TT 1cde 00

INTRODUCTION
TO THE READER
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form at the end of this man-
• Be sure to thoroughly read this manual for correct ual.
product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog
MANUAL COMPOSITION
• This manual consists of three portions: the Techni- • Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
• Information included in the Technical Manual • Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redeliver and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
PAGE NUMBER
• Each page has a number, located on the center

lower part of the page, and each number contains
the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and • CAUTION:

signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. • IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropri- • NOTE:
ate lifting techniques and equipment when lifting heavy Indicates supplementary technical information or
parts. know-how.
UNITS USED
2
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKS system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 Power kW PS 1.360
Volume L US qt 1.057 kW HP 1.341
3 3
m yd 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
• This is the SAFETY ALERT SYMBOL.
• When you see this symbol on your machine or in

this manual, be alert to the potential for personal
injury.
• Follow recommended precautions and safe
operating practices.
001-E01A-0688 SA-688
UNDERSTAND SIGNAL WORDS
• On machine safety signs, signal words designating

the degree or level of hazard - DANGER, WARNING,
or CAUTION - are used with the safety alert symbol.
• DANGER indicates an imminently hazardous

situation which, if not avoided, will result in death
or serious injury.
• WARNING indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury.
• CAUTION indicates a potentially hazardous

situation which, if not avoided, may result in minor
or moderate injury.
• DANGER or WARNING safety signs are located

near specific hazards. General precautions are
listed on CAUTION safety signs.
• Some safety signs don’t use any of the SA-1223

designated signal words above after the safety
alert symbol are occasionally used on this
machine.
• CAUTION also calls attention to safety messages in

this manual.
• To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT
indicates a situation which, if not avoided, could
result in damage to the machine.
• NOTE indicates an additional explanation for an

element of information.
002-E01C-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
• Carefully read and follow all safety signs on the ma-

chine and all safety messages in this manual.
• Safety signs should be installed, maintained and re-

placed when necessary.
• If a safety sign or this manual is damaged or miss-

ing, order a replacement from your authorized
dealer in the same way you order other replace-
ment parts (be sure to state machine model and
serial number when ordering).
SA-003
• Learn how to operate the machine and its controls

correctly and safely.
• Allow only trained, qualified, authorized personnel to

operate the machine.
• Keep your machine in proper working condition.
• Unauthorized modifications of the machine may

impair its function and/or safety and affect ma-
chine life.
• The safety messages in this SAFETY chapter are

intended to illustrate basic safety procedures of ma-
chines. However it is impossible for these safety
messages to cover every hazardous situation you
may encounter. If you have any questions, you
should first consult your supervisor and/or your
authorized dealer before operating or performing
maintenance work on the machine.
003-E01B-0003
PREPARE FOR EMERGENCIES
• Be prepared if a fire starts or if an accident occurs.
• Keep a first aid kit and fire extinguisher on hand.

• Thoroughly read and understand the label at-
tached on the fire extinguisher to use it properly.
• To ensure that a fire-extinguisher can be always
used when necessary, check and service the fire-
extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
• Establish emergency procedure guidelines to
cope with fires and accidents.
• Keep emergency numbers for doctors, ambu- SA-437
lance service, hospital, and fire department

posted near your telephone.
004-E01A-0437
SA-2
SAFETY
WEAR PROTECTIVE CLOTHING
• Wear close fitting clothing and safety equipment

appropriate to the job.
You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear SA-438
Respirator or filter mask.
Be sure to wear the correct equipment and clothing
for the job. Do not take any chances.
• Avoid wearing loose clothing, jewelry, or other

items that can catch on control levers or other
parts of the machine.
• Operating equipment safely requires the full

attention of the operator. Do not wear radio or music
headphones while operating the machine.
005-E01A-0438
PROTECT AGAINST NOISE
• Prolonged exposure to loud noise can cause

impairment or loss of hearing.
• Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against
objectionable or uncomfortably loud noises.
006-E01A-0434 SA-434
INSPECT MACHINE
• Inspect your machine carefully each day or shift by

walking around it before you start it to avoid personal
injury.
• In the walk-around inspection be sure to cover all

points described in the “PRE-START
INSPECTION” chapter in the operator’s manual.
S007-E01A-0435
SA-435
SA-3
SAFETY
GENERAL PRECAUTIONS FOR CAB
• Before entering the cab, thoroughly remove all dirt

and/or oil from the soles of your work boots. If any
controls such as a pedal is operated while with dirt
and/or oil on the soles of the operator’s work
boots the operator’s foot may slip off the pedal,
possibly resulting in a personal accident.
• Don’t leave parts and/or tools lying around the op-

erator’s seat. Store them in their specified loca-
tions.
• Avoid storing transparent bottles in the cab. Don’t

attach any transparent type window decorations
on the windowpanes as they may focus sunlight,
possibly starting a fire.
• Refrain from listening to the radio, or using music

headphones or mobile telephones in the cab while
operating the machine.
• Keep all flammable objects and/or explosives

away from the machine.
• After using the ashtray, always cover it to extin-

guish the match and/or tobacco.
• Don’t leave cigarette lighters in the cab. When the

temperature in the cab increases, the lighter may
explode.
524-E01A-0000
SA-4
SAFETY
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.
• When you mounting and dismounting the ma-

chine, always face the machine and maintain a
three-point contact with the steps and handrails.
• Do not use any controls as hand-holds.
• Never jump on or off the machine. Never mount or

dismount a moving machine.
SA-439
• Be careful of slippery conditions on platforms,
steps, and handrails when mounting and dis-
mounting the machine.
008-E01B-0439
ADJUST THE OPERATOR'S SEAT
• A poorly adjusted seat for either the operator or for

the work at hand may quickly fatigue the operator
leading to misoperations.
• The seat should be adjusted whenever changing

the operator for the machine.
• The operator should be able to fully depress the
pedals and to correctly operate the control levers
with his back against the seat back.
• If not, move the seat forward or backward, and
check again. SA-378
009-E01A-0378
SA-5
SAFETY
FASTEN YOUR SEAT BELT
• If the machine should overturn, the operator may

become injured and/or thrown from the cab.
Additionally the operator may be crushed by the
overturning machine, resulting in serious injury or
death.
• Prior to operating the machine, thoroughly

examine webbing, buckle and attaching hardware.
If any item is damaged or worn, replace the seat
belt or component before operating the machine.
• Be sure to remain seated with the seat belt SA-237
securely fastened at all times when the machine is
in operation to minimize the chance of injury from
an accident.
• We recommend that the seat belt be replaced
every three years regardless of its apparent
condition.
010-E01A-0237
MOVE AND OPERATE MACHINE SAFELY
• Bystanders can be run over.
• Take extra care not to run over bystanders.

Confirm the location of bystanders before moving,
swinging, or operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the SA-426
machine.
011-E01A-0426
SA-6
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
• Inappropriate engine starting procedures may cause

the machine to runaway, possibly resulting in serious
injury or death.
• Start the engine only when seated in the

operator's seat.
• NEVER start the engine while standing on the
track or on ground.
• Do not start engine by shorting across starter
terminals. SA-444
• Before starting the engine, confirm that all control
levers are in neutral.
012-E01B-0444
JUMP STARTING
• Battery gas can explode, resulting in serious injury.
• If the engine must be jump started, be sure to

follow the instructions shown in the “OPERATING
THE ENGINE” chapter in the operator’s manual.
• The operator must be in the operator’s seat so
that the machine will be under control when the
engine starts. Jump starting is a two-person
operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures SA-032
could result in a battery explosion or a runaway
machine.
S013-E01A-0032
SA-7
SAFETY
KEEP RIDERS OFF MACHINE
• Riders on machine are subject to injury such as

being struck by foreign objects and being thrown off
the machine.
• Only the operator should be on the machine.

Keep riders off.
• Riders also obstruct the operator’s view, resulting
in the machine being operated in an unsafe
manner.
SA-379
014-E01B-0379
PROVIDE SIGNALS FOR FOBS INVOLV-

ING MULTIPLE NUMBERS OF MACHINES
• For jobs involving multiple numbers of machines,

provide signals commonly known by all personnel
involved. Also, appoint a signal person to coordinate
the job site. Make sure that all personnel obey the
signal person’s directions.
018-E01A-0481
SA-481
CONFIRM DIRECTION OF MACHINE TO

BE DRIVEN
• Incorrect travel pedal/lever operation may result in

serious injury death.
• Before driving the machine, confirm the position of

the undercarriage in relation to the operator’s po-
sition. If the travel motors are located in front of
the cab, the machine will move in reverse when
travel pedals/levers are operated to the front.
SA-491
017-E01A-0491
SA-8
SAFETY
DRIVE MACHINE SAFELY
• Before driving the machine, always confirm that the

travel levers/pedals direction corresponds to the di-
rection you wish to drive.
• Be sure to detour around any obstructions.

• Avoid traveling over obstructions. Soil, fragments
of rocks, and/or metal pieces may scatter around
the machine. Don’t allow personnel to stay around
the machine while traveling.
SA-387
• Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or death.
• When driving up or down a slope, keep the bucket

facing the direction of travel, approximately 200 to
300 mm (A) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop traveling.
SA-388
SA-441
• Driving across the face of a slope or steering on a

slope may cause the machine to skid or turnover.
If the direction must be changed, move the ma-
chine to level ground, then, change the direction
to ensure sage operation.
019-E01D-0492
SA-589
SA-9
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
• Death or serious injury may result if you attempt to

mount or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park
machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle / acceleration seleclter and the SA-391
H/P mode switch off.
• Run the engine at slow idle speed without load for
5 minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK
position.
• Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
SA-392
020-E08A-0493
SA-10
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
• If any person is present near the machine when

backing or swinging the upperstructure, the machine
may hit or run over that person, resulting in serious
injury or death.
To avoid back-over and swing accidents:

• Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
SA-383
• Keep the travel alarm in working condition (if
equipped).
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP

IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a signal
person. SA-384
• No machine motions shall be made unless signals

are clearly understood by both signalman and
operator.
• Learn the meanings of all flags, signs, and

markings used on the job and confirm who has
the responsibility for signaling.
• Keep windows, mirrors, and lights clean and in

good condition.
• Dust, heavy rain, fog, etc., can reduce visibility. As

visibility decreases, reduce speed and use proper
lighting.
• Read and understand all operating instructions in

the operator’s manual.
S021-E01A-0494
SA-11
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING

MACHINE---SERIOUS OR FATAL CRUSHING
INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU

CAN JUMP FREE
FASTEN YOUR SEAT BELT
• The danger of tipping is always present when

operating on a grade, possibly resulting in serious SA-012
injury or death.
To avoid tipping:
• Be extra careful before operating on a grade.
• Prepare machine operating area flat.

• Keep the bucket low to the ground and close to
the machine.
• Reduce operating speeds to avoid tipping or
slipping.
• Avoid changing direction when traveling on
grades.
• NEVER attempt to travel across a grade steeper SA-440
than 15 degrees if crossing the grade is

unavoidable.
• Reduce swing speed as necessary when swinging
loads.
• Be careful when working on frozen ground.
• Temperature increases will cause the ground to

become soft and make ground travel unstable.
S025-E01B-0495
SA-12
SAFETY
AVOID POWER LINES
• Serious injury or death can result if the machine or

front attachments are not kept a safe distance from
electric lines.
• When operating near an electric line, NEVER

move any part of the machine or load closer than
3 m (10 ft) plus twice the line insulator length.
• Check and comply with any local regulations that
may apply.
• Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the
site. SA-381
029-E01A-0381
OBJECT HANDLING
• If a lifted load should fall, any person nearby may be

struck by the falling load or may be crushed
underneath it, resulting in serious injury or death.
• When using the machine for craning operations,

be sure to comply with all local regulations.
• Do not use damaged chains or frayed cables,
sables, slings, or ropes.
• Before craning, position the upperstructure with
the travel motors at the rear.
• Move the load slowly and carefully. Never move it
suddenly.
• Keep all persons well away from the load.
• Never move a load over a person's head.
• Do not allow anyone to approach the load until it is
SA-014
safely and securely situated on supporting blocks
or on the ground.
• Never attach a sling or chain to the bucket teeth.
They may come off, causing the load to fall.
032-E01A-0014
SA-13
SAFETY
PROTECT AGAINST FLYING DEBRIS
• If flying debris hit eyes or any other part of the body,

serious injury may result.
• Guard against injury from flying pieces of metal or

debris; wear goggles or safety glasses.
• Keep bystanders away from the working area
before striking any object.
SA-432
031-E01A-0432
PARK MACHINE SAFELY
To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Turn auto-idle / acceleration selector and H/P
mode switch off.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK
position. SA-390
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.
033-E09B-0390
SA-14
SAFETY
HANDLE FLUIDS SAFELYҥ
ҥAVOID FIRES
• Handle fuel with care; it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur,
possibly resulting in serious injury or death.
• Do not refuel the machine while smoking or when

near open flame or sparks.
• Always stop the engine before refueling the
machine.
• Fill the fuel tank outdoors.
• All fuels, most lubricants, and some coolants are SA-018

flammable.
• Store flammable fluids well away from fire

hazards.
• Do not incinerate or puncture pressurized
containers.
• Do not store oily rags; they can ignite and burn
spontaneously.
• Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-019
SA-15
SAFETY
SAFETY TRANSPORTING
• The danger of tipping is present when

loading/unloading the machine onto/from a truck or
trailer bed.
• Be sure to observe local regulations when

transporting the machine on public roads.
• Provide an appropriate truck or trailer for
transporting the machine.
Take the following precautions when loading /

unloading the machine: SA-395
1) Select firm level ground.
2) Be sure to use a loading dock or ramp.
3) Be sure to have a signal person when
loading/unloading the machine.
4) Always turn the auto-idle / acceleration selector
and the H/P mode switch OFF when loading or
unloading the machine, to avoid unexpected
speed increase due to unintentional operation of
a control lever.
5) Always select the slow speed mode with the
travel mode switches. In the high speed mode,
travel speed may automatically increase.
6) Avoid steering while driving up or down the ramp
as it is extremely dangerous. If steering is
unavoidable, first move back to the ground or
flatbed, modify traveling direction, and begin to
drive again.
7) Do not operate any levers besides the travel
levers when driving up or down the ramp.
8) The top end of the ramp where it meets the
flatbed is a sudden bump. Take care when
traveling over it.
9) Prevent possible injury from machine tipping
while the upperstructure is rotating.
10) Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
11) Securely fasten chain or cables to the machine
frame. Refer to "transporting" chapter in the
operator's manual for details.
S035-E08A-0395
SA-16
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
• Understand service procedures before doing

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

1) Park the machine on a level surface.
2) Lower the bucket to the ground.
3) Turn the auto-idle / acceleration selecltor off.
4) Run the engine at slow idle speed without load
for 5 minutes. SA-028
5) Turn the key switch to OFF to stop engine.
6) Relieve the pressure in the hydraulic system by
moving the control levers several times.
7) Remove the key from the switch.
8) Attach a “Do Not Operate” tag on the control
lever.
9) Pull the pilot control shut-off lever to the LOCK
position.
10) Allow the engine to cool.
• If a maintenance procedure must be performed

with the engine running, do not leave machine
unattended.
• If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
• Never work under a machine raised by the boom.
• Inspect certain parts periodically and repair or SA-527
replace as necessary. Refer to the section

discussing that part in the “MAINTENANCE”
chapter in the operator’s manual.
• Keep all parts in good condition and properly
installed.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or
debris.
• When cleaning parts, always use nonflammable
detergent oil. Never use highly frammable oil such
as fuel oil and gasoline to clean parts or surfaces.
• Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
• Illuminate your work area adequately but safely.
S500-E02B-0497
SA-17
SAFETY
• Use a portable safety light for working inside or
under the machine.
• Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
• Sufficiently illuminate the work site. Use a
maintence work light when working under or
inside the machine.
• Always use a work light protected with a guard. In SA-037
case the light bulb is broken, spilled fuel, oil

antifreeze fluid, or window washer fluid may catch
fire.
S500-E02B-0497
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause serious

injury.
• Before performing any work on the machine,

attach a “Do Not Operate” tag on the control lever.
S501-E01A-0287
SA-287
SUPPORT MACHINE PROPERLY
• Never attempt to work on the machine without

securing the machine first.
• Always lower the attachment to the ground before

you work on the machine.
• If you must work on a lifted machine or
attachment, securely support the machine or
attachment. Do not support the machine on cinder
blocks, hollow tires, or props that may crumble
under continuous load. Do not work under a
SA-527
machine that is supported solely by a jack.
519-E01A-0527
STAY CLEAR OF MOVING PARTS
• Entanglement in moving parts can cause serious

injury.
• To prevent accidents, care should be taken to

ensure that hands, feet, clothing, jewelry and hair
do not become entangled when working around
rotating parts.
502-E01A-0026
SA-026
SA-18
SAFETY
PREVENT PARTS FROM FLYING
• Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in
serious injury, blindness, or death.
• Do not attempt to remove GREASE FITTING or

VALVE ASSEMBLY.
• As pieces may fly off, be sure to keep body and
face away from valve.
• Travel reduction gears are under pressure.

SA-344
• As pieces may fly off, be sure to keep body and
face away from AIR RELEASE PLUG to avoid
injury. GEAR OIL is hot.
• Wait for GEAR OIL to cool, then gradually loosen
AIR RELEASE PLUG to release pressure.
503-E01B-0344
STORE ATTACHMENTS SAFELY
• Stored attachments such as buckets, hydraulic

hammers, and blades can fall and cause serious
injury or death.
• Securely store attachments and implements to

prevent falling. Keep children and bystanders
away from storage areas.
SA-034
504-E01A-0034
USE TOOLS PROPERLY
• Use tools appropriate for the work to be done.

• Makeshift tools, parts, and procedures can create
safety hazards.
• For loosening and tightening hardware, use the
correct size tools to avoid injury caused by
slipping wrenches.
• Use only recommended replacement parts.
(See the parts catalog.)
SA-040
S522-E01A-0040
SA-19
SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under

pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
• To avoid possible injury from hot spraying water.

DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the SA-039
stop. Allow all pressure to be released before
removing the cap.
• The hydraulic oil tank is pressurized. Again, be
sure to release all pressure before removing the
cap.
Hot fluids and surfaces:
• Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot
as well.
SA-225
• Wait for the oil and components to cool before

starting any maintenance or inspection work.
505-E01B-0498
REPLACE RUBBER HOSES

PERIODICALLY
• Rubber hoses that contain flammable fluids under

pressure may break due to aging, fatigue, and
abrasion. It is very difficult to gauge the extent of
deterioration due to aging, fatigue, and abrasion of
rubber hoses by inspection alone.
• Periodically replace the rubber hoses. (See the

page of “Periodic replacement of parts” in the
operator’s manual.)
SA-019
• Failure to periodically replace rubber hoses may
cause a fire, fluid injection into skin, or the front
attachment to fall on a person nearby, which may
result in severe burns, gangrene, or otherwise
serious injury or death.
S506-E01A-0019
SA-20
SAFETY
AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under

pressure can penetrate the skin or eyes causing
serious injury, blindness or death.
• Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take
care to protect hands and body from high- SA-031
pressure fluids. Wear a face shield or goggles for

eye protection.
• If an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.
SA-292
507-E03A-0499
SA-044
SA-21
SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to

fires.
• Check for oil leaks due to missing or loose clamps,

kinked hoses, lines or hoses that rub against each
other, damage to the oil-cooler, and loose oil-
cooler flange bolts.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and oil- SA-019
cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or
hoses.
Check for Shorts:
• Short circuits can cause fires.
• Clean and tighten all electrical connections.

• Check before starting work for loose, kinked,
hardened or frayed electrical cables and wires.
• Check before starting work for missing or
damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..
Clean up Flammables:
• Spilled fuel and oil, and trash, grease, debris,

accumulated coal dust, and other flammables may
cause fires.
• Prevent fires by inspecting and cleaning the

machine daily and by removing spilled or
accumulated flammables immediately.
Check Key Switch:
• If a fire breaks out, failure to stop the engine will

escalate the fire, hampering fire fighting.
• Always check key switch function before

operating the machine every day:
1) Start the engine and run it at slow idle.
2) Turn the key switch to the OFF position to
confirm that the engine stops.
• If any abnormalities are found, be sure to repair

them before operating the machine.
S508-E02B-0019
SA-22
SAFETY
Check Emergency Engine Stop Switch:
• If a fire breaks out, failure to release pressurized air
inside the hydraulic tank will escalate fire, hampering
fire fighting.
• Check the emergency engine stop switch function
every 250 hours:
1) Start the engine and run it at slow Idle.
2) Turn the emergency engine stop switch to the
EMERG. STOP position.
3) Confirm that both engines stop and that pres-
surized air inside the hydraulic oil tank is re-
leased (a hissing sound should be heard).
• If any abnormalities are found, be sure to repair
them before operating the machine.
Check Heat Shields:

• Damaged or missing heat shields may lead to fires.
• Damaged or missing heat shields must be
repaired or replaced before operating the
machine.
S508-E02B-0019
EVACUATING IN CASE OF FIRE
• If a fire breaks out, evacuate the machine in the

following way:
• Stop the engine by turning the key switch to the

OFF position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.
SA-393
• In an emergency, if the cab door and/or the front
window cannot be opened, break the front or rear
window panes with the emergency evacuation
hammer to escape from the cab.
Refer to the explanation page on “EMERGENCY
EXIT” in Operator’s Manual.
518-E02B-0393
SS-1510
SA-23
SAFETY
BEWARE OF EXHAUST FUMES
• Prevent asphyxiation. Engine exhaust fumes can

cause sickness or death.
• If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.
509-E01A-0016
SA-016
PRECAUTIONS FOR WELDING AND

GRINDING
• Welding may generate gas and/or small fires.

• Be sure to perform welding in a well ventilated and
prepared area. Store flammable objects in a safe
place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
• Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before start-
ing grinding.
• After finishing welding and grinding, recheck that SA-818
there are no abnormalities such as the area sur-

rounding the welded area still smoldering.
523-E01A-0818
AVOID HEATING NEAR PRESSURIZED

FLUID LINES
• Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
• Do not heat by welding, soldering, or using a torch

near pressurized fluid lines or other flammable
materials.
• Pressurized lines can be accidentally cut when
heat goes beyond the immediate flame area.
Install temporary fire-resistant guards to protect
SA-030
hoses or other materials before engaging in
welding, soldering, etc..
AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that

contain flammable fluids.
• Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.
510-E01B-0030
SA-24
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
• Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
• Avoid potentially toxic fumes and dust.

• Do all such work outside or in a well-ventilated
area. Dispose of paint and solvent properly.
• Remove paint before welding or heating:

1) If you sand or grind paint, avoid breathing the SA-029
dust.
Wear an approved respirator.
2) If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers and
other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.
511-E01A-0029
PREVENT BATTERY EXPLOSIONS
• Battery gas can explode.
• Keep sparks, lighted matches, and flame away

from the top of battery.
• Never check battery charge by placing a metal ob-
ject across the posts. Use a voltmeter or hy-
drometer.
• Do not charge a frozen battery; it may explode.
Warm the battery to 16 °C ( 60 °F ) first.
• Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion SA-032
of the battery may result.
• Loose terminals may produce sparks. Securely
tighten all terminals.
• Battery electrolyte is poisonous. If the battery should

explode battery electrolyte may be splashed into
eyes, possibly resulting in blindness.
• Be sure to wear eye protection when checking

electrolyte specific gravity.
512-E01C-0032
SA-25
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
• If spilled onto skin, refrigerant may cause a cold

contact burn.
• Refer to the freon container for proper use when

servicing the air conditioning system.
• Use a recovery and recycling system to avoid
venting freon into the atmosphere.
• Never let the freon stream make contact with the
skin.
SA-405
513-E01A-0405
HANDLE CHEMICAL PRODUCTS SAFELY
• Direct exposure to hazardous chemicals can cause

serious injury. Potentially hazardous chemicals used
with your machine include such items as lubricants,
coolants, paints, and adhesives.
• A Material Safety Data Sheet (MSDS) provides

specific details on chemical products: physical
and health hazards, safety procedures, and
emergency response techniques.
• Check the MSDS before you start any job using a SA-309
hazardous chemical. That way you will know
exactly what the risks are and how to do the job
safely. Then follow procedures and use
recommended equipment.
S515-E01A-0309
SA-26
SAFETY
DISPOSE OF WASTE PROPERLY
• Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids. Do

not use food or beverage containers that may
mislead someone into drinking from them.
• Do not pour waste onto the ground, down a drain,
or into any water source.
• Air conditioning refrigerants escaping into the air SA-226
can damage the Earth’s atmosphere.
Government regulations may require a certified air
conditioning service center to recover and recycle
used air conditioning refrigerants.
• Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center.
S516-E01A-0226
BEFORE RETURNING THE MACHINE TO

THE CUSTOMER
• After maintenance or repair work is complete,

confirm that:
• The machine is functioning properly, especially
the safety systems.
• Worn or damaged parts have been repaired or
replaced
S517-E01A-0435 SA-435
SA-27
SAFETY
(Blank)
SA-28
SECTION AND GROUP SECTION 4 OPERATIONAL PER-
CONTENTS FORMANCE TEST
Group 1 Introduction
Group 2 Engine Test
Group 3 Excavator Test
Group 4 Component Test
Group 5 Standard
TECHNICAL MANUAL
SECTION 5 TROUBLESHOOTING
(Troubleshooting) Group 1 General
Group 2 Component Layout
Group 3 Troubleshooting A
Group 4 Troubleshooting B
Group 5 Troubleshooting C
Group 6 Electrical System Inspection
Group 7 ICX
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Control System Group 5 Travel Device
Group 2 Hydraulic System Group 6 Others (Upperstructure)
Group 3 Electrical System Group 7 Others (Undercarriage)
WORKSHOP MANUAL
All information, illustrations and speci-
SECTION 1 GENERAL INFORMA- SECTION 3 UNDERCARRIAGE
fications in this manual are based on
TION Group 1 Swing Bearing
the latest product information available
Group 1 Precautions for Disassem- Group 2 Travel Device
at the time of publication. The right is
bling and Assembling Group 3 Center Joint
reserved to make changes at any time
Group 2 Tightening Torque Group 4 Track Adjuster
without notice.
Group 3 Painting Group 5 Front Idler
SECTION 2 UPPERSTRUCTURE Group 6 Upper and Lower Roller
Group 1 Cab Group 7 Track
Group 2 Counterweight SECTION 4 FRONT ATTACHMENT
Group 3 Main Frame Group 1 Front Attachment
Group 4 Pump Device Group 2 Cylinder
Group 5 Control Valve SECTION 5 ENGINE
COPYRIGHT(C)2001
Group 6 Swing Device
Hitachi Construction Machinery Co., Ltd.
Group 7 Pilot Valve
Tokyo, Japan
Group 8 Pilot Shut-Off Valve
All rights reserved
Group 9 Shockless Valve
Group 10 Solenoid Valve
SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction Group 4 Component Test
Operational Performance Tests ................T4-1-1 Primary Pilot Pressure ..............................T4-4-1
Preparation for Performance Tests ...........T4-1-2 Secondary Pilot Pressure .........................T4-4-3
Solenoid Valve Set Pressure ....................T4-4-4
Group 2 Engine Test Main Pump Delivery Pressure...................T4-4-6
Engine Speed...........................................T4-2-1 Main Relief Valve Set Pressure.................T4-4-7
Engine Compression Pressure .................T4-2-3 Overload Relief Valve Set Pressure ........T4-4-12
Valve Clearance Adjustment.....................T4-2-4 Main Pump 1 and 2 Flow Rate
Nozzle Check ...........................................T4-2-6 Measurement .........................................T4-4-14
Injection Timing ........................................T4-2-8 Main Pump 3 Flow Rate
Measurement .........................................T4-4-18
Group 3 Excavator Test Swing Motor Drainage ............................T4-4-21
Travel Speed ............................................T4-3-1 Travel Motor Drainage ............................T4-4-23
Track Revolution Speed ...........................T4-3-2
Mistrack Check ........................................T4-3-3 Group 5 Standard
Travel Parking Function Check .................T4-3-4 Operational Performance Standard
Swing Speed ............................................T4-3-5 Table ......................................................T4-5-1
Swing Function Drift Check ......................T4-3-6 Main Pump 1 and 2 P-Q Diagram .............T4-5-4
Swing Motor Leakage ...............................T4-3-7 Main Pump 3 P-Q Diagram .......................T4-5-5
Swing Bearing Play ..................................T4-3-8 Injection Pump .........................................T4-5-6
Maximum Swingable Slant Angle..............T4-3-9 Dr.EX Monitor Indicating Values................T4-5-7
Hydraulic Cylinder Cycle Time ................T4-3-10
Dig Function Drift Check ........................T4-3-12
Control Lever Operating Force ...............T4-3-13
Control Lever Stroke ..............................T4-3-14
Combined Boom Raise/Swing
Function Check ....................................T4-3-15
1CDT-4-1
(Blank)
1CDT-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedure to quanti-

tatively check all system and functions on the machine.
Purpose of Performance Tests

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

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

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

1. Operation speed values and dimensions of the
new machine.
2. Operational performance of new components ad-
justed to specifications. Allowable errors will be
indicated as necessary.
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, be-
fore starting to test.
TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run
straight more than 20 m (65 ft 7 in), and to make a
full swing with the front attachment extended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among cowork-
ers. Once the test is started, be sure to communi- T105-06-01-003
cate with each other using these signals, and to
follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid accidents
due to landslides or contact with high-voltage
power lines. Always confirm that there is sufficient
space for full swings.
4. Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil. Pay
special attention to this when removing hydraulic
pipings.
MAKE PRECISE MEASUREMENT

