GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM

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

Note 7
Note 3
Note 5
Note 6
Note 2
Note 1

Analog 1
Analog 1 Analog22
Analog 1409S6HS01

(2) Specification
No. Description Specification
Note 1 Pilot pump pressure 40+20 bar
Note 2 Swing pilot pressure 0~40 bar
Note 3 Boom up pilot pressure 0~40 bar
Note 5 P1 pump control pressure 0~25 bar
Note 6 P2 pump control pressure 0~25 bar
Note 7 Pump 1 pressure 350 bar

6-4
2. DRIVE SYSTEM
1) UNUSUAL NOISE COMES OUT OF PUMP CONNECTION

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

6-5
 2) ENGINE STARTS BUT MACHINE DOES NOT OPERATE AT ALL

Cause Remedy
NO
Replenish
specified oil to
the standard
Is oil level in Abnormal noise level.
hydraulic oil YES comes out of YES
Hydraulic pump Disassemble
tank within hydraulic pump
standard level? is broken. and repair.
Do not hydraulic Abnormal noise
pump and pump YES comes out of YES
connections pump See item 1).
YES
make abnormal connection at page 6-5
noise?

Is pilot pump
pressure within ⓐ
NO standard level?

See Note 1
YES
Clean pilot
Is pilot piping piping interior
YES clogged or is oil
leakage present
or repair piping.
on pilot piping?
NO
RCV and safety Disassemble
solenoid valve is and repair.
ⓐ faulty.
YES
Pilot relief valve Repair or
in gear pump is replace.
Is gear pump
NO delivering oil?
faulty.

Gear pump is Disassemble

NO
broken. and repair.

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

Cause Remedy
YES
Water is mixed. Put hydraulic oil
still, separate
Drop hydraulic oil water and
sample on hot dispose it or
plate and check if replace
foams come up. hydraulic oil.

NO
Air is intruded. Check suction
line and return
line and
eliminate the air
intruding source.

2) HYDRAULIC OIL TEMPERATURE HAS RISEN ABNORMALLY

Cause Remedy
NO
Replenish
specified oil to
the standard
Is hydraulic oil level.
volume proper? YES
Oil cooler clogged. Clean oil cooler.
Is oil cooler clogged Bypass check Replace
and is bypass valve is defective.
YES check valve always YES
ⓐ
open?
Is fan belt
NO tension proper?
Adjust belt
NO
tension or
replace belt.
Is not the set
pressure of main YES Readjust set
relief, port relief pressure.
ⓐ and travel relief
Is main relief
valve lower than
valve used very YES Reduce load.
the standard NO often?
level?

6-7
 3) CAVITATION OCCURS WITH PUMP

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

4) HYDRAULIC OIL IS CONTAMINATED

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

6-8
4. SWING SYSTEM
1) BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE

Cause Remedy
NO
Replenish
Does safety YES
specified oil to the
YES solenoid valve
standard level.
operation
Is gear pump pilot normal? Safety solenoid Repair or replace.
NO
pressure within valve faulty or not
YES standard level?
YES
Is oil in hydraulic operated.
tank within See Note 1 Gear pump faulty. Repair or replace.
standard level? NO
YES
Are broken pieces Pump connection Disassemble and
of coupling present coupling is broken. repair.
ⓐ when dust plug
under engine fly Is main relief NO
Are attachment wheel is removed? NO valve faulty? Hydraulic pump is Disassemble and
and travel out of order. repair.
motions
impossible at all? NO
Does swing Swing control valve Disassemble and
YES
control valve spool is stuck. repair.
Is MCV swing spool move?
YES pilot pressure YES
within standard See Note 5
level?
Is RH travel See Note 2 NO
NO function normal?
Does not symptom
change when front YES
and rear pump Hydraulic pump is Disassemble and
NO
discharge hoses broken. repair.
are exchanged?
YES
Swing parking Disassemble and
brake release valve repair.
Is swing parking is broken.
ⓑ brake release
valve faulty? YES
Swing reduction Disassemble and
Does swing unit is broken. repair.
NO motor rotate?

NO
Swing motor is Disassemble and
broken. repair.

YES
Pilot relief valve in Disassemble and
NO Is gear pump gear pump is faulty. repair or replace.
delivering oil?
Gear pump is out Disassemble and
NO
Is gear pump pilot of order. repair.
ⓒ pressure within
standard level? YES
Is there oil Clean pilot piping
See Note 1
leakage from interior or repair
YES pilot piping or is piping.
it clogged?
RCV is broken. Disassemble and
NO
repair.

6-9
 2) SWING SPEED IS LOW
Cause Remedy
YES
Swing port relief Disassemble and
YES Does swing valve is faulty. repair or replace.
spool move?
Swing control Disassemble
Is MCV pilot NO
valve spool is and repair.
pressure same
stuck.
on LH and RH YES Clogged or oil
sides? Clean pilot
leak. piping interior or
See Note 2 Is pilot piping
Single direction clogged or is it repair piping.
NO leaking oil?
Is the trouble in
one direction or RCV or shuttle Disassemble
NO
in both valve is faulty. and repair.
YES
direction? ⓐ
YES Does swing
Both directions spool move?
YES Is MCV pilot Swing spool is Disassemble
pressure within NO
Is Arm speed See Note 5 stuck. and repair.
standard level?
within standard ⓑ
value? See Note 2 NO ⓒ
NO

Is swing motor's NO
ⓐ drain rate within Swing motor is Disassemble
standard value? broken. and repair.
Check that pilot
YES piping is clogged NO
or oil is leaking RCV or shuttle Disassemble
from it? valve is faulty. and repair.

Clogged or oil leak. Clean pilot

Is gear pump pilot piping interior or
ⓑ pressure within
repair piping.
standard level?
Pilot relief valve Disassemble and
YES
See Note 1 in gear pump is repair or replace.
Is gear pump defective.
NO delivering oil?
Gear pump is Disassemble
NO
broken. and repair.
NO
Main relief valve Main relief valve
faulty. pressure resetting
or repair.
Is main relief Does the symptom YES
ⓒ valve setting Hydraulic pump Disassemble
YES
change when front
pressure normal? and rear pump is broken. and repair.
discharge hoses
See Note 7
are exchanged? NO Shuttle valve is Repair or
Is MCV pilot faulty. replace.
YES pressure within
standard level? YES
Is gear pump Pilot relief valve Repair or
See Note 2 output pressure is faulty. replace.
NO within standard
level? Gear pump is Repair or
See Note 1
NO
faulty. replace.

6-10
 3) SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION

Cause Remedy
YES
Does symptom Swing port relief Disassemble
change when LH valve is faulty. and repair.
YES
and RH port
relief valves are
exchanged? Shuttle valve is Disassemble
NO
YES Does swing control faulty. and repair.
valve spool move?

Is MCV pilot Swing control Disassemble

NO
pressure same valve spool is and repair.
for LH and RH? stuck.
YES
See Note 2
Check if pilot RCV is faulty. Disassemble
piping is clogged and repair.
NO or does have oil
leakage. Clogged or oil
Clean pilot
NO leak.
piping interior
or repair piping.

4) MACHINE SWINGS BUT DOES NOT STOP

Cause Remedy
YES
Pilot relief valve Disassemble
is faulty. and repair or
YES Is MCV pilot YES Is gear pump pilot
pressure within pressure within replace.
standard value? standard level?
See Note 2 See Note 1 Gear pump is Disassemble
NO
broken. and repair.
YES Does swing spool
move?
NO
RCV is faulty. Disassemble
and repair.
Is swing control
valve's return
spring normal? Swing spool is Disassemble
NO
stuck. and repair.

NO
Return spring is Disassemble
faulty. and replace.

6-11
 5) THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE

Cause Remedy
YES
ⓐ
YES Is swing shuttle
valve normal?
Shuttle valve is Disassemble
NO
faulty. and replace.
YES Is brake spring
normal?

Is return spring
of swing spool Brake spring is Disassemble
NO
normal? faulty. and replace.

Return spring of Disassemble

NO
swing control and replace.
valve is faulty.
YES
Is drain rate of Swing port relief Disassemble
YES swing motor valve is faulty. and repair or
within standard replace.
Is swing relief value? Swing motor is Disassemble
NO
ⓐ pressure within broken. and repair.
standard level?
SPEC : 265±10kgf/cm2 Adjust swing
NO
relief valve
pressure or
replace swing
relief valve.

6-12
5. TRAVEL SYSTEM
1) TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE

Cause Remedy
YES
Does ⓐ
YES counterbalance
spool move lightly
by hand?
Is travel brake Counter spool is Disassemble
NO
YES valve pressure stuck. and repair or
within standard
Does the symptom replace.
level?
change when
relief valves in YES
NO travel motor are
Relief valve built Disassemble
YES Has travel spool exchanged? in travel motor is and repair.
changed over faulty.
positively?
YES
Control system Disassemble
is defective. inspect and
Does travel spool
repair.
NO move?

NO Travel spool is Disassemble

stuck. and repair.

Is bucket or arm
operation YES
Travel reduction Disassemble
possible? Do not metallic
particles come unit is faulty. and repair.
ⓐ out of drain port
in travel
reduction unit?
NO
Travel motor is Disassemble
out of order. and repair.
Does the symptom
NO
change when front
YES
and rear pump Hydraulic pump Disassemble
Does the discharge hoses
symptom change is broken. and repair.
are exchanged?
when LH/RH
NO
travel relief valves
are exchanged?
YES Travel relief Disassemble
valves are faulty. and repair or
replace.

6-13
 2) SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES

Cause Remedy
YES
Brake valve is Disassemble
Do LH and RH defective. and repair or
travel speeds
YES change when LH replace.
YES
and RH travel Does the symptom Relief valve built Disassemble
brake valves are change when in travel motor is and repair.
exchanged? relief valves in faulty.
NO LH and RH
YES Has travel spool travel motors are
changed over exchanged? ⓐ
positively? NO
YES
Control system Disassemble,
is faulty . inspect and
Does spool move? repair.
Is the lower NO
speed (bucket or
See Note 5, 6 Control valve Disassemble
arm) within NO
standard level? spool is stuck. and repair.

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

Travel motor is Disassemble

NO
faulty. and repair.

6-14
 3) MACHINE DOES NOT STOP ON A SLOPE
Machine is pulled forward as sprocket rotates during digging operation.

Cause Remedy
None Is parking brake YES
friction plate Friction plate is Disassemble
YES Check if parking worn? faulty. and repair.
brake pilot line is
clogged.
Clogged Disassemble
and clean pilot
Is drain rate of piping.
Is travel brake YES NO
travel motor
pressure within Travel motor is Disassemble
within standard
standard level? defective. and repair.
value?
SPEC : 11kgf/cm2

Brake valve is Disassemble

NO
faulty. and repair or
replace.

4) LH AND RH TRAVEL MOTIONS ARE IMPOSSIBLE

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

Short Replenish
hydraulic oil.

6-15
 5) TRAVEL ACTION IS POWERLESS (travel only)

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

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

6) MACHINE RUNS RECKLESSLY ON A SLOPE

Cause Remedy
Travel brake valve
(counterbalance Disassemble
valve) is faulty. and repair or
replace.

6-16
 7) MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL
AND ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME

Cause Remedy
YES
Normal.

YES Is straight spool

normal?

Straight spool is Repair or

Is pilot pressure NO faulty. replace.
for travel straight
spool within
standard level? YES
Remove dirt on
signal orifice.
Is signal orifice
YES Is pilot relief NO
NO clogged? Pilot relief valve Disassemble
valve normal?
is defective. and repair or
Is gear pump replace.
NO delivering oil?

Gear pump is Disassemble

NO
broken. and repair.

6-17
6. ATTACHMENT SYSTEM
1) BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL

Cause Remedy
YES
Does the Port relief valve Disassemble
YES symptom change is faulty. and repair or
when port relief replace.
valve is replaced
with other valve? NO ⓐ
YES Is MCV pilot
pressure within
standard level?
Inspect if pilot
See Note 3, 4 piping is clogged OK
NO or oil is leaking
RCV is faulty. Disassemble
YES Are other from the piping. and repair.
attachments
operatable?
YES
Pilot relief valve Disassemble
Is gear pump
pilot pressure YES Is gear pump is faulty. and repair or
NO within standard delivering oil? replace.
level? Gear pump is Disassemble
See Note 1 NO
zzzz broken. and repair.
Are LH/RH
operations OK
possible? Hydraulic pump Disassemble
Disassemble is broken. and repair.
YES main relief valve
Remove dust plug and check if it is
under engine not irregular.
OK flywheel and Main relief valve Disassemble
Faulty
check if coupling is defective. and repair or
element particles replace.
Inspect oil are not present. Particles present Coupling at Disassemble
NO
volume in
hydraulic oil tank. pump connection and repair.
is broken.
Short Replenish
hydraulic oil.

YES
Cylinder interior Disassemble
Does control
is broken. and repair.
ⓐ valve spool
move?
NO
MCV spool is Disassemble
See Note 5, 6
stuck. and repair.

6-18
 2) BOOM, ARM OR BUCKET SPEED IS LOW
Cause Remedy
YES
Normal.
YES
Are other ⓐ
YES attachment
Is combination speeds within
Is speed low only of oil streams standard levels? NO ⓑ
in composite YES
normal at boom YES
operation? up and at arm Does spool of flow Flow summation Disassemble
extrusion? summation check check valve is and repair.
NO valve move lightly stuck.
Are LH/RH travel by hand?
NO speeds within NO
standard levels?
YES
Hydraulic pump Disassemble
Are both LH/RH is faulty. and repair.
travel speeds YES ⓒ
NO
low? Is MCV pilot
pressure within
NO
standard? ⓓ
NO
See Note 3, 4
OK
Does the Port relief valveDisassemble
symptom change is faulty. and repair or
YES
when port relief
valve is replaced replace.
Does control with other valve? Cylinder is faulty. Disassemble
YES valve spool NO
and repair.
move ?
See Note 7
NO MCV spool is Disassemble
Is MCV pilot
ⓐ pressure within stuck. and repair.
standard level?
Is not MCV pilot YES
See Note 3, 4
Clean pilot
pressure piping piping interior
clogged or is not
NO
there oil or repair piping.
leakage? NO
RCV is defective. Disassemble
and repair.
YES
Pilot relief valve Disassemble
Is pilot pressure NO is faulty. and repair or
ⓑ Is gear pump
within standard
level?
delivering oil? replace.
Gear pump is Disassemble
See Note 1 NO
broken. and repair.
AIs engine NO
ⓒ revolution within Adjust engine
standard level? revolution.
YES
Clean orifice in
control valve.
Is not orifice in
ⓓ main control YES
valve clogged? Is pilot piping Clean pilot
clogged or is oil piping interior
NO leaking from the or repair piping.
piping? Is RCV normal?
NO NO
RCV is faulty. Disassemble
and repair.

6-19
 3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS

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

OK
Pressure Disassemble
Disassemble and tightness and repair.
inspect load between control
YES
check valve in
MCV and check valve casing and
for any fault. spool is poor.
Is cylinder
Abnormal Contact surface Disassemble
internal leakage
ⓐ between poppet and repair.
within standard
level? and seat is poor.

Cylinder is faulty. Disassemble

NO
and repair.

6-20
 4) BOOM, ARM OR BUCKET POWER IS WEAK

Cause Remedy
YES
Check
according to the
Is cylinder
YES internal leakage procedure in
within standard Item "Speed is
level? low".
Is relief pressure
YES in port relief Cylinder is faulty. Disassemble
valve within NO
and repair.
standard level?
Is relief pressure
in main relief Port relief valve Adjust
valve within NO
is faulty. pressure, repair
standard level?
See Note 7 or replace.
Main relief valve Adjust
NO
is defective. pressure, repair
or replace.

5) ONLY BUCKET OPERATION IS TOTALLY IMPOSSIBLE

Cause Remedy
YES
Port relief valveDisassemble
Does the is defective. and repair or
YES
symptom change
when port relief replace.
YES
valve is replaced Cylinder interior Disassemble
with other valve? Does control is broken. and repair.
valve spool
Is MCV pilot NO move?
YES
pressure within MCV spool is Disassemble
standard level? See Note 5 NO
stuck. and repair.
See Note 4

Is LH travel RCV is faulty. Disassemble

NO
possible? and repair.

Does the YES

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

6-21
 6) BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED

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

Boom foot pin Supply grease

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

6-22
※ HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE
1. Lower the bucket teeth to the ground with
bucket cylinder fully retracted and arm
cylinder rod retracted almost in full.

16096TS01

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

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

(210-7) 6-20(2)

3. Raise bucket OFF the ground by retracting

the arm cylinder rod.
If oil leaks from piping side and boom
cylinder rod is retracted there is an internal
leak in the cylinder.
If no oil leaks from piping side and boom
cylinder rod is retracted, there is an internal
leak in the control valve.
16096TS02

6-23