Technical Manual

EX400-5, EX400LC-5, EX450LC-5
Technical Manual
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 1
GENERAL
—CONTENTS—
Group 1 Specification
Specifications ...........................................T1-1-1
Working Ranges / Transporting
Dimensions ............................................T1-1-9
Group 2 Component Layout

Main Components ....................................T1-2-1
Electrical System (1) ................................T1-2-2
Control Valve............................................T1-2-6
Others ....................................................T1-2-10
Group 3 Component Specifications

Engine......................................................T1-3-1
Engine Accessories ..................................T1-3-4
Hydraulic Device ......................................T1-3-4
Filters .......................................................T1-3-8
Electrical Equipment.................................T1-3-8
166T-1-1
(Blank)
166T-1-2
GENERAL / Specification
SPECIFICATIONS
EX400-5: Serial No.007661 or earlier
EX400LC-5: Serial No.007703 or earlier
(BACKHOE)
Model EX400-5 Hydraulic Excavator EX400LC-5 Hydraulic Excavator
Type of Front-End Attachment 3.4 m (11 ft 2 in) Arm
3 3 3 3 3 3
Bucket Capacity (Heaped) PCSA 1.82 m (2.38 yd ), CECE 1.6 m PCSA 2.07 m (2.71 yd ), CECE 1.8 m
Operating Weight 41900 kg (92400 lb) 44500 kg (98100 lb)
Basic Machine Weight 33000 kg (72800 lb) 35500 kg (78300 lb)
1 –1
Engine Isuzu:∗ A-6RB1TQA 221 kW / 2000 min (305 PS / 2000 rpm)
2 –1
Isuzu:∗ A-6RB1TQA-02 226 kW / 2000 min (307 PS / 2000 rpm)
A: Overall Width
3670 mm (12 ft 0 in) 3750 mm (12 ft 4 in)
(Excluding Rear-View
Mirrors)
B: Cab Height 3130 mm (10 ft 3 in) 3280 mm (10 ft 9 in)
C: Rear End Swing Radius 3450 mm (11 ft 4 in) 3450 mm (11 ft 4 in)
3 3
D: Minimum Ground Clearance ∗ 496 mm (20 in) ∗ 738 mm (29 in)
3 3
E: Counterweight Clearance ∗ 1230 mm (4 ft 0 in) ∗ 1350 mm (4 ft 5 in)
F: Engine Cover Height 2720 mm (8 ft 11 in) 2840 mm (9 ft 4 in)
G: Overall Width of
3610 mm (11 ft 10 in) 3610 mm (11 ft 10 in)
Upperstructure
H: Undercarriage Length 5050 mm (16 ft 7 in) 5470 mm (17 ft 11 in)
3520 mm (11 ft 7 in)/
I: Undercarriage Width 3370 mm (11 ft 1 in) 3020 mm (9 ft 11 in)
(Extended/Retracted)
J: Sprocket Center to Idler Center 4050 mm (13 ft 3 in) 4470 mm (14 ft 8 in)
K: Track Shoe Width 600 mm (24 in) (Grouser shoe)
2 2
Ground Pressure 78 kPa (0.79 kgf / cm , 11.2 psi) 75 kPa (0.77 kgf / cm , 10.9 psi)
-1 -1
Swing Speed 9.0 min (rpm) 9.0 min (rpm)
Travel Speed (Fast / Slow) 5.5 / 3.4 km/h (3.4 / 2.1 mph)
Gradeability 35° (70 %)
A C
G
B F
E
D
K J
I H
T166-01-01-004
1
NOTE: ∗ Engine on serial No.007295 or earlier.
∗2 Engine on serial No.007296 or after.
∗3 The dimensions do not include the
height of the shoe lug.
T1-1-1
EX450H-5: Serial No.007661 or earlier
EX450LCH-5: Serial No.007703 or earlier
(BACKHOE)
Model EX450H-5 Hydraulic Excavator EX450LCH-5 Hydraulic Excavator
Type of Front-End Attachment 3.4 m (11 ft 2 in) HD Arm
3 3 3
Bucket Capacity (Heaped) PCSA 1.82 m (2.38 yd ), CECE 1.6 m
1 –1
2 –1
A: Overall Width
3670 mm (12 ft 0 in) 3750 mm (12 ft 4 in)
(Excluding Rear-View Mirrors)
3 3
D: Minimum Ground Clearance ∗ 496 mm (20 in) ∗ 738 mm (29 in)
3 3
E: Counterweight Clearance ∗ 1230 mm (4 ft 0 in) ∗ 1350 mm (4 ft 5 in)
G: Overall Width of Upperstructure 3610 mm (11 ft 10 in) 3610 mm (11 ft 10 in)
3520 mm (11 ft 7 in)/
2 2
-1 -1
A C
G
B
F
E
D
K J
I H
T166-01-01-006
1
T1-1-2
(BACKHOE)
Model EX450LC-5 Hydraulic Excavator
3 3 3
Operating Weight 44500 kg (98100 lb)
Basic Machine Weight 35500 kg (78300 lb)
1 –1
2 –1
A: Overall Width
3750 mm (12 ft 4 in)
B: Cab Height 3280 mm (10 ft 9 in)
C: Rear End Swing Radius 3450 mm (11 ft 4 in)
3
D: Minimum Ground Clearance ∗ 738 mm (29 in)
3
E: Counterweight Clearance ∗ 1350 mm (4 ft 5 in)
F: Engine Cover Height 2840 mm (9 ft 4 in)
G: Overall Width of Upperstructure 3610 mm (11 ft 10 in)
H: Undercarriage Length 5470 mm (17 ft 11 in)
3520 mm (11 ft 7 in) / 3020 mm (9 ft 11 in)
I: Undercarriage Width
(Extended / Retracted)
J: Sprocket Center to Idler Center 4470 mm (14 ft 8 in)
2
Ground Pressure 75 kPa (0.77 kgf / cm , 10.9 psi)
-1
Swing Speed 9.0 min (rpm)
A C
G
B
F
E
D
K J
I H
T166-01-01-004
1
T1-1-3
(LOADING SHOVEL)
Model EX400-5
Type of Front-End Attachment Loading front atta.
3 3 3 3
Bucket Capacity (Heaped) PCSA 2.3 m PCSA 2.6 m PCSA 2.6 m PCSA 2.8 m
3 3 3 3
(3.01 yd ) (3.40 yd ) (3.40 yd ) (3.66 yd )
(Bottom Dump) (Bottom Dump) (Tilt Dump) (Tilt Dump)
Operating Weight 43900 kg 43500 kg 43200 kg 43300 kg
(96800 lb) (95900 lb) (95200 lb) (95500 lb)
1 –1
Isuzu:∗ A-6RB1TQA 221 kW / 2000 min (305 PS / 2000 rpm)
Engine 2 –1
A: Overall Width 3670 mm (12 ft 0 in)
3
3
G: Overall Width of 3610 mm (11 ft 10 in)
Upperstructure
I: Undercarriage Width 3370 mm (11 ft 1 in)
K: Track Shoe Width 600 (24 in) (Grouser shoe)
Ground Pressure 82 kPa 81 kPa 81 kPa 81 kPa
2 2 2 2
(0.83 kgf/cm , (0.82 kgf/cm , (0.82 kgf/cm , (0.82 kgf/cm ,
11.8 psi) 11.7 psi) 11.7 psi) 11.7 psi)
-1
Travel Speed (Fast / Slow) 5.5/3.4 kw/h (3.4/2.1 mph)
Gradeability 35°(70 %)
A C
G
B F
E
D
K J
I H
T166-01-01-004
1
NOTE: ∗ Engine on serial No.007295 or earlier. ∗3 The dimensions do not include the
∗2 Engine on serial No.007296 or after. height of the shoe lug.
T1-1-4
EX400-5: Serial No.007662 or after
EX400LC-5: Serial No.007704 or after
(BACKHOE)
Model EX400-5 Hydraulic Excavator EX400LC-5 Hydraulic Excavator
3 3 3 3 3 3
Bucket Capacity (Heaped) PCSA 1.82 m (2.38 yd ), CECE 1.6 m PCSA 2.07 m (2.71 yd ), CECE 1.8 m
–1
Engine Isuzu A-6RB1TQA-02 226 kW / 2000 min (307 PS / 2000 rpm)
A: Overall Width
3670 mm (12 ft 0 in) 3750 mm (12 ft 4 in)
(Excluding Rear-View
Mirrors)
D: Minimum Ground Clearance ∗496 mm (20 in) ∗738 mm (29 in)
E: Counterweight Clearance ∗1230 mm (4 ft 0 in) ∗1350 mm (4 ft 5 in)
G: Overall Width of
3610 mm (11 ft 10 in) 3610 mm (11 ft 10 in)
Upperstructure
3520 mm (11 ft 7 in)/
2 2
-1 -1
A C
G
B F
E
D
K J
I H
T166-01-01-004
NOTE: ∗ The dimensions do not include the height

of the shoe lug.
T1-1-5
EX450H-5: Serial No.007662 or after
EX450LCH-5: Serial No.007704 or after
(BACKHOE)
Model EX450H-5 Hydraulic Excavator EX450LCH-5 Hydraulic Excavator
3 3 3
–1
A: Overall Width
3670 mm (12 ft 0 in) 3750 mm (12 ft 4 in)
D: Minimum Ground Clearance ∗496 mm (20 in) ∗738 mm (29 in)
E: Counterweight Clearance ∗1230 mm (4 ft 0 in) ∗1350 mm (4 ft 5 in)
G: Overall Width of Upperstructure 3610 mm (11 ft 10 in) 3610 mm (11 ft 10 in)
3520 mm (11 ft 7 in)/
2 2
-1 -1
A C
G
B
F
E
D
K J
I H
T166-01-01-006

of the shoe lug.
T1-1-6
(BACKHOE)
Model EX450LC-5 Hydraulic Excavator
3 3 3
Operating Weight 44800 kg (98800 lb)
–1
A: Overall Width
3750 mm (12 ft 4 in)
D: Minimum Ground Clearance ∗738 mm (29 in)
E: Counterweight Clearance ∗1350 mm (4 ft 5 in)
G: Overall Width of Upperstructure 3610 mm (11 ft 10 in)
3520 mm (11 ft 7 in) / 3020 mm (9 ft 11 in)
I: Undercarriage Width
(Extended / Retracted)
2
Ground Pressure 76 kPa (0.78 kgf / cm , 10.9 psi)
-1
A C
G
B F
E
D
K J
I H
T166-01-01-004

of the shoe lug.
T1-1-7
(LOADING SHOVEL)
Model EX400-5
Type of Front-End Attachment Loading front atta.
3 3 3 3
Bucket Capacity (Heaped) PCSA 2.3 m PCSA 2.6 m PCSA 2.6 m PCSA 2.8 m
3 3 3 3
(3.01 yd ) (3.40 yd ) (3.40 yd ) (3.66 yd )
(Bottom Dump) (Bottom Dump) (Tilt Dump) (Tilt Dump)
Operating Weight 43900 kg 43500 kg 43200 kg 43300 kg
(96800 lb) (95900 lb) (95200 lb) (95500 lb)
–1 (
Engine Isuzu A-6RB1TQA-02 226 kW/2000 min 307 PS/2000 rpm)
A: Overall Width
3670 mm (12 ft 0 in)
G: Overall Width of 3610 mm (11 ft 10 in)
Upperstructure
I: Undercarriage Width 3370 mm (11 ft 1 in)
K: Track Shoe Width 600 (24 in) (Grouser shoe)
Ground Pressure 82 kPa 81 kPa 81 kPa 81 kPa
2 2 2 2
(0.84 kgf/cm , (0.83 kgf/cm , (0.83 kgf/cm , (0.83 kgf/cm ,
11.8 psi) 11.7 psi) 11.7 psi) 11.7 psi)
-1
Travel Speed (Fast / Slow) 5.5/3.4 km/h (3.4/2.1 mph)
Gradeability 35°(70 %)
A C
G
B F
E
D
K J
I H
T166-01-01-004

of the shoe lug.
T1-1-8
WORKING RANGES / TRANSPORTING
DIMENSIONS
(BACKHOE)
Backhoe
M111-11-002
Working Range (EX400-5, EX400LC-5)

Category 2.9 m (9 ft 6 in) Arm 3.4 m (11 ft 2 in) Arm 3.9 m (12 ft 10 in) Arm 4.9 m (16 ft 1 in) Arm
Item Backhoe Backhoe Backhoe Backhoe
EX400-5 EX400LC-5 EX400-5 EX400LC-5 EX400-5 EX400LC-5 EX400-5 EX400LC-5
A: Maximum Digging mm 11390 11420 12050 12050 12480 12480 13340 13340
Reach (ftxin) (37’4”) (37’6”) (39’6”) (39’6”) (40’11”) (40’11”) (43’9”) (43’9”)
B: Maximum Digging mm ∗7390 ∗7300 ∗7890 ∗7760 ∗8390 ∗8260 ∗9240 ∗9110
Depth (ftxin) (24’3”) (23’11”) (25’11”) (25’6”) (27’6”) (27’1”) (30’4”) (29’11”)
C: Maximum Cutting mm ∗10150 ∗10270 ∗10950 ∗11080 ∗11050 ∗11180 ∗11610 ∗11730
Height (ftxin) (33’4”) (33’8”) (35’11”) (36’4”) (36’3”) (38’8”) (38’1”) (38’6”)
D: Maximum Dumping mm ∗6910 ∗7040 ∗7540 ∗7660 ∗7660 ∗7780 ∗8540 ∗8670
Height (ftxin) (22’8”) (23’1”) (24’9”) (25’2”) (25’2”) (25’6”) (28’0”) (28’5”)
E: Transport Height mm 3560 3600 3450 3480 3470 3480 4660 4660
(ftxin) (11’8”) (11’10”) (11’4”) (11’5”) (11’5”) (11’5”) (15’3”) (15’3”)
F: Overall Transport mm 11900 11880 11820 11790 11820 11790 11630 11700
Length (ftxin) (39’1”) (39’0”) (38’9”) (38’8”) (38’9”) (38’8”) (38’2”) (38’5”)
G: Minimum Swing mm 4920 4920 4840 4840 4810 4810 4820 4820
Radius (ftxin) (16’2”) (16’2”) (15’11”) (15’11”) (15’9”) (15’9”) (15’10”) (15’10”)

of the shoe lug.
T1-1-9
EX450H-5: Serial No.007661 or earlier
EX450LCH-5: Serial No.007703 or earlier
(BACKHOE)
Backhoe
M111-11-002
Working Range (EX450H-5, EX450LCH-5)

Category 3.4 m (11 ft 2 in) HD Arm
Backhoe
Item EX450H-5 EX450LCH-5
A: Maximum Digging Reach mm 12050 12050
(ftxin) (39’6”) (39’6”)
B: Maximum Digging Depth mm ∗7890 ∗7760
(ftxin) (25’11”) (25’6”)
C: Maximum Cutting Height mm ∗10950 ∗11080
(ftxin) (35’11”) (36’4”)
D: Maximum Dumping Height mm ∗7540 ∗7660
(ftxin) (24’9”) (25’2”)
E: Transport Height mm 3450 3480
(ftxin) (11’4”) (11’5”)
F: Overall Transport Length mm 11820 11790
(ftxin) (38’9”) (38’8”)
G: Minimum Swing Radius mm 4840 4840
(ftxin) (15’11”) (15’11”)

of the shoe lug.
T1-1-10
(BACKHOE)
Backhoe
M111-11-002
Working Range (EX450LC-5)

EX450LC-5 EX450LC-5 EX450LC-5 EX450LC-5
A: Maximum Digging mm 11420 12050 12480 13340
Reach (ftxin) (37’6”) (39’6”) (40’11”) (43’9”)
B: Maximum Digging mm ∗7300 ∗7760 ∗8260 ∗9110

Depth (ftxin) (23’11”) (25’6”) (27’1”) (29’11”)
C: Maximum Cutting mm ∗10270 ∗11080 ∗11180 ∗11730

Height (ftxin) (33’8”) (36’4”) (38’8”) (38’6”)
D: Maximum Dumping mm ∗7040 ∗7660 ∗7780 ∗8670

Height (ftxin) (23’1”) (25’2”) (25’6”) (28’5”)
E: Transport Height mm 3600 3480 3480 4660

(ftxin) (11’10”) (11’5”) (11’5”) (15’3”)
F: Overall Transport mm 11880 11790 11790 11700

Length (ftxin) (39’0”) (38’8”) (38’8”) (38’5”)
G: Minimum Swing mm 4920 4840 4810 4820

Radius (ftxin) (16’2”) (15’11”) (15’9”) (15’10”)

of the shoe lug.
T1-1-11
(LOADING SHOBEL)
Bottom Dump Tilt Dump

T166-01-01-002
Loader
Working Range (EX400-5)

Category
Item
(mm) 2860 2360
A: Minimum Digging Reach (ftxin) (9’4”) (7’10”)
(mm) 5070 5030
B: Minimum Level Crowding Reach (ftxin) (16’8”) (16’6”)
(mm) 3340 3370
C: Level Crowding Distance (ftxin) (11’0”) (11’1”)
(mm) 8760 8720
D: Maximum Digging Reach (ftxin) (28’9”) (28’7”)
(mm) 4260 4230
E: Maximum Digging Depth (ftxin) (14’0”) (13’11”)
(mm) 9940 9900
F: Maximum Cutting Height (ftxin) (32’7”) (32’6”)
(mm) 7370 4290
G: Maximum Dumping Height (ftxin) (24’3”) (14’1”)
H: Maximum Bucket Tilting (°) 54° 51°
Degree to Ground
(mm) 1390
I: Maximum Bucket Opening Width -
(ftxin) (4’7”)
T1-1-12
(BACKHOE)
Backhoe
M111-11-002
Working Range (EX400-5, EX400LC-5)

EX400-5 EX400LC-5 EX400-5 EX400LC-5 EX400-5 EX400LC-5 EX400-5 EX400LC-5
A: Maximum Digging mm 11390 11420 12050 12050 12480 12480 13340 13340
Reach (ftxin) (37’4”) (37’6”) (39’6”) (39’6”) (40’11”) (40’11”) (43’9”) (43’9”)
B: Maximum Digging mm ∗7390 ∗7300 ∗7890 ∗7760 ∗8390 ∗8260 ∗9240 ∗9110
Depth (ftxin) (24’3”) (23’11”) (25’11”) (25’6”) (27’6”) (27’1”) (30’4”) (29’11”)
C: Maximum Cutting mm ∗10150 ∗10270 ∗10950 ∗11080 ∗11050 ∗11180 ∗11610 ∗11730
Height (ftxin) (33’4”) (33’8”) (35’11”) (36’4”) (36’3”) (38’8”) (38’1”) (38’6”)
D: Maximum Dumping mm ∗6910 ∗7040 ∗7540 ∗7660 ∗7660 ∗7780 ∗8540 ∗8670
Height (ftxin) (22’8”) (23’1”) (24’9”) (25’2”) (25’2”) (25’6”) (28’0”) (28’5”)
E: Transport Height mm 3560 3600 3450 3480 3470 3480 4660 4660
(ftxin) (11’8”) (11’10”) (11’4”) (11’5”) (11’5”) (11’5”) (15’3”) (15’3”)
F: Overall Transport mm 11900 11880 11820 11790 11820 11790 11630 11700
Length (ftxin) (39’1”) (39’0”) (38’9”) (38’8”) (38’9”) (38’8”) (38’2”) (38’5”)
G: Minimum Swing mm 4920 4920 4840 4840 4810 4810 4820 4820
Radius (ftxin) (16’2”) (16’2”) (15’11”) (15’11”) (15’9”) (15’9”) (15’10”) (15’10”)
NOTE: ∗ The dimensions do not include the

heightof the shoe lug.
T1-1-13
EX450H-5: Serial No.007662 or after
EX450LCH-5: Serial No.007704 or after
(BACKHOE)
Backhoe
M111-11-002
Working Range (EX450H-5, EX450LCH-5)

Category 3.4 m (11 ft 2 in) HD Arm
Backhoe
Item EX450H-5 EX450LCH-5
A: Maximum Digging Reach mm 12050 12050
(ftxin) (39’6”) (39’6”)
B: Maximum Digging Depth mm ∗7890 ∗7760
(ftxin) (25’11”) (25’6”)
C: Maximum Cutting Height mm ∗10950 ∗11080
(ftxin) (35’11”) (36’4”)
D: Maximum Dumping Height mm ∗7540 ∗7660
(ftxin) (24’9”) (25’2”)
E: Transport Height mm 3450 3480
(ftxin) (11’4”) (11’5”)
F: Overall Transport Length mm 11820 11790
(ftxin) (38’9”) (38’8”)
G: Minimum Swing Radius mm 4840 4840
(ftxin) (15’11”) (15’11”)

of the shoe lug.
T1-1-14
(BACKHOE)
Backhoe
M111-11-002
Working Range (EX450LC-5)