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. T105-06-01-004
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 / Engine Test
ENGINE SPEED 1
1. Use an engine speed meter.
2. Measure the engine speeds in each mode.
2
NOTE: Measure the engine speed before
performing all other tests to check that the
engine speed meets specification. Because,
if the engine speed is not adjusted correctly,
all other performance data will be
unreliable.
Preparation:
1. Install speed pickup (1) to injection pipe (2). Engine Speed Meter T1CC-04-02-001
2. Warm up the machine until the engine coolant

temperature reaches 50 °C (122 °F) or more, and 3
hydraulic oil is 50±5 °C (122±9 °F).
IMPORTANT: Never attempt to the readjust

stopper (3).
T1CC-04-02-002
T4-2-1
Measurement: Evaluation:
1. Check engine speeds for, auto-idle, slow idle, fast Refer to T4-5 Operational Performance Standard.
idle (when normal), fast idle (when the ECO is de-
activated), fast idle (in the E mode), and fast idle Remedy:
(in relief operation). Refer to T5-4 Troubleshooting B.
2. Select the switch positions and the test conditions
corresponding to the engine speed to be meas-
ured as shown in the table below. NOTE: ECO stands for the auto engine speed re-
-1
duction system by 100 min . The system
functions when all levers are returned to
neutral position.
Engine Power
Control Mode Auto-Idle Switch Test Conditions
Dial Switch
Slow Idle Min. Speed P OFF
Fast Idle
Max. Speed P OFF
(Normal)
Fast Idle Check in the Dr. EX special
(With ECO deac- Max. Speed P OFF functions with ECO deacti-
tivated) vated.
Fast Idle Check the engine speed while
Max. Speed P OFF
(Relief operation) relieving the boom raise circuit.
Fast Idle
Max. Speed E Mode OFF
(E mode)
Check engine speed 4 seconds
Auto-Idle Max. Speed P Auto-Idle after returning all control levers
to neutral.
Switch Panel
Engine Control Dial
Auto-Idle Switch
××××
Power Mode Switch
M1CC-01-002
T4-2-2
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in the cylinders to
check for a decline in engine power.
2. Check exhaust gas color. Keep track of engine oil

consumption.
3. Check for abnormalities in the intake system,

including the air filter.
Preparation:
1. Confirm that valve clearances are correct.
2. Confirm that the batteries are charged properly.
3. Run the engine until the coolant temperature

gauge reaches the operating range.
4. Stop the engine. Remove glow plugs from each

cylinder. T105-06-02-001
NOTE: Unless the fuel delivery pipes are discon-

nected, fuel will ignite in the cylinders so
that pressure in the cylinders will increase.
5. Install an adaptor (Isuzu 5-85317-001-0) and

compression gauge in place of the glow plug in
one cylinder. (Be sure to sufficiently tighten the
adaptor and compression gauge to prevent air
leakage.)
Measurement:
1. Turn the starter to crank the engine. Record the
compression pressure of each cylinder.
2. Repeat measurement three times for each

cylinder and calculate the mean values.
Evaluation:
Refer to Group-5 in this section.
RemedyȚ Ț
Refer to engine shop manual.
T4-2-3
VALVE CLEARANCE ADJUSTMENT
Summary:
1. Perform the measurement when the engine is
cold.
2. Before starting work, clean the head cover

mounting area to avoid contamination in the
engine.
PreparationȚ Timing Gear Case Pointer

1. Locate the top dead center (TDC) in the
compression stroke.
Align the TDC mark on the crank pulley with the
pointer located on the timing gear case as
illustrated. Piston No.1(or piston No.4) is now
positioned at the TDC in its compression stroke.
NOTE: When rotating the crank pulley, remove the

fan guard. Then, rotate the fan while hold-
ing the fan belt. If it is difficult to rotate, re-
move all glow plugs to release the com- T197-04-02-001
pression pressure. Crank Pulley TDC Mark
2. Remove the head cover.
3. Move push rods for the intake and exhaust valves

on the No.1 cylinder up and down by hand. If any
clearances on the both ends of the push rods are
found, piston No.1 is positioned at TDC in the
compression stroke. (If the exhaust valve of
cylinder No.1 is pushed down, piston No.4 is
positioned at TDC in the compression stroke.
Start measurement from the cylinder (No.1 or
Screw Driver
No.4) positioned at TDC in the compression
stroke.
Adjust Screw
Measurement: Thickness Gauge
1. Insert a thickness gauge into the clearance
between the rocker arm and the valve stem end to Lock Nut
measure the valve clearance.
NOTE: The cylinders are aligned from No.1 to No.4

in that order, as viewed from the fan side . Rocker Arm
Valve Stem T107-02-12-005
T4-2-4
2. When the measurement is started from No.1
cylinder, perform the same measurement to all
valves indicated with the mark “ӝ” in the table
below. (When the measurement is started from
No.4 cylinder, perform the measurement in the
valves shown with mark “ѱ”.)
Cylinder No. No.1 No.2 No.3 No.4

Valve locations I E I E I E I E
When the measurement is
{ { { {
started from No.1 cylinder
When the measurement is
× × × ×
started from No.4 cylinder
3. Rotate the crankshaft 360° clockwise. Align the

TDC mark with the pointer. Then, continue
measurement of other valves in the same way.
Evaluation:
Refer to Group-5 in this section.
Adjustment:
If the measurement results are out of specification,
adjust the valve clearance in the same order of
measurement.
1. Loosen the adjusting screw lock nuts for the

rocker arms. Insert the thickness gauge set at 0.4
mm, adjust the adjusting screws.
2. After adjusting, retighten the lock nuts to the

specification.
Recheck the valve clearance after the lock nuts
are tightened.
: 15.5±5.0 N⋅m
(1.5±0.5 kgf⋅m, 10.8±3.6 lbf⋅ft)
T4-2-5
NOZZLE CHECK
Summary:
1. Check the injection pressure and the spray
pattern with a nozzle tester.
2. Before starting work, clean the nozzle holder

mounting area to avoid contamination in the
engine.
PreparationȚ
1. Remove the nozzle holders.
Remove all nozzle holders and fuel injection
pipings from the engine.
2. Attach a nozzle holder to the nozzle tester.
Measurement:
CAUTION: Never touch spray directly. The
fuel spray from the nozzle may penetrate the
skin, resulting in serious injury. If fuel
penetrates into the blood stream, it may
cause blood toxication.
IMPORTANT: Use clean diesel oil.

T107-06-02-006
1. Injection pressure
After attaching the nozzle holder to the nozzle
tester, strongly make several strokes of the tester
to inject fuel. Then, while operating the tester at
approx. 60 time strokes a minute, measure the
fuel injection pressure.
If adjustment is required, loosen the lock nuts and
adjust the adjusting screws. Turn clockwise to
increase the pressure, and counterclockwise to
decrease the pressure.
2. Spray pattern
For this test, turn the pressure tester knob to
bypass the pressure gauge. Attach the nozzle
holder to the nozzle tester. Strongly make several
strokes of the tester and check the fuel spray
pattern.
3. Oil tight condition

Keep the pressure slightly below the injection
pressure. Check for fuel leak from around the
nozzle tip.
T4-2-6
Evaluation:
1. Standard Injection Pressure:
Normal
Refer to T4-5 in this section.
2. Spray Pattern
• Large-size spray should not be visible to the
naked eye.
• No stray sideways sprays should be seen.
• During initial injection stage, spray size should be

fine and injected intermittently.
• There should be no drips found.

T102-02-11-005
• Injection spray angle must be normal.
Abnormal
3. Oil Tight Condition
• No fuel leaks.
T102-02-11-006
Adjustment:
• To adjust the injection pressure, loosen the lock
nuts. Adjust the adjusting screw.
Turn clockwise to increase the pressure, and
counterclockwise to decrease the pressure.
• After adjusting, retighten the lock nuts.
T107-06-02-007
T4-2-7
INJECTION TIMING
Inspection: 30ѯ Pointer
1. Position No.1 piston to the top dead center. Turn TDC Mark
the crank pulley in the direction of rotation
(clockwise as seen from the front of the engine) to
set a ”TDC” mark on the crank pulley under the
΁pointer", located on the timing gear case.
NOTE: When rotating the crank pulley, remove the

fan guard. Then, rotate the fan while
holding the fan belt. If it is difficult to rotate,
remove all glow plugs to release the Timing Mark (13°)
compression pressure. T197-04-02-003
Crank Pulley
2. Turn the crank pulley at approx. 30 degrees

counterclockwise. Delivery
Valve Holder
Spring
3. Remove the injection piping from No.1 cylinder.
Delivery Valve
4. Remove the delivery valve holder for No.1 cylinder
from the injection pump to pull the delivery valve
and the spring out. Reinstall the delivery valve
holder.
: 39 to 43 N⋅m
(4.0 to 4.4 kgf⋅m, 28.9 to 31.8 lbf⋅ft) T105-02-12-006
5. While supplying fuel with the feed pump, turn the Injection Pump
crank pulley slowly clockwise just until fuel cannot
be seen from the top of the delivery valve hole.
This is the position where the injection starts.
Adjustment:
1. Turn the crank pulley so that the pointer comes
just above the correct timing position (13 degrees
before the TDC) on the crank pulley.
Nut
2. Loosen the mounting nuts of the injection pump.
Alignment
Mark
3. When advancing timing, tilt the injection pump T197-04-02-002
outward against the cylinder block.
When delaying timing, tilt the injection pump
inward against the cylinder block.
NOTE: The angle changes 2 degrees when the

alignment mark separates for 1 mm.
T4-2-8
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary:
Measure the time required for the excavator to travel
a 20 m (65.6 ft) test track.
Preparation:
1. Adjust the track sag on both side tracks equally.
2. Prepare a flat and solid test track 20 m (65.6 ft) in
length with extra length of 3 to 5 m (9.8 to 16 ft) on
Arm Roll-In, Bucket Roll-In
both ends for machine acceleration and decelera- End
tion. Bucket Height: 0.3 to 0.5 m
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above
the ground with the arm and bucket rolled in. Start
20 m Deceleration
4. Maintain hydraulic oil temperature at 50±5 °C Zone
(122±9 °F). 3 to 5 m
Acceleration
Measurement: Zone
3 to 5 m
1. Measure both the slow and fast speeds of the
machine. T105-06-03-001
2. Select the following switch positions:
Travel Mode Engine Power Mode Auto-Idle
Switch Control Dial Switch Switch
Slow Mode Fast Idle P Mode OFF
Fast Mode Fast Idle P Mode OFF
3. Start traveling the machine in the acceleration

zone with the travel levers to full stroke.
4. Measure the time required to travel 20 m (65.6 ft).
5. After measuring the forward travel speed, turn the
upperstructure 180° and measure the reverse
travel speed.
6. Repeat steps 4. to 5. three times in each direction
and calculate the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-5.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-3-1
TRACK REVOLUTION SPEED
Summary:
Measure the track revolution cycle time with the track
raised off ground.
Preparation:
1. Adjust the track sag of both side tracks to be
equal.
2. On the track to be measured, mark one shoe with
chalk. 90 to 110°
3. Swing the upperstructure 90° and lower the
bucket to raise the track off ground. Keep the
boom-arm angle between 90 to 110° as shown.
Place blocks under the machine frame.
M104-07-067
Mark
CAUTION: Securely support the raised track
using wooden blocks.
4. Maintain the hydraulic oil temperature at 50±5 °C

(122±9 °F).
Measurement:
Engine Power Mode
Auto-Idle Switch
Control Dial Switch
Fast Idle P Mode OFF
2. Operate the travel control lever of the raised track

to full stroke.
3. Measure the time required for 3 revolutions in
both directions after a constant track revolution
speed is obtained.
4. Raise the other side and repeat the above
procedures.
5. Repeat steps 2. to 4. three times and calculate the
average values.
Evaluation:
T4-5.
NOTE: The measurement data obtained through

the raised track revolution test may have
wide variations. Therefore, the evaluation
based on the results obtained from the 20
m travel speed check described before is
more recommendable.
Remedy:
T4-3-2
MISTRACK CHECK
Summary:
1. Allow the machine to travel 20 m (65.6 ft).
Measure the maximum tread deviation from the
tread chord line drawn between the travel start Maximum Distance
and end points to check the performance
equilibrium between both sides of the travel
device systems (from the main pump to the travel Acceleration
motor). Zone:
2. If measured on a concrete surface, the tread 3 to 5 m
20 m
deviation has a trend to decrease.
Preparation:
1. Adjust the track sag of both tracks to be equal.
2. Provide a flat, solid test yard 20 m (65.6 ft) in
length, with extra length of 3 to 5 m (9.8 to 16 ft) T105-06-03-022
on both ends for machine acceleration and

deceleration.
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above
the ground with the arm and bucket rolled in.
(122±9 °F).
Measurement:
1. Measure the amount of mistracking in both fast,
and slow travel speeds.
Engine Power Mode
Auto-Idle Switch
Control Dial Switch
3. Start traveling the machine in the acceleration

zone with the travel levers at full stroke.
4. Measure the maximum distance between a
straight 20 m (65.6 ft) tread chord line and the
tread made by the machine.
5. After measuring the tracking in forward travel, turn
the upperstructure 180° and measure in reverse
travel.
average values.
Evaluation:
T4-5.
Remedy:
T4-3-3
TRAVEL PARKING FUNCTION CHECK
Summary:
To measure the parking brake function on a specified
slope.
Preparation:
1. The surface of the test slope shall be even with a
gradient of 20 % (11.31°).
0.2 to 0.3 m
2. Hold the bucket 0.2 to 0.3 m (8 to 12 in) above the
ground with the arm and bucket fully rolled in.
(122±9 °F).
Measurement: T105-06-03-004
1. Measure the travel parking brake slip amount
while parked.
1-1. Climb the slope and place the travel levers in
neutral.
1-2. Stop the engine.
1-3. After the machine stops, put alignment marks
on a track link or shoe, and the track side
frame.
1-4. After 5 minutes, measure the distance between
the marks on the track link or shoe and the
track side frame.
Evaluation:
T4-5.
Displacement measured
after 5 minutes.
T105-06-03-006
T4-3-4
SWING SPEED
Summary:
Measure the time required to swing three complete
turns.
Preparation:
1. Check the lubrication of the swing gear and swing
bearing.
2. Place the machine on flat, solid ground with ample
space for swinging. Do not conduct this test on
slopes.
3. With the arm rolled out and bucket rolled in, hold The same height as the
the bucket so that the height of the bucket pin is boom foot pin height
the same as the boom foot pin. The bucket must
be empty. T105-06-03-013
NOTE: In case a sufficient space for the measure-

ment is difficult to find, carry out the meas-
urement with the boom fully raised and the
arm fully rolled-in.

(122±9 °F).
CAUTION: Prevent personal injury. Always

make sure that the area is clear and that co-
workers are out of the swing area before
starting the measurement.
Measurement:
Engine Control Power Mode Auto-Idle T178-04-03-001
Dial Switch Switch
2. Operate swing control lever fully.

3. Measure the time required to swing 3 turns in one
direction.
4. Operate swing control lever fully in the opposite
direction and measure the time required for 3
turns.
average values.
Evaluation:
T4-5.
Remedy:
T4-3-5
SWING FUNCTION DRIFT CHECK
Summary:
Measure the swing drift on the bearing outer
circumference when stopping after a 180° full-speed
swing.
Preparation:
bearing.
2. Place the machine on flat, solid ground with ample
space for swinging. Do not conduct this test on a Two Check Marks
slope.
T105-06-03-008
3. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
the same as the boom foot pin. The bucket must
be empty.
4. Make two chalk marks: one on the swing bearing
and one directly below it on the track frame.
5. Swing the upperstructure 180°.
(122±9 °F).

make sure that the area is clear and that co- T105-06-03-009

Measure Difference Between Marks
Measurement:
Engine Control Power Mode Auto-Idle
Dial Switch Switch
Marking on the Track Frame
2. Operate the swing control lever fully and return it
to the neutral position when the mark on the Marking on the Swing Bearing
upperstructure aligns with that on the track frame
after swinging 180° . T105-06-03-010
3. Measure the distance between the two marks.
4. Align the marks again, swing 180°, then test in the
opposite direction.
5. Repeat steps 3. to 5. three times each and
calculate the average values.
Evaluation:
T4-5.
Remedy:
T4-3-6
SWING MOTOR LEAKAGE
Summary:
Check for upperstructure drift while suspending a
load on a slope.
Preparation:
bearing.
2. Park the machine on a smooth slope with a
gradient of 26.8 % (15°).
3. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
W=375 kg (825 lb)
4. With the arm rolled out, and bucket rolled in, T105-06-03-011
position the arm top pin height to be level with the
boom foot pin.
5. Swing the upperstructure to position it 90° to the
slope. Make aligning marks on the swing bearing
periphery and track frame using tape, as
illustrated.
(122±9 °F).
Measurement:
1. Select the following switch position:
Power Mode Measure Difference Between Marks
Auto-Idle Switch
Switch
P Mode OFF
2. Maintain the engine at slow idle. After five minutes,

measure the difference between the marks along
the swing bearing periphery and the track frame. Marking on the Track Frame
3. Perform the measurement in both right and left Marking on the Swing Bearing
swing directions.
4. Perform the measurement three times in each
T105-06-03-010
direction and calculate the average values.
Evaluation:
T4-5.
Remedy:
T4-3-7
SWING BEARING PLAY
Summary:
Measure the swing bearing play using a dial gauge to
check the wear of bearing races and balls.
Preparation:
1. Check swing bearing mounting bolts for loose-
ness.
2. Check the lubrication of the swing bearing. Con-
firm that bearing rotation is smooth and without
noise.
3. Install a dial gauge on the track frame as shown, Magnetic Dial
using a magnetic base. Base Gauge
T105-06-03-014
4. Position the upperstructure so that the boom
aligns with the tracks facing towards the front
idlers.
5. Position the dial gauge so that its needle point
comes into contact with the bottom face of the
bearing outer race.
6. Bucket should be empty.
NOTE: The measured value will vary depending on Round Trunk

where the magnet base is secured. Se-
cure the magnet base onto the round trunk
or in a position as close to the round trunk
as possible.
T105-06-03-015
Measurement:
1. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
the same as the boom foot pin. Record the dial
gauge reading (h1).
2. 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).
3. Calculate bearing play (H) from this data (h1 and
h2) as follows:
H=h2-h1
Measurement: (h1) Measurement: (h2)
The same height

as the boom foot
pin height
T105-06-03-017
T105-06-03-007
Evaluation:
T4-5.
T4-3-8
MAXIMUM SWINGABLE SLANT ANGLE
Summary:
With the upperstructure swung 90° to the slope,
check the maximum slant angle on which the upper-
structure can swing to the uphill side.
Preparation:
1. Check that the swing gear and bearing are well
lubricated.
2. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
W=375 kg (825 lb)
3. With the arm cylinder fully retracted and the
bucket cylinder fully extended, hold the arm top
pin to the position flush with the boom foot pin T105-06-03-011
height.
4. Climb a slope and swing the upperstructure 90° to
the slope.
(122±9 °F).
Measurement:
Dial Switch Switch
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. Increase the slope angle and repeat steps 2. and
3. Check both clockwise and counterclockwise.
5. Perform the measurement three times.
Evaluation:
T4-5.
Remedy:
T4-3-9
HYDRAULIC CYLINDER CYCLE TIME
Summary: Boom Cylinder
1. To totally check the front function performance by
measuring each cylinder cycle time.
2. Bucket should be empty.
Preparation:
1. Take the following machine position:
1-1. When measuring the boom cylinder: T191-04-03-010
With the arm cylinder fully retracted and the Arm Cylinder
bucket cylinder fully extended, lower the bucket
to the ground.
1-2. When measuring the arm cylinder:

With the bucket cylinder fully extended, adjust
the boom and arm cylinder strokes so that
when the arm is moved half the full stroke, the
arm longitudinal center line perpendicularly
points to the ground and the bucket bottom
clearance above the ground is approx. 0.5 m T191-04-03-011
(20 in).
Bucket Cylinder
1-3. When measuring the bucket cylinder:
Adjust the boom and arm cylinder strokes so
that when the bucket is moved half the full
stroke, the bucket edge points to the ground
perpendicularly.
1-4. When measuring the offset cylinder (optional):

Set the offset cylinder in either the right or left
offset stroke end position.
T105-06-03-020
1-5. When measuring the blade cylinder (optional): Offset Cylinder

Lower the bucket to the ground to raise the
machine front off the ground and secure the
space to allow the blade to move up-and-down
full stroke.
2. Maintain hydraulic oil temperature at 50±5 °C

(122±9 °F).
M190-05-034
Blade Cylinder
T191-04-03-009
T4-3-10
Measurement:
Engine Power Mode Auto-Idle
Control Dial Switch Switch
All Cylinders Fast Idle P Mode OFF
2. Operate each cylinder as follows:

(The cylinder stroke includes the cushion range.)
2-1. Measuring the boom cylinder.

Measure the time required to raise or lower the
boom while operating the boom control lever
full stroke.
2-2. Measuring the arm cylinder.

Measure the time required to roll in or out the
arm while operating the arm control lever full
stroke.
2-3. Measuring the bucket cylinder.

Measure the time required to roll in or out the
bucket while operating the bucket control lever
full stroke.
2-4. Measuring the offset cylinder (optional)

Measure the time required to offset the front at-
tachment from right to left or vice versa while
operating the offset control pedal full stroke.
2-5. Measuring the blade cylinder (optional)

Measure the time required to raise or lower the
blade while operating the blade control lever
full stroke.
3. Repeat each measurement three times and calcu-

late the average values.
Evalution:
Refer to Performance Standard Table in Group T4-5.
Remedy:
Refer to Troubleshooting B in Group T5-4.
T4-3-11
DIG FUNCTION DRIFT CHECK
Summary:
Measure dig function drift, which can be caused by oil
leakage in the control valve and boom, arm, and
bucket cylinders, with the loaded bucket.
NOTE: When testing the dig function drift just after

cylinder replacement, slowly operate each
cylinder to its stroke end to purge air.
Extended
Preparation: Retracted
Distance
Distance
1. Load bucket fully. In lieu of loading the bucket, Retracted
weight (W) of the following specification can be Distance
used.
W=375 kg (825 lb) Same Height
2. Position the arm cylinder with the rod 50 mm (2 in)
extended from the fully retracted position.
3. Position the bucket cylinder with the rod 50 mm (2 Bucket Bottom
in) retracted from the fully extended position.
4. With the arm rolled out and the bucket rolled in,
hold the bucket so that the height of the bucket T105-06-03-021
pin is the same as the boom foot pin. Arm Cylinder Extension
(122±9 °F).
Measurement:
1. Stop the engine.
Mark
2. Five minutes after the engine has been stopped,
measure the change in the position of the bottom
of the bucket, as well as the boom, arm and
bucket cylinders.
3. Repeat step 2. three times and calculate the
average values.
Evalution: T110-06-03-001
Refer to the Performance Standard Table in Group Boom and Bucket Cylinder Retraction
T4-5.
Mark Mark
Remedy:
T110-06-03-002
T4-3-12
CONTROL LEVER OPERATING FORCE
Summary:
1. Use a spring scale to measure the maximum
resistance of each control lever as illustrated.
2. Measure the maximum operating force of the front
attachment control lever.
3. Measure the operating force at the grip center of
each control lever.
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
T107-06-03-003
1. Start the engine.
Dial Switch Switch

3. Operete each boom, arm bucket and swing

lever to relieve the circuit, and measure the
maximum operating force for each.
4. When lowreing boom, it becomes the jacked-up T107-06-03-004
position. Be careful that the machine does not roll
over.
5. When measuring swing lever, secure the
upperstmcture so it is immovable.
6. Lower the bucket to the ground to raise one track
off the ground. Operate the travel lever to full
stroke and measure the maximum operating force
required. When finished, lower the track and then
jack-up the other track.
average values.
Evalution:
T4-5.
T4-3-13
CONTROL LEVER STROKE
Summary:
1. Measure each lever stroke at the lever top using a
ruler.
2. Measure the lever stroke at the grip center of
each control lever.
3. In case lever stroke play is present in the neutral
position, add half (1/2) the play present to both
side lever strokes.
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement: T107-06-03-005
1. Stop the engine.

2. Measure each lever stroke at the lever top from
neutral to the stroke end using a ruler.
3. Repeat step 2. Three times and calculate the
average values.
Evalution:
T4-5.
T4-3-14
COMBINED BOOM RAISE/SWING
FUNCTION CHECK
Summary:
1. Check boom raise and swing movement and
speeds while operating both functions
simultaneously.
2. Start the engine and run it at fast idle. Operate the
boom raise function and check to be sure that the
cylinder movement is smooth, with out sticking.
T107-06-03-009
Preparation:
1. With the arm fully rolled out and bucket fully rolled
in, lower the bucket to the ground. The bucket
must be empty.
(122±9 °F).

Measurement:
1. Select the following switch positions: T107-06-03-010

Dial Switch Switch
2. Raise the boom and swing simultaneously, both at

full stroke.
3. When the upperstructure rotates 90°, release the
control levers to stop both functions. Measure the
time required to swing 90ѯand the height(H) of H
the bucket teeth.
average values.
Evalution: T107-06-03-011

T4-5.
Remedy:
T4-3-15
(Blank)
T4-3-16
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Stop the engine.
2. Press the air release valve on the filler cap to
release any remaining pressure.
3. Disconnect the plug in the pilot filter.
Connect adapter (ST 6069) and pressure gauge
(ST 6942)to the test port.
4. Start the engine. Check the pressure gauge
connection for oil leaks.
Plug
(122±9 °F).
Measurement:
1. Select the following switch positions: T178-03-07-001
Engine Power Work Auto-Idle /

Control Mode Mode Acceleration
Dial Switch Switch Selector
Fast Idle P Mode Digging OFF
Slow Idle P Mode Digging OFF
2. Measure the pilot pressure at both fast and slow

idle engine speed.
3. Repeat the measurement three times and
Evaluation:
Refer to Performane Standard Table in Group T4-5.
T4-4-1
Primary Pilot Pressure Adjustment Procedure
Adjust the set pressure of the pilot relief valve as

necessary.
1. Remove plug (1) from the relief valve.

: 41 mm
: 12 mm
2. Remove spring (2), shim (3) and plunger (4) out

of the relief valve.
Install the estimated necessary number of shims
(3) onto plunger (4). Relief Valve
4. Install plunger (4), shim (3) and spring (2) into the
relief valve.
Tighten plug (1).
: 68±6.8 N⋅m (7±0.7 kgf⋅m 50±5 Ibf·ft) T178-03-07-001
2 3
5. Check the set pressure after adjustment. 1 4
NOTE: Standard Change in Pressure (Reference)

Shim Thick-
Pressure Change
ness (mm)
kPa (kgf/cm2) (Psi)
T178-04-04-002
0.2 61.8 (0.63) (9.0)
0.4 124.6 (1.27) (18.0)
0.8 249.2 (2.54) (36.1)
T4-4-2
SECONDARY PILOT PRESSURE
Preparation:
1. Stop the engine. Pilot Port
3. Install tee (ST 6451) and pressure gauge (ST
6942) to the control valve spool pilot port located
in the pilot circuit to be measured.
: 17 mm, 19 mm
4. Start the engine and check the pressure gauge
connection for oil leaks.
(122±9 °F).
Measurement:
CAUTION: Before measuring, check that
there are no obstacles or personnel within
the swing radius. When measuring the boom Pilot Port
lower pilot pressure, raise the machine off T1CD-03-03-017
the ground while paying attention not to al-

low the base machine (counterweight) to
contact with the ground. Be careful not to
tip-over due to a loss of balance.

Tee
Dial Switch Switch
Pressure
Fast Idle P Mode OFF Gauge
Slow Idle P Mode OFF
2. Measure the pilot pressure with the

corresponding control lever operated full stroke.

T157-05-04-011
Evaluation:
Remedy:
Refer to Troubleshooting B in Groupe T5-4.
T4-4-3
SOLENOID VALVE SET PRESSURE
Measure solenoid valve set pressure with both the

built-in diagnostic system (or Dr.EX) and the pressure
gauge.
Delivery Port
Preparation: Travel Mode Control
1. Stop the engine. Solenoid Valve
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Disconnect delivery Port from the solenoid valve
to be measured. Install hose (Parts Number: Pilot Port
4216453), tee (ST 6451), adapter (ST 6461), and
pressure gauge (ST 6942) to the disconnected
end at the solenoid valve side, as illustrated.
: 17 mm, 19 mm, 22 mm
Connect built-in diagnostic system (or Dr.EX) to

the machine for solenoid valve set pressure
Drain Port
monitoring.
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50±5 °C T1CD-03-06-001
(122±9 °F).
Measurement: Solenoid Valve

Unit
Engine Power Mode Auto-Idle Pressure Gauge
Control Dial Switch Switch
1
Slow Idle P Mode OFF
2. Operate as instructed below for each measuring

solenoid valve:
Travel Mode Control Solenoid Valve: Select the
travel mode switch to fast mode position. Test Hose Tee Adapter T157-05-04-002
(4216453)
3. Read the values on both built-in diagnostic
system (or Dr.EX) and the pressure gauge.
Evaluation:
Refer to the performance Standard Table in Group
T4-5.
T4-4-4
Solenoid Valve Set Pressure Adjustment
Procedure Lock Nut
IMPORTANT: Do not loosen the adjusting screw Adjusting

Screw
excessively.
The O-ring on the threads may come
off the sealing surface, causing oil
leakage. Be sure not to loosen over
two turns. T107-06-04-020
The distance between the

lock nut end and screw end
1. Loosen the lock nut. Turn the adjusting screw to should be 2.0 mm (0.78 in)
adjust the set pressure of the solenoid valve. or less.
2. Retighten the lock nut.
: 10 mm
: 5 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)
: 3 mm
Adjusting
Screw
Screw Turns 1/4 1/2 3/4 1 Lock Nut
kPa 78 156 234 312 T107-06-05-001
Change in 2
(kgf/cm ) (0.8) (1.6) (2.4) (3.2)
Pressure
(psi) (11) (23) (34) (46)
3. Check the set pressure of the solenoid valve. Adjusting

Screw
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-4-5
MAIN PUMP DELIVERY PRESSURE
Preparation:
Main Pump 1 and 2
1. Stop the engine. Pressure Measured Port
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Remove the plug from the main pump delivery
port. Install adapter (ST 6069), hose (ST 6943)
and pressure gauge (ST 6941) on the port.
: 6 mm
: 19 mm
4. Start the engine. Confirm that no oil leakage is

observed at the pressure gauge connection.
(122±9 °F).
Measurement: T1CD-04-04-002
Engine Power Mode Auto-Idle Main Pump 3
Control Dial Switch Switch Pressure Measured Port
2. Measure the pressure with the control levers in

neutral.
Evaluation:
T4-5.
Remedy:
T1CD-04-04-001
Refer to the Troubleshooting B in Groupe T5-4.
T4-4-6
MAIN RELIEF VALVE SET PRESSURE
Summary:
To check the main relief valve set pressure at the
Main Pump 1 and 2
main pump delivery port. Pressure Measured Port
Preparation:
1. Stop the engine.
3. Remove the plug from the pressure check port at
the main pump delivery port. Then, install adapter
(ST 6069), hose (ST 6943) and pressure gauge
(ST 6941) to the port.
: 6 mm
: 19 mm, 27 mm, 36 mm
4. Start the engine and check the pressure gauge

connection for oil leak. T1CD-04-04-002
(122±9 °F). Main Pump 3
Pressure Measured Port
Measurement:
Dial Switch Switch
2. Relieve each cylinder circuit by gradually

operating the bucket, arm, and boom control
lever to extend or retract each cylinder full stroke.
3. When checking the swing circuit, secure the
upperstructure so it is immovable. Then, slowly
operate the swing lever to relieve the swing
T1CD-04-04-001
function.
When checking the travel circuit, secure the
tracks against an immovable object. Then, slowly
operate the travel levers to relieve the travel
function.
In case of offset, grab the ground using the
bucket to relieve.
When lowering the blade, it becomes the jacked-
up position. Be careful that the machine does not
roll over.
4. Measure the relief oil pressure with the pressure
gauge.
caluculate the average values.
Evaluation:
T4-4-7
NOTE: If the measured pressures for all functions Main Relief Valve
(For Main Pump 3)
are lower, a decrease in the main relief
valve set pressure may be the probable
cause.
If the relief pressure of a particular function
is lower, the probable cause may be other
than the main relief valve.
Adjusting Main Relief Valve (For Main Pump 1

and 2) Set Pressure:
• Control Valve
Ȁ Loosen lock nut (1) (low pressure) or lock nut (4)
(high pressure) to adjust the pressure with plug (3)
(low pressure) or plug (5) (high pressure).
Adjusting High Pressure Main Relief Set Pressure: Main Relief Valve
1. Loosen lock nut (1). Lightly tighten plug (3) until it (For Main Pump 1 and 2)
T1CD-03-03-017
comes in contact with piston (2). Tighten lock nut
(1). 3
: 27 mm
: Plug (3): 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
1
Lock Nut (1): 59 to 69 N⋅m
(6 to 7 kgf⋅m, 43 to 50 Ibf·ft)
5
2. Loosen lock nut (4). While holding the condition
set in step 1. , turn plug (5) until the desired pres-
sure is obtained. 4
: 27 mm, 32 mm
: Lock Nut (4): 78 to 88 N⋅m
(8 to 9 kgf⋅m, 58 to 65 lbf⋅ft)
2
Adjusting Low Pressure Main Relief Set Pressure:

3. Loosen lock nut (1). Turn plug (3) counter-
clockwise until the specified pressure is obtained.
Tighten lock nut (1).
: 27 mm
: Lock Nut (1): 59 to 69 N⋅m T157-05-04-009
(6 to 7 kgf⋅m, 43 to 50 lbf⋅ft)
4. Recheck the set pressure.
Plug 5 3
Plug Turns 1/4 1/2 3/4 1
MPa 7.1 14.2 21.3 28.4
Plug (5) 2
(kgf/cm ) (72.5) (145) (217.5) (290) Pressure
(High Pressure) Pressure Decrease
(psi) (1031) (2062) (3093) (4124) Increase
MPa 5.3 10.7 16.0 21.3
Plug (3) 2
(kgf/cm ) (54) (109) (163) (217)
(Low Pressure)
(psi) (768) (1550) (2318) (3086) W107-02-05-127
T4-4-8
Adjusting Main Relief Valve (For Main Pump 3) Main Relief Valve
Set Pressure: (For Main Pump 3)
1. Loosen the lock nut.

2. Turn the adjusting screw until the desired pres-
sure is obtained.
3. Tighten the lock nut.
: 17 mm
: 27 to 31 N⋅m (2.8 to 3.2 kgf⋅m, 20 to 23
Ibf·ft)

Screw Turns 1/4 1/2 3/4 1
MPa 4.5 8.9 13.2 17.7
Change in 2
(kgf/cm ) (45) (91) (135) (180) Main Relief Valve
Pressure
(Psi) (640) (1294) (2346) (2560) (For Main Pump 1 and 2) T1CD-03-03-017
Adjusting Screw
Lock Nut Adjusting Screw
Pressure Pressure
Increase Decrease
Lock Nut
T505-06-04-007
T132-02-05-001
T4-4-9
Adjusting Swing Relief Valve Set Pressure:
If necessary, be sure to adjust the set pressure of the
relief valve.
1. Remove plug (2) from the relief valve.

: 14 mm
2. Pull out piston (3), sleeve (1), spring seat (4) and
shim (5) from the relief valve.
3. Replace the estimated necessary number of
shims (5).
4. Install spring seat (4), sleeve (1) and piston (3)
into the relief valve.
Tighten plug (2).
: 78 N⋅m (8 kgf⋅m, 58 Ibf·ft)
Swing Relief
Valve

T1CD-01-02-005
Shim Thickness
Pressure Change 1 2
(mm)
2
kPa (kgf/cm ) (Psi)
0.1 490 (5) (71)
T1CD-03-02-007
6 5 4 3
T4-4-10
Adjusting Travel Relief Valve Set Pressure:
1. Remove the travel relief valve assembly.

: 10 mm
2. Remove cartridge (2) and plug (5).
Remove spring (4) and spring guide (3).
3. Provide shims (5) between poppet (1) and spring
guide (3) to adjust the pressure setting. Travel Relief
Valve
4. Install the relief valve assembly.
: 120 N⋅m (12.2 kgf⋅m, 88 Ibt·ft)
T155-01-01-006
NOTE: Standard Change in Pressure (Reference) 1 3 4 5

2
Shim Change in Relief Pressure
Thickness Part No. 2
kPa (kgf/cm ) (psi)
(mm)
0.3 A590102 785 to 980 (8 to 10) (114 to 142)
6 T1CD-04-04-003
T4-4-11
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 setting
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 over-
load relief valve must be checked correctly, re-
move the overload relief valve from the machine
and check the overload relief valve unit perform-
ance 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 relief
pressure of each cylinders in the same method
as of main relief pressure setting in previous sec-
tion.
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.
T4-4-12
Adjusting Overload Relief Valve Set Pressure:
For Offset
NOTE: In principle, adjust the overload relief valve

set pressure on a specified test stand. For Blade
• Control Valve
2. Turn the adjusting screw to adjust the set
For Arm
pressure.
: 17 mm
: 27 to 31 N⋅m (2.8 to 3.2 kgf⋅m, 20 to 23
Ibt·ft)
: 6 mm
For Boom
For Bucket
T1CD-03-03-018

Change in MPa 7.1 14.2 21.3 28.4 Lock Nut
2
Relief (kgf/cm ) (72.5) (145) (217.5) (290)
Pressure (psi) (1031) (2062) (3093) (4124)
Lock Nut Adjusting Screw

Adjusting Screw
T152-03-03-015
Pressure Pressure
Increase Decrease
T505-06-04-007
T4-4-13
MAIN PUMP 1 AND 2 FLOW RATE MEAS-
UREMENT
5. Install the engine speed meter to the injection
Summary: pipe. Fully open the hydraulic tester loading valve.
To check the main pump performance by measuring 6. Disconnect the vacuum pump. Loosed the plug
the pump flow rate with a hydraulic portable tester in- on top of the pump casing. Start the engine and
stalled at the pump delivery port. Oil pressure should bleed air until oil flows out of the clearance
also be measured using a pressure gauge at the around the plug. Check pipe connections for oil
same time. leaks at this time.
IMPORTANT: This measurement procedure is a Measurement:

simple method. The measured data IMPORTANT: The delivery oil pressure from main
will be lower by approx. 5 % than the pump 3 controls the flow rates of
accurately measured value. To main pumps 1 and 2. Accordingly,
measure accurately, disconnect the measure the flow rates twice with
return circuit from the control valve main pump 3 in neutral (no load)
and connect it to the hydraulic oil and in relieving (loading).
tank. 1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
Preparation: 2. Select the following switch positions:
1. Stop the engine and push the air release valve on Engine Control Power Mode Auto-Idle
top of the hydraulic oil tank to release any remain- Dial Switch Switch
ing pressure. Connect a vacuum pump. Fast Idle P Mode OFF
NOTE: Operate the vacuum pump while connect- 3. While gradually closing the hydraulic tester load-
ing the hydraulic portable tester to the main ing valve, measure the flow rates, and engine
pump. speeds at the set oil pressures. (Refer to page
T4-5-3.) Measure the flow rates twice with main
2. Remove the plug at the main pump pressure test pump 3 under no load and loading (relieving the
port. Install adapter (ST 6069), hose (ST 6943) swing system).
and pressure gauge (ST 6941). (Fig. A) 4. Repeat the measurement three times and calcu-
: 6 mm late the average values.
3. Disconnect the hoses and the adapters in the Evaluation:

main pump delivery ports. Convert the measured pump flow rate into the one
Install plug (ST 6254) into the adapter on the dis- for the rated pump speed. Then, refer to the Per-
connected hose. formance Standard Table in Group T4-5.
: 32 mm, 36 mm
Qc = (Np × Q) / (i × Ne)
4. Install the flow rate gauge between the delivery
ports on main pumps 1 and 2 and the control Qc : Converted Pump Flow Rate
valve. (Fig. B) Q : Measured Pump Flow Rate
: 32 mm, 36 mm, 41 mm, 71 mm i : Pump Transmission Gear Ratio (=1)
-1
Np : Rated Pump Speed (2100 min )
Ne : Measured Engine Speed
T4-4-14
Fig. A Air Bleeding Valve Pressure Test Port
Injection Pipe
T1CD-04-04-002
Engine
Speed
Delivery Port
Meter T1CC-04-02-001
Fig. B
Test Hose
AdapterЁST 6025Ђ ЁST 6145Ђ Adapter(ST 6012Ђ Control Valve
Adapter Test Hose
Hydraulic Tester ЁST 6012Ђ ЁST 6145Ђ
ЁST 6299Ђ
Front
Port
Rear
Port
Block Adapter
ЁST 6289Ђ ЁST 6146Ђ T1CD-04-04-004
Block Adapter
Test Hose ЁST 6289Ђ ЁST 6025Ђ
ЁST 6145Ђ
T4-4-15
Adjusting Pump 1 and 2 Flow Rates:
(When Main Pump 3 has no load.)
NOTE: The pump flow rate is adjusted by chang-

ing the swash plate set pressure when
main pump 3 has no load.
Loosen the lock nut and turn the adjusting screw as

necessary.
1. Loosen the lock nut. ㈦

(Flow Rate) A
2. Turn the adjusting screw clockwise to increase
pressure and counterclockwise to decrease pres-
sure.
: 30 mm
: 10 mm
: 220 to 260 N⋅m (22.5 to 26.5 kgf⋅m, 163
to 192 Ibf·ft)
4. Recheck the flow rate after the set adjusting
pressure.
Pump 1+Pump 2 (Pressure)
Change in MPa 0.5 1.0 1.5 2
Set Pressure (kgf/cm2) (5) (11) (15) (22.5)
from point A (Psi) (71) (156) (213) (320)
Lock Nut
Adjusting Screw
T1CD-03-01-002
T4-4-16
Adjusting Pump 1 and 2 Flow Rates:
(When Main Pump 3 has a load.)

ing the reducing valve set pressure.

necessary.

2. Turn the adjusting screw clockwise to increase ㈦ A
(Flow Rate)
pressure and counterclockwise to decrease pres-
sure.
NOTE: When the pressure of the reducing valve
increases, changes in the pressure of main
pump 1 and 2 decrease.
: 13 mm
: 4 mm
: 21 to 25 N⋅m (2.2 to 2.6 kgf⋅m, 16 to 18.8
Ibf·ft)
4. Recheck the flow rate after the set adjusting Pump 1+Pump 2 (Pressure)
pressure.

Screw Turns 1/2 turn 1/4 turn 1/4 turn coun- 1/2 turn counter-
clockwise clockwise terclockwise clockwise
Change in MPa 2.15 1.07 -1.07 -2.07
Pressure of (kgf/cm )
2
(22) (11) (-11) (-21.1)
Reducing
Valve (Psi) (313) (156) (-156) (-300)
MPa -2.2 -1.1 1.1 2.2
Change in 2
Set Pressure (kgf/cm ) (-22.5) (-11.3) (11.3) (22.5)
from Point A (Psi) (-320) (-161) (161) (320)
Reducing Valve
Adjusting Screw
Lock Nut
T1CD-04-04-006
T1CD-03-01-003
T4-4-17
MAIN PUMP 3 FLOW RATE MEASURE-
MENT
5. Install the engine speed meter to the injection
Summary: pipe. Fully open the hydraulic tester loading valve.
To check the main pump performance by measuring 6. Disconnect the vacuum pump. Loosed the plug
the pump flow rate with a hydraulic portable tester in- on top of the pump casing. Start the engine and
stalled at the pump delivery port. Oil pressure should bleed air until oil flows out of the clearance
also be measured using a pressure gauge at the around the plug. Check pipe connections for oil
same time. leaks at this time.
IMPORTANT: This measurement procedure is a Measurement:

simple method. The measured data 1. Maintain hydraulic oil temperature at 50±5 °C
will be lower by approx. 5 % than the (122±9 °F).
accurately measured value. To 2. Select the following switch positions:
measure accurately, disconnect the Engine Control Power Mode Auto-Idle
return circuit from the control valve Dial Switch Switch
and connect it to the hydraulic oil Fast Idle P Mode OFF
tank.
3. While gradually closing the hydraulic tester load-
Preparation: ing valve, measure the flow rates, and engine
1. Stop the engine and push the air release valve on speeds at the set oil pressures. (Refer to page
top of the hydraulic oil tank to release any remain- T4-5-3.)
ing pressure. Connect a vacuum pump. 4. Repeat the measurement three times and calcu-
late the average values.
NOTE: Operate the vacuum pump while connect-
ing the hydraulic portable tester to the main Evaluation:
pump. Convert the measured pump flow rate into the one
for the rated pump speed. Then, refer to the Per-
2. Remove the plug at the main pump pressure test formance Standard Table in Group T4-5.
port. Install adapter (ST 6069), hose (ST 6943)
and pressure gauge (ST 6941). (Fig. A) Qc = (Np × Q) / (i × Ne)
: 6 mm
Qc : Converted Pump Flow Rate
3. Disconnect the hoses and the adapters in the Q : Measured Pump Flow Rate
main pump delivery ports. i : Pump Transmission Gear Ratio (=1)
-1
Install plug (ST 6254) into the adapter on the dis- Np : Rated Pump Speed (2100 min )
connected hose. Ne : Measured Engine Speed
: 32 mm, 36 mm
4. Install the flow rate gauge between the delivery

ports on main pump 3 and the control valve. (Fig.
B)
: 32 mm, 36 mm, 41 mm, 71 mm
T4-4-18
Fig. A Air Bleeding Valve Delivery Port
Injection Pipe
T1CD-04-04-001
Engine
Speed
Pressure Test Port Meter T1CC-04-02-001
Fig. B
Control Valve
AdapterЁST 6025Ђ Test Hose
ЁST 6145Ђ
Hydraulic Tester Test Hose
ЁST 6299Ђ ЁST 6145Ђ
Main
Pump 3
Adapter Adapter T1CD-04-04-007

ЁST 6146Ђ ЁST 6025Ђ
T4-4-19
Adjusting Pump 3 Flow Rate:

ing the reducing valve set pressure.

necessary.
1. Remove the cover.

: 32 mm
: 150 N⋅m (15.3 kgf⋅m, 111 Ibf·ft) ㈦ A
(Flow Rate)
: 18 mm, 10 mm
: 10 N⋅m (1.1 kgf⋅m, 8 Ibf·ft)
3. Turn the adjusting the screw clockwise to in-
crease pressure and counter decrease pressure.
: 18 mm
: 2.5 mm
5. Recheck the flow rate.
NOTE: Standard Change in Pressure (Reference) Pump 1+Pump 2 (Pressure)

MPa 0.3 0.6 0.9 1.2
Change in 2
Set Pressure (kgf/cm ) (3) (6.2) (9.2) (12.3)
from point A
(Psi) (43) (88) (131) (175)
Main Pump 3 Cover

Lock Nut
Adjusting
Screw
T1CD-04-04-008
T1CD-03-01-003
T4-4-20
SWING MOTOR DRAINAGE
Summary:
1. To check the swing motor performance by meas-
uring the oil drainage from the swing motor while
rotating the upperstructure.
NOTE: The amount of drain oil from the swing mo-

tor will change depending on hydraulic oil
temperature. Maintain hydraulic oil tem-
perature at 50±5 °C (122±9 °F) during the
measurement.
Preparation:
(122±9 °F). Rotate the swing motor to warm the
inside of the motor.
2. Stop the engine. Press the air release valve on
top of the hydraulic oil tank to release any remain-
ing pressure.
3. Disconnect the swing motor drain hose at the
swing motor end. Install a plug to the discon-
nected end on the hydraulic oil tank. Connect test
hose (3/4-16UNF) to the disconnected end on
T105-06-06-001
swing motor.
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
Drain Port

starting the measurement. Also, take care
not to fall off the machine while the meas-
urement.
Preconditions for Measurement:

Dial Switch Switch
T1CD-01-02-005
T4-4-21
Measurement:
1. Amount of Oil Drained While Swinging the Up-
perstructure
(1) With the arm cylinder fully retracted and the
bucket cylinder fully extended, raise the boom
so that the bucket hinge pin height is flush with
the boom foot pin height. Be sure that the
bucket is empty. Same Level as Boom
(2) Start the engine. Operate and hold the swing Foot Pin
lever full stroke. After the swing speed reaches
a constant maximum speed, start to receive the T105-06-03-013
amount of oil drained from the drain hose with a

container and measure the time.
(3) The measuring time should be more than 45
seconds.
(4) Repeat the measurement at least three times in
both clockwise and counterclockwise directions,
2. Amount of Oil Drained While Relieving Swing Mo-

tor
(1) Securely thrust the bucket teeth into the ground
to prevent the upperstructure from rotating.
(2) Start the engine. Operate and hold the swing
lever full stroke. Receive the amount of oil T107-06-06-005
drained from the drain hose with a container
and measure the time.
(3) The measuring time should be more than 45
seconds.
(4) Repeat the measurement at least three times in
Evaluation:
* Conversion of the amount of drain oil measured
into the per-minute value.
First measure the amount of the drain oil using a
calibrated container. Then, convert the measured
drain oil into the per-minute value using the for-
mula below:
Qc = 60 × q / t
Where:
Qc: Amount of Drain Oil Per-Minute (L/min)
t : Measuring Time (sec)
q : Measured Drain Oil (L)
T4-4-22
TRAVEL MOTOR DRAINAGE
Summary:
To check the travel motor performance by measuring
the oil drainage from the travel motor while rotating
the travel motor with the corresponding track raised
off the ground.
NOTE: The amount of drain oil from the travel mo-

tor will change depending on hydraulic oil
temperature. Maintain hydraulic oil tem-
perature at 50±5 °C (122±9 °F) during the
measurement.
Preparation:
(122±9 °F). Rotate the travel motor to warm the
inside of the motor.
2. Stop the engine. Press the air release valve on
top of the hydraulic oil tank to release any remain-
ing pressure.
3. Disconnect the drain hose at the travel motor end.
Install a plug to the disconnected hose end. Con-
nect test hose (9/16-18UNF) to the disconnected
T105-06-06-001
end on the travel motor.
: 22 mm Drain Hose
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
Preconditions for Measurement:

Dial Switch Switch
M197-00-001
T4-4-23
Measurement:
CAUTION: To prevent accidents, care
should be taken to ensure that hands, feet,
and clothing do not become entangled when
working around rotating parts.
Securely support the raised track with 90 ∼110°
wooden blocks.
1. Start the engine. Raise the measuring side track

using the front attachment as illustrated.
M195-07-003
2. Rotate the raised track with the travel lever oper-
ated full stroke. Receive the drain oil from the test
hose and measure the time at the same time.
3. The measuring time should be more than 45 sec-
onds.
4. Repeat the measurement at least three times in
Evaluation:
NOTE: Operational performance of the travel mo-

tor should be totally evaluated taking test
results on the travel speed and mistrack
into consideration.
* Conversion of the amount of drain oil measured T157-05-04-019

into the per-minute value.
First measure the amount of the drain oil using a
calibrated container. Then, convert the measured
drain oil into the per-minute value using the for-
mula below:
Qc = 60 × q / t
Where:
Qc: Amount of Drain Oil Per-Minute (L/min)
t : Measuring Time (sec)
q : Measured Drain Oil (L)
T4-4-24
OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE
STANDARD TABLE
The standard Performance values are listed in the

table below. Refer to the Group T4-2 to T4-4 for
performance test procedures. Values indicated in
parentheses are reference values.
* The following switch positions shall be selected:
Engine Control Dial: Fast Idle
Power Mode Switch: P Mode
Oil Temperature: 50±5 °C
Performance
PERFORMANCE TEST DESIGNATION Remarks
Standard
ENGINE SPEED min-1
Fast Idle(Normal) 2260±50 ECO Relieved
2160±50 ECO
Fast Idle(When relieving) 2160±100 1P, 2P and 3P relief
Fast Idle(E Mode) 1900±100
+100
Slow Idle 1100 -50
Auto-Idle 1200±100
ENGINE COMPRESSION PRESSURE After warming -up
2.9 (30) or more
(After warming up) MPa (kgf/cm2)
VALVE CLEARANCE(IN, EX) mm 0.40 With the engine cold
NOZZULE INJECTION PRESSURE MPa (kgf/cm2) 18.1 (185)
INJECTION TIMING(Degrees before TDC) deg. 10ѯ
TRAVEL SPEED sec/20 m
Fast Speed 14.4±1.0
Slow Speed (Reference) (21.2±2.0)
TRACK REVOLUTION SPEED (Fast Speed) sec/3 rev 12.3±1.0 ZX70LC: (12.9)
MISTRACK(in fast and slow speed mode)
200 or less
mm/20 m
TRAVEL PARKING FUNCTION CHECK mm/5 min 0
SWING SPEED sec/3 rev 15.9±1.0
SWING FUNCTION DRIFT CHECK mm /180° 280 or less
SWING MOTOR LEAKAGE mm/5 min 0
MAXIMUM SWINGABLE SLANT ANGLE deg. 22.0 or possibly more
SWING BEARING PLAY mm 0.7 or less
T4-5-1
Performance
Standard
HYDRAULIC CYLINDER CYCLE TIME sec 1.62 m Arm
3
0.28 m (PCSA heaped) Bucket
Boom Raise 2.6±0.3
Boom Lower 2.5±0.3
Arm Roll-In 2.7±0.3
Arm Roll-Out 2.3±0.3
Bucket Roll-In 3.8±0.3
Bucket Roll-Out 2.2±0.3
Blade Raise 1.2±0.3
Blade Lower 1.9±0.3
DIG FUNCTION DRIFT CHECK mm/5min 1.62 m Arm
3
0.28 m (PCSA heaped) Bucket
Weight: 375kg
Boom Cylinder 10 or less
Arm Cylinder 20 or less
Bucket Cylinder 10 or less
Bucket Bottom 100 or less
CONTROL LEVER OPERATING FORCE N(kgf) HITACHI Lever Pattern
Boom Lever 18 (1.8) or less
Arm Lever (ISO Lever Pattern: Swing Lever) 15 (1.5) or less
Bucket Lever 15 (1.5) or less
Swing Lever (ISO Lever Pattern: Arm Lever) 18 (1.8) or less
Travel Lever 28 (2.8) or less
Blade Lever 33 (3.3) or less
CONTROL LEVER STROKE mm HITACHI Lever Pattern
Boom Lever 105±10
Arm Lever (ISO Lever Pattern: Swing Lever) 84±10
Bucket Lever 84±10
Swing Lever (ISO Lever Pattern: Arm Lever) 105±10
Travel Lever 120±10
Blade Lever 70±10
COMBINED BOOM RAISE/SWING FUNCTION 1.62 m Arm
2.5±0.3 3
CKECK; With Bucket Empty sec 0.28 m (PCSA heaped) Bucket
Bucket Tooth Height (H) mm 4000 or more
T4-5-2
Performance
Standard
HYDRAULIC COMPONENT PERFORMANCE
PRIMARY PILOT PRESSURE MPa (kgf/cm2)
Fast Idle 4.0±0.5 (41±5)
Slow Idle 3.0 (31) or more
SECONDARY PILOT PRESSURE MPa (kgf/cm2) 3.4~4.0 Lever: Full Stroke
[at both fast idle(normal)and slow idle speed] (35~41)
OVERLOAD RELIEF SET PRESSURE
MPa (kgf/cm2)
+0.8 +8
Front Attachment 27.9 0 (285 -0) 10 L/min
+0.8 +8
Blade 32.0 0 (325 -0) 10 L/min
+0.8 +8
Swing 22.6 0 (230 -0) 24 L/min
+1.96 +20
Travel 31.9 0(325 -0) 32 L/min
MAIN PUMP DELIVERY PRESSURE Mpa(kgf/cm2)
Engine: Fast Idle P1, P2, P3=
1.5±1(15±10)
Front Attachment Relieved P1, P2, P3= P3: Arm Roll-In only
+2.0 +20
26.0 -0.5(265 -5)
+2.5
Swing Relieved P3=22.6 +0.5 Swing relieved
+25
(230 +5)
+2.0
Travel Relieved P1= P2=31.4 -0 One side relieved
+20
(320 -0)
+2.0
Blade Relieved P3=26.0 -0
+20
(265 -0)
MAIN PUMP FLOW RATE Refer to T4-4-16, T-4-5-4.
SWING MOTOR DRAINAGE
0.8 or less Allowable Limit: 1.2
(at constant speed) L/min
(at relief pressure) L/min 2.0 or less Allowable Limit: 2.5
TRAVEL MOTOR DRAINAGE
1.0 or less Allowable Limit: 2.0
(while being raised off ground) L/min
(at relief pressure) L/min 2.0 Allowable Limit: 4.0
T4-5-3
MAIN PUMP 1 AND 2 P-Q DIAGRAM
• Main Pumps 1 and 2

• Rated Pump Speed : 2100 min-1 (rpm) P-Q Point
• Hydraulic Oil Temperature : 50±5 °C Delivery
Flow Rate
Pressure
L/min L/min
MPa
A 2.0 (63±2)
80
B 8.3 63±3
C 9.8 (62)
D 14.7 (51)
70 E 21.6 (32)
A,A’
F 26.0 (23)
H B,B’ G 31.4 8.5 or more
’
C,C’ A 2.0 (63±2)
60 B’ 8.3 63±3
C’ 9.8 (62±2)
D’ 14.7 (49±2)
D 1 E’ 21.6 (30)
50 F’ 26.0 (22±2)
D’
I 2 G’ 31.4 8 or more
H 2.0 (63±2)
I 9.8 (48±2)
40
J 14.7 (32±2)
K 31.4 5 or more
3 E
30 J
E’ Main Pump 3 Delivery Pressure
2
1 - 0.5 Mpa (5 kgf/cm , 7.1 Psi)
F 2
2 - 1.96 Mpa (20 kgf/ cm , 284Psi)
3 - 12.3 to 26.0 Mpa (125 to 265
20 F’ 2
kgf/cm , 1780 to 3770 Psi)
10 G
G’ NOTE: Delivery Pressure of Main Pump
3 in Neutral
K
: approx. 1.5 MPa
0 2
50 100 150 200 250 300 350 MPa
(15 kgf/cm , 213 Psi)
T1CD-04-05-001
T4-5-4
MAIN PUMP 3 P-Q DIAGRAM
• Main Pump 3
P-Q Point
• Rated Pump Speed : 2100 min (rpm)
-1 Delivery Pres- Flow Rate
• Hydraulic Oil Temperature : 50±5 ѵ sure L/min
MPa
N 2.0 (52.5±2)
O 9.8 52.5±3
P 14.7 (44±2)
Q 19.6 (34)
L/min R 21.6 (30±2)
S 26.0 20 or more
80
70
60
N O
50
40
Q
R
30
S
20
10
0
5 10 15 20 25 30 35 MPa
T1CD-04-05-002
T4-5-5
INJECTION PUMP
Test Conditions:
1. Nozzle assembly: 105780-8140
2. Nozzle: 105780-0000
3. Nozzle holder: 105780-2080
2
4. Nozzle opening pressure: 17.2 MPa (175 kgf/cm )
5. Test fuel: ISO 4113 or SAE J967d
2
6. Transfer pump pressure: 157 kPa (1.6 kgf/cm )
7. Injection pipe:
Inner Dia. 2 ×Outer Dia. 6 - Length 600 mm
(0.07×0.236−23.6 in)
8. Fuel temperature: 40 ±1 °C (104 ±2 °F)
NOTE: The nozzle test injection pressure is 17.2

2
MPa (175 kgf/cm ). However, actual ma-
chine injection pressure is 18.1 MPa (185
2
kgf/cm ).
Maximum Variance
Pump Speed Rack Position Average Injec-
Strokes Between Cylinders Fixed Remarks
(min-1) (mm) tion Rate (cm3)
(%)
1050 9.0 58 ± 1 ± 2.5
500 7.2 17 ± 2 ± 15
Governor adjustment
Idling Sub Spring Set

Governor Spring Set
Rack Position
(mm)
-1
Pump Speed min (rpm) T1CD-04-05-003
T4-5-6
Dr.EX MONITOR INDICATING VALUES
Unless specified, test under the following conditions. ∗
NOTE: Items marked ( ) are measurable
Engine Speed: Fast Idle with the built-in diagnostic system.
Power Mode Switch: P Mode
Auto-Idle Switch: OFF
Reference Measured Value

Item First Second Third Average Remarks
Value
TARGET ENGINE SPEED (min-1)
∗
Fast Idle (P Mode) 2000
Fast Idle (When operating a con-
∗ 2100
trol lever)
∗
Fast Idle (E Mode) 1750
∗
Auto-Idle 1050
∗
Slow Idle 950
EC ANGLE (V)
∗
Slow Idle 2.51
∗
Fast Idle 3.51
DIAL ANGLE (V)
∗
Slow Idle 0.44
∗
Fast Idle 4.27
TRAVEL PILOT CONTROL
∗ 3.93
PRESSURE (MPa)
TRAVEL MOTOR CONTROL
2.92
PRESSURE (MPa)
EC MOTOR POSITION (step)
∗
Slow Idle 0
∗
Fast Idle 424
(504)
T4-5-7
(Blank)
T4-5-8
MEMO
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SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 General Group 3 Troubleshooting A
Introduction ..............................................T5-1-1 Troubleshooting A Procedure ...................T5-3-1
Diagnosing Procedure ..............................T5-1-2 Fault Code List .........................................T5-3-2
Built-In Diagnosing System Operation ......T5-1-4 Fault Code 01, 02, 03 ...............................T5-3-3
Built-In Diagnosing Function Display List ..T5-1-5 Fault Code 04...........................................T5-3-3
Dr. EX Operation ......................................T5-1-6 Fault Code 06...........................................T5-3-4
Dr. EX Fault Code List ..............................T5-1-7 Fault Code 07...........................................T5-3-5
Dr. EX Monitoring Item List.......................T5-1-8 Fault Code 18...........................................T5-3-6
Dr. EX Special Function..........................T5-1-10 Sensor Activating Range ..........................T5-3-7
Dr. EX Service Mode ..............................T5-1-12
Adjustment Data List ..............................T5-1-20 Group 4 Troubleshooting B
Troubleshooting B Procedure ...................T5-4-1
Group 2 Component Layout Relationship between Machine Trouble
Main Components ....................................T5-2-1 Symptoms and Related Parts..................T5-4-2
Electrical Component (Overall System) ....T5-2-2 Correlation between Trouble
Electrical System Symptoms and Part Failures ...................T5-4-6
(Monitors and Switches) .........................T5-2-4 Engine System Troubleshooting .............T5-4-13
Others ......................................................T5-2-5 All Actuator System Troubleshooting ......T5-4-22
Control Valve............................................T5-2-6 Front Attachment System
Troubleshooting ....................................T5-4-24
Swing System Troubleshooting...............T5-4-28
Travel System Troubleshooting...............T5-4-31
Blade System Troubleshooting ...............T5-4-36
Other System Troubleshooting ...............T5-4-38
Engine Speed Adjustment and
Engine Learning ...................................T5-4-56
Exchange Inspection ..............................T5-4-58
Emergency Boom Lowering
Procedure.............................................T5-4-60
1CDT-5-1
Group 5 Troubleshooting C Group 7 ICX
Troubleshooting C Procedure ...................T5-5-1 Outline .....................................................T5-7-1
Malfunction of Coolant ICX Fault Code List ..................................T5-7-6
Temperature Gauge................................T5-5-2 Satellite Terminal Fault Code List .............T5-7-6
Malfunction of Fuel Gauge .......................T5-5-4 Fault Code 1 to 6......................................T5-7-7
Malfunction of Indicator Light Fault Code 7 to 10 ....................................T5-7-7
Check System ........................................T5-5-6 Some Parts of Data in Daily Report,
Malfunction of Alternator Indicator ............T5-5-8 Frequency Distribution, Cumulative
Malfunction of Engine Oil Pressure Operation Hours are not Recorded .........T5-7-8
Indicator ...............................................T5-5-10 Troubleshooting and Setting of ICX and
Malfunction of Overheat Indicator ...........T5-5-12 Satellite Terminal Using Dr. EX .............T5-7-10
Malfunction of Air Filter Restriction Satellite Communication System ............T5-7-27
Indicator ...............................................T5-5-14
Malfunction of Buzzer .............................T5-5-16
Malfunction of LCD.................................T5-5-18
Malfunction of Hour Meter ......................T5-5-19
Malfunction of Hydraulic Oil Filter
Indicator (Optional) ...............................T5-5-20
Group 6 Electrical System Inspection

Precautions for Inspection and
Maintenance ...........................................T5-6-1
Instructions for Disconnecting
Connectors .............................................T5-6-3
Fuse Inspection........................................T5-6-4
Fusible Link Inspection .............................T5-6-5
Battery Voltage Check ..............................T5-6-6
How to Troubleshoot Alternator
Malfunctions ...........................................T5-6-7
Continuity Check ......................................T5-6-8
Voltage and Current Measurement .........T5-6-10
Check by False Signal ............................T5-6-13
Test Harness ..........................................T5-6-14
1CDT-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 quickly find the cause
of the machine trouble and solution.
The troubleshooting section in this manual consists of

7 groups; General, Component Layout, Troubleshoot-
ing A (base machine diagnosis using fault codes),
Troubleshooting B (base machine diagnosis starting
with inspection of abnormal operational status), Trou-
bleshooting C (monitor diagnosis), Electrical System
Inspection, and ICX.
• General • Electrical System Inspection

Refer to this group when required to obtain pre-
• Component Layout cautions and/or information for the electrical sys-
tem inspection.
• Troubleshooting A (base machine diagnosis using
fault codes) Example: Fuse Inspection
Refer to these procedures if any fault codes are
displayed when the main controller (MC) is diag- • ICX
nosed with Dr. EX. (or the built-in diagnosing sys- Refer to these procedures after any fault code is
tem) displayed after diagnosing ICX (Information Con-
(MC self-diagnosing function retains a record of troller) or the satellite terminal (optional) with Dr.
the electrical signal system malfunction in the EX. (The controller self-diagnosing function re-
form of fault codes.) tains a record of the electrical signal system mal-
function in the form of fault codes.)
Example: Fault Code 06: Abnormal EC Sensor
Example: ICX Fault Code 7: MC Communication
• Troubleshooting B (base machine diagnosis start- Time Out
ing with inspection of abnormal operational status)
Refer to these procedures when no fault codes In addition, information on the following items is
are displayed after diagnosing the machine with described in this group.
Dr. EX (or the built-in diagnosing system). Trace (1) Trouble shooting and setting procedures of
the cause of trouble based on the inspected result ICX and satellite terminal using Dr. EX.
of the abnormal symptom. (2) Information on the satellite communication
system
Example: Even if the engine control dial is oper-
ated, engine speed remains unchanged.
• Troubleshooting C (monitor diagnosis)

Refer to these procedures when gauges and/or
indicators are malfunctioning.
Example: Malfunction of fuel gauge
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.
2. Ask the operator T107-07-01-001

Before inspecting, get the full story of
malfunctions from your star witness Ά the
operator.
(a) How is the machine being used? (Find out if

the machine is being operated correctly)
(b) When was the trouble noticed, and what

types of work the machine doing at that time?
(c) What are the details of the trouble? Is the

trouble getting worse, or did it appear
suddenly for the first time?
(d) 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,
wasting 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 T107-07-01-003
fuses.
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
CAUTION: Never attempt to disconnect T107-07-01-004
harnesses or hydraulic lines while the engine

is running. The machine may malfunction or
pressurized oil may spout, possibly resulting
in personal injury. Be sure to stop the engine
before disconnecting harnesses or hydraulic
lines.
Perform self-diagnosis by connecting Dr. EX to

the machine or by operating the built-in self-
diagnosing system. In case any fault code has
been displayed by diagnosis using Dr. EX (or the
built-in self-diagnosing system), delete the fault
code once and retry self-diagnosis again. If the
fault code is displayed again, check the cause of T107-07-01-005
the trouble by referring to Troubleshooting A in

this section. After the machine trouble has been
corrected, the fault code (displayed by the built-in
self-diagnosing function) will be deleted. There-
fore, in case problems which are not easily re-
predicable are encountered, use Dr. EX to display
the fault code. In case no fault codes are dis-
played, check all related parts/component operat-
ing condition using the monitor function of Dr. EX
(or the built-in self-diagnosing system) while refer-
ring to troubleshooting B in this section.
Ұ Note that the fault codes displayed do not

necessarily indicate machine trouble. The
controller stores even temporary electrical
malfunctions, such as a drop in battery output T107-07-01-006
voltage or disconnections of the switches, sensors,

etc., for inspections.
For this reason, the “RETRIAL” is required to
erase the accumulated fault codes from the
controller memory and to confirm if any fault
codes are indicated after the “RETRIAL”.
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
BUILT-IN DIAGNOSING SYSTEM OPERA-
TION
IMPORTANT: This system is to be operated by the
HITACHI Dealer Only. Do not explain
this system function to the customer.
In the service mode, the monitor LCD displays the

diagnosing items, fault codes and monitored results
(not all of them) without using Dr. EX.
Built-In Diagnosing System Activation

1. While pressing the monitor SET switch, turn the
key switch ON.
Display
×××× Selection
Built-In Diagnosing System Operation ×××× Switch
1. Each time the display selection switch is pressed,
the displayed item will be changed as shown on SET Switch
next page. ××××
NOTE: The fault code is indicated in the display

order 8. All fault codes (Refer to T5-1-7)
can be indicated. In case more than one
LCD
fault code is indicated, they will be dis-
played with an interval of 1 second in order.
After the machine malfunction has been re-
paired, the fault codes are automatically de-
leted. Accordingly, if any trouble, which is
not reproducible, is encountered, it is rec-
ommended to use Dr. EX.
• The LCD in the service mode displays only the item
No. on the left and the monitored result on the right.
The item description is not displayed. M1CC-01-001
T5-1-4
BUILT-IN DIAGNOSING FUNCTION DISPLAY LIST
Display
Description Monitored Result Unit Remarks
Order
1 Hour Meter {{{{{ h Standard Mode
2 Trip 1 {{{{{ h Standard Mode (Subtraction)
3 Trip 2 {{{{{ h Standard Mode (Subtraction)
-1
4 Engine Actual Speed n {{{{ min Not available
5 Hydraulic Oil Tempera- {{{ °C Not available
ture
6 L1 {{{ − Not available
7 Overload Alarm L2 {{{ % European Spec. Only
8 Fault Code* 0 {{ − Possible to display
9 ML Switch** 1 {{ 0: Switch OFF Possible to display
1: Switch ON
10 Arm Cylinder Bottom 2 {{ MPa Not available
Pressure
11 Pump 2 Delivery Pres- 3 {{ MPa Not available
sure
12 Pump 1 Pump (Flow) 4 {{ MPa Not available
Control Pressure
13 Pump 2 Pump (Flow) 5 {{ MPa Not available
Control Pressure
-1
14 Engine Target Speed 6 {{ min Possible to display
15 EC Angle 7 {{ V Possible to display
16 Dial Angle 8 {{ V Possible to display
17 Boom Raise Pilot Pres- 9 {{ MPa Not available
sure
18 Arm Roll-In Pilot Pres- A {{ MPa Not available
sure
19 Swing Control Pilot b {{ MPa Possible to display
Pressure
20 Travel Control Pilot c {{ MPa Possible to display
Pressure
21 Front Att. Operation d {{ 0: Not Operating Possible to display
1: Operating
22 Att. Control Pressure E {{ MPa Not available
23 Work Mode F {{ 0: Digging Not available
1: Breaker
2: Secondary
Crusher
(Demolisher)
3: Crusher
4: Vibro-Hammer
NOTE: *: Refer to T5-1-7 for the Fault Codes.

**: ML specification is only available in Japanese domestic market.
T5-1-5
Dr. EX OPERATION Rear Console
Dr. EX is a troubleshooting tool to diagnose the elec-

tronic control system including the MC (main Control-
ler) and ICX (Information Controller). When Dr. EX is
connected to either the MC or the ICX, it displays
whether the controllers and sensors operate normally
in the form of fault codes (Self-Diagnosing Result Dis-
play Function).
In addition, Dr. EX can display the inputs from sensors T1CC-01-02-006
and switches to the MC and/or the outputs to actuators
such as solenoid valves from the MC in real time while
operating the machine (Monitor Display Function). Dr.EX Connector
(MC)
NOTE: This group describes how to operate Dr. EX Dr.EX Connector

connected to the MC. Refer to Group 7 (ICX)
“ICX” for operation of Dr. EX connected to
the ICX.
Operation
1. Connect the Dr. EX harness to the diagnosis con-
nector in the cab. T1CD-01-02-009
IMPORTANT: The Dr. EX harness functions the
self-diagnosing switch so that be Start
sure to use the specified one.
2. Turn the key switch ON, or start the engine.
3. When the Dr. EX power is turned ON, Dr. EX dis-
plays the following screens in order. Title Screen
3-1. Title Screen
3-2. Model Name Screen
(Example) Model: ZX70
Model Name
3-3. Function Selection Screen Cannot Confirmation
F1: Self-Diagnosing Result Communicate
F2: Monitor Display
· Check harness.
F3: Special Functions NOT OK
· Check fuse.
OK ?
NOTE: Special functions allow the ECO deactiva-
tion. (Refer to T5-1-10) OK
Replace software.
4. Select F1. Then, continue to operate Dr. EX by

following instructions to be displayed at the screen Self-Diagnosing
bottom hereafter. Result Display Special
Function Select Monitor Function
function.
NOTE: Refer to the Dr. EX Operation Manual for
the detailed operation of Dr. EX.
Self-diagnosing
result by controller Select data to
is displayed. Record.
be monitored.
Monitored data
Retry B is displayed.
Self-diagnosing
result is displayed.
T5-1-6
Dr. EX FAULT CODE LIST
Fault Code Trouble Cause

01 Abnormal EEPROM • Faulty MC
02 Abnormal RAM
03 Abnormal A/D Conversion
04 Abnormal Sensor Voltage • Faulty MC
• Faulty Sensor
06 Abnormal EC Sensor • Faulty MC
• Faulty Harness
• Faulty EC Sensor
07 Abnormal Engine Control Dial Angle • Faulty MC
• Faulty Harness
• Faulty Engine Control Dial
18 Abnormal Travel Pilot Pressure • Faulty MC
• Faulty Harness
• Faulty Pilot Pressure Sensor
T5-1-7
Dr. EX MONITORING ITEM LIST
Dr. EX displays the input signals from the switches and

sensors to the MC and the control signals to the actua-
tors from the MC.
Item Data Unit

-1 -1
Engine Target Speed Target speed when loaded. Approx. 150 min differs min
from speed when unloaded.
EC Angle Input signal from EC sensor V
Dial Angle Input signal from engine control dial V
Travel Control Pressure Input signal from pressure sensor (travel) MPa
Front Att. Operation Input signal from pressure sensor (front att.) MPa
E/P Mode Switch Power mode switch selection status E, P
Auto-Idle Switch Auto-Idle switch selection status AI
Travel Mode Travel mode switch selection status Lo, Hi
Key Switch Key switch selection status ON, OFF, Acc,
Start, HEAT
Work mode Not required
ATT. Mode Not required
Engine Learning Status Done, Undone,
Aborted Ky
Travel Motor Control Pres- Control signal to solenoid valve SI MPa
sure
EC Motor Position step
T5-1-8
Optional
Item Data Unit
Boom Cylinder Bottom Pressure MPa
Boom Cylinder Rod Pressure MPa
Boom Angle V
Arm Angle V
Travel/Swing/Overload Alarm Tr, Sw, Load
Initial *ML Setting Unf, Done, Abrt,
Und
Initial Boom-Angle Setting Unf, Done, Abrt,
Und
NOTE: ML specification is only available in Japanese domestic market.
T5-1-9
Dr. EX SPECIAL FUNCTION
HITACHI
Special function related to Dr.EX screen panels,
Dr.EX
beginning with the start screen, are shown along
VER
**** with the corresponding Dr.EX key operations.
However, Dr.EX screen panels which are not
related to the Dr.EX key operation are excluded.
(C)Hitachi Construction
Machinery Co.,Ltd.
F1: Start F10: Model Menu
F1 Press
Model : ZX70
Ver : 0100
Is model correct?
F1: Correct F10: ESC
F1 Press
Special Functions NOTE: WU function is not available for ZX70.
F6: WU Deactivation
F7: ECO Deactivation 2
F8:
F5: ESC
F7 Press
T5-1-10
1 2
ECO Deactivation?
Push key F1 or F5
F5 Press
F1: Execute F5: ESC
F1 Press
ECO Deactivated.
F5 Press
F5: ESC
T5-1-11
Dr. EX SERVICE MODE
Rear Console
Dr. EX has three (3) modes, learning value display,
parameter change, and monitor display information
setting.
Learning Value Display

Displays the values set by learning function.
Parameter Change
Engine speed, pump delivery flow rate, and solenoid T1CC-01-02-006
valve output pressure can be adjusted.
Monitor Display Information Setting Dr.EX Connector

(MC)
Items to be displayed on the monitor LCD can be
added.
• Accessing Service Mode

1. After turning the key switch OFF, wait for more
than 10 seconds.
2. Connect Dr. EX to the connector on the base ma-
chine.
3. Turn the engine learning switch to the learning T1CD-01-02-009
position (E mark side).
4. Turn the key switch ON. Don’t start the engine at Turn the engine
this time. learning switch
to E mark side.
5. Turn Dr. EX switch ON.
Engine Learning
switch
E Mark
T1CC-05-01-001
Door Side
T5-1-12
Item Data
Learning Data Display
EC Motor Stop Position Display of the engine stop value in engine learning
EC Motor Maximum Speed Position Display of max. engine speed valve in engine learning
Boom Angle Sensor Correction Value Display of boom angle sensor correction value
Arm Angle Sensor Correction Value Display of arm angle sensor correction value
Parameter Change
Li Speed Adjustment Adjustment of minimum engine speed
AI Speed Adjustment Adjustment of auto-idle engine speed
E Speed Adjustment Adjustment of E-mode engine speed
P Speed Adjustment Adjustment of P-mode engine speed
*ML Crane Front Code Change Setting of front att. code for ML models
*ML Crane Bucket Code Change Setting of bucket code for ML models
Max. *ML Crane Speed Adjustment Setting of engine speed in crane mode
*ML Crane Bucket Weight Adjustment
Min, Boom CYL. Bottom Pressure Over Bal-
ance
Monitor Display Change
Hydraulic Oil Filter LED Display/No-display Monitor setting of ON/OFF for hydraulic oil filter LED
Over Load Alarm Monitor setting of display/no-display of overload alarm
NOTE: ML specification is only available in Japanese domestic market.
T5-1-13
HITACHI
Service mode related to Dr.EX screen panels,
Dr.EX
beginning with the start screen, are shown along
VER
**** with the corresponding Dr.EX key operations.
However, Dr.EX screen panels which are not
related to the Dr.EX key operation are excluded.
(C)Hitachi Construction
Machinery Co.,Ltd.
F1: Start F10: Model Menu
F1 Press
Model : ZX70
Ver : 0100
Is model correct?
F1: Correct F10: ESC
F1 Press
Service mode selected.
In service mode, self-diagnostic

operation and/or monitor display
will not be conducted.
F1: Rechecked F5: ESC
F1 Press
T5-1-14
Select Functions
F3: Special Functions
4
F5: ESC
F8 Press
F3 Press
Select Functions Select item

F6: EC Moter Stop
F6: Learning Data Display Position
F6 Press F7: EC Moter Maximum
F7: Parameter Change Speed Position
F8: Boom Angle Sensor
F8: Monitor Display Correction Value
F5: ESC F3: Next F5: ESC
F7 Press F6 Press F5 Press
Select item EC Moter Stop Position

F6: Li Speed Adjustment
Refer to Learning data
F7: AI Speed Adjustment adjustment data 1500 digit is displayed
list.
F8: E Speed Adjustment
F3: Next F5: ESC F5: ESC
F3 Press
Select item
F6: P Speed Adjustment
F7: Breaker Engine Speed Adj.
F8:Secondary Crusher Engine An example of “F6: P Speed Adjustment” operation is
Speed Adj. shown on the next page.
F3: Next F4: Prev. F5: ESC
F6 Press
T5-1-15
P Speed Adjustment P Speed Adjustment

Adjustable range in HELP HELP
F7 Press Adjustable range:
-1
Input the adjusting −120 to 0 min
-1
deviation you want. Initial: 0 min
F5 Press Minimum Adjusting Deviation:
-1
F3: Next F5: ESC F7: HELP 10 min
F5: ESC
F3 Press Values
Adjusted In
Tens
P Speed Adjustment
123
-1
Current : 0 min F7 Press
-1
Adjustment : min
F1: Execution F2: Corr

F4: Prev. F5: ESC F7: HELP F5 Press
− Press “-100” is entered as an example here.
1 Press
0 Press
0 Press
F1 Press
∗ Adjusting Deviation ∗
∗ Data Confirmation ∗
Adjusting Deviation Data Name:

P Speed Adjustment
F3: Next F5: ESC
F3 Press F4 Press
-1
Current : 0 min
-1
Adjustment : −100 min
F1: Execute
F4: Prev. F5: ESC
F1 Press
T5-1-16
Adjustment was made as follows:
Adjusting Deviation Data Name:
P Speed Adjustment
F3: Next
F1 Press
-1
Current : 0 min
-1
Adjustment : −100 min The last screen for the “P Speed Adjustment”
will be displayed.
F4: Prev. F5: ESC
Turn off Dr.EX
End
T5-1-17
Select item
F6: Hyd. Oil Filter Restriction
Ind.
F7:
F8: Over Load Alarm %
F3: Next F5: ESC 5
F6 Press
Hyd. Oil Filter Restriction Ind.
F5
Press
F1: ON F2: OFF
F5: ESC
6
F1 Press F2 Press
∗∗∗ Data Sent ∗∗∗ ∗∗∗ Data Sent ∗∗∗

Hyd. Oil Filter Restriction Ind. Hyd. Oil Filter Restriction Ind.
Monitor: OFF
Monitor: ON
F1: Execute F5: ESC

F1: Execute F5: ESC
F1 Press F5 Press F1 Press F5 Press
Hyd. Oil Filter Restriction Ind. 6 Hyd. Oil Filter Restriction Ind. 6
Monitor: ON Monitor: OFF
F5: ESC F5: ESC
F5 Press F5 Press
5 5
T5-1-18
• Operational Performance Check After Adjustment
(Check that pump flow rate and engine speed
have been changed.)
IMPORTANT: After adjusting the engine speed and

flow rate to the attachment, turn the
engine learning switch to neutral. If
the engine is started with the engine
learning switch in the engine learn-
ing position, the MC will not control
the engine, pumps, and valves so
that change in the pump flow rate
and the engine speed cannot be
checked.
1. Turn the key switch OFF.

2. Wait approx. 10 seconds.
3. Turn the engine learning switch to neutral.
4. Disconnect the Dr. EX. connector (When monitor-
ing with Dr. EX, pass this step.)
5. Turn the key switch ON.
6. Start the engine.
7. Check operational performances of the machine.
T5-1-19
ADJUSTMENT DATA LIST
Min. Adjust- Adjustable Range Standard

Adjustment Data Remarks
ment Value Model Range Adjustment
Li Speed 10 min
-1
ZX70 0 to 120 0 min
-1
AI Speed 10 min
-1
ZX70 -120 to 120 0 min
-1
E Speed 10 min
-1
ZX70 -120 to 120 0 min
-1
P Speed 10 min
-1
ZX70 -120 to 120 0 min
-1
Breaker Speed 10 min

-1
ZX70 -500 to 0 0 min
-1
Secondary Crusher -1 -1
10 min ZX70 -500 to 0 0 min
(Demolisher) Speed
Crusher Speed 10 min
-1
ZX70 -500 to 0 0 min
-1
Vibro-Hammer Speed 10 min

-1
ZX70 -500 to 0 0 min
-1
ATT Speed Increase

500 ms ZX70 0 to 3000 0 ms
Down Wait Time
*ML Crane Front Code 1 ZX70 0 to 2 0
*ML Crane Bucket Code 1 ZX70 0 to 1 0
Max. *ML Crane Speed 10 min
-1
ZX70 -400 to 300 0 min
-1
*ML Crane Bucket Weight 4 kg ZX70 -512 to 508 0 kg

Min Boom CYL Bottom
0.1 MPa ZX70 -10.0 to 10.0 0 MPa
Pressure Over Balance
2
NOTE: 1 MPa = 10.1972 kgf/cm
1 kgf⋅m = 9807 N⋅m
ML specification is only available in Japa-
nese domestic market.
T5-1-20
TROUBLESHOOTING / Component Layout
MAIN COMPONENTS
2
Offset Front Attachment (Optional) T1CD-01-02-003
5
4 6
7
8
9
10
25 11
24 12
13
23 14
15, 16
17
21
20
19
18
T1CD-01-02-001
1- Bucket Cylinder 8- Control Valve 15 - Oil Cooler 21 - Pilot Valve(Travel)

2- Arm Cylinder 9- Hydraulic Oil Tank 16 - Radiator 22 - Travel Device
3- Offset Cylinder (Optional) 10 - Air Cleaner 17 - Blade Cylinder (Optional) 23 - Pilot Valve (Blade) (Optional)
4- Boom Cylinder 11 - Solenoid Valve Unit 18 - Shockless Valve 24 - Pilot Valve
(Front Attachment/Swing)
5 - Center joint 12 - Pilot Filter 19 - Swing Bearing 25 - Pilot Valve (Offset) (Optional)
6 - Fuel Tank 13 - Pump Device 20 - Pilot Shut-Off Valve
7 - Swing Device 14 - Engine
T5-2-1
ELECTRICAL SYSTEM (Overall System)
2
18
3
17
15, 16 4
14
13
12
6, 7
8
11
9
10
T1CD-01-02-002
1 - Horn 6 - Coolant Temperature 11 - Battery 15 - Upper : Pressure

Sensor Sensor (Travel)
2 - Air Cleaner Restriction 7 - Overheat Switch 12 - Glow Relay 16 - Lower : Pressure
Switch Sensor (Front
Attachment / Swing)
3 - EC Motor / EC Sensor 8 - Alternator 13 - Battery Relay 17 - Wiper Motor
4 - Engine Oil Pressure Switch 9 - Air Conditioner Ambient 14 - Fusible Link 18 - Solar Radiation Sensor
Temperature Sensor
5 - Starter Motor 10 - Starter Relay
T5-2-2
ELECTRICAL SYSTEM 1 2
(Monitor and Switches)
13
xxx 3
12 xxx
4
xxx
11
10
9 5
6
7
T1CC-01-02-005 8
M1CC-01-001
14
15 xxx
16
17 xxx
18
19
M1CC-01-002
1 - Coolant Temperature 6 - Air Filter Restriction Switch 11 - Overheat Indicator 16 - Power Mode Switch
Gauge
2 - Fuel Gauge 7 - Alternator Indicator 12 - Liquid Crystal Display 17 - Travel Mode Switch
(Hour Meter etc.)
3 - Display Selection Switch 8 - Hydraulic Oil Filter 13 - Auto-Idle Indicator 18 - Work Light Switch
Indicator (Optional)
4 - SET Switch 9 - Engine Oil Level Indicator 14 - Engine Control Dial 19 - Wiper / Washer Switch
5 - Fuel Level Indicator 10 - Preheat Indicator 15 - Auto-Idle Switch
T5-2-3
Seat Rear Side
4
15
14
13
12
11
10 5
T1CC-01-02-006
1 2 3
6
9
8 7
T1CC-01-02-007
1 - ICX (Information Controller) 5 - Diode D1, D2, D3, D4 9 - Engine Learning Switch 13 - Washer Relay (R2)
2 - MC (Main Controller) 6 - Fuse Box 10 - Horn Relay (R5) 14 - Load Dump Relay (R1)
3 - Satellite Terminal 7 - Dr. EX Connector to MC 11 - Work Light Relay 1 (R4) 15 - Wiper Relay A (R6)
(Optional) (Optional)
4 - Download Connector (Not 8 - Dr. EX Connector to ICX 12 - Work Light Relay 2 (R3)
provided on satellite
terminal equipped
machines)
T5-2-4
OTHERS
Pump Device Swing Device

6
1
2
5
T1CD-01-02-004 T1CD-01-02-005
Travel Device Solenoid Valve Unit

8
T1CD-01-02-006
10
T1CD-01-02-007
1 - Pilot Pump 4 - Swing Relief Valve 7 - Travel Relief Valve 9 - Travel Speed Control
Solenoid Valve
2 - Main Pump 3 5 - Make-Up Valve 8 - Counterbalance Valve 10 - Solenoid Valve(Optional)
3 - Main Pump 1, 2 6 - Oil Pressure Timer
T5-2-5
Control Valve Layout
3 4 5 6
7
8
2
1
9
36
35
34
10
33
32 11
31
30
12
13
29
28
14
15
16
27
26
25
17
18
19
24 23 22 21 20 T1CD-02-02-002
1 - Overload Relief Valve 10 - Load Check Valve (Arm 1) 19 - Check Valve (Flow 28 - Load Check Valve (Boom
(Blade) Combiner Valve Circuit) 1)
2 - Overload Relief Valve 11 - Overload Relief Valve (Arm 20 - Check Valve (Main Relief 29 - Overload Relief Valve
(Blade) Bottom Side) Circuit) (Boom Bottom Side)
3 - Load Check Valve (Swing) 12 - Overload Relief Valve (Arm 21 - Main Relief Valve (For 30 - Boom Anti-Drift Valve
Rod Side) Main Pump 1and 2) (Check Valve)
4 - Load Check Valve (Blade) 13 - Check Valve (Boom Raise 22 - Check Valve (Main Relief 31 - Overload Relief Valve
Flow Combining Circuit) Circuit) (Boom Rod Side)
5 - Load Check Valve (Offset) 14 - Load Check Valve (Boom 2) 23 - Orifice 32 - Boom Anti-Drift Valve
(Selector Valve)
6 - Overload Relief Valve 15 - Check Valve (Bucket Flow 24 - Swing Parking Brake 33 - Load Check Valve (Arm
(Offset) (Optional) Combining Circuit) Selector Valve 2)
7 - Overload Relief Valve 16 - Load Check Valve (Right 25 - Load Check Valve (Bucket) 34 - Check Valve (Auxiliary
(Offset) (Optional) Travel) Flow Combining Circuit)
8 - Main Relief Valve (For Main 17 - Check Valve (Travel Flow 26 - Overload Relief Valve 35 - Check Valve (Arm Roll-In
Pump 3) Combining Circuit) (Bucket Bottom Side) Flow Combining Circuit)
9 - Load Check Valve (Auxiliary) 18 - Flow Combiner Valve 27 - Overload Relief Valve 36 - Arm Roll-In Flow
(Bucket Rod Side) Combining Selector Valve
T5-2-6
Main Relief Valve

(For Main Pump 3)
Offset
A
Blade B
Swing C
Arm Roll-In Combining D
Selector Valve E
Auxiliary Combining F
Arm 2 G
H
Boom 1
Auxiliary Bucket Boom Anti- II
Left Travel Drift Valve
Arm 1
Boom 2
Right Travel
J T1CD-03-03-018
Flow Combiner T1CD-03-03-017
Valve Main Relief Valve
(For Main Pump
1and 2) 3
Section B
Section A 1 4 2
Swing
Blade
Offset
8 T1CD-03-03-015
7 5 6
T1CD-03-03-014
Section D 34
Section C 35
Auxiliary Combining
Auxiliary
36
9 T1CD-03-03-007
T1CD-03-03-016
T5-2-7
3 4 5 6
7
8
2
1
9
36
35
34
10
33
32 11
31
30
12
13
29
28
14
15
16
27
26
25
17
18
19
24 23 22 21 20 T1CD-02-02-002
1 - Overload Relief Valve 10 - Load Check Valve (Arm 1) 19 - Check Valve (Flow 28 - Load Check Valve (Boom
(Blade) Combiner Valve Circuit) 1)
2 - Overload Relief Valve 11 - Overload Relief Valve (Arm 20 - Check Valve (Main Relief 29 - Overload Relief Valve
(Blade) Bottom Side) Circuit) (Boom Bottom Side)
3 - Load Check Valve (Swing) 12 - Overload Relief Valve (Arm 21 - Main Relief Valve (For 30 - Boom Anti-Drift Valve
Rod Side) Main Pump 1and 2) (Check Valve)
4 - Load Check Valve (Blade) 13 - Check Valve (Boom Raise 22 - Check Valve (Main Relief 31 - Overload Relief Valve
Flow Combining Circuit) Circuit) (Boom Rod Side)
5 - Load Check Valve (Offset) 14 - Load Check Valve (Boom 2) 23 - Orifice 32 - Boom Anti-Drift Valve
(Selector Valve)
6 - Overload Relief Valve 15 - Check Valve (Bucket Flow 24 - Swing Parking Brake 33 - Load Check Valve (Arm
(Offset) (Optional) Combining Circuit) Selector Valve 2)
7 - Overload Relief Valve 16 - Load Check Valve (Right 25 - Load Check Valve (Bucket) 34 - Check Valve (Auxiliary
(Offset) (Optional) Travel) Flow Combining Circuit)
8 - Main Relief Valve (For Main 17 - Check Valve (Travel Flow 26 - Overload Relief Valve 35 - Check Valve (Arm Roll-In
Pump 3) Combining Circuit) (Bucket Bottom Side) Flow Combining Circuit)
9 - Load Check Valve (Auxiliary) 18 - Flow Combiner Valve 27 - Overload Relief Valve 36 - Arm Roll-In Flow
(Bucket Rod Side) Combining Selector Valve
T5-2-8
Section E Section F
29 33
32 30 28 31
Arm 2
Boom 1
Arm 1
Boom 2
12 10 11
T1CD-03-03-008
14 13
T1CD-03-03-009
Section G
26 28 27 Section H
23
Bucket
Left Travel
Right Travel
18
16 17 T1CD-03-03-019 20 22
T1CD-03-03-010
View J
Section I 15
19 24
21
T1CD-03-03-011 T1CD-03-03-021
T5-2-9
(Blank)
T5-2-10
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Refer to troubleshooting A procedure in case any fault

codes are displayed after diagnosing the main control-
ler (MC) using Dr. EX (or the built-in diagnosing
system).
• How to Read Troubleshooting Flow Charts
YES(OK)
(1) After completing the checking and/or measuring procedures in box
Ȁ
ȀО (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
NO(NOT OK)
Ȁ Instructions, reference, and/or inspection methods and/or measurements are occasionally

ȀО
described under the box. If incorrectly checked or measured, not only will troubleshooting
· Key switch: ON be unsuccessful but also damage to the components may result.
Refer to “Electrical System Inspection” Group (Group 6) for descriptions in the dotted-line
ȀȀ
О
box.
ȀȀ
О Use Dr. EX (or the built-in diagnosing system) for descriptions in the double-line box.
ȀȀ
О Causes of machine problems are stated in the thick-line box. Scanning quickly through the
thick-line boxes allows you to estimate the possible causes before actually following the flow
chart.
NOTE: All harness end connectors are seen from

the open end side.
Harness
Open End
Side
Harness End Connector
T158-05-03-001
T5-3-1
FAULT CODE LIST
Fault code Problem Cause

01 Abnormal EEPROM • Faulty MC
02 Abnormal RAM
04 Abnormal Sensor Voltage • Faulty MC
• Faulty Sensor
06 Abnormal EC Sensor • Faulty MC
• Faulty Harness
• Faulty EC Sensor
07 Abnormal Engine Control Dial Angle • Faulty MC
• Faulty Harness
• Faulty Engine Control Dial
18 Abnormal Travel Lever Stroke • Faulty MC
• Faulty Harness
• Faulty Pilot Pressure Sensor
Ȁ
NOTE: In case all fault codes from 06 to 18 are
displayed, one of sensors may be short-
circuited. Disconnect all sensors. Then, re-
connect sensors one at a time. When the
connected sensor is normal, the corre-
sponding fault code will disappear.
When the short-circuited sensor is recon-
nected, all fault codes are displayed again.
Thereby, finding which sensor is faulty can
be found.
T5-3-2
FAULT CODE 01 (ABNORMAL EEPROM)
FAULT CODE 02 (ABNORMAL RAM)
FAULT CODE 03
(ABNORMAL A/D CONVERSION)
YES * Faulty MC
Check if engine and machine

actuators operate normally.
Faulty MC
NO
· Refer to T5-4-56.
* Even if any fault codes are still displayed after retry-
ing, as long as the engine and machine operate
normally, the machine can be operated as it is.
FAULT CODE 04
(ABNORMAL SENSOR VOLTAGE)
NO Faulty MC
Check if fault code 06,07, or 18 is

displayed
Faulty sensor or short circuited
YES harness between MC and sensor
T5-3-3
FAULT CODE 06
(ABNORMAL EC SENSOR) YES Faulty harness be-
Check harness be-
tween MC and EC
tween MC connector
sensor
YES C (31P) terminal #18
and EC sensor termi-
nal #2 for breakage or
short circuit. Faulty MC
Disconnect EC sen- NO
sor. Check if voltage
Disconnect EC sensor. YES between harness end · Refer to T5-4-56.
Check if resistance be- connectors #1 and #3
tween sensor side is 5±0.5 V. Check if voltage be- YES Broken harness be-
tween MC and EC
connector terminals #1 tween EC sensor
· Key switch: ON sensor terminal #3.
and #3 is less than harness end connec-
2.0±0.4 kΩ. Connect test tor terminal #1 and
harness between EC NO vehicle frame
sensor and base ma- Broken harness be-
matches specification.
chine side harness. tween MC and EC
· Key switch: ON NO sensor terminal #1.
Check if voltage changes
in accordance with speci- · Specification: 5±0.5 V
fications when engine
control dial is rotated. Faulty EC sensor
· Test Harness: ST 7129 NO
· Specification: See table be- · Refer to T5-4-56.
low.
EC Sensor Specification
Minimum Speed 2.5 to 2.7 V
Maximum Speed (All 3.2 to 3.6 V
control levers are in (Auto-Idle Switch: OFF, Power
neutral position.) Mode: P Mode)
Maximum Speed 3.3 to 3.7 V
(Control lever is op- (Auto-Idle Switch: OFF, Power
erated.) Mode: P Mode)
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
C1 C10
C23 C31
#18
EC Sensor
1 2 3
T5-3-4
FAULT CODE 07
(ABNORMAL ENGINE CONTROL DIAL
ANGLE) Faulty harness be-
Check harness be- YES
tween MC connector C tween MC and engine
(31P) harness end ter- control dial
YES minal #6 and switch
panel terminal #3 for
breakage or short cir- Faulty MC
Disconnect switch cuit.
NO
panel. Check if voltage · Refer to T5-4-56.
YES between harness end
Disconnect switch panel. connector terminals #2 Broken harness be-
Check if resistance be- and #4 is 5±0.5 V. YES tween MC and engine
Check if voltage be-
tween switch panel side control dial terminal
· Key switch: ON tween switch panel
connector terminals #2 and #4
harness end connec-
#4 is 5±0.5 kΩ. tor terminal #2 and
Reconnect switch panel. NO Broken harness be-
vehicle frame
Insert tester probe into tween MC and engine
matches specification.
connector terminal #3 from NO control dial terminal
the reverse side. Check if · Key switch: ON #2
voltage varies as specified · Specification: 5±0.5 V
when engine control dial is
turned. Faulty engine control
· Specification: See table NO dial
below.
Engine Control Dial Specification

Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#6
C1 C10
C23 C31
Switch Panel
#4 #3 #2
T5-3-5
FAULT CODE 18
(ABNORMAL TRAVEL PILOT PRESSURE)
Faulty harness be-

Check harness be- YES tween MC and
tween MC connector C pressure sensor
YES (31P) harness end
terminal #3 and pres-
sure sensor terminal
#2 for breakage or Faulty MC
short circuit NO
· Refer to T5-4-56
Disconnect Pressure
NO sensor. Check if voltage
between harness end
ʝ
connector terminals #1
ʝ
and #3 is 5±0.5.
ʝ
ʝ · Key switch: ON
ʝ
ʝ Broken harness be-
ʝ Check if fault code dis- Check if voltage be- YES tween MC and
appears after switching tween pressure pressure sensor ter-
travel pressure sensor sensor harness end minal #3
with another pressure connector terminal #1
NO and vehicle frame
sensor (either front at- Broken harness be-
tachment or swing). matches specifica-
tween MC and
tion.
NO pressure sensor ter-
· Key switch: ON minal #1
· Specification: 5±0.5
Faulty pressure sen-

YES sor
Connector (Harness End Connector Viewed from Open End Side)
MC Conector C
#3 #5
C1 C10
C23 C31
Pilot Pressure Sensor
1 2 3
T5-3-6
SENSOR ACTIVATING RANGE
1. Checking Method
• Hydraulic Oil Temperature: 50 ± 5 °C

• Unless specified:
Engine Power
Auto-Idle
Control Mode
Switch
Dial Switch
Maximum
P Mode OFF
Speed
Ȁ
• Monitor each sensor using Dr. EX.
2. Sensor Activating Range
Sensor Operation Specification

Engine Control Dial
EC Sensor Maximum Speed (Control Lever: Neutral) 3.2 to 3.6 V
Maximum Speed (Control Lever: Operated) 3.3 to 3.7 V
2
Control Lever: Neutral 0 to 0.1 MPa (0 to 1.0 kgf/cm )
Pressure Sensor Pilot Control Shut-Off Lever: LOCK
2
(Travel) Control Lever: Full Stroke 3.3 to 3.9 MPa (34 to 40 kgf/cm )
Pilot Control Shut-Off Lever: UNLOCK
T5-3-7
(Blank)
T5-3-8
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault code

is displayed on the Dr.EX (or the built-in diagnosing
system) although the machine’s operation is abnormal.
On the front section pages of this group T5-4, are
tables indicating the relationship between machine
trouble symptoms and related parts which may cause
such trouble if failed.
Start the troubleshooting with more probable causes
selected by referring to these tables.
• How to Read the Troubleshoting Flow Charts
YES(OK)
(2)
• After checking or measuring item (1), select either YES (OK) or
О (1) NO (NOT OK) and proceed to item (2) or (3), as appropriate.
(3)
NO(NOT OK)
О • Special instructions or reference item are indicated in the spaces under the box.
Incorrect measuring or checking methods will render troubleshooting impossible,
· Key switch: ON and may damage components as well.
• Explanation of how to use test harness kit required. Refer to “Electrical System
О
Inspection” Group (Group 6) in this section.
О • Use Dr.EX (or the built-in diagnosing system) function.
О • Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes can be seen without going through the flow chart.
T5-4-1
RELATIONSHIP BETWEEN MACHINE
TROUBLE SYMPTOMS AND RELATED
PARTS
This table indicates the relationship between machine
trouble symptoms and the potential problem parts,
which may cause trouble if failed, and the evaluation
methods of these components.
Parts
EC Motor EC Sensor Engine Control Dial
• Moves governor. • Detects minimum governor • Indicates governor lever posi-
speed position (2.5 V) only tion (engine target speed).
when key switch is turned ON.
• Detects minimum and maxi-
Function mum speed position when en-
gine learning is conducted.
• Governor lever doesn’t move. • Engine speed is controlled • Engine speed doesn’t change
based on idle position set even if engine control dial is
Symptoms in control when key switch is turned ON. turned.
system when trouble Therefore, engine speed is • If discontinuity or short circuit
always controlled with error in occurs in engine control dial,
occurs. idle position setting if set in- target speed of 1400 min-1 is
correctly. used as back-up value.
• Even if engine control dial is • Error in setting will seldom • Engine speed is kept un-
turned, engine speed doesn’t occur so that change in ma- changed from 1400 min-1.
increase from slow idle speed. chine operation will not be no- (Auto-idle system functions.
• Engine start may be difficult ticed. Engine can be stopped by key
though starter rotates. • In case error is set on lower switch.)
• Engine will stall if discontinuity side, engine speed changes
occurs in EC motor while en- but runs slower than normal
gine is running at more than a through the full range when
specified speed. engine control dial is turned.
• Engine will become uncontrol- (Note: In case error is set on
Symptoms in machine lable if discontinuity occurs in upper side, EC motor is driven
EC motor while engine is run- so that it runs faster than the
operation when trouble ning at lower than a specified control range. However, motor,
occurs. speed. Engine cannot be a worm gear type, holds gover-
stopped with key switch. nor lever at maximum constant
position, preventing engine
stall. When engine control dial
is turned to minimum speed
position, governor lever is re-
turned to idle position.)
• When starting engine, engine
speed fluctuates.
• Starting engine is occasionally
difficult.
By Fault Code Fault code 06 is displayed. Fault code 07 is displayed.

Monitor Item: EC Angle Monitor Item: Engine Target
(Displayed by built-in diagnostic Speed, Dial Angle (Displayed by
By Monitor
 system) built-in diagnostic system)
Evalu-
Function
ation
• Install lamp harness (ST
Using Test 7125) to check EC output sig-
nal and harness for any ab-  
Harness
normality.
Others   
• Engine is stopped by EC mo- • If EC sensor is faulty, engine
tor. (Engine stop motor is not learning is not performed.
NOTE provided.) 
Fuel cut-off cable is provided.
Descriptions of Control T2-1 T2-1 T2-1

(Operational Principle
Section in T/M)
T5-4-2
Pressure Sensor (Travel) Pressure Sensor Engine Learning Switch Travel Mode Switch
(Front Att, Swing)
• Monitors travel pilot pressure • Monitors front attachment • Starts engine learning. • Changes travel mode.
to control auto-idle and idle- pilot pressure to control ON: 0 V→Learning Fast Mode: 0 V
up controls. auto-idle and idle-up angle OFF: 5 V→Normal Control Slow Mode: 5 V
control.
• No signals arrive to MC • No signals arrive to MC • Engine learning is not per- • Broken circuit in switch:
formed. Travel speed remains un-
changed in slow mode (5 V).
• Short circuit in switch:
Travel speed remains un-
changed in fast mode (0 V).
• Engine speed doesn’t in- • Engine speed doesn’t in- • Machine will operate nor- • Even if travel mode switch is
crease even if traveling is crease even if any front at- mally if problem is caused by turned to the FAST position,
performed while auto-idle tachment actuator is oper- broken circuit or discontinuity fast travel mode cannot be
switch is ON. ated with auto-idle/auto- of switch. (Only learning selected.
• Occasionally, engine speed acceleration selector is auto- cannot be performed.) • Even if travel mode switch is
hunts while traveling at slow idle position. • If short circuit occurs, learn- turned to the SLOW position,
idle. • Occasionally, engine speed ing mode operation starts slow travel mode can not be
hunts while operating front when key switch is turned selected.
attachment at slow idle. ON. Therefore, engine will
stall at 2 second or 20 sec-
onds after engine starts.
Fault code 18 is displayed.   

Monitor Item: Travel Control Monitor Item: Front Attachment Monitor Item: Engine Learning Monitor Item: Travel Mode
Pressure (displayed built-in Operation (displayed built-in
diagnostic system). diagnostic system).
Monitor pressure change while Monitor pressure change while
traveling machine. operating front attachment.
   
   
• Judge if pressure sensor is • Judge if pressure sensor is  
faulty or port is clogged by faulty or port is clogged by
switching pressure sensor switching pressure sensor
with another pressure sen- with another pressure sen-
sor. sor.
T2-1 T2-1 T2-1 T2-1
T5-4-3
Parts MC Auto-Idle Switch Power Mode Switch

(E Mode)
Function • Controls engine, pump and • Activates auto-idle control. • Selects E mode.
valve operation. ON: 0 V → Auto-idle is op- ON: 0 V → E mode
erable. OFF: 5 V → Normal
OFF: 5 V → Inoperable.
Symptoms in control • Depending on trouble situa- • Broken Circuit: Auto-idle • Broken Circuit: Even if E
tions, control system mal- system is inoperable. mode is selected, engine
system when trouble function may differ. (The fol- • Short Circuit: Even if auto- speed doesn’t decrease.
occurs. lowing symptoms in ma- idle switch is OFF, auto-idle • Short Circuit: Engine speed
chine operation indicates control is always performed. doesn’t increase to the
that MC logic circuit has maximum. Auto-idle control
failed.) is inoperable.
Symptoms in machine • Even if key switch is turned • Same as described above. • Same as described above
ON, step motor will not
operation when trouble move to the START position
occurs. so that engine cannot start.
Even though engine starts,
speed stays slow.
• Since pump displacement is
held at minimum, all actua-
tor speeds are slow.
By Fault Code Fault codes 01, 02 and 03 are  

displayed. Other fault codes
may be displayed.
By Monitor  Monitor Item: Auto-Idle Switch Monitor Item: E/P Mode Switch
Function
Evalu-
ation
Using Test   
Harness
Others   
• Before suspecting a failure  

NOTE in MC, be sure to check the
fuses in control system. If
any sensor in 5 V system is
short-circuited, all sensor
fault codes will be dis-
played.
Descriptions of Control T2-1 T2-1 T2-1
(Operational Principle
Section in T/M)
T5-4-4
Flow Combiner Valve Boom Anti-Drift Valve Swing Parking Brake Travel Mode Solenoid
Control Valve Valve
• Supplies hydraulic oil to both • Prevents boom from drifting • Controls the swing parking • Controls travel motor dis-
right and left travel spools due to oil leaks in control brake release pressure. placement angle control
from pump 1 during com- valve. Check valve in boom pressure.
bined operation of travel and lower return circuit is forcibly
front/swing. opened to allow boom to
move only when boom is
lowered.
• During combined operation • If switch valve is bound, • If the spool is bound in the • If solenoid valve is not oper-
of travel and front/swing, in- check valve doesn’t open. open position, swing parking ated, motor swash angle is
sufficient oil is supplied to left brake is kept released, in- fixed.
travel spool. creasing swing drift at stop-
ping.
• If the spool is bound in the
closed position, swing park-
ing brake is not released so
that the upperstructure can-
not swing or swing motion
becomes jerky.
• While traveling, when • If check valve is kept closed, • Same as described above. • Travel speed does not
front/swing lever is operated, boom doesn’t lower. change.
machine mistracks to the • If check valve is kept
left. opened, front attachment
drift increases due to oil
leaks in control valve.
• Boom moves jerky or arm
speed becomes slow de-
pending on valve bound
conditions.
  
  • Monitor Item: Travel Motor

Control Pressure
• Operate travel mode switch
while monitoring control
pressure.
 
 • If travel mode switch is nor-

mal, solenoid valve is faulty.
  
T2-2 T3-3 T2-1 T2-1
T5-4-5
CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
This table indicates the relationship between machine

troubles and parts contributing to the cause of the
trouble if failed.
Engine System Troubleshooting

E-1 E-2 E-3 E-4
Starter doesn’t rotate Although starter ro- When engine control dial is Even if engine control
Trouble tates, engine doesn’t fully rotated, engine stalls. dial is rotated, engine
Symptom start. Occasionally engine stalls speed remains un-
during operation with engine changed.
control dial fully rotated and
auto-idle ON. Engine speed
is slower than specification
in all operating range. Idle
speed is faster or slower
Parts than specification.
MC(Main Controller) z z z
EC Motor z z
EC Sensor { z {
Pressure Sensor (Travel) {
Pressure Sensor
{
(Front Att./Swing)
Key Switch z
Engine Control Dial z
Auto-Idle Switch
Power Mode Switch
Engine Learning Switch z
Battery Relay z
Glow Relay
Engine Electrical Equipment z
Engine Unit z z z
Governor z z z
Check Batteries and Check fuel system Check fuel cut-off handle Check engine control
fused. (filters and piping) and engine control cable. cable.
Remarks Be sure to perform engine
learning after replacing en-
gine.
T5-4-6
NOTE: The trouble symptoms in this table are de-

scribed provided that each trouble occurs
independently.
In case more than one trouble occurs at the
same time, find out all faulty components
while checking all suspected components
in each trouble symptom.
E-5 E-6 E-7 E-8 E-9

Even if key switch is Auto-idle system is inop- Even if power mode Engine stalls within Engine is difficult to start
turned OFF, engine erable. switch is turned to the E several seconds after at low temperature.
doesn’t stop. mode position, engine engine has started.
speed remains un-
changed.
{ z z
{ { {
{ {
{
{
{
{ { {
z
{ z
{ z
z
z
{ z
{ {
Check fuel system for Check batteries.
clogging.
z : Related, required to check

{ : Related. However, in case this component fails, other trouble
symptom will be more noticeable so that this component will not
be the direct cause of the trouble concerned.
T5-4-7
All Actuator System Troubleshooting

A-1 A-2
All actuator speeds are Actuator doesn’t stop
Trouble slow. even if control lever is
Symptom returned to neutral.
Parts
Engine Unit z
Spool z
Main Relief Valve {
Main Pump {
Pilot Pump z
Pilot Valve z
Pilot Relief Valve z
Remarks

scribed provided that each trouble occurs { : Related. However, in case this component fails, other trouble
independently. In case more than one trou- symptom will be more noticeable so that this component will not
ble occurs at the same time, find out all be the direct cause of the trouble concerned.
faulty components while checking all sus-
pected components in each trouble symp-
tom.
T5-4-8
Front Attachment System Troubleshooting

F-1 F-2 F-3 F-4 F-5
All front attachment Some cylinder are Arm is slow in arm Front attachment When boom raise
Trouble actuator power is inoperable or roll-in operation. drifts remarkably. is operated, boom
Symptom weak. speeds are slow. starts to move after
slightly moving
downward.
Parts
Pressure Sensor (Front
{
Attachment, Swing)
Spool z z z
Main Relief Valve z
Overload Relief Valve z z
Load Check Valve z
Arm Roll-In Combining z
Control Valve
Boom Anti-Drift Valve z z
Shockless Valve z
Pilot Valve z z z
Cylinder z z z
Main Pump 1, 2 z
Main Pump 3 z
Pilot Pump z
Pilot Relief Valve z
Remarks

scribed provided that each trouble occurs { : Related. However, in case this component fails, other trouble
independently. In case more than one trou- symptom will be more noticeable so that this component will not
ble occurs at the same time, find out all be the direct cause of the trouble concerned.
faulty components while checking all sus-
pected components in each trouble symp-
tom.
T5-4-9
Swing/Travel/Blade System Troubleshooting

S-1 S-2 T-1 T-2
Swing is slow or unmov- Engine stalls when Both right and left One side track doesn’t
Trouble ing. swing operated daring tracks do not rotate or rotate or rotates slowly.
Symptom front attachment op- rotate slowly. Machine mistracks.
eration.
Parts
MC (Main Controller)
Main Pump 1, 2 z
Main Pump 3 {
Pressure Sensor
{
(Front Att., Swing)
Pressure Sensor (Travel) { {
Travel Mode Switch {
Travel Mode Solenoid Valve {
Spool z { z
Load Check Valve
Flow Combiner Valve {
Swing Parking Brake Control
z
Valve
Shockless Valve z
Swing Device z
Travel Device z z
Center Joint z z
Pilot Valve z z z
Cylinder
Main Relief Valve {
Overload Relief Valve {
Remarks
T5-4-10
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at the
scribed provided that each trouble occurs same time, find out all faulty components
independently. while checking all suspected components
in each trouble symptom.
T-3 T-4 B-1 B-2

Machine mistracks dur- Travel speed does not Blade does not move, Blade drifts remarkably.
ing travel and front at- change. weak or its speed is
tachment combined slow.
operation.
z
{
z
z
z z
z
z
z
z z
z
z z
z
z z

{ : Related. However, in case this component fails, other trouble
symptom will be more noticeable so that this component will not
be the direct cause of the trouble concerned.
T5-4-11
Other System Troubleshooting

O-1 O-2
Wiper is inoperable or Air Conditioner Mal-
Trouble not retracted function
Symptom
Parts
MC (Main Controller) {
Wiper Motor z
z
Door Switch
Remarks
T5-4-12
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter doesn’t rotate.
Related Fault Code: None
• This trouble has nothing to do with the electronic

control system such as the MC.
• Check for loose harness connections beforehand.
Faulty starter or
YES faulty harness
between starter
Check if voltage at and battery relay.
YES battery relay
terminal A is 24 V.
Faulty battery
NO relay.
Check if both voltages
YES at key switch terminal
#5 and #6 are 24 V.
· Key switch: START YES Faulty key switch.
Check for
Check if battery
continuity between
voltage and
battery positive
electrolyte density NO terminal and key
is normal, and Faulty harness
switch terminal #1.
fusible link (45 A, between battery
65 A) is not blown. NO and key switch.
· Voltage: More than
24 V
Density: More than
1.26 Faulty battery or
NO fusible link.
Key Switch Battery Relay

Terminal A
T178-05-04-001
T105-07-04-002
T5-4-13
E-2 Although starter rotates, engine doesn’t
start.
• Check the fuel cut lever position during cranking.

If the position is normal, the engine unit and/or
fuel system may have trouble.
YES Faulty engine.
· Refer to Engine Shop Manual.
Check if governor lever moves

to the START position when
key switch is turned ON. YES Faulty EC motor.
· Key switch: ON
Check if EC motor drive

NO circuit is normal.
· Test Harness: 4274589
(ST 7125) Faulty MC.
NO
• Governor Lever and Fuel Cut Lever
1 2 3 4
T1CC-05-04-003
1 - Governor Lever
2 - Fuel Cut Lever
3 - Fuel Cut-Off Cable
(Fuel Cut-Off Handle)
4 - Governor Cable (From EC
Motor)
T5-4-14
• Governor Lever Position
A - Key Switch ON (Engine Start Position)

B - Key Switch OFF (Engine Stop Position)
A B
STOP
FULL
FULL
T1CC-05-04-003
STOP
• Fuel Cut Lever Position
A - Fuel Cut-Off Handle Returned Position

B - Fuel Cut-Off Handle Pulled Position
A B
T1CC-05-04-003
T5-4-15
E-3 When engine control dial is fully rotated,
engine stalls.
Occasionally engine stalls during operation
with engine control dial fully rotated and
auto-idle ON.
Engine speed is slower than specification in
all operating ranges.
Idle speed is faster or slower than
specification.
Related Fault Code: 06
• In case engine learning has not been performed

or engine learning has been incorrectly performed,
engine speed becomes slower than specification
across the operating range.
• In case the EC sensor is faulty, engine speed is
controlled based on the governor lever position,
which is judged as the idle position when the key
switch is turned ON. Accordingly, discrepancies in
engine speed from specification will result.
Depending on where the governor lever is
positioned when the key switch is turned ON,
discrepancy will differ, causing this trouble to be
not reproducible.
• Refer to pages for Engine Learning in the
SYSTEM/Control System group in the T/M
(Operational Principle).
Return fuel cut

YES lever to original
position.
Check if fuel cut YES Faulty EC sensor.

lever has been
moved up to half
way stroke. · Refer to T5-4-56.
Check if fault code

NO 06 is displayed. YES End
Check if problem is
corrected after
NO engine learning.
· Refer to T5-4-56 for Monitor engine
engine learning NO learning status.
procedures.
· Monitor item:
Engine Learning
Control
T5-4-16
YES Faulty engine and/or fuel

system.
OK Check if governor lever comes
in contact with stopper when
performing engine learning. Faulty control cable and/or
incorrectly adjusted engine
NO governor lever.
Ë ⏠
· Adjust engine speed.
(Refer to T5-4-56.)
Faulty MC, faulty learning

switch, or broken harness
NOT OK between learning switch and
MC.
· Refer to T5-4-56.
T5-4-17
E-4 Even if engine control dial is rotated, engine
speed remains unchanged.
Related Fault Code: 07
• If the EC fails, the engine will not stop with the key
switch ON.
Faulty engine control dial or

YES broken harness between
engine control dial and MC.
Check if fault code 07 is
displayed. Using Dr. EX,
monitor engine control dial
angles (standard voltages). YES Faulty EC motor.
Check if voltages are normal.
Install test harness (ST 7125)
· Standard Voltages to EC motor. Check if lamp · Refer to T5-4-56.
Minimum Speed Position: comes ON while turning
0.3 to 1 V NO engine control dial.
Maximum Speed Position: Faulty MC or broken harness
4.0 to 4.7 V between MC and EC motor.
· Possible to display with built-in NO
diagnostic system · Refer to T5-4-56.
E-5 Even if key switch is turned OFF, engine

doesn’t stop. (In case the engine doesn’t
stop, stop the engine by pulling the engine
stop handle located under the seat stand.
Then, begin inspection.)
Related Fault Codes: 06 and 07
• Probably symptoms such as “Engine speed is

slower than specification in all operating ranges”
or “Even if engine control dial is rotated, engine
speed remains unchanged” will come up. Perform
troubleshooting for these symptoms.
T5-4-18
E-6 Auto-idle system is inoperable.
• In case trouble symptoms E1 to E4 are

recognized, perform the troubleshooting of these
troubles beforehand.
• Although the failure in pressure sensors (travel
and front attachment) will have relevance to
malfunction of the auto-idle control. However, if
these sensors fail, other operating functions will
also be affected. (Refer to the relationship
between machine trouble symptoms and related
parts on page T5-4-2.)
• Refer to the pages for Auto-Idle Control in the
SYSTEM / Control System group in the T/M
Normal (Turn power

YES mode switch to a
position other than
the E mode.)
YES Check if power mode

switch is in the E
mode position.
Faulty MC.
Monitor auto-idle NO
switch. Check if · Refer to T5-4-56.
displayed “AI” is
turned OFF or ON
in response to
auto-idle switch
operation.
Faulty auto-idle
· Monitor item: switch or broken
Auto-Idle Switch harness between
NO auto-idle switch and
MC.
T5-4-19
E-7 Even if power mode switch is turned to the E
mode position, engine speed remains
unchanged. (Engine speed doesn’t
decrease.)
• In case trouble symptoms E-1 to E-6 are

recognized, perform the troubleshooting of these
troubles beforehand.
• Refer to the pages for E Mode Control in the
SYSTEM / Control System group in the T/M
Faulty power mode switch or
NO
broken harness between
Monitor power mode switch. power mode switch and MC.
Check if displayed “E Mode” is
turned OFF or ON in response
to power mode switch
operation. Faulty MC.
· Monitor item: YES
E/P Mode Switch · Refer to T5-4-56.
E-8 Engine stalls within several seconds after

engine has started.
• Refer to the pages for Engine Learning Control in

the SYSTEM / Control System group in the T/M
• If the engine learning switch is turned to the
learning position, the engine will stall in 5 seconds
after the engine starts.
YES Normal (Return switch

to neutral.)
Check if engine
learning switch is
turned to the learning Faulty learning switch,
position. or short-circuited
harness between
learning switch and MC,
NO
or check fuel system for
clogging.
T5-4-20
E-9 Engine is difficult to start at low temperature.
(During cold weather or in cold districts, the • Measurement of Glow Plug Voltage and Resistance
engine is difficult to start or doesn’t start
Voltage Check
although pre-heated.)
• Check if electricity is routed to the glow plugs.

Check the glow plugs for any abnormality.
• Check battery at the same time.
Remove
• Check for loose harness connections beforehand. the
copper
plate.
Specification: 20 to 24 V
T105-07-04-006
Resistance Check
Specification: Below 10 Ω
T105-07-04-007
∞Ω Faulty glow plug.
YES
Faulty glow relay.
Measure each glow Disconnect glow relay.

plug resistance. YES Connect harness end
· Key switch: ON connector terminal #4 to
· Before measuring, vehicle frame. Check if Faulty engine unit.
remove copper plates voltage at glow plug is NO
Disconnect glow relay. · Refer to the Engine
connecting each glow 20 to 24 V.
Check if voltage at glow Shop Manual
plug. relay harness end · Key switch: ON
Below
connector terminals #1
10 Ω In case voltage at terminal
or #3 is 20 to 24 V.
#1 is 0 V, harness
· Key switch: ON between glow relay and
NO batteries is broken.
In case voltage at terminal
#3 is 0 V, harness
between glow relay and
key switch terminal M is
broken.
· Verity that fuse #19 normal.
T5-4-21
ALL ACTUATOR SYSTEM TROUBLE-
SHOOTING
A-1 All actuator speeds are slow.

• Swing and blade operations use different main re-
lief valve from that of front attachment operation.
Therefore, there is a small possibility to have
faulty main relief valves at the same time.
YES Trace cause of trouble by

checking other symptoms
NO Check if primary pilot pres-

sure is normal.
· Refer to the Operational Check if pilot filter is clogged
Performance Test section C
Check if engine speed is NO
corrected.
· Refer to the Operational
Performance Test section Faulty engine
YES
YES Clogged pilot filter
Faulty pilot relief valve or

NO pilot pump
T5-4-22
A-2 Actuator doesn’t stop even if control lever is re-
turned to neutral.

• Bound spool in the pilot valve or bound main spool
in the control valve is suspected.
YES
Faulty pilot valve.
Check if actuator stops when · When control lever is in

pilot control shut-off lever is neutral, pilot pressure is
raised. routed to spool end in
control valve.
Faulty control valve.
NO
· Although pilot pressure
is not routed to spool
end in control valve,
spool is kept opened
due to binding of spool.
T5-4-23
FRONT ATTACHMENT SYSTEM TROU-
BLESHOOTING
F-1 All front attachment actuator power is weak.

• The faulty main relief valve is suspected if speed
is enough but the power is weak.
The faulty main pump 1, 2 or faulty pump control
system is suspected if speed is extremely slow.
The faulty pilot system is suspected if swing and
blade operations are also slow or the power is
weak.
YES Faulty main pump
Check if primary
pilot pressure is
correct.
· Refer to the Opera- NO Faulty pilot relief
tional Performance valve or pilot pump.
Test section Check if pilot filter
NO is clogged.
Clogged pilot filter.
YES
T5-4-24
F-2 Some cylinders are inoperatable or speeds
are slow.
• Determine whether the cause of the trouble is in

the pilot system or in the main circuit system. YES End (Bound spool
Disassemble and clean in control valve)
control valve
YES corresponding to the
Check if overload cylinder.
relief pressure corre- Check if trouble is
YES sponding to the cylin- Faulty cylinder seal
corrected.
der is correct. NO
· Refer to the Operational
Performance Test sec-
tion. Faulty overload
Check if secondary · Replace overload relief NO relief valve
pilot pressure corre- valve with other overload
sponding to the cylin- relief valve (same specifi-
der is correct. cation).
YES Faulty shockless
· Refer to the Opera- Check if secondary valve
tional Performance pilot pressure at inlet
Test section. port of shockless
NO valve is correct.
Faulty pilot valve
· Only boom corresponding to
raise/lower, arm roll- NO the cylinder
out and swing are to
be checked. Other
functions should go to
step ”NO”.
F-3 Arm is slow in arm roll-in operation Arm Roll-In

Combining
Control Valve
• At arm roll-in operation, pressure oil from main
pump 3 is combined to arm cylinder bottom side
to increase the arm roll-in speed.
If the main pump 3 is faulty, swing and blade op-
erations may become slow.
In case only this trouble occurs, the arm roll-in
combining control valve in the control valve is
suspected to be binding. Disassemble to clean
the arm roll-in combining control valve.
Arm Roll-In Combining

Control Valve T1CD-03-03-017
Section C
T1CD-03-03-016
T1CD-03-03-018
T5-4-25
F-4 Front attachment cylinder drifts remarkably.
Rlated Fault Code: None
YES Normal
Check if each front

attachment YES Faulty cylinder
cylinder drift is seals.
within specified NO Check if cylinder
value. internal leakage is
present. Scored control
valve spool,
Check if cylinder
broken spring, or
drift is reduced NO loosened spool
NO when pilot shut-off
end.
valve is closed.
Faulty pilot valve

YES
• Boom Cylinder Internal Leakage Check
1. With the bucket cylinder fully retracted and the

arm cylinder slightly extended from the fully
retracted position, lower the bucket tooth tips onto
the ground.
2. Disconnect hoses to the boom cylinder rod side.

T105-07-04-009
Then, drain oil from hoses and cylinders. (Plug the
disconnected hose ports.)
3. Retract the arm cylinder to lift the bucket above

the ground.
At this time, if oil flows out of the pipes from which

the hoses were disconnected and the boom
cylinder is retracted, internal leakage in the boom
cylinder exists.
If no oil flows out of the pipes from which the
hoses were disconnected but the the boom
cylinder is retracted, internal leakage in the control
valve exists.
T5-4-26
F-5 When boom raise is operated, boom start to
move after moving slightly downward.
YES Faulty boom anti-drift

valve.
Check if boom anti-
YES drift valve is bound or
scored.
Oil leaks in cylinder.
Check if load check NO
valve in control
valve is normal.
· Disassemble /
Faulty load check
Visual Inspection
NO valve.
NOTE: 1. During the initial stage of operation, oil

pressure and flow rate from the pump is
low. Therefore, if the load check valve is
malfunctioning, the oil in the bottom side
of the boom cylinder flows back into the (B)
circuit through the load check valve,
causing the boom cylinder to temporar- When the load check
ily retract. valve is faulty:
(A)
2. Since oil pressure and flow rate from the
pump is low, if oil leaks from bottom side
(A) to rod side (B) due to faulty boom
cylinder piston or cylinder barrel, the
boom cylinder is temporarily retracted
during the initial stage of operation. In
addition, cylinder force is reduced, in-
creasing the cylinder drift in this case.
T105-07-04-012
T5-4-27
SWING SYSTEM TROUBLESHOOTING
S-1 Swing is slow or unmoving.
• The same type of the trouble will occur even if

main pump 3 fails. In this case, the arm roll-in
speed may also become slow. If the arm roll-in
speed is normal, faulty main relief valve (in the
main pump 3 system) is suspected.
• In case other functions (front attachment and
travel) operate normally, the pilot pump is consid-
ered to be normal. If the pilot system is displaying
a problem, the cause of the trouble may exist in
the circuit after the pilot valve. Check if swing re-
NO lief pressure is cor-
rect.
· Refer to the Opera-
Check if symptom is tional Performance
corrected after dis- Test section.
NO assembling and
cleaning swing park-
ing brake control
Disassemble and
valve spool in con- End (Bound swing
YES clean swing spool in
trol valve. parking brake con-
control valve.
Check if trouble is YES trol valve spool.)
corrected.
Faulty swing relief
YES valve
Check if secondary
pilot pressure for
swing is correct.
tional Performance NO Faulty pilot valve
Test section. Check if secondary
pilot pressure at inlet
NO port of shockless
valve is correct. Faulty shockless
YES valve
T5-4-28
YES Faulty swing re-

duction gear.
Check if swing mo-
YES
tor drain volume is
correct.
tional Performance Faulty swing motor
Test section. NO
Faulty swing relief

NO valve
T5-4-29
S-2 Engine stalls when swing and front attach-
ment are operated at the same time.
• When the blade or swing function is operated, the

delivery oil pressure of main pump 3 is routed to
the main pumps 1 and 2 control pistons so that
main pumps 1 and 2 decrease the oil flow rate. If
the control pistons for the main pumps 1 and 2 are
bound, the flow rates of main pump 1 and 2 will
not be reduced, possibly causing the engine to
stall. Disassemble main pump 1 and 2 to check
the control piston for seizure.
Control Piston T1CD-03-01-002
T5-4-30
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Both right and left tracks do not rotate or ro-
tate slowly.
• Both right and left pilot valves, travel motors,

and/or control valve spools are unlikely to be
faulty at the same time.
• In case both travel systems do not operate, the pi-
lot system, which is applied to both side travel mo-
tors, may be faulty. If the primary pilot pressure is
lower than specification, the front attachment op-
erating speed becomes slow as well. Refer to A-1.
• In case the fast travel mode cannot be selected,
refer to T-4.
T5-4-31
T-2 One side track doesn’t rotate or rotates
slowly. Machine mistracks.
• Check that both side track sags are equally ad-

justed.
• In one side track only doesn’t rotate, the pilot
valve, control valve, travel motor, or center joint
may be faulty. Check if travel motor
drain oil amount is nor-
mal.
Refer to Operational
Performance Test
Check if travel relief section
NO
pressure in slow speed
side is normal.
Refer to Operational
Performance Test
Check if symptom is section
reversed when right Switch forward travel
YES and left travel line relief valve with reverse
hoses are switched travel one, or right travel
each other at the top of relief valve with left one.
center joint. NO Check if symptom is
reversed.
Check if secondary
travel pilot pressure
is normal. Bound control valve
Monitor item: YES spool.
Travel pilot pressure
Refer to Operational Faulty pilot valve.
Performance Test NO
section
Relationship between Faulty Seal Location

and Mistrack Direction Seal Location
Seal When traveling When pivot turn
No. straight: is performed:
1 External Oil ← 1
Leak
2
2
3
3
Left Travel
(Reverse)
Right
4 4 Travel
Left Travel (Reverse)
(Forward) 5
Right
5 6 Travel
(Forward)
7
6
T105-07-04-015
7 External Oil ←
Leak
T5-4-32
NO Faulty travel motor.
YES Faulty counterbalance

valve.
Disassemble and
clean travel motor
counterbalance valve.
YES
Check if same symp-
tom occurs. Faulty travel reduction
NO gear.
NO Faulty center joint.
Faulty travel relief

YES valve.
Arrangement of Pipe Line
Front
Left Travel Right Travel

(Forward) (Reverse)
Right Travel
Left Travel (Forward)
(Reverse)
Rear T1CC-05-04-002
T5-4-33
T-3 Machine mistracks during travel and front at-
tachment combined operation.

YES Faulty load check
valve.
NO Check load check
valve for any abnor-
mality. Find out cause of
Check flow com- trouble by tracing
biner valve in con- NO other trouble symp-
trol valve for any toms.
abnormality.
Faulty flow combiner

YES valve
T-4 Travel speed does not change

YES Faulty travel mode

switch.
Check if fast travel
mode is selected when
Fast switch panel connector
(16 P) terminal #5 is End (Bound solenoid
connected to vehicle YES
Check if fast travel valve).
frame.
mode is selected
· Travel mode switch: after disassembling
Fast NO and cleaning travel Faulty MC or faulty
· Without disconnecting mode solenoid valve. harness between MC
connector, ground to NO and travel mode sole-
Check which travel noid valve.
the vehicle frame from
mode is inoperable.
the reverse side of the
connector using a
jumper wire such as a YES Faulty travel mode
clip. switch.
Remove connector Faulty MC or faulty

Slow from switch panel. YES harness between MC
Check if continuity Check if fast travel and travel mode sole-
between switch box mode is selected noid valve.
side connector termi- after disassembling
nal #5 and vehicle NO and cleaning travel
mode solenoid valve. Faulty MC or Short-
frame exists.
circuited harness MC
NO
· Travel mode switch: and travel mode
Slow switch.
Switch Panel
#5
T5-4-34
(Blank)
T5-4-35
BLADE SYSTEM TROUBLESHOOTING
B-1 Blade does not move, weak or its speed is
slow.
• If swing is also malfunctioning, faulty main relief

valve for main pump 3 system, or faulty main
pump 3 is suspected.
YES Faulty cylinder or

Disassemble and clean center joint seal.
YES blade spool in control
valve.
Check if main relief Check if same symp- End (Bound blade
pressure and over- tom occurs. spool in control
load relief pressure NO valve).
in blade circuit are
normal.
Faulty main relief
valve or overload
NO relief valve.
B-2 Blade drifts remarkably.
YES Faulty cylinder.

(Replace seal kit.)
Remove blade cylin-
der and fully retract
it. Then, connect
hydraulic line to cyl-
inder rod side only
and perform blade YES Faulty center joint
raise operation. seal.
Check if oil flows out Connect center joint
of cylinder bottom upper hose and lower
side oil port. blade hose directly. End (Bound blade
NO NO
Check if symptom dis- spool in control
appears. Disassemble and valve).
clean blade spool in
NO control valve.
Check if same symp- Faulty overload relief
tom occurs. valve in control valve.
YES
T5-4-36
(Blank) ȀȀ
T5-4-37
OTHER SYSTEM TROUBLESHOOTING
O-1 Wiper is inoperable or not retracted.
Connector (Harness End Connector Viewed from the
Related Fault Code: None Open End Side.)
• The wiper driven by electric power routed via the
relay circuit controlled by the monitor assembly. Wiper Relay Wiper Motor
• If the front window is open, the wiper won’t oper-
ate. Check that the front window is securely Ȓ Ȕ ȑ
Ȱ Ȣ
closed. ȕ
ȥ ȳ
ȓ
Faulty CPU or broken

YES harness between CPU
and wiper relay #2 ter-
minal.
Check if any voltage
YES exists at wiper relay
YES Faulty wiper relay.
#2 terminal.
Replace wiper relay
· Without disconnect- with horn relay.
ing connector, NO Check if wiper cor-
Disconnect wiper mo- ground connector to Faulty wiper motor, bro-
rectly moves. ken harness between
tor. vehicle frame using
Check if voltage at har- such jumper wire as wiper relay and wiper
ness end connector clip from reverse motor terminal #S, or
NO broken harness be-
terminal #B is 24 V. side of connector.
tween fuse and wiper
relay.
Broken harness be-

tween fuse and wiper
NO motor terminal B.
T5-4-38
Wiper Operating Range

Door Switch
Intermittent Stop Position
Retracted Position
Operating Range
T1CC-05-04-004
T5-4-39
O-2 Air Conditioner Malfunction
The air conditioner operation system has a self-

diagnosing function. This system performs the diag-
nosis by 6-steps as shown in the flow chart below:
Check Model Confirmation, Display Function Confir-
mation, Present Trouble Diagnosing, Past Trouble
Diagnosing, Sensing Temperature Display, and Com-
ponent Operation Check.
Normal Operation
Turn key switch ON while pressing air

conditioner switch and mode switch.
Keep pressing OFF switch

for more than 3 seconds. STEP 0
Check Model
Confirmation
Press lower side fan switch. Press upper side fan switch.
Display Function
Confirmation
Present Trouble
Diagnosing
Keep pressing OFF switch Keep pressing air conditioner
STEP 3 switch for more than 3 seconds.
for more than 3 seconds.
Past Trouble
Diagnosing
Keep pressing OFF switch STEP 4
for more than 3 seconds. Sensing Tem-
perature Display
Component Op-
eration Check
Self-Diagnosis
T5-4-40
Self-Diagnostic System Activation
Fan Switch LCD Air Conditioner Switch
Turn the key switch ON while pressing the air condi-
tioner switch and mode switch on air conditioner con-
trol panel.
STEP 0 Check Model Confirmation

The liquid crystal display (LCD) indicates the machine
model name this system can diagnose. T178-05-08-001
Mode Switch OFF Switch

• The LCD will indicate “5d” as the check model
name.
• Select next step to be performed by operating the
switch as described below.
• Upper side fan switch: To proceed to Step 1
• Keep pressing OFF switch for more than 3 sec-
onds: To return to normal operation
NOTE: The system operation will automatically
proceed to STEP 1 after 5 seconds have
passed after the check model is displayed.
STEP 1 Display Function Confirmation

Turn all indicators ON to check indicator bulbs.
• The LCD panel and all switch indicators light.

• Select the next step to be performed by operating
the switches as follows:
• Press the upper side of the fan switch: To proceed
to “STEP 2.”
• Press the lower side of the fan switch: To return to
“STEP 0.”
• Keep pressing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed)
T5-4-41
STEP 2 Present Trouble Diagnosing
The LCD indicates the fault codes for present abnor-
Fan Switch LCD
malities of the mix door, mode encoder, and/or sen-
sors.
• In case any abnormalities are present, the LCD indi-

cates the fault codes. If more than one fault code is
detected, the following fault code is displayed after
flashing (0.5 seconds) twice.
Fault Code T178-05-08-001
Breakage Short Circuit OFF Switch
Mix Door 21 −21
Mode Encoder 22
In-Cab Ambient 23 −23
Temperature Sen-
sor
Outdoor Ambient 24 −24
Temperature Sen-
sor
Coolant Tempera- 25 −25
ture Sensor
∗
Solar Radiation 26 −26
Sensor
∗
: When solar radiation is shaded, the solar radiation
sensor indicates the fault code of breakage.
NOTE: In case no failures are present, the LCD
indicates “20.”
to “STEP 3.”
“STEP 1.”
T5-4-42
STEP 3 Past Trouble Diagnosing
The LCD indicates the fault codes for past abnormali-
ties of the mix door, mode encoder, and/or sensors.
The past stored fault codes are deleted.
• In case any abnormalities occurred in the past, the

LCD indicates the fault codes. If more than one fault
code is detected, the following fault code is dis-
played after flashing (0.5 seconds) twice.
Fault Code T178-05-08-001
Breakage Short Circuit OFF Switch
Mix Door 21 −21
Mode Encoder 22
In-Cab Ambient
Temperature Sen- 23 −23
sor
Outdoor Ambient
Temperature Sen- 24 −24
sor
Coolant Tempera- 25 −25
ture Sensor
Solar Radiation −26
Sensor
NOTE: In case no failures are present, the LCD
indicates “30.”
• When the air conditioner switch is kept pressed for
more than 3 seconds, failure records are deleted. Af-
ter this operation, the air conditioner switch indicator
flashes 5 times. Then, the self-diagnosing system is
deactivated. (Normal functions are resumed.)Ж
the switches as follows:Ж
to “STEP 4.”
“STEP 2.”
T5-4-43
STEP 4 Sensing Temperature Display Fan Mark
The LCD indicates the sensing temperature detected
by each temperature sensor (excluding the insulation
sensor).
• The sensing temperature detected by the in-cab

ambient temperature sensor, outdoor ambient tem-
perature sensor, and coolant temperature sensor
are displayed on the LCD in real time. (Figures less
than the decimal point are not displayed.) T178-05-08-001
NOTE: The coolant temperature sensor indicates Fresh Air Vent Switch OFF Switch
“H” when coolant temperature is more than
21 °C(70 °F) and “L” when coolant tempera-
ture is less than 21 °C (70 °F).
• Sensing temperature detected by each sensor is
automatically displayed on the LCD and is cycled at
an interval of 3 seconds with the timer. The timer is
turned ON or OFF by operating the fresh air vent
switch.
• Referring to the fan mark can check which sensing
temperature is displayed.
to “STEP 5.”
“STEP 3.”
T5-4-44
STEP 5 Component Operation Check
Fan Switch LCD
Each component operation is checked by performing
pattern operation.
• Each time the fresh air vent switch is pressed, the

component to be checked is selected in order.
Check which component has been selected by refer-
ring to No. indicated on the LCD. (See table 1.)
• Operating pattern of the selected component is T178-05-08-001
shifted at an interval of 10 seconds. Operating pat-
Fresh Air Vent switch OFF Switch
tern is cycled. (See table 1.)
NOTE: The components other than selected oper-
ate under the standard conditions (shown
by marks* in table 1).
“STEP 4.”
Table 1
Component Indication Operation Pattern Remarks
on LCD
Air Mix Damper 51 Controls opening extent of air mix 0%, 50%, 100%: “C”, “5”, and “H” are
damper: 0% (fully closed) → 50%*→ indicated next to the decimal point
100% (fully opened) respectively.
Fan 52 Controls air flow volume: Lo → Indicators corresponding to air flow
M(Lo) → M(Hi) → Hi volume light.
Air Vent Location 53 Selects air vent: Front*→ Front/Rear Indicator corresponding to selected air
→ Front/Foot → Foot vent lights.
Fresh/Circulation 54 Select Ventilation Mode: Circulation* Indicator corresponding to selected
Air Vent Selection → Fresh mode light.
Air Conditioner 55 Turns air conditioner switch: ON* → ON: Indicator lights.
OFF OFF: Indicator is extinguished.
T5-4-45
∗ 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
Air Induction Re-Circulation Fresh Air Circulation
Control
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
Symptom Not turned ON <Check Result>
Not turned OFF (1) Is problem reproducible ?
Others Reproducible
Uncontrollable air temperature Not reproducible
Symptom No cool air (2) Pressure (To be measured at gauge manifold)
No warm air Low Pressure
Others High Pressure
Uncontrollable air volume (3) Which parts have been replaced ?
Symptom Air flows in Hi mode only 1
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 Indica- Vent Hole
tor A/C
AUTO
Fresh Air Circulation
Fan OFF
Fan (Lo • •• Hi)
Temperature Control
Symptom Stays OFF

Stays ON
Blinks
Others
T5-4-46
Refrigerant Quantity....................... 900±50 g

3
Compressor Oil Quantity................ 210 cm
T5-4-47
Cooling Circuit
Refrigerant pressure Piping and/or parts are stained with

Bubbles can be seen in sight oil, respond to gas detector.
in both high and low glass.
pressure sides is low.
No oil stain is found or gas detector
doesn’t respond. Refrigerant has not
been refilled for longer than one sea-
son.
No bubbles are seen in sight
glass.
After cooling at fast speed continu-

ously, cooling power is reduced. Air
flow volume remains unchanged.
Air flow volume is reduced.

Refrigerant pres-
sure in low pressure Bubbles can be seen in sight Compressor cylinder is extremely hot,
side is high. glass. emitting a smell.
Insuff-
icient
Cooling Refrigerant pressure in high Compressor cylinder is extremely hot,
Power pressure side is low. emitting a smell.
Heater unit emits hot air.
Refrigerant pres- Bubbles can be seen in sight Refrigerant pressure in low pressure
sure in high pres- glass. side is low.
sure side is high.
Condenser is stained and clogged.
Even if condenser is sprayed with water, few bubbles appear. Receiver dryer tem-
perature is low.
After cooling at fast speed continu-

ously, cooling power is reduced. Air Frost Thermistor doesn’t cool.
flow volume is reduced. forms.
Thermistor cools.
T5-4-48
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 Readjust or replace expansion valve.

expansion valve.
Remove clog, or replace receiver and/or expan-
Clogged expansion valve. sion valve.
Clogged low pressure circuit and/or evaporator. Remove clog, or replace parts.
Frozen expansion valve or water in circuit. After evacuation, refill refrigerant and/or replace
receiver dryer.
Gas leaks from case.
Seal gaps using vinyl tape or packing compound.
Poor contact of expansion valve temperature Make good contact. Replace temperature sensing
sensing cylinder. stay.
Improper adjustment (excessive open) of expan-
Readjust or replace.
sion valve.
Insufficient compressor discharge (faulty gasket Replace.

and/or valve).
Improper water stop valve wire adjustment and/or Check and readjust or replace.
faulty stop valve.
Repair.
Poor airtight fitting of outside air damper (outside
air induction type).
Remove clog, or replace parts.

Clogged high pressure circuit before receiver
dryer.
Clean Condenser.
Excessive refrigerant. Remove excessive refrigerant to proper level.
After evacuation, refill refrigerant and/or replace

Air is mixed in system. receiver 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 on correct air-conditioner operation.
when air-conditioner is kept operated for a long (Reset thermistor to either minimum or middle
time with thermistor in max. cooling position and cooling position or increase air flow.)
air flow in M or L mode, frost may form.
T5-4-49
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 con-
tact noise.
Gas blowing sound (roaring). Gas vibration noise (compressor discharge and/or
suction 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
Absorbed cigarette and dust smell on evaporator fins.

Abnormal smell.
T5-4-50
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.
-1
Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min in
L mode for more than 10 minutes, flush smell out by condensed water.
T5-4-51
Compressor
Compressor doesn’t rotate. Clutch terminal voltage is normal 24 V.
Inoperable Clutch terminal voltage is low.

cooling
system.
Clutch terminal voltage is 0 V.
Bubbles exist even after refrigerant is refilled.
Check for oil and refrigerant leaks from parts other than
Both high and low side
compressor and pipe joints using gas detector.
pressures are low.
Both com-
pressor
and blower
motor ro- Check for oil and
tate. refrigerant leaks
from compressor Refer to NOTE 1 and 2 on page T5-4-55.
(no leaks from
Refrigerant has not been refilled for longer
parts other than
than one season.
compressor) using
gas detector.
Stain Refrigerant is discharged within 1 to 2
on months after being recharged. Check for
exterior. refrigerant leaks using gas detector.
Refrigerant is kept charged for longer than

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

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

Refer to the Cooling Circuit Troubleshoot-
ing Table on page T5-4-48.
Temperature is not cooled when compressor is
operated at fast speed continuously.
Air flow from blower is insufficient.
Compressor rotation is abnormally draggy.

Overheating
is susceptible
to occur.
Trouble other than compressor. Refer to the Cooling Circuit Troubleshooting Table on page
T5-4-48.
T5-4-52
Seized clutch. Replace.
Improper gap between amature and rotor (improper air gap).

Replace.
Broken or short-circuited core cable.
Shaft doesn’t rotate (internally locked). Replace.
Faulty Electrical System.
Faulty Electrical System.
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 T5-4-84.
Broken valve (See NOTE 3 on page T5-4-55.)

Replace.
Blown gasket (See NOTE 3 on page T5-4-55.)
Excessive oil. Check and

adjust oil level.
Broken clutch bearing due to overly tightened belt. Replace.
Shaft doesn’t rotate.

Replace.
Shaft rotates draggy.
T5-4-53
Compressor
Noise is heard when clutch is OFF.
Abnormal
noise
Noise is heard when clutch is ON.
T5-4-54
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 T5-4-48.
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 T5-4-48.
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 sur-
face 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
2
high pressure side and low pressure side is 0.49 MPa (5 kgf/cm ) or less. When the clutch is
turned OFF, the pressure difference between high pressure side and low pressure side will disap-
pear within about 10 seconds.
T5-4-55
ENGINE SPEED ADJUSTMENT AND EN-
GINE LEARNING
After removing and/or replacing the components as
described below for repair and/or inspection, or if error
in engine speed is found, readjust engine speed and
perform engine learning.
• Removal of the engine, engine control cable, or

EC motor
• Replacement of MC
Adjustment of Engine Speed:

1. Turn the key switch to the START position to start
the engine.
NOTE: Turn the air conditioner OFF.
2. Rotate the engine control dial to the minimum
speed position. (The output voltage from the EC
sensor is 2.5 V.)
3. Loosen the bolt holding the control lever to the EC
motor output shaft.
4. While monitoring the actual engine speed with the Control Lever Holding Bolt
engine speed meter, adjust the control lever so
that the minimum speed (slow idle) matches the
specification.
Specification: See the OPERATIONAL PER-
FORMANCE TEST section.
5. Tighten the lever holding bolt to secure the control
lever to the motor output shaft.
: 13 N⋅m (1.3 kgf⋅m, 9.4 lbf⋅ft)
NOTE: Don’t lubricate the motor output shaft.
6. Perform engine learning.
T191-05-04-004
T5-4-56
Engine Learning:
1. Turn the key switch OFF Rear Console
NOTE: In case the engine doesn’t stop when the
key switch is turned OFF, pull the handle
located under the seat to stop the engine.
2. Disconnect Dr. EX. Wait for 5 seconds.
3. Turn the engine learning switch ON.
4. Turn the key switch ON. Wait for 5 seconds.
5. Turn the key switch OFF. Wait for 5 seconds.
6. Turn the engine learning switch OFF.
7. Check the engine speed.
T1CC-01-02-006
Dr.EX connector
(MC)
T1CD-01-02-009
OFF
ON
Turn the engine

learning switch
to E mark side.
Engine Learning
Switch
E Mark
T1CC-05-01-001
T5-4-57
EXCHANGE INSPECTION
Machine Front
Exchange inspection method is a troubleshooting
method to find the trouble location by exchanging the
suspected part / component with another part
/component having identical characteristics.
Pressure Sensor
Many sensors and solenoid valves used on this ma- (Travel)
chine are identical. Therefore, using this switch-check
method, faulty part /component, and/or harness can be
easily found.
Example: Abnormal Travel Pilot pressure (Fault

code:18)
Check Method:
1. Switch two pressure sensors located as shown in Pressure Sensor
(Front Att, Swing)
figure.
2. Retry troubleshooting.
Result: In case no fault codes are displayed, suspect a

faulty pressure sensor (travel).
T1CD-05-04-002
T5-4-58
Applicability of Switch-Check Method

Fault Code Trouble Applicability
01 Abnormal EEPROM Not Applicable
02 Abnormal RAM
04 Abnormal Sensor Voltage
06 Abnormal EC Angle Sensor Not Applicable
07 Abnormal EC Dial Not Applicable
18 Abnormal Travel Pilot Pressure Applicable (Harness/Sensor)
T5-4-59
EMERGENCY BOOM LOWERING PRO-
CEDURE Machine Front
CAUTION: Prevent personal injury. Confirm

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

boom to lower the bucket to the ground referring to the
emergency boom lowering procedure stated below.
1. Loosen lock nut (1). Loosen screw (2) one half of

a turn. The boom will start to lower. The boom
lowering speed can be somewhat adjusted by
loosening screw (2) more.
NOTE: Never loosen screw (2) more than 2 turns.

Screw (2) may come off.
2. After the bucket is lowered to the ground,

retighten screw (2), then lock nut (1) to the speci-
fications below.
T1CD-05-04-002
Lock Nut (1)
: 13 mm Emergency
: 13±0.6 N⋅m (1.3 kgf⋅m, 9.4 lbf⋅ft) Valve
Screw (2)
: 4 mm
: 6.9±0.6 N⋅m (0.7 kgf⋅m, 5.0 lbf⋅ft)
NOTE: Excessive leakage may result if the screw

and the lock nut are tightened insufficiently.
Be sure to retighten the screw and the lock
nut to specifications.
Emergency
Valve
T1CD-05-04-001
T5-4-60
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C
(TROUBLESHOOTING FOR MONITOR)
PROCEDURE
Use troubleshooting C when any monitors, such as

gauges or indicators malfunction.
• How to Read Troubleshooting Flow Charts
YES(OK)
(2)
After completing the checking and/or measuring procedures in box
О (1) (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
(3)
NO(NOT OK)
О Instructions, reference, and/or instruction methods on inspection and/or measurements

are occasionally described under the box. If incorrectly checked or measured, not only
· Key switch: ON will troubleshooting be unsuccessful but also damage to components may result.
О Causes of machine problems are stated in the thick-line box. Scanning quickly through
the thick-line boxes, allows you to estimate the possible causes before actually following
the flow chart.
NOTE: All harness end connector are seen from

the open end side.
Wire Harness Side
Open End
Side Harness End Connector
T158-05-03-001
T5-5-1
MALFUNCTION OF COOLANT TEMPERA-
TURE GAUGE
YES
Disconnect coolant temperature

Gauge pointer doesn’t move sensor. Ground harness end
Without connecting coolant
at all. terminal to vehicle frame. Check
temperature sensor, remove
if pointer swings to (H) side.
connector B (20P) from moni-
· Key switch: ON tor. Check for continuity be-
NO tween monitor harness end
connector terminal #18 and
coolant temperature sensor
terminal.
YES
Disconnect coolant tempera-

Gauge pointer swings over ture sensor. Check if pointer
scale. Without connecting coolant
returns to zero.
temperature sensor, remove
· Key switch: ON connector B (20P) from moni-
tor. Check for continuity be-
NO tween monitor harness end
terminal #18 and vehicle
frame.
YES
Disconnect coolant tempera-

ture sensor. Ground harness
Gauge pointer keeps moving end terminal to vehicle frame,
unstably. Check if pointer swings and is
stabilized to (H) side.
· Key switch: ON
NO
T5-5-2
Coolant Temperature Gauge
105 °C
95 °C
Faulty coolant temperature

sensor
70 °C
YES Faulty monitor
M178-01-104
Broken harness between

NO monitor and sensor
Coolant Temperature Sensor

Coolant Temperature Resistance (kΩ)
°C (°F)
25 (77) 7.6
40 (104) 4.0±0.32
Faulty coolant temperature 50 (122) 2.7±0.22
sensor
80 (176) 0.92
95 (203) 0.56
105 (221) 0.42
YES Short-circuited harness be- 120 (248) 0.28±0.01
tween monitor and sensor
Faulty monitor
NO
Connector (Harness end connector terminals seen

from the open end side)
Faulty coolant temperature
sensor Monitor Connector B (20P)
ȑȐ ș Ș ȗ Ȗ ȕ Ȕ ȓ Ȓ ȑ
ȒȐ ȑș ȑȘ ȑȗ ȑȖ ȑȕ ȑȔ ȑȓ ȑȒ ȑȑ
Faulty monitor
T5-5-3
MALFUNCTION OF FUEL GAUGE
YES
Disconnect fuel sensor. Con-

nect harness end connector
Fuel gauge pointer doesn’t terminal #1 to terminal #2 using
move at all. jumper wire such as clip. Check
Without connecting fuel sensor,
if pointer swings to (FULL) side.
remove connector B (20P) from
· Key switch: ON monitor. Check for continuity
NO between monitor terminal #19
and fuel sensor terminal 1.
YES
Fuel gauge pointer swings over Disconnect fuel sensor. Check

scale. if pointer returns to zero.
Without connecting fuel sensor,
· Key switch: ON remove connector B (20P) from
monitor. Check for continuity
NO between monitor harness end
terminal #19 and vehicle frame.
YES
Disconnect fuel sensor. Con-

nect harness end connector
Fuel gauge pointer keeps mov- terminal #1 to terminal #2 using
ing unstably. jumper wire such as clip. Check
if pointer swings and is stabi-
lized to (FULL) side.
· Key switch: ON NO
T5-5-4
Fuel Sensor
Float
Faulty fuel sensor
FULL
YES Faulty monitor

279 mm
R363
NO monitor and sensor
1/2
104°
293 mm
Faulty fuel sensor

EMPTY
YES Short-circuited harness be- T190-04-04-001

tween monitor and sensor
NOTE: 1 mm = 0.03937 in
Float Position Resistance (Ω)
Faulty monitor Upper Limit (FULL)
+0
10 -4
NO 1/2 38
+10
Lower Limit (EMPTY) 90 -0

Faulty fuel sensor
Monitor Connector B (20P) Fuel Sensor
ȒȐ ȑș ȑȘ ȑȗ ȑȖ ȑȕ ȑȔ ȑȓ ȑȒ ȑȑ ȑ Ȓ
Faulty monitor
T5-5-5
MALFUNCTION OF INDICATOR LIGHT
CHECK SYSTEM
YES Faulty fuse or monitor.

Remove connector C
(20P) from monitor.
YES Check for continuity
between harness end
terminal #1 and fuse
terminal #5. Broken harness between
Indicator doesn’t light NO fuse and monitor.
when indicator light Check if all indicators
check operation is don’t light.
performed.
Troubleshoot unlit indicator

NO individually.

Monitor Connector C (20P)
T5-5-6
(Blank)
T5-5-7
MALFUNCTION OF ALTERNATOR INDICA-
TOR
NOTE: Regulator terminals L are water-resistant

type connectors so that it is not practical to
measure voltage at these terminals. Meas-
ure voltage at starter relay terminal R in-
stead. Check for continuity between starter
relay terminal R and regulator terminal L
beforehand.
Between 13 V
and 33.5 V
Between 13 V
and 33.5 V Measure voltage at
monitor connector A
(16P) terminal #2.
Alternator indicator Measure voltage at · Engine: Running Less than 13 V or
stays ON after en- regulator terminal L.
∗
higher than 33.5 V
gine is started.
· Engine: Running
Less than 13 V or
higher than 33.5 V
Between 10 V
and 33.5 V
YES Measure voltage at

regulator terminal L.
· Key switch: ON
Although alternator · Engine: Stopped
Check if indicator Less than 10 V or
output is low, alter-
lights when key higher than 33.5 V
nator indicator
switch is turned ON.
doesn’t light.
· Key switch: ON
NO
T5-5-8

Faulty monitor from the open end side)
Starter Relay
Broken harness between ȥ

regulator terminal L and moni-
ȳ Ȳ
tor
Faulty regulator or alternator

Monitor Connector A (16P)
Ș ȗ Ȗ ȕ Ȕ ȓ Ȓ ȑ
ȑȖ ȑȕ ȑȔ ȑȓ ȑȒ ȑȑ ȑȐ ș
Faulty monitor
Faulty regulator
Burned indicator light
T5-5-9
MALFUNCTION OF ENGINE OIL PRES-
SURE INDICATOR
NOTE: During one or two minutes after the engine

is stopped, engine oil pressure may still ex-
ist. When the engine is restarted under this
condition, the indicator may not light.
YES
Disconnect engine oil
pressure switch. Check
if indicator light when
YES
harness end connector
terminal #1 (white and Reconnect engine oil pres-
red cable) is grounded sure switch. Check if indica-
to vehicle frame. tor lights when monitor con-
Indicator doesn’t Check if indicator · Key switch: ON NO nector C (20P) terminal #18
light even if engine lights when key is grounded to vehicle frame.
oil pressure is low. switch is turned ON.
· Key switch: ON
· Key switch: ON · Without disconnecting con-
· Engine: Stopped nector, ground connector to
vehicle frame using such
jumper wire as clip from re-
verse side of connector.
NO
YES
Check if indicator
Indicator stays ON goes OFF when
after engine is engine oil pressure YES
Reconnect engine oil
started. switch is discon-
pressure switch and
nected.
· Check oil filter for remove connector C
clogging. · Key switch: ON (20P) from monitor.
· Engine: Stopped NO Check for continuity
between harness end
connector terminal #18
and vehicle frame.
NO
T5-5-10
Engine Oil Pressure Switch

Pressure Operation
Approx. 39 kPa
2
Faulty engine oil pressure (0.4 kgf/cm , 5.7 psi) or ON
switch less
Approx. 39 kPa
2
(0.4 kgf/cm , 5.7 psi) or OFF
YES Broken harness between
monitor and engine oil pres-
higher
sure switch
Faulty monitor
NO

Monitor Connector C (20P)
Faulty engine oil pressure ȑȐ ș Ș ȗ Ȗ ȕ Ȕ ȓ Ȓ ȑ

switch or engine oil pressure ȒȐ ȑș ȑȘ ȑȗ ȑȖ ȑȕ ȑȔ ȑȓ ȑȒ ȑȑ
system, or clogged oil filter
Short-circuited harness be-

tween monitor and engine oil
pressure switch
Faulty monitor
T5-5-11
MALFUNCTION OF OVERHEAT INDICA-
TOR
YES
Remove connector
(red and blue cable)
from overheat switch.
YES
Check if indicator lights
when harness end
Key Switch:
·terminal ON
is grounded to
vehicle frame.
· Key switch: ON NO
Indicator doesn’t light Check if indicator

even if engine over- lights when key
heats. switch is turned ON.
· Key switch: ON
NO
YES
Check if indicator
Indicator lights even
goes OFF when
if coolant tempera-
overheat switch is
ture is low.
disconnected.
Disconnect overheat YES
· Key switch: ON
switch. Remove con-
· Engine: Stopped
nector B (20P) from
monitor. Check for con-
NO
tinuity between connec-
tor terminal #6 and ve-
hicle frame.
NO
T5-5-12
Overheat Switch
Faulty overheat switch Coolant Temperature Operation
Lower than 105 °C
OFF
(221 °F)
105 °C (221 °F) or
ON
higher
Reconnect overheat YES Broken harness between
monitor and overheat
switch. Check if indica-
switch
tor lights when monitor
connector B (20P)
terminal #6 is
grounded to vehicle Faulty monitor
frame. NO
· Key switch: ON
· Without disconnect- Connector (Harness end connector terminals seen
ing connector, from the open end side)
ground connector to
Monitor Connector B (20P)
vehicle frame using
such jumper wire as
clip from reverse side ȑȐ ș Ș ȗ Ȗ ȕ Ȕ ȓ Ȓ ȑ
of connector. ȒȐ ȑș ȑȘ ȑȗ ȑȖ ȑȕ ȑȔ ȑȓ ȑȒ ȑȑ
Faulty overheat switch
Short-circuited harness
between monitor and
overheat switch
Faulty monitor
T5-5-13
MALFUNCTION OF AIR FILTER RESTRIC-
TION INDICATOR
YES
Disconnect air filter re-
striction switch at plug
receptacle with green
YES and blue cable. Check if
indicator lights when Reconnect air filter restric-
harness end plug con- tion switch. Remove con-
nector is grounded to nector B (20P) from moni-
vehicle frame. tor. Check for continuity
Even if air filter is Check if indicator NO between monitor harness
clogged, indicator lights when key · Key switch: ON
end connector terminal #7
doesn’t light. switch is turned ON. and vehicle frame.
· Key switch: ON
NO
YES
Although air filter is Check if indicator

Disconnect air filter re-
not clogged, indica- goes OFF when air YES
striction switch at plug
tor lights. filter restriction switch
receptacle with green
is disconnected.
and blue cable and re-
· Disassemble and
· Key switch: ON move connector B (20P)
visually inspect.
from monitor. Check for
· Verify that air filter NO continuity between con-
is not moist.
nector terminal #7 and
vehicle frame.
NO
T5-5-14
Faulty air filter restriction

switch Air Filter Restriction Switch
Pressure Operation
YES Faulty monitor 5.1 kPa (520 mmH2O) OFF
6.2 kPa (630 mmH2O) ON

monitor and air filter re-
NO striction switch

Monitor Connector B (20P)
Faulty air filter restriction

switch
between monitor and air
filter restriction switch
Faulty monitor
T5-5-15
MALFUNCTION OF BUZZER
∗
beforehand.
13 V or more Faulty regulator

Buzzer continues to
sound when key Measure voltage at
switch is turned ON monitor connector A
without starting (16P) terminal #2.
engine. · Key switch: ON Faulty monitor
(without starting Less than 13
engine)
YES Faulty engine oil pres-

sure system
Buzzer continues to Check if engine oil
sound when engine pressure indicator YES Overheat of engine
is started. lights.
Check if overheat indi-
NO cator lights.
Faulty monitor
NO
NO Normal
Buzzer doesn’t
sound even if en- Check if engine
gine oil pressure speed is 900 min
-1
NO Perform troubleshooting
indicator or over- (rpm) or faster. of indicator staying ON.
heat indicator lights
with engine running. Check if alternator
YES indicator lights.
Measure voltage at regu-
∗
YES lator terminal L.
-1
· Engine speed: 900 min
(rpm) or faster
T5-5-16

Monitor Connector A (16P) Starter Relay
Ș ȗ Ȗ ȕ Ȕ ȓ Ȓ ȑ ȥ
ȑȖ ȑȕ ȑȔ ȑȓ ȑȒ ȑȑ ȑȐ ș ȳ Ȳ
Lower than 13 V or
more than 33.5 V Faulty regulator and alternator
Lower than 13 V or
higher than 33.5 V Broken harness between
regulator terminal L and moni-
tor
Measure voltage at monitor
connector A (16P) terminal #2.
Between 13 V Faulty monitor
and 33.5 V · Engine speed: 900 min
-1
Between 13 V
(rpm) or faster and 33.5 V
T5-5-17
MALFUNCTION OF LCD
• The following items are described:

1 to 3: To be displayed in the standard mode.
4 to 23: To be displayed in the user’s mode.
system
• In case only LCD is abnormal, the machine will
normally operate.
Display
Description Cause of Trouble
Order
1 Hour Meter Refer to the next page.
2 Trip 1 Faulty Monitor
3 Trip 2
4 Actual Engine Speed Not necessary to check because of no sensor.
5 Hydraulic Oil Tempera-
ture
6 Faulty monitor or interrupted communication between ML controller and
7 Load Alarm monitor
8 Fault Code Faulty monitor
9 ML Switch In case Dr. EX can display data, monitor is abnormal or communication
10 Arm Cylinder Bottom between monitor and MC is interrupted. In case Dr. EX doesn’t display
Pressure data, corresponding signal sensor is faulty. (The machine must have
11 Pump 2 Delivery Pres- any abnormality in the control system. Refer to Troubleshooting B.)
sure
12 Pump 1 Control Pres-
sure
13 Pump 2 Control Pres-
sure
14 Target Engine Speed
15 EC Angle
16 Dial Angle
17 Boom Raise Lever
Stroke
18 Arm Roll-In Lever Stroke
19 Swing Lever Stroke
20 Travel Lever Stroke
21 Front Attachment Lever
Stroke
22 Attachment Lever Stroke
23 Work Mode
T5-5-18
MALFUNCTION OF HOUR METER
∗
beforehand.
Lower than 13 V or
higher than 33. V Faulty regulator or
alternator
Hour meter
doesn’t count Between 13V
Measure voltage at
operating hours ∗ and 33.5 V Faulty monitor
regulator terminal L.
with engine run-
-1
ning. · Engine speed: 900 min Measure voltage
· Engine: Running (rpm) or faster at monitor connec-
Between 13V tor A (16P) termi-
and 33.5 V nal #2. Broken harness be-
tween regulator ter-
Lower than 13 V or minal L and monitor
higher than 33.5 V

Monitor Connector A Starter Relay
ȥ
Ș ȗ Ȗ ȕ Ȕ ȓ Ȓ ȑ
ȑȖ ȑȕ ȑȔ ȑȓ ȑȒ ȑȑ ȑȐ ș ȳ Ȳ
T5-5-19
MALFUNCTION OF HYDRAULIC OIL FIL-
TER INDICATOR (Optional)
YES
Disconnect hydraulic
oil filter restriction
switch at plug recepta-
YES cle with white and blue
cable. Check if indica-
tor lights when harness
end plug connector is
grounded to vehicle NO
· Key switch: ON
Even if hydraulic oil Check if indicator

filter is clogged, indi- lights when key
cator doesn’t light. switch is turned ON.
· Key switch: ON
NO
YES
Although hydraulic Check if indicator

oil filter is not goes OFF when
clogged, indicator hydraulic oil filter
restriction switch is Disconnect hydraulic oil
lights. filter restriction switch at
disconnected. YES
plug receptacle with
· Key switch: ON white and blue cable
· Engine: Stopped and remove connector
NO C (16P) from monitor.
Check for continuity be-
tween connector termi-
nal #13 and vehicle
frame.
NO
T5-5-20
Faulty hydraulic oil filter

restriction switch
Reconnect hydraulic Broken harness between Connector (Harness end connector terminals seen
YES
oil filter restriction monitor and hydraulic oil from the open end side)
switch. Check if indica- filter restriction switch
tor lights when monitor Monitor Connector C (16P)
connector C (16P)
terminal #14 is Faulty monitor Ș ȗ Ȗ ȕ Ȕ ȓ Ȓ ȑ
grounded to vehicle
NO ȑȖ ȑȕ ȑȔ ȑȓ ȑȒ ȑȑ ȑȐ ș
frame.
· Key switch: ON
· Without disconnect-
ing connector,
ground connector to
vehicle frame using
jumper wire such as
clip from reverse side
of connector. Burned indicator light
Faulty hydraulic oil filter

restriction switch
between monitor and hy-
draulic oil filter restriction
switch
Faulty monitor
T5-5-21
(Blank)
T5-5-22
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the 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 circuiting.
2. Color coding of wire harnesses. Code Color Code Color
The color codes of the wire harnesses in the R Red W White
electrical system are shown inn the table onn the L Blue G Green
right. Or Orange Lg Light green
In cases on the design sheet where two colors are Y Yellow B Black
indicated for one wire, the left initial stands for the Br Brown P Pink
base color, while the right initial stands for the
Gr Gray V Violet
marking color.
NOTE: 1) Code BW indicates a black base wire

with white fine-line marking.
Right Wrong
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.
T107-07-06-001
3. Precautions for connecting and disconnecting

terminal connectors.
1) When disconnecting harnesses, grasp them
by their connectors. Do not pull on the wire
itself. Be sure to release the lock first before
attempting to separate connectors, if a lock Right
is provided. (Refer to “Instructions for Rust
Disconnecting Connector” on page T5-6-3.)
Wrong
2) Water-resistant connectors keep water out (Deformation)
so that if water enters them, water will not
easily drain from them. When checking Wrong
(Separation)
water-resistant connectors, take extra care
not to allow water to enter the connectors. In T107-07-06-002
case water should enter the connectors,

reconnect only after the connectors are
thoroughly dried.
3) Before connecting terminal connectors,
check that no terminals are bent or coming
off. In addition, as most connectors are made
of brass, check that no terminals are rusting.
4) When connecting terminal connectors
provided with a lock, be sure to insert them
together until the lock “clicks.”
T5-6-1
4. Precaution for using a circuit tester.
1) Before using a circuit tester, refer to the
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object Wind a Piece of Wire Tester Probe
to be measured, voltage range and current
polarity.
2) Before starting the connector test, always
check the connector terminal numbers,
Sharpen the end of the Wire
referring to the circuit diagram. T107-07-06-003
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
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
• Push to Unlock and Separate Type
NOTE: Connectors will not be easily separated

even if the lock is pushed while being pulled.
Push the lock first before pulling the con-
nectors.
The lock is located on female side connec-
tor (harness end side). T107-04-05-002
Locations of This Type Connector

Fuel Gauge EC Motor Air Conditioner Radio
Hydraulic Oil Level Switch EC Sensor Alternator Speaker
Horn General Relay Diode Learning Switch
Cab Harness Buzzer Key Switch Wiper
Pressure Sensor Travel Mode Solenoid Valve Engine Control Dial Monitor
Washer
• Pull Up to Unlock and Separate Type
Locations of This Type Connector
T107-04-05-003
T107-04-05-004
T5-6-3
FUSE INSPECTION
Cracks in a fuse are so fine that it is very difficult or NOTE: All terminals located along the lengthwise
impossible to find by visual inspection. Use a tester to centerline of the fuse box are connected to
correctly inspect fuse continuity by following the in- the power source, while terminals located
structions described below. away from the center of the fuse box are
connected to loads (accessories). There-
1. Turn Key Switch ON fore, test all fuses in the same method ex-
When the key switch is turned ON, current from cept for the glow plug relay circuit fuse.
key switch terminal M activates the battery relay Check the glow plug relay circuit fuse with
so that electric power is supplied to all circuits ex- the key switch turned to the ON position
cept the glow plug relay circuit. (Refer to the cir- then follow the procedure in step 3.
cuit diagram.)
2. Remove the fuse box cover. Set the tester voltage 20 19 18 17 16 15 14 13 12 11
to meet the circuit specification to be measured.
(Measurement Range: 0 to 30 V)
3. Ground the negative probe of the tester to the ve-
hicle frame. Touch the terminals located away
from the center of the fuse box with the positive
probe of the tester one at a time. When normal
continuity of a fuse is intact, the tester will indicate
20 to 25 volts (battery voltage).
M1CC-01-007
10 9 8 7 6 5 4 3 2 1
Fuse Fuse
Capacity Connected to Capacity Connected to
No. No.
1 5A Radio, Monitor, ICX (Backup 11 20 A Work Light Relays 1 and 2
Power)
2 5A MC (Main Power) 12 10 A Wiper Relays A, Wiper Motor,
Washer Relay
3 10 A MC (EC Motor Power) 13 20 A Heater (Air Conditioner Unit)
4 10 A MC (Solenoid Valve Power) 14 10 A Horn Relay
5 5A Monitor 15 5A Radio
6 5A MC, ICX (Power ON Signal) 16 10 A Cigarette Lighter
7 5A Air Conditioner 17 5A Room Light
8 5A Optional 1 18 10 A Auxiliary
9 10 A Optional 2 19 5A Glow Relay
10 5A Optional 3 20 − Empty
T5-6-4
FUSIBLE LINK INSPECTION
Inspection
1. Remove the negative cable from the battery.

2. Loosen bolt M8 holding the cable routed in front of
the fusible link box to move the cable out of the
way of the front cover.
3. Open the fusible link box front cover and visually Fusible Link
inspect the fusible link. Box
Battery Relay
Cable
M8 Bolt
T107-04-02-006
Cover
Replacement
1. Check that the negative cable is removed from Fusible Link

the battery. T107-04-05-007
2. Remove bolt M8 to take the fusible link off the bat-
tery relay.
3. Open the upper and bottom side covers of the Battery
fusible link box. Remove two screws M6. Relay
Bolt M8
4. Take out the fusible link to replace it.
5. Retighten two screws M6.
6. Install the fusible link box and the cable to the bat-
tery relay.
7. Reconnect the negative cable to the battery.
Cable Screw M6
T107-04-05-008
T5-6-5
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between

the battery positive terminal and the vehicle
frame.
Normal Voltage: 24 V
NOTE: If voltage is abnormal, recharge or replace

the battery.
2. Start the engine. Check voltage between the

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

system.
T157-07-06-007
T5-6-6
HOW TO TROUBLESHOOT ALTERNATOR
MALFUNCTIONS
In general, the alternator indicator remains off when

the alternator is generating power.
If the alternator indicator comes on while the engine is
running, the alternator might be defective.
How to check the circuit
1. Stop the engine. Turn the key switch to the ON

position. Confirm that the alternator indicator
comes on.
2. Measure the voltage between the B and E

terminals of the alternator. If the measured E
voltage is around 24 V, the alternator circuit can
be considered normal. If the measured voltage
is low, a shortage in battery capacity or looseness
of the wire connectors of the alternator circuit
might be the cause of the malfunction. When the
voltage is 0 V, the wiring between the fuse box
B
and alternator might be loose or disconnected.
Also, the alternator cannot generate electricity if
the ground line is disconnected.
M197-07-072
3. Next, start the engine and measure the voltage
generated while as the alternator rotates.
As described above, measure the voltage
between terminals B and E on the side of the
alternator. If the voltage is around 28 V, the
alternator is operating normally.
If the rated voltage is not being generated, there is
some trouble with the alternator or the regulator.
T5-6-7
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
NOTE: When the one end connector is far apart

from the other, connect one end of Connect to A a
connector (A) to the machine chassis using the vehicle
a clip. Then, check continuity of the frame.
harness through the vehicle frame as
illustrated.
Connect to
Ω
the vehicle
If the ohm-meter reading is: 0 Ω = Continuity frame.
∞ Ω = Discontinuity
A a
Single-line short-circuit check
Disconnect both end connectors of the harness and × Short-circuit
check continuity between one end connector of the between the
harness and
harness and the vehicle frame: the vehicle
Ω frame.
If the ohm-meter reading is:
0 Ω = Short circuit is present.
∞ Ω = No short circuit is present.
T107-07-05-003
Multi-line continuity check
Disconnect both end connectors of the harness, and First short-circuit
short-circuit two terminals, (A) and (B), at one end
connector, as illustrated. Then, check continuity
between terminals (a) and (b) at the other connector. A a
If the ohm-meter reading is ∞ Ω, either line (A) - (a), B b
C c
or (B) - (b) is in discontinuity. To find out which line is
discontinued, conduct the single line continuity
Second short-circuit
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

T107-07-05-004
check twice, it is possible to find out which
line is discontinued. With terminals (A) and Short-circuit between harnesses.
(C) short-circuited, 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) or Ω
(C).
If the ohm-meter reading is:
0 Ω = Short-circuit exists between the lines.
T107-07-05-005
∞ Ω = No short-circuit exists between the lines.
T5-6-8
(Blank)
T5-6-9
VOLTAGE AND CURRENT MEASURE-
MENT
Turn key switch ON so that the specified voltage

(current) is supplied to the location to be measured.
Judge if the circuit is normal by evaluating whether the
measured voltage (current) matches the specification.
24-Volt Circuit
Start checking the circuit in order up to the loca-
tion to be measured from either power source or
actuator side. Thereby, the faulty location in the
circuit will be found.
Black Probe (Minus) of Tester: To ground to the vehi-
cle frame
Red Probe (Plus) of Tester : To touch the location
to be measured
Engine Key Location to be Measured Specification
Switch
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 Batteries 20 to 25 V
Stopped OFF Between (4) and Ground: Battery Power 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link 20 to 25 V
Stopped OFF Between (1) and Ground: Backup Current* 6 mA
Preheat Circuit
Stopped HEAT Between (6) and Ground: Key Switch 20 to 25 V
Stopped HEAT Between (7) and Ground: Glow Plug 20 to 25 V
Starting Circuit
Started START Between (8) and Ground: Key Switch 20 to 25 V
Started ON Between (9) and Ground: Battery Relay (Coil) 20 to 25 V
Started ON Between (10) and Ground: Battery Relay (Switch) 20 to 25 V
Started ON Between (11) and Ground: Starter (B) 20 to 25 V
Started START Between (12) and Ground: Starter Relay (S) 20 to 25 V
Charging Circuit
Fast Speed ON Between (13) and Ground: Alternator Generating Voltage (B) 26 to 30 V
Fast Speed ON Between (10) and Ground: Battery Relay (A) / Generating Voltage 26 to 30 V
Fast Speed ON Between (14) and Ground: Fuse Box Generating Voltage 26 to 30 V
Fast Speed ON Between (15) and Ground: Starter Relay (R) Generating Voltage 13 to 15 V
Fast Speed ON Between (16) and Ground: Monitor 13 to 15 V
Surge Voltage
Prevention Circuit
Slow Idling ON Between (13) and Ground: Alternator (B) 26 to 30 V
Slow Idling ON Between (15) and Ground: Starter Relay (R) 13 to 15 V
Slow Idling ON Between (17) and Ground: Load Damp Relay 26 to 30 V
Slow Idling ON Between (10) and Ground: Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (18) and Ground: Horn 20 to 25 V
Stopped ON Between (19) and Ground: Radio 20 to 25 V
Stopped ON Between (20) and Ground: Ciger Lighter 20 to 25 V
Stopped ON Between (21) and Ground: Room Light 20 to 25 V
Stopped ON Between (22) and Ground: Auxiliary 20 to 25 V
*Measure after disconnecting the negative cable from the battery.
T5-6-10
Key Switch
Battery
1 2 3 5 4 9 10 14
6 8
Battery Relay
Starter Load
Dump Fuse
B box
Relay
C
11 17
S
18
22
E
19 21
12
Starter Relay R
20
15
Alternator
Glow
B Plug Relay
13
L
7
Glow Plug
Monitor
A2
16
T1CC-05-06-001
T5-6-11
5 Volt Circuit
Signal or
• Voltage between terminal No.1 and the vehicle Two polarities Power source ground
frame (ground) 1 2
With the key switch turned OFF, disconnect the
sensor connector.
Measure the voltage between terminal No.1 on the
machine harness side connector and the vehicle
(ground) under the following conditions.
V
• Key switch position: ON
• Tester black terminal (negative):
Connected to the vehicle (ground)
• Tester red terminal (positive):
T107-07-05-006
Connected to terminal No.1
Three polarities Power source Signal Ground
Evaluation: 1 2 3
If the measuring voltage is within 5±0.5 volts, the
circuit up to terminal No.1 is normal.
• Voltage between terminal No.1 and the ground T107-07-05-007
terminal
With the key switch turned OFF, disconnect the Two polarities
1 2
sensor connector.
Measure the voltage between terminal No.1 on the
machine harness side connector and the ground
terminal (terminal No.2 for two polarities, or terminal
No.3 for three polarities) under the following V
conditions.
• Key switch position: ON

• Tester black terminal (negative):
Connected to the ground terminal
(terminal No.2 or 3) T107-07-05-008
• Tester red terminal (positive):
Connected to terminal No.1 Three polarities
1 2 3
Evaluation:
If the measuring voltage is within 5±0.5 volts, the
circuit up to terminal No.1 or the ground terminal is
normal.
V
T107-07-05-009
T5-6-12
CHECK BY FALSE SIGNAL
Tow-Polarities
Turn the key switch OFF. After disconnecting the sen- (Pressure Sensor)
sor connector, turn the key switch ON. Then, connect 1 2
machine side harness end connector terminal #1
(power) to terminal #2 (signal). (Power voltage is used
as a false signal.) Check the controller using Dr. EX
monitor function under this condition. When the maxi-
mum value is displayed, the MC and the circuit up to
the machine side harness end connector are normal.
When the pressure switch circuits are normal, Dr. EX Connect
displays “ON.”
IMPORTANT: Don’t connect terminal #1 or #2 to

terminal #3 or to the vehicle frame Three Polarities
T107-07-05-010
(ground) when checking a three-

polarity connector. (Pressure Sensor)
(EC Sensor)
1 2 3
NOTE: Some kinds of sensors can be monitored
by the built-in diagnosing system. (Refer to
the TROUBLESHOOTING / General
group.)
Connect
T107-07-05-011
T5-6-13
TEST HARNESS
With a test harness installed between connectors, the

circuit condition is checked depending on whether the
test harness lamp lights or extinguishes during opera-
tion.
Parts Number 4283594 (ST 7126)

Use to check a single-line (discontinuity and/or volt-
age).
During Operation: Lamp is ON.
To Location to be Measured.
To Ground
T107-07-05-012

Use to check the EC motor circuit.
5
(Refer to T5-4-18.)
6
50
• EC Motor Circuit
1 2 2 1
When the engine control dial is rotated: 150 50
50
Both lamps ON: Normal 4 3 4 3
Only one lamp ON: Check for continuity of the cir- 7 50
cuit connected to the lamp OFF. 8
Both lamps OFF: Check the harness together with
the relay.
T107-07-06-024
Parts Number 4284347 (ST 7129) (Red)

Use to measure the EC sensor circuit signal line volt-
age (between terminals #2 and #3).
(Black)
Parts Number 4284347 (ST 7129) T107-07-03-009
T5-6-14
TROUBLESHOOTING / ICX
OUTLINE
The ICX (information controller) stores signals from

various kinds of sensors and switches provided on the
machine as data. The various input signals are
grouped into “Daily Report Data List”, “Frequency Dis-
tribution Data List”, “Cumulative Operation Hour List”,
“Alarm List”, and “Trouble List” and are recorded in the
ICX.
The machine equipped with the optional satellite termi-

nal which will send the data to the center server via the
satellite communication system. (Refer to T5-7-35 for
the satellite communication system.)
T5-7-1
Daily Report Data List
Data Details
1 Key Switch ON Time Time when key switch is first turned ON during daily operation
(Time is recorded by key switch ON signal.)
2 Key Switch OFF Time Time when key switch is last turned OFF during daily operation
(Time is recorded by key switch ON signal.)
3 Engine Start Time Time when engine is first started during daily operation
(Time is recorded by alternator output signal.)
4 Engine Stop Time Time when engine is last stopped during daily operation
(Time is recorded by alternator output signal.)
5 Hour Meter Hour meter cumulative hours
(Hours are recorded by hour meter signal from monitor.)
6 Remaining fuel level Remaining fuel level at the end of daily operation (Level is re-
corded by fuel sensor signal from monitor.)
7 Engine Operating Hours Total engine operating hours during daily operation
(Hours are recorded by alternator output signal.)
8 Travel Operating Hours Total travel operating hours during daily operation
(Hours are recorded by signals from travel pressure sensor.)
9 Front Attachment Operating Hours Total front attachment operating hours during daily operation
(Hours are recorded by signals from front attachment pressure
sensor.)
10 *ML Operating Hours Total *ML crane operating hours during daily operation
(Hours are recorded by signals from crane mode switch.)
11 Engine Operating Hour Distribution Engine operating hour distribution during daily operation
(Operating hours are recorded only when alternator output signal
is continuously delivered for more than 10 minutes.)
NOTE: The daily operation in this table is equiva-

lent to the hours between 0:00 and
23:59:59 counted by the ICX built-in clock.
In case the engine is kept operated beyond
0:00, such data are recorded as those for
the following day.
* ML/ML crane specification is only avail-

able in Japanese domestic market.
T5-7-2
Frequency Distribution Data List
Data Details
1 Coolant Temperature in Radiator Frequency distribution of coolant temperature
(Temperatures are recorded by signals from coolant temperature
sensor.)
Cumulative Operation Hour List
Data Details
1 Engine Operation Hour Cumulative engine operation hours
(Hours are recorded by alternator output signal.)
2 Travel Operation Hour Cumulative travel operation hours
(Hours are recorded by signals from travel pressure sensor.)
3 Front Attachment Operation Hour Cumulative front attachment operation hours
(Hours are recorded by signals from front attachment pressure
sensor.)
4 *ML Operation Hour Cumulative *ML operation hours
(Hours are recorded by signals from crane mode switch.)
NOTE: ML specification is only available in Japa-

T5-7-3
Alarm List
Code Data Details

86 Hydraulic Oil Filter Date and time when hydraulic oil filter indicator lighted are recorded
by signals from hydraulic oil filter restriction switch.
89 Overheat Date and time when overheat indicator lighted are recorded by sig-
nals from overheat switch.
90 Engine Oil Pressure Date and time when engine oil pressure indicator lighted are re-
corded by signals from engine oil pressure switch.
93 Air Filter Restriction Date and time when air filter restriction indicator lighted are recorded
by signals from air filter restriction switch.
94 Alternator Indicator Date and time when alternator indicator lighted are recorded by sig-
nals from monitor controller.
NOTE: In case the above alarms are recorded,

check individual item. If malfunction of the
monitor is found, refer to troubleshooting C.
T5-7-4
Trouble List
Fault
Trouble Details
Code
01 Abnormal EEPROM Occurrence time and date of fault code 01
02 Abnormal RAM Occurrence time and date of fault code 02
03 Abnormal A/D Conversion Occurrence time and date of fault code 03
04 Abnormal Sensor Voltage Occurrence time and date of fault code 04
06 Abnormal EC Sensor Occurrence time and date of fault code 06
07 Abnormal Engine Control Dial Occurrence time and date of fault code 07
18 Abnormal Travel Lever Stroke Occurrence time and date of fault code 18
64 MC Communication Error Time and date when communication error between MC
and ICX occurred.
65 Monitor Communication Error Time and date when communication error between moni-
tor and ICX occurred.
66 Satellite Terminal Communication Error Time and date when communication error between satel-
lite terminal and ICX occurred.
NOTE: In case the above fault codes are recorded,

refer to troubleshooting A.
T5-7-5
ICX FAULT CODE LIST
Fault
Trouble Remarks
Code
1 Abnormal Internal Ram In case of SAM error
2 Abnormal Flush Memory In case of SAM error
3 Abnormal Exterior In case of SAM error or read-write error
4 Abnormal EEPROM In case of SAM error
5 Overwritten Data Save Area In case data save area was overwritten.
6 Abnormal Time In case RTC data was other than figures.
7 MC Communication Timeout In case MC communication lasted for less than 100 ms.
8 Monitor Communication Timeout In case monitor communication didn’t last for more than
12 seconds.
9* MC Communication Timeout In case MC communication didn’t last for more than 20
seconds.
10 Satellite Terminal Communication Timeout In case satellite communication didn’t last for more than
20 seconds.
NOTE: *Fault code 9 may be displayed on only the

machine to which the ICX is installed later.
SATELLITE TERMINAL FAULT CODE LIST
Fault
Trouble Remarks
Code
101 Satellite Terminal: Internal Error Abnormal EEPROM
102 Satellite Terminal: Internal Error Abnormal sent data
103 Satellite Terminal: Internal Error In case reception is difficult.
104 Satellite Terminal: Communication Error In case satellite communication cannot be accomplished.
105 Satellite Terminal: Internal Error In case sending retry over occurred or local loop back
test failed with power ON.
106 Satellite Terminal: Communication Error In case sending retry over occurred.
107 Satellite Terminal: Abnormal Harness In case reception data doesn’t match sending data.
T5-7-6
FAULT CODE 1 TO 6
YES Faulty ICX
Check if all data are normally

cumulated.
Faulty ICX
NO
· Refer to T5-7-10 for replacing
*even if the fault code remains displayed after retrying, ICX.
the machine can be operated as it is when data rec-
ord is normally cumulated.
FAULT CODE 7 TO 10
YES Faulty ICX
Check for continuity between · Refer to T5-7-10 for replacing

ICX and corresponding com- ICX.
ponent while referring to the
following table.
Broken harness between ICX
and corresponding compo-
NO nent
Fault Code ICX terminal # Corresponding component terminal #

7 Connector C terminal #11 MC connector D terminal #10
8 Connector C terminal #1 Monitor connector B terminal #3
10 Connector B terminal #5 Satellite terminal #2
T5-7-7
SOME PARTS OF DATA IN DAILY REPORT,
FREQUENCY DISTRIBUTION, CUMULA-
TIVE OPERATION HOURS ARE NOT RE-
CORDED
• All necessary data signals may not be input into

the ICX. Individual signals are utilized to record
more than one data. While referring to the table
below, check the corresponding system for any
abnormality.
Related Data Input Signal

Key switch ON and OFF time Key switch
Engine start and stop time, Engine operating hours (Daily report and cumu- Alternator
lative operation hour), Engine operating hour distribution
Hour meter Monitor controller
Coolant temperature distribution in radiator Coolant temperature sensor
Remaining fuel level (detected at regular data sending time) Fuel level sensor
Travel operating hours (Daily report and cumulative operation hour), Aver- Travel pressure sensor
age pump delivery pressure distribution in travel operation
Front attachment operating hours (Daily report and cumulative operation Front attachment pressure sensor
hour)
*ML operating hours (Daily report and cumulative operation hour) Crane mode switch
NOTE: *ML specification is available only in Japa-

T5-7-8
Corrective Action Remarks

Check harness between ICX terminal A5 and key In case engine doesn’t start, refer to troubleshooting B.
switch terminal M.
Check harness between ICX terminal A2 and alternator In case alternator indicator malfunctions, refer to trou-
terminal L. bleshooting C.
Check harness between ICX terminal B1 and monitor In case hour meter malfunctions, refer to troubleshoot-
terminal B3. ing C.
Check harness between ICX terminal B1 and monitor In case coolant temperature gauge malfunctions, refer
terminal B3. to troubleshooting C.
Check harness between ICX terminal B1 and monitor In case fuel gauge malfunctions, refer to troubleshoot-
terminal B3. ing C.
Check harness between ICX terminal C11 and MC ter- In case machine control system malfunctions, refer to
minal D10. troubleshooting B.
T5-7-9
TROUBLESHOOTING AND SETTING OF
ICX AND SATELLITE TERMINAL USING
DR.EX
Troubleshooting of ICX can be performed using Dr. EX.

Before starting satellite communication, or after replac-
ing the satellite terminal and/or the ICX, initial setting of
the ICX must be conducted as described in the follow-
ing page using Dr. EX.
ICX initial setting

ICX Enter Enter Enter time Internal Satellite Enter
diagnosis model date difference hour terminal gateway
and and time between meter diagnosis control
serial the local time setting center
No. and UTC ID No.
Dr. EX Work No. 2 3-1 3-2 3-3 3-4 4 5-1
ICX setting/confirmation
• • • • • •
after ICX replacement
• • • • • • •
• • • • • •
when battery is installed
Satellite terminal set-

ting/confirmation • • • • • •
Satellite terminal set-
ting/confirmation after
satellite terminal re-
placement
• • • • • •
ICX and satellite termi-
nal/confirmation after
ICX and satellite terminal
replacement
• • • • • • •
NOTE: When required to conduct both Dr. EX
Work No. 5-6 and 5-7, conduct these steps
in the order of Dr. EX work No. 5-6 and 5-7
after completing all other steps described in
the table.
Don’t conduct step Dr. EX work No. 3-4 un-
less the ICX is replaced.
• :Work to be done.
T5-7-10
Satellite terminal initial setting Remarks

Enter Mail Satellite Satellite Satellite Satellite
geodetic switch terminal communication terminal communication
system con- No. con- line inbound-cue start/stop
firmation firmation confirmation initialization setting
5-2 5-3 5-4 5-5 5-6 5-7
• • • • • • Should be done during

delivery to customer
If ICX has been re-
placed, ICX setting and
• • • • • • confirmation are re-

quired even when satel-
lite communication is
not made.
• • • • • •
For details, see the
service bulletin. (No.
Dr. EX-018)
• • • • • • Should be done during

delivery to customer.
• • • • • •
• • • • • •
T5-7-11
1. Basic Operation of Dr. EX for Diagnosing and
Setting The ICX and Satellite Terminal
1-1 Starting Dr. EX

Rear Console
IMPORTANT: Setting the ICX and satellite terminal
should be done while the engine
stopped.
(1) Turn on the key (do not start the engine).
(2) Connect the Dr. EX connector (For ICX) located at
left side of the rear console
(3) Start Dr. EX program. When the Model Menu is
displayed, select "ICX1-E".
<< Model Menu >> (S01)

1.ICX1-E Ver 2.00 Select
2.
3. T1CC-01-02-006
4.
5.
Select number
F3: Next↓ V1.00
(4) ICX1-E version display screen

Press F1. The screen will change to the "Function
Selection".
ICX Controller
• C/U Software Revision

Ver 2.00
F1: Next F10: Escape
(5) Function Selection screen

The Function Selection screen consists of 3 Dr.EX Connector T1CD-01-02-009
(For ICX)
pages. Each screen below appears by pressing
F3 and F4.
Select Function Select Function

F5: F5: Satellite Terminal No.
F6: ICX Initial Setting F3 F6: ICX Diagnosis
F7: Mail Switch Confirmation F7: Satellite Terminal Diagnosis
F3: Next↓ F10: Escape F3: Next↓ F4: Previous↑ F10: Escape
F3
Select Function
F5: Satellite Comm. Line Confirmation
F6: Satellite Terminal Inbound-Cue Init
F7: Satellite Comm. Start/Stop Set
F4: Previous↑ F10: Escape
T5-7-12
1-2 Stopping Dr. EX
(1) Press F10: Escape several times to change the Rear Console
screen to the Function Selection.
F10: Escape
Select Function
F5:
F6: ICX Initial Setting
F7: Mail Switch Confirmation
F3: Next↓ F10: Escape

T1CC-01-02-006
(2) Turn off the Dr. EX power switch.

(3) Disconnect the Dr. EX cable from Dr. EX connec-
tor (For ICX) located at left side of the rear con-
sole.
(4) Turn off the key.
2. ICX Diagnosis
NOTE: Wait one minute or more after turning the
key switch on.
(1) Select ICX Diagnosis on the Function Selection
screen.
Confirm the message: "No trouble exists".
If any trouble exists, refer to page T5-7-6.
Dr.EX Connector T1CD-01-02-009

(For ICX)

F5: F5: Satellite Terminal No. Confirmation
F6: ICX Initial Setting F3 F6: ICX Diagnosis Select
T5-7-13
3. ICX Initial Setting
3-1 Enter Model and Serial Number
(1) Select ICX Initial Setting on the Function Selection

screen.
Select Function
F5:
F6: ICX Initial Setting Select
(2) Select Enter Model and Serial No. on the Function

Selection screen
Select Function
F5: Enter Model and Serial No. Select
F6: Enter Date and Time
F7: Enter Time Difference from UTC
(3) Confirm that the model and serial number on the

machine nameplate and those displayed on the Dr.
EX screen are identical.
Example:When the nameplate shows 1S1P060001, Dr.

EX displays: Model: 01S1, Serial No.:
060001
Model and Serial No.
• Model: 01S1
• Serial No.: 060001
F1: Correct F10: Escape
T5-7-14
(4) If the model and serial number displayed on Dr.
EX are incorrect, correct them.
(Use F1, F2, F4 or F5 to move the inverted display
portion. Press ENT to set characters at the in-
verted display portion.)
NOTE: When the model is 1S1, enter 4-digit char-
acters or 01S1 on the screen.
Model and Serial No. Enter Model

• Model: ∗∗∗∗ • Model: ∗∗∗∗
• Serial No.: ∗∗∗∗∗∗ F1 ABCDEFGHIJKLMNOPQRSTUVWXYZ

0123456789→←
F1: ↑ F2: ↓ F4: ← F5: →

F1: Correct F10: Escape ENT: Input
Enter the model on the nameplate.
NOTE: When the serial number is

60001, enter 6-digit nu-
merical figure or 060001.
Enter Model Enter Serial No.
• Model: ∗∗∗∗ • Serial No.: ∗∗∗∗∗∗
F1 ENT
F1: OK F2: NG F10: Escape ENT: Confirm

Press F1 if the entered data is correct. Enter the model on the nameplate.
Enter Serial No.

• Serial No.: ∗∗∗∗∗∗
F1 Setting has been completed F10
F1: OK F2: NG F10: Escape F10: Escape
Press F1 if the entered data is correct.
Model and Serial No.

• Model: ∗∗∗∗
• Serial No.: ∗∗∗∗∗∗
Reconfirm that the model and serial

number displayed on the screen agree
with those on the nameplate.
T5-7-15
3-2 Enter Date and Time
(1) Select ICX Initial Setting on the Function Selection (4) If the local year/month/date data are incorrect or, if
screen. the time inaccuracy is more than 5 minutes, key in
the correct year, month, date and time. (Key in by
Select Function selecting the keys from 0 through 9 on Dr. EX.)
F5:
F6: ICX Initial Setting Select Date, Time

• Local Time
F7: Mail Switch Confirmation YY MM DD : 2000/06/01
Time : 09:00:00
F3: Next↓ F10: Escape • UTC
YY MM DD : 2000/06/01
Time : 00:00:00
(2) Select Enter Date and Time on the Function Se-
lection screen below.
F1
Select Function
F5: Enter Model and Serial No. Date, Time
• Local Time
F6: Enter Date and Time Select YY MM DD : 2000/06/01
Time : 10:00:00

ENT: Confirm
Determine the current date

and time by pressing ENT. ENT
(3) Confirm the current date and time.
NOTE: The local time of 13:27:53 is equivalent to
13 hours, 27 minutes and 53 seconds. Date, Time
• Local Time
YY MM DD : 2000/06/01
Time : 10:00:00
Date, Time • UTC
• Local Time YY MM DD : 2000/06/01
YY MM DD : 2000/06/01 Time : 01:00:00
Time : 13:27:53 F1: OK F2: NG F10: Escape
• UTC
YY MM DD : 2000/06/01
Time : 04:27:53 F1
If the local year/month/date data are correct and the

time inaccuracy is between 5 minutes, press F10.
Setting has been completed
F10: Escape
F10
Date, Time
• Local Time
YY MM DD : 2000/06/01
Time : 10:00:00
• UTC
YY MM DD : 2000/06/01
Time : 01:00:00
Reconfirm that the local day,

month, year and time data are
correct.
T5-7-16
3-3 Enter time difference from UTC
(1) Select ICX Initial Setting on the Function Selection (4) If the time difference between the local time and
screen. UTC is incorrect, enter the correct time difference.
Enter Time Difference

Select Function
F5: Time Difference: +0900
(Japan: +0900)

F1
(2) Select Enter Time Difference from UTC on the
Function Selection screen.
Select Function Time Difference: +0900
F5: Enter Model and Serial No. (Japan: +0900)
F1: Previous↑ F2: Next↓
F7: Enter Time Difference from UTC Select F3: Confirm F10: Escape
F3: Next↓ F10: Escape Pressing F1 and F2 changes Ex: Press
the time difference in units of F1 twice
30 minutes.
(3) Confirm the time difference between the local time
of the area in where the machine is operating and Enter Time Difference
UTC. Time Difference: +0900
Example:In case of Japan, time difference is displayed (Japan: +0900)
as +0900.
Enter Time Difference F3: Confirm F10: Escape
Time Difference: +0900

(Japan: +0900) F3
F10: Escape
F10
Time Difference: +0900

(Japan: +0900)
Reconfirm the time difference

is correct.
T5-7-17
3-4 Internal hour meter setting
key switch on.
(1) Select ICX Initial Setting on the Function Selection

screen.
Select Function
F5:
(2) Select Internal Hour Meter Setting.

F5: Enter Model and Serial No. F5: Internal Hour Meter Setting Select
F6: Enter Date and Time F3 F6: Enter Gateway

Control Center ID No.
F7: Enter Time Difference from UTC F7: Enter Operation Start Time
(3) Press F1 to set hour.
Hour Meter
• ICX Internal Hour Meter To the next step
00000.00
• External Hour Meter F1 Setting has been completed
00100.00
F1: Set F10: Escape F10: Escape
(4) Confirm that the ICX internal hour displayed and

the external hour displayed are identical.
Hour Meter
• ICX Internal Hour Meter
00100.00
• External Hour Meter
00100.00
F1: Set F10: Escape
T5-7-18
4. Satellite Terminal Diagnosis
key switch on.
(1) Select Satellite Terminal Diagnosis on the Func-

tion Selection screen.
Confirm the message: "No trouble exists".
If any trouble exists, refer to page T5-7-6.

F7: Mail Switch Confirmation F7: Satellite Terminal Diagnosis Select
T5-7-19
5. Satellite Terminal Initial Setting
(4) If the gateway control center ID No. is incorrect,
5-1 Enter gateway control center ID No. enter the correct data.
(The gateway control center ID No. must be checked
since the ORBCOMM satellite base station ID is dif-
ferent depending on region.) Gateway Control Center
GCC ID:
(1) Select ICX Initial Setting on the Function Selection Japan
screen.
Select Function F1: Correct F10: Escape

F5:
F6: ICX Initial Setting Select F1
F3: Next↓ F10: Escape Gateway Control Center
GCC ID:
Japan
(2) Select Gateway Control Center ID No.
F2: Next↓
Select Function F1: Correct F10: Escape
F5: Enter Model and Serial No.
Press F2 until the correct Ex: Press
F6: Enter Date and Time gateway control center ID is F2 once.
displayed.
Gateway Control Center
GCC ID:
F3 USA
Select Function
F5: Internal Hour Meter Setting F1: Previous↑ F2: Next↓
F3: Confirm F10: Escape
F6: Enter Gateway Select
F7: Enter Operation Start Time F3
F3: Next↓ F4: Previous↑ F10: Escape
(3) Confirm that the correct gateway control center ID Setting has been completed
No. is correct.
NOTE: Since there is no gateway control center in
some regions, contact Hitachi Construction F10: Escape
Machinery Co. Ltd. International Product
Support department for details. F10

GCC ID:
Japan GCC ID:
USA

Reconfirm that the gateway

control center ID is correct.
T5-7-20
5-2 Enter Geodetic System
(The geodetic system must be checked since the (4) If the geodetic system data is incorrect, enter the
GPS geodetic system is different depending region.) correct data.
(1) Select ICX Initial Setting on the Function Selection GPS Datum Table
screen.
Coordinate System:
Select Function WGS84
F5:
F6: ICX Initial Setting Select F1: Correct F10: Escape

F3: Next↓ F10: Escape F1
(2) Select GPS Geodetic System. GPS Datum Table
Select Function Coordinate System:

F5: Enter Model and Serial No. WGS84

F2: Next↓
F7: Enter Time Difference from UTC F1: Confirm F10: Escape
F3: Next↓ F10: Escape Press F2 until the correct Ex: Press
GPS geodetic system is F2 twice.
displayed.
F3
Select Function GPS Datum Table

F5: Internal Hour Meter Setting
Coordinate System:
F6: Enter Gateway ADINDAN
F7: Enter Operation Start Time
F3: Next↓ F4: Previous↑ F10: Escape F3: Confirm F10: Escape
F3 F3
Select Function
F5: Enter Controller Type
F6: Enter Downloaded

Operator's Name
F7: Enter GPS Geodetic System Select

F10: Escape
(3) Confirm that the GPS geodetic system data is cor-

F10
rect.
NOTE: Since GPS geodetic system is different de-
pending on region and map software, con- GPS Datum Table
tact Hitachi Construction Machinery Co. Ltd. Coordinate System:
International Product Support department ADINDAN
for details.
GPS Datum Table F1: Correct F10: Escape

Coordinate System:
Reconfirm that the GPS
TOKYO
geodetic system
data is correct.
T5-7-21
5-3 Mail Switch Confirmation
(1) Select Mail Switch Confirmation on the Function
Selection screen.
Select Function
F5:
F6: ICX Initial Setting
F7: Mail Switch Confirmation Select
(2) Mail switch status confirmation
Mail Switch Status Display
Mail Switch: ON OFF
F1: HOLD F10: Escape
Turn on and off the mail switch to

confirm that character color
(black/while) changes according to
the switch status.
T5-7-22
5-4 Satellite terminal number
(1) Select Satellite Terminal No. on the Function Se-
lection screen.

F5: F5: Satellite Terminal No. Confirmation Select
(2) Confirm that the serial number and the satellite

communication contract number are identical.
Satellite Terminal No. Confirmation
Serial No.: 8GBDA701086
F10: Escape
T5-7-23
5-5 Satellite communication line confirmation
NOTE: Do not perform this work at places out of
the range of satellite electric wave, such as
inside the house, tunnel, etc.
(1) Select Satellite Communication Line Confirmation

on the Function Selection screen.

F3
Select Function
F5: Satellite Communication Select
Line Confirmation
(2) Confirm the satellite communication line status.

NOTE: Identify the cause if both of the GPS and
rod antenna statuses are NG after 5 min-
utes.
However, it may take time to become OK
depending on the place or time zone since
satellite is always moving.
Satellite Communication Line Display
GPS Antenna: OK NG
Rod Antenna: OK NG
F1: HOLD F10: Escape
Confirm that GPS antenna and rod

antenna become OK.
T5-7-24
5-6 Satellite terminal inbound-cue initialization
(1) Select Satellite Terminal Inbound-Cue Initialization
on the Function Selection screen.

F6: INX Initial Setting F3 F6: ICX Diagnosis
F3
Select Function
F5: Satellite Communication
Line Confirmation
F6: Satellite Terminal Inbound-Cue Init Select
(2) Initialization processing
Press F1 to initialize all data. F1 Wait. Initializing
F1: Initialize F10: Escape
Initialization has been completed
F10: Escape
T5-7-25
5-7 Satellite communication start/stop setting
(1) Select Satellite Comm. Start/Stop Set on the
Function Selection screen.
F3
Select Function
F5: Satellite Comm. Line Confirmation
F7: Satellite Comm. Start/Stop Set Select
(2) Satellite communication start/stop setting

When setting Satellite Communication Start:
Satellite Communication Start/Stop Satellite Communication Start/Stop
Sate. Comm.: Start Stop Sate. Comm.: Start Stop

F1
F4:← F5: →
F1: Correct F10: Escape ENT: Confirm
Press F4 and F5 to move the ENT
cursor to "Start", then press
ENT.
Satellite Communication Start/Stop
Sate. Comm.: Start Stop

Setting has been completed F1
F10: Escape F1: OK F2: NG F10: Escape
When setting Satellite Communication Stop:

Satellite Communication Start/Stop Satellite Communication Start/Stop
Sate. Comm.: Start Stop Sate. Comm.: Start Stop

F1
F4:← F5: →
F1: Correct F10: Escape ENT: Confirm
Press F4 and F5 to move the ENT
cursor to "Stop", then press
ENT.
Satellite Communication Start/Stop
Sate. Comm.: Start Stop

Setting has been completed F1
F10: Escape F1: OK F2: NG F10: Escape
T5-7-26
SATELLITE COMMUNICATION SYSTEM
The satellite communication system is used for the GPS Antenna

maintenance of the machine by transmitting various
data of the machine regularly via a low earth orbit sat- Communication
Antenna
ellite.
NOTE: Since the satellite communication system is

available depending on region, contact Hi-
tachi Construction Machinery Co. Ltd. In-
ternational Product Support department for
details.
Depending on the circumstances of the
machine (ex. in the constructions, in the
tunnel, affected by the surrounding building
and affected of noise), the data transfer
rate may become slower, or the communi- M1CC-01-035
cation might not be established.

Also, the satellite communication system
using a low earth orbit satellite transmits
digital data through the radio wave. If there
is excessively noise or use of electrical
equipment which caused noise placed near Mail Switch
the machine, they cause reduces data
transfer rate or communication might not be
established at worst. Operator Seat
The satellite communication system is composed of:

Satellite terminal, GPS antenna, communication an-
tenna and mail switch. The functions of each equip-
ment are:
M1CC-01-015
• Satellite Terminal
It receives the data from ICX, GPS antenna and
mail switch, and send the data to the communica- Rear Console
tion antenna.
• GPS Antenna
It receives the location information of the machine
from a low earth orbit satellite.
• Communication Antenna
It communicates the data with a low earth orbit
satellite.
• Mail Switch
It sends date and time information, latest location
of the machine and the fuel level (%) when the
switch is pressed. Satellite T1CC-01-02-006
Terminal
T5-7-27
On the machine equipped with the satellite communi-
cation system, the data are sent according to the con-
dition as follows:
Kinds of data sent from the machine by satellite com-

munication:
Items Kinds of Data Condition
Periodical Operation Record, Latest Location Infor- The data are transmitted once every day.
Transmission mation, Fuel Level To avoid congested traffic in the commu-
nication line, the data is transmitted ran-
domly between 0:00 and 02:00.
Transmitting Data at Latest Location Information The data is transmitted only when the
Engine Start machine is moved more than 5 km from
the place where it is recorded lastly.
Emergency Alarm and Error Information The transmission starts immediately
Transmission when the alarm and error occurs.
Hour Meter 100 Hours Frequency Distribution Information The data is transmitted when the hour
Transmission meter exceeds every 100 hours.
Transmission by Mail Date and time when the switch is pressed, The transmission starts immediately
Switch Latest location of the machine, Fuel level when the mail switch is pressed.
T5-7-28
MEMO
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162
SERVICE MANUAL REVISION REQUEST FORM
NAME OF COMPANY: MODEL:

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

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

THE ATTACHED DIAGRAM LIST
(The following diagrams are attached to this manual.)
ZAXIS70/70LC HYDRAULIC CIRCUIT DIAGRAM
ZAXIS70/70LC ELECTRICAL CIRCUIT DIAGRAM (1)
ZAXIS70/70LC ELECTRICAL CIRCUIT DIAGRAM (2)
ZAXIS70/70LC ENGINE HARNESS
ZAXIS70/70LC CAB HARNESS
ZAXIS70/70LC MONITOR HARNESS

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INTRODUCTION

• Each page has a number, located on the center

Consecutive Page Number for Each Group

In this manual, the following safety alert symbol and • CAUTION:

• This is the SAFETY ALERT SYMBOL.

• When you see this symbol on your machine or in

UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating

• DANGER indicates an imminently hazardous

• WARNING indicates a potentially hazardous

• CAUTION indicates a potentially hazardous

• DANGER or WARNING safety signs are located

• Some safety signs don’t use any of the SA-1223

• CAUTION also calls attention to safety messages in

• To avoid confusing machine protection with personal

• NOTE indicates an additional explanation for an

• Carefully read and follow all safety signs on the ma-

• Safety signs should be installed, maintained and re-

• If a safety sign or this manual is damaged or miss-

• Learn how to operate the machine and its controls

• Allow only trained, qualified, authorized personnel to

• Keep your machine in proper working condition.

• Unauthorized modifications of the machine may

• The safety messages in this SAFETY chapter are

PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.

lance service, hospital, and fire department

• Wear close fitting clothing and safety equipment

You may need:

• Avoid wearing loose clothing, jewelry, or other

• Operating equipment safely requires the full

PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause

• Wear a suitable hearing protective device such as

• Inspect your machine carefully each day or shift by

• In the walk-around inspection be sure to cover all

• Before entering the cab, thoroughly remove all dirt

• Don’t leave parts and/or tools lying around the op-

• Avoid storing transparent bottles in the cab. Don’t

• Refrain from listening to the radio, or using music

• Keep all flammable objects and/or explosives

• After using the ashtray, always cover it to extin-

• Don’t leave cigarette lighters in the cab. When the

• Falling is one of the major causes of personal injury.

• When you mounting and dismounting the ma-

• Do not use any controls as hand-holds.

• Never jump on or off the machine. Never mount or

ADJUST THE OPERATOR'S SEAT

• A poorly adjusted seat for either the operator or for

• The seat should be adjusted whenever changing

• If the machine should overturn, the operator may

• Prior to operating the machine, thoroughly

MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.

• Take extra care not to run over bystanders.

• Inappropriate engine starting procedures may cause

• Start the engine only when seated in the

• Battery gas can explode, resulting in serious injury.

• If the engine must be jump started, be sure to

• Riders on machine are subject to injury such as

• Only the operator should be on the machine.

PROVIDE SIGNALS FOR FOBS INVOLV-