47.

TROUBLESHOOTING
(BY TROUBLE)
TABLE OF CONTENTS

47.1 HYDRAULIC SYSTEM ....................................................................................................47-3

47.2 ELECTRIC SYSTEMS .....................................................................................................47-27
47.2.1 WIRING CHECKING PROCEDURE ......................................................................47-27
47.2.2 TROUBLE...............................................................................................................47-30
47.3 ENGINE RELATED TROUBLESHOOTING ....................................................................47-33

47

Book Code No. S5LC4711E02

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47. TROUBLESHOOTING (BY TROUBLE)

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC4711E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)
S5LC4711E02
Revision February, 2007 ↑ K
(ASIA, OCE)

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 47. TROUBLESHOOTING (BY TROUBLE)

47.1 HYDRAULIC SYSTEM

Preface:
The troubleshooting for the failures shown below is explained here.
Identify the failure and trouble and carry forward the troubleshooting in order of the failure item number.

(1) All controls do not function/slow

(2) Engine down/stalled
(3) Move at lever neutral position
(4) Poor fine operability
(5) Slow boom up, insufficient power
(6) Slow boom down, insufficient power for lifting up body
(7) Slow arm in, insufficient power
(8) Slow independent arm out (in the air)
(9) Slow bucket digging
(10)Slow bucket dumping
(11)Swing operation not functioned/slow
(12)Noise during swing operation
(13)Swing on a slope drifts when control lever is in neutral position
(14)Swing drifts when swing operation is stopped
(15)Slow travel speed/weak
(16)Travel deviation
(17)Travel 1st/2nd speed not changed
(18)Travel parking on a slope is not held
(19)Travel does not run straightly when both crawlers and attachment operated simultaneously.
(20)Slow breaker (crusher) operation, weak power
(21)Option selector valve malfunction: not switched to breaker circuit
(22)Option selector valve malfunction: not switched to nibbler circuit

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47. TROUBLESHOOTING (BY TROUBLE)

(1) All controls do not function/slow

No. Sections Contents/normal value Corrective action, others

1 Fuse Check fuse No.4 If the fuse is blown out, check on
(10A) the short-circuited section.
2 Safety lever lock Carry out service No.4 K-4 switch: Check action of switch by tester,
switch diagnosis Push down the lever and it turns on, push or check that the power voltage
up and it turns off. is lowered by pushing the lever
down.
3 Safety lever lock Check that the Measure both terminals of solenoid Check solenoid unit for possible
switching solenoid is switched connector. 24V by pushing the lever down, failure.
correctly 0V by pushing it up Check harness for possible
failure.
4 Safety lever lock relay Carry out service No.4 K-4 lock lever: Check action of relay by tester
diagnosis Push down the lever and it turns off, push
up and it turns on.
5 Pilot pressure sensor •Stop engine stop and key is on position. Check 5V power for controller
All pilot low pressure sensors are 0MPa to
0.1MPa.
6 Solenoid valve for Measure pressure of About 0MPa by pushing the lever up, and Replace solenoid valve
safety lock lever solenoid A1 port 4MPa or more by push it down.
7 Pilot line filter Disassemble and Check filter for clogging Clean filter
check it visually
8 Pilot gear pump Measure pilot primary Check that it is 4MPa or more in high idling Check gear pump and the relief
pressure at gear valve for possible failure
pump
9 Multi control valve (in Change position Since all are blocked due to poor switching
case that travel is performance, check that the lever select
operable) pattern is set to the proper position.
10 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.3 Boom up full lever & relief proportional valve and controller
for possible failure.
11 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure 0.5~1.2MPa in boom up full lever and high
directly at the ports A7 idling operation
and A5 of 8 sections
solenoid block
12 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis. E-2 P2 pump largely differed from the actually
pump proportional •See Service Diagnosis Data List measured value, check
valve Operation No.18 Travel right full lever & proportional valve and controller
idling for possible failure.
Operation No.19 Travel left full lever &
idling
13 Secondary pressure of Measure the pump Check that pump proportional valve Replace proportional valve
pump proportional proportional valve secondary pressure is 2.7MPa or more in
valve secondary pressure right (left) travel full lever and high idling
directly in idling operation
operation. (Ports a3, Right travel: P1 pump proportional valve
a4) Left travel: P2 pump proportional valve

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 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

14 Main relief pressure Carry out service •See Service Diagnosis Data List Measure the relief pressure
diagnosis Operation No.3 Boom up full lever & relief actually
15 Check set pressure Check that P1 and P2 pump pressures are Reset or replace
32MPa in boom up full lever, high idling
and H mode operation.
16 Pump regulator Visual check When removing, free from abnormal Replace
resistance against sliding.
Free from abnormal damage, etc on
outside surface
Spring free from breakage, damage, etc.
17 Pump Visual check When removing, inside parts (cylinder Replace
block, piston, valve plate, shaft, etc.) are
free from abnormal resistance against
sliding, abnormal damage, etc.

(2) Engine down/stalled

No. Sections Contents/normal value Corrective action, others

1 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No. 1 Operation is nil proportional valve and controller
for possible failure.
2 Secondary pressure of Measure the pump Check that P1/P2 pump proportional Replace proportional valve
P1, P2 pump proportional valve valve pressures are within the range of
proportional valve secondary pressure 0.5 to 1.0MPa in control lever neutral
directly (Ports a3, a4) and high idling operation.
3 Pressure sensor of P1, Check pressure •See Service Diagnosis Data List Check pressure sensor and
P2 pump Operation No. 1 Operation is nil replace it if necessary
Operation No.3 Boom up full lever &
relief
4 Pump regulator Visual check When removing, free from abnormal Replace
resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring free from breakage, damage,
etc.
5 Pump Visual check When removing, inside parts (cylinder Replace
block, piston, valve plate, shaft, etc.)
are free from abnormal resistance
against sliding, abnormal damage, etc.

(3) Move at lever neutral position

No. Sections Contents/normal value Corrective action, others

1 Pilot pressure sensor Carry out service Check that targeted pilot pressure of Check remote control valve
diagnosis sensor is 0MPa in high idling
2 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
3 Main spool Check targeted spool Check that spool is free from abnormal Replace
visually damage and spring is free from
breakage
4 Over load relief valve Check targeted spool Free from dust entered in port relief Replace
visually valve. Seat is free from abnormality

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47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

5 Lock valve poppet Check targeted poppet Seat is free from abnormality Replace
(in case of boom and visually
arm)
6 Lock valve selector Exchange lock valve Check that the trouble is reversed Replace
(in case of boom and selector of boom/arm
arm) and boom/arm
7 Holding valve spool for Check that smooth Free from abnormal resistance against Replace
boom sliding of spool in sleeve sliding Do not pull spool out of sleeve
(in case of boom) forcibly.
8 Holding valve relief Check targeted spool Filter free from abnormal Replace
valve for boom visually contamination
(in case of boom)
9 Cylinder Check targeted cylinder Make sure of no problem of seals by Replace cylinder or seals
visually disassembling and investigation

