressure side is too Lack of refrigerant Go to B
low (pressure is Clogged in refrigeration cycle Go to C
approx. 0.05 MPa or Faulty expansion valve Go to D
less) Frosted evaporator Go to A
Pressure is high on Lack of condenser cooling Clogged fin with dirt or mud Cleaning of fin (washing)
both sides of high- Overcharge of air Discharge refrigerant thoroughly and recharge refrigerant to proper
pressure and low- conditioner with refrigerant level after purging.
pressure
Pressure is low on Lack of refrigerant
both sides of high-
pressure and low-
pressure
T5-7-18
Frosted evaporator Stop air conditioner and melt ice.
Faulty wiring of frost Short circuit check Repair
sensor
Faulty frost sensor Characteristic check Replace the frost sensor
characteristics
sensitivity)
clutch.
B: Lack of refrigerant
Lack of refrigerant Lack of refrigerant quantity Charge refrigerant to proper level.
Gas leak Check leak and charge with refrigerant
after repairing faulty.
C: Clogged in refrigeration cycle

Clogged in refrigeration cycle Clogged receiver dryer Replace
Clogged foreign matter in piping Replace
D: Faulty expansion valve

Faulty expansion valve Clogged valve (foreign matter) Replace the valve.
Temporary clogged due to freezing valve Thoroughly perform purging after
(moisture in the system) replacing valve and receiver.
T5-7-19
Faulty cooling (4)
Condition:
 Compressor: Compressor does not rotate normally
Broken V belt or slipping Replace V belt.
Faulty compressor (locked) Replace
Faulty magnet Repair or Open circuit in stator coil Replace
clutch replace Air gap between rotor and stator is too large Repair or
Replacement
Clutch slipping Slip caused by key breakage or inserting no key Replace the key.
Greasy clutch surface Remove oil.
Layer short of coil Replace
Battery voltage drop Charge
Caught foreign matter between rotor and stator Overhaul
Clutch does Check Faulty controller Replace the
not operate wiring controller.
due to faulty Faulty compressor clutch relay Replace
electrical Faulty frost sensor Replace
system Faulty high/low refrigerant pressure switch Replace
Abnormal high Too high Abnormally high ambient temperature
pressure (2.54 MPa or Lack of Clogged fin with Cleaning of fin
more) condenser dirt or mud (washing)
cooling
Overcharge air Discharge refrigerant thoroughly and
conditioner with recharge refrigerant to proper level
refrigerant after purging.
Air mixed in Discharge refrigerant thoroughly and
refrigeration recharge refrigerant to proper level
cycle after purging.
Too low Abnormally low ambient temperature
(0.98 MPa or Lack of refrigerant Go to B
less) Clogged during refrigeration cycle Go to C
Faulty expansion valve Go to D
T5-7-20
Frosted evaporator Stop air conditioner and melt ice.
sensor
Faulty frost sensor Characteristic check Replace the frost sensor
characteristics
of evaporator (faulty mm or less).
sensitivity)
clutch.
B: Lack of refrigerant
Lack of refrigerant Lack of refrigerant quantity Charge refrigerant to proper level.
Gas leak Check leak and charge with refrigerant
after repairing faulty.
C: Clogged in refrigeration cycle

Clogged in refrigeration cycle Clogged receiver dryer Replace
Clogged foreign matter in piping Replace
D: Faulty expansion valve

Temporary clogged due to freezing valve Thoroughly perform purging after
(moisture in the system) replacing valve and receiver.
T5-7-21
Faulty cooling (5)
Condition:
 Fault Code: 44 (Abnormal air mix damper servo motor)
Faulty wiring, open Wirings inspection
circuit, disconnection of
connector
Faulty servo motor Replace
Caught foreign matter Remove foreign matter.
Condition:
 Fault Code: 51 (Abnormal high/low refrigerant pressure)
High pressure cut is Abnormally high ambient temperature
operated Lack of condenser Clogged fin with dirt or mud Cleaning of fin (washing)
cooling
Overcharge air Discharge refrigerant thoroughly and recharge refrigerant to
conditioner with proper level after purging
refrigerant
Air mixed in refrigeration Discharge refrigerant thoroughly and recharge refrigerant to
cycle proper level after purging
Low pressure cut is Abnormally low ambient temperature
operated Lack of refrigerant Lack of refrigerant quantity Charge refrigerant to proper
level.
Gas leak Check leak and charge with
refrigerant after repairing faulty.
Faulty compressor Swash plate shoe is locked Replace the compressor.
Piston is locked Replace the compressor.
Faulty suction discharge valve Replace the compressor.
Temporary clogged due to Thoroughly perform purging
freezing valve (moisture in the after replacing valve and
system) receiver.
T5-7-22
(Blank)
T5-7-23
Faulty heating (1)
Condition:
 Fault code: Un-displayed
Faulty air flow Blower motor Normal speed Clogged re-circulated air filter Filter cleaning
volume rotates. Clogged fresh air filter Filter cleaning
Obstacles are found in inlet area Remove obstacles.
Deformation or breakage of blower Replacement of blower
Adhered dirt on evaporator surface Evaporator surface
cleaning
Slow speed Power source decreases. Check battery charging
system.
Poor battery terminal contact Repair
Blower motor Blowout of fuse Replace with the Blower motor is Replace the blower
does not rotate. same capacity fuse, locked, motor.
Faulty wire harness Refer to wire harness
diagram and check.
Short circuit Check the wire harness.
Faulty blower motor relay Replace
Blower interferes with case Repair
Faulty controller Replace the controller.
Faulty ground in body Make sure to ground.
Faulty wire harness, disconnection of connector Check the wire harness.
Blowout of power transistor thermal fuse due to locked Replace the motor.
motor
Air flow volume Coolant temperature is low.
is normal Coolant Disconnection of air mix damper link Set the link again.
temperature is Air incorporation in hot-water circuit Bleed air from the circuit.
normal. Clogging, breakage, and bending of piping Repair or replace
Extremely low ambient temperature
Lack of engine coolant Charge engine coolant
to proper level.
Broken heater core Replace the heater core.
T5-7-24
Frosted evaporator Stop air conditioner and melt ice
With voltage applied to Faulty magnet clutch Check of clutch circuit Replace the clutch
magnet clutch circuit relay.
sensor
Faulty the frost sensor Characteristic check Replace the frost
characteristics sensor.
sensitivity)
clutch.
T5-7-25
Faulty heating (2)
Condition:
 Fault Code: 44 (Abnormal air mix damper servo motor)
Caught foreign matter Remove foreign
matter.
Faulty wire harness, open circuit, Check the wire
disconnection of connector harness.
Faulty air mix damper servo motor Replace
T5-7-26
Others
 Faulty air vent switch

Fault code is un-displayed. Disconnection of link Set the link again.
Fault code 43 (Abnormal air vent damper Faulty wire harness, open circuit, Check the wire harness.
servo motor) disconnection of connector
 Faulty fresh / re-circulated air selection

Fault code is un-displayed. Disconnection of link Set the link again.
Faulty wire harness, open circuit, Check the wire harness.
disconnection of connector
 Ambient temperature is higher or lower than set temperature

Fault code 11 (Open circuit in re- Open circuit in wire harness, Check the wire harness.
circulated air temperature sensor) disconnection of connector
Open circuit in air circulation sensor Replace
Fault code 12 (Short circuit in re- Short circuit in wire harness Check the wire harness.
circulated air temperature sensor) Short circuit in air circulation sensor Replace
Fault code is un-displayed. (Normal re- Faulty cooling, faulty heating Check by referring to the items of
circulated air temperature sensor) faulty cooling and faulty heating.
T5-7-27
 Noise
Related parts of case Louver resonance Repair or replace.
Related parts of blower fan motor Fan contacts case, Foreign matter Remove foreign matter. Readjust fan
enters case motor location.
Brush friction noise, metal and/or Slight noise is unavoidable. Replace if
thrust washer contact loud.
Gas blowing sound (roaring) Gas vibration noise (compressor No functional problem exists.
discharge and/or suction gas noise)
Expansion valve connection, Whistle Abnormal noise from expansion Replace expansion valve if whistle
sound, Gas blowing sound. valve, Expansion valve is normally sound is heard. Gas flow noise can be
functioning slightly heard.
Clutch disengaging sound Faulty clutch bearing, and/or idle Replace
pulley bearing
Contact of clutch amature due to Repair or replace the clutch. Re-tighten
resonance. Loose belt, Loose screws screws.
Compressor rotating sound Noisy compressor Repair or replace
Vibration due to V belt looseness, Re-adjust the belt. Re-tighten screws.
Loose screws
 Others
Water leak, Water splash Broken heater core, Broken hose Replace
Clogged case drain port and/or drain Clean
hose
Abnormal smell Absorbed cigarette and dust smell on Clean the evaporator. When humidity
evaporator fins is high, open door. While rotating fan
at approx. 1500 min-1 in L mode for
more than 10 minutes, flush smell out
by condensed water.
T5-7-28
(Blank)
T5-7-29
Blower motor does not operate.

Preparation
Procedure Inspection Method Condition Evaluation Cause (check point)

1 Switch compressor relay with Key Switch: ON Blower motor YES: Faulty blower motor
blower motor relay. Blower Switch: ON does not operate. relay
NO: Go to Procedure No. 2
2 Measure voltage between Key Switch: ON 0V YES: Open circuit in wire
terminal #41B of blower motor harness between fuse #3
relay harness end and the body. and blower motor relay
terminal #43A of blower motor Blower Switch: ON harness between blower
harness end and the body. motor relay and blower
motor
4 Check continuity between - 0Ω YES: Faulty blower motor
terminals #43B and #44A of NO: Go to Procedure No. 5
blower motor harness end.
5 Measure voltage between Key Switch: ON 0V YES: Open circuit in
terminal #44B of power transistor Blower Switch: ON wire harness between
harness end and the body. blower motor and power
transistor
6 Measure voltage between Key Switch: ON 0V YES: Faulty air conditioner
terminal #9B of power transistor Blower Switch: ON controller
harness end and the body. NO: Faulty power
transistor

 Blower Motor Relay  Blower Motor
TDC1-05-07-014 TDAB-05-07-027
 Power Transistor
TDAB-05-07-028
T5-7-30
Compressor clutch does not operate.

Preparation
 Check that outdoor air temperature is 0 °C or
more first. When outdoor air temperature is less
than 0 °C, the air conditioner controller turns OFF
the compressor clutch in order to protect the
compressor.
 Check that fault code 21 or 22 (abnormal frost
sensor) is not displayed. When the frost sensor is
abnormal, the compressor clutch does not operate.
Procedure Inspection Method Condition Evaluation Cause (check point)

1 Switch compressor relay with Key Switch: ON Compressor is not YES: Faulty compressor
blower motor relay. Blower Switch: ON operable. relay
terminal #48A of compressor relay harness between fuse #3
harness end and the body. and compressor relay
3 Measure voltage between Key Switch: ON 0V YES: Open circuit in
terminal #42B of compressor Blower Switch: ON wire harness between
clutch harness end and the body. compressor relay and
compressor clutch
NO: Faulty compressor
clutch

 Compressor Relay  Compressor Clutch
TDAB-05-07-019 TDAB-05-07-024
T5-7-31
Cooling circuit check by using manifold gauge
Condition:
 Engine Speed: 1500 min-1
 Cab Window: Fully Open
 Air Conditioner: ON
 Airflow volume: Maximum
 Temperature Control Switch: Maximum cool
 Fresh/re-circulated air selection: Re-circulated Air
 Air conditioner inlet temperature: 30 to 35 °C
1. In normal
 Low-pressure side pressure: 0.15 to 0.25 MPa
 High-pressure side pressure: 1.37 to 1.57 MPa
f NOTE: The reading of manifold gauge may depend on
conditions.
TDAA-05-07-018
2. Lack of refrigerant quantity
TroublePressure is low on both sides of high-pressure

and low-pressure. Cooling performance is
low.
Cause Lack of refrigerant quantity Gas leak.
Remedy Check and repair of gas leak. Charge air
conditioner with refrigerant.
TDAA-05-07-019
3. Excessive refrigerant, lack of condenser cooling
TroublePressure is high on both sides of high-

pressure and low-pressure. Cooling
performance is low.
Cause Overcharge air conditioner with refrigerant.
Lack of condenser cooling.
Remedy Adjust refrigerant quantity. Clean condenser.
Check for machine cooling system.
TDAA-05-07-020
4. Water incorporation in circuit.
TroubleAfter using a certain period of time, low-

pressure side gradually indicates negative
pressure.
Cause Water is mixed in circuit.
Remedy Replace receiver tank. Thoroughly perform
purging before charging refrigerant to
remove water.
TDAA-05-07-021
T5-7-32
5. Faulty compression of compressor
TroubleLow-pressure side is high and high-pressure

side is low. High-pressure becomes equal to
low-pressure immediately after stopping the
air conditioner.
Cause Faulty compressor.
Remedy Check and repair of compressor.
TDAA-05-07-022
6. Refrigerant does not circulate (clogged circuit)
TroubleWhen absolutely clogging, low-pressure side

indicates negative pressure quickly. When
slightly clogging, low-pressure side gradually
indicates negative pressure.
Cause Dirt or water adheres or freezes to expansion
valves, refrigerant does not flow.
Remedy Replace receiver tank. Perform purging. TDAA-05-07-023
7. Air mixed in circuit

pressure and low-pressure. When touching
low-pressure piping, it is not cold.
Cause Air is mixed in system.
Remedy Replace refrigerant. Perform purging.
TDAA-05-07-024
8. Excessive open of expansion valve

pressure and low-pressure. Frost (dew)
adheres to low-pressure piping.
Cause Faulty expansion valve.
Remedy Check for installation of thermal cylinder.
TDAA-05-07-025
T5-7-33
Work after Replacing Components

The following work is required after replacing compressor,
high pressure hose, low pressure hose, condenser,
receiver tank, liquid hose, and air conditioner unit. The
same work is required when a large amount of gas
leakage has occured.
1. Refill Compressor Oil
2. Charge Air Conditioner with Refrigerant

 Purging
 Charge air conditioner with refrigerant
 Warm-up operation
 Inspection
T5-7-34
Refill Compressor Oil

When replacing the refrigeration circuit parts, refill
compressor oil to the specified level.
Replacement Compressor Condenser Evaporator Receiver D hose L hose S hose

parts (between (between (between
compressor condenser unit and
and and unit) compressor)
condenser)
Refill oil Refer to the 40 cm3 40 cm3 20 cm3 6 to 9 cm3/m 2 to 4 cm3/m 8 to 11 cm3/m
quantity following.
 When of replacing compressor

New compressor (1) is charged with oil required for  Compressor oil refill container
refrigeration circuit. When replacing to new compressor Oil type Part No Quantity
(1), drain excess oil from new compressor (1). Adjust oil
ND-OIL8 4422696 40 cm3
level so that oil in new compressor (1) is the same level as
oil (B) in compressor (2) to be replaced.
fNOTE: Compressor oil quantity: 160 cm3
1 2
TDAA-05-07-015
1- New Compressor 2- Replacing Compressor
T5-7-35
Charge Air Conditioner with Refrigerant

Necessity of Purging
The following problems can arise if air or other gases
remain in the air conditioner circuit. Be sure to perform
purging the air conditioner circuit with a vacuum pump
before charging with refrigerant (R134a).
1. Pressure rise in the high pressure side

If air remains in the air conditioner circuit, this disturbs
the heat exchange between refrigerant and air in the
condenser. This causes pressure to rise in the high
pressure side (compressor side).
Refrigerant gas is easily liquefied, but air cannot
be liquefied and remains as a gas in the condenser
because the temperature at which air liquefies is
extremely low. Therefore, liquefaction of the refrigerant
gas in the condenser decreases by the amount of air in W115-02-10-001
the circuit, and the gas pressure in the high pressure
side increases accordingly.
2. Metal corrosion
If air remains in the air conditioner circuit, a chemical
reaction between refrigerant and moisture in the
air takes place, and as a result, hydrochloric acid is
produced. Hydrochloric aid corrodes metals such as
aluminum, copper and iron.
W115-02-10-002
3. Plugging of the expansion valve by moisture

When high pressure refrigerant gas passes through
the expansion valve, gas pressure decreases and
temperature drops. Moisture included in high pressure
refrigerant gas in the air conditioner circuit freezes at
the expansion valve orifice, plugging refrigerant flow.
Operation of the air conditioner becomes unstable and
cooling efficiency lowers.
W115-02-10-003
T5-7-36
Procedures for charging air conditioner with

refrigerant
1
7
IMPORTANT: Do not mistake the charge hose
connections.
6
1. Close high pressure valve (2) and low pressure valve
(7) of manifold gauge (1). Connect high-pressure 2
side charge hose (3) and low-pressure side charge
hose (6) of manifold gauge (1) to the high-pressure
3
side charge valve (“D” marked) and to the low-
pressure side charge valve (“S” marked) located on
the compressor respectively. Connect charge hose 5
(5) located on the center of manifold gauge (1) to
vacuum pump (4). 4
W115-02-10-005
2. Open high pressure valve (2) and low pressure valve

(7) of manifold gauge (1). Perform purging for over 1
10 minutes by operating vacuum pump (4). 7
W115-02-10-005
T5-7-37
IMPORTANT: If the pointer of the low pressure gauge 7

returns to 0, retighten the line connections and
perform purging again.
3. When the low pressure gauge reading falls below
2
-0.1 MPa (-750 mm Hg), close high pressure valve (2)
and low pressure valve (7) and stop vacuum pump
(4). Wait for approximately five minutes and confirm
that the pointer of the low pressure gauge does not
return to 0.
W115-02-10-005
4. With high pressure valve (2) and low pressure valve
(7) on manifold gauge (1) closed, connect charge
hose (5) to refrigerant container (8). 7 1
 Refrigerant
Specification Part No. Volume (g)
R134a 4333767 200 2
4454005 250
4351827 300
8
5. Open valve (9) of refrigerant container (8). Push air
bleed valve (10) on manifold gauge (1) to purge
W115-02-10-007
air in charge hose (5) with the refrigerant pressure.
When draining refrigerant, immediately release air
bleed valve (10).
10 1
5
9
W115-02-10-007
T5-7-38
IMPORTANT:
 Always stop the engine when charging the air
conditioner with refrigerant.
 Do not position the refrigerant container upside
down during charging operation.
 When changing the refrigerant container during
charging operation, be sure to perform the
procedure in step 10.
 Charge the low-pressure side hose first.
6. Fully tighten charge hose (5) to manifold gauge
(1). Open high pressure valve (2) and valve (9) of
refrigerant container (8). Charge with refrigerant
(R134a). Close high pressure valve (2) and valve
(9) of refrigerant container (8) when high pressure
gauge (11) reading reaches 98 kPa. W115-02-10-008
fNOTE: Use warm water of 40 °C or less to warm

refrigerant container (8) to aid in charging operation. 1
11
2
5
9
IMPORTANT: Use the leak tester for R134a.

8
7. After charging, check the line connections for gas
leaks using the leak tester.
W115-02-10-007
T5-7-39
8. Confirm that high pressure valve (2) and low 1

pressure valve (7) on gauge manifold (1) and valve
7
(9) of refrigerant container (8) are closed. Start the
engine and operate the air conditioner.
Operating Conditions of the Air Conditioner 2
 Engine Speed: Slow Idle
9
W115-02-10-007
IMPORTANT: Do not open high pressure valve (2) on
manifold gauge (1).
9. Open low pressure valve (7) on manifold gauge (1)
1
and valve (9) of refrigerant container (8) to charge
with refrigerant. 7
fNOTE: Required refrigerant quantity: 850±50 g

2
10. If refrigerant container (8) becomes empty during
the charging work, replace refrigerant container (8)
with a new refrigerant container as follows:
 Close high pressure valve (2) and low pressure valve
(7) on manifold gauge (1). 9
 Replace the empty container with new refrigerant
container (8).
8
 Tighten, then slightly loosen refrigerant container (8)
joint.
 Slightly open low pressure valve (7) on manifold
gauge (1).
 When refrigerant container (8) joint starts to leak,
W115-02-10-007
immediately tighten refrigerant container (8) joint
and close low pressure valve (7) on manifold gauge
(1).
11. After charging, close low pressure valve (7) on

manifold gauge (1) and valve (9) of refrigerant
container (8), and stop the engine.
T5-7-40
IMPORTANT: If the air conditioner is operated with

very low level of refrigerant, it will cause the
damage of the compressor. If the air conditioner
is overcharged with refrigerant, cooling efficiency
will lower and abnormal high pressure will arise in
the air conditioner circuit, causing danger.
12. Start the engine and operate the air conditioner
again. Check that cold air blows out from the vents.
Operating Conditions of the Air Conditioner
dCAUTION: When disconnecting the high pressure

side charge hose, refrigerant and compressor oil
may spout. Disconnect the high pressure side
charge hose after the high pressure side pressure
drops to less than 980 kPa.
13. After checking that cold air blows out, disconnect
the charge hoses. Disconnect the low pressure side
charge hose first. Wait for the high pressure side
pressure to drop to less than 980 kPa. Disconnect
the high pressure side charge hose.
T5-7-41
Warm-up Operation
After charging air conditioner with specified volume
of refrigerant, carry out warm-up operation for five
minutes to lubricate system with compressor oil.

Inspection
After warm-up operation, carry out gas leak check and
performance check.
dCAUTION: Refrigerant will produce poisonous

material if exposed to heat of 1000 °C or more.
Never bring refrigerant close to a fire.
1. Check the air conditioner for gas leaks using a leak
tester.
 Perform checking under well-ventilated conditions.
 Thoroughly wipe off dust from the charge hose
connections of the compressor.
 Pay special attention to check the piping
connections.
 If any gas leaks are found, retighten the piping
connections.
2. Carry out performance check of the air conditioner W115-02-10-013

after checking each air conditioner component.
 Check each component for abnormalities.
 Carry out ON-OFF check of the compressor clutch.
 Check compressor fan belt tension.
 Check the coolant level in the radiator.
 Operate the air conditioner and check the
performance.
W115-02-10-014
T5-7-42
3. Check before the summer season

 Check each air conditioner component for
abnormalities.
 Check the piping connections for oil leaks.
 Check refrigerant quantity.
 Check the engine cooling circuit.
 Check V belt for wear. Replace if necessary.
 Check for clogged condenser.
4. Maintenance during off-season

 During off-season, operate the idler pulley and
compressor pulley at least once a month for a short
time to check for any abnormal sounds.
 Do not remove the compressor belts during off-
season. Operate the compressor occasionally at
slow speed for 5 to 10 minutes with the belt slightly
loosened in order to lubricate the compressor.
fNOTE: When the machine is in normal and the air

conditioner is operated with the following conditions, air
vent temperature decrease approx. 20 °C or less. (it may
be different under special environment.)

 Engine Speed: Fast Idle
 Cab Window: Fully closed
 Fresh/re-circulated air selection: Re-circulated Air
 Season: Summer
T5-7-43
Hose and Pipe Tightening Torque A
Use the following tightening torque values when

connecting the pipes.
Joint Location Tube or Bolt Size Tightening

Torque
N·m (kgf·m)
TDAA-05-07-016
Nut type Pipe with dia. 8 12 to 15
(Fig. A) (1.2 to 1.5)
B
Pipe with D1/2 20 to 25
(2.0 to 2.5)
Pipe with D5/8 30 to 35
(3.0 to 3.5)
Block joint M6 Bolt (4T) for 4.0 to 7.0
(Fig. B) receiver (0.4 to 0.7)
M6 Bolt (6T) 8.0 to 12
for other than (0.8 to 1.2)
Receiver
TDAA-05-07-017
T5-7-44
MEMO
MEMO
Hitachi Construction Machinery Co., Ltd. Hitachi Ref. No.
Attn: Technical Information Center
Tel: 81-29-832-7084
Fax: 81-29-831-1162
E-mail: HCM-TIC-GES@hitachi-kenki.com
SERVICE MANUAL REVISION REQUEST FORM
COMPANY NAME: MODEL:

PUBLICATION PART NO.:
YOUR NAME: (Located at the left top corner in the cover page)
DATE: PAGE NO.:
FAX: (Located at the bottom center in the page. If two or more revisions
are requested, use the comment column)
E-mail:
YOUR COMMENTS / SUGGESTIONS:

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

The Attached Diagram List
The following diagrams are attached to this manual.
1. ELECTRICAL CIRCUIT DIAGRAM

AIR CONDITIONER CIRCUIT DIAGRAM
2. CONNECTORS
3. CAB HARNESS
MAIN HARNESS
4. ENGINE HARNESS
PUMP HARNESS
5. CONTROL VALVE HARNESS
6. MONITOR HARNESS
KEY SWITCH HARNESS
7. OIL COOLER FAN REVERSE ROTATION SWITCH HARNESS

ENGINE STOP SWITCH HARNESS
8. PILOT SHUT-OFF SOLENOID VALVE HARNESS
9. GSM (MOBILE COMMUNICATION TERMINAL) HARNESS

SATELLITE COMMUNICATION HARNESS
10. AUTO LUBRICATION ON/OFF SWITCH HARNESS

CAMERA HARNESS
11. BOOM MODE SWITCH AND SEAT HEATER SWITCH HARNESS (OPTION)
12. WORK LIGHT (ON THE CAB ROOF) HARNESS 1 (OPTION)

WORK LIGHT (ON THE CAB ROOF) HARNESS 2 (OPTION)
13. HYDRAULIC CIRCUIT DIAGRAM

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PART NO.

Service Manual consists of the following separate Part No.

Technical Manual (Operational Principle) : Vol. No.TOJAE-EN

Quantity To Convert From Into Multiply By

fNOTE: The numerical value in this manual might be

Symbol/ Name Explanation

Recognize Safety Information

Understand Signal Words

 CAUTION also calls attention to safety message in this

 NOTE: indicates an additional explanation for an

Follow Safety Instructions

Prepare for Emergencies

Wear Protective Clothing

You may need:

Protect Against Noise

Use Handholds and Steps

Adjust the Operator's Seat

Fasten Your Seat Belt

Move and Operate Machine Safely

Operate Only from Operator's Seat

Keep Riders off Machine

Precautions for Operations

Investigate Job Site Beforehand

Install OPG Guard

OPG: Operator Protective Guard

Restriction of Attachment Installation

Provide Signals for Jobs Involving Multiple

Confirm Direction of Machine to Be Driven

Drive Machine Safely

 Driving on a slope may cause the machine to slip or SA-657

Avoid Injury from Rollaway Accidents

Avoid Injury from Back-Over and Swing

Keep Person Clear from Working Area

Never Position Bucket Over Anyone

 Be careful when working on frozen ground.

Never Undercut a High Bank

Dig with Caution

Operate with Caution

Avoid Power Lines

Precautions for Lightning

If lightning comes close, immediately stop the operation,

Protect Against Flying Debris

Park Machine Safely

Handle Fluids Safely−Avoid Fires

 All fuels, most lubricants, and some coolants are flammable.

3. Turn auto-idle switch OFF.

Be sure to further follow the details described in the

Practice Safe Maintenance

Before servicing the machine:

7. Remove the key from the key switch.

 If a maintenance procedure must be performed with the

Warn Others of Service Work

Support Machine Properly

Stay Clear of Moving Parts

Prevent Parts from Flying

 Travel reduction gears are under pressure.

Avoid Injury from Attachment Falling Accident

 After operation, engine coolant is hot and under pressure.

Hot fluids and surfaces:

Replace Rubber Hoses Periodically

 Failure to periodically replace rubber hoses may cause a fire,

Avoid High-Pressure Fluids

Check Key Switch: