3600-Performance Test &troubleshooting

SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction Group 5 Component Test
Operational Performance Tests ................T4-1-1 Primary Pilot Pressure Check ...................T4-5-1
Preparation for Performance Tests ...........T4-1-2 Secondary EHC Valve Pressure Check.....T4-5-2
Secondary D.Q.R Valve Pressure Check ..T4-5-4
Group 2 Standard Main Relief Pressure Check .....................T4-5-6
Operational Performance Standard...........T4-2-1 Overload Relief Pressure Check.............T4-5-10
Main Pump P-Q Diagram, Main Pump Flow Rate Measurement ......T4-5-12
Main Pump Pi-Q Diagram .......................T4-2-5 Fan Motor Drive Pump Flow
Fan Motor Drive Pump P-Q Diagram, Rate Measurement ...............................T4-5-20
Fan Motor Drive Pump Pi-Q Diagram .....T4-2-6 Swing Motor Drain Check .......................T4-5-28
Electric Lever ...........................................T4-2-7 Travel Motor Drain Check .......................T4-5-30
Group 3 Engine Test

Engine Speed ...........................................T4-3-1
Group 4 Excavator Test

Travel Speed ............................................T4-4-1
Track Revolution Speed ...........................T4-4-2
Mistrack ...................................................T4-4-3
Travel Motor Drift Check...........................T4-4-4
Swing Speed ............................................T4-4-5
Swing Function Drift .................................T4-4-6
Swing Motor Leakage ...............................T4-4-7
Maximum Swingable Slant Angle ..............T4-4-8
Swing Bearing Play ................................T4-4-10
Hydraulic Cylinder Cycle Time ................T4-4-12
Cylinder Drift ..........................................T4-4-14
Control Lever Operating Force ...............T4-4-15
Control Lever Stroke...............................T4-4-16
Boom Raise/Swing Combined
Operation Check ..................................T4-4-17
18MT-4-1
(Blank)
18MT-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TEST
Use operational performance test procedure to quan-

titatively check all system and functions on the ma-
chine.
Purpose of Performance Tests

1. To comprehensively evaluate each operational
function by comparing the performance test data
with the standard values.
2. According to the evaluation results, repair, adjust,
or replace parts or components as necessary to
restore the machine’s performance to the desired
standard.
3. To economically operate the machine under op-
timal conditions.
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the op-
erational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
“Performance Standard” is shown in tables to evalu-
ate the performance test data.
Precautions for Evaluation of Test Data

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

rate as the working hours increase. However, the
machine performance is normally considered to re-
duce in proportion to the increase of the operation
hours. Accordingly, restoring the machine perform-
ance by repair, adjustment, or replacement shall con-
sider the number of the machine’s working hours.
Definition of “Performance Standard”

1. Operation speed values and dimensions of the
new machine.
2. Operational performance of new components
adjusted to specifications. Allowable errors will be
indicated as necessary.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out
performance tests accurately and safely.
THE MACHINE
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.
TEST AREA AND MEASURING EQUIPMENT

1. Select a hard and flat surface.
2. Secure enough space to allow the machine to
run straight more than 20 m (65 ft 7 in), and to
make a full swing with the front attachment ex-
tended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.
4. Prepare measuring instruments and apparatus
suitable to test requirements.
5. Arrange a test weight or an equivalent heavy T105-06-01-003
material.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among cowork-
ers. Once the test is started, be sure to commu-
nicate 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 acci-
dents 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 hy-
draulic pipings. T105-06-01-004
MAKE PRECISE MEASUREMENT

1. Accurately calibrate test instruments in advance
to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.
T4-1-2
OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE
STANDARD
The standard performance values are listen in the table

below. Refer to the Groups 3 to 5 for performance test
procedures. Values indicated in parentheses are
reference values. The fuel lever shall be placed in the
fast idle position and the hydraulic oil temperature is to
be maintained at 50 ± 5 °C (122 ± 9 °F) unless
otherwise specified.
NOTE: 1 mm=0.3937 in
EX3600-6
Reference
Performance Test (Standard Remarks
Page
Performance)
ENGINE SPEED min
-1
T4-3-1
Fast Idle Speed 1900±50
Slow Idle Speed 800±50
Auto-Idle Speed 1400±50
TRAVEL SPEED sec /20 m T4-4-1
Fast Speed Mode 33±2
Slow Speed Mode 44±3
TRACK REVOLUTION SPEED sec /3 rev T4-4-2
Fast Speed Mode 92±5
Slow Speed mode 123±6
MISTRACK mm /20 m
250 T4-4-3
(in both fast and slow mode)
TRAVEL MOTOR DRIFT mm /5 min 0 Brake: ON T4-4-4
SWING SPEED sec /3 rev 57±3 T4-4-5
SWING FUNCTION DRIFT mm /180° T4-4-6
(Loading Shovel) 1200 or less LD: 21.0 m3 Bucket
(Empty)
(Backhoe) 1200 or less BH: 22.0 m3 Bucket
(Empty)
SWING MOTOR DRIFT mm /5 min 0 Brake: ON T4-4-7
MAXIMUM SWINGABLE SLANT ANGLE deg T4-4-8
(Loading Shovel) 10 or possibly LD: 21.0 m3 Bucket
more
(Backhoe) 9 or possibly BH: 22.0 m3 Bucket
more
SWING BEARING PLAY mm 0.5 or less Allowable Limit: 8 mm T4-4-10
NOTE: LD: Loading Shovel

BH: Backhoe
T4-2-1
NOTE: 1 mm=0.3937 in
EX3600-6
Reference
Performance Test (Standard Remarks
Page
Performance)
CYLINDER CYCLE TIME sec T4-4-12
BACKHOE 22.0 m3 Bucket
Boom Raise 8.2±0.5
Boom Lower 5.9±0.5
Arm Roll-In 7.0±0.5
Arm Roll-Out 7.0±0.5
Bucket Roll-In 4.7±0.5
Bucket Roll-Out 4.2±0.5
LOADING SHOVEL 21.0 m3 Bucket
Boom Raise 8.4±0.5
Boom Lower 5.9±0.3
Arm Extend 4.5±0.3
Arm Retract 3.9±0.3
Bucket Tilt-In 4.4±0.3
Bucket Tilt-Out 3.2±0.3
Bucket Open 2.3±0.3
Bucket Close 2.3±0.3
DIG FUNCTION DRIFT mm/5 min T4-4-14
3
BACKHOE 22.0 m Bucket
Boom Cylinder 40 or less
Arm Cylinder 60 or less
Bucket Cylinder 40 or less
Bucket Bottom 430 or less
LOADING SHOVEL 21.0 m3 Bucket
Boom Cylinder 40 or less
Arm Cylinder 30 or less
Bucket Cylinder 25 or less
Bucket Bottom 350 or less
NOTE: * In the case of backhoe specification, the

operation is bucket tilt-in
** In the case of backhoe specification, the
operation is bucket tilt-out
T4-2-2
Referen
EX3600-6
Performance Test Remarks ce
(Standard Performance)
Page
CONTROL LEVER OPERATING FORCE N (kgf)
T4-4-15
(ISO Control Pattern)
Boom Lever (Raise / Lower) 6.1 to 7.6 (0.6 to 0.8)
5.1 to 6.4 (0.5 to 0.7)
Arm Lever (Extend / Retract) HITACHI Control
5.1 to 6.4 (0.5 to 0.7) Pattern:
6.1 to 7.6 (0.6 to 0.8) Swing Lever
(Right / Left)
Bucket Lever (Tilt-in / Tilt-out) 5.2 to 6.5 (0.5 to 0.7)
5.9 to 7.4 (0.6 to 0.8)
Swing Lever (Right / Left) HITACHI Control
Pattern:
5.2 to 6.5 (0.5 to 0.7)
Arm Lever
5.9 to 7.4 (0.6 to 0.8)
(Extend /
Retract)
Travel Lever 21.6 to 26.3 (2.2 to 2.7)
Bucket Open-Close Pedal 82 to 100 (8.4 to 10.2)
LEVER STROKE mm
T4-4-16
(HITACHI Control Pattern)
Boom Lever 55.0±7.0
Arm Lever (HITACHI
55.0±7.0 Control Pattern:
Swing Lever)
Bucket Lever 55.0±7.0
Swing Lever (HITACHI
55.0±7.0 Control Pattern:
Arm Lever)
Travel Lever 138±10
Bucket Open/Close Pedal 33.0±3.0
BOOM RAISE AND SWING COMBINED OPERATION
T4-4-17
(Bucket: Empty)
Time (LD) sec/90° 6.9±0.5
Time (BH) sec/90° 7.3±0.5
Bucket Clearance H (LD) mm 8200 or more
Bucket Clearance H (BH) mm 6600 or more

BH: Backhoe
T4-2-3
Referen
EX3600-6
Performance Test Remarks ce
(Standard Performance)
Page
HYDRAULIC SYSTEM MPa (kgf/cm2, psi)
PRIMARY PILOT PRESSURE: Fast Idle 4.4±0.5 (45±5, 640±71) T4-5-1
Slow Idle 3.5 (35, 498) or more
SECONDARY EHC VALVE PRESSURE: Fast Idle With Lever
4.4±0.5 (45±5, 640±71) T4-5-2
Full Stroke
Slow Idle With Lever
3.5 (35, 498) or more
Full Stroke
SECONDARY D.Q.R VALUE PRESSURE: Fast Idle With Lever
4.3±0.5 (43±5, 619±71) T4-5-4
Full Stroke
Slow Idle With Lever
3.3 (32, 455) or more
Full Stroke
MAIN PUMP DELIVERY PRESSURE MPa (kgf/cm , psi)
2
29.4±1.0
(300±10, 4266±142)
MAIN RELIEF SET-Pressure MPa (kgf/cm2, psi) T4-5-6
Boom, Arm, Bucket, and Bucket Open 29.4＋2.0-0
Circuit Relief Pressure (300 -0, 4266＋284-0)
＋20
Travel Circuit Relief Pressure 29.4＋2.0-0

(300 -0, 4266＋284-0)
＋20
Swing Circuit Relief Pressure 29.4＋2.0-0

(300 -0, 4266＋284-0)
＋20
Bucket Close Circuit Relief Pressure 16.7＋1.5-0

(170＋ -0, 2417＋213-0)
15
OVERLOAD RELIEF SET-PRESSURE MPa (kgf/cm2, psi) 31.4＋1.0-0

T4-5-10
(320＋ -0, 4550＋142-0)
10
Bucket Close Circuit Relief Pressure 16.7＋1.5-0

(170 -0, 2417＋213-0)
＋15
MAIN PUMP FLOW RATE L/min − T4-5-12

OIL COOLER FAN DRIVE PUMP FLOW RATE L/min − T4-5-20
SWING MOTOR DRAIN AMOUNT L/min Allowable
(at constant swing speed)
3.5 or less Limit: T4-5-28
5.0 l/min
TRAVEL MOTOR DRAINAGE AMOUNT L/min Allowable
(While rotating at slow speed with the undercarriage
15 or less Limit: T4-5-30
raised off the ground.)
25 L/min

BH: Backhoe
T4-2-4
MAIN PUMP P-Q DIAGRAM MAIN PUMP Pi-Q DIAGRAM
• Hydraulic P-Q Control • Hydraulic Pi-Q Control
• Rated Pump Speed: 1838 min-1 (rpm) • Rated Pump Speed: 1838 min-1 (rpm)
• Pump Gear Reduction Ratio: 1.02 • Pump Gear Reduction Ratio: 1.02
• Hydraulic Oil Temperature: 50±5 °C (122±9 °F) • Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
NOTE: Refer to T4-5-12. NOTE: Refer to T4-5-14.
Main Pump P-Q Diagram Main Pump Pi-Q Diagram

Q P Q Pi
Location Location
L/min (US gal/min) MPa (kgf/cm2, psi) L/min (US gal/min) MPa (kgf/cm2, psi)
A 502±5 (132±1.3) 4.9 (50, 711) A 0.39±0.1
100±5 (26.4±1.3)
B [5.5±1.5 (56±15, (4±1, 57±14)
[501 (132)]
796±213)] B 3±0.1
502±5 (132±1.3)
C 400±30 (106±8) 9.8 (100, 1422) (28.9±1, 411±14)
D [13.4±0.5 (137±5,
[491 (130)]
1948±71)] Q (Flow Rate)
E 415±15 (109±3.9) 16.7 (170, 2417) L/min
F 258±30 (68±8) 19.6 (200, 2844) 500
B
G 284±15 (75±3.9) 24.5 (250, 3555) 400
H [227 (60)] [29.4 (300, 4266)]
I [19.2±1.0 (196±10, 300
[483 (127)]
2787±142)]
200
J 406±30 (107±8) 22.5 (230, 3271)
A
NOTE: [ ]: Reference Value 100
0 1 2 3
Q
(Flow Rate) Pi (Flow Rate Control Pilot Pressure)
L/min MPa
600
AB
500 D I
C J
E
400
300
F G
200 H
100
0
50 100 150 200 250 300 P (Pressure)
MPa
T146-04-04-004
T4-2-5
FAN MOTOR DRIVE PUMP P-Q DIAGRAM FAN MOTOR DRIVE PUMP Pi-Q DIAGRAM
• Hydraulic P-Q Control • Hydraulic Pi-Q Control
• Rated Pump Speed: 2198 min-1 (rpm) • Rated Pump Speed: 2198 min-1 (rpm)
• Pump Gear Reduction Ratio: 1.108 • Pump Gear Reduction Ratio: 1.108
• Hydraulic Oil Temperature: 50±5 °C (122±9 °F) • Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
NOTE: Refer to T4-5-20. NOTE: Refer to T4-5-22.
Radiator Fan Drive Pump P-Q Diagram Fan Motor Drive Pump Pi-Q Diagram
Q P Q Pi
Location Location
L/min (US gal/min) MPa (kgf/cm2, psi) L/min (US gal/min) MPa (kgf/cm2, psi)
A 390 (103) 4.9 (50, 711) 0.6±0.1
A 390±3 (103±0.8)
14.32±0.5 (6±1.85±14)
B 383 (101) 2.6±0.2
(146±5, 2076±71) B 80±5 (21±1.3)
C 313 (82) 17.65 (180, 2560) (26.5±2, 377±28)
Oil Cooler Fan Drive Pump P-Q Diagram 400 A

Q P 350
Location
L/min (US gal/min) MPa (kgf/cm2, psi)
A 390 (103) 4.9 (50, 711) 300
16.18±0.5 250
B 381 (101)
(165±5, 2346±71) Q (Flow Rate)
L/min 200
C 271 (72) 21.58 (220, 3128)
150
100 B
Q (Flow Rate)
L/min 50
400 A A’ B B’
0 1 (10.2) 2 (20.4) 3 (30.6)

Pi (Flow Rate Control Pilot Pressure)
2
300 C MPa (kgf/cm )
C’
200
100
0
9.8 19.6 29.4 P (Pressure)
2
(100) (200) (300) (kgf/cm )
T146-04-04-005
T4-2-6
ELECTRIC LEVER
When moving the electric lever, command current is
sent from the controller to ELU according to lever
stroke.
Boom, Arm, Bucket, Swing
15 to 20° 15 to 20°
-
+
Controller
To ELU X
T18G-03-04-001
Travel, Bucket Open/Close 12.4°±1° 12.4°±1°
Controller
To ELU
T18G-03-04-002
T4-2-7
Boom, Arm, Bucket, Swing
90%±2%
Short Zone
About 3°
Output
50%±1.5% Voltage
Ratio
10%±2%
Center
±15° to ±20°
Mechanical Control Angle
2 (Red)
1 (Yellow) 3 (Green)
Short Zone 4 (White) Short Zone
Resistor for Calibration Resistor for Calibration
30°±5°
Electrical Turning Angle
Total Resistance 2kΩ±15%
+ Direction on XY Axis
T18G-03-04-003
Travel, Bucket Open/Close

(Control Curve 25±5°C)
Control Torque Output Voltage

N⋅m Vout
100 v
16.0
15.3±1.5 80±7.5
Output
Voltage 50±5
12.0
Ratio
20±7.5
8.0
0 deg
5.5±1.0 12.4±1 0 12.4±1
T18M-03-04-004
4.0 Neutral Switch Voltage
0
12.4±1 0 12.4±1 deg
T18M-03-04-003
deg
T18G-03-04-006
T4-2-8
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Performance Test Conditions:

Oil Temperature : 50±5 °C(122±41 °F)
Ground Conditions : Solid, level ground
Measurement:
1. Turn the key switch to the OFF position to stop
the engine.
2. Disconnect the engine speed sensor connector.

Connect the pulse counter harness to engine
speed sensor harness.
3. Start the engine, run it at the specified speeds,

and read the pulse counter.
Calculate the engine speed using the following
formula:
-1
Engine speed (min ) = Pulse Number×60/168
Evaluation:
Refer to T4-2 Operational Performance Standard.
Engine Speed Sensor
T18M-04-03-001
T4-3-1
OPERATIONAL PERFORMANCE TEST / Engine Test
(Blank)
T4-3-2
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary:
1. Check the overall operational performance of the
travel power system (between the hydraulic
pumps and travel motors) by measuring time
required for the machine to travel the specified
distance.
Preparation:
1. Adjust the track sag equally on both right and left
undercarriages to 600±20 mm(23.6±0.8 in).
2. Prepare a flat and firm travel test yard 20 m (65.6
ft) long with fringes 2 to 3 m (6.5 to 9.8 ft) on both
ends for machine acceleration and deceleration. Track Sag:
600±20 mm
3. Empty the bucket and roll in the arm. (23.6±0.8 in)
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
T145-05-03-001
Backhoe
Deceleration Zone: Finish Travel Test Distance: Start Acceleration Zone:

2 to 3 m 20.0 m 2 to 3 m T142-05-03-001
(6.5 to 9.8 ft) (65.6 ft) (6.5 to 9.8 ft)
Measurement:
1. Measure travel time at both fast and slow travel Loading Shovel
speeds.
2. Engine Control Dial: Maximum Position.
Auto Idle Switch: OFF
3. Start machine to travel from the rear end of the
acceleration zone by moving the travel levers full
stroke.
4. Measure the time required to travel the travel test
distance 20 m (65.6 ft).
5. After measuring the forward travel time, rotate
the machine upperstructure 180°. Then, measure T145-05-03-006
the reverse travel time on the way back to the
starting position in the same method.
6. Repeat steps (3) and (5) three times and
calculate the average values.
Evaluation:
T4-4-1
TRACK REVOLUTION SPEED
Summary:
Check the overall operational performance of the
travel power system (between the hydraulic pumps
and travel motors) by measuring the track revolu- 90 to 110°
tion cycle time.
Preparation:
1. Adjust the track sag equally on both right and left T142-05-03-011
undercarriages to 600±20 mm (23.6±0.8 in).
2. Mark one shoe with chalk or a piece of cloth on
the track to be measured.
3. Rotate the upperstructure 90° to the track and
lower the bucket to raise the track to be meas-
ured off the ground. Keep the boom and arm an-
gle between 90 to 110° as illustrated.
90 to 110°
CAUTION: Never work under a machine

raised and solely supported by the boom.
Place blocks under the machine frame to T142-05-03-012
support the machine.
4. Maintain the hydraulic oil temperature at 50±5

°C(122±9 °F).
Measurement:
1. Measure the track rotation time at both fast and
slow travel speeds.
3. Operate the travel control lever of the raised
track in full forward and reverse.
Forward
4. After the track revolution attains to constant
speed, measure the time required for the marked Reverse
shoe to rotate three times in both directions.
5. Raise the other side of the track and repeat the
procedure. Travel Device T145-05-03-001
6. Repeat steps (3) and (4) three times and calcu-
late the average values.
Evaluation:
T4-4-2
MISTRACK
Summary:
1. Check the equilibrium in operational performance
between the right and left travel power systems
(between the hydraulic pumps and travel motors)
by measuring the amount of mistrack found while
the machine travels for the specified distance.
NOTE: When tested on a concrete surface road,

the amount of mistrack may be reduced.
T145-05-03-005
Preparation:
1. Adjust the track sag equally on both right and left
undercarriages to 600±20 mm (23.6±0.8 in).
2. Prepare a flat and firm travel test yard 20 m (65.6
ft) long with fringes 2 to 3 m (6.5 to 9.8 ft) on both
ends for machine acceleration and deceleration.
3. Empty the bucket and set the front attachment in
the driving position as illustrated.
(122±9 °F).
T145-05-03-006
Measurement:
1. Measure the amount of mistracking in both fast
and slow travel speeds.
3. Start machine to travel from the rear end of the
acceleration zone by moving both travel levers
full stroke.
Deceleration Zone:
4. Draw a 20 m (65.6 ft) straight line from the travel 2 to 3 m
test start point to the end point as illustrated. (6.5 to 9.8 ft)
Measure the maximum distance (A) between the
rut and the straight line.
5. Conduct the measurement in both forward and Maximum Distance (A)
reverse travel operation in the same method.
6. Repeat steps (3) and (5) three times and 20 m (65.6 ft)
Evaluation:
Acceleration Zone:
2 to 3 m
(6.5 to 9.8 ft)
T115-07-03-005
T4-4-3
TRAVEL MOTOR DRIFT CHECK
Summary:
The travel motor parking brake function and drift are
measured on a specified slope.
0.5 to 1.0 m
(20 to 40 in)
Preparation:
1. The test slope surface shall be flat with a gradi-
ent of 20 % (11.31°).
2. Empty the bucket. Fully extend the arm and
bucket cylinders. Hold the bucket 0.5 to 1.0 m T142-05-03-002
(20 to 40 in) above the ground as illustrated to
the right.
(122±9 °F).
Measurement: 0.5 to 1.0 m

(20 to 40 in)
1. Climb the slope. Return the travel levers to neu-
tral.
2. Stop the engine.
3. After the machine stops, put alignment marks on
the track shoe and the track side frame.
4. After five minutes have passed, measure the dif- T118-04-03-001
ference between the marks on the track shoe

and the track side frame.
Evaluation:
Alignment Marks on
Track Side Frame and Shoe
When Machine Stops.
Difference after 5 Minutes
T105-06-03-006
T4-4-4
SWING SPEED
Summary:
swing power system (between the hydraulic
pumps and swing motors) by measuring time
required for the machine upperstructure to make
three complete turns.
Preparation:
T145-05-03-007
1. Confirm that the swing gears and bearing are
sufficiently greased.
2. Secure a space wide enough for the machine
upperstructure to swing on a flat and firm surface.
Never attempt to perform this test on a slope.
3. Empty the bucket and position the front
attachment as described in the following.
Backhoe:
With the arm cylinders fully retracted and the
bucket cylinders fully extended, position the arm
top pin height flush with the boom foot pin height.
Loading shobel: T145-05-03-008
With the arm cylinder fully extended and the

(122±9 °F).
NOTE: In case it is difficult to secure the space

wide enough, test the machine with the
boom raised and the arm retracted.
CAUTION: Prevent personal injury. Always

make sure that the area is clear and that
coworkers are out of the swing area before
starting the measurement.
Measurement:
1. Engine Control Lever: Maximum Position
2. Operate the swing control lever at full stroke.
3. After the swing attains to constant speed,
3 Revolutions
measure the time required for the upperstructure
to rotate three times.
4. Measure in both directions (clockwise and
counterclockwise).
5. Repeat steps (2) and (4) three times and
Evaluation:
T145-05-03-009
T4-4-5
SWING FUNCTION DRIFT
Summary
1. Use the swing drift (measured on the circumfer-
ence of the swing bearing) when stopping after a
180° full-speed swing, to evaluate the swing
brake performance.
NOTE: The swing motor is equipped with a swing
parking mechanical brake.
Preparation: T145-05-03-007
1. Confirm that the swing gears and bearing are

sufficiently greased.
2. Secure a space wide enough for the machine
upperstructure to swing on a flat and firm surface.
Never attempt to perform this test on a slope.
3. Empty the bucket and position the front
attachment as described in the following.
Backhoe:
With the arm cylinders fully retracted and the
Loading shovel:
With the arm cylinder fully extended and the T145-05-03-008

4. Put aligning marks on the outer circumference of
the swing bearing and the track frame.
5. Swing the upperstructure 180°.
(122±9 °F).
make sure that the area is clear and that Return the
swing control
coworkers are out of the swing area before lever to the
starting the measurement. neutral position.
Measurement:
Drift
Auto Idle Switch: OFF Amount
2. Operate the swing lever full stroke. When the
upperstructure rotates 180° back to the original
position (when the marks on the swing bearing
and track frame aligns with each other), return
the swing lever to neutral.
3. After the upperstructure stops, measure the
distance between the two marks along the outer
circumference of the swing bearing.
4. Align the marks again. Then, measure in the
opposite direction.
5. Repeat steps (2) to (4) three times and calculate Rotate 180 °
the average values.
Evaluation:
T142-05-03-003
T4-4-6
SWING MOTOR LEAKAGE
Summary:
Park the machine on the specified slope with the
upperstructure swing 90° to the slope.
The upperstructure drift caused by the
uppersuructure weight is measured at the outer
diameter of the swing bearing to check the swing
parking brake performance (the swing device is
equpped with a mechanical type swing parking
brake).
Preparation:
1. Check the lubrication of the swing gear and
swing bearing.
2. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be T142-05-03-004
used.
Backhoe: W=30900 kg (68000 lb)
Loading Shovel: W=30000 kg (66000 lb)
3. Position the front attachment as described in the
following.
Loading shovel: With the arm cylinder fully
extended and the bucket cylinders fully extended,
position the arm top pin height flush with the
boom foot pin height.
Backhoe: With the arm cylinders fully retracted
and the bucket cylinders fully extended, position
the arm top pin height flush with the boom foot
pin height.
4. Park the machine on a smooth slope with a
gradient of 26.8 % (15°),
5. Swing the upperstructure to position it 90° to the
slope. Make aligning marks on the swing bearing
periphery and track frame using tape, as
illustrated.
(122±9 °F).
Measure Difference Between Marks
Measurement:
1. Stop the engine. After five minutes, measure the
difference between the marks along the swing
bearing periphery and the track frame.
2. Perform the measurement in both right and left
Marking on the Track Frame
swing directions.
3. Perform the measurement three times in each
Marking on the Swing Bearing
direction and calculate the average values.
T105-06-03-010
Evaluation:
T4-4-7
MAXIMUM SWINGABLE SLANT ANGLE
Summary:
1. With the upperstructure swung 90° to the slope,
check the maximum slant angle on which the
upperstructure can swing to the uphill side.
Preparation:
1. Check that the swing gear and bearing are well
lubricated.
weight (W) of the following specification can be
used.
following.
Loading shovel: With the arm cylinder fully
extended and the bucket cylinders fully extended, T142-05-03-004
position the arm top pin height flush with the

boom foot pin height.
Backhoe: With the arm cylinders fully retracted
and the bucket cylinders fully extended, position
the arm top pin height flush with the boom foot
pin height.
4. Climb a slope and swing the upperstructure 90°
to the slope.
(122±9 °F).
Measurement:
2. Operate the swing lever to full stroke to swing the
upperstructure to the uphill side.
3. If the machine can swing, measure the cab floor
slant angle.
4. When the machine can swing, increase the slant
angle. Then, repeat the test until the maximum
swingable angle is obtained. Check in both
clockwise and counterclockwise directions.
5. Perform the measurement three times in each
direction and calculate the average values.
Evaluation:
T4-4-8
(Blank)
T4-4-9
SWING BEARING PLAY
Summary:
Wear on the swing bearing races and rollers is
checked by measuring the play between the outer
and inner races of the swing bearing.
Dial
Gauge
Preparation:
1. Confirm that the swing bearing mounting bolts
are securely tightened. Round Trunk
2. Confirm that the swing bearing is well lubricated
and rotates smoothly with no noise.
3. Attach a dial gauge on the track frame using a Magnet
magnet base. (Secure the magnet base onto the Base
round trunk or a location as close to the round T105-06-03-015
trunk as possible.)
4. Position the upperstructure so that the bucket
faces toward the front idlers. A
5. Position the dial gauge so that its needle point D B
comes in contact with the bottom face of the
swing bearing outer race. C Take measurement of
6. Empty the bucket the plays at points A,
B, C, and D
NOTE The measured value will vary depending
on the location where the magnet base is
secured.
T145-05-03-023
T4-4-10
Measurement:
1. Take measurements of the play at positions A, B,
C, and D.
2. Position the front attachment as described in the A
following. D B
Backhoe: Measure the plays at
With the arm cylinders fully retracted and the positions A, B, C and
C D.
Loading shovel:
With the arm cylinder fully extended and the
3. Record the dial gauge reading (h1). Lower the
bucket to the ground and use it to raise the front
idler 0.5 m (20 in). Record the dial gauge reading
(h2).
4. Calculate bearing play (H) from this data (h1 and
h2) as follows:
H=h2 － h1
T145-05-03-023
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Backhoe
Measurement : (h1) Measurement : (h2)
T142-05-03-006
Loading Shovel
Measurement : (h1) Measurement : (h2)
T142-05-03-005
T4-4-11
HYDRAULIC CYLINDER CYCLE TIME
Summary:
front attachment hydraulic system (between the Backhoe
hydraulic pumps and each cylinder) by
measuring the cycle time of the boom, arm,
bucket, and bucket dump (open/close) cylinders Boom Cylinder
with the bucket emptied.
Preparation:
(122±9 °F). T145-05-03-012

following.
• Backhoe
Boom Cylinder:
With the bucket cylinder fully extended and the
arm cylinder fully retracted, lower the bucket to Arm Cylinder
the ground.
Arm Cylinder: T18M-04-04-001
With the center line between the boom tip pin and
arm tip pin vertical with the ground, adjust the
bucket bottom horizontal to the ground.
Bucket Cylinder:
Bucket Cylinder
Adjust the boom and arm cylinder so that the
center of full stroke movement of the bucket is
T145-05-03-014
positioned vertically.
• Loading Shovel Loading Shovel
Boom Cylinder:
With the bucket cylinder and the arm cylinder
fully extended, lower the bucket to the ground.
Arm Cylinder: Boom Cylinder
With the arm fully retracted, position the bucket
so that the rear bucket does not come in contact
with the arm stopper. Then, adjust the boom
cylinder stroke to position the bucket bottom 1 m
T145-05-03-015
(39 in) above the ground.
Bucket Cylinder:
With the bucket closed and held in a load dump
position, adjust the boom cylinder stroke so that
bucket bottom height is approx. 1 m (39 in) above Arm Cylinder
the ground.
Bucket Dump (Open-Close) Cylinder: T145-05-03-016
With the bucket cylinder and arm cylinder fully

extended, adjust the boom cylinder stroke so that
the bucket bottom height approx. 1 m (39 in)
above the ground. Bucket Cylinder
T145-05-03-017
Dump Cylinder
T145-05-03-018
T4-4-12
Measurement:
1. Select the following lever and switch positions:
Engine Control Lever: Maximum Position
Auto-Idle Switch: OFF
2. To measure cylinder cycle times:
(Cylinder full stroke includes cylinder cushioning
zone.)
(1) Boom cylinders:
Measure the time it takes to raise the boom, and
the time it takes to lower the boom. To do so,
position the boom at one stroke end, then move
the control lever to the other stroke end as
quickly as possible.
(2) Arm cylinder:
Measure the time it takes to roll in the arm, and
the time it takes to roll out the arm. To do so,
position the arm at one stroke end, then move
the control lever to the other stroke end as
quickly as possible.
(3) Bucket cylinder:
Measure the time it takes to roll in the bucket,
and the time it takes to roll out the bucket. To do
so, position the bucket at one stroke end, then
move the control lever to the other stroke end
as quickly as possible.
(4) Bucket dump (Open-Close) cylinder:
Mesure the time it takes to open the bucket, and
the time it takes to close the bucket. To do so,
position the bucket dump at one stroke end,
then move the bucket open-close pedal to the
other stroke end as quickly as possible.
3. Repeat the measurement three times and
Evaluation:
T4-4-13
CYLINDER DRIFT
Summary:
1. While holding the soil weight of or a specified
weight in the bucket, the dig function drift is
measured to check for internal oil leaks in the
control valve, boom, arm, and bucket cylinders.
2. After replacing the hydraulic cylinders, slowly
operate each cylinder for approx. 10 minutes to T145-05-03-020
bleed air from the hydraulic circuit before starting
the test.
Preparation:
weight (W) of the following specification can be
used.
2. Position the front attachment as described in the T145-05-03-021
following. BH: Boom and Bucket Cylinders Retraction

LD: Boom, Arm and Bucket Cylinders Retraction
Backhoe:
With the arm cylinder with rod approx.50 mm (2 Mark Mark
in) extended from the fully retracted position, and
bucket cylinder with the rod approx. 50 mm (2 in)
retracted from the fully extended, position the
arm top pin height flush with the boom foot pin
height.
Loading shovel:
With the arm cylinder with the rod approx. 50 mm
(2 in) retracted from the fully extended position,
and bucket cylinder with the approx. 50 mm (2 in) T110-06-03-002
retracted from the fully extended, position the

arm top pin height flush with the boom foot pin BH: Arm Cylinder Extension
height.
(122±9 °F).
Measurement: Mark
1. Stop the engine.
2. After five minutes have passed, measure the re-
tractions of the boom, arm, and bucket cylinders
as illustrated
3. Repeat step (2) three times and calculate the
average values.
Evaluation: T110-06-03-001
Refer to T4-2 Operational Performance Standard. NOTE: BH: Backhoe

LD: Loading Shovel
T4-4-14
CONTROL LEVER OPERATING FORCE
Summary:
1. Measure each control lever stroke play and op-
erating force, and check if it can be moved
smoothly.
2. Measure the maximum operating force for the
front attachment control levers.
3. Measure operating force at each lever grip top.
T18G-04-04-002
Measurement:
1. Stop the engine.
2. Measure all control levers.
Evaluation:
Refer to T4-2 Operational Performance Standard
T107-06-03-004
T4-4-15
CONTROL LEVER STROKE
Summary:
1. Measure each control lever stroke and stroke
play, and check if it can be moved smoothly.
2. Measure each lever stroke at the lever grip cen-
ter.
3. If a stroke play is present in the neutral position,
add half the value of the play to the one side
stroke.
Measurement:
1. Stop the engine.
2. Measure the full stroke of the boom, arm, bucket,
swing, and travel levers from the neutral position T107-06-03-005
at the lever grip top center.

3. Measure the stroke straight from the neutral posi-
tion to the stroke end.
4. Repeat each measurement three times and cal-
culate the average values.
Evaluation:
T4-4-16
BOOM RAISE/SWING COMBINED OP-
ERATION CHECK
Summary:
1. Check the combined operation performance
while operating the boom raise and swing
simultaneously.
2. Run the engine at full speed and check if the
boom cylinders move without hesitating. T142-05-03-007
Preparation:
1. Empty the bucket and position the machine with
front attachment positioned as illustrated.
2. Maintain the hydraulic oil temperature at 50 ± 5
°C (122 ± 9 °F).
CAUTION: Prevent personal injury. Always T142-05-03-008

co-workers are out of the swing area before
starting the measurement.
Measurement:
1. Run the engine at the maximum speed with the
auto idle switch OFF.
2. Operate the boom raise and swing levers full
stroke. Measure the time required for the ma-
chine to swing 90 ° and bucket tooth tip height H
raised while swinging.
3. Repeat the measurement in both directions three
times and calculate the average values.
T142-05-03-009
Evaluation:
T142-05-03-010
T4-4-17
(Blank)
T4-4-18
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE CHECK
Preparation:
1. Stop the engine.
CAUTION: The air breather cap may pop off if

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

ing the air breather cap at the oil supply port on
the hydraulic oil tank.
: 4 mm
3. Disconnect the pilot hose from the pilot relief valve.

Install tee (ST 6450) and a pressure gauge.
: 19 mm, 22 mm
Pilot
Filter
4. Start the engine. Check for oil leaks from the
pressure gauge connection.
(122±9 °F).
Pilot
Measurement: Hose
1. Measure the primary pilot pressure at the maxi-
mum and minimum engine speeds with the
auto-idle switch OFF.
2. Repeat each measurement three times and cal- Pilot Relief
Valve
T18M-04-05-001
Evaluation:
T4-5-1
SECONDARY EHC VALVE PRESSURE
CHECK
Preparation: Measurement:
1. Stop the engine.
CAUTION: Before starting measurement,
CAUTION: The air breather cap may fly off if check that there are no bystanders and/or
turned quickly. Slowly turn it to release in- obstructions within the swing radius.
ternal pressure before removing it. When measuring the boom lower secondary
pilot pressure, the base machine front may be
2. Release air from the hydraulic oil tank by loosen- raised off the ground. Take care not to allow
ing the air breather cap at the oil supply port on the rear of the machine to come in contact
the hydraulic oil tank. with the ground, which may make the ma-
: 4 mm chine become unbalanced, possibly resulting
3. Disconnect the hose (1 to 14) which corresponds in the machine overturning.
to the circuit to be checked. Install tee (ST 6450)
between the EHC valve and D.Q.R valve 1 or 2. 1. Measure the pilot pressure at the maximum and
Then, install a pressure gauge to the tee. minimum engine speeds with auto-idle switch
: 19, 22 mm OFF.
4. Start the engine. Check for oil leaks from the 2. Operate the control lever corresponding to the
pressure gauge connections. secondary pilot pressure to be checked. Measure
5. Maintain the hydraulic oil temperature at 50±5 °C the pressure with the control lever fully stroked.
(122±9 °F). 3. Repeat the measurement three times and calcu-
Evaluation:
NOTE: In case the measurement data is abnormal,
measure the primary pilot pressure. When
the primary pressure is normal, the EHC
valve can be determined as faulty.
T4-5-2
D.Q.R Valve 1 D.Q.R Valve 2
1 14
2 13
3 12
4 11
5 10
6 9
7 8
W18M-02-06-002 W18M-02-06-003
1- Right Travel Forward 5- Bucket Close (LD Only) 9 - Bucket Tilt-Out 12 - Right Swing
2- Right Travel Reverse 6- Bucket Open (LD Only) 10 - Boom Lower 13 - Left Swing
3- Left Travel Forward 7- Arm Retract (BH:Arm Out) 11 - Bucket Tilt-In 14 - Boom Raise
4- Left Travel Reverse 8- Arm Extent (BH:Arm In)
BH: Back-hoe Front

LD: Loader Front
T4-5-3
SECONDARY D.Q.R Valve PRESSURE
CHECK
Preparation: Measurement:
1. Stop the engine.
CAUTION: Before starting measurement,
CAUTION: The air breather cap may fly off if check that there are no bystanders and/or
turned quickly. Slowly turn it to release in- obstructions within the swing radius.
ternal pressure before removing it. When measuring the boom lower secondary
pilot pressure, the base machine front may
2. Release air from the hydraulic oil tank by loosen- be raised off the ground. Take care not to al-
ing the air breather cap at the oil supply port on low the rear of the machine to come in con-
the hydraulic oil tank. tact with the ground, which may make the
: 4 mm machine become unbalanced, possibly re-
3. Disconnect the hose (1 to 14) which corresponds sulting in the machine overturning.
to the circuit to be checked. Install a tee between
the shuttle valve and D.Q.R valve 1 or 2. Then, 1. Measure the pilot pressure at the maximum and
install a pressure gauge to the tee. minimum engine speeds with auto-idle switch
: 22, 27 mm OFF.
4. Start the engine. Check for oil leaks from the 2. Operate the control lever corresponding to the
pressure gauge connections. secondary pilot pressure to be checked. Measure
5. Maintain the hydraulic oil temperature at 50±5 °C the pressure with the control lever fully stroked.
(122±9 °F). 3. Repeat the measurement three times and calcu-
Evaluation:
NOTE: In case the measurement data is abnormal,
measure secondary EHC Valve pressure.
When secondary EHC Valve pressure is
normal, either D.Q.R valve 1 or 2 can be
determined as faulty.
T4-5-4
D.Q.R Valve 1 D.Q.R Valve 2
1 14
2 13
3
12
4
11
5
10
6
9
7
8
W18M-02-06-003
W18M-02-06-002
1- Right Travel Forward 5- Bucket Close (LD Only) 9 - Bucket Tilt-Out 12 - Right Swing
2- Right Travel Reverse 6- Bucket Open (LD Only) 10 - Boom Lower 13 - Left Swing
3- Left Travel Forward 7- Arm Retract (BH:Arm Out) 11 - Bucket Tilt-In 14 - Boom Raise
4- Left Travel Reverse 8- Arm Extent (BH:Arm In)
BH: Back-hoe Front

LD: Loader Front
T4-5-5
MAIN RELIEF PRESSURE CHECK
Preparation:
1. Stop the engine.
Plug
CAUTION: The air breather cap may pop off
if turned quickly. Slowly turn it to release in-
ternal pressure before removing it.
2. Release air from the hydraulic oil tank by loos-

ening the air breather cap at the oil supply port
on the hydraulic oil tank.
: 4 mm
3. Remove the plug from top of the high pressure

strainer. Install a pressure gauge to the plughole.
: 6 mm
4. Start the engine. Check for oil leaks from the

pressure gauge connection.
M146-07-036
5. Maintain the hydraulic oil temperature at 50±5 °C High Pressure
(122±9 °F). Strainer
Measurement:
1. Measure the pressure at the maximum engine
speed with auto-idle switch OFF.
2. Relieve each actuator to measure main relief
pressures.
First, slowly operate bucket, arm, and boom con-
trol levers to the stroke end to relieve each func-
tion one at a time.
2-1. As for the swing function, secure the upper-
structure so it is immovable. Slowly operate
the swing lever to relieve the swing function.
2-2. As for the travel function, secure the tracks
against an immovable object. Slowly operate
the travel levers to relieve the travel function.
3. Measure each relief pressure.
4. Repeat each measurement three times and cal-
Evaluation:
NOTE: In case the relief pressure in all circuits is

lower than specification, the main relief
set- pressure might be reduced. If the relief
pressure in one circuit is lower than speci-
fication, the overload relief set-pressure in
the corresponding circuit might be re-
duced.
T4-5-6
Set-Pressure Adjustment of Main Relief Valve
IMPORTANT: Do not use these in this section in Main Relief

order to customize the machine il- Valve
legally. For example; the machine
performance is set beyond the
specification. Otherwise, the ma-
chine life including the components
and so on may become short or be
broken. Future in addition, a serious
trouble may occur.
Adjustment:
1. Loosen lock nut.
: 17 mm
T118-05-02-043
2. Adjust the main relief valve set-pressure by turn-

ing adjusting screw. Lock Nut
: 6 mm
3. Retighten the lock nut.
: 17 mm
: 27.5 to 31.4 N⋅m Adjusting

(2.8 to 3.2 kgf⋅m, 20 to 23 lbf⋅ft) Screw
T145-02-03-001
4. Recheck the set-pressure after adjustment.
NOTE: Approximate Pressure Change

Adjusting Screw Turns 1/4 1/2 3/4 1 Lock Nut Adjusting Screw
MPa 4.5 8.9 13.4 17.8
Pressure
(kgf/cm2) (45.3) (90.5) (135.8) (181)
Change
(psi) (645) (1285) (1930) (2575)
Pressure Increase Pressure Decrease
W107-02-05-129
T4-5-7
Set-Pressure Adjustment of Swing Relief Valve
IMPORTANT: Do not use these in this section in

order to customize the machine il-
trouble may occur.
Adjustment:
1. Loosen the lock nut.
: 41 mm M144-07-012
Swing Relief Valve

2. Adjust the swing relief valve set-pressure by turn-
ing the adjusting screw. Lock Nut Adjusting
Screw
: 27 mm
: 41 mm
: 19.5 to 29.5 N⋅m

(2 to 3 kgf⋅m, 14.5 to 21.5 lbf⋅ft) T117-02-02-004
NOTE: Approximate Pressure Change Adjusting Screw

Adjusting Screw Turns 1/4 1/2 3/4 1
MPa 2.92 5.84 8.75 11.7
Pressure
(kgf/cm2) (30) (59.5) (89) (119)
Change
(psi) (426) (846) (1265) (1692)
T157-05-04-023
T4-5-8
Set-Pressure Adjustment of Travel Relief Valve
Travel Brake Valve
IMPORTANT: Do not use these in this section in
order to customize the machine il-
trouble may occur.
T144-03-05-002
Adjustment:
Travel Relief Valve
1. Loosen the lock nut.
: 17 mm
Lock Nut
2. Adjust the travel relief valve set-pressure by turn-

ing the adjusting screw.
: 6 mm
: 17 mm Adjusting Screw
: 34 to 44 N⋅m
(3.5 to 4.5 kgf⋅m, 25.5 to 32 lbf⋅ft)
T145-05-04-004

Lock Nut Adjusting Screw
MPa 1.96 3.92 5.88 7.85
Pressure
(kgf/cm2) (20) (40) (60) (80)
Change
(psi) (284) (569) (853) (1138)
W107-02-05-129
T4-5-9
OVERLOAD RELIEF VALVE SET PRES-
SURE
Checking the pressure setting of the overload relief
valves on the machine is not recommended for the
following reasons:
1. With the return circuit from the control valve

blocked, the circuit pressure must be increased
by applying an external load. This checking
method is hazardous and the results obtained
with this method are unreliable.
2. Pressure setting of the overload relief valve must
be made at a specified oil flow rate normally far
smaller than the delivery flow rate of the main
pump. Accordingly, even if the engine speed is
reduced and the main relief valve pressure set-
ting can be reset higher than the setting pressure
of the overload relief valve, the main pump sup-
plies too much oil to correctly measure the set-
ting pressure of the overload valve.
The main relief valve has pre-leaking function.
Accordingly, the main relief valve pressure setting
may not be reset higher than the set pressure of
the overload relief valve plus the pressure at
pre-leaking.
Therefore, when the setting pressure of the
overload relief valve must be checked correctly,
remove the overload relief valve from the ma-
chine and check the overload relief valve unit
performance using the test stand and test block
prepared for this purpose.
If the poppet of overload relief valve seats to the
body of control valve, the test block requires pre-
cise machining.
Use other control valve unit for the measurement
instead of the test block.
3. As an easier method, however, measure the re-
lief pressure of each cylinders in the same
method as of main relief pressure setting in pre-
vious section.
Then, when each relief pressure meets its re-
spective specifications, judge that the setting
pressure of the overload relief valve is correct.
Measurement:
Repeat the measurement three times and calculate
the average values.
Evaluation:
Refer to T4-5 Standard.
T4-5-10
Set-Pressure Adjustment of Overload Relief
Valve
IMPORTANT: In principle, adjust the overload re-

Overload
lief valve set pressure on a test Relief Valve
stand.
Adjustment:
1. Loosen lock nut.
: 17 mm
2. Adjust the overload relief valve set-pressure by

turning adjusting screw.
: 6 mm
3. Retighten lock nut. T118-05-02-043
: 17 mm
: 27.5 to 31.4 N⋅m
Lock Nut
(2.8 to 3.2 kgf⋅m, 20 to 23 lbf⋅ft)
Adjusting
Screw
T145-02-03-001
Adjusting Screw
MPa 5.3 10.6 15.9 21.2
Pressure
(kgf/cm2) (54) (108) (162) (216)
Change
(psi) (768) (1536) (2304) (3072) Pressure Increase Pressure Decrease
W107-02-05-129
T4-5-11
MAIN PUMP FLOW RATE MEASUREMENT
• P-Q Control (Torque Control) NOTE: The symbols put on the regulator ports
Summary: corresponds to the symbols used in the
Main pump performance is checked by measuring hydraulic circuit diagram as follows.
the pump flow rate with a hydraulic tester installed at
the main pump delivery port. Symbol in Hydraulic
Symbol on Regulator Port
Circuit Diagram
Preparation: Pi i1 to i8
1. Stop the engine.
Psv P1 to P8
CAUTION: The air breather cap may pop off
if turned quickly, possibly causing personal 5. Disconnect pipes from pump regulator ports Psv
injury. Slowly turn it to release internal pres- and Pi. Install tee (2) to port Psv. Connect hose
sure before removing it. (3) between tee (2) and circuit Psv. Connect hose
2. Remove the air breather cap from the hydraulic (1) to tee (2). Connect the other end of hose (1)
oil tank to bleed air. to port Pi using elbow (4). Install a plug to the
: 4 mm pipe end disconnected from port Pi.
3. Disconnect the delivery pipe from the main pump. (Connecting pump servo assist pressure (Psv)
Connect a hydraulic tester between the main circuit to port Pi allows the pump to be operated
pump and the disconnected delivery pipe. Nec- under ths same condition as the regulator re-
essary components and parts are as follows: ceives the maximum Pi pressure routed when the
• Hydraulic Tester (ST 6299) control lever is operated full stroke (maximum
• Adapter (ST 6146) flow rate operating condition).)
• Joint (ST 6330) 6. Disconnect the power increase solenoid valve
• Test Hose (ST 6120) (2 used) and the power decrease solenoid valve (SE and
• Pipe (ST 6132) SD port of the EHC Valve (for main pump con-
• Split Flange (ST 6133) (2 used) trol)).
• Socket Bolt (ST 6379) (4 used) 7. Install the engine speed pickup to the fuel injec-
• Flange (ST 6140) tion pipe.
4. Bleed air from the main pump. 8. Fully open the loading valve of the hydraulic
tester.
9. Start the engine. Check the line connections for
any oil leaks.
1 2 3
Psv (Port Size: PF1/4) Pressure
Pi Psv
Pressure Check Port (PF1/4)

Pi (Port Size: PF1/4)
Psv
4
T118-04-04-009
T4-5-12
Measurement:
1. Measure the maximum flow rate.
2. Auto-idle switch: OFF
3. Engine Control Dial: Fast idle position
4. Slowly close the loading valve of the hydraulic
tester to obtain the specified pressure on the P-Q
curve, and measure the pump flow rate and en-
gine speed.
NOTE: In case, a hydraulic tester in which a
pressure gauge is not provided is used, in-
stall a pressure gauge to the main pump
pressure check port before starting the
test.
5. Repeat the measurement three times and calcu-
Evaluation:
Convert the measured flow rates to those at the
specified pump speed using the following formulas:
Qc : Converted Flow Rate
Q : Measured Flow Rate
i : Pump Drive Gear Ratio (1.02)
Np : Specified Pump Speed (1838 min-1)
Ne : Measured Engine Speed
Qc = (Np × Q) ⁄ (i × Ne)
Main Pump P-Q Diagram

P Q
Q (Flow Rate)
Location MPa (kgf/cm2) L/min L/min
(psi) (US gal/min) 600
4.9 (50) 502±5
A AB
(711) (132±1.3) 500 D I
[5.5±1.5 J
B (56±15) [501 (132)] C E
400
(796±213)]
9.8 (100) 400±30
C 300
(1422) (106±8)
[13.4±0.5 F G
200 H
D (137±5) [491 (130)]
(1948±71)]
16.7 (170) 415±15 100
E
(2417) (109±3.9)
19.6 (200) 258±30 0
F 5 10 15 20 25 30 P (Pressure)
(2844) (68±8) MPa
24.5 (250) 284±15 T146-04-04-004
G
(3555) (75±3.9)
[29.4 (300)
H [277 (73)]
(4266)]
[19.2±1.0
I (196±10) [483 (127)] NOTE: [ ]: Reference Value
(2787±142)]
22.5 (230) 406±30
J
(3271) (107±8)
T4-5-13
• Pi-Q Control (Flow Rate Control by Flow Rate Con-
trol Pilot Pressure Pi) (Pilot Pressure Characteris-
tics)
Measurement:
Summary: 1. Measure the main pump flow rate corresponding
Main pump performance is checked by measuring to the flow control pilot pressure.
the pump flow rate with a hydraulic tester installed at 2. Turn the auto-idle switch OFF. Move the fuel
the main pump delivery port. lever to the fast idle position.
3. Adjust the reducing valve set-pressure to the
Preparation: specified pressure shown on the Pi-Q diagram
1. Referring to steps 1 to 3 on page T4-4-12, con- (pilot pressure characteristics) of the main pump.
nect a hydraulic tester to the main pump to be Measure the pump flow rate and engine speed at
measured. each specified pressure on the Pi-Q diagram.
2. Disconnect the pipe from regulator port Pi. Con- 4. Repeat the measurement three times and calcu-
nect hose (10) to port Pi. Plug the pipe end dis- late the average values.
connected from port Pi.
3. Install adapters (6) (3 used) to reducing valve (8). Evaluation:
Disconnect the pilot line from the pilot relief valve. Convert the measured flow rates to those at the
Connect tee (9) to the pilot relief valve. Connect specified pump speed using the following formulas:
adapter (4) and hose (7) to tee (9). Connect hose
(7) to port P1 on reducing valve (8). Qc : Converted Flow Rate
: 19 mm : 6 mm Q : Measured Flow Rate
4. Connect tee (9) to port P2 on reducing valve (8). i : Pump Drive Gear Ratio (1.02)
Connect pressure gauge (3) and hose (10) to tee Np : Specified Pump Speed (1838 min-1)
(9). Ne : Measured Engine Speed
: 19 mm
5. Connect hose (5) to port T on reducing valve (8).
After disconnecting the drain line from the pump, Qc = (Np×Q)/(i×Ne)
install tee (11) to the pump drain port. Connect
adapter (4) and hose (5) to tee (11).
: 19 mm, 22 mm Pi-Q Diagram
6. Bleed air from the pump. Flow Rate Control
Flow Rate
7. Fully open the loading valve of the hydraulic Location Pilot Pressure
2 L/min (US gal/min)
tester. MPa (kgf/cm ) (psi)
8. Start the engine. Check the line connections for 0.39±0.1(4±1) 100±5
A
any oil leaks. (57±14) (26.4±1.3)
2.83±0.1(28.9±1) 502±5
B
(411±14) (132±1.3)
Q (Flow Rate)
L/min
500
B
400
300
200
A
100
0 1 2 3

MPa
T4-5-14
Drain Line
Pilot Line
Pilot Relief
Valve
T18M-04-05-001
Regulator Pi
T146-04-04-001
Pi T117-02-01-004
Reducing Valve Port Location

To pump drain line
Reducing Valve (8)
T 11
4
3
P1 P2 5
6 To pilot line
10
To regulator
port Pi
9 6 8 6 7 4 9
T146-04-04-003
1- Plug PF1/4 4- Adapter UNF7/16 × PF1/4 7- Hose UNF7/16 × UNF7/16 10- Hose UNF7/16 × UNF7/16
(Parts No. 4042037)
2- Plug PF1/4 5- Hose UNF7/16 × UNF7/16 8- Reducing Valve 11- Tee PF1/4 × PF1/4 × PF1/4
(Parts No. 4325439) (ST 6640)
3- Pressure Gauge (ST 6931) 6- Adapter PF3/8 × UNF7/16 9- Tee UNF7/16 × UNF7/16 × PF1/4
(Parts No. 4200465) (ST 6451)
T4-5-15
Adjustment of Maximum and Minimum Flow Rate
The pump flow rate can be adjusted by changing NOTE: Turning screw (2) clockwise decreases the
the maximum servo piston stroke. When adjusting maximum flow rate, and turning counter-
the maximum flow rate, loosen nut (1) and adjust clockwise increases. 1/4 turn of screw (2)
screw (2) on the servo piston large chamber side. changes the flow rate approx. 9 L/min (2.4
When adjusting the minimum flow rate, loosen nut US gal/min).
(3) and adjust screw (4) on the servo piston small Turning screw (4) clockwise increases the
chamber side. minimum flow rate, and turning counter-
clockwise decreases. 1/4 turn of screw (4)
changes the flow rate approx. 9 L/min (2.4
US gal/min).
: 30 mm : Nut (1), Nut (3)

: 13 mm : Screw (2)
: 10 mm : Screw (4)
4 3 1 2 2 1 3 4
T117-02-01-004
(Pump Maximum Flow Rate Adjustment (Pump Minimum Flow Rate Adjustment
Flow Rate) Flow Rate)
Q Q
Pi
Pi
(Flow Rate Control (Flow Rate Control
Pressure) Pressure)
T4-5-16
Adjustment of Torque Control
The torque control is performed by pump delivery NOTE: When adjusting screw (4) is turned, inner
pressure P. Therefore, the torque constant control is spring (2) set-force varies. Therefore,
adjusted by changing the set-force of inner spring when adjusting screw (4) is turned, turn
(2) and outer spring (1). adjusting screw (6) 2.17 times the turns of
(Before adjust the screws (4) and (6), mark the end adjusting screw (4) in the opposite direc-
of the adjusting screw with a white marker for the tion to keep inner spring (2) set-force un-
record of the original position.) changed.
When resetting inner spring (2), loosen nut (5) and
adjust screw (6). : 36 mm : Nut (3)
When resetting outer spring (1), loosen nut (3) and : 24 mm : Screw (4)
adjust screw (4). : 13 mm : Nut (5)
: 4 mm : Screw (6)
1 2
3 4
5 6
T117-05-04-005
Outer Spring Adjustment Data Inner Spring Adjustment Data

Adjusting Screw Turn 1/4 Adjusting Screw Turn 1/4
Flow Rate Change 42 L/min (11 US gal/min) Flow Rate Change 19 L/min (5 US gal/min)
Pressure Change 1.86 MPa (19 kgf/cm2) Pressure Change 1.77 MPa (18 kgf/cm2)
(270 psi) (256 psi)
Engine Torque Change 74.5 N⋅m (7.6 kgf⋅m) Engine Torque Change 85 N⋅m (8.7 kgf⋅m)
(55 lbf⋅ft) (63 lbf⋅ft)
(Pump Flow (Pump Flow
Rate) Rate)
Q Q
P (Pump Delivery P (Pump Delivery

Pressure) Pressure)
T4-5-17
Adjustment of Flow Rate Control
The flow rate control is performed by pump flow NOTE: When the flow rate control is adjusted, the
rate control pressure Pi. Therefore, the flow rate relief oil minimizing control is also changed
control is adjusted by resetting the set-force of at the same time.
spring (1).
Loosen nut (2) and turn screw (3) to reset the : 13 mm : Nut (2)
set-force of spring (1). : 4 mm : Screw (3)
2 3
T117-05-04-006
Spring Adjustment Data

Adjusting Screw Turn 1/4
Pressure Change (Pi) 0.26 MPa (2.7 kgf/cm2)
(38.4 psi)
Flow Rate Change 44 L/min (11.6 US gal/min)
(Pump Flow Flow Rate Control Relief Oil Minimizing Control

Rate) (Pump Flow
Rate)
Q
Q
Pi (Flow Rate Control

P (Pump Delivery
Pressure) Pressure)
T4-5-18
(Blank)
T4-5-19
FAN MOTOR DRIVE PUMP FLOW RATE
MEASUREMENT
• P-Q Control (Torque Control) NOTE: The symbols put on the regulator ports
Summary: correspond to the symbols used in the hy-
Fan motor drive pump performance is checked by draulic circuit diagram as follows.
measuring the pump flow rate with a hydraulic tester
installed at the fan motor drive pump delivery port.
Symbol in Hydraulic
Symbol on Regulator Port
Circuit Diagram
Preparation: Pi i9 to i10
1. Stop the engine.
Psv P 9 to P10
CAUTION: The air breather cap may pop off 4. Bleed air from the fan motor drive pump.
if turned quickly, possibly causing personal 5. Disconnect the pipe from regulator ports Pi.
injury. Slowly turn it to release internal pres- Leave the port Pi open to the atmosphere. Plug
sure before removing it. the disconnected pipe end.
2. Remove the air breather cap from the hydraulic NOTE: Connectors to each solenoid valve are the
oil tank to bleed air. same in form. Put identification marks on
: 4 mm them to make reconnection easier.
3. Disconnect the delivery pipe from the fan drive 6. Disconnect the oil cooler fan speed control sole-
pump. Connect a hydraulic tester between the noid valve and the radiator fan speed control so-
fan drive pump and the disconnected delivery lenoid valve (SH and SB port of the EHC valve
pipe. Necessary components and parts are as (For main pump control)).
follows: 7. Install the engine speed meter to the fuel injec-
• Hydraulic Tester (ST 6299) tion pipe.
• Adapter (ST 6146) 8. Fully open the loading valve of the hydraulic
• Joint (ST 6330) tester.
• Test Hose (ST 6120) (2 used) 9. Start the engine. Check the line connections for
• Pipe (ST 6128) any oil leaks.
• Split Flange (ST 6130) (2 used)
• Socket Bolt (ST 6379) (4 used)
• Flange (ST 6118)
Radiator Fan Motor Drive Pump Oil Cooler Fan Motor Drive Pump
Pi
Pressure Check Port (PF1/4) Pi

(Port Size: PF1/4)
T117-02-01-004
T4-5-20
Measurement:
1. Measure the maximum flow rate.
2. Auto-idle switch: OFF
3. Engine Control Dial: Maximum position
4. Slowly close the loading valve of the hydraulic
tester to obtain the specified pressure on the P-Q
curve shown below, and measure the pump flow
rate and engine speed.
NOTE: In case, a hydraulic tester in which a
pressure gauge is not provided is used, in-
stall a pressure gauge to the pump pres-
sure check port before starting the test.
5. Repeat the measurement three times and calcu-
Evaluation:
Convert the measured flow rates to those at the
specified pump speed using the following formulas:
Qc: Converted Flow Rate
Q : Measured Flow Rate
i : Pump Drive Gear Ratio (1.108)
Np : Specified Pump Speed (2198 min-1)
Ne : Measured Engine Speed
QC = (Np × Q) ⁄ (i × Ne)
Radiator Fan Motor Drive Pump P-Q Diagram

Q P Oil Cooler Fan Motor Drive Pump P-Q Diagram
Location L/min MPa (kgf/cm2) Q P
(US gal/min) (psi) Location L/min MPa (kgf/cm2)
390 4.9 (50) (US gal/min) (psi)
A A’ 390 4.9 (50)
(103) (711)
383 14.32±0.5 (146±5) (103) (711)
B B’ 381 16.18±0.5 (165±5)
(101) (2076±71)
313 (101) (2346±71)
C 17.65 (180) (2560) C’ 271 21.58 (220)
(82)
(72) (3128)
Q (Flow Rate)
L/min A A’
400 B B’
300 C
C’
200
100
0
9.8 19.6 29.4 P (Pressure)
(100) (200) (300) Mpa (kgf/cm2)
T146-04-04-005
T4-5-21
• Pi-Q Control (Flow Rate Control by Flow Rate Con-
trol Pilot Pressure Pi) (Pilot Pressure Characteris-
tics)
Measurement:
Summary: 1. Measure the pump flow rate corresponding to the
Fan motor drive pump performance is checked by flow control pilot pressure.
measuring the pump flow rate with a hydraulic tester 2. Turn the auto-idle switch OFF. Move the fuel
installed at the fan motor drive pump delivery port. lever to the fast idle position.
3. Adjust the reducing valve set-pressure to the
Preparation: specified pressure shown on the Pi-Q diagram
1. Referring to steps 1 to 3 on page T4-4-20, con- (pilot pressure characteristics) of the fan motor
nect a hydraulic tester to the fan motor drive drive pump. Measure the pump flow rate and en-
pump to be measured. gine speed at each specified pressure on the
2. Disconnect the connectors from each fan speed Pi-Q diagram.
control solenoid valve (SH and SB of the EHC 4. Repeat the measurement three times and calcu-
valve (for main pump control)). late the average values.
3. Install adapters (6) (3 used) to reducing valve (8).
Disconnect the pilot line from the pilot relief valve. Evaluation:
Connect Tee (9) to the pilot relief valve. Connect Convert the measured flow rates to those at the
adapter (4) and hose (7) to tee (9). Connect hose specified pump speed using the following formulas:
(7) to port P1 on reducing valve (8).
: 19 mm : 6 mm Qc : Converted Flow Rate
4. Connect tee (9) to port P2 on reducing valve (8). Q : Measured Flow Rate
Connect pressure gauge (3) and hose (10) to tee i : Pump Drive Gear Ratio (1.108)
(9). Np : Specified Pump Speed (2198 min-1)
: 19 mm Ne : Measured Engine Speed
5. Connect hose (5) to port T on reducing valve (8).
After disconnecting the drain line from the pump, Qc = (Np×Q)/(i×Ne)
install tee (11) to the pump drain port. Connect
adapter (4) and hose (5) to tee (11). Fan Drive Pump Pi-Q Diagram
: 19 mm, 22 mm Flow Rate Control
6. Bleed air from the pump. Flow Rate
Location Pilot Pressure
7. Fully open the loading valve of the hydraulic L/min (US gal/min)
MPa (kgf/cm2) (psi)
tester.
0.6±0.1(6±1)
8. Start the engine. Check the line connections for A 390±3 (103±0.8)
(85±14)
any oil leaks.
2.6±0.2(26.5±2)
B 80±5 (21±1.3)
(377±28)
400 A
350
300
250
Q (Flow Rate)
L/min 200
150
100 B
50
0 1(10.2) 2(20.4) 3(30.6)

2
MPa(kgf/cm )
T4-5-22
Drain Line
Pilot Line
Pilot Relief
Valve
T18M-04-05-001
Regulator Pi
T146-04-04-001
Pi T117-02-01-004
Reducing Valve Port Location

To pump drain line
Reducing Valve (8)
T 11
4
3
P1 P2 5
6 To pilot line
10
To regulator
port Pi
9 6 8 6 7 4 9
T146-04-04-003
1- Plug PF1/4 4- Adapter UNF7/16 × PF1/4 7- Hose UNF7/16 × UNF7/16 10- Hose UNF7/16 × UNF7/16
(Parts No. 4042037)
2- Plug PF1/4 5- Hose UNF7/16 × UNF7/16 8- Reducing Valve 11- Tee PF1/4 × PF1/4 × PF1/4
(Parts No. 4325439) (ST 6640)
3- Pressure Gauge (ST 6931) 6- Adapter PF3/8 × UNF7/16 9- Tee UNF7/16 × UNF7/16 × PF1/4
(Parts No. 4200465) (ST 6451)
T4-5-23
Adjustment of Maximum and Minimum Flow Rate
of Fan Motor Drive Pump
The pump flow rate can be adjusted by changing the NOTE: Turning screw (2) clockwise decreases the
maximum servo piston stroke. When adjusting the maximum flow rate, and turning counter-
maximum flow rate, loosen nut (1) and adjust screw clockwise increases. 1/4 turn of screw (2)
(2) on the servo piston large chamber side. When changes the flow rate approx. 8.0 L/min
adjusting the minimum flow rate, loosen nut (3) and (2.1 US gal/min).
adjust screw (4) on the servo piston small chamber Turning screw (4) clockwise increases the
side. minimum flow rate, and turning counter-
clockwise decreases. 1/4 turn of screw (4)
changes the flow rate approx. 8.0 L/min
(2.1 US gal/min).
: 30 mm : Nut (1)
: 24 mm : Nut (3)
: 13 mm : Screw (2)
: 8 mm : Screw (4)
4 3 1 2 2 1 3 4
T117-02-01-004
(Pump Flow Maximum Flow Rate Adjustment (Pump Flow Minimum Flow Rate Adjustment
Rate) Q Rate) Q
Pi (Flow Rate Pi (Flow Rate

Control Control
Pressure) Pressure)
T4-5-24
Adjustment of Constant Torque Control System
Pump drive torque is controlled by own pump deliv- NOTE: When adjusting screw (4) is turned,
ery pressure (P). Therefore, pump drive torque is set-force of inner spring (2) also changes.
adjusted by changing the set-force of inner spring (2) Therefore, turn adjusting screw (6) in the
and outer spring (1). (Before adjusting, mark the end reverse direction by 2.17 times the number
faces of screws (4 and 6) with white paint to record adjusting screw (4) was turned.
their original positions.)
When adjusting inner spring (2), loosen nut (5) and : 36 mm: Nut (3)
turn screw (6). When adjusting outer spring (1), : 24 mm: Screw (4)
loosen nut (3) and turn screw (4). : 13 mm: Nut (5)
: 13 mm: Nut (5)
1 2
3 4
5 6
T117-05-04-005
Change in Flow Rate When Adjusting Outer Spring Change in Flow Rate When Adjusting Inner Spring
Adjusting Screw Turn 1/4 Adjusting Screw Turn 1/4
Flow Rate Change 32.0 L/min (8.5 US gal/min) Flow Rate Change 32.0 L/min (8.5 US gal/min)
1.57 MPa (16.0 kgf/cm2) 3.73 MPa (38.0 kgf/cm2)
Pressure Change Pressure Change
(228 psi) (540 psi)
44 N⋅m (4.5 kgf⋅m) 29 N⋅m (3.0 kgf⋅m)
Engine Torque Change Engine Torque Change
(33 lbf⋅ft) (22 lbf⋅ft)
(Pump (Pump
Flow Rate) Flow Rate) Q
Q
P (Pump Delivery Pressure)

P (Pump Delivery Pressure)
T4-5-25
Adjustment of Flow Rate Control
The flow rate control is performed by pump flow rate
control pressure Pi. Therefore, the flow rate control
is adjusted by resetting the set-force of spring (1).
Loosen nut (2) and turn screw (3) to reset the
set-force of spring (1).
: 13 mm : Nut (2)
: 4 mm : Screw (3)
2 3
T117-05-04-006
Spring Adjustment Data

Adjusting Screw Turn 1/4
Pressure Change (Pi) 0.15 MPa (1.5 kgf/cm2)
(21.3 psi)
Flow Rate Change 23 L/min (6 US gal/min)
(Pump Flow
Flow Rate Control
Rate)
Q
Pi (Flow Rate Control

Pressure)
T4-5-26
(Blank)
T4-5-27
SWING MOTOR DRAIN CHECK
Summary:
1. While rotating the upperstructure, measure the
drain oil amount from the swing motor to check
the swing motor performance.
NOTE: 1. The drain oil amount from the swing

motor fluctuates depending on oil tem-
perature. Maintain the correct oil tem-
perature to check correctly.
2. Evaluate all swing motors one by one.
Preparation:
1. Rotate the swing motor to warm the inside of the
motor.
CAUTION: If the air breather cap is quickly

removed, the air breather cap may pop off
due to air pressure, possibly causing per-
sonal injury. Be sure to slowly loosen the air
breather cap to release air pressure before
removing the air breather cap.
2. Stop the engine. Slowly loosen the air breather

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

adapters at the hydraulic oil tank side from the
return pipe. Put plugs (PF1) to the adapter dis-
connected ports on the pipes.
Disconnect hose at
Hose: Disconnect hose at this position
: 36 mm, 41 mm this position Drain
: 295 N⋅m (30 kgf⋅m, 215 lbf⋅ft) Swing Hose
Motor Swing
Motor
Adapter:
: 41 mm
: 205 N⋅m (21 kgf⋅m, 152 lbf⋅ft)

co-workers are out of the swing area before
starting machine operation. Also, take care
not to fall off the machine during the meas-
urement.
Preconditions:
1. Engine: Fast Idle Speed
Pipe
T146-04-04-002
T4-5-28
Measurement:
1. Amount of Oil Drained While Swinging the
Upperstructure
(1) Fully roll out: Backhoe extend: Loading shovel
the arm. Fully roll in: Backhoe tilt in: Loading
shovel the bucket. Raise the boom so that the
arm tip pin height is the same as the boom foot
pin height. Be sure that the bucket is empty.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start draining oil measurement
T145-05-03-007
after the swing speed reaches a constant
maximum speed. The measuring time should
be more than 20 seconds.
(3) Repeat the measurement at least three times in
both clockwise and counterclockwise directions,
and calculate the average values.
2. Amount of Oil Drained While Relieving Swing

Motor Circuit
(1) Thrust the bucket teeth into the ground so that
the upperstructure does not rotate when the
swing lever is operated full stroke.
(2) Start the engine. Operate and hold the swing T145-05-03-008
lever full stroke. Start drain oil measurement

when drain oil starts coming out of the drain
hose end. The measuring time should be more
than 20 seconds.
both clockwise and counterclockwise directions,
and calculate the average values.
Evaluation:
* Conversion of the amount of drain oil measured

into the per-minute value
First measure the amount of drain oil using a

calibrated container. Then, convert the measured
drain oil into the per-minute value using the
formula below:
∆Q=60×q / t
Where:
∆Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-5-29
TRAVEL MOTOR DRAIN CHECK
Summary:
While rotating the travel motor with the measuring
side track jacked up, measure the drain oil amount
from the travel motor to check the travel motor per-
formance.
NOTE: 1. The drain oil amount from the travel

motor fluctuates depending on the oil
temperature. Maintain the correct oil
temperature to check correctly.
2. Evaluate total performance of the travel
motor taking travel speed and mistrack
test data into consideration.
Preparation:
1. Rotate the travel motor to warm the inside of the
motor.
CAUTION: If the air breather cap is quickly

removed, the air breather cap may pop off
due to air pressure, possibly causing per-
sonal injury. Be sure to slowly loosen the air
breather cap to release air pressure before
removing the air breather cap.
2. Stop the engine. Slowly loosen the air breather

cap to release air pressure from the hydraulic oil
tank.
3. Disconnect the travel motor drain hose and Disconnect hose at
adapters at the hydraulic oil tank side. Put plugs this position
(1-1/16-12 UNF) to the adapter disconnected
ports on the manifold.
: 36 mm
: 177 N⋅m (18 kgf⋅m, 130 lbf⋅ft)
Preconditions:
Engine: Fast Idle Speed
Drain Hose T146-04-04-006
Travel Motor
T4-5-30
Measurement:
(1) Start the engine. Jack up the measuring side
track using the front attachment, as illustrated.
CAUTION: When working around moving

parts is unavoidable, pay special attention to 90 to 110°
ensure that hands, feel, and clothing do not
become entangled. Securely support the
raised track using wooden blocks.
T142-05-03-011
(2) Rotate the raised track with the travel lever

operated full stroke. Start drain oil
measurement after the track rotation speed
reaches a constant maximum speed. The
measuring time should be more than 20
seconds.
90 to 110°

both forward and reverse directions and
calculate the average values. T142-05-03-012
Evaluation:
* Conversion of the amount of drain oil measured

into the paramount value
First measure the amount of drain oil using a

calibrated container. Then, convert the measured
drain oil into the paramount value using the
formula below:
∆Q= 60×q/t
Where:
∆Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-5-31
(Blank)
T4-5-32
SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 General Group 4 Troubleshooting B
Introduction ..............................................T5-1-1 Troubleshooting B Procedures..................T5-4-1
Diagnosing Procedure ..............................T5-1-2 How to Read Fault Codes .........................T5-4-2
Starting Check Indication..........................T5-1-4 Fault Code for Engine...............................T5-4-4
Alarm Indication .......................................T5-1-6
Group 5 Troubleshooting C
Fault Diagnosis Indication ........................T5-1-8
Troubleshooting C Procudure ...................T5-5-1
Automatic Snapshot Indication ...............T5-1-10
Diagnosis by blinking of Indicator ...........T5-5-14
Monitor And Manual Snapshot Indicator..T5-1-12
Maintenance History Display ..................T5-1-16 Group 6 Electrical System Inspection
Life Data Display ....................................T5-1-18 Precautions for Inspection and
Machine Information Indication ...............T5-1-20 Maintenance ...........................................T5-6-1
Various Setup Indication .........................T5-1-22 Disconnection of Connector......................T5-6-3
Maintenance Setup.................................T5-1-24 Battery Voltage Check ..............................T5-6-4
Fusible Link Inspection .............................T5-6-6
Group 2 Component Layout
Fuse Continuity Check..............................T5-6-8
Main Components ....................................T1-2-1
Alternator Check ....................................T5-6-15
Control Valve............................................T1-2-4
Voltage Check ........................................T5-6-16
Under Carrige...........................................T1-2-6
5 Volt Circuit ...........................................T5-6-23
Travel Device ...........................................T1-2-7
Check Using False Signal.......................T5-6-24
Swing Device ...........................................T1-2-8
Continuity Check ....................................T5-6-25
Electrical Components..............................T1-2-9
Circuit Check by Lamp Harness .............T5-6-26
Pilot Piping .............................................T1-2-26
Fast Filling Device ..................................T1-2-28
Group 3 Troubleshooting A
Troubleshooting A Procedures ..................T5-3-1
Fault Diagnosis Indication Fault Code ......T5-3-4
18MT-5-1
(Blank)
18MT-5-2
TROUBLESHOOTING / General
INTRODUCTION
Refer to the inspection and troubleshooting procedures

after any machine trouble has occurred. The inspection
and troubleshooting procedures are presented in an
orderly fashion in this section to help you quickly find
the cause and solution of the machine trouble.
The troubleshooting section in this manual consists of

6 groups; General, Component Layout, Troubleshoot-
ing A (base machine diagnosis indicated in the monitor
display fault codes), Troubleshooting B (engine diag-
nosis indicated by the flashing pattern of indicator
lights), Troubleshooting C (Air conditioner diagnosis),
and Electrical System Inspection.
• General
• Component Layout
• Troubleshooting A (base machine diagnosis indi-
cated in the monitor display fault codes)
• Troubleshooting B (engine diagnosis relies on the
flashing pattern of indicator lights)
The engine is diagnosed by referring to the flash-
ing pattern of the engine warning indicator.
• Troubleshooting C (Air conditioner diagnosis)
Refer to these procedures when troubleshooting
by inspecting abnormal machine operational
status.
Example: Air conditioner malfunction.
• Electrical System Inspection

Refer to this group when required to obtain pre-
cautions and/or information for the electrical sys-
tem inspection.
Example: Fuse Inspection
T5-1-1
DIAGNOSING 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.
T107-07-01-001
2. Ask the operator

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

Before starting the troubleshooting procedure,
check the machine’s daily maintenance points, as
shown in the operator's manual.
Also, check the electrical system, including the

batteries, as troubles in the electrical system such
as low battery voltage, loose connections and
blown fuses will result in malfunction of the
controllers, causing total operational failure of the
machine.
If troubleshooting is started without checking for

blown fuses, a wrong diagnosis may result, wast-
ing time. Be sure to check for blown fuses before
troubleshooting. Even if a fuse looks normal by
visual inspection, a fine crack is difficult to find.
Always use a tester when checking the fuses.
T107-07-01-003
T5-1-2
4. Operate the machine yourself
Try to identify the trouble by operating the
machine yourself.
If the trouble cannot be confirmed, stop the engine
and obtain further details of the malfunction from
the operator.
Also, check for any incomplete connections of the
wire harnesses.
5. Perform troubleshooting T107-07-01-004
CAUTION: If a harness or pipe is discon-

nected with the engine running, the machine
may operate incorrectly, or high pressure oil
may spray, causing personal injury. Be sure
to disconnect harnesses or pipes after stop-
ping the engine.
Perform self-diagnosis by operating the monitor

display. In case any fault code has been displayed
by diagnosis using the monitor display, check the
cause of the trouble by referring to Troubleshoot-
ing A in this section. After the machine trouble has
been corrected, the fault code will be deleted. If
the engine stop indicator and the engine warning
indicator in the electrical equipment box start
flashing by the ECM diagnosis system, check the
cause of the trouble by referring to Troubleshoot-
ing B in this section. Therefore, in case problems
which are not easily repredicable are encountered,
use the built-in self-diagnosing system and ECM
diagnosis system to display the fault code.
T107-07-01-006
6. Trace possible causes

Before reaching a conclusion, check the most
likely causes again. Try to identify the actual
cause of the trouble.
Based on your conclusion, make a plan for

appropriate repairs to avoid consequent
malfunctions.
T107-07-01-007
T5-1-3
STARTING CHECK INDICATION
IDU indicates the starting check information on the
monitor display in response to level sensor signals
received from each controller through CAN.
IMPORTANT: Monitor display can be switched by

the keypad.
Indication Key Pad T18G-02-01-108
Starting Window
1. When the engine is not running and Meter Win-
dow appears on the monitor display, press the ?
key to display the Starting Check Window on the
monitor display.
To return to the Meter Window, press the × key
again.
Automatic Transition T18M-05-01-003
Meter Window
T18M-05-01-001
Starting Check Window
T18M-05-01-002
T5-1-4
(Blank)
T5-1-5
ALARM INDICATION
IDU indicates the alarm information on the monitor
display in response to alarm signals received from
each controller through CAN.

the keypad.
Starting Window
1. When the Meter Window appears on the monitor
display, press the ← key to display the Current
Alarms List Window on the monitor display.
again.
Meter Window
2. Select the required item from the list, using the ↑
and ↓ keys, and press the ○ key. The Alarm Ex-
planation Window will appear. (See to next page.)
To return the Current Alarms List Window, press
the × key again.
T18M-05-01-001
Current Alarm List Window
T18M-05-01-004
T5-1-6
3. To display the Detailed Circuit Diagram Window,
press the ○ key. Alarm Explanation Window
To return to the Alarm Explanation Window, press
the × key again.
T18G-05-01-004
Detailed Circuit Diagram Window
T18G-05-01-005
T5-1-7
FAULT DIAGNOSIS INDICATION
IDU indicates the fault diagnosis results on the monitor
display in response to fault signals received from each
controller through CAN.
IMPORTANT: Monitor display window can be

switched by the keypad.
Starting Window
display, press the → key to display the Current
Faults List Window on the monitor display.
again.
Meter Window
and ↓ keys, and press the ○ key. The Faults Ex-
planation Window of the selected item will appear.
(See to next page.)
To return the Current Faults List Window, press
the × key again.
T18M-05-01-001
Current Faults List Window
T18M-05-01-005
T5-1-8
press the ○ key. Faults Explanation Window
To return to the Fault Explanation Window, press
the × key again.
T18G-05-01-007
Detailed Circuit Diagram Window
T18G-05-01-027
T5-1-9
AUTOMATIC SNAPSHOT INDICATION
IDU indicates the related snapshot lists on the monitor
display on time-series basis in response to event log
received from DLU through CAN.

Starting Window
display, press the ○ key. Service Menu Window
will appear.
again.
Meter Window
2. Select Automatic Snapshot List from menu, using
the ↑ and ↓ keys, and press the ○ key. Automatic
Snapshot List Window will appear. (See to next
page.)
To return to the Service Menu Window, press the
× key again.
T18M-05-01-001
Service Menu Window
T18M-05-01-008
T5-1-10
and ↓ keys, and press the → key. Snapshot Win- Automatic Snapshot List Window
dow of the selected item will be appear.
To return the Automatic Snapshot List Window,
press the × key again.
IMPORTANT: If there is no auto snapshot data,

reproduction will not appear on the
display.
T18M-05-01-011
Snapshot Window
T18M-05-01-015
T5-1-11
MONITOR AND MANUAL SNAPSHOT IN-
DICATION
IDU receives operating status of devices used for the
corresponding control from DLU, MC or ELU through
CAN, and indicates it on the monitor display, records
and reproduce it.

Monitor/Record/Replay
Starting Window
will appear.
again.
Meter Window
2. Select Monitor and Manual Snapshot from menu,
using the ↑ and ↓ keys, and press the ○ key.
Monitor and Manual Snapshot Menu Window will
appear. (See to next page.)
× key again.
T18M-05-01-001
Service Menu Window
T18M-05-01-008
T5-1-12
3. Select Monitor/Record/Replay from menu, using
the ↑ and ↓ keys, and press the ○ key. Moni- Monitor and Manual Snapshot Menu Window
tor/Record/Replay List Window will appear.
To return to Monitor and Manual Snapshot Menu
Window, press the × key again.
T18G-05-01-011
4. Select the required item from the list, using the ←, Monitor / Record / Replay List Window
→, ↑ and ↓ keys, and press the ○ key. Snapshot
Window of the selected item will appear.
To return to Monitor/Record/Replay List Window,
T18M-05-01-006
Snapshot Window
5. Select an item you want to record from the snap-
shot, using the ↑ and ↓ keys, and press the ○ key.
Data on the selected item will be recorded.
T18M-05-01-014
T5-1-13
Replay

the keypad.
Key Pad T18G-02-01-108
Indication
1. Display Monitor and Manual Snapshot Menu Monitor and Manual Snapshot Menu Window
Window. (See T5-1-12.)
T18G-05-01-011
Replay List Window

2. Select Replay from menu, using the ↑ and ↓ keys,
and press the ○ key. Replay List Window will ap-
pear.
To return to Monitor and Manual Snapshot Menu
Window, press the × key again.
3. Select an item you want to display from the list,

using the ↑ and ↓ keys, and press the ○ key. The
Reproduction Window of the selected item will
appear.
To return to the Replay List Window, press the ×
key again. T18G-05-01-013
Reproduction Window
4. Select the data reproduction item from the Re-
production Window, using the ←, →, ↑ and ↓ keys,
and press the ○ key. Data on the selected item will
be reproduced.
T18G-05-01-014
T5-1-14
(Blank)
T5-1-15
MAINTENANCE HISTORY DISPLAY
IDU Indicates the log (maintenance history) at the re-
placement of air filter, engine oil and hydraulic oil in
terms of hourmeter reading, number of replacement
and time length until the next replacement.
As replacement items are shown in the list, select the
required item from the list to record replacement his-
tory.

Starting Window
1. When the Meter Window appears on the Monitor
will appear.
again.
Meter Window
2. Select Maintenance History from menu, using the
↑ and ↓ keys, and press the ○ key. Maintenance
History List Window will appear. (See to next
page.)
× key again.
T18M-05-01-001
Service Menu Window
T18M-05-01-008
T5-1-16
3. Select the required maintenance name from the
list, using the ↑ and ↓ keys, and press the ○ key. Maintenance History List Window
Maintenance Name, Hourmeter Hours and Main-
tenance Date Window will appear on the display.
To return to the Maintenance History List Window,
T18G-05-01-015
Maintenance Name, Hourmeter Hours

and Maintenance Date Window
T18G-05-01-016
T5-1-17
LIFE DATA DISPLAY
IDU receives cumulative information, including cumu-
lative engine running hours and machine operating
hours, from DLU through CAN, and indicates it on the
monitor display.

Starting Window
will appear.
again.
Meter Window
2. Select Life from menu, using the ↑ and ↓ keys, and
press the ○ key. Life Data Window will appear.
(See to next page.)
× key again.
T18M-05-01-001
Service Menu Window
T18M-05-01-008
T5-1-18
Life Data Window
T18G-05-01-017
T5-1-19
MACHINE INFORMATION INDICATION
IDU indicates controller configuration, as well as
hardware and software (version) used in respective
controllers.

Starting Window
will appear.
again.
Meter Window
2. Select Machine Information from menu, using the
↑ and ↓ keys, and press the ○ key. Machine In-
formation Window will appear.
(See to next page.)
× key again.
T18M-05-01-001
Service Menu Window
T18M-05-01-008
T5-1-20
Machine Information Window
T18M-05-01-007
T5-1-21
VARIOUS SETUP INDICATION
Maintenance Setup, Event Display Setup, Time Adjust
and Setting Put-out Lights Delay Time can be set from
the Various Setup window.

Starting Window
will appear.
again.
Meter Window
2. Select Various Setup from menu, using the ↑ and
↓ keys, and press the ○ key. Setting Menu Window
will appear. (See to next page.)
× key again.
T18M-05-01-001
Service Menu Window
T18M-05-01-008
T5-1-22
Setting Menu Window
T18M-05-01-009
T5-1-23
Maintenance Setup
Replacement intervals of air filter, engine oil,
hydraulic oil, etc. can be set up on the monitor
display.

Key Pad T18G-02-01-108
Indication
Setting Menu Window
1. Indicate Setting Menu Window. (See T5-1-22.)
T18M-05-01-009
Maintenance Setup List Window

2. Select Maintenance Setup from menu, using the ↑
and ↓ keys, and press the ○ key. Maintenance
Setup List Window will appear.
To return to the Setup Menu Window, press the ×
key again.
3. Select an item you want to change from the list,

using the ↑, ↓, ← and → keys, and press the ○ key.
The selected item will blink, showing its settable
state.
4. Select the number, using the ↑, ↓ and × keys, and T18M-05-01-012

press the ○ key. Now setup is completed. Maintenance Setup Window
↑ : Increase
↓ : Decrease
× : Cancellation
T18M-05-01-013
T5-1-24
Snapshot Setup
Initialization of manual snapshot data can be done on

the display.

Key Pad
T18G-02-01-108
Indication
Setting Menu Window
T18M-05-01-009
Snapshot Setup Window

2. Select Snapshot Setup from menu, using the ↑
and ↓ keys, and press the ○ key. Snapshot Setup
Window will appear.
To return to the Setting Menu Window, press the ×
key again.
3. Press the ○ key to initialize the snapshot data.
T18M-05-01-010
T5-1-25
Time Adjust
Set the world standard time, local standard time and

time difference.

IMPORTANT: If DLU setting is incorrect, reset the

Greenwich Mean Time, Local
Standard Time, and Time Difference.
When DLU setting is correct, adjust
time difference only.
Key Pad T18G-02-01-108
Indication
Setting Menu Window
T18M-05-01-009
Time Adjust Window

2. Select Time Adjust from menu, using the ↑ and ↓
keys, and press the ○ key. Time Adjust Window
will appear.
key again.
T18G-05-01-022
Adjust Window
3. Press the ○ key to indicate Adjust Window.
4. Select the required item by using the ← and →

keys, and adjust time or time difference using the
↑, ↓ and × keys. After adjustment, press the ○ key.
Now time or time difference is set up.
↑ : Increase
↓ : Decrease
× : Cancellation
T18G-05-01-023
T5-1-26
Setting Put-out Lights Delay Time
Select and set up the put-out delay time of light from

the setting time.

Key Pad T18G-02-01-108
Indication
Setting Menu Window
T18M-05-01-009
Setting Put-out Lights Delay

Time Setting Window
2. Select Setting Put-out Lights Delay Time from
menu, using the ↑ and ↓ keys, and press the ○ key.
Setting Put-out Lights Delay Time Setting Window
will appear.
key again.
3. Select the required time from the list, using the ↑

and ↓ keys, and press the ○ key. Now delay time is
set up.
T18G-05-01-024
T5-1-27
(Blank)
T5-1-28
TROUBLESHOOTING / Component Layout
MAIN COMPONENTS
Overall 2 3 4 5
6
1 7
8
9
10
11
12
13
14
15
16
41 40
42
17
43
39 18
41 38
42
19
20
2 3
37 21
36 22
35 23
34 24
33 25
32 26
4 31 27
1
30 28
T18M-01-02-001
29
1 - Bucket 12 - Control Valve (4 Used) 23 - Fast Filling Device 34 - Adjuster Cylinder (2 Used)
(Refer to T5-2-4) (Refer to T5-2-28)
2 - Arm 13 - Air Cleaner (2 Used) 24 - Water Tank 35 - Front Idler (2 Used)
3 - Boom 14 - Muffler 25 - LTA Cooler (2 Used) 36 - Electrical Equipment box
Radiator (2 Used) (Refer to T5-2-14)
Radiator Fan Motor (4 Used)
4 - Boom Cylinder (2Used) 15 - Battery (4 Used) 26 - Travel Brake Valve 37 - Fuel Tank
(4 Used)
5 - Cab (Refer to T5-2-10) 16 - High Pressure Strainer 27 - Travel Device (2 Used) 38 - Washer Tank
(8 Used)
6 - Lubricator, Grease Tank 17 - Relay Box 28 - Drive Tumbler (2Used) 39 - Emergency Escape Unit
7 - Oil Cooler (4 Used) 18 - Pump Transmission Oil 29 - Track (2 Used) 40 - Level Cylinder (LD Only)
Filter (2 Used)
8 - Swing Device (4 Used) 19 - Pump Device 30 - Lower Roller (16 Used) 41 - Arm Cylinder
9 - Oil Cooler Fan Motor 20 - Engine (Refer to T5-2-16) 31 - Accumulator (2 Used) 42 - Bucket Cylinder (2 Used)
(2 Used) (For Adjuster)
10 - Center Joint 21 - Engine Oil Reserve Tank 32 - Upper Roller (6 Used) 43 - Dump Cylinder (2 Used)
(LD Only)
11 - Hydraulic Tank 22 - Air Fan 33 - Air Conditioner Compressor
Unit
BH: Back Hoe
T5-2-1
Engine and Pump Components
3 6
2 4
1 5
5 10 9 8 7
13
12 11 1
T18M-01-02-002
1 - Main Pump 1 (Transmission Side) 3 - Radiator Fan Motor Drive 5 - Main Pump 7 9- Generator
Main Pump 2 Pump (Transmission Side) 10 - Oil Filter (4 Used)
(Pump Tip Side) (Transmission Side) Main Pump 8 11 - CUMMINS ECM
Pump Transmission Oil Circulation Oil Cooler Fan Motor Drive (Pump Tip Side) 12 - Fuel Filter (3 Used)
Pump (Pump Tip) Pump (Pump Tip Side) Pilot Pump (Pump Tip) 13 - Coolant Filter (2 Used)
2- Main Pump 3 (Transmission Side) 4 - Main Pump 5 6 - Water Tank
Main Pump 4 (Pump Tip Side) (Transmission Side) 7 - LTA Cooler (2 Used)
Air Conditioner Compressor Drive Main Pump 6 8 - Radiator (2 Used)
Pump (Pump Tip) (Pump Tip Side)
Air Fan
Motor Drive Pump
(Pump Tip)
T5-2-2
(Blank)
T5-2-3
CONTROL VALVE
NOTE: This drawing indicates the arrangement

viewed from the base machine front.
Control Valve 4 (Upper-Right) Control Valve 2 (Upper-Left)
1 2 3 4 23 24 25 26 27 28 29 30 31
14 15 16 17 38 39 40 41 42
13
18
12 11
32
5 6 7 8 9 10 33 34 35 36 37
19 20 21 22 43 44 45 46 47 48
Control Valve 3 (Lower-Right) Control Valve 1 (Lower-Left)
T146-01-03-013
T5-2-4
Control Valve 4 (Upper-Right) Control Valve 2 (Upper-Left)

1 - Overload Relief Valve (Boom Raise) 23 - Main Relief Valve
2 - Make-Up Valve (Boom Raise) 24 - Overload Relief Valve (LD: Bucket Close)
3 - Overload Relief Valve 25 - Overload Relief Valve (LD: Bucket Close)
(LD: Bucket Tilt-Out, BH: Bucket Roll-Out) 26 - Overload Relief Valve (LD: Arm Extend, BH: Arm Roll-In)
4 - Make-Up Valve (LD: Bucket Tilt-Out, BH: Bucket Roll-Out) 27 - Make-Up Valve (LD: Arm Extend, BH: Arm Roll-In)
5 - Make-Up Valve (BH: Arm Roll-In) 28 - Overload Relief Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In)
6 - Overload Relief Valve (BH: Arm Roll-In) 29 - Make-Up Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In)
7 - Make-Up Valve (Boom Lower) 30 - Overload Relief Valve (Boom Raise)
8 - Overload Relief Valve (Boom Lower) 31 - Make-Up Valve (Boom Raise)
9 - Make-Up Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In) 32 - Make-Up Valve (LD: Bucket Open)
10 - Overload Relief Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In) 33 - Overload Relief Valve (LD: Bucket Open)
11 - Main Relief Valve 34 - Make-Up Valve (LD: Arm Retract, BH: Arm Roll-Out)
35 - Overload Relief Valve (LD: Arm Retract, BH: Arm Roll-Out)
36 - Make-Up Valve (LD: Bucket Tilt-Out, BH: Bucket Roll-Out)
37 - Overload Relief Valve
(LD: Bucket Tilt-Out, BH: Bucket Roll-Out)
Control Valve 3 (Lower-Right) Control Valve 1 (Lower-Left)

12 - Main Relief Valve 38 - Main Relief Valve
13 - Overload Relief Valve (Boom Raise) 39 - Overload Relief Valve (LD: Arm Retract, BH: Arm Roll-Out)
14 - Make-Up Valve (Boom Raise) 40 - Make-Up Valve (LD: Arm Retract, BH: Arm Roll-Out)
15 - Overload Relief Valve (Left Swing) 41 - Overload Relief Valve (Boom Raise)
16 - Make-Up Valve (Left Swing) 42 - Make-Up Valve (Boom Raise)
17 - Overload Relief Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In) 43 - Make-Up Valve (LD: Arm Extend, BH: Arm Roll-In)
18 - Make-Up Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In) 44 - Overload Relief Valve (LD: Arm Extend, BH: Arm Roll-In)
19 - Make-Up Valve (Right Swing) 45 - Make-Up Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In)
20 - Overload Relief Valve (Right Swing) 46 - Overload Relief Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In)
21 - Make-Up Valve (LD: Arm Extend, BH: Arm Roll-In) 47 - Make-Up Valve (Boom Lower)
22 - Overload Relief Valve (LD: Arm Extend, BH: Arm Roll-In) 48 - Overload Relief Valve (Boom Lower)

BH: Backhoe
T5-2-5
UNDER CARRIAGE
Front Side 1
T18G-01-02-002
View A
1- Adjuster Cylinder
2- Center Joint 4
3- Accumulator (For Adjuster)
4- Manifold
5- Reducing Valve
6- Relief Valve
6 5 T18M-01-02-017
T5-2-6
TRAVEL DEVICE
Rear Side
Front Side
Travel Mode Change Line
Travel Mode
Change Line
2
Rear Side Front Side
3
T146-01-03-030
1 Drain Line
1 - Travel Motor 2 - Brake Valve 3 - Travel Reduction Gear
T5-2-7
SWING DEVICE
1
3
T18G-03-02-001
1 - Swing Motor 2 - Relief Valve 3 - Make-Up Valve
T5-2-8
ELECTRICAL COMPONENTS
Left Frame
11
10
2
9
8 5
7
7 6
T18M-01-02-003
1- Work Light (2 Used) 4- Fuel Level Switch 7- Work Light 10 - Horn

(On the Cab) (Fuel Gauge) (Left-Frame Front)
2- Air Conditioner Unit 5- Fuel Level Switch 8- A/C Condenseｒ(3 Used) 11 - Wiper Motor
(3 Used) (Fuel Indicator) Condenser Fan Motor
(6 Used)
3- Fuel Tank 6- Electrical Equipment Box 9- Receiver Dryer Control
(Refer to T5-2-4) Pressure Switch (3 Used)
T5-2-9
Cab Inside
1
2
T18M-01-02-004 T18G-01-02-053
29 3 4 5
28 6
27 7
8
26 9
25 10
24
11
23
22 12
21 13
20
14
T18M-01-02-005
19 18 17 16 15 13
1 - Monitor Display 9 - Dome Light Switch 16 - Travel Speed Switch 23 - Air Conditioner Control
(Front)
2 - Hour Meter 10 - Entrance Light Switch 17 - Maintenance Switch 24 - Wiper/Washer Switch
3 - Left Control Lever/Horn 11 - Auto-Idle Switch 18 - Work Light Switch 25 - Wiper Interval Switch
Switch
4 - Right Control Lever/Horn 12 - Fast Filling System Switch 19 - Engine Stop Switch 26 - Display Contrast Switch
Switch
5 - Pilot Control Shutoff Lever 13 - Auxiliary 20 - Radio 27 - Key Pad
6 - Emergency Switch 14 - Key Switch 21 - Air Conditioner Control 28 - Engine Warning Lamp
(Rear) (Yellow)
7 - Engine Control Dial 15 - Buzzer Stop Switch 22 - Air Conditioner Control 29 - Engine Stop Lamp (Red)
(Side)
8 - Engine Start Switch
T5-2-10
3 T18M-01-02-006
1 - Monitor Display 2 - IDU 3 - ELU
T5-2-11
T18G-01-02-030
1
M18M-01-007
2 3 4 5 6 7
10
T18G-01-02-026
13 12 11
Layout of Power Source Terminal T146-01-03-023
1 - Fuse Box (Cab) 5- Data Link Connector 9- DC/DC Converter 13 - Controller

(Auxiliary) (View Camera)
2 - DC/DC Converter 6 - Data Link Connector 10 - Power Source Terminal
(ECM)
3 - Cigar Lighter 7 - Data Link Connector (DLU) 11 - DLU
4 - ORBCOMM (Option) 8 - Buzzer 12 - Data Link Connector
(MMS)
T5-2-12
(Blank)
T5-2-13
Electrical Equipment Box
T18M-01-02-003
10 11 12 13
5
Relay
Arrangement
(Refer to T1-2-15)
4
3
T18M-01-02-007
1 - Fuse Box2 5 - Auto Lubricator Interval 9- Fault code INC/DEC 13 - Box Light
Switch Switch
2 - Fuse Box 1 6 - Engine Fault Indicator 10 - HMU
3 - Fuse Box 4 7 - MC 11 - CSU
4 - Fuse Box 3 8 - Engine Diagnostic Switch 12 - Limit Switch (Box Light)
T5-2-14
Relay Arrangement in Electrical Equipment Box
1 2 3 4 5 6 7
8
9
10
11
40
12
39 13
38 14
37 15
16
36
35 17
18
34
19
33 20
21
22
23
24
25
26
32 31 30 29 28 27
T18M-01-02-007
1 - Wiper Relay 3（Low (L5) 11 - Work Light Relay 3 (3) 21 - Washer Motor Relay (21) 31 - ELU PWM Power (26)
Speed Control) (Upper Cab Work Relay 1 （Key ON
Light (L)(R)) Signal）
2 - A/C Main Relay (L6) 12 - Work Light Relay 4 (4) 22 - A/C Fan Relay (Front) (22) 32 - ELU Pilot Solenoid (25)
(Front) (Right Frame Front Relay
Work Light (L)(R))
3 - Air Horn Compressor (L1) 13 - Work Light Relay 5 (5) 23 - A/C Fan Relay (Side) (23) 33 - Air Horn Compressor (17)
Relay (L1) (Engine Frame Rear Relay (L2)
Work Light (L)(R))
4 - Air Horn Compressor (L2) 14 - Work Light Relay 6 (6) 24 - A/C Fan Relay (Rear) (24) 34 - Air Horn Compressor (18)
Relay (R1) (Option) (Center L/R Side Relay (R2) (Option)
Work Light)
5 - Wiper Relay 1（Low (L3) 15 - Entrance Light Relay (7) 25 - Sliding Fold-In Ladder (32) 35 - Horn Relay (19)
Speed Control） Alarm and Flash Light
Relay 2
6 - Wiper Relay 2（Low (L4) 16 - Maintenance Light (8) 26 - Sliding Fold-In Ladder (31) 36 - Wiper Relay 4 (20)
Speed Control） Relay (Engine Room) Alarm and Flash Light （Hi Speed Control）
Relay 1
7- A/C Main Relay (Side) (L7) 17 - Fast Filling Panel (13) 27 - Engine Oil Reserve (30) 37 - Maintenance Light (9)
Position Relay (Store Tank Pumping Unit Relay (Pump Room
Signal) Relay and Radiator Room)
8 - A/C Main Relay (L8) 18 - Delayed Power Off (14) 28 - Sliding Fold-In Ladder (29) 38 - Maintenance Light (10)
(Rear) Relay Relay Relay (Cab Bed)
9 - Work Light Relay 1 (1) 19 - Travel Speed Select (15) 29 - ELU PWM Power (28) 39 - Maintenance Light (11)
(Left Frame Front Relay Relay 3 (Emergency Relay (Control Valve
Work Light (L)) Switch Signal) and Oil Cooler Room)
10 - Work Light Relay 2 (2) 20 - Fast Filling Device (16) 30 - ELU PWM Power (27) 40 - Charge Signal Relay (12)
(Left Frame Front Relay Relay 2 （Gate Lock
Work Light (R)) Switch Signal）
NOTE: Numbers in parentheses correspond to the
numbers used in the electric circuit
diagram.
T5-2-15
Engine Frame (1)
1
1
4
10
9 8 7 6 5 T18M-01-02-008
1 - Engine Stop Switch 4 - Fast Filling Proximity 7 - Travel Mode Solenoid 9- Fast Filling Pressure
(4 Used) Switch Valve Sensor
2 - Battery (4 Used) 5 - Travel Alarm 8 - Reducing Valve 10 - Sliding Fold-In Ladder Limit
(Travel Mode Selection) Switch
3 - Relay Box 6 - Fast Filling panel Control
(Refer to T5-2-18) Solenoid Valve
T5-2-16
Engine Frame (2)
2
3
1
1 4, 7
5
11 10 9 8 6
12
13
15 14
T18M-01-02-009
1 - Air Cleaner Restriction 5 - Coolant Temperature 9 - Alternator (Cummins) 13 - Pump Transmission Oil
Switch (4 Used) (Radiator In) Temperature Switch
2 - Coolant Level Switch 6 - Coolant Temperature 10 - Prelude Pressure Switch 14 - Contamination Sensor
(For Warning Indicator) (LTA Middle) (8 Used)
3 - Coolant Level Switch 7 - Coolant Temperature 11 - Engine Speed Sensor 15 - Starter Motor (2 Used)
(For Level Indicator) (LTA Out) （Cummins）
4 - Coolant Temperature 8 - Coolant Temperature 12 - Pump Transmission Level
Sensor (LTA In) (Radiator Out) Switch
T5-2-17
Relay Box
1
T18M-01-02-010
6
25
24
23
7
8
22 9
21 10
11
20
12
19
13
18 17 16 15 14 T18M-01-02-011
1- Battery Relay (3 Used) 8- Engine Oil Reserve Tank 14 - Fusible Link5 (75A) 20 - Starter Relay (Lower)
System Relay 2 (Fuse Box)
2- Fusible Link 10A (Engine 9 - Fusible Link6 (75A) 15 - Fusible Link4 (75A) 21 - Engine Pre-lube Relay
Oil Reserve Tank Valve) (Fuse Box) (Fuse Box)
3 - Fusible Link 30A 10 - Fusible Link7 (45A) 16 - Fusible Link3 (75A) 22 - Circuit Breaker
(Zener Diode) (Option) (Fuse Box)
4 - Fusible Link 5A (IDU 11 - Fusible Link8 (75A) 17 - Fusible Link2 (75A) 23 - Fusible Link 250A (Sliding
Pre-lube Signal) (Starter Relay) (Fuse Box) Fold-In Ladder Motor
(Rear))
5- Safety Relay 12 - Fusible Link9 (45A) 18 - Fusible Link1 (75A) 24 - Fusible Link 250A (Sliding
(ECM Main Power) (Fuse Box) Fold-In Ladder Motor
(Front))
6- Engine Pre-lube Timer 13 - Fusible Link10 (75A) 19 - Starter Relay (Upper) 25 - Fusible Link 400A (Engine
(Sliding Fold-In Ladder Pre-lube Relay)
Relay)
7- Engine Oil Reserve Tank
System Relay 1
T5-2-18
EHC Valve (For Electric Lever Control)
EHC Valve (Left Side) EHC Valve (Right Side)
1 5 9 13
2 6 10 14
3 7 11 15
4 8 12 16
T18M-03-04-001
T18M-03-04-002
1- Right Travel Forward 5- Arm Retract 9- Boom Raise 13 - Arm Extend

2- Right Travel Reverse 6- Bucket Open 10 - Left Swing 14 - Bucket Tilt-Out
3- Left Travel Forward 7- Bucket Close 11 - Right Swing 15 - Boom Lower
4- Auxiliary 8- Left Travel Reverse 12 - Bucket Tilt-In 16 - Auxiliary
T5-2-19
EHC Valve (For Main Pump Control)
8 1
7 2
6 3
5 4
T18M-03-07-005
1 - Main Pump Displacement 3 - Radiator Fan Control 5 - Auxiliary 7 - Power Decrease Control
Control (No.4 Main Pump)
2 - Main Pump Displacement 4 - Oil Cooler fan Control 6 - Main Pump Displacement 8 - Power Increase Control
Control (No.3 Main Pump) Control (No.1, 2, 5, 6, 7, 8
Main Pump)
T5-2-20
Sliding Fold-In Ladder
2
View A
3 4 5 6
10
T18M-01-02-019
1 - Valve Unit 4- Limit Switch 7- Lock Lever 9- Sliding Fold-In Ladder

(Storage Slowdown) Cylinder
2 - Motor Pump Unit 5 - Limit Switch 8- Limit Switch (Lock Lever) 10 - Sliding Fold-In Ladder
(Expansion Slowdown) Beacon/Alarm
3 - Limit Switch 6 - Limit Switch
(Storage Detection) (Expansion Detection)
T5-2-21
Valve Unit (For Sliding Fold-In Ladder)
3 4
2
5
1 7 6
T18M-01-02-018
1- Main Relief Valve 3- Solenoid 1 5- Valve 7- Solenoid 3

2- Over Load Relief Valve 4- Solenoid 2 6- Over Load Relief Valve
(For Cylinder Rod side) (For Cylinder Bottom side)
T5-2-22
Right Frame
1 4
5
6
7
12
11
10
T18M-01-02-012
9
1- Work Light (2 Used) 4- Hydraulic Oil Tank Pressure 7- Hydraulic Oil Level Switch 10 - Valve Limit Switch (2 Used)
(Right-Frame Front) Release Valve 2 (Level Warning Indicator) (Return Pipe Line)
2 - Out side Temperature 5 - Electric Pump 8 - Hydraulic Oil Temperature 11 - Engine Stop Switch
Sensor (Maintenance Work) Sensor (Hydraulic Oil (Oil Cooler Room)
(Optional) Temperature Gauge)
3- Work Light 6 - Hydraulic Oil Level Switch 9 - Valve Limit Switch (2 Used) 12 - Lubricator
(Right-Frame Right) (Level Check Indicator) (Suction Pipe Line)
(Optional)
T5-2-23
Contamination Sensor Layout
Main Pump Swing Motor, Travel Motor
Rear Side
3 4
2
1
T146-01-03-020
5
7
6
8
Front Side
T146-05-02-048
View A View B
9 10
12 13
11
Center Joint
T18M-01-02-014
T18M-01-02-013
1 - Contamination Sensor 5 - Contamination Sensor 8 - Contamination Sensor 11 - Contamination Sensor

(Main Pump 4) (Main Pump 7) (Main Pump 2) (Travel Motor)
(Main Pump 3) (Main Pump 8) (Right Side Rear Swing (Left Side Front Swing
Motor) Motor)
(Main Pump 6) (Main Pump 1) (Left Side Rear Swing (Right Side Front Swing
Motor) Motor)
4 - Contamination Sensor
(Main Pump 5)
T5-2-24
LEDs for Contamination Sensor Amplifier
2 4 6 7
1 3 5 8
Auxiliary
Auxiliary 9 11 13
10 12
T146-05-02-049
T18M-01-02-007
1 - Main Pump 1 5 - Main Pump 5 8 - Main Pump 8 11 - Right Side Front Swing
Motor
2 - Main Pump 2 6 - Main Pump 6 9 - Left Side Front Swing 12 - Right Side Rear Swing
Motor Motor
3 - Main Pump 3 7 - Main Pump 7 10 - Left Side Rear Swing 13 - Travel Motor
Motor
4 - Main Pump 4
T5-2-25
PILOT PIPING
Control Valve Panel (Rear)
2 3
6
5 4
T18M-01-02-015
10 11
12
15 13
14 (Backside)
T18M-01-02-016

BH: Backhoe
1- EHC Valve (For Electric 5- Arm Priority Selector Valve 9- D.Q.R Valve 2 13 - Pilot Pressure Control
Lever Control) (LD: Extend, BH: Roll-In) Valve (Adjuster)
2 - Control Valve 2 6 - Gate Lock Solenoid Valve 10 - Swing Motor (2 Used) 14 - Relief Valve (Adjuster)
(Upper-Left)
3 - Control Valve 4 7- Control Valve 1 11 - Center Joint 15 - Reducing Valve (Adjuster)
(Upper Right) (Lower-Left)
4 - Control Valve 3 8 - D.Q.R Valve1 12 - Accumulator (3 Used)
(Lower-Right) (Pilot Pressure)
T5-2-26
Lubricator Panel
Grease Tank 4
1
6
2
5
3
T146-01-03-026
T18M-03-07-002
T18M-03-07-001 T18M-03-07-006
1- Pressure Switch 3- Auto-Lubrication ON/OFF 5 - Auto-Lubrication Pump 7- Auto-Lubrication Interval

(Auto-Lubrication) Switch Switch
2 - Pressure Switch 4 - Vent Valve 6- Auto-Lubrication Solenoid
(Manual Lubrication) Valve 1
T5-2-27
FAST FILLING DEVICE
1 2
T18M-03-07-004
4 5 6 7 8 9 10 11
22
21 12
13
20 19 18 17 16 15 14 T18M-03-07-003
1 - Lift Cylinder (2 Used) 7 - Engine Oil Reserve Tank 13 - Auxiliary 18 - Gear Oil
Filling System Power (Front Left Side Swing
Switch Device)
2 - Fast-Filling Panel 8 - Engine Oil Reserve Tank 14 - Pump Transmission Oil 19 - Coolant
Filling System Control (Radiator Engine Side)
Switch
3 - Proximity Switch 9 - Engine Oil Out 15 - Grease 20 - Fuel
(Reserve Tank)
4 - Fuel Fill Indicator 10 - Engine Oil 16 - Gear Oil (Rear-Right) 21 - Coolant
(Engine Oil Pan) (Radiator Outside)
5 - Engine Oil Reserve Tank 11 - Hyd. Oil 17 - Gear Oil (Left-Right) 22 - Engine Oil In
Fill Indicator (Reserve Tank)
6 - Engine Oil Reserve Tank 12 - Gear Oil (Front Right Side
Shut-off Valve Open Swing Device)
Indicator
T5-2-28
TROUBLESHOOTING/Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Refer to troubleshooting A procedure in case any fault

codes are displayed after diagnosing the controller
using Monitor Display.
Cummins Code is the fault code HCM Code is the fault code of Hitachi Construction
of Cummins Inc.. Machinery Co.,Ltd.
T18M-05-01-005
T5-3-1
FAULT DIAGNOSIS INDICATION
IDU indicates the fault diagnosis results on the monitor
display in response to fault signals received from each
controller through CAN.

Starting Window
display, press the → (or ←) key to display the
Current Faults (or Alarm) List Window on the
monitor display.
To return to the Meter Window, press the × key.
Automatic Transition
T18M-05-01-003
Meter Window
and ↓ keys, and press the ○ key. The Fault (or
Alarm) Explanation Window of the selected item
will appear. (See to next page.)
To return the Current Faults (or Alarm) List Win-
dow, press the × key.
T18M-05-01-001
Current Faults (or Alarm) List Window
T18M-05-01-005
T5-3-2
press the ○ key. Faults (or Alarm) Explanation Window
To return to the Fault (or Alarm) Explanation
Window, press the × key.
T18G-05-01-007
Detailed Circuit Diagram
T18G-05-01-027
T5-3-3
FAULT CODE
HCM Cummins Warning Related
Description
CODE CODE Buzzer Controller
00006-000 00151 High Coolant Temperature Yes ECM
00006-003 00144 Coolant Temperature Sensor Failed High No ECM
00006-004 00145 Coolant Temperature Sensor Failed Low No ECM
00006-016 00146 Coolant Temperature Above Normal Yes ECM
00007-001 00235 Low Coolant Level Yes ECM
00007-003 00195 Coolant Level Sensor Failed High No ECM
00007-004 00196 Coolant Level Sensor Failed Low No ECM
00007-018 00197 Coolant Level Below Normal No ECM
00008-001 00228 Very Low Coolant Pressure Yes ECM
00008-003 00231 Coolant Pressure Sensor Failed High No ECM
00008-004 00232 Coolant Pressure Sensor Failed Low No ECM
00009-000 00266 High Fuel Temperature (Most Sever Level) Yes ECM
00009-003 00263 Fuel Temperature Sensor Failed High No ECM
00009-004 00265 Fuel Temperature Sensor Failed Low No ECM
00009-016 00261 High Fuel Temperature (Moderate Level ) Yes ECM
00011-001 00415 Very Low Oil Pressure Yes ECM
00011-003 00135 Oil Pressure Sensor Failed High No ECM
00011-004 00141 Oil Pressure Sensor Failed Low No ECM
00011-018 00143 Low Oil Pressure No ECM
00012-003 00212 Oil Temperature Sensor Failed High No ECM
00012-004 00213 Oil Temperature Sensor Failed Low No ECM
00012-016 00421 Engine Oil Temperature Above Normal Yes ECM
00014-016 01362 High Lube Oil Filter Restriction No ECM
00015-000 00556 High Crankcase Pressure Yes ECM
00015-003 01843 Crankcase Pressure Sensor Failed High No ECM
00015-004 01844 Crankcase Pressure Sensor Failed Low No ECM
00021-000 00155 High Inlet Manifold Temperature 1 Yes ECM
00021-003 00153 Inlet Manifold Temperature 1 Sensor Failed High No ECM
00021-004 00154 Inlet Manifold Temperature 1 Sensor Failed Low No ECM
00021-010 00783 Rapid Rise Inlet Manifold Temperature 1 No ECM
00021-016 00488 High Intake Manifold Temperature Yes ECM
00022-016 01984 Inlet Manifold Temperature 2 Above Normal Yes ECM
00041-000 00449 High Rail Pressure No ECM
00041-003 00451 Rail Pressure Sensor Failed High No ECM
T5-3-4

Description
00041-004 00452 Rail Pressure Sensor Failed Low No ECM
00041-018 00559 Rail Pressure 1 Below Normal No ECM
00043-003 00221 Ambient Air Pressure Failed High No ECM
00043-004 00222 Ambient Air Pressure Failed Low No ECM
00046-000 00234 Eng Over speed No ECM
00046-002 00689 Engine Crankshaft Speed Erratic No ECM
00048-003 01358 Axel Pedal Sensor 1 Sensor Failed High No ECM
00048-004 01359 Axel Pedal Sensor 1 Sensor Failed Low No ECM
00048-008 01514 Axel Pedal Position Sensor 1 Freq Issue No ECM
00096-003 TEMP Sensor Fault (Inlet Air) High No MC
00096-004 TEMP Sensor Fault (Inlet Air) Low No MC
00097-003 TEMP Sensor Fault (Radiator Outlet) High No MC
00097-004 TEMP Sensor Fault (Radiator Outlet) Low No MC
00098-003 Pressure Sensor Fault (Cooler Fan Motor Inlet) High No MC
00098-004 Pressure Sensor Fault (Cooler Fan Motor Inlet) Low No MC
00100-003 Pressure (Cooler Fan Motor Negative Control) High No MC
00100-004 Pressure (Cooler Fan Motor Negative Control) Low No MC
00120-016 02121 High Exhaust Temperature Cylinder 1 No ECM
00188-003 Level sensor fault (Fuel) High No MC
00188-004 Level sensor fault (Fuel) Low No MC
00227-005 EHC Valve Current Low (Radiator Fan) No MC
00227-006 EHC Valve Current High (Radiator Fan) No MC
T5-3-5

Description
00233-016 01987 Inlet Manifold Temperature 5 Above Normal No ECM
00234-016 01988 Inlet Manifold Temperature 6 Above Normal No ECM
00239-003 TEMP Sensor Fault (Radiator Inlet) High No MC
00239-004 TEMP Sensor Fault (Radiator Inlet) Low No MC
00249-003 TEMP Sensor Fault (LTA Radiator Inlet) High No MC
00249-004 TEMP Sensor Fault (LTA Radiator Inlet) Low No MC
00250-003 TEMP Sensor Fault (LTA Radiator Outlet) High No MC
00250-004 TEMP Sensor Fault (LTA Radiator Outlet) Low No MC
01001-003 Pressure Sensor Fault (Positive Control 1) High No ELU
01001-004 Pressure Sensor Fault (Positive Control 1) Low No ELU
01003-000 EHC Valve Stick/High Pressure (Positive Control 1) No ELU
01003-001 EHC Valve Stick/Low Pressure (Positive Control 1) No ELU
01003-005 EHC Valve Current Low (Positive Control 1) No ELU
01003-006 EHC Valve Current High (Positive Control 1) No ELU
01050-000 Contamination Alarm (CH1) No CSU
T5-3-6

Description
01066-000 Contamination Alarm (Travel Motor CH21) No CSU
01068-003 Pressure Sensor Fault (Power Increase) High No MC
01068-004 Pressure Sensor Fault (Power Increase) Low No MC
01070-005 EHC Valve Current Low (Power Increase) No MC
01070-006 EHC Valve Current High (Power Increase) No MC
01072-003 Pressure Sensor Fault (Power Reduction) High No MC
01072-004 Pressure Sensor Fault (Power Reduction) Low No MC
01074-005 EHC Valve Current Low (Power Reduction) No MC
01074-006 EHC Valve Current High (Power Reduction) No MC
01108-000 EHC Valve Stick/High Pressure (Positive Control1) No ELU
01108-001 EHC Valve Stick/Low Pressure (Positive Control1) No ELU
01112-001 EHC Valve Stick/Low Pressure (Positive Control2) No ELU
02001-003 Pressure Sensor Fault (Travel) High No MC
02001-004 Pressure Sensor Fault (Travel) low No MC
T5-3-7

Description
02003-003 Pressure Sensor Fault (Adjustor Cylinder) High No ELU
02003-004 Pressure Sensor Fault (Adjustor Cylinder) Low No ELU
03006-000 Contamination Alarm (Swing Motor CH17) No CSU
05006-013 Boom Raise Cylinder End Memory Error No ELU
05008-013 Arm In Cylinder End Memory Error No ELU
05009-013 Arm Out Cylinder End Memory Error No ELU
05010-013 Bucket In Cylinder End Memory Error No ELU
05011-013 Bucket Out Cylinder End Memory Error No ELU
07000-003 TEMP sensor fault (Hydraulic oil) High No MC
07000-004 TEMP sensor fault (Hydraulic oil) Low No MC
08008-003 Pressure (Cooler Fan Motor Negative Control) High No MC
08008-004 Pressure (Cooler Fan Motor Negative Control) Low No MC
08011-005 EHC Valve Current Low (Oil Cooler Fan) No MC
08011-006 EHC Valve Current High (Oil Cooler Fan) No MC
10017-012 TEMP Sensor Fault (Radiator Inlet) High No ELU
10018-012 Travel Operation Signal to MC Fault No ELU
11001-003 Pressure Sensor Fault (Boom Raise) High No ELU
11001-004 Pressure Sensor Fault (Boom Raise) Low No ELU
11003-000 EHC Valve Stick/High Pressure (Boom Raise Operation) Yes ELU
11003-001 EHC Valve Stick/Low Pressure (Boom Raise Operation) Yes ELU
11003-005 EHC Valve Current Low (Boom Raise Operation) No ELU
11003-006 EHC Valve Current High (Boom Raise Operation) Yes ELU
11006-003 Pressure Sensor Fault (Boom Lower) High No ELU
11006-004 Pressure Sensor Fault (Boom Lower) Low No ELU
11008-000 EHC Valve Stick/High Pressure (Boom Lower Operation) Yes ELU
11008-001 EHC Valve Stick/Low Pressure (Boom Lower Operation) Yes ELU
11008-005 EHC Valve Current Low (Boom Lower Operation) No ELU
11008-006 EHC Valve Current High (Boom Lower Operation) Yes ELU
11011-003 Pressure Sensor Fault (Bucket In) High No ELU
11011-004 Pressure Sensor Fault (Bucket In) Low No ELU
11013-000 EHC Valve Stick/High Pressure (Bucket In Operation) Yes ELU
11013-001 EHC Valve Stick/Low Pressure (Bucket In Operation) Yes ELU
11013-005 EHC Valve Current Low (Bucket In Operation) No ELU
11013-006 EHC Valve Current High (Bucket In Operation) Yes ELU
11016-003 Pressure Sensor Fault (Bucket Dump) High No ELU
T5-3-8

Description
11016-004 Pressure Sensor Fault (Bucket Dump) Low No ELU
11018-000 EHC Valve Stick/High Pressure (Bucket Out Operation) Yes ELU
11018-001 EHC Valve Stick/Low Pressure (Bucket Out Operation) Yes ELU
11018-005 EHC Valve Current Low (Bucket Out Operation) No ELU
11018-006 EHC Valve Current High (Bucket Out Operation) Yes ELU
11021-003 Pressure Sensor Fault (Bucket Open) High No ELU
11021-004 Pressure Sensor Fault (Bucket Open) Low No ELU
11023-000 EHC Valve Stick/High Pressure (Bucket Open Operation) Yes ELU
11023-001 EHC Valve Stick/Low Pressure (Bucket Open Operation) Yes ELU
11023-005 EHC Valve Current Low (Bucket Open Operation) No ELU
11023-006 EHC Valve Current High (Bucket Open Operation) Yes ELU
11026-003 Pressure Sensor Fault (Bucket Close) High No ELU
11026-004 Pressure Sensor Fault (Bucket Close) Low No ELU
11028-000 EHC Valve Stick/High Pressure (Bucket Close Operation) Yes ELU
11028-001 EHC Valve Stick/Low Pressure (Bucket Close Operation) Yes ELU
11028-005 EHC Valve Current Low (Bucket Close Operation) No ELU
11028-006 EHC Valve Current High (Bucket Close Operation) Yes ELU
11031-003 Pressure Sensor Fault (Arm Out) High No ELU
11031-004 Pressure Sensor Fault (Arm Out) Low No ELU
11033-000 EHC Valve Stick/High Pressure (Arm Out Operation) Yes ELU
11033-001 EHC Valve Stick/Low Pressure (Arm Out Operation) Yes ELU
11033-005 EHC Valve Current Low (Arm Out Operation) No ELU
11033-006 EHC Valve Current High (Arm Out Operation) Yes ELU
11036-003 Pressure Sensor Fault (Arm In) High No ELU
11036-004 Pressure Sensor Fault (Arm In) Low No ELU
11038-000 EHC Valve Stick/High Pressure (Arm In Operation) Yes ELU
11038-001 EHC Valve Stick/Low Pressure (Arm In Operation) Yes ELU
11038-005 EHC Valve Current Low (Arm In Operation) No ELU
11038-006 EHC Valve Current High (Arm In Operation) Yes ELU
11041-003 Pressure Sensor Fault (Right Swing) High No ELU
11041-004 Pressure Sensor Fault (Right Swing) Low No ELU
11043-000 EHC Valve Stick/High Pressure (Right Swing Operation) Yes ELU
11043-001 EHC Valve Stick/Low Pressure (Right Swing Operation) Yes ELU
11043-005 EHC Valve Current Low (Right Swing Operation) No ELU
11043-006 EHC Valve Current High (Right Swing Operation) Yes ELU
11046-003 Pressure Sensor Fault (Left Swing) High No ELU
11046-004 Pressure Sensor Fault (Left Swing) Low No ELU
11048-000 EHC Valve Stick/High Pressure (Left Swing Operation) Yes ELU
T5-3-9

Description
11048-001 EHC Valve Stick/Low Pressure (Left Swing Operation) Yes ELU
11048-005 EHC Valve Current Low (Left Swing Operation) No ELU
11048-006 EHC Valve Current High (Left Swing Operation) Yes ELU
11051-003 Pressure Sensor Fault (Right Travel Forward) High No ELU
11051-004 Pressure Sensor Fault (Right Travel Forward) Low No ELU
11053-000 EHC Valve Stick/High Pressure (Right Travel Forward) Yes ELU
11053-001 EHC Valve Stick/Low Pressure (Right Travel Forward) Yes ELU
11053-005 EHC Valve Current Low (Right Travel Forward) No ELU
11053-006 EHC Valve Current High (Right Travel Forward) Yes ELU
11056-003 Pressure Sensor Fault (Right Travel Backward) High No ELU
11056-004 Pressure Sensor Fault (Right Travel Backward) Low No ELU
11058-000 EHC Valve Stick/High Pressure (Right Travel Backward) Yes ELU
11058-001 EHC Valve Stick/Low Pressure (Right Travel Backward) Yes ELU
11058-005 EHC Valve Current Low (Right Travel Backward) No ELU
11058-006 EHC Valve Current High (Right Travel Backward) Yes ELU
11061-003 Pressure Sensor Fault (Left Travel Forward) High No ELU
11061-004 Pressure Sensor Fault (Left Travel Forward) Low No ELU
11063-000 EHC Valve Stick/High Pressure (Left Travel Forward) Yes ELU
11063-001 EHC Valve Stick/Low Pressure (Left Travel Forward) Yes ELU
11063-005 EHC Valve Current Low (L Travel Forward) No ELU
11063-006 EHC Valve Current High (Left Travel Forward) Yes ELU
11066-003 Pressure Sensor Fault (Left Travel Backward) High No ELU
11066-004 Pressure Sensor Fault (Left Travel Backward) Low No ELU
11068-000 EHC Valve Stick/High Pressure (Left Travel Backward) Yes ELU
11068-001 EHC Valve Stick/Low Pressure (Left Travel Backward) Yes ELU
11068-005 EHC Valve Current Low (L Travel Backward) No ELU
11068-006 EHC Valve Current High (Left Travel Backward) Yes ELU
11100-003 Right Lever (F/R) Signal Fault (High) Yes ELU
11100-004 Right Lever (F/R) Signal Fault (Low) Yes ELU
11100-013 Right Lever (F/R) Interlock Yes ELU
11101-003 R Lever (F/R) Center Signal Fault (High) Yes ELU
11101-004 R Lever (F/R) Center Signal Fault (Low) Yes ELU
11101-013 R Lever (F/R) Center Signal out of range Yes ELU
11103-003 Right Lever (L/R) Signal Fault (High) Yes ELU
11103-004 Right Lever (L/R) Signal Fault (Low) Yes ELU
11103-013 Right Lever (L/R) Interlock Yes ELU
11104-003 R Lever (L/R) Center Signal Fault (High) Yes ELU
11104-004 R Lever (L/R) Center Signal Fault (Low) Yes ELU
T5-3-10

Description
11104-013 R Lever (L/R) Center Signal out of range Yes ELU
11106-003 Left Lever (F/R) Signal Fault (High) Yes ELU
11106-004 Left Lever (F/R) Signal Fault (Low) Yes ELU
11106-013 Left Lever (F/R) Interlock Yes ELU
11107-003 L Lever (F/R) Center Signal Fault (High) Yes ELU
11107-004 L Lever (F/R) Center Signal Fault (Low) Yes ELU
11107-013 L Lever (F/R) Center Signal out of range Yes ELU
11109-003 Left Lever (L/R) Signal Fault (High) Yes ELU
11109-004 Left Lever (L/R) Signal Fault (Low) Yes ELU
11109-013 Left Lever (L/R) Interlock Yes ELU
11110-003 L Lever (L/R) Center Signal Fault (High) Yes ELU
11110-004 L Lever (L/R) Center Signal Fault (Low) Yes ELU
11110-013 L Lever (L/R) Center Signal out of range Yes ELU
11112-003 Bucket Pedal (Open) Signal Fault (High) Yes ELU
11112-004 Bucket Pedal (Open) Signal Fault (Low) Yes ELU
11112-013 Bucket Pedal (Open) Interlock Yes ELU
11114-013 Bucket Pedal (Open) Center Signal Fault Yes ELU
11115-003 Bucket Pedal (Close) Signal Fault (High) Yes ELU
11115-004 Bucket Pedal (Close) Signal Fault (Low) Yes ELU
11115-013 Bucket Pedal (Close) Interlock Yes ELU
11117-013 Bucket Pedal (Close) Center Signal Fault Yes ELU
11118-003 Travel Pedal (Right) Signal Fault (High) Yes ELU
11118-004 Travel Pedal (Right) Signal Fault (Low) Yes ELU
11118-013 Travel Pedal (Right) Interlock Yes ELU
11120-013 Travel Pedal (Right) Center Signal Fault Yes ELU
11121-003 Travel Pedal (Left) Signal Fault (High) Yes ELU
11121-004 Travel Pedal (Left) Signal Fault (Low) Yes ELU
11121-013 Travel Pedal (Left) Interlock Yes ELU
11123-013 Travel Pedal (Left) Center Signal Fault Yes ELU
11124-013 Multi lever Selection Abnormalities Yes ELU
11125-013 Front Attachment Selection Abnormalities Yes ELU
11126-013 Machine Selection Abnormalities Yes ELU
11126-019 Machine Information Reception Failure No ELU
12037-003 Pressure Sensor Fault (Gate Lock Valve) High No ELU
12037-004 Pressure Sensor Fault (Gate Lock Valve) Low No ELU
12037-018 Below normal Operation Pressure (Gate Lock Valve) No ELU
12038-012 Gate lock Signal Output Fault Yes ELU
12039-019 Communication Error ELU-MC No ELU
T5-3-11

Description
13011-003 TEMP sensor fault (Pump Lube Oil) High No MC
13011-004 TEMP sensor fault (Pump Lube Oil) Low No MC
13015-001 Pump Transmission Oil Level Low Yes MC
14000-000 Alternator Charge Fault No MC
14005-000 Hydraulic Oil Level Low Yes MC
14009-001 Auto-Lubrication OFF No MC
14009-002 Manual-Lubrication No MC
14009-003 Auto-Lubrication Alarm No MC
14013-000 Emergency Switch ON No MC
14015-000 Air Cleaner Restriction No MC
14017-000 Hydraulic Oil Temperature High No MC
14049-000 Fast Fill Panel Low Yes MC
14051-000 Ladder Limit Switch Yes MC
14052-000 Tension Indicator No ELU
14053-000 Valve Close (Suction Piping) Yes MC
14055-000 Valve Close (Return Piping) Yes MC
15038-031 Control Box Door Open No MC
20000-019 MC Communication Error No MC
20600-019 ELU Communication Error No ELU
20610-012 ELU Internal Memory Error Yes ELU
20611-003 ELU 5V Output (Travel/Bucket) High Yes ELU
20611-004 ELU 5V Output (Travel/Bucket) Low Yes ELU
20612-003 ELU 5V Output (Front/Swing) High Yes ELU
20612-004 ELU 5V Output (Front/Swing) Low Yes ELU
20613-003 ELU 5V Output (Angle Sensor/Pressure Sensor) High No ELU
20613-004 ELU 5V Output (Angle Sensor/Pressure Sensor) Low No ELU
20614-003 ELU PWM Power High Yes ELU
20614-004 ELU PWM Power Low Yes ELU
20615-003 ELU SOL Power High No ELU
20615-004 ELU SOL Power Low No ELU
20616-003 ELU Sensor 24V Output High No ELU
20616-004 ELU Sensor 24V Output Low No ELU
20618-003 ELU Main Power High Yes ELU
20618-004 ELU Main Power Low Yes ELU
20800-019 DLU Communication Error No DLU
21000-019 HMU Communication Error No HMU
21200-019 CSU Communication Error No CSU
21800-019 ECM Communication Error (Parent) No ECM
T5-3-12

Description
23000-019 ECM Communication Error (Child 1) No ECM
23200-019 ECM Communication Error (Child 2) No ECM
30001-004 01361 Remote Accelerator Pedal 1 Circuit Failed High No ECM
30002-016 01852 Water Indicator Above Normal No ECM
30003-003 00224 Sentinel Burn Valve Above Normal No ECM
30003-004 00223 Sentinel Burn Valve Below Normal No ECM
30006-013 00342 Calibration Incompatibility Error No ECM
30007-009 00781 J1939 Data link 2 Can Not Transmit No ECM
30010-003 02377 Fan Control Circuit Failed High No ECM
30010-004 00245 Fan Control Circuit Failed Low No ECM
30011-002 01257 Module ID Input State Error No ECM
30012-002 00431 Idle Validation Invalid No ECM
30015-009 00285 J1939 PGN Timeout Error No ECM
30015-013 00286 J1939 Configuration Error No ECM
30020-003 02265 Lift Pump Supply Circuit Failed High No ECM
30020-004 02266 Lift Pump Supply Circuit Failed Low No ECM
30021-003 00272 Fuel Pump Pressure 1 Circuit Failed High No ECM
30021-004 00271 Fuel Pump Pressure 1 Circuit Failed Low No ECM
30022-003 00546 Fuel Del Pressure Circuit Failed High No ECM
30022-004 00547 Fuel Del Pressure Circuit Failed Low No ECM
30022-018 02215 Fuel Pump Pressure Below Normal No ECM
30100-012 00351 Injector Power Supply Failed No ECM
30101-031 02311 Fuel Injection Valve Circuit Error No ECM
30102-005 00322 Injector Solenoid Driver Cylinder 1 Below Normal No ECM
T5-3-13

Description
T5-3-14
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURES
Troubleshooting B is used for executing troubleshoot-

ing of the engine by use of the Engine Fault Indicator
inside the electrical equipment box at (A) below the
cab.
A
In case the engine control system suffers a fault, the
Engine Fault Indicator is lit.
Each warning lamp means the following.

• Engine Stop Lamp (Red)
Stop the engine immediately, and repair the de-
fective portion.
• Engine Warning Lamp (Amber) T18M-05-04-001

Working can be continued for a while, but repair
the defective portion within 24 hours.
• Engine Maintenance Lamp (Yellow) Electrical

Equipment Box
Further operation can be allowed, but repair the
defective portion in the next periodic maintenance.
NOTE: Fault codes related to the Engine Stop Engine Fault

Lamp (Red) and the Engine Warning Lamp Indicator
(Amber) can be confirmed by the monitor
display also. Therefore, in case the monitor
display is functioning normally, execute
troubleshooting utilizing Troubleshooting A.
NOTE: Fault codes related to the Engine Mainte-

nance Lamp (Yellow) cannot be confirmed
by the monitor display. Therefore, periodi-
cally examine whether the Engine Mainte- T18M-05-04-002
nance Lamp (Yellow) is lit or not, and in
case it is lit, read the fault code(s), and re-
Engine Stop Lamp
pair the portion(s) needing remedy in the (Red)
next periodic maintenance.
T18M-05-04-003
Engine Maintenance Engine Warning
Lamp (Yellow) Lamp (Amber)
T5-4-1
HOW TO READ FAULT CODES
Engine Diagnostic
Switch
1. Stop the engine, and turn the key switch ON.
2. In case a fault code exists, the Engine Warning
Lamp (Amber) alone is lit, but in case no fault
code exists, none of the lamps are lit.
3. Turn the Engine Diagnostic Switch ON. Fault Code
INC/DEC
4. The Engine Warning Lamp (Amber) flickers once, Switch
and in a second, the Engine Stop Lamp (Red) in-
dicates the fault code at stake twice consecutively,
which is repeated.
5. A Fault code has four digits at the maximum. A
numeral is indicated by the number of times of Engine Stop
Lamp (Red) T18M-05-04-003
flickering of the Engine Stop Lamp (Red) for each
digit, and remains unlit for 1 second between digit Engine Maintenance Engine Warning
Lamp (Yellow) Lamp (Amber)
change.
6. When the key switch is turned off, indication of the
fault code is finished.
Example: Flickering of Engine Stop Lamp (Red)
NOTE: In case a plural number of fault codes are in in case of Fault Code 132
existence, the Engine Warning Lamp (Am-
ber) flickers once each time indication of a 100s digit 10s digit 1s digit
fault code is over, and a second later, the
Engine Stop Lamp (Red) indicates the next Lit
fault code twice, which is repeated.
NOTE: When indication of all the fault codes is over,

the Engine Warning Lamp (Amber) flickers
once, and a second later, the Engine Stop Unlit
Lamp (Red) repeats indication of the fault 1 second 1 second T141-05-03-004
codes from the first one.
NOTE: IN case the Fault Code INC/DEC Switch is

moved toward INC once, indication of the
next fault code begins. In case the Fault
Code INC/DEC Switch is moved toward
DEC once, indication is changed to the
previous fault code.
T5-4-2
(Blank)
T5-4-3
FAULT CODE FOR ENGINE
Cummins Warning HCM

Description Effect On Engine
Code Lamp Color Code
115 Red 30036-002 Speed Signal Lost Fueling to the injectors is disabled and the
engine can not be started.
122 Amber 00016-003 Intake Manifold Pressure 1 Circuit

Failed High
123 Amber 00016-004 Intake Manifold Pressure 1 Circuit
Failed Low
124 Amber 00016-016 High Intake Manifold Press 1
135 Amber 00011-003 Oil Press Circuit Failed High None on performance. No engine protection
for oil pressure.
141 Amber 00011-004 Oil Press Circuit Failed Low None on performance. No engine protection
for oil pressure.
143 Amber 00011-018 Low Oil Pressure Calibration dependent progressive power
derate and calibration dependent engine
shutdown with increasing time after alert.
144 Amber 00006-003 Coolant Temperature Circuit Failed Possible white smoke. No engine protection
High for engine coolant temperature.
145 Amber 00006-004 Coolant Temperature Circuit Failed Possible white smoke. No engine protection
Low for engine coolant temperature.
146 Amber 00006-016 Coolant Temperature Above Normal Progressive power derate increasing in se-
verity from time of alert.
151 Red 00006-000 High Coolant Temperature Calibration dependent progressive power
153 Amber 00021-003 Intake Manifold Temperature 1 Circuit Possible white smoke.
Failed High No engine protection for intake manifold air
temperature.
Failed Low No engine protection for intake manifold air
temperature.
155 Red 00021-000 High Intake Manifold Temperature 1 Calibration dependent progressive power
156 Amber 00022-003 Intake Manifold Temperature 2 Circuit Possible white smoke. No engine protection
Failed High for intake manifold air temperature.
temperature.
T5-4-4
Instruction 1 Instruction 2
Inspect the engine harness connectors for correct connec- If the warning continues to be on afterward, report
tions. Make sure the engine crankshaft speed/position sensor it to your local Cummins dealer along with all ex-
and engine camshaft speed/position sensor are connected to isting Cummins fault codes and any symptoms.
the engine wiring harness correctly.
Fix it as soon as possible within 12 hours. Make sure engine

oil level is optimal and re-fill if not.
Fix it as soon as possible within 12 hours. Make sure engine
oil level is optimal and re-fill if not.
Shut the engine off. Call your local Cummins dealer along with all ex-
isting Cummins fault codes and any symptoms
Fix them as soon as possible within 12 hours. And monitor

radiator inlet temperature if the operation continues under this
condition
Fix them as soon as possible within 12 hours. And monitor
radiator inlet temperature if the operation continues under this
condition
Run the engine at High idle speed or auto idle speed to cool
down the engine.
Stop the engine after cooling down and check radiator for re-
striction and clean fins.
Run the engine at high idle speed or auto idle speed to cool If the warning continues to be on afterward, report
down the engine. it to your local Cummins dealer along with all ex-
Stop the engine after cooling down and check radiator for re- isting Cummins fault codes and any symptoms.
striction and clean fins.
Check also coolant level.
Fix it as soon as possible within 12 hours. Make sure LTA
outlet temperature is at optimal. Keep an eye on other three.

Check LTA radiator for restrictions. Clean the radiator thor- If the warning continues to be on afterward, report
oughly. it to your local Cummins dealer along with all ex-
If all four temperatures are high, there may be restrictions on isting Cummins fault codes and any symptoms.
radiators, If a single one is high, internal problem may exist.
Check LTA radiator for restrictions. If the warning continues to be on afterward, report
Clean the radiator thoroughly. it to your local Cummins dealer along with all ex-
T5-4-5
Cummins Warning HCM

temperature.
temperature.
temperature.
temperature.
187 Amber 21812-004 Sensor Supply 2 Circuit Failed Low Multiple sensor faults possible.
Loss of sensor functionality.
195 Amber 00007-003 Coolant Level Circuit Failed High None on performance.
196 Amber 00007-004 Coolant Level Circuit Failed Low None on performance.
197 Amber 00007-018 Coolant Level Below Normal None on performance.

212 Amber 00012-003 Oil Temperature Circuit Failed High No engine protection for engine oil tempera-
ture.
213 Amber 00012-004 Oil Temperature Circuit Failed Low No engine protection for engine oil tempera-
ture.
221 Amber 00043-003 Ambient Air Pressure Failed High Power derate may occur.
222 Amber 00043-004 Ambient Air Pressure Failed Low Power derate may occur.
223 Amber 30003-004 Sentinel Burn Valve Below Normal ECM turns off the engine oil burn valve so-
lenoid driver supply voltage and the system is
disabled.
224 Amber 30003-003 Sentinel Burn Valve Above Normal ECM turns off the engine oil burn valve so-
lenoid driver supply voltage and the system is
disabled.
227 Amber 21812-003 Sensor Supply 2 Circuit Failed High Multiple sensor faults possible.
228 Red 00008-001 Very Low Coolant Pressure Calibration dependent progressive power
231 Amber 00008-003 Coolant Press Circuit Failed High No engine protection for coolant pressure.
232 Amber 00008-004 Coolant Press Circuit Failed Low No engine protection for coolant pressure.
T5-4-6


Call your local Cummins dealer along with all ex-
isting Cummins fault codes and any symptoms.
Check on wires for damages and connections. Fix them as

soon as possible within 12 hours.
Check on wires for damages and connections. Fix them as
soon as possible within 12 hours.
Check for wire damages and connections. Call your local Cummins dealer along with all ex-
Fix them as soon as possible. isting Cummins fault codes.
Check for wire damages and connections. Call your local Cummins dealer along with all ex-
Fix them as soon as possible. isting Cummins fault codes.
Look for damages on wiring and connectors. If there are no damages, call your Cummins
Look for damages on wiring and connectors. If there are no damages, call your Cummins
Check for wire damages and connections.
Call your Cummins dealer to fix them as soon as possible.


Check coolant level add coolant water if it is at low level. If the warning continues to be on afterward, report
it to your local Cummins dealer along with all ex-
T5-4-7
Cummins Warning HCM

234 Red 00046-000 Engine Over speed Fuel injection disabled until engine speed
falls below the over speed limit.
235 Red 00007-001 Low Coolant Level Calibration dependent progressive power
237 Amber 30008-002 Multi Unit Synchronization Error
245 Amber 30010-004 Fan Control Circuit Failed Low The fan can possibly stay on continuously or
not run at all.
261 Amber 00009-016 High Fuel Temperature Calibration dependent progressive power
(Moderate Level) derate and calibration dependent engine
263 Amber 00009-003 Fuel Temperature Circuit Failed High ECM will set a default value for fuel tem-
perature. No other action taken by ECM.
265 Amber 00009-004 Fuel Temperature Circuit Failed Low ECM will set a default value for fuel tem-
perature. No other action taken by ECM.
266 Red 00009-000 High Fuel Temperature Calibration dependent progressive power
(Most Sever Level) and speed derate and calibration dependent
engine shutdown with increasing time after
alert.
271 Amber 30021-004 Fuel Pump Pressure 1 Circuit Failed Engine will run poorly at idle. Engine will
Low have low power.
Fuel pressure will be higher than com-
manded.
272 Amber 30021-003 Fuel Pump Pressure 1 Circuit Failed Engine will not run or engine will run poorly.
High
285 Amber 30015-009 J1939 PGN Timeout Error One or more multiplexed devices will not
operate properly.
One or more symptoms will occur.
286 Amber 30015-013 J1939 Configuration Error At least one multiplexed devices will not op-
erate properly.
296 Red 21822-014 Aux Pressure 1 Exception
319 Yellow 30016-002 Real Time Clock Data Erratic None on performance.
Data in the ECM will not have accurate time
and date information.
322 Amber 30102-005 Injector Solenoid Driver Cylinder 1 Engine can misfire or possibly run rough.
Below Normal
Below Normal
Below Normal
Below Normal
Below Normal
Below Normal
342 Red 30006-013 Calibration Incompatibility Error Hard to start or no start.
T5-4-8
Check on operating conditions. If the condition has not changed, report it to your
local Cummins dealer along with all existing
Cummins fault codes and any symptoms.
Look for any external leaks and fix them if there are any. If you cannot find any leaks, report it your Cum-
And fill up coolant water. mins dealer along with all existing Cummins fault
codes and any symptoms.

Wiring problem should be fixed.
Monitor coolant temperature.
Check for fuel cooler restrictions and clean it.
Shut down engine as soon as possible. If the warning continues to be on afterward, report
Check for fuel cooler restrictions and clean it. it to your local Cummins dealer along with all ex-


Call Hitachi Dealer for investigation.
Let your Cummins dealer set dates and time.

T5-4-9
Cummins Warning HCM

343 Amber 21800-012 ECM Hardware Issue Non Mission Possible none on performance, or severe
Disabling derate.
349 Amber 30035-016 Trans Output Shaft Speed Above Engine will run off of a default auxiliary
Normal speed.
351 Amber 30100-012 Injector Power Supply Failed
386 Amber 21811-003 Sensor Supply 1 Circuit Failed High Multiple sensor faults possible.
415 Red 00011-001 Very Low Oil Pressure Calibration dependent progressive power
418 Yellow 30002-015 WIF Indicator Warning Possible white smoke, loss of power, or hard
starting.
421 Amber 00012-016 Engine Oil Temperature Above Nor- Severity based torque derate.
mal
426 Yellow 30015-002 J1939 Data link Can Not Transmit
431 Amber 30012-002 Idle Validation Invalid Engine will run at idle.
432 Red 30012-013 Idle Validation Calibration Error Engine will run at idle.
441 Amber 21817-018 Low Battery Voltage ECM voltage supply approaching level at
which unpredictable operation will occur.
442 Amber 21817-016 High Battery Voltage Possible electrical damage to all electrical
components.
449 Red 00041-000 High Rail Pressure Fuel injection noise.
451 Amber 00041-003 Rail Press Circuit Failed High Power and or speed derate.
452 Amber 00041-004 Rail Press Circuit Failed Low Power and or speed derate.
487 Amber 30000-018 Ether Bottle Empty Ether Injection is disabled.

488 Amber 00021-016 High Intake Manifold Temperature Calibration dependent progressive power
489 Amber 30005-018
AXG Speed Low Error
497 Amber 30033-002
Multi Unit Synchronization Error
527 Amber 21920-003
Dual Output A Failed High
529 Amber 21921-003
Dual Output B Failed High
546 Amber 30022-003
Fuel Delivery Pressure Circuit Failed No action taken by the ECM.
High
547 Amber 30022-004 Fuel Delivery Pressure Circuit Failed No action taken by the ECM.
Low
555 Amber 00015-016 Crankcase Pressure Above Normal
556 Red 00015-000 High Crankcase Pressure Ramps to full derate in 20 seconds.
559 Amber 00041-018 Rail Pressure 1 Below Normal Low Power, possible shutdown, or no start.
T5-4-10

Shut the engine off immediately. Call your local Cummins dealer along with all ex-
Drain the water from the fuel filter.
Make sure coolant water is not overheating. Call your local Cummins dealer along with all ex-
Check OEM wirings for any damages. Call your local Cummins dealer along with all ex-
If these damages are not causes, call your Cummins dealer. isting Cummins fault codes and any symptoms if
there is no damage to the OEM wiring.
Check on alternator and battery capacity.
Check battery voltage on the display.

It must be below 32VDC.
Change alternator.
Replace ether bottle.
Inspect the following item:
-Plugged LTA radiator fins
-Coolant level

T5-4-11
Cummins Warning HCM

599 Red 30009-014 Aux Commanded Dual Output Shut-
down
611 Yellow 30032-031 Engine Hot Shutdown
621 Yellow 00120-017 Low Power Cylinder 1 Possible power loss.
671 Yellow 00120-004 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature meas-
Low Cylinder 1 urement.
T5-4-12

T5-4-13
Cummins Warning HCM

689 Amber 00046-002 Engine Crankshaft Speed Erratic Engine can run rough.
Possibly poor starting capability.
Engine runs using backup speed sensor.
Engine power is reduced.
697 Amber 30013-003 ECM Temperature Circuit Failed
698 Amber 30013-004 ECM Temperature Circuit Failed Low
731 Amber 30036-007 Engine Speed Cam/Crank Mis- Engine will run derate.
alignment Excessive smoke, hard start, and rough idle
possible.
781 Amber 30007-009 J1939 Data link 2 Can Not Transmit Engine will lose power or stop running.
783 Red 00021-010 Rapid Rise Intake Manifold Tem- Calibration dependent progressive power
perature 1 and speed derate and calibration dependent
alert.
1117 Yellow 30100-002 Power Lost with Ignition On
1135 Red 30007-009 J1939 Data link 2 Can Not Transmit Engine will lose power or stop running.
1256 Amber 30011-002 Module ID Input State Error Low Power, possible shutdown, or no start.
1257 Red 30011-002 Module ID Input State Error Hard to start or no start.
Lose power.
1357 Amber 30027-018 Remote Oil Level Below Normal No action taken by ECM.
Possible damage to engine if left unresolved
(SENTINEL application only).
1358 Amber 00048-003 Accelerator Pedal Sensor 1 Sensor Calibration dependent power and speed
Failed High derate.
Engine speed will be locked to 1000 min-1
1359 Amber 00048-004 Accelerator Pedal Sensor 1 Sensor Calibration dependent power and speed
Failed Low derate.
Engine speed will be locked to 1000 min-1
1361 Amber 30001-004 Remote Accelerator Pedal 1 Circuit Calibration dependent power and speed
Failed High derate.
T5-4-14



Look for any damage on the throttle dial and its stopper. Also
look for any worn on harness.
Look for any damage on the throttle dial and its stopper. Also
look for any worn on harness.

Fix them as soon as possible.
T5-4-15
Cummins Warning HCM

1362 Amber 00014-016 High Lube Oil Filter Restriction Calibration dependent progressive power
derate and engine shutdown with increasing
time after alert.
1363 Yellow 00016-017 Intake Manifold Pressure 1 Below Possible low power.
Normal
1367 Yellow 30026-003 Pre Filter Oil Press Circuit Failed None on performance.
High
1368 Yellow 30026-004 Pre Filter Oil Press Circuit Failed None on performance.
Low
1369 Yellow 21820-003 Aux Temperature Input 1 Circuit None on performance.
Failed High
1371 Yellow 21822-003 Aux Press Input 1 Circuit Failed High None on performance.
1372 Yellow 21822-004 Aux Press Input 1 Circuit Failed Low None on performance.
1373 Yellow 30004-011 Ether Injection Circuit Failed Ether injection feature is disabled.
Hard to start in cold temperatures.
1374 Yellow 30037-003 Turbo Speed Sensor Circuit Failed Possible performance degration.
High
1375 Yellow 30037-004 Turbo Speed Sensor Circuit Failed Possible performance degration.
Low
1376 Yellow 30036-002 Engine Speed Cam/Crank data Er- Possible poor starting.
ratic Engine power derate.
1377 Yellow 30031-003 Post Filter Oil Press Circuit Failed None on performance.
High
1378 Yellow 30031-004 Post Filter Oil Press Circuit Failed None on performance.
Low
1381 Yellow 21820-014 Aux Temperature Input 1 Circuit Ex- Calibration-dependent progressive power
ception and speed derate and engine shutdown with
increasing time after alert. (Not included in
HCM application?)
1383 Yellow 00016-003 Intake Manifold Pressure 1 Failed Possible performance degration.
High
Low
High
Low
1387 Yellow 30017-031 J1939 Engine Commanded Shut-
1411 Amber 30031-003 Gen Output Freq Circuit Failed High
1412 Amber 30031-003 Droop Adjust Circuit Failed High
1418 Amber 30031-003 Gain Adjust Circuit Failed High
1427 Amber 30031-031 Over speed Shutdown Relay Driver
Error
1428 Amber 30031-031 Low Oil Pressure Shutdown Relay
Driver Error
T5-4-16
Replace filters and at the same time cut open filters and in- If there are coolant or metals, do not start engine
spect for coolant and metals. and ｃall your local Cummins dealer along with all
Do not start engine until the inspection is made. existing Cummins fault codes and any symptoms.
Check air filters for restrictions and replace them if they are
clogged.
Check ether injection system. If there is no external problem, call your local
Cummins dealer along with all existing Cummins
fault codes and any symptoms.

T5-4-17
Cummins Warning HCM

1429 Amber 30031-031 High Engine Temperature Shutdown
Relay Driver Error
1431 Amber 30031-031 Oil Pressure Relay Driver Error

1432 Amber 30031-031 High Engine Temperature Relay
Driver Error
1435 Amber 30030-031 Engine Cold Potential Starting Issue
1514 Amber 00048-008 Accelerator Pedal Position Sensor 1 Engine operates at idle.
Frequency Issue
1516 Yellow 00046-015 Engine Crankshaft Speed Above

Normal
1517 Red 21800-031 ECM Detects Most Severe Fault Dependent on particular faults from ECM 1
and/or ECM 2 that triggered Fault Code
1517.
1518 Amber 21800-031 ECM Detects Moderately Severe Dependent on particular faults from ECM 1
Fault and/or ECM 2 that triggered Fault Code
1518.
1519 Yellow 21800-031 ECM Detects Least Severe Fault Dependent on particular faults from ECM 1
and/or ECM 2 that triggered Fault Code
1518.
High Cylinder 3 urement.
T5-4-18
Check OEM wirings for any damages. Call your local Cummins dealer along with all ex-
If these damages are not causes, call your Cummins dealer. isting Cummins fault codes and any symptoms if
there is no damage to the OEM wiring.

Look if any other faults are apparent. Call your local Cummins dealer along with all ex-
Look if any other faults are apparent. Call your local Cummins dealer along with all ex-

T5-4-19
Cummins Warning HCM

1544 Yellow 21821-014 Aux Pressure Sensor Input 1 Excep- Possible engine power derate.
tion
1548 Amber 30108-005 Injector Solenoid Driver 7 Below Engine can misfire or possibly run rough.
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
1595 Amber 30001-003 Remote Accelerator Pedal 1 Circuit
Failed High
1596 Yellow 21820-004 Aux Temperature Sensor Input 1 Cir- None on performance.
cuit Failed Low
1597 Yellow 21800-012 ECM Critical Internal Failure Engine will possibly not start.
Normal
1634 Amber 00017-016 Intake Manifold Pressure 2 Above
Normal
1638 Yellow 00017-017 Intake Manifold Pressure 2 Below Possible low power.
Normal
1843 Amber 00015-003 Crankcase Press Circuit Failed High No engine protection.
1844 Amber 00015-004 Crankcase Press Circuit Failed Low No engine protection.
1845 Yellow 30002-003 WIF Indicator Circuit Failed High None on performance.
No water in fuel warning available.
1846 Yellow 30002-004 WIF Indicator Circuit Failed Low None on performance.
No water in fuel warning available.
1847 Red 00006-014 Engine Coolant Temperature Excep-
tion
1852 Amber 30002-016 WIF Indicator Above Normal Possible white smoke, loss of power, or hard
starting.
1888 Yellow 00048-019 J1939 Accelerator Pedal Error Engine could possibly only idle or engine will
not accelerate to full speed.
T5-4-20


Check air filters for restrictions and replace them if they are
clogged.
Check wires and connections from a filter to the engine

connection.
Check wires and connections from a filter to the engine
connection.
Drain water from all filters.
Check pedals for any damages. Call your local Cummins dealer along with all ex-
T5-4-21
Cummins Warning HCM

1889 Yellow 30001-019 J1939 Remote Accelerator Pedal Engine will not respond to the remote throt-
Error tle.
Engine could possibly only idle.
The primary or cab accelerator could possi-
1891 Amber 30025-031 Engine Oil Change Interval Ex-
ceeded
1911 Amber 00041-000 Injector Rail Pressure Above Normal Engine performance derate.
1978 Amber 30014-003 Load Bias Circuit Failed High

1979 Amber 30014-004 Load Bias Circuit Failed Low
1984 Amber 00022-016 Intake Manifold Temperature 2 Calibration dependent progressive power
Above Normal derate and calibration dependent engine
1992 Red 00046-016 Engine Speed Above Normal
2121 Amber 00120-016 High Exhaust Temperature Cylinder Possible engine smoke and engine damage.
1
3
5
7
9
11
T5-4-22
Shut the engine off. Call your local Cummins dealer along with all ex-

- Plugged LTA radiator fins
- Coolant level
- Coolant level
- Coolant level
Inspect the following items: Call your local Cummins dealer along with all ex-
- Restricted air flow through the exhaust isting Cummins fault codes and any symptoms.
manifold or exhaust system
- Air Cleaner Restriction Warning
- LTA output temperature
T5-4-23
Cummins Warning HCM

13
15
2131 Amber 00121-016 High Exhaust Temperature Cylinder 2 Possible engine smoke and engine damage.
10
12
14
16
T5-4-24
T5-4-25
Cummins Warning HCM

alert.
alert.
alert.
2185 Amber 21820-003 Sensor Supply 4 Circuit Above Nor- Multiple sensor faults possible.
mal Loss of sensor functionality.
It may cause throttle problem.
2186 Amber 21820-004 Sensor Supply 4 Circuit Below Nor- Multiple sensor faults possible.
mal Loss of sensor functionality.
It may cause throttle problem.
2215 Amber 30022-018 Fuel Pump Pressure Below Normal Low power.
2261 Yellow 30022-015 Fuel Pump Delivery Pressure Above Low power or engine smoke.
Normal
2262 Yellow 30022-017 Fuel Pump Delivery Pressure Below Low power.
Normal
2265 Amber 30020-003 Lift Pump Supply Circuit Failed High Engine can be difficult to start.
2266 Amber 30020-004 Lift Pump Supply Circuit Failed Low Engine can be difficult to start.
2311 Amber 30101-031 Fuel Injection Valve Circuit Error Possible low power.
2321 Yellow 00046-002 Engine Crankshaft Speed - Data Er-

ratic
2322 Yellow 30036-002 Engine Camshaft Speed Data Erratic
2377 Amber 30010-003 Fan Control Circuit Failed High The fan can possibly stay on continuously or
not run at all.
2557 Amber 21960-003 Aux PWM Driver 1 Circuit Failed
2558 Amber 21960-004 Aux PWM Driver 1 Circuit Failed Low
2963 Yellow 00006-015 Engine Coolant Temperature Above
Normal
2964 Yellow 00021-015 Intake Manifold Temperature 1
Above Normal
T5-4-26


Check for fuel restriction and high 1st stage filter restriction. If no restriction is found, call your local Cummins
dealer along with all existing Cummins fault codes
and any symptoms.
- Stage 2 fuel filter restriction isting Cummins fault codes and any symptoms.
- Fuel quality
If there are restrictions, change all filters.
- High stage 1 fuel filter restriction isting Cummins fault codes and any symptoms
- High fuel inlet restriction
- Fuel quality
If there are restrictions, change all filters.
Look for any wiring damages. If there are no damages or mis-connection, call
your local Cummins dealer along with all existing
Cummins fault codes and any symptoms.
Look for any wiring damages. Call your local Cummins dealer along with all ex-
Wiring problem should be fixed.

Monitor coolant temperature.
T5-4-27
(Blank)
T5-4-28
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C PROCEDURE
Fault Diagnosis C is used for the failure of the air con-

ditioner.
T5-5-1
Air conditioner malfunction.
• When the air conditioner system control panel in-

dicator flashes, see T5-5-14.
• When reporting the malfunction of the air condi-
tioner to HITACHI, use the Air Conditioner Trou-
ble Report form shown on page T5-5-16.
Cooling Circuit
Piping and/or parts are stained
Refrigerant pressure in Bubbles can be seen
with oil, respond to gas detector.
both high and low in sight glass.
pressure sides is low. No oil stain is found or gas de-
tector doesn’t respond. Refrig-
erant has not been refilled for
longer than one season.
No bubbles are seen in sight
glass.
After cooling at fast speed con-

tinuously, cooling power is re-
duced. Air flow volume remains
unchanged.
Air flow volume is reduced.

Refrigerant pressure Bubbles can be seen in sight Compressor cylinder is not hot.
in low pressure side glass. (Refrigerant returns into com-
is high. pressor in liquid form.)
Insufficient
Cooling
Power Refrigerant pressure in high pres- Compressor cylinder is ex-
sure side is low. tremely hot, emitting a smell.
Heater unit emits hot air.
Refrigerant pressure Bubbles can be seen in sight Refrigerant pressure in low

in high pressure side glass. pressure side is low.
is high.
Condenser is stained and clogged.
Even if condenser is sprayed with water, few bubbles appear. Receiver dryer
temperature is low.
After cooling at fast speed continu- Frost

ously, cooling power is reduced. Air Thermistor doesn’t cool.
forms.
flow volume is reduced.
Thermistor cools.
T5-5-2
Gas leaks from pipe joints and/or parts. Re-tighten or replace parts.
Normal leakage of refrigerant from hoses. Refill refrigerant.
Improper adjustment (excessive restriction) of ex- Readjust or replace expansion valve.

pansion valve.
Remove clog, or replace receiver and/or expansion
Clogged expansion valve. valve.
Clogged low pressure circuit and/or evaporator. Remove clog, or replace parts.
After evacuation, refill refrigerant and/or replace re-

Frozen expansion valve or water in circuit. ceiver dryer.
Gas leaks from case. Seal gaps using vinyl tape or packing compound.
Poor contact of expansion valve temperature sen- Make good contact. Replace temperature sensing
sor. stay.
Improper adjustment (excessive open) of expan-
sion valve. Readjust or replace.
Insufficient compressor discharge (faulty gasket Replace.

and/or valve).
Improper water stop valve wire adjustment and/or

faulty stop valve. Check and readjust or replace.
Poor airtight fitting of outside air damper (outside Repair.

air induction type).
Remove clog, or replace parts.
Clogged high pressure circuit before receiver Clean Condenser.

dryer.
Excessive refrigerant. Remove excessive refrigerant to proper level.
After evacuation, refill refrigerant and/or replace re-

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

Instruct user correct air-conditioner operation. (Re-
when air-conditioner is kept operated for a long
set thermistor to either minimum or middle cooling
time with thermistor in max. cooling position and
position or increase air flow.)
air flow in M or L mode, frost may form.
T5-5-3
Cooling Circuit
Case connection. Louver resonance.
Fan contacts case, or foreign matter enters case.

Blower fan connection.
Brush friction noise, metal and/or thrust washer contact
noise.
Gas vibration noise (compressor discharge and/or suc-

Gas blowing sound (roaring). tion gas noise).
Expansion valve connection, whistle Abnormal noise from expansion valve (Expansion
Noise sound, gas blowing sound. valve is normally functioning.).
Faulty clutch bearing, and/or idle pulley bearing.

Clutch disengaging sound.
Contact of clutch amature due to resonance, or loose
belt and/or screws.
Noisy compressor.
Compressor rotating sound.

Vibration and/or loose screws due to excessive drive
belt looseness.
Broken heater core and/or hose.

Water leak and/or splash.
Clogged case drain port and/or drain hose.

Others
Abnormal smell. Absorbed cigarette and dust smell on evaporator fins.
T5-5-4
Repair or replace.
Remove foreign matter. Readjust fan motor location.
Slight noise is unavoidable. Replace if loud.
No functional problem exists. Provide silencer if intolerable.
Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.
Replace.
Repair or replace clutch. Re-tighten screws.
Repair or replace.
Re-adjust drive belt.
Replace.
Clean.
Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min-1 in L
mode for more than 10 minutes, flush smell out by condensed water.
T5-5-5
Electrical Circuit
Both
clutch and Not blown.
(1) blower Check fuses.
don’t op-
erate. Blown.
Not drawn.
Only
Directly connect bat-
(2) clutch tery to clutch termi-
is not ac-
tivated. nal.
Directly connect battery only to ther-
Drawn. mostat (relay), and clutch circuit.
Blower doesn’t rotate.

Only Directly connect bat-
blower tery to blower motor
(3)
doesn’t positive terminal.
rotate.
Connect blower switch terminals L, M,
Blower rotates. and H directly to terminal B.
Fan doesn’t rotate.
Electric
Directly connect bat-
fan Check for voltage between fan motor
(4) doesn’t tery to fan motor posi-
tive terminal. relay connectors terminal #1 and #2.
rotate.
Fan rotates. 24 V (12 V)
Short circuit between relay connec-

tors terminal #3 and #5.
Check air gap.
Clutch Measure clutch drawing voltage (16 v on 24

(5)
slips. V-system circuit).
Check if compressor shaft rotates smoothly.
T5-5-6
Move to steps
(2 and 3).
Short-circuited clutch and/or blower circuit (In-
Repair.
correct power input terminal)).
Follow instructions.
Faulty clutch. Replace.
Clutch is drawn. Faulty parts (thermostat and/or relay). Replace.
Clutch is not drawn. Broken clutch system harness. Repair.
Faulty blower motor. Replace.
Blower rotates. Faulty blower switch. Replace.
Broken blower system harness. Repair.

Blower doesn’t ro-
tate.
Faulty resister. Replace.
Faulty motor. Replace.
0V Broken signal circuit harness. Repair.
Fan rotates. Faulty relay. Replace.
Fan doesn’t rotate. Broken fan motor power circuit harness. Repair.
T5-5-7
Electronic Thermo
Clutch stays ON. Short-circuited thermistor. Check thermistor connector resistance with tester.
Short-circuited thermo volume. Thermo volume is turned OFF.
Poor relay contact and/or faulty am- Disconnect thermistor.

plifier.
Clutch stays OFF. Faulty thermistor. Check for thermistor connector resistance with tester.
Check for thermo volume terminal resistance with

Broken circuit in thermo volume.
tester.
Faulty thermostat (or broken harness Check for resistance with tester after turning switch
to thermo volume). ON (continuity check).
Poor relay contact and/or faulty am- Disconnect thermistor. Ground amplifier connector.
plifier.
Clutch chatters. Poor thermostat contact. Check for continuity at volume switch terminal with
tester.
Faulty soldering in amplifier. Disconnect thermistor. Ground amplifier side connec-

tor.
Poor connector contact. Vibrate connectors.
Temperature is not suf-

ficiently cooled (clutch Faulty thermistor. Replace thermistor.
operates ON/OFF).
Improper thermistor location. Locate thermistor in evaporator center.
Failure in amplifier. Replace thermistor.
Temperature is not suf- Trouble exists outside electronic ※Standard Thermistor Temperature Characteristics:
ficiently cooled (clutch thermo. (Refer to the troubleshooting 0 °C (32 °F): approx. 7.2 kΩ
stays ON). tables on previous pages.) 25 °C (77 °F): approx. 2.2 kΩ
Noisy relay (chattering) Poor ground line contact. Check for ground line contact.
T5-5-8
Resistance is small. Replace thermistor.
(When resistance is approx. 2 kΩ at 25 °C (77 °F), thermistor is normal.)
Clutch is turned OFF. Replace thermo volume.
Clutch is not turned OFF. Replace amplifier.
Replace thermistor. Check ampli-

Resistance is 7 kΩ or more.
fier.
Resistance is infinite. Replace thermo volume.
Normal when resistance is 0. Replace thermo volume.
Abnormal when resistance is infinite.

Clutch stays OFF. Replace amplifier.
Tester needle moves when thermo volume is vibrated. Replace thermo volume.
Normal if tester needle is unmoving when thermo volume is vibrated.
Clutch chatters when amplifier is vibrated. Replace amplifier.
Clutch chatters. Faulty connector. Repair connector.
Temperature is cooled. Faulty thermistor. Replace thermistor.
Temperature is not cooled. Faulty thermistor. Replace thermistor.
Faulty cooling function.

Normal when cooled.
Temperature is not cooled. Faulty amplifier. Replace amplifier.
Normal. Faulty amplifier. Replace.
Poor connection. Repair.
T5-5-9
Compressor
Compressor doesn’t rotate. Clutch terminal voltage is normal 24 V.
Clutch terminal voltage is low.
Clutch terminal voltage is 0 V.

Inoper-
able
Bubbles exist even after refrigerant is refilled.
cooling
system Both high and low side Check for oil and refrigerant leaks from parts other than
pressures are low. compressor and pipe joints using gas detector.
Both
Check for oil and refrigerant leaks from com-
com-
pressor (no leaks from parts other than com-
pressor
pressor) using gas detector.
and
blower
motor
rotate. Refer to NOTE 1 and 2 on page T5-5-13.
Stain
on Refrigerant has not been refilled for longer
exterior than one season.
Refrigerant is discharged within 1 to 2
months after being recharged. Check for
refrigerant leaks using gas detector.
Refrigerant is kept charged for longer than

2 years.
Compressor cylinder is not hot. (Refrigerant returns to com-

pressor in liquid form.)
High pressure side is
slightly low and low pres- No refrigerant returns in liquid form. High pressure side is low.
sure side is high.
Bubbles can be seen through Others
sight glass.
High pressure side is high. Refer to the Cooling Circuit Troubleshooting

Table on page T5-5-4.
Temperature is not cooled when compressor is
operated at fast speed continuously.
Air flow from blower is insufficient.
Compressor rotation is abnormally draggy.

Over-hea
ting is
suscep-ti
ble to
occur.
Trouble other than compressor Refer to the Cooling Circuit Troubleshooting Table on page
T5-5-4.
T5-5-10
Seized clutch. Replace.
Improper gap between am

Replace.
Broken or short-circuited core cable.
Shaft doesn’t rotate (internally locked). Replace.
Refer to the Electrical Circuit Troubleshooting Table on page T5-5-6.
Refer to the Cooling Circuit Troubleshooting Table on page T5-5-4.
Faulty mechanical seal, gasket, and/or charge valve.

Replace.
Oil leaks from oil plug.
Oil and refrigerant leaks from front housing, and/or cylinder block joint. Replace.
Normal leaks from hoses. Charge

refrigerant.
No leaks (normal).
Refer to the Cooling Circuit Troubleshooting Table on page T5-5-4.
Broken valve (See NOTE 3 on page T5-5-13.).
Replace.
Blown gasket (See NOTE 3 on page T5-5-13.).
Check and
Excessive oil. adjust oil level.
Broken clutch bearing due to overly tightened belt. Replace.
Shaft doesn’t rotate.

Replace.
Shaft rotates draggy.
T5-5-11
Compressor
Noise is heard when clutch is OFF.
Abnormal
noise
Noise is heard when clutch is ON.
T5-5-12
Broken clutch bearing.

Replace
Contact or slip due to poor air gap.
Faulty idle pulley bearing.
Saggy belt. Refer to the Cooling Circuit

Troubleshooting Table on
page T5-5-4.
Loose screws.
Broken valve.
Replace
Blown gasket.
Abnormal internal noise. Replace
Vibration due to saggy belt.

Refer to the Cooling Circuit
Loose screws. Troubleshooting Table on
page T5-5-4.
NOTE:
1. Don’t quickly decide that oil is leaking when a stain around the clutch and/or gasket is found. A
slight oil seepage will appear due to the seal construction. However, this oil seepage will not
cause malfunction. Be sure to accurately check whether oil is leaking or seeping only.
2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose
surface may be detected. As long as the specified rubber hoses are used, the problem should
not occur. (In case a large leaks is detected, the hose may be broken.)
3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between
high pressure side and low pressure side is 0.49 MPa (5 kgf/cm2, 71 psi) or less. When the
clutch is turned OFF, the pressure difference between high pressure side and low pressure side
will disappear within about 10 seconds.
T5-5-13
DIAGNOSIS BY BLINKING OF INDICATOR
The air conditioner system has a function to detect the
abnormality of the system by blinking of the indicator
IMPORTANT: Once abnormality is detected, the

detection state remains even after
normal state resumes. To release
this detection state, turn OFF the
key switch, or stop the air condi-
tioner with ON/OFF switch on the
control panel. Notice that the limita-
tion of M/A (motor actuator) can be
released only when the key switch
is OFF.
Open-Circuit Detection Abnormal Communication

• Blinking of HOT Mark • Blinking of Temperature Control Bar Frame
When the power is ON, HOT mark blinks if the har- 1. If communication between control panel and con-
ness of the air mix M/A disconnects or shorts. The trol amplifier fails, thus disabling reception, the
air mix M/A remains disabled until the power is control panel makes the temperature control bar
turned ON again. frame blink about 30 seconds later.
• Blinking of Inside/Outside Air Mark 2. At this time, the control amplifier makes all out-
When the main key power is ON, the inside/outside puts turn OFF.
air mark blinks if the harness of the inside/outside
air selection M/A disconnects or shorts. The in- 3. Even when is blinking, the control panel receives
side/outside air selection M/A remains disabled until all switch inputs.
the power is turned ON again.
4. When reception resumes, the temperature con-
• Blinking of A/C Mark (Open- or Short-Circuit of trol bar frame is turned ON instead of blinking
Evaporation Sensor and Its Input Circuit) state, and the control panel and control amplifier
The A/C mark blinks if the harness disconnects or resume.
shorts.
At this time, compressor control is not made, and
the compressor clutch is always turned OFF. Notice
that anti-fretting control is made.
T5-5-14
Control Panel
ON/OFF Switch
A/C Mark
Inside/Outside
Air Mark
HOT Mark
Temperature Control
Bar Frame
T18G-05-06-001
T5-5-15
* Please fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to Hitachi Tsuchiura Works Quality Assurance Dept. after
experiencing a problem with your machine’s air conditioning system.
< AIR CONDITIONER TROUBLE REPORT > File No.

(1) What Checked by:
Model (Serial No. )
Operation Type Manual Semi-Auto Full-Auto
Delivery Date Year Month
(2) When
Date Year Month Day Operating Hour ( h)
Time Morning Daytime Evening Night
Frequency Every Day Once a Week Once a Month Times per
(3) Where
Job Site Address State County Town
Access Road Condition Paved Not Paved (Gravel Sand Soil)
(4) How (Operating Conditions)
Weather Fine Cloudy Rain Snow
Atmospheric Temperature Very Hot Hot Cold Very Cold
Operating Conditions Parking Traveling Working
Temperature Control Paint blanks equal to red indicators. / Fill in set-temperature when
full-auto operation
A/C ON OFF
Control Air Induction Re-Circulation Fresh Air Circulation
Panel AUTO ON OFF Not Available
Fill following items when operated in manual mode or when manual control type unit is used.
Vent Position Front Front / Rear Foot Front / Rear and Foot
Fan First Second Third Fourth Fifth Sixth
(5) How (Problem Symptom)
Abnormal Compressor Operation
<Check Result>
Symptom Not turned ON
(1) Is problem reproducible ?
Not turned OFF
Reproducible
Others
Not reproducible
Uncontrollable air temperature (1) Pressure (To be measured at gauge manifold)
Symptom No cool air Low Pressure
No warm air High Pressure
Others (1) Which parts have been replaced ?
Uncontrollable air volume 1
Symptom Air flows in Hi mode only
No air flows 2
Small air volume
Others ∗ Before replacing the control amplifier, be sure to
check that the connectors are correctly connected
Uncontrollable vent hole
while repeatedly disconnecting and reconnecting
Symptom Vent hole isn’t selected connectors.
Others
Abnormal panel indication
Faulty Indicator Vent Hole
A/C
AUTO
Fresh Air Circulation
Fan OFF
Fan (Lo • •• Hi)
Temperature Control
Symptom Stays OFF
Stays ON
Blinks
Others
T5-5-16
Refrigerant Quantity....................... 4500±50 g

Compressor Oil Quantity ............... 240 cm3
T5-5-17
(Blank)
T5-5-18
TROUBLESHOOTING / Electrical System Inspection Procedure
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect Power Source

Be sure to remove the negative terminals from
the batteries first when taking wire harnesses
and connectors off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses, and fusible links and, in some
cases, cause fire due to short circuit.
2. Color Coding of Wire Harnesses

The color codes of the wire harnesses in the
electrical system are shown in the table on the
light. In some cases, where two colors are indi-
cated for one wire, the left initial stands for the
base color, while the right initial stands for the
marking color.
Code R W L G Y B
Color Red White Blue Green Yellow Black
Code Or Lg Br p Gr V
Orange Light
Color Brown Pink Gray Violet
Green
NOTE: 1) Code BW indicates a black base wire

with white fine-line marking.
2) Initials “O” and “Or” both stand for the
color orange.
3) Wires with longitudinal stripes printed
on them are not color coded. Be sure
not to confuse them with color coded
wires.
T5-6-1
3. Precautions for Connecting and Disconnecting
Terminal Connectors
Correct Incorrect
3-1. When disconnecting harnesses, grasp them by
their connectors. Do not pull on the wire itself.
Be sure to release the lock first before at-
tempting to separate connectors, if a lock is
provided.
3-2. Water-resistant connectors keep water out so T107-07-06-001
that if water enters the connector, water will not
easily drain. When checking water-resistant
connectors, take extra care not to allow water
to enter these types of connectors. In case
water should enter this connector, reconnect Correct
only after thoroughly drying the connector. Rust
3-3. Before connecting terminal connectors, check Bending
that no terminals are bent or missing. In addi-
tion, as most connectors are made of brass,
Separation
check that no terminals are corroding.
3-4. When connecting terminal connectors provided
T107-07-06-002
with a lock, be sure to insert them together until
the lock “clicks.”
4. Precaution for Using a Circuit Tester

Wind wire around the probe. Probe
4-1. Before using a circuit tester, refer to the in-
structions in the circuit tester manual.
Then, set the circuit tester to meet the object to
be measured, voltage range and current polar-
ity. Sharpen the tip of wire.
4-2. Before starting the connector test, always T107-07-06-003
check the connector terminal numbers, refer-
ring to the circuit diagram. When the connector
size is very small, and the standard probe size
is too large to be used for testing, wind a fine
piece of sharpened wire or a pin around the
probe to make the test easier.
T5-6-2
DISCONNECTION OF CONNECTOR
• Connector with a lock to press
NOTE: 1. Press the lock first, then pull the con-

nector.
The lock is difficult to press after the
connector is pulled.
2. The lock is located on the female (har-
ness) end of the connector.
T107-04-05-002
• Connector to pull apart
NOTE: Remove locks (if any) using a needle nose

pliers before pulling the connector.
T107-04-05-004
• Connector to pull apart

Use a 10 mm wrench to tighten the screw until the Screw
torque mark (convex) appears when re-tightening.
Convex
T107-04-05-005
T5-6-3
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between
the battery positive terminal and the vehicle
frame.
Normal Voltage:Between 24 to 26 V
NOTE: If voltage is abnormal, recharge or replace

the battery (ies).
2. Start the engine. Check charging voltage

between the battery positive terminal and the
vehicle frame.
Normal Voltage:Between 26 to 28 V
NOTE: If voltage is abnormal, check the charging

system.
T157-07-08-007
T5-6-4
(Blank)
T5-6-5
FUSIBLE LINK INSPECTION
• Fusible Link 1
Relay Box
Pull off the fusible link to visually inspect.
6
3
7
4 8
9
5
10
T18M-01-02-011
No Part Name Capacity Connected to

1 Fusible Link 1 75A Fuse Box 1,3 (Fuse No.1,2,4 to 12,55)
2 Fusible Link 2 75A Fuse Box 2,4 (Fuse No.31 to 33,69,70)
3 Fusible Link 3 75A Fuse Box 2,3,4 (Fuse No.30,34 to 36,48 to 50,73)
4 Fusible Link 4 75A Fuse Box 2,3,4 (Fuse No.37 to 39,44 to 47,53,59,60,67,68,77 to 79)
5 Fusible Link 5 75A Fuse Box 4 (Fuse No.61 to 66)
6 Fusible Link 6 75A Fuse Box 3,4 (Fuse No.41,51,52,75,76)
7 Fusible Link 7 45A Option Terminal
8 Fusible Link 8 75A Engine Starter Relay
9 Fusible Link 9 45A ECM Main Power
10 Fusible Link 10 75A Sliding Fold-In Ladder Relay
T5-6-6
• Fusible Link2
Check continuity between both ends of the fusible
link.
1 2
3
T183-05-08-001
T18M-01-02-011

1 Fusible Link 400A 400A Engine Pre-Lube Relay
2 Fusible Link 250A 250A Sliding Fold-In Ladder Motor (Rear)
3 Fusible Link 250A 250A Sliding Fold-In Ladder Motor (Front)
T5-6-7
FUSE CONTINUITY CHECK
The fuse failure is often caused by a fine crack in the
fuse, and such fine cracks are very hard to detect by
visual inspection.
Checking fuse continuity with a tester is far superior to
visual inspection.
1. Turn the key switch ON.

In doing so, the battery relay is activated by the
current from terminal M of the key switch, and
electric power is supplied to all circuits.
2. Remove the fuse box cover and set the correct

voltage measurement range (0 to 30 V) of the
tester.
Power Source Side
3. Connect the negative probe to the machine for (Positive)
grounding, and touch the accessory (down-
stream) side terminal of each fuse with the posi-
tive probe of the tester. If voltage (battery volt-
age) of approx. 20 to 25 V is observed at the
tester, fuse is not blown.
NOTE: 1.The inside terminals of the fuses in the

fuse box 1 and 2 are connected to the
power source, while the outside terminals
are connected to the accessory (down-
stream) side.
2.The left side terminals of the fuses in the Accessory Side
(Negative)
fuse box 3 are connected to the power
source, while the right side terminals are
connected to the accessory (down-
stream) side.
T105-07-01-008
3.The upper side terminals of the fuses in
the fuse box (cab) are connected to the
power source, while the lower side ter-
minals are connected to the accessory
(downstream) side.
T5-6-8
Fuse Box (Cab)
20 19 18 17 16 15 14 13 12 11
T18G-01-02-030
10 9 8 7 6 5 4 3 2 1
T18G-01-02-028
Fuse Box (Cab)

1 Main Power Key SW 20A Key Switch B Terminal
2 ELU Main Power 5A ELU
3 IDU Main Power 5A IDU
4 DLU Main Power 5A DLU
5 ORBCOMM Battery Power 5A ORBCOMM Unit (Option)
6 Radio Backup 5A Radio
7 ELU Key ON Sig. 5A ELU
8 IDU Key ON Sig. 5A IDU
9 DLU Key ON Sig. 5A DLU
10 Buzzar 5A BUZZAR
11 Key ON Sig. (Control Box) 5A Fuse Box 1 (Fuse No.13)
12 ECM Key ON Sig. 5A ECM
13 Radio (ACC) 5A Radio
14 Air Horn Comp. ACC Sig. 5A Air Horn Compressure Relay, Horn Relay
15 Lighter 10A Radio, Ciger Lighter
16 Terminal (ACC) 10A Terminal 1
17 Terminal (12V) 15A Terminal 1
18 − − −
19 Monitor Control Unit 5A Monitor Display
20 Pilot Control Shut-Off Lever SW. 5A Pilot Control Shut-Off Lever SW
T5-6-9
Fuse Box 1
1 2 3 4 5 6 7 8 9 10
T18G-05-07-001
11 12 13 14 15 16 17 18 19 20
T18M-05-06-002
Fuse Box 1 Connection Table

1 MC Main Power 5A MC
2 Delayed Power OFF Relay 5A Delayed Power Off Relay
3 − − −
4 MMS Back-up 5A MMS (Optional)
5 HMU Main Power 5A HMU
6 Air Horn Compressor (L) 30A Air Horn Compressor Relay (L)
7 Air Horn Compressor (R) 30A Air Horn Compressor Relay (R)
8 Sliding Fold-In Ladder Sol. (A) 10A Sliding Fold-In Ladder Solenoid (A)
9 BOX LIGHT 5A Box Light
10 Cab.Battery Power 30A Fuse Box (Cab) Fuse #1, 2, 3, 4, 5 ,6
11 Opt. C/U Main Power 10A Oprion Control Unit
12 Opt. C/U Main Power 10A Oprion Control Unit
13 Opt. C/U Key ON Sig. 5A Oprion Control Unit
14 Opt. C/U Key ON Sig. 5A Oprion Control Unit
15 MC Key ON Sig. 5A MC
16 ELU PWM Power Relay 5A ELU PWM Power Relay
17 DLU Key SW ON Sig. 5A DLU
18 − − −
19 ECM SW Power 5A Engine Diagnostic Switch
20 HMU Key ON Sig. 5A HMU
T5-6-10
Fuse Box 2
21 22 23 24 25 26 27 28 29 30
T18G-05-07-001
31 32 33 34 35 36 37 38 39 40
T18M-05-06-002

21 Washer Motor Relay 5A Washer Motor Relay
22 Travel Speed Select relay 5A Travel Speed Select Relay
23 A/C Main Relay (Front) 5A A/C Main Relay (Front)
24 A/C Main Relay (Side) 5A A/C Main Relay (Side)
25 A/C Main Relay (Rear) 5A A/C Main Relay (Rear)
26 Battery Relay 5A Battery Relay
27 A/C Control AMP (Front) 5A A/C Control AMP (Front)
28 A/C Control AMP (Side) 5A A/C Control AMP (Side)
29 A/C Control AMP (Rear) 5A A/C Control AMP (Rear)
30 Motion Alarm 5A Motion Alarm
31 A/C Main Power (Front) 15A A/C Main Power (Front)
32 A/C Main Power (Side) 15A A/C Main Power (Side)
33 A/C Main Power (Rear) 15A A/C Main Power (Rear)
34 A/C Condenser Fan (Front) 20A Air Compressure Fan Relay (FRONT)
35 A/C Condenser Fan (Side) 20A Air Compressure Fan Relay (SIDE)
36 A/C Condenser Fan (Rear) 20A Air Compressure Fan Relay (REAR)
37 DLU Service Tool 5A DLU
38 ORBCOMM Main Power 5A ORBCOMM Unit (Option)
39 MMS Main Power 5A MMS (Option)
40 Charge Signal 5A Alternator
T5-6-11
Fuse Box 3
41 42 43 44 45 46 47 48 49 50
T18G-05-07-001
51 52 53 54 55 56 57 58 59 60
T18M-05-06-002

41 Suspention Seat Air Compressor 15A Suspention Seat Air Compressure
42 − − −
43 − − −
44 Travel Speed Select Sol. 5A Travel Speed Select Relay
45 Sliding Fold-In Ladder Sol. 5A Sliding Fold-In Ladder Solenoid Valve B
46 Dome LED Light 5A Dome LED Light in the Cab
47 Air Breather Sol. 5A Air Breather Solenoid Valve
48 Terminal (24V) 15A Terminal
49 DC/DC Converter1 15A DC-DC Converter 1
50 DC/DC Converter2 15A DC-DC Converter 2
51 MC Sol. Power 10A MC
52 MC PWM. Power 10A MC
53 ELU Sol. Power 15A ELU PWM.Power Relay, ELU
54 − − −
55 ECM Power 15A ECM
56 − − −
57 − − −
58 − − −
59 Engine Oil Reserve Tank Pump 15A Engine Oil Reserve Tank Pump
60 Oil Pump 20A Air Release Solenoid Valve
T5-6-12
Fuse Box 4
61 62 63 64 65 66 67 68 69 70
T18G-05-07-001
71 72 73 74 75 76 77 78 79 80
T18M-05-06-002

61 Wark Light (1) 10A Wark Light Relay (1)
67 Maintenance Light (1) 10A Maintenance Light Relay (1)
71 − − −
72 − − −
73 Entrarce Light 10A Entrarce Light Relay
74 − − −
75 Wipir Motor (Low Speed) 30A Wipir Motor Relay (Low Speed)
76 Wipir Motor (High Speed) 30A Wipir Motor Relay (High Speed)
77 Washer Motor 10A Washer Motor Relay
78 Fast Filling System Sol. 5A Fast Filling System Relay
79 CSU Main Power 5A CSU
80 − − −
T5-6-13
Check Continuity between both ends of the fuse.
Fuse 10A
Fuse 5A
Fuse 30A
T18M-01-02-011
Part Name Connected to

Fuse 10A (L) Engine oil Reserve Tank Valve
Fuse 5A (R) IDU (Prelube Signal)
Fuse 30A Zener diode
T5-6-14
ALTERNATOR CHECK
The alternator indicator should go off after the engine
Terminal R
is started.
Terminal B
If the alternator indicator stays (comes) on while the
engine is running, the alternator may be failed.
Measurement of Generating Voltage

Start the engine. Measure voltage at terminals R and
B.
If the voltage at terminal R is 1.0 V or higher, and if
that at the terminal B is approximately 28 V, the al-
ternator is normal.
T18M-05-06-001
T5-6-15
VOLTAGE CHECK
The voltage check is performed not only for determi-
nation of the voltage values at the measurement point,
but also for the confirmation of the electrical validity
between the measurement point and power supply.
24 Volt Circuit
Before voltage check, turn appropriate switch ON to

apply voltage at the measurement line.
Measurement Example 1: When current is not flowing
Black Negative (-) Probe: Vehicle Frame
Red Positive (+) Probe: Each Measurement Point
If the rated voltage (battery voltage) is measured,

probably the circuit from the battery (alternator) to the
measurement point is in good condition. However, if
Measurement Point
the current flowing through the circuit, the voltage may
not be reached the rated value (this voltage drop is
caused by resistance of electrical components). T141-05-06-002
If the rated voltage is not measured, faulty power sup- Measured Voltage
ply, short-circuited circuit and/or broken line on circuit 24 V: The circuit from power source to the meas-
may be suspected. In this case, the faulty parts in the urement point is normal.
circuit can be found out by checking each parts in or- 0 V: There is open or short circuit between power
der of the circuit from the upstream (or downstream). supply and the measurement point.
Rated Voltage (with normal power source): Measurement Example 2: When power flows
When engine is not running: Battery voltage
approx. 25.5 V 2
When engine is running: Alternator generated
voltage
approx. 28 V
1 3
T141-05-06-003
Measurement Point Measured Value

1 24 V
2 20 V
3 0V
The measurement voltage does not become same to
the power supply value because of voltage drops by
resistance of the electrical components.
However, if the voltage is measured, it can be decided
that there are no open wires in the upstream circuit
from measurement point.
T5-6-16
Engine Key Switch Check Point Standard

Power Source 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 Battery 20 to 25 V
Stopped OFF Between (4) and Ground: Power Source 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link 1 20 to 25 V
Accessory Circuit
Stopped ACC Between (6) and Ground: Radio, Cigarette Lighter 20 to 25 V
Stopped ACC Between (7) and Ground: Air Horn Compress Relay 20 to 25 V
Stopped (L2)
Stopped ACC Between (8) and Ground: Air Horn Compress Relay 20 to 25 V
Stopped (R2)
Stopped ACC Between (9) and Ground: Horn Relay 20 to 25 V
Starting Circuit
Engine Start Switch: ON
Started ON Between (10) and Ground : Pre-Lube Timer Relay (#2) 20 to 25 V
Started ON Between (11) and Ground : Pre-Lube Timer Relay (#5) 20 to 25 V
Started ON Between (12) and Ground : Starter Relay (Upper) 20 to 25 V
(Switch)
Started ON Between (13) and Ground : Starter Relay (Upper) 20 to 25 V
(Coil)
Started ON Between (14) and Ground : Starter Relay (Lower) 20 to 25 V
(Switch)
Started ON Between (15) and Ground : Starter Relay (Lower) 20 to 25 V
(Coil)
Started ON Between (16) and Ground : Safety Relay (Switch) 20 to 25 V
Started ON Between (17) and Ground : Starter Motor (Upper) (S) 20 to 25 V
Started ON Between (18) and Ground : Starter Motor (Lower) (S) 20 to 25 V
Charging Circuit
Running ON Between (19) and Ground: Alternator Generating 26 to 30 V
Voltage (B)
Running ON Between (20) and Ground: Battery Relay (B) 20 to 25 V
Surge Voltage Prevention Cir-
cuit
Running−Stopped ON – OFF Between (21) and Ground: Delayed Power Off Relay 20 to 25 V
(Coil)
Running−Stopped ON - OFF Between (22) and Ground: Battery Relay (Coil) 20 to 25 V
T5-6-17
Limit Switch Fuse Box
LED (Cab)
(Box light switch)
To MC Delayed Power OFF

Relay Terminals Sliding Fold-In Ladder To ELU
#1 and #3 Relay (1) Terminal #3 To IDU
To MMS
Communication Sliding Fold-In Ladder Relay To DLU
Unit Alarm Flash Light (1) #12 ORBCOMM
To HUM Air Horn Compressor C/U Main Power Terminal #2 (Option)
Relay (L1) Terminal #3 Source
Air Horn Compressor Terminal #1 (Option) To Radio
Relay (R1) Terminal #3
C/U (Ke-CAN)
Terminal #1
(Option)
Fuse Box 1 Key Switch

ECM
(Datalink)
Fuse Box 3
Sliding Fold-In Ladder Relay (2)
Sliding Fold-In Ladder Relay (3)

Fusible Link #9
Fusible Link 1
Fusible Link #10
Fusible Link (250A)
Fusible Link (250A)
Battery Relay 1
4
Battery Relay 2 4
Battery Relay 3 4 3
Battery
Sliding Fold-In Sliding Fold-In
Ladder Motor 1 Ladder Motor 2 1
T18M-02-05-001
T5-6-18
Accessory Circuit
Fuse Box 1
Fuse #7
Fuse #6 Fuse Box
(Cab)
Fuse Box 1
Fuse #10
Air Horn Key Switch

Compressor Relay (L2) To Radio
Air Horn
Compressor Relay (L1)
Cigarette Lighter
Fusible Link 1
7
Power Source
Terminal (1)
6
8
Air Horn Air Horn
Compressor Relay (R2) Compressor Relay (R1)
9
Horn Relay
Horn Switch
Horn (R) Horn (L)
Air Horn
Compressor (R1) Air Horn
Compressor (L1)
Battery
Horn Pressure
Horn Pressure Switch (L1)
Switch (R1)
Horn Pressure
Horn Pressure Switch (L2)
Switch (R2)
T18M-02-05-002
T5-6-19
Starting Circuit
From Key Switch
Engine Start Terminal M
Switch
Prelube Timer
11 10
Charge SIG Relay
Starter Relay (Upper)

12
13
Engine Oil Reserve
Fuse Box 3 Pump Unit Relay
Starter Relay (Lower)
14 Fuse #59
15
Charge Relay Engine Oil Reserve

Safety Relay Pump Unit Switch
16 From
EHU
Fusible
Link 4 Fuse Box 2
Fuse #40
Alternator ECM Fuse Box 2

Battery Relay (1)
Fuse #26
Battery Relay (2)
Battery Relay (3)

17
Crank Speed
Sensor
Fuse Box
(Cab)
18
Starter (1)
(Upper) From Battery
Key Switch
Starter (2)
(Lower)
T18M-02-05-006
T5-6-20
To 2-5-15, -17, -19、& -21

Fusible Link
Terminal (Main)
Fusible Link 9
Terminal
(Sub)
Circuit Braker
(200A)
20 Battery Relay 1
20 Battery Relay 2
20 Battery Relay 3
19
From Alterna-
tor Terminal B
From Key Switch
Terminal M
Sliding Fold-In
Ladder Relay (2)
Sliding Fold-In
Ladder Relay (3)
ECM
Battery
Sliding Fold-In Sliding Fold-In

Ladder Motor 2 Ladder Motor 1
T18M-02-05-008
T5-6-21
Surge Voltage Prevention Circuit
Fuse Box (Cab)
Fuse #11
Fuse #1
Key Switch
Fuse Box 1
Fuse #2
Delayed Power Off

Relay Fuse Box 2 Fuse #15
Fuse #26 Fuse #10
21 MC Fusible Link 1
Battery Relay 1
22 Battery Relay 2
22 Battery Relay 3
22
Alternator (L)
Battery
T18M-02-05-016
T5-6-22
5 Volt Circuit
Power Source Signal or Ground
Voltage between terminal No.1 and the machine 1 2
chassis (Ground): Two Polarities
With the key switch turned OFF, disconnect the
sensor connector.
Measure the voltage between terminal No.1 of the
harness side connector and the vehicle frame
under the following conditions
V
• Key switch position: ON

• Tester black probe (negative):
Connected to the vehicle frame (ground)
• Tester red probe (positive): T107-07-05-006
Connected to terminal No.1

Power Source Signal Ground
Evaluation: 1 2 3
If the measured voltage is within 5±0.5 volts, the Three Polarities
circuit up to terminal No.1 is normal.
T107-07-05-007
Voltage between terminal No.1 and the ground 1 2

Two Polarities
terminal:
sensor connector.
Measure the voltage between terminal No.1 of the V
harness side connector and the ground terminal
(terminal No.2 for two polarities, or terminal No.3 for
three polarities) under the following conditions.
• Key switch position: ON

• Tester black probe (negative):
T107-07-05-008
Connected to the ground terminal (terminal No.2
or 3)
• Tester red probe (positive): 1 2 3
Connected to terminal No.1 Three Polari-
ties
Evaluation:
If the measured voltage is within 5±0.5 volts, the V
circuit lines up to terminal No.1 and the ground
terminal are normal.
T107-07-05-009
T5-6-23
CHECK USING FALSE SIGNAL
sensor connector. Two Polarities 1 2
Connect terminal No.1 (power source) and No.2
(signal) of the harness side connector to supply the
power source voltage as a false signal to the
controller.
This makes it to create the same situation as the ex-
treme situation on the sensor input signal. If the ma- Connect
chine and/or gauge actuate with the maximum signal
accordingly, the related harness is considered to be
normal. On the pressure switch, the switch indicates
"ON" status. T107-07-05-010
IMPORTANT: On three-polarity connectors, do not

connect terminals No.1 and No.2 to
No.3 or the machine chassis Three Polarities 1 2 3
(ground).
Connect
T107-07-05-011
T5-6-24
CONTINUITY CHECK Harness
Single-line continuity check A a
Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is:
0 Ω = Continuity
∞ Ω = Discontinuity Ω
Connect To
NOTE: When the one end connector is far apart Machine
Chassis. A a
from the other, connect one end of
connector (A) to the machine chassis
using a clip. Then, check continuity of the
harness through the vehicle frame as Connect To
illustrated. Machine
Ω
Chassis.
0 Ω = Continuity
∞ Ω = Discontinuity A a
Single-line short-circuit check ×

Disconnect both end connectors of the harness and
check continuity between one end connector of the
harness and the vehicle frame: Ω
0 Ω = Short circuit is present. Short-Circuit
∞ Ω = No short circuit is present. Between
Harness and T107-07-05-003
Machine
Multi-line continuity check Chassis
Disconnect both end connectors of the harness,
First Terminal Connection
and connect two terminals, (A) and (B), at one end
connector, as illustrated. Then, check continuity
between terminals (a) and (b) at the other A a
connector. If the ohm-meter reading is ∞ Ω, either B b
C c
line (A)-(a), or (B)-(b) is in discontinuity. To find out
which line is discontinued, conduct the single line
Second Terminal Connection
continuity check on both lines individually, or, after
changing the short-circuit terminals from (A)-(B) to
(A)-(C), check continuity once more between
terminals (a) and (c). Ω
NOTE: By conducting the multi-line continuity

check twice, it is possible to find out which T107-07-05-004
line is discontinued. With terminals (A) and Short-Circuit Between Harness

(C) connected, check continuity between
terminals (a) and (c). A a
If the ohm-meter reading is: B × b
0 Ω = Line (B)-(b) has discontinuity. C c
∞ Ω = Line (A)-(a) has discontinuity.
Multi-line short-circuit check

Disconnect both end connectors of the harness,
and check continuity between terminals (A) and (B) Ω
or (C).
0 Ω = Short-circuit exists between the lines.
T107-07-05-005
∞ Ω = No short-circuit exists between the lines.
T5-6-25
CIRCUIT CHECK BY LAMP HARNESS
Check the power at the measurement point using a
lamp harness.
#4283594 (ST 7126)

Used for single line inspection (an open, voltage).
Light should come on when the line is activated.
NOTE: On the PWM signal circuit, the lamp does

not show light if the ON signal duration ra- To measurement point
tio is too small. Grounding
#4283594(ST 7126) T107-07-05-012
Connect an end of the lamp harness to the meas-

urement point, and connect the other end to the
ground.
Turn ON the circuit to be measured.
Check the circuit conditions with the lamp flashing
simultaneously with the system operation.
T5-6-26

3600-Performance Test &troubleshooting

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SECTION 4

Group 3 Engine Test

Group 4 Excavator Test

Use operational performance test procedure to quan-

Purpose of Performance Tests

Precautions for Evaluation of Test Data

The machine performance does not always deterio-

Definition of “Performance Standard”

TEST AREA AND MEASURING EQUIPMENT

MAKE PRECISE MEASUREMENT

The standard performance values are listen in the table

NOTE: LD: Loading Shovel

NOTE: * In the case of backhoe specification, the

NOTE: LD: Loading Shovel

Travel Circuit Relief Pressure 29.4＋2.0-0

Swing Circuit Relief Pressure 29.4＋2.0-0

Bucket Close Circuit Relief Pressure 16.7＋1.5-0

OVERLOAD RELIEF SET-PRESSURE MPa (kgf/cm2, psi) 31.4＋1.0-0

Bucket Close Circuit Relief Pressure 16.7＋1.5-0

MAIN PUMP FLOW RATE L/min − T4-5-12

NOTE: LD: Loading Shovel

• Hydraulic P-Q Control • Hydraulic Pi-Q Control

NOTE: Refer to T4-5-12. NOTE: Refer to T4-5-14.

Main Pump P-Q Diagram Main Pump Pi-Q Diagram

• Hydraulic P-Q Control • Hydraulic Pi-Q Control

NOTE: Refer to T4-5-20. NOTE: Refer to T4-5-22.

Oil Cooler Fan Drive Pump P-Q Diagram 400 A

0 1 (10.2) 2 (20.4) 3 (30.6)

Boom, Arm, Bucket, Swing

Travel, Bucket Open/Close 12.4°±1° 12.4°±1°

Travel, Bucket Open/Close

Control Torque Output Voltage

4.0 Neutral Switch Voltage

Performance Test Conditions:

2. Disconnect the engine speed sensor connector.

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

Engine Speed Sensor

Deceleration Zone: Finish Travel Test Distance: Start Acceleration Zone:

CAUTION: Never work under a machine

support the machine.

4. Maintain the hydraulic oil temperature at 50±5

NOTE: When tested on a concrete surface road,

Measurement: 0.5 to 1.0 m

ference between the marks on the track shoe

With the arm cylinder fully extended and the

NOTE: In case it is difficult to secure the space

CAUTION: Prevent personal injury. Always

1. Confirm that the swing gears and bearing are

bucket cylinders fully extended, position the arm

Measure Difference Between Marks

position the arm top pin height flush with the

2. Position the front attachment as described in the

With the bucket cylinder and arm cylinder fully

following. BH: Boom and Bucket Cylinders Retraction

retracted from the fully extended, position the

Refer to T4-2 Operational Performance Standard. NOTE: BH: Backhoe

at the lever grip top center.

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

make sure that the area is clear and that

CAUTION: The air breather cap may pop off if

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

3. Disconnect the pilot hose from the pilot relief valve.

BH: Back-hoe Front