(4) Poor fine operability

No. Sections Contents/normal value Corrective action, others

1 Pressure sensor Carry out service •See Service Diagnosis Data List Replace pressure sensor
diagnosis Operation No. 1 Operation is nil
•All low pressure sensors are 0MPa to
0.1MPa
2 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No. 1 Operation is nil proportional valve and controller
for possible failure.
3 Secondary pressure of Measure the Check that P1/P2 unloads secondary Replace proportional valve
unload proportional proportional valve pressures is within the range of
valve secondary pressure 2.7MPa or more in control lever neutral
directly at the ports A7 and high idling operation
and A8 of 8 sections
solenoid block
4 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No. 1 Operation is nil proportional valve and controller
for possible failure.
5 Secondary pressure of Measure the pump Check that P1/P2 pump proportional Replace proportional valve
P1, P2 pump proportional valve valve pressures are within the range of Check regulator
proportional valve secondary pressure 0.5~1.0MPa in control lever neutral
directly. (Ports a3, a4) and high idling operation
6 Slow return check valve Visual check Check that slow return check valve Clean and replace
of pilot line installed on pilot line is free from dust
(in case of boom up or entered
arm out)

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 47. TROUBLESHOOTING (BY TROUBLE)

(5) Slow boom up, insufficient power

No. Sections Contents/normal value Corrective action, others

1 Boom up pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.3 boom up full lever and sensor
relief Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve
control pressure of in boom up full lever and high idling When equipped with multi
boom up operation control valve, check it while
changing lever pattern
3 Pump pressure sensor Carry out service •See Service Diagnosis Data List When there is difference
diagnosis for P1, P2 Operation No.4 boom up full lever and between P1 and P2 pump
pump pressures in in operation pressures, check high pressure
operation. sensor.
4 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.3 Boom up full lever & proportional valve and controller
relief for possible failure.
5 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure 0.5~1.2MPa in boom up full lever and
directly at the ports A7 high idling operation
and A5 of 8 sections
solenoid block
6 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No.4 boom up full lever & in proportional valve and controller
operation for possible failure.
7 Secondary pressure of Measure the pump Check that P1/P2 pump proportional Replace proportional valve
P1, P2 pump proportional valve valve pressures are within the range of
proportional valve secondary pressure 2.1 to 3.0MPa in boom up full lever and
directly (Ports a3, a4) high idling operation
8 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean and replace
<Trouble> poppet and no contamination on orifice
Only P2 pressure is low. No problem for sliding ability of internal
piston (Check it through PBp2 port.)
9 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
10 Lock valve poppet Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Both P1 and P2 Free from abnormal damage, etc on damage)
pressures are low. outside surface
11 Conflux check valve Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Only P2 pressure is Free from abnormal damage, etc on damage)
high. outside surface
12 Holding valve for boom Visual check When removing, free from abnormal Replace
(poppet) resistance against sliding (Check on the casing side for
<Trouble> Free from abnormal damage, etc on damage)
Both P1 and P2 outside surface
pressures are high.

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No. Sections Contents/normal value Corrective action, others

13 Boom spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Only P1 pressure is Spring is free from breakage. damage)
high.
14 Check boom spool and Disassembly and Free from abnormal resistance against Replace spool assembly
recirculation investigation sliding
<Trouble> Spring is free from breakage.
Only P1 pressure is low.
15 Conflux spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Only P2 pressure is Spring is free from breakage. damage)
high. Free from abnormal damage, etc on
outside surface
16 Main relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 boom up full lever and
Relief pressure is low. relief
17 Over load relief valve Visual check (Head Pressure is 32MPa or more in boom up When only relief pressure of
<Trouble> side) full lever and high idling. Free from boom up is low, replace valve
Relief pressure is low. dust entered in over load relief valve.
Seat is free from abnormality

(6) Slow boom down/insufficient power for lifting up body

No. Sections Contents/normal value Corrective action, others

1 Boom down pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.5 boom down full lever sensor.
& in operation Check remote control valve.
2 Remote control valve Measure remote control Check that pressure is 3.0MPa or more Check remote control valve
pressure of boom down in boom down full lever and high idling When equipped with multi
directly operation control valve, check it while
changing lever pattern.
3 Actual measuring Carry out service P1 unload valve (cut valve) In case where the reading is
current value of P1 diagnosis •See Service Diagnosis Data List largely differed from the actually
unload proportional Operation No.5 boom down full lever & measured value, check
valve in operation proportional valve and controller
for possible failure.
4 Secondary pressure of Measure the Check that P1 unload secondary Replace proportional valve
P1 unload proportional proportional valve pressures are within the range of
valve secondary pressure 0.8~1.2MPa in boom down full lever
directly at the ports A7 of and high idling operation
8 sections solenoid
block.
5 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1 diagnosis •See Service Diagnosis Data List largely differed from the actually
pump proportional valve Operation No.5 boom down full lever measured value, check
& in operation proportional valve and controller
for possible failure.
6 Secondary pressure of Measure the pump Check that P1 pump proportional valve Replace proportional valve
P1 pump proportional proportional valve pressures are within the range of 1.9 to
valve secondary pressure 2.5MPa in boom down full lever and
directly (Ports a3, a4) high idling operation

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 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

7 Actual measuring Carry out service Check that the value is not change •Check pressure sensor of
current value of travel diagnosis regardless of operation travel
straight proportional •See Service Diagnosis Data List •In case where the reading is
valve Operation No. 1 Operation is nil largely differed from the
Operation No.18 Travel right full lever actually measured value, check
& idling proportional valve and
Operation No.19 Travel left full lever & controller for possible failure.
idling
8 Travel straight Measure directly the High idling pressure is 0.8MPa or less Replace proportional valve
proportional valve travel straight regardless neutral/operation
secondary pressure proportional valve
secondary pressure.
9 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
10 Lock valve poppet Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Boom down is low. Free from abnormal damage, etc on damage)
outside surface
11 Holding valve (poppet) Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding Free from (Check on the casing side for
Boom down is slow. abnormal damage, etc on outside damage)
surface
12 Boom spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Boom down is slow. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
13 Check boom spool and Disassembly and Free from abnormal resistance against Replace spool assembly
recirculation investigation sliding
<Trouble> Spring is free from breakage.
Machine can not be
lifted by supporting with
boom.
14 Main relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 boom up full lever and
Relief pressure is low. relief
15 Over load relief valve Visual check Free from dust entered in port relief Replace
<Trouble> valve.
Machine can not be Seat is free from abnormality
lifted by supporting with
boom.

(7) Slow arm in, insufficient power

No. Sections Contents/normal value Corrective action, others

1 Arm in pressure sensor Carry out service •See Service Diagnosis Data List Check and replace pressure
diagnosis Operation No.6 arm in full lever and sensor
relief Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve
pressure control pressure of arm in arm in full lever and high idling When equipped with multi
in operation control valve, check it while
changing lever pattern

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47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

3 Pump pressure sensor Carry out service •See Service Diagnosis Data List When there is difference
diagnosis for P1, P2 Operation No.7 arm in full lever and in between P1 and P2 pump
pump pressures in operation pressures, check high pressure
operation. sensor
4 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.6 Arm in full lever & proportional valve and controller
relief for possible failure.
5 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure 0.5~1.2MPa in arm in full lever and
directly at the ports A7 high idling operation.
and A5 of 8 sections
solenoid block.
6 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No.7 Arm in full lever & in proportional valve and controller
operation for possible failure.
7 Secondary pressure of Measure the pump Check that P1/P2 pump proportional Replace proportional valve
P1, P2 pump proportional valve valve pressures are 2.8MPa or more in
proportional valve secondary pressure arm in full lever and high idling
directly. (Ports a3, a4) operation. (Secondary pressure is
affected by oil temperature and
attachment weight)
8 Actual measuring Carry out service •See Service Diagnosis Data List In case where the reading is
current value of arm in diagnosis Operation No. 1 Operation is nil largely differed from the actually
spool 2 proportional Operation No.6 Arm in full lever & measured value, check
valve relief proportional valve and controller
Operation No.7 Arm in full lever & in for possible failure.
operation
9 Secondary pressure of Measure directly the Check that secondary pressure of Replace proportional valve
arm in spool 2 proportional valve proportional valve secondary
proportional valve secondary pressure at pressures are within the range of
the ports A8 (arm 2 following
spool) of 8 sections Lever neutral: 0MPa
solenoid block. Motion in the air: 1.7 to 2.2MPa
Arm in relief: 2.5MPa or more
10 Actual measuring Carry out service Check that the value is not change •Check pressure sensor of
current value of travel diagnosis regardless of operation travel
straight proportional •See Service Diagnosis Data List •In case where the reading is
valve Operation No. 1 Operation is nil largely differed from the
Operation No.18 Travel right full lever actually measured value, check
& idling proportional valve and
Operation No.19 Travel left full lever & controller for possible failure.
idling
11 Secondary pressure of Measure directly the 0.8MPa or less in high idling operation Replace proportional valve
travel straight proportional valve regardless of neutral/operation
proportional valve secondary pressure at
the ports A6 (travel
straight) of 8 sections
solenoid block

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 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

12 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
13 Main relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 boom up full lever and
Relief pressure is low. relief
14 Over load relief valve Visual check (Head Pressure is 32MPa or more in arm in When only relief pressure of arm
<Trouble> side) and relief. in is low, replace valve
P1, P2 pressure is low. Free from dust entered in over load
relief valve.
Seat is free from abnormality
15 Over load relief valve Visual check (Rod side) Pressure is 32MPa or more in arm out When only relief pressure of arm
<Trouble> and relief. out is low, replace valve
P1, P2 pressure is low. Free from dust entered in over load
relief valve.
Seat is free from abnormality.
16 Arm 1 spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1, P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
17 Arm 2 spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1, P2 pressure is high Free from abnormal damage, etc on damage)
or low. outside surface
Spring is free from breakage.
18 Check arm 2 spool and Disassembly and Free from abnormal resistance against Replace spool assembly
recirculation investigation sliding
<Trouble> Spring is free from breakage.
Arm in power is poor.
19 Check lock valve poppet Visual check Free from abnormal resistance against Replace
<Trouble> sliding (Check on the casing side for
Both P1, P2 pressures Free from abnormal damage, etc on damage)
are high. outside surface

(8) Slow independent arm out (in the air)

No. Sections Contents/normal value Corrective action, others

1 Arm out pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.8 arm out full lever and sensor
relief Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve
control pressure of arm in arm out full lever and high idling When equipped with multi
out operation control valve, check it while
changing lever pattern
3 Pump pressure sensor Carry out service •See Service Diagnosis Data List When there is difference
diagnosis for P1, P2 Operation No.9 arm out full lever and between P1 and P2 pump
pump pressures in in operation pressures, check high pressure
operation. sensor
4 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.8 Arm out full lever & proportional valve and controller
relief for possible failure.

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47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

5 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure 0.5~1.2MPa in arm out full lever and
directly at the ports A7 high idling operation
and A5 of 8 sections
solenoid block
6 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No.9 Arm out full lever & in proportional valve and controller
operation for possible failure.
7 Secondary pressure of Measure the pump Check that P1/P2 pump proportional Replace proportional valve
P1, P2 pump proportional valve valve pressures are within the range of
proportional valve secondary pressure 1.7 to 2.9MPa in arm out full lever and
directly (Ports a3, a4) high idling operation
(Secondary pressure is affected by oil
temperature and attachment weight)
8 Actual measuring Carry out service Check that the value is not change •Check pressure sensor of
current value of travel diagnosis regardless of operation travel
straight proportional •See Service Diagnosis Data List •In case where the reading is
valve Operation No. 1 Operation is nil largely differed from the
Operation No.18 Travel right full lever actually measured value, check
& idling proportional valve and
Operation No.19 Travel left full lever & controller for possible failure.
idling
9 Secondary pressure of Measure directly the 0.8MPa or less in high idling operation Replace proportional valve
travel straight proportional valve regardless of neutral/operation
proportional valve secondary pressure at
the ports A6 (travel
straight) of 8 sections
solenoid block
10 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
11 Main relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 boom up full lever and
Relief pressure is low. relief
12 Over load relief valve Visual check (Rod side) Pressure is 32MPa or more in arm out When only relief pressure of arm
<Trouble> and relief. out is low, replace valve
P1, P2 pressure is low. Free from dust entered in over load
relief valve. Seat is free from
abnormality
13 Arm 1 spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
14 Arm 2 spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.

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No. Sections Contents/normal value Corrective action, others

15 Check arm 2 spool and Disassembly and Free from abnormal resistance against Replace spool assembly
recirculation investigation (spring sliding
<Trouble> side) Spring is free from breakage.
Both P1, P2 pressures
are low.
16 Check lock valve poppet Visual check Free from abnormal resistance against Replace
<Trouble> sliding (Check on the casing side for
Both P1, P2 pressures Free from abnormal damage, etc on damage)
are high. outside surface

(9) Bucket digging is slow

No. Sections Contents/normal value Corrective action, others

1 Bucket digging pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.12 bucket digging full sensor
lever and relief Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve
control pressure of in bucket digging full lever and high When equipped with multi
bucket digging idling operation control valve, check it while
changing lever pattern
3 Pump pressure sensor Carry out service •See Service Diagnosis Data List When there is difference
diagnosis for P1, P2 Operation No.13 Bucket digging full between P1 and P2 pump
pump pressures in lever and in operation pressures, check high pressure
operation. sensor
4 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.12 Bucket digging full proportional valve and controller
lever & relief for possible failure.
5 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure 0.5~1.2MPa in bucket digging full lever
directly at the ports A7 and high idling operation
and A5 of 8 sections
solenoid block
6 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No.13 Bucket digging full proportional valve and controller
lever & in operation for possible failure.
7 Secondary pressure of Measure the pump Check that P1 pump proportional valve Replace proportional valve
P1, P2 pump proportional valve pressures is 2.3MPa or more and P2
proportional valve secondary pressure pump proportional valve pressure is
directly (Ports a3, a4) 1.9 to 2.5MPa in bucket digging full
lever and high idling operation.
8 Attachment boost Carry out service No.3 POWER BOOST Check harness
solenoid command diagnosis Bucket digging COMP OFF MEAS Replace solenoid valve
OFF
9 Attachment boost Measure switching Check that pressure is 0MPa in bucket Replace solenoid valve
solenoid secondary valve secondary digging full lever and high idling
pressure pressure operation

47-13
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

10 Actual measuring Carry out service •See Service Diagnosis Data List In case where the reading is
current value of travel diagnosis Operation No.12 Bucket digging full largely differed from the actually
straight proportional lever & relief measured value, check
valve proportional valve and controller
for possible failure.
11 Secondary pressure of Measure directly the Check that travel straight secondary Replace proportional valve
travel straight proportional valve pressure is 2.7MPa or more in bucket
proportional valve secondary pressure at digging full lever and high idling
the ports A6 (travel operation
straight) of 8 sections
solenoid block
12 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean or replace
<Trouble> poppet and no contamination on orifice
Only P2 pressure is low. No problem for sliding ability of internal
piston (Check it through PBp2 port.)
13 Check stroke limiter Visual check When piston is removed from cover, it Replace
<Trouble> is free from abnormal resistance (Check on the casing side for
Both P1, P2 pressures against sliding damage.)
are high. Free from abnormal damage, etc on
outside surface
14 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
15 Main relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
Operation No.3 Boom up full lever and
relief
16 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
17 Bucket spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Both P1, P2 pressures Free from abnormal damage, etc on damage)
are high. outside surface
Spring is free from breakage.
18 Over load relief valve Check targeted spool Free from dust entered in over load Replace
visually relief valve.
Seat is free from abnormality.

(10)Bucket dump is slow

No. Sections Contents/normal value Corrective action, others

1 Bucket dump pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.14 Bucket dump full sensor
lever and relief Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve
control pressure of in bucket dump full lever and high When equipped with multi
bucket dump idling operation control valve, check it while
changing lever pattern
3 Pump pressure sensor Carry out service •See Service Diagnosis Data List When there is difference
diagnosis for P1, P2 Operation No.15 Bucket dump full between P1 and P2 pump
pump pressures in lever and in operation pressures, check high pressure
operation. sensor

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 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

4 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.14 Bucket dump full proportional valve and controller
lever & relief for possible failure.
5 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure 0.5~1.2MPa in bucket dump full lever
directly at the ports A7 and high idling operation. Replace
and A5 of 8 sections proportional valve
solenoid block
6 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Carry out service Operation No.15 Bucket dump full proportional valve and controller
diagnosis. lever & in operation for possible failure.
7 Secondary pressure of Measure the pump Check that P1 pump proportional valve Replace proportional valve
P1, P2 pump proportional valve pressures is 1.6MPa or more and P2
proportional valve secondary pressure pump proportional valve pressure is
directly (Ports a3, a4) 1.6MPa or more in bucket dump full
lever and high idling operation.
8 Actual measuring Carry out service •See Service Diagnosis Data List In case where the reading is
current value of travel diagnosis Operation No.14 Bucket dump full largely differed from the actually
straight proportional lever & relief measured value, check
valve proportional valve and controller
for possible failure.
9 Secondary pressure of Measure directly the Check that travel straight secondary Replace proportional valve
travel straight proportional valve pressure is 2.7MPa or more in bucket
proportional valve secondary pressure at dump full lever and high idling
the ports A6 (travel operation
straight) of 8 sections
solenoid block
10 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean and replace
<Trouble> poppet and no contamination on orifice
Only P2 pressure is low. No problem for sliding ability of internal
piston (Check it through PBP2 port.)
11 Check stroke limiter Visual check Free from abnormal damage and wear Replace
<Trouble> on outside of piston inside cover (Check on the casing side for
Pilot pressure is low. damage.)
12 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
13 Main relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 Boom up full lever and
Relief pressure is low. relief
14 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
15 Bucket spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Both P1, P2 pressures Free from abnormal damage, etc on damage)
are high. outside surface
Spring is free from breakage.

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47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

16 Over load relief valve Check targeted spool Free from dust entered in over load Replace
visually relief valve.
Seat is free from abnormality.

(11)Swing does not move/slow

No. Sections Contents/normal value Corrective action, others

1 Swing pressure sensor Carry out service •See Service Diagnosis Data List Check and replace pressure
diagnosis Operation No.11 Swing full lever and sensor
in operation Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve
control pressure of in boom up full lever and high idling When equipped with multi
swing operation control valve, check it while
changing lever pattern
3 Swing parking brake Carry out service No.3 F-2 SWING-BRAKE Check swing pressure sensor
solenoid diagnosis Lever neutral: COMP. ON MEAS Check harness
ON Swing: COMP OFF MEAS OFF
Swing parking brake Measurement of Lever neutral: 0MPa Replace solenoid valve
4
solenoid solenoid valve A2 port In operation: 4MPa or more
5 Shuttle valve Visual check No contamination on spool cover Clean or replace
<Trouble> (short side) and orifice
Pilot pressure is low. No damage on spool cover (long side)
and shuttle
6 Pump pressure sensor Carry out service •See Service Diagnosis Data List Check high pressure sensor
diagnosis for P2 pump Operation No.11 Swing full lever and
pressures in operation in operation
7 Actual measuring Carry out service •No.8 D-2 P2 unload valve (cut valve) In case where the reading is
current value of P2 diagnosis •See Service Diagnosis Data List largely differed from the actually
unload proportional Operation No.11 Swing full lever & in measured value, check
valve operation proportional valve and controller
for possible failure.
8 Secondary pressure of Measure the Check that P2 unload secondary Replace proportional valve
P2 unload proportional proportional valve pressures are within the range of
valve secondary pressure 0.5~1.2MPa in swing full lever and high
directly at the ports A5 of idling operation
8 sections solenoid
block
9 Actual measuring Carry out service •No.9 E-2 P2 pump In case where the reading is
current value of P2 diagnosis largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No.11 Swing full lever & in proportional valve and controller
operation for possible failure.
10 Secondary pressure of Measure the pump Check that P2 pump proportional valve Replace proportional valve
P2 pump proportional proportional valve pressure is 2.7MPa or more in swing
valve secondary pressure full lever and high idling operation
directly (Ports a3, a4)
11 Actual measuring Carry out service Check that the value is not change •Check pressure sensor of
current value of travel diagnosis regardless of operation travel
straight proportional •See Service Diagnosis Data List •In case where the reading is
valve Operation No. 1 Operation is nil largely differed from the
(Check this trouble by Operation No.18 Travel right full lever actually measured value, check
only swing operation) & idling proportional valve and
Operation No.19 Travel left full lever & controller for possible failure.
idling

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 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

12 Secondary pressure of Measure directly the 0.8MPa or less in high idling operation Replace proportional valve
travel straight proportional valve regardless of neutral/operation
proportional valve secondary pressure at
(Check this trouble by the ports A6 (travel
only swing operation) straight) of 8 sections
solenoid block
13 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
14 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P2 pressure is low. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
15 Swing spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
16 Swing relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.10 Swing full lever and
Relief pressure is low. relief
17 Swing motor Visual check Inner parts (cylinder block, piston, Replace
valve brake etc) are to be free from
abnormal resistance against sliding.
Free from abnormal damage, etc on
outside surface (brake plate etc)
18 Swing reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
swing reduction gear metal powder. reduction gear
drain
19 Swing reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.

(12)Noise occurred at swing operation

No. Sections Contents/normal value Corrective action, others

1 Swing parking brake Carry out service No.3 F-2 SWING-BRAKE Check swing pressure sensor
solenoid diagnosis Lever neutral: COMP. ON MEAS. ON Check harness
Swing: COMP OFF MEAS OFF
2 Measurement of Lever neutral: 0MPa Replace solenoid valve
solenoid valve A2 port In operation: 4MPa or more
3 Boost check valve Visual check When removing, free from abnormal Replace
(Sound of cavitation at resistance against sliding
stopping) Spring is free from breakage.
4 By-pass check valve Visual check When removing, free from abnormal Replace
(Sound of cavitation at resistance against sliding
stopping) Spring is free from breakage.
5 Swing motor Visual check Disassemble and inspect abnormal Replace
(Brake valve/friction wear and scuffing
plate)
6 Swing motor piston Visual check When removing, free from abnormal Replace
resistance against sliding
Spring is free from breakage.

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47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

7 Swing reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
swing reduction gear metal powder. reduction gear
drain.
8 Swing reduction Visual check Tooth surface has no abnormally worn Replace
and chipped.

(13)Swing drifts on a slope while swing control lever is in neutral position

No. Sections Contents/normal value Corrective action, others

1 Swing pressure sensor Carry out service •Engine stop & starter key ON Check and replace pressure
diagnosis All pilot low pressure sensors are sensor
within range of 0 to 0.1MPa.
2 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
3 Swing parking brake Carry out service No.3 F-2 SWING-BRAKE Check swing pressure sensor
solenoid diagnosis Lever neutral: COMP. ON MEAS. ON Check harness
Swing: COMP OFF MEAS OFF Check parking brake release
switch
4 Measurement of Lever neutral: 0MPa Replace solenoid valve
solenoid valve A2 port In operation: 4MPa or more
5 Swing motor Visual check Disassemble and inspect abnormal Replace
(Brake valve/friction wear and scuffing
plate)
6 Parking brake Visual check Piston and friction plate do not have Replace
abnormal resistance against sliding
Free from spring damage

(14)Swing drifts at stopping

No. Sections Contents/normal value Corrective action, others

1 Shuttle valve Visual check No contamination on spool cover Clean or replace
<Trouble> (short side) and orifice. No damage on
Pilot pressure is low spool cover (long side) and shuttle.
2 Swing pressure sensor Carry out service •Engine stop & starter key ON Replace pressure sensor
diagnosis All pilot low pressure sensors are
within range of 0 to 0.1MPa.
3 Swing relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.10 Swing full lever and
Relief pressure is low. relief
4 Anti-reaction valve Visual check Free from dirt entering Clean or replace
Sliding part should be free from foreign
matter entering, abnormal damage and
wear.
5 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
6 Swing motor Visual check Inner parts (cylinder block, piston, Replace
valve brake etc) are to be free from
abnormal resistance against sliding.
Free from abnormal damage, etc on
outside surface (brake plate etc)

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 47. TROUBLESHOOTING (BY TROUBLE)

(15)Travel speed is slow/poor

No. Sections Contents/normal value Corrective action, others

1 Travel right and left Carry out service •See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.18 Travel right full lever sensor
and idling Check remote control valve
Operation No.19 Travel left full lever
and idling
2 Remote control valve Measure directly remote Check that pressure is 2.1MPa or more Check remote control valve
control pressure of in travel right (left), forward (reverse)
travel right and left full lever and high idling operation
3 Actual measuring Carry out service •No.9 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.18 Travel right full lever proportional valve and controller
& idling for possible failure.
Operation No.19 Travel left full lever &
idling
4 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure followings in travel right (left), forward
directly at the ports A7 (reverse) full lever and high idling
and A5 of 8 sections operation
solenoid block Travel right (P1 unload): 0.5 to 1.0MPa
Travel left (P2 unload): 0.5 to 1.0MPa
5 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No.18 Travel right full lever proportional valve and controller
& idling for possible failure.
Operation No.19 Travel left full lever &
idling
6 Secondary pressure of Measure the pump Check that P1/P2 unload secondary Replace proportional valve
P1, P2 pump proportional valve pressures are within the range of
proportional valve secondary pressure followings in travel right (left), forward
directly (Ports a3, a4) (reverse) full lever and high idling
operation
Travel right (P1 pump): 2.7MPa or
more
Travel left (P2 pump): 2.7MPa or more
7 Actual measuring Carry out service Check that the value is not change •Check voltage of low pressure
current value of travel diagnosis regardless of operation sensor other than sensor for
straight proportional •See Service Diagnosis Data List travel
valve Operation No. 1 Operation is nil •In case where the reading is
Operation No.18 Travel right full lever largely differed from the
& idling actually measured value, check
Operation No.19 Travel left full lever & proportional valve and
idling controller for possible failure
8 Secondary pressure of Measure directly the 0.8MPa or less in high idling operation Replace proportional valve
travel straight proportional valve regardless of neutral/operation
proportional valve secondary pressure
9 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
Check sealing ability of shuttle valve
and entry of dust in orifice

47-19
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

10 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
11 Travel spool Visual check of targeted When removing, free from abnormal Replace
<Trouble> spool resistance against sliding (Check on the casing side for
Pump pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
12 Travel motor relief valve Check set pressure Check P1 and P2 pump pressures are If P1 is low, right travel motorÅfs
32MPa or more in right and left travel relief valve is failed.
levers full lever (relief operation at If P2 is low, left travel motorÅfs
locked crawler belt) and high idling relief valve is failed.
13 Travel motor Visual check Inner parts (piston, cylinder block, Replace
valve plate, brake valve spool) are to
be free from abnormal resistance
against sliding.
Free from abnormal damage, etc on
outside surface (brake plate etc)
14 Parking brake in travel Visual check When removing, free from abnormal Replace
motor resistance against sliding
No sticking on friction plate and
separator plate
15 Travel reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
travel reduction gear metal powder. reduction gear
drain
16 Travel reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.

(16)Travel deviation

No. Sections Contents/normal value Corrective action, others

1 Travel right and left Carry out service •See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.18 Travel right full lever sensor
and idling Check remote control valve
Operation No.19 Travel left full lever
and idling
2 Remote control valve Measure directly remote Check that pressure is 2.1MPa or more Check remote control valve
control pressure of in travel right (left), forward (reverse)
travel right and left full lever and high idling operation
3 Actual measuring Carry out service Check that the value is not change •Check voltage of low pressure
current value of travel diagnosis regardless of operation sensor other than sensor for
straight proportional •See Service Diagnosis Data List travel
valve Operation No. 1 Operation is nil •In case where the reading is
Operation No.18 Travel right full lever largely differed from the
& idling actually measured value, check
Operation No.19 Travel left full lever & proportional valve and
idling controller for possible failure.
4 Secondary pressure of Measure directly the 0.8MPa or less in high idling operation Replace proportional valve
travel straight proportional valve regardless of neutral/operation
proportional valve secondary pressure

47-20
 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

5 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.18 Travel right full lever proportional valve and controller
& idling for possible failure.
Operation No.19 Travel left full lever &
idling
6 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure followings in travel right (left), forward
directly at the ports A7 (reverse) full lever and high idling
and A5 of 8 sections operation
solenoid block Travel right (P1 unload): 0.5 to 1.0MPa
Travel left (P2 unload): 0.5 to 1.0MPa
7 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No.18 Travel right full lever proportional valve and controller
& idling for possible failure.
Operation No.19 Travel left full lever &
idling
8 Secondary pressure of Measure the pump Check that P1/P2 unload secondary Replace proportional valve
P1, P2 pump proportional valve pressures are within the range of
proportional valve secondary pressure followings in travel right (left), forward
directly (Ports a3, a4) (reverse) full lever and high idling
operation
Travel right (P1 pump): 2.7MPa or
more
Travel left (P2 pump): 2.7MPa or more
9 Exchange P1 for P2 Exchange delivery pipe Check the direction of deviation If the direction is changed,
of P1 for P2 inspect a pump. If the direction
is not changed, inspect a valve
and travel unit.
10 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
Check sealing ability of shuttle valve
and entry of dust in orifice
11 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage
12 Travel spool Visual check of targeted When removing, free from abnormal Replace
<Trouble> spool resistance against sliding (Check on the casing side for
Pump pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage
13 Travel motor relief valve Check set pressure Check P1 and P2 pump pressures are If P1 is low, right travel motorÅfs
32MPa or more in right and left travel relief valve is failed.
levers full lever (relief operation at If P2 is low, left travel motorÅfs
locked crawler belt) and high idling relief valve is failed.
Replace as necessary

47-21
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

14 Travel motor Visual check Inner parts (piston, cylinder block, Replace
valve plate, brake valve spool) are to
be free from abnormal resistance
against sliding.
Free from abnormal damage, etc on
outside surface (brake plate etc)
15 Travel reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
travel reduction gear metal powder. reduction gear
drain
16 Travel reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.
17 Pump regulator Visual check When removing, free from abnormal Replace
resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring free from breakage, damage,
etc.
18 Pump Visual check When removing, inside parts (cylinder Replace
block, piston, valve plate, shaft, etc.)
are free from abnormal resistance
against sliding, abnormal damage, etc.

(17)Travel 1/2 speed cannot be switched

(In case of the traveling under heavy loading (for example traveling on a slope or traveling on a soft ground), the
speed may sometimes does not change from 1st to 2nd because this machine equips the function of automatic
speed change.)

No. Sections Contents/normal value Corrective action, others

1 Travel 1/2 speed Carry out service Switch travel 1/2 speed to 2nd speed Check pressure sensor
switching solenoid diagnosis No.3 F-3 1/2-TRAVEL Check harness
Lever neutral COMP OFF MEAS OFF Check travel 1/2 speed switch
Travel operation COMP ON MEAS ON on gauge cluster
2 Travel 1/2 speed Measure A3 port Lever neutral: 0MPa Replace solenoid valve
switching solenoid pressure on solenoid In operation: 4MPa or more
valve
3 1/2 speed switching Visual check Check that spool is free from abnormal Replace
spool in travel motor damage and spring is free from (Check on the casing side for
breakage damage)
4 1/2 speed switching Visual check Free from entry of dust Remove dust or replace
orifice in travel motor
5 Tilting piston in travel Visual check Free from abnormal wear on piston Replace
motor and seal (Check on the casing side for
damage)

(18)Machine does not stay on a slope in traveling

No. Sections Contents/normal value Corrective action, others

1 Pilot pressure sensor Carry out service •Engine stop & starter key switch is ON Check pressure sensor and
diagnosis Targeted pilot low pressure sensor is replace as necessary
in range of 0 to 0.1MPa Check remote control valve
2 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage

47-22
 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

3 Parking brake in travel Visual check When removing, free from abnormal Replace
motor resistance against sliding
Spring free from breakage, damage,
etc.
4 Orifice of passage for Visual check Free from entry of dust Remove dust or replace
parking brake in travel
motor

(19)Machine does not travel straight in simultaneous operation of traveling and attachment

No. Sections Contents/normal value Corrective action, others

1 Actual measuring Carry out service No.8 D-3 S-TRAVEL is should be •Check voltage of low pressure
current value of travel diagnosis COMP 580mA and MEAS 550 to sensor other than travel sensor
straight proportional 610mA in both travel full lever and in •In case where the reading is
valve boom up full lever at high idling largely differed from the
actually measured value, check
proportional valve and
controller for possible failure.
2 Secondary pressure of Measure directly the Check secondary pressure is within Replace proportional valve
travel straight proportional valve range of 1.8 to 2.2MPa in both travel
proportional valve secondary pressure full lever and in boom up full lever at
high idling
3 Travel straight spool Visual check When removing, free from abnormal Replace
resistance against sliding (Check on the casing side for
Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.

(20)Breaker works slowly and power is poor (In case of conflux, check p1 unload/pump and travel straight)

No. Sections Contents/normal value Corrective action, others

1 Pressure sensor for Carry out service •See Service Diagnosis Data List Check and replace pressure
optional attachment diagnosis Operation No.16 P2 side OPT full senso
lever and relief Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 2.1MPa or more Check remote control valve0
control pressure of in optional attachment full lever and
travel right and left high idling operation
3 Actual measuring Carry out service •See Service Diagnosis Data List •In case where the reading is
current value of P1/P2 diagnosis Operation No.16 P2 side OPT full largely differed from the
unload proportional lever and relief actually measured value, check
valve proportional valve and
controller for possible failure.
4 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of 0.5 to
proportional valve secondary pressure 1.2MPa
directly at the ports A7
and A5 of 8 sections
solenoid block
5 Actual measuring Carry out service •See Service Diagnosis Data List •Check voltage of low pressure
current value of travel diagnosis Operation No.16 P2 side OPT full sensor other than sensor for
straight proportional lever & relief optional attachment
valve •In case where the reading is
largely differed from the
actually measured value, check
proportional valve and
controller for possible failure.

47-23
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

6 Secondary pressure of Measure directly the Check that travel straight secondary Replace proportional valve
travel straight proportional valve pressure is 2.7MPa or more in optional
proportional valve secondary pressure at attachment full lever and high idling
the ports A6 (travel operation
straight) of 8 sections
solenoid block
7 P1 by-pass cut valve Visual check No problem for sliding ability of main Clean or replace
<Trouble> poppet and no contamination on orifice
Only P1 pressure is low. No problem for sliding ability of internal
piston (Check it through PBp2 port.)
8 Relief pressure Check set pressure •See Service Diagnosis Data List Reset or replace
Operation No.16 P2 side OPT full
lever and relief
(Set value of factory shipment is
24.5MPa.)
9 Remote control valve Check targeted remote Check sealing ability of shuttle valve Replace
control valve and entry of dust in orifice.
10 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
11 Spool for optional Visual check When removing, free from abnormal Replace
attachment resistance against sliding (Check on the casing side for
<Trouble> Free from abnormal damage, etc on damage)
P1, P2 pressures are outside surface
high. Spring is free from breakage.
12 Over load relief valve Check targeted spool Free from dust entered in over load Replace
visually relief valve
Seat is free from abnormality.

(21)Selector valve for option malfunctions: Breaker circuit is not obtained.

(Indication of failure is displayed. For reference, see "Table47-1 Action of optional selector solenoid valve")

No. Sections Contents/normal value Corrective action, others

1 N&B selector spool Visual check When removing, free from abnormal Replace
resistance against sliding (Check on the casing side for
Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage
2 N&B selector solenoid Screw for emergency Check that the error indication is Replace solenoid valve
disappeared by turning emergency
screw
3 N&B selector solenoid Carry out service •No.11 F-4 Option selector is B mode Check solenoid valve
diagnosis COMP ON, MEAS ON Check harness
Spool position BRK
Selector switch BRK
4 N&B selector pressure Carry out service •No.16 B-11 Check pressure sensor
sensor diagnosis Data List Check harness
3.0MPa at B mode and 0.0MPa at A
mode

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 47. TROUBLESHOOTING (BY TROUBLE)

(22)Selector valve for option malfunctions: Nibbler circuit is not obtained.

(Indication of failure is displayed. For reference, see "Table47-1 Action of optional selector solenoid valve")

No. Sections Contents/normal value Corrective action, others

1 N&B selector spool Visual check When removing, free from abnormal Replace
resistance against sliding (Check on the casing side for
Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
2 N&B selector solenoid Carry out service •No.11 F-4 Option selector is A mode Check solenoid valve
diagnosis COMP OFF, MEAS OFF Check harness
Spool position NIB
Selector switch NIB

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47. TROUBLESHOOTING (BY TROUBLE)

Table47-1 Action of optional selector solenoid valve

Optional Selector
Safety lock Safety lock selector valve
Engine Work Spool Failure diagnosis
No. lever SW's lever relay's valve detecting Warning display
condition mode position display
input output COMP. pressure
MEAS. sensor
1 Running ON OFF A OFF Nibbler Normal — —
2 "SELECTOR VALVE [F042] displayed
Running ON OFF A ON Breaker Normal
FAILURE" simultaneously
3 "SELECTOR VALVE
Running ON OFF A OFF Breaker Normal —
FAILURE"
4 Running ON OFF A ON Nibbler Normal — [F042] displayed
5 Running ON OFF B ON Breaker Normal — —
6 "SELECTOR VALVE [F043] displayed
Running ON OFF B OFF Nibbler Normal
FAILURE" simultaneously
7 "SELECTOR VALVE
Running ON OFF B ON N&B Normal —
FAILURE"
8 Running ON OFF B OFF Breaker Normal — [F043] displayed
9 "SELECTOR VALVE
Running ON OFF — — — Failure [B113] displayed
FAILURE"
10 Stopping — — — — — — — —
11 — OFF — — — — — — —
12 — — ON — — — — — —

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 47. TROUBLESHOOTING (BY TROUBLE)

47.2 ELECTRIC SYSTEMS

47.2.1 WIRING CHECKING PROCEDURE
Check for continuity between connector terminals, CONNECTOR
presence or absences of short-circuit with other wires,
and presence or absences of short-circuit with machine
body grounding.
WIRE
(1) Checking for disconnection between connectors.
(When both ends measurement is easy because of
TESTER
short distance between connectors,)
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is zero (0), it is in normal
condition.

(When both ends measurement is difficult because

of long distance between connectors,)
Measure the resistance using tester. JUMPER
Pull out opposite connector first. WIRE
Where the resistance is zero (0), if the terminal on
one side is connected to frame body grounding with TESTER
jumper wire, it is in normal condition. FRAME BODY GROUNDING
The resistance is 1M or more when the terminal
on one side is not connected to frame body
grounding with jumper wire, it is in normal condition.

(2) Checking for presence or absence of short-circuit

with machine body
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is 1M or more, it is in normal
condition.
TESTER
FRAME BODY GROUNDING

(3) Checking for presence or absence of short-circuit

between wirings.
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is 1M or more, it is in normal
condition. TESTER

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47. TROUBLESHOOTING (BY TROUBLE)

(4) Checking connector terminal for contact

Insert male terminal into female terminal unit, and INSERT
then check that the inserting force is equivalent to
other female terminals. MALE TERMINAL FEMALE TERMINAL
If looseness is there, replace the female terminal
with new one.
Clean the dirt terminal.

Do not insert the male terminal the thickness differs. It

may cause loose connection.

(5) Caution which should be paid in measuring voltage

When measuring the power supply to electric
equipment at connector position with the grounding
terminal contained inside of connector, measure
the voltage between grounding inside of connector
and power terminal.
When measuring the voltage between frame body
grounding and power source, the disconnection of
wiring to grounding inside of connector cannot be
identified.
Since the voltage may vary between with connector
connected and with connector not connected.
Measure the voltage with each connector
connected whenever possible.
(6) Checking the general view of connector CRIMPED
PART
a. Check the terminal crimped condition.
Pull one electric cable with the about 3kg force,
RUBBER
and make sure that the cable does not come out PLUG
RECEPTACLE.
of the terminal. CONTACT

When came out, replace the terminal and crimp PLUG

SEALING
it again. (is housed in plug)

b. Check connector for imperfect insertion DOUBLE LOCK

PLATE FOR PLUG
Check that all top ends form a line on the same DOUBLE LOCK
PLATE FOR CAP
position as seen from the connector engaged
side. CAP

When moved along, push it in further through TAB.CONTACT

wire inserting hole. RUBBER PLUG

c. Check connector for intruding of water.

Pull out the connector and check that the inside
is free from intruding of water.
When water intruding is found, check rubber plug
for damage and also that the sealing is fitted
properly.

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 47. TROUBLESHOOTING (BY TROUBLE)

(7) When abnormality occurs at intervals

When the abnormality situation can not be
reoccurred during checking operation, try the
following operations.
a. Check that variable of display exists or not on the
service diagnosis screen while shaking the
harness or giving shock by operating the
machine.
b. Check that variables of resistance and voltage
exist or not using tester while shaking the
harness.
c. Turn starter switch on and apply electricity
continuously, and check it again after the
temperature of wiring and equipment was raised.
(8) Checking on body grounding
Check attaching bolts of grounding terminal for
loosening.
And also check that there is no loose connection
due to corrosion.

There are multiple groundings like centralized

grounding box shown in the figure and battery
grounding, engine grounding, horn grounding fixed
together with horn, body grounding placed on
attaching section of boom working light.
Block of grounding is located
under floor plate of cab.

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47. TROUBLESHOOTING (BY TROUBLE)

47.2.2 TROUBLE
(1) Engine does not stop.
(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.
(3) Auto accel does not actuate. (The engine speed does not automatically slow down.)
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)
(5) Wiper does not function.

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 47. TROUBLESHOOTING (BY TROUBLE)

(1) Engine does not stop.

No. Sections Contents/normal value Corrective action, others

1 Starter key switch Check signal of starter No.4 K-3 Key switch Check continuity between
key switch ON by OFF at starter key switch OFF position terminals of starter switch using
carrying out service ON at starter key switch ON position tester
diagnosis.
2 Engine forcible stop When ON is displayed No.4 K-3 Key switch Check on engine forcible stop
relay with the starter switch OFF at starter key switch OFF position relay
OFF, then pull out R-25 ON at starter key switch ON position
engine forcible stop
relay and carry out the
service diagnosis.
3 Wiring Voltage between line 0V when starter switch is OFF Check harness
No.62 among starter Check diode D-9 between
switch, engine forcible starter switch and auto idling
stop relay, mechatro stop relay 1
controller and the body
grounding

(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.

No. Sections Contents/normal value Corrective action, others

1 Fuse No.1 fuse (5A) Not blown fuse Check harness
Replace fuse
2 Mechatro controller Accel control Engine speed varies according to Check mechatro controller and
accel potentiometer operation. replace as necessary
(Use remote control because the auto
accel function is working.)
3 Wiring Transmission circuit line See "WIRING CHECKING Repair wiring
No.770 from mechatro PROCEDURE"
controller to gauge
cluster
4 Gauge cluster Gauge cluster Replace gauge cluster

(3) Auto accel does not actuate. (The engine speed does not automatically slow down).

No. Sections Contents/normal value Corrective action, others

1 Engine coolant Check engine coolant No.2 G-5 WATER TEMP Replace engine coolant sensor
temperature temperature by carrying Auto accel does not work in the
out service diagnosis. temperature -15°C or less.
Warm up and raise the coolant
temperature to – 15°C or more
2 Gauge cluster Indication of auto accel Mark "Display/not display" for auto Replace gauge cluster
accel switches by auto accel switch
operation on gauge cluster.
3 Low pressure sensor Service diagnosis Each control pressure of No.5 and Check low pressure sensor
No.6 is in the range of 0~0.1MPa at
control lever neutral position.

(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)

No. Sections Contents/normal value Corrective action, others

1 Low pressure sensor Service diagnosis Each control pressure of No.5 and Check low pressure sensor
No.6 is raised with control lever
operated.

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47. TROUBLESHOOTING (BY TROUBLE)

(5) Wiper does not function

Wiping range of
forward and
reverse movements

Wiper motor
Rise up (storing) position Rise up limit switch's ON range
Upper reversing position Reverse limit switch's ON range
Lower reversing position

No. Sections Contents/normal value Corrective action, others

1 Fuse Check fuse No.20 Replace fuse
2 SW-19: Service diagnosis No.19 D125 Check wiper interlock switch
Wiper interlock switch Wiper switch display (D125) is OFF with front window closed. and repair it if necessary
Check according to "WIRING
CHECKING PROCEDURE" and
repair it if necessary
3 Rise up limit switch built- Service diagnosis No.25 Wiper system Check according to "WIRING
in wiper motor CHECKING PROCEDURE"
Reverse limit switch Switch action in operation

Normal condition
Rise up limit switch ON OFF OFF
Reverse limit switch ON ON OFF

4 R-31: Service diagnosis No.25 Wiper system

Arc prevention relay When started by forward rotation: STOP START (STOP) (REVERSE) (STOP) (FORWARD)
R-29: Arc prevention relay OFF ON ON ON ON OFF ON ON ON OFF ON
Forward rotation relay Forward rotation relay OFF ON ON ON ON OFF OFF OFF OFF OFF ON
Reverse rotation relay OFF OFF OFF OFF OFF OFF ON ON ON OFF OFF
R-30:
Check that the relay is worked as shown in the table. Check that the relay is excited.
Reverse rotation relay * When the limit switch does not change in OFF after 4 seconds Check relay & fuse box and replace it
from the wiper startup, turn OFF all relay's outputs. if necessary.

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 47. TROUBLESHOOTING (BY TROUBLE)

47.3 ENGINE RELATED TROUBLESHOOTING

Checking
Filters Liquid Leak, clogging

Air leak between turbocharger and intake manifold

Factors

Leak, clogging of fuel system and intruding of air

Contamination of water and fuel with oil
Breather hose crushed or clogged
Fan belt slipped, fan pulley worn

Poor or deteriorated battery

Shortage of fuel level

Improper fuel in use

Air cleaner clogged
Fuel filter clogged

Oil level of oil pan

Oil filter clogged

Muffler clogged
Engine oil leak
Coolant level
Trouble

Poor start ability (Take a long time)

Faulty starting

Faulty engine starting/engine does not rotate.

Faulty engine starting/engine rotates but no
exhaust gas (No fuel injection)

Faulty engine starting/exhaust gas is emitted

but engine does not start (With fuel injection)
Poor output Insufficient

Engine poor run-up (Low follow-up ability)

rotation

Rotation in bad condition (hunting)

Engine stalled during operation.
Output is lowered.
Overheating
Exhaust smoke is in black
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Other failures

Early contamination of oil

Larger fuel consumption
Intruding of oil in coolant, back flow, reduction
of coolant quantity
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Vibration

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47. TROUBLESHOOTING (BY TROUBLE)

Checking Electric equipment

Shovel side Shovel side Engine side

Loose mounting bolts, damage of mounting rubber

Factors

Radiator core clogged/fin clogged and crushed

Peeling of space insulation around radiator

Loose connection of battery cable terminal

Failure of radiator pressure cap

Failure of hydraulic system

Startup circuit wiring
Starter key switch

Hydraulic switch
Starter motor
Safety relay
Battery rely

Glow relay
Glow plug
Alternator
Trouble

Poor start ability (Take a long time)

Faulty starting

Faulty engine starting/engine does not rotate.

Faulty engine starting/engine rotates but no
exhaust gas (No fuel injection)

Faulty engine starting/exhaust gas is emitted

but engine does not start (With fuel injection)
Poor output Insufficient

Engine poor run-up (Low follow-up ability)

rotation

Rotation in bad condition (hunting)

Engine stalled during operation.
Output is lowered.
Overheating
Exhaust smoke is in black
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Other failures

Early contamination of oil

Larger fuel consumption
Intruding of oil in coolant, back flow, reduction
of coolant quantity
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Vibration

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 47. TROUBLESHOOTING (BY TROUBLE)

Intake and Lubrication Cooling

Fuel system exhaust system system
system

Factors

Seizing and interference of turbocharger

Seal of turbocharger worn, damaged
Turbocharger oil drain tube clogged

Leak and crush of hydraulic piping

Failure of thermostat (Not open)

Fuel leak into the head cover
Improper fuel injection time

Failure of regulator valve

Damage of water pump

Damage of EGR cooler
Failure of supply pump

Failure of relief valve

Failure of oil pump
Failure of injector
Trouble

Poor start ability (Take a long time)

Faulty starting

Faulty engine starting/engine does not rotate.

Faulty engine starting/engine rotates but no
exhaust gas (No fuel injection)

Faulty engine starting/exhaust gas is emitted

but engine does not start (With fuel injection)
Poor output Insufficient

Engine poor run-up (Low follow-up ability)

rotation

Rotation in bad condition (hunting)

Engine stalled during operation.
Output is lowered.
Overheating
Exhaust smoke is in black
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Other failures

Early contamination of oil

Larger fuel consumption
Intruding of oil in coolant, back flow, reduction
of coolant quantity
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Vibration

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47. TROUBLESHOOTING (BY TROUBLE)

Engine body
Factors

Wear and damage of rear oil seal and seal surface

Damage and seizing of piston and connecting rod
Damage of engine oil cooler core and O-ring

Damage of cylinder head and head gasket

Wear and failure of valve and valve guide

Wear of piston ring and liner, ring stick

Strainer clogged, damage of oil pipe

Failure of injection holder sleeve

Damage of flywheel gear

Hole due to cavitation

Damage of dumper
Trouble

Poor start ability (Take a long time)

Faulty starting

Faulty engine starting/engine does not rotate.

Faulty engine starting/engine rotates but no
exhaust gas (No fuel injection)

Faulty engine starting/exhaust gas is emitted

but engine does not start (With fuel injection)
Poor output Insufficient

Engine poor run-up (Low follow-up ability)

rotation

Rotation in bad condition (hunting)

Engine stalled during operation.
Output is lowered.
Overheating
Exhaust smoke is in black
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Other failures

Early contamination of oil

Larger fuel consumption
Intruding of oil in coolant, back flow, reduction
of coolant quantity
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Vibration

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