EX450LC-5 EX450LC-5 EX450LC-5 EX450LC-5
A: Maximum Digging mm 11420 12050 12480 13340
Reach (ftxin) (37’6”) (39’6”) (40’11”) (43’9”)
B: Maximum Digging mm ∗7300 ∗7760 ∗8260 ∗9110

Depth (ftxin) (23’11”) (25’6”) (27’1”) (29’11”)
C: Maximum Cutting mm ∗10270 ∗11080 ∗11180 ∗11730

Height (ftxin) (33’8”) (36’4”) (38’8”) (38’6”)
D: Maximum Dumping mm ∗7040 ∗7660 ∗7780 ∗8670

Height (ftxin) (23’1”) (25’2”) (25’6”) (28’5”)
E: Transport Height mm 3600 3480 3480 4660

(ftxin) (11’10”) (11’5”) (11’5”) (15’3”)
F: Overall Transport mm 11880 11790 11790 11700

Length (ftxin) (39’0”) (38’8”) (38’8”) (38’5”)
G: Minimum Swing mm 4920 4840 4810 4820

Radius (ftxin) (16’2”) (15’11”) (15’9”) (15’10”)

of the shoe lug.
T1-1-15
(LOADING SHOVEL)

T166-01-01-002
Loader
Working Range (EX400-5)

Category
Item
A: Minimum Digging Reach (mm) 2860 2360
(ftxin) (9’4”) (7’10”)
B: Minimum Level Crowding Reach (mm) 5070 5030
(ftxin) (16’8”) (16’6”)
C: Level Crowding Distance (mm) 3340 3370
(ftxin) (11’0”) (11’1”)
D: Maximum Digging Reach (mm) 8760 8720
(ftxin) (28’9”) (28’7”)
E: Maximum Digging Depth (mm) 4260 4230
(ftxin) (14’0”) (13’11”)
F: Maximum Cutting Height (mm) 9940 9900
(ftxin) (32’7”) (32’6”)
G: Maximum Dumping Height (mm) 7370 4290
(ftxin) (24’3”) (14’1”)
H: Maximum Bucket Tilting
Degree to Ground (°) 54° 51°
I: Maximum Bucket Opening Width (mm) 1390 -
(ftxin) (4’7”)
T1-1-16
GENERAL / Component Layout
MAIN COMPONENTS
2
3
1
4
36 5
6
7
8
9
10
11
12
13
14
15
35 16
34
33 17
18
32 19
31 20
30 21
29 22
28 23
27 24
26 T166-01-02-007
25
1 - Bucket Cylinder 10 - Fuel Tank 19 - Muffler 28 - Swing Shuttle Valve

2 - Arm 11 - Control Valve 20 - Drain Filter 29 - Shockless Valve (Front)
3 - Arm Cylinder 12 - Air Filter 21 - Solenoid Valve Unit 30 - Lower Roller
(3 Solenoid Valve Used)
4- Boom 13 - Engine 22 - Pump Device 31 - Travel Shuttle Valve
5- Boom Cylinder 14 - Radiator 23 - Pilot Filter 32 - Pilot Shut-Off Valve
6- Front/Swing Pilot Valve 15 - Oil Cooler 24 - Hydraulic Oil Tank 33 - Track Adjuster
7- Swing Bearing 16 - Counterweight 25 - Travel Device 34 - Front Idler
8- Center Joint 17 - Fuel Filter 26 - Shockless Valve (Travel) 35 - Travel Pilot Valve
9- Swing Device 18 - Engine Oil Filter 27 - Upper Roller 36 - Bucket
T1-2-1
ELECTRICAL SYSTEM(1) 2
3
(Overall System) 4
5 12
1 6 13
7
8 14
9 15
38 10 16
(Option) 11 17
37
18
19
36 20
35
21
34 22
33 23
32 24
31 25
30
29 T166-01-02-015
28
27
26
1 - Work Light (On Boom) 11 - Coolant Temperature Sensor 21 - Engine Stop Motor 30 - Hydraulic Oil Temperature
(For Monitor) Switch
2 - Monitor 12 - Overheat Switch H 22 - Engine Oil Pressure Switch 31 - Pressure Switch (Other)
3 - Pressure Switch (Travel) 13 - Alternator 23 - EC Motor 32 - Pressure Switch (Swing)
4 - Horn 14 - Starter Relay 24 - N (Engine Speed) Sensor 33 - Pressure Switch
(Arm Roll-In)
5 - Work Light 15 - Fusible Link 25 - Starter 34 - Pressure Switch
(on Right Side Frame) (Boom Raise)
6 - Fuel Sensor 16 - Battery Relay 26 - Coolant Level Switch 35 - Windshield Washer Motor
7 - Low Fuel Level Switch 17 - Emergency Relay 27 - DP Sensor (5-Spool Side) 36 - Fuse Box
8 - DP Sensor (4-Spool Side) 18 - Battery 28 - 3-Spool Solenoid Valve Unit 37 - ∗Outside Temperature Sensor
9 - Air Filter Restriction Switch 19 - Magnetic Valve 29 - Hydraulic Oil Level Switch 38 - ∗Work Light (on Cab)
(Option)
10 - Overheat Switch L 20 - Engine Oil Level Switch
NOTE: Electrical components marked with ∗ are
installed on the following machines:
EX400-5: Serial No. 007662 and after EX450LC-5: Serial No. 007704 and after
EX400LC-5: Serial No. 007704 and after EX450H-5: Serial No. 007662 and after
EX450LCH-5: Serial No. 007704 and after
T1-2-2
ELECTRICAL SYSTEM (2)
Relays
2
3
4
5
6
7
24
8 (Option)
9
10
11
12
23
13
22 14
15, 16
T166-01-02-016
21 20 19 18 17
1 - Power Boost Switch 7 - Wiper Relay BM 13 - Preheat Relay 2 19 - Blower Medium Position
Relay 1
2- Load Dump Relay 8- EC Motor Relay 14 - Preheat Relay 1 20 - Compressor Clutch Relay
3- Wiper Relay B1 9- Work Light Relay 1 15 - EC 21 - Blower Main Relay
4- Washer Relay 10 - Work Light Relay 2 16 - PVC 22 - Dr. EX Connector
5- Wiper Relay B2 11 - Horn Relay 17 - Blower Fast Position Relay 23 - Fuse Box
6- Engine Stop Motor Relay 12 - Wiper Relay A 18 - Blower Medium Position 24 - ∗Work Light Relay 3
Relay 2 (Option)
NOTE: Work light relay 3 marked with ∗ is installed
on the following machines:
EX400-5: Serial No. 007662 and after
EX400LC-5: Serial No. 007704 and after
EX450H-5: Serial No. 007662 and after
T1-2-3
Monitor and Switch Panels Monitor Panel
10 11 12
37
1 13
36
14
2 35
15
34 16
33 17
18
32
19
3
9
8 31
20
7 30
21
6 22
29
23
5 24
4 28
25
27 26 M166-01-013
T166-01-02-017
1- Monitor Panel 11 - Coolant Temperature Gauge 20 - Attachment Mode Indicator 29 - Washer Switch
2- Switch Panel 12 - Fuel Gauge 21 - Precision Mode Indicator 30 - Work Light Switch
3- Cigar Lighter 13 - SP Mode Indicator 22 - Trenching Mode Indicator 31 - Level Check Switch
4- Option Switch 14 - E Mode Indicator 23 - General Purpose Mode 32 - Overheat Indicator
Indicator
5 - Air Conditioner Control Panel 15 - Auto-Idle Indicator 24 - Work Mode Switch 33 - Engine Oil Pressure
Indicator
6- Engine Control Dial 16 - Hydraulic Oil Level Indicator 25 - Buzzer Stop Switch 34 - Alternator Indicator
7- E Mode Switch 17 - Preheat Indicator 26 - Travel Mode Switch 35 - Engine Oil Level Indicator
8- SP Mode Switch 18 - Air Filter Restriction Indicator 27 - Auto-Idle Switch 36 - Coolant Level Indicator
9- Key Switch 19 - Fuel Level Indicator 28 - Wiper Switch 37 - ∗ Solar Radiation Sensor
10 - Warm Up Complete Indicator
NOTE: Solar radiation sensor marked with ∗ is in-
stalled on the following machines:
T1-2-4
(Blank)
T1-2-5
Control Valve
1 2 3 43 4 5 6 7 8 9 10 11 12 13 14 15
42
41 Swing Motor
Boom Cylinder
Arm Cylinder
40
39
16
Bucket Cylinder
17
38 18
19
37
20
36 21
22
35
23
34
33
Right Travel Motor Left Travel Motor

32 31 30 29 28 27 26 25 24 T166-01-02-019
1 - Holding Valve Shift Valve 12 - Load Check Valve 23 - DP Sensor 34 - Load Check Valve (Bucket
(Boom) (Arm 1 Tandem Circuit) (5-Spool Side) Tandem Circuit)
2 - Load Check Valve 13 - Holding Valve Shift Valve 24 - Pump Control Valve 35 - Check Valve (∗Aux. Parallel
(Arm 2 Tandem Circuit) (Arm) (5-Spool Side) Circuit)
3 - Pump Control Valve 14 - Overload Relief Valve 25 - Load Check Valve (Left 36 - Load Check Valve (Boom 1
(4- Spool Side) (Swing) Travel Parallel Circuit) Parallel Circuit)
4 - Load Check Valve 15 - Overload Relief Valve 26 - Load Check Valve 37 - Overload Relief Valve
(Arm 2 Parallel Circuit) (Arm) (∗Aux. Parallel Circuit) (Bucket)
5 - Check Valve (Arm Flow 16 - Holding Check Valve (Arm) 27 - Check Valve (Bucket Flow 38 - Check Valve (Boom Flow
Combining Circuit) Combining Circuit) Combining Circuit)
6 - Check Valve (∗Aux. Flow 17 - Make-Up Valve (Boom 2) 28 - Check Valve (Main Relief 39 - Overload Relief Valve (Boom)
Combining Circuit) Pressure Combining Circuit)
7 - Arm Regenerative Flow 18 - Load Check Valve (Boom 2 29 - Flow Combiner Valve 40 - Holding Check Valve (Boom)
Control Valve Tandem Circuit)
8 - Check Valve 19 - Load Check Valve 30 - Check Valve (Travel Flow 41 - Make-Up Valve (Arm 2)
(Arm 1 Parallel Circuit) (Boom 2 Parallel Circuit) Combining Circuit)
9 - Load Check Valve 20 - Load Check Valve 31 - Check Valve 42 - DP Sensor (4-Spool Side)
(Arm 1 Parallel Circuit) (∗Aux. Tandem Circuit)
10 - Load Check Valve 21 - Overload Relief Valve (∗Aux.) 32 - Shuttle Valve 43 - Center Bypass Valve
(Swing Tandem Circuit)
11 - Arm Regenerative Valve 22 - Load Check Valve (Left Travel 33 - Main Relief Valve
Tandem Circuit)
NOTE: ∗ In the case of Loading shovel specifica-
tion (bottom dump), this valve is used for
bucket’s opening and closing.
T1-2-6
Swing Arm 1
Boom 2 32 33 24 23
∗Aux.
Left Travel
Arm 2
Boom 1
Bucket
31
Right Travel
Front Side
T162-05-02-012
30 29 T162-05-02-009
44 28 45
37 48 35 49 21
Right Travel Left Travel Bucket ∗Aux.
22
20
34 26
25
21
T166-01-02-004
T162-05-02-004
47 46 37 51 6 27 50
44 - Right Travel Forward Port 46 - Left Travel Reverse Port 48 - Bucket (Roll-Out) Port 50 - ∗Aux. Port
45 - Left Travel Forward Port 47 - Right Travel Reverse Port 49 - ∗Aux. Port 51 - Bucket (Roll-In) Port
T1-2-7
1 2 3 43 4 5 6 7 8 9 10 11 12 13 14 15
42
41 Swing Motor
Boom Cylinder
Arm Cylinder
40
39
16
Bucket Cylinder
17
38 18
19
37
20
36 21
22
35
23
34
33

32 31 30 29 28 27 26 25 24 T166-01-02-019
Tandem Circuit)
NOTE: ∗ In the case of Loading shovel specifica- BH: Backhoe
tion (bottom dump), this valve is used for LD: Loading Shovel
T1-2-8
56 5 57
Arm 2 Arm 1
52 53
7
Boom 1 Boom 2
41 16 13
17
39 8
36 18 12
1
19 4 9
15
38 59 58 T166-01-02-003
40 55 38 54 T166-01-02-002
42 3 60
14
Swing
15
43
10
14
T162-05-02-010
40 61
T162-05-02-008
52 - Boom 1 (Lower) Port 55 - Boom 1 (Raise) Port 58 - BH: Arm 1 (Roll-In) Port 60 - Swing (Left) Port
LD: Arm 1 (Extend) Port
53 - Boom 2 (Lower) Port 56 - BH: Arm 2 (Roll-Out) Port 59 - BH: Arm 2 (Roll-In) Port 61 - Swing (Right) Port
LD: Arm 2 (Retract) Port LD: Arm 2 (Extend) Port
54 - Boom 2 (Raise) Port 57 - BH: Arm 1 (Roll-Out) Port
LD: Arm 1 (Retract) Port
T1-2-9
OTHERS
Pump Device
4
3
2
9 8 T166-01-02-010
3-Spool Solenoid Valve Unit
10 11 12 13
T166-01-02-011
1 - Pump Control Proportional 5- Main Pump 1 8 - P (Pressure) Sensor (Main Pump 2) 11 - Travel Mode Shift
Solenoid Valve (Main Pump 2) Solenoid Valve
2 - A (Displacement Angle) 6- Pilot Pump 9 - Main Pump 2 12 - Main Relief Pressure
Sensor (Main Pump 2) Shift Solenoid Valve
3 - Pump Control Proportional 7- A (Displacement Angle) 10 - Swing Parking Brake 13 - Pilot Relief Valve
Solenoid Valve (Main Pump 1) Sensor (Main Pump 1) Release Solenoid Valve
4 - P (Pressure) Sensor
(Main Pump 1)
T1-2-10
Swing Device Travel Device
1
T142-01-02-012
T166-01-02-012
1 - Swing Relief Valve 2 - Counterbalance Valve 3 - Travel Relief Valve
T1-2-11
(Blank)
T1-2-12
GENERAL / Specifications
COMPONENT SPECIFICATIONS
ENGINE
MAIN SPECIFICATIONS
Manufacture ...................................... ISUZU
Model ................................................ Before Machine Serial Number. 007295: A-6RB1TQA
After Machine Serial Number 007296: A-6RB1TQA-02
Type .................................................. Diesel 4 cycle, vertical, 6-cylinder inline, turbocharged,
water-cooled, direct injection type
Cyl. No.-bore x stroke........................ 6-135 mm x 160 mm (5.32 in x 6.30 in)
3 3
Piston displacement .......................... 13741 cm (839 in )
–1
Rated output ..................................... Before Machine Serial Number 007295: 221 kW/2000 min
(305 PS/2000 rpm)
–1
After Machine Serial Number 007296: 226 kW/2000 min
(307 PS/2000 rpm)
Compression ratio ............................. 16.5
Dry weight ......................................... Before Machine Serial Number 007295: 1075 kg (2370 lb)
......................................................... After Machine Serial Number 007296: 1110 kg (2447 lb)
Firing order ....................................... 1-4-2-6-3-5
Rotation direction .............................. Clockwise (viewed from fan side)
Length x width x height...................... Before Machine Serial Number 007295:
1581 mm x 892 mm x 1274 mm (62.24x 35.12 x 50.16 in)
After Machine Serial Number 007296:
1600 mm x 896 mm x 1274 mm (62.99 x 35.28 x 50.16 in)
COOLING SYSTEM
Cooling fan........................................ Before Machine Serial Number 007295: Dia. 700 mm, 6 blades,
draw-in type
After Machine Serial Number 007296: Dia. 800 mm, 6 blades,
draw-in type
Fan pulley ratio.................................. Before Machine Serial Number 007295: Engine rpm x 1.08
After Machine Serial Number 007296: Engine rpm x 0.89
Thermostat........................................ Cracking temp.: 82 °C (180 °F)
(under atmospheric pressure) ........... Full open temp.: 95 °C (203 °F)
Water pump ...................................... Centrifugal type, belt driven
LUBRICATION SYSTEM
Lubrication pump type ....................... Gear pump
Oil filter ............................................. Full-flow paper element type with bypass function
Oil cooler........................................... Water-cooled, built-in
STARTING SYSTEM
Motor................................................. Magnetic pinion shift system, reduction type
VoltagexOutput .................................. 24 Vx11 kW
PRE-HEAT SYSTEM
Heating method ................................. Intake heater with magnetic valve
ENGINE STOP SYSTEM

Stop method...................................... Fuel cut
(Employes both key switch and engine stop motor)
T1-3-1
ALTERNATOR
Type .................................................. AC type (with IC regulator)
VoltagexOutput .................................. 24 Vx40 A (Consumption electric current is with in the limits of
alternator capacity by normal use. However, when
horn, lighter and so on are used, or working lights are
added, there is the case which consumption electric
current is beyond the limit of the Alternator capacity.)
NOTE: Actual consumption electric current …39.8 A
SUPERCHARGING SYSTEM
Type .................................................. Exhaust-gas-turbo type AID T51 REVISION
FUEL SYSTEM
Injection pump model ........................ Bosch-type-P model
Governor ........................................... Centrifugal all speed control EP/RSV
Injection nozzle ................................ Multihole nozzle
PERFORMANCE
3
Lubrication oil consumption ............... Less than 100 mL/h (6.1 in /h)
(New engine, at rated horsepower)
Fuel consumption ratio Before Machine Serial Number 007295:
243±14 g/kWxh (178±10 g/PS⋅h)
-1
@ 2000 min
(New engine, at rated horse power)
242±14 g/kWxh (178±10 g/PS⋅h)
-1
@ 2000 min
(New engine, at rated horse power)
Injection timing .................................. 14° before T.D.C.
Max. output torque ............................ 1226 Nxm (125 kgfxm, 904 lbfxft)
-1
or more at 1400 min
2
Injection pressure.............................. 19.6 MPa (200 kgf/cm , 2844 psi)
2 -1
Cylinder compression ........................ 2.84 MPa (29 kgf/cm , 412 psi) at 200 min
Valve clearance (inlet/exhaust) .......... 0.6/0.6 mm (when cool)
-1
No load speed ................................... Min.: 775±25 min
-1
Max.: 2200±30 min
T1-3-2
Engine Performance Curve A-6RB1TQA
(Before Machine Serial Number 007295: A-
6RB1TQA)
(After Machine Serial Number 007296: A-6RB1TQA-
02)
Test Conditions:
1. In conformity with JIS D1005 (Performance test 2. With fan and generator.
method for diesel engines used for construction 3. Without air cleaner.
machinery), under standard atmospheric
pressure.
PS kW Torque
1226 Nxm (125 kgfxm)/1400 min-1 (rpm)
TORQUE
Before Machine Serial Number 007295:

221 kW (305 PS)/2000 min-1 (rpm)
226 kW (307 PS)/2000 min-1 (rpm)
N⋅m kgf⋅m
HORSE POWER
Horse
Power
Fuel
Before Machine Serial Number 007295: Consumption
243±13.6 g/kWxh (179±10 g/PSxh) Rate
242±13.6 g/kWxh (178±10 g/PSxh)
FUEL CONSUMPTION
g/kW⋅h g/PS⋅h
ENGINE SPEED min-1 (rpm) T166-01-03-002
T1-3-3
ENGINE ACCESSORIES
RADIATOR ASSEMBLY
Type .................................................. Radiator/Oil cooler tandem type assembly
Weight Before Machine Serial Number 007295: 228 kg (503 lb)
After Machine Serial Number 007296: 235 kg (518 lb)
Radiator Oil cooler
Capacity ............................................ Before Serial Number 007295: Before Serial Number 007295:
12.5 L (3.3 US gal) 15.5 L (4.1 US gal)
After Serial Number 007296: After Serial Number 007296:
14 L (3.7 US gal) 16.5 L (4.4 US gal)
Air-tight testing pressure ................... 68.6 kPa 981 kPa
2 2
(0.7 kgf/cm , 1 psi) (10 kgf/cm , 142 psi)
Cap opening pressure ....................... 49 kPa –
2
(0.5 kgf/cm , 7 psi)
BATTERY
Capacity ............................................ 170 Ah (20 hours)
Voltage .............................................. 12 V
Weight .............................................. 49 kg (108 lb) x 2
HYDRAULIC DEVICES
PUMP DEVICE
Reduction ratio .................................. Engine: Main pump 1 : 1
Engine: Pilot pump 1 : 1.080
Weight .............................................. 274 kg (604 lb)
MAIN PUMP
Model ................................................ K3V180DHT19RR
Type .................................................. Variable displacement plunger pump:
regulator attached type
Max. flow (Theoretical value)............. 368 L/min (97.2 US gpm) x 2
PILOT PUMP
Model ................................................ HY/ZFS 11/16.8
Type .................................................. Fixed displacement type gear pump
Max. flow (Theoretical value)............. 36.0 L/min (9.51 US gpm)
T1-3-4
CONTROL VALVE (BACKHOE)
Model ................................................ UHX36-52
Type .................................................. Pilot pressure operated type (4-spool + 5-spool)
Main relief pressure........................... Front attachment:
2
29.4 MPa (300 kgf/cm , 4266 psi)
@ 80 L/min (21 US gpm)
Power boost (Travel):
2
34.3 MPa (350 kgf/cm , 4977 psi)
@ 200 L/min (53 US gpm)
Overload relief pressure ................... Boom, Arm, Bucket:
2
30.9 MPa (315 kgf/cm , 4480 psi)
@ 110 L/min (29 US gpm)
Swing:
2
26.5 MPa (270 kgf/cm , 3840 psi)
@ 160 L/min (42.3 US gpm)
Auxiliary 1:
2
35.3 MPa (360 kgf/cm , 5119 psi)
@ 110 L/min (29.1 US gpm)
Auxiliary 2:
2
27.9 MPa (285 kgf/cm , 4053 psi)
@ 110 L/min (29.1 US gpm)
CONTROL VALVE (LOADING SHOVEL)

Model ................................................ UHX36-55
Type .................................................. Pilot pressure operated type (4-spool + 5-spool)
Main relief pressure........................... Front attachment:
2
28.0 MPa (285 kgf/cm , 4053 psi)
@ 80 L/min (21 US gpm)
Power boost (Travel):
2
34.3 MPa (350 kgf/cm , 4977 psi)
@ 200 L/min (53 US gpm)
Overload relief pressure ................... Boom, Arm, Bucket, Bucket open:
2
30.9 MPa (315 kgf/cm , 4480 psi)
@ 110 L/min (29 US gpm)
Swing:
2
26.5 MPa (270 kgf/cm , 3840 psi)
@ 160 L/min (42.3 US gpm)
Bucket close:
2
12.7 MPa (130 kgf/cm , 1849 psi)
@ 110 L/min (29 US gpm)
SWING DEVICE
Type .................................................. Two-stage planetary reduction type
Reduction ratio .................................. 16.2
Weight .............................................. 280 kg (617 lb)
SWING MOTOR
Type ................................................... Swash-plate type, fixed-displacement plunger motor
Model ................................................ M2X150CAB-10A-06/250
Displacement .................................... 148.5 cm3/rev (9.06 in3/rev)
T1-3-5
SWING VALVE BRAKE
Type .................................................. Non counterbalence valve type
2
Relief pressure .................................. 24.5 MPa (250 kgf/cm , 3560 psi)
@ 90 L/min (23.7 US gpm)
SWING PARKING BRAKE

Type .................................................. Multiple-wet-disc negative type
2
Brake release cracking pressure ....... 2 MPa (20 kgf/cm , 284 psi)
TRAVEL DEVICE
Type .................................................. Three-stage planetary reduction gear
Reduction gear ratio .......................... 55.318
Weight .............................................. 660 kg (1455 Ib)
TRAVEL MOTOR
Model ................................................ MSF-270VP-CB
Type .................................................. Swash-plate type variable displacement plunger motor
3 3
Displacement (Theoretical value) ...... Fast speed: 175.7 cm (10.7 in )/rev.
3 3
Slow speed: 271.5 cm (16.6 in )/rev.
TRAVEL BRAKE VALVE

Type .................................................. Counter balance valve type
2
Relief pressure .................................. 36.8 MPa (375 kgf/cm , 5330 psi)
TRAVEL PARKING BRAKE

Type .................................................. Multiple-wet-disc negative type
2
Brake release cracking pressure ....... 1.67 MPa (17 kgf/cm , 242 psi)
CYLINDER (BACKHOE)
Boom Arm Bucket
Rod dia. ............................................
115 mm (4.53 in) 130 mm (5.11 in) *
Cylinder bore.....................................
170 mm (6.68 in) 190 mm (7.47 in) 170 mm (6.68 in)
Stroke ...............................................
1590 mm (62.5 in) 1940 mm (76.2 in) 1325 mm (52.1 in)
Fully retracted length.........................2260 mm (88.8 in) 2710 mm (106.5 in) 2041 mm (80.2 in)
25 µm or more
Plating thickness ............................... 25 µm or more 25 µm or more
(0.98 µin or more) (0.98 µin or more) (0.98 µin or more)
ңȀ3.4 m (11 ft 2 in) Standard Arm before Front No. 193: 115 mm (4.53 in)
Ȁ 3.4 m (11 ft 2 in) Standard Arm after Front No. 194: 120 mm (4.72 in)
Ȁ 3.4 m (11 ft 2 in) HD Arm before Front No. D13: 115 mm (4.53 in)
Ȁ 3.4 m (11 ft 2 in) HD Arm after Front No. D14: 120 mm (4.72 in)
Ȁ 3.9 m (12 ft 10 in) Semi-Long Arn before Front No. 019: 115 mm (4.53 in)
Ȁ 3.9 m (12 ft 10 in) Semi-Long Arn after Front No. 020: 120 mm (4.72 in)
Ȁ 2.9 m (9 ft 6 in) Short Arm before Front No. 046: 115 mm (4.53 in)
Ȁ 2.9 m (9 ft 6 in) Short Arm after Front No. 047: 120 mm (4.72 in)
T1-3-6
CYLINDER (LOADING SHOVEL)
Boom Arm Tilt Bucket Dump Buket Level
Rod dia. ............................................ 115 mm 115 mm 115 mm 65 mm 115 mm
(4.53 in) (4.53 in) (4.53 in) (2.56 in) (4.53 in)
Cylinder bore..................................... 170 mm 170 mm 150 mm 100 mm 170 mm
(6.68 in) (6.69 in) (5.91 in) (3.94 in) (6.69 in)
Stroke ............................................... 1590 mm 1205 mm 1230 mm 285 mm 560 mm
(62.5 in) (47.4 in) (48.4 in) (11.2 in) (22.0 in)
Fully retracted length......................... 2260 mm 1935 mm 2060 mm 745 mm 1265 mm
(88.8 in) (76.2 in) (79.9 in) (29.3 in) (49.8 in)
Plating thickness ............................... 25 µm 25 µm 25 µm 25 µm 25 µm
or more or more or more or more or more
(0.98 µin (0.98 µin (0.98 µin (0.98 µin (0.98 µin
or more) or more) or more) or more) or more)
ACCUMULATOR
Model ................................................ MU70-300
Type .................................................. Nitrogen gas sealed bladder type
3 3
Capacity ............................................ 300 cm (18.3 in )
2
Gas charging pressure ...................... 2.4 MPa ( 24 kgf/cm , 341 psi)
PILOT SHUT-OFF VALVE

Model ................................................ RC50
Type .................................................. Rotary type
SHOCKLESS VALVE (Front functions)

Model ................................................ VUP149J/0
Type .................................................. 4 valve block flow regulator type
SHOCKLESS VALVE (Travel function)

Type .................................................. 4 valve block flow regulator type
3-SPOOL SOLENOID VALVE UNIT

Application ........................................ SA: Main relief pressure shift
SB: Travel speed mode shift
SC: Swing parking brake release
2
Pilot relief pressure ........................... 3.9 MPa (40 kgf/cm , 569 psi)
@ 13 Liters (3.4 US gal)/min
SOLENOID VALVE
Application ........................................ Swing preference circuit shift
FRONT ATTACHMENT PILOT VALVE

Model ................................................ HVP04D-040-101
Plunger stroke ................................... Ports 1 and 3 : 7.2 mm (0.28 in),
Ports 2 and 4 : 9.25 mm (0.4 in)
TRAVEL PILOT VALVE

Model ................................................ HVP04A-040-101
Plunger stroke ................................... Ports 1, 2, 3, and 4 : 8.7 mm (0.34 in)
T1-3-7
DAMPER
Stroke ............................................... Fully extended: 189 mm (7.4 in),
Fully retracted: 124 mm (4.9 in)
OIL COOLER BYPASS CHECK VALVE

2
Cracking pressure ............................. 340 kPa (3.5 kgf/cm , 50 psi)
@ 40 Liters (10.6 US gal)/min
FILTERS
Nominal filtration rating

• Full flow filter .......................... 10 µm or less
• Suction filter............................ 177 µm (80 meshes)
• Pilot filter................................. 10 µm
• Drain filter ............................... 10 µm
ELECTRICAL EQUIPMENT
COOLER
Cooling capacity ............................... 16744 x 103 J/h (4000 kcal/h) or larger
3 3
Blower capacity ................................ 550 m (719 yd )/h or larger
HEATER
Heating capacity............................... 20930 x 103 J/h (5000 kcal/h) or larger
3 3
Blower capacity ................................ 400 m (523 yd )/h or larger
RADIO
Frequency range .............................. AM: 522 to 1629 kHz (9 kHz intervals)
FM: 76.0 to 90.0 MHz
Speaker (Impedance) ....................... 8 Ω
LIGHTS
Specifications ................................... Work light: 24 V/70 W (Halogen light)
Dome light: 24 V/10 W
HORN
Type ................................................. Before Machine Serial Number 007492: 072200-5650 (Low)
072100-5650 (High)
After Machine Serial Number 007493: MBL⋅3E (Low)
MBH⋅3E (High)
Specifications ................................... Before Machine Serial Number 007492: 24 V⋅1.5±0.5
113±5 dB (A)
After Machine Serial Number 007493: 24 V⋅1.5±0.5
110±5 dB (A)
BATTERY RELAY
Voltage / Current .............................. 24 V/100 A
T1-3-8
STARTER RELAY
Voltage .............................................. 24 V
Operating voltage .............................. 10.5 V
GENERAL PURPOSE RELAY

Application ........................................ EC motor, wiper, eng. stop motor, lubricator, work light, washer,
load dump, horn relays
Voltage/Current ................................. 24 V/10 A
AUTOMATIC LUBRICATION PUMP

Model ................................................ FP pump FP-25
Voltage/Current ................................. DC 24 V/13 A or less
Maximum discharge rate ................... 38 Liters (10.0 US gal)/min
ENGINE CONTROL MOTOR (EC MOTOR)

Model ................................................ KP56RM2G-002
Coil resistance .................................. 5.7 Ω (at 20 °C, 68 °F)
Effective operating angle ................... 80 degrees
ENGINE OVERHEAT SWITCH

Operating temperature ...................... Low temprature: 98 °C (208 °F)
High temprature: 101 °C (214 °F)
ENGINE OIL PRESSURE SWITCH

2
Operating Pressure ........................... 30 to 50 kPa (0.3 to 0.5 kgf/cm , 4 to 7 psi)
AIR FILTER RESTRICTION SWITCH

Operating pressure ........................... 6.23 kpa [635 mm (25 in) H2O]
COOLANT TEMPERATURE SENSOR

Operating temperature ...................... 50 to 120 °C (122 to 248 °F)
FUEL LEVEL SENSOR

Resistance value (Ω) ......................... Empty: 90 Ω, Full: 10 Ω (at 20 °C, 68 °F)
HYDRAULIC OIL LEVEL SENSOR

Type .................................................. Lead switch type
Rated voltage .................................... DC 28 V
T1-3-9
COOLANT LEVEL SWITCH (RESERVOIR)
Type .................................................. Float lead switch type
FUEL LEVEL SWITCH

Type .................................................. Lead switch type
ELECTRICAL GREASE LUBRICATOR (OPTIONAL)

Manufacturer ..................................... Yamada
Model ................................................ KPL-24
Discharge pressure ........................... 23.5 to 27.4 MPa (240 to 280 kgf/cm 2, 3413 to 9982 psi)
(30 minutes rated)
Discharge.......................................... 70 to 80 g (0.15 to 0.18 lb)/min (30 minutes rated)
Motor ................................................ DC 24 V, 100 to 130 W
Weight ...................................................... 10.5 kg (23 lb)
T1-3-10
SECTION 2
SYSTEM
—CONTENTS—
Group 1 Control System
Outline .....................................................T2-1-1
Engine Control .........................................T2-1-2
Pump Control ...........................................T2-1-6
Valve Control..........................................T2-1-14
Other Control .........................................T2-1-19
Group 2 Hydraulic System

Outline .....................................................T2-2-1
Main Circuit ..............................................T2-2-2
Pilot Circuit...............................................T2-2-7
Counterweight Remove/Install
Circuit (Optional) ..................................T2-2-10
Group 3 Electrical System

Outline .....................................................T2-3-1
Power Circuit............................................T2-3-2
Bulb Check Circuit....................................T2-3-3
Preheat Circuit .........................................T2-3-4
Engine Start Circuit ..................................T2-3-6
Charging Circuit .......................................T2-3-9
Accessory Circuit ...................................T2-3-10
Surge Voltage Prevention Circuit ............ T2-3-11
Engine Stop Circuit.................................T2-3-12
166T-2-1
(Blank)
166T-2-2
SYSTEM / Control System
OUTLINE
A microcomputer-built-in pump/valve controller (PVC)

and engine controller (EC) are used for machine
control.
Processing signals from the engine control dial,
various sensors and switches, the controllers (PVC
and EC) actuate solenoid valves and the EC motor to
control the engine, pumps and valves.
Engine Control
• Engine Speed Control
• Engine Learning Control
• Auto-Idle Control
• Auto Warming Up Control
• SP Mode Control
Pump Control
• Pump Flow Rate Control
• Speed Sensing Control
• E Mode Control
• Horsepower Control
• Relief Flow Rate Reducing Control
• Swing Horsepower Reducing Control
• Pump Maximum Flow Rate Control
• Attachment Mode Control
Valve Control
• Travel Speed Mode Shift Control
• Main Relief Pressure Shift (Power Boost) Control
• Swing Preference Control
• Swing Parking Brake Release Control
Other Control
• Work Mode Control
T2-1-1
ENGINE CONTROL
Engine Speed Control
Purpose: Operation:
To control engine speed in proportion to engine con- The EC stores the governor lever position of which
trol dial setting. the EC sensor output is 2.5 V as the slow idle posi-
tion (origin). (The EC sensor has been adjusted so
Operation: that it outputs 2.5 V when the governor lever comes
An electrical signal in proportion to the engine con- into contact with the slow idle side stopper.)
trol dial setting is input to the controller EC. Conse- When the engine control dial is turned to the fast idle
quently, the EC actuates the EC motor. The degree position, the EC motor rotates until the governor
of the EC motor rotated is detected by the EC sen- lever comes into contact with the fast idle stopper.
sor. The EC sensor then sends a voltage signal back After the governor lever comes to a stop, the EC
to the EC. sensor output is stabilized (unchanged). Conse-
When the engine is running at slow idle speed, out- quently, the EC stores the incremental pulse number
put voltage from the EC sensor is set to be 2.5 V. At to reach this point (movable) as the fast idle speed.
fast idle speed, it is set to be 4.5 V or less. (This re-input of the fast idle speed takes place
when the engine control dial output is 4.0 V or
Engine Learning Control larger.)
Purpose: The maximum speed with SP Mode OFF and the
To re-input (learn) the governor lever positions for auto-idle speed, which represents the speeds be-
the fast idle speed and auto-idle speed. The EC re- tween the slow idle and the maximum speed with the
inputs the engine speed, of which the governor lever SP Mode ON, are then calculated and stored as
comes into contact with the stopper, as the fast idle proportional points within the pulse range from the
speed. slow idle (origin) to the maximum speed with the SP
Mode ON (movable point).
Governor Lever
4.5 V or less
3.8±0.2 V
EC Sensor EC Sensor
Output 3.5 V
Voltage
EC Motor
2.5 V (With (With
SP SP
Mode Mode
OFF) ON)
Slow Idle Auto-Idle Fast Idle

Position Position Position
(Origin) (Movable)
Proportionally
Distributed Range
EC Motor Movement
T166-02-01-013
Controller
(EC)
Key Switch
Engine Control Dial
T162-02-01-001
T2-1-2
Auto-Idle Control
Purpose: When a control lever is operated, the respective

To save fuel and to lower noise by lowering the en- pressure switch is turned on. Then the EC stops
gine speed while all control levers are in neutral. sending the electrical signals to lower the engine
speed to the EC motor. As a result, the engine
Operation: speed increases to the speed set by the engine con-
When all control levers are in neutral, the front att. trol dial.
pressure switch located on the shockless valve and
the travel, swing, and other pressure switches lo-
cated on the shuttle valves are turned off. At this
moment, if the auto-idle switch is in the ON position,
the controller (PVC) detects that all pressure
switches are off, and sends a signal indicating that
all pressure switches are off, to the EC.
Approximately four seconds later, the EC sends a
signal to the EC motor. The EC motor then moves
the governor lever, lowering the engine speed to 1 Governor Lever
–1
200±100 min (1200±100 rpm).
EC Motor
EC Sensor
Pressure Switch (Swing)
Shuttle Valve
Pressure Switch (Bucket,

Pressure Switch Boom Lower, Arm Roll-Out)
(Boom Raise)
Shockless Valve
Pressure Switch (Arm Roll-In)
Shuttle Valve
Controller (EC) Controller (PVC)
Pressure Switch (Travel)
Auto-Idle Switch T162-02-01-003
T2-1-3
Auto Warming Up Control
Purpose:
To automatically warm up the hydraulic system.
(Equivalent to the automatic choke for automobiles)
Operation:
When the hydraulic oil temperature is less than 25
°C (77 °F), the controller (EC), upon receiving sig-
nals from the key switch and the hydraulic oil tem-
perature sensor, actuates the EC motor, increasing
the engine speed to a speed slightly higher than the
slow idle speed until the hydraulic oil temperature
rises to 30 °C (86 °F). This system is active up to 15
minutes after the engine starts.
Governor Lever
EC Motor EC Sensor
Controller
(EC)
Key Switch Hydraulic Oil Temperature Sensor
T166-02-01-004
T2-1-4
SP Mode Control
Purpose: As the engine speed increases approximately 8%,

To increase the engine speed approximately 8% the main pump flow rate also increases. Conse-
compared to the engine speed with the SP mode quently, actuator's speed and power increase.
switch turned off. As the pump flow rate increases
due to an increase of the engine speed, actuator NOTE: Since the governor lever stopper position is
speeds increase, increasing the production. set for the maximum speed with the SP
The engine torque also increases (when compared mode turned on, the governor lever does
to the engine torque with the SP mode off). Conse- not come into contact when the engine
quently, the speed sensing (increased horsepower) control dial is turned to the maximum
control function is activated to increase pump flow position with the SP mode switch turned off.
rate, thus increasing the production. (Refer to page
T2-1-7.)
Operation:
When the engine control dial is turned to the maxi-
mum speed position and the SP mode switch is
turned on, the controller (EC) actuates the EC motor,
increasing the engine speed approximately 8%, thus
increasing horsepower.
Governor Lever
EC Sensor
SP Mode
EC Motor
Flow
Rate
Normal Mode
Pressure P
Pump P-Q Curve
T166-02-01-005
Controller
(EC)
Key Switch Engine Control Dial T166-02-01-009
SP Mode Switch
T2-1-5
PUMP CONTROL
Pump Flow Rate Control
Purpose: (Refer to the heading Pump Control Valve in the

To have the main pump deliver the required oil flow Control Valve group , the COMPONENT OPERA-
to each actuator in proportion to control lever stroke. TION section.)
When control lever is in neutral:
Operation: As the control valve spool returns to the neutral posi-
When control lever is operated: tion, oil flowing through the orifice in the pump con-
Oil quantity flowing through an orifice in the pump trol valve, which is located in the most downstream
control valve, which is located in the most down- part of the control valve neutral passage, increases,
stream part of the control valve neutral passage, de- resulting in a large pressure difference between the
creases, resulting in less pressure difference be- inlet and the outlet of the orifice. Detecting this pres-
tween the inlet and the outlet of the orifice. Detecting sure difference, the DP sensor sends signals to the
this pressure difference, the differential pressure PVC. Consequently, the PVC calculates the required
(DP) sensor sends signals to the controller (PVC). oil flow and, at the same time, compares the pump
Consequently, the PVC calculates the required oil replacement angle necessary to have the calculated
flow and, at the same time, compares the pump dis- oil flow with the one detected by the A sensor. Then,
placement angle necessary to have the calculated the PVC actuates the pump control proportional so-
oil flow with the one detected by the pump displace- lenoid valve, reducing the main pump displacement
ment angle (A) sensor. angle to the minimum angle, thus decreasing the
Then, the PVC actuates the pump control propor- main pump flow rate.
tional solenoid valve, increasing the main pump dis-
placement angle, thus increasing the main pump
flow rate.
Pump Control Valve

(4-Spool Block Side)
Orifice Neutral
Passage
Main Pump
Differential Pressure (DP)
Sensor
Pump Displacement
Pump Con- Angle (A) Sensor
trol Propor-
Control Valve tional Sole-
noid Valve
Main Pump
Controller (PVC)
Pump Control
Orifice Proportional
Neutral Pz
Solenoid
Valve
Differential Pressure
(DP) Sensor
Pr
Pump Control Valve

4-Spool Block Side 5-Spool Block Side
T162-02-01-005
T2-1-6
Speed Sensing Control
Purpose: If the actual engine speed drops to a speed less

To effectively utilize engine horsepower by varying than the target engine speed due to an increased
the pump delivery rate in proportion to the moment- load on the engine, the EC and PVC actuate the
to-moment engine speed changes which occur due pump control proportional solenoid valve to reduce
to the various loads applied. (This control functions the main pump displacement angle, reducing the
to prevent the engine from stalling when the ma- main pump delivery rate. Consequently, the load on
chine is operated in severe environments, such as the engine is reduced, preventing the engine speed
when operating at high altitude.) from dropping and the engine from stalling.
(Horsepower Increase Control)
Operation: Contrarily, if the actual engine speed exceeds the
As a target engine speed is set by the engine control target engine speed, the EC and PVC actuate the
dial, the controller (EC) compares the target engine pump control proportional solenoid valve, increasing
speed with the actual engine speed detected by en- the main pump displacement angle, thus utilizing
gine speed (N) sensor and calculates the difference engine horsepower efficiently. (Horsepower De-
between these two engine speed values, which is crease Control)
subsequently sent to the controller (PVC). Then, the This speed sensing control works for the entire en-
PVC calculates a target pump displacement angle gine speed range: from the slow idle to the fast idle.
using the engine speed difference value and a signal However, when the engine speed is less than 1500
-1
from the pump delivery pressure (P) sensor. min , only the horsepower decrease control part of
Afterward, comparing the target pump displacement the speed sensing control is available.
angle with the actual pump displacement angle de-
tected by the pump displacement angle (A) sensor,
the PVC actuate the pump control proportional sole- Q
Engine Speed: more
noid valve to adjust the main pump delivery rate. than 1500 min-1
Increase
Engine Flow
Control Rate
Dial
Decrease
Base Torque
Controller Controller
(EC) (PVC)
Engine Speed Sensor Pressure P
(N Sensor) T111-05-02-004
Pump Delivery Pump P-Q Curve
Pressure Q
(P) Sensor
Pump Control
Proportional Engine Speed: less
Solenoid Valves than 1500 min-1
Flow
Rate
Decrease
Base Torque
Pump Displace-
ment Angle Sensor
(A Sensor) Pressure P
T166-02-01-014
T162-02-01-006
T2-1-7
E Mode Control
Purpose: Then, comparing the target pump displacement an-

To increase fuel efficiency by reducing the load ap- gle with the actual pump displacement angle de-
plied to the engine, i.e. lowering the pump driving tected by the pump displacement angle (A) sensor,
torque to 85% of the torque in the SP mode. This the PVC actuates the pump control proportional so-
control also functions to prevent the engine from lenoid valve to compensate for the difference be-
stalling when the machine is operated in severe en- tween the actual and target pump displacement an-
vironments, such as when operating at high altitude. gles, reducing the pump displacement angle, thus
reducing the main pump flow rate.
Operation:
When the E mode switch is turned on, the controller NOTE: Engine speed is not controlled (lowered) in
(EC) sends a signal to the controller (PVC). Subse- this E mode control. In other words, engine
quently, also having a signal from the pump delivery speed does not change but the E mode
pressure (P) sensor, the PVC calculates a target function is activated upon pushing the E
pump displacement angle. mode switch.
Flow
Rate Decrease
Base Torque
E Mode
Pressure P
T166-02-01-006
Engine E Mode
Control Switch
Dial
(EC) (PVC)
Engine Speed Sensor

(N Sensor) Pump Delivery
Pressure
(P) Sensor
Pump Control
Proportional
Solenoid Valves
Pump Displace-
ment Angle Sensor
(A Sensor)
T162-02-01-006
T2-1-8
Horsepower Control
Purpose: Then, the PVC calculates a target pump displace-

To effectively utilize engine horsepower by control- ment angle using signals from two pump delivery
ling the delivery rate of each main pump so that the pressure (P) sensors and compares them with the
sum of the two main pumps torque does not exceed actual pump displacement angles detected by the A
the engine output torque. sensors. Subsequently, the PVC actuates the pump
control proportional solenoid valve of the larger load
Operation: applied main pump, increasing the delivery rate of
Delivery pressure of each main pump usually differs the larger load applied main pump to the extent that
from each other: i.e. the larger the load applied to a the sum of the two main pumps torque does not ex-
main pump, the higher the delivery pressure and ceed the engine output torque. Consequently, the
vice versa. The pump delivery pressure (P) sensors sum of the two main pumps torque is approximately
and the pump displacement angle (A) sensors de- the same as the engine output torque.
tect the actual status (conditions) of two main pump,
sending signals to the controller (PVC).
(EC) (PVC)
Pump Delivery
Pressure (P) Sensors
Pump Control
Proportional
Solenoid Valves
Pump Displacement
Angle (A) Sensor
T162-02-01-007
T2-1-9
Relief Flow Rate Reducing Control
Purpose: When the pump delivery pressure rises to 28.4 MPa

2
To reduce hydraulic energy loss and to prevent the (290 kgf/cm , 4124 psi), the PVC compares the ac-
hydraulic oil temperature from rising. tual pump displacement angle detected by the pump
displacement angle (A) sensor with the target pump
Operation: displacement angle (A) demanded by the PVC.
When an actuator is operated, the pump delivery Consequently, the PVC decreases the pump flow
pressure varies due to changing load applied to rate to the minimum (which is demanded by the PVC
each actuator. Detecting the pump delivery pressure, when the actuator circuit is relieved).
the pump delivery pressure (P) sensor sends signals In addition, when the pressure switch (travel) is
to the controller (PVC). turned on or when the precision mode switch is
turned on, the controller (PVC) deactivates the Re-
lief Flow Rate Reducing Control.
Qm
Flow
Q
Rate
Relief Flow Cut

Qo
P
Pc Pr
Pressure
T162-01-02-012
Pilot Pilot Pilot

Valve Valve Valve
Pressure Switches
Control Valve
Precision Mode
Switch Controller Controller
(EC) (PVC)
Main Pump 1
Pump Delivery
Pressure
(P) Sensor
Pump Control
Proportional
Solenoid Valves
1 2
Main
Pump 2 4-Spool Block 5-Spool Block
Pump Displacement
Angle (A) Sensor
T166-02-01-011
T2-1-10
Swing Horsepower Reducing Control
Purpose: If the “travel” or “other” pressure switch is turned on

To effectively utilize engine horsepower by reducing in swing combined operations, the PVC actuates the
the flow rate of the main pump 1 in which the swing main pump 2 control proportional solenoid valve
circuit is located and by increasing the flow rate of upon receiving a signal from the pressure switch, in-
the main pump 2 when the swing pressure switch is creasing the pump flow rate.
turned on, i.e. when swing function is operated Q
whether in single or combined operation.
Operation:
The swing pressure switch sends a signal to the con-
troller (PVC) as it is turned on, i.e. when the swing Flow
Rate
function is operated. Then, the PVC compares the
actual pump displacement angle detected by the
pump displacement angle (A) sensor with the target
pump displacement angle demanded by the PVC.
Consequently, the PVC actuates the main pump 1 P
control proportional solenoid valve, decreasing the Pressure
Main Pump 1
pump flow rate. Q T162-02-01-010
Flow
Rate
Pilot Pilot Pilot

Valve Valve Valve
P
Pressure
Main Pump 2
Pressure Switch T162-02-01-011
(Travel) (Other)
(Swing)
Control Valve
(EC) (PVC)
Main
Pump 1 Pump Delivery
Pressure (P)
Sensor
Pump Control
Proportional So-
lenoid Valves
Main 4-Spool Block 5-Spool Block

Pump 2
Pump Displacement
Angle (A) Sensor
T162-02-01-009
T2-1-11
Pump Maximum Flow Rate Control
Q
Purpose:
To prevent the engine from overheating by reducing
the main pump maximum flow rate setting and pump
Flow
torque, thus reducing the load applied to the engine Rate
when the overheat switch (L) is turned on.
Operation:
When the overheat switch (L) is turned on (98 °C,
208 °F) or hydraulic oil temperature sensor is turned P
on (120 °C, 248 °F), a signal from the switch is sent Pressure
to the controller (PVC) via the controller (EC). Then,
T162-02-01-013
the PVC compares the actual pump displacement
angle detected by the pump displacement angle (A)
sensor with the target pump displacement angle
demanded by the PVC. Consequently, the PVC ac-
tuates the pump control proportional solenoid valve,
re-setting the maximum pump displacement angle to
cut the maximum flow rate seven percent. In addi-
tion, the pump torque is also lowered.
Overheat Switch (L)
(EC) (PVC)
Pump Control
Proportional So-
lenoid Valves
Pump Displacement
Angle (A) Sensor
T162-02-01-014
T2-1-12
Attachment Mode Control
NOTE: This control system functions only on ma-

chines equipped with the attachment op-
tional kit.
Purpose: Operation:
When the attachment pilot valve is operated with the When the attachment mode is selected by the work
work mode switch in the attachment mode, the mode switch, the signal from the word mode switch
maximum flow rate of main pump 1 is reduced to is sent to the controller (PVC). Then, when the at-
280 L/min (74 US gal), approx. 20 % less than the tachment pilot valve is operated, the pressure switch
normal control maximum flow rate (360 L/min (95 is turned ON, delivering the signal to the PVC via the
US gal)) in the general purpose mode, to balance controller (EC).
with the hydraulic breaker operation. The pump displacement angle is always monitored
by the displacement angle (A) sensor. The PVC is
kept instructed by the signal from the A sensor.
Q
(L/min) 360
Therefore, when the pump displacement angle in-
creases to a point 20 % lower than normal control
maximum flow rate in the general purpose mode,
280 the PVC operates the pump control proportional so-
lenoid valve so that the pump displacement angle is
held in that position. The attachment is controlled by
the auxiliary spool in the 5-spool side control valve.
Then, the maximum flow rate of the main pump 1
only is regulated.
Pressure P
Attachment Control Pedal
Attachment
Pilot Valve
Engine Work Mode Switch Control Valve

Control Pressure (Attachment Mode)
Dial Switch
Pump Delivery (EC) (PVC)
Pressure (P) Sensor
Auxiliary Spool
(Attachment)
Main Pump 1
Pump Control
Proportional
Solenoid Valve
5 Spool Side
Main
Pump 2 4 Spool Side
Displacement
Angle (A)
Sensor
T166-02-01-017
T2-1-13
VALVE CONTROL
Travel Speed Mode Shift Control
• Slow Travel Mode:

With the travel mode switch turned to the
position, no electrical current flows to the travel
mode shift solenoid valve. As the travel mode shift
solenoid valve is not activated (shifted), the
pressure oil from the pilot pump is not supplied to
the travel mode shift valve. For this reason, the
travel mode shift valve is not shifted, and the
pressure oil in the main control valve travel circuit
is not supplied to the tilt pistons. Consequently,
the travel motors rotate in the slow speed mode.
(Refer to the heading Travel Motor in the Travel
Device group, the COMPONENT OPERATION
section for travel motor displacement angle shift.)
From the Main Pump
Travel Mode
Shift Solenoid
Valve
Pilot Pump Brake

Valve
Hydraulic
Oil Tank
Travel Mode
Travel Motor Shift Valve
Controller
Travel Mode (PVC) Tilt Piston
Switch Parking Brake
T166-02-01-007
T2-1-14
• Fast Travel Mode:
With the travel mode switch turned to the
position, electrical current flows to the travel mode
shift solenoid valve. As the travel mode shift
solenoid valve is activated (shifted), the pressure
oil from the pilot pump is supplied to the travel
mode shift valve. For this reason, the travel mode
shift valve is shifted, and the pressure oil in the
main control valve travel circuit is supplied to the
tilt pistons. Consequently, the travel motors rotate
in the fast speed mode.
(Refer to the heading Travel Motor in the Travel
Device group, the COMPONENT OPERATION
section for travel motor displacement angle shift.)
From the Main Pump
Travel Mode
Shift Solenoid
Valve
Brake Valve
Pilot Pump
Hydraulic
Oil Tank
Travel Mode
Travel Motor Shift Valve
Controller
Travel Mode (PVC)
Switch
Parking Brake
Tilt Piston
T166-02-01-008
T2-1-15
Main Relief Pressure Shift (Power Boost) Control
Purpose:
To increase the main relief pressure setting by apply-
ing back pressure to the main relief valve.
Operation:
Either when travel pressure switch is turned on,
when the precision work mode is selected, or when
the power boost switch is pressed, a signal from the
travel pressure switch enters the controller (PVC).
Consequently, the PVC actuates the main relief
pressure shift solenoid valve (only for 10 seconds in
the case the power boost switch was pressed), rout-
ing pressure oil from the pilot pump to the shuttle
valve. As a result, the main relief valve spring is
compressed, increasing the main relief pressure set-
2
ting from 29.4 MPa (300 kgf/cm , 4266 psi) to 34.3
2
MPa (350 kgf/cm , 4977 psi).
Control Valve
Pilot Pilot Pilot
Valve Valve Valve
Travel
Pressure
Switch
Work Mode Switch

(Precision Mode)
Controller Controller Main Relief
(EC) (PVC) Pressure
Shift Solenoid
Power Boost Switch Valve
Spring
Main Relief Valve
Shuttle Valve
Pilot Pump
T166-02-01-012
T2-1-16
Swing Preference Control
• Swing/Boom Raise Combined Operation (in the

general purpose mode, attachment mode, or
precision mode)
With the work mode set in any of the three work
modes indicated above, the controller (PVC)
actuates the swing preference circuit shift
solenoid valve. For this reason, the boom raise
operating pressure 1A flows to 1B, shifting both
boom 1 and 2 spools. The swing spool is also
shifted at the same time.
Swing Preference Circuit Shift Solenoid Valve
From the controller (PVC).
1A P S 1B 1A - Boom 1 Raise Section Operating Pressure

F
1B - Boom 2 Raise Section Operating Pressure
D2 G D2 - To the hydraulic oil tank.
T166-02-01-002
• Swing/Boom Raise Combined Operation (in the

trenching mode)
In swing/boom combined operation with the work
mode in the trenching mode, the controller (PVC)
deactivates the swing preference circuit shift
solenoid valve.
Consequently, boom raise operating pressure 1A
does not flow to 1B and the boom spool (raise)
operating pressure line is connected to the
hydraulic oil tank line. For this reason, pressure oil
from the pump 1 flows only to the swing circuit in
swing/boom raise combined operation. (Swing
Preference Control)
Swing Preference Circuit Shift Solenoid Valve
From the controller (PVC).
1A P S 1A - Boom 1 Raise Section Operating Pressure

F 1B
1B - Boom 2 Raise Section Operating Pressure
D2 G D2 - To the hydraulic oil tank.
T166-02-01-003
T2-1-17
Swing Parking Brake Release Control
When the swing or front control lever is operated, the

swing or front attachment pressure switch is turned
on, sending a signal to the PVC. Consequently, the
PVC actuates the swing parking brake release
solenoid valve, sending pressure oil from the pilot
pump to the swing motor, thus releasing the swing
parking brake.
Swing Motor
Swing Parking
Brake
Pilot Pump
Swing Parking Brake

Release
Solenoid Valve
Swing or Front Attachment

Pressure Switch
Controller
PVC
T166-02-02-009
T2-1-18
OTHER CONTROL
Work Mode Control
The work modes provide the ideal pressures and

operating speeds for each type of work by controlling
main pump flow rate, main relief pressure shift
(power boost) circuit, etc.
Characteristics of each work mode are as follows:
General Purpose Mode:

Standard work mode. Designed for general
digging and truck loading.
Trenching Mode
In swing/boom raise operation, the swing
preference circuit shift valve is actuated so that
only one boom section (out of two) in the control
valve is operated, giving priority to swing move-
ment during trenching work. (Refer to page T2-1-
17.)
Precision Mode:
Main pump flow rate is decreased approximately
45% from that in the general purpose mode. At
the same time, the controller (PVC) actuates the
main relief pressure shift solenoid valve, raising
the main relief pressure. This mode is designed
for work in confined work areas that require
precision front attachment movement. (Refer to
page T2-1-16, 17.)
Attachment Mode:
This mode functions when an optional attachment
is installed. When the attachment pilot valve is
operated, the main pump maximum flow rate will
be reduced approximately 20% in this mode.
(Applied when a breaker is used.) (Refer to page
T2-1-13.)
T2-1-19
(Blank)
T2-1-20
SYSTEM / Hydraulic System
OUTLINE
The hydraulic system consists of the main circuit and

pilot circuit.
Main Circuit:
A hydraulic circuit that actuates cylinders and
motors using pressure oil delivered from the main
pumps.
Pilot Circuit:
A hydraulic circuit that shifts the control valve
spools, that controls the pumps, valves, and
motors, and that also releases the parking brakes.
T2-2-1
MAIN CIRCUIT
Main pumps 1 and 2 draw hydraulic oil from the Return oil from cylinders and motors is routed to the
hydraulic oil tank. Main pump 1 supplies pressure oil to hydraulic oil tank via the control valve and oil cooler,
the 5-spool control valve block while main pump 2 cooling hydraulic oil. If oil resistance through the oil
supplies pressure oil to the 4-spool control valve block. cooler is high, i.e. if oil temperature is low and viscosity
Main pump discharged oil is routed to cylinders and is high, the bypass check valve opens to directly route
motors via the control valve as control valve spool(s) hydraulic oil to the hydraulic oil tank, bypassing the oil
are shifted. cooler.

Bucket Arm Boom
bucket’s opening and closing. Cylinder Cylinder Cylinder
Pilot
Shut-Off
Valve
Pilot Valve
Center Joint
Shockless Valve
Hydraulic
Oil Tank Swing Motor
Travel (L)
∗Aux.
Boom 2 Travel (R)
Arm 1 Bucket
Swing Boom 1
Arm 2
Control Valve
Solenoid Valve Unit
(3 Solenoid Valve Used) Bypass
Check Valve
Accumulator
Oil Cooler
Main Pump 1 High Pressure Oil

Main Pump 2 Low Pressure Oil (Return Line)
Center Joint
Circuit Line
Pilot Line
Drain Line
Left Travel Motor Right Travel Motor

T166-02-02-001
T2-2-2
Neutral Circuit Single Operation Circuit
When the control levers are in neutral, pressure oil Pressure oil from main pump 2 flows into the travel
from the main pumps returns to the hydraulic oil tank (R), bucket, boom 1, and arm 2 spool sections in the
via the neutral passage in the control valve and the 4-spool control valve block. Pressure oil from main
pump control valve. pump 1 flows into the swing, arm 1, boom 2, ∗aux.,
and travel (L) spool sections in the 5-spool control
valve block. For boom raise and arm roll-out/roll-in
single operations, two main pump flows are combined
before flowing into each cylinder.
NOTE: ∗ In the case of Loading shovel specification

(bottom dump), this valve is used for
Pump Control Valve Hydraulic Oil Tank
Swing
Neutral
Passage Swing Motor
Arm 1
Arm 2
Boom Cylinder
Boom 2
Boom 1
∗Aux. Oil Flow Combining

Bucket Cylinder Passages
Bucket
Travel (R) Travel (L)
Neutral
Passage
Pump
4-Spool Control
Block Valve 5-Spool Block
Right Travel Motor Main Pump 2 Main Pump 1 Left Travel Motor
T166-02-02-002
T2-2-3
Combined Operation Circuit Ȁ
Ȁ
• Boom/Arm Combined Operation (Boom Lower Ȁ
and ∗Arm Roll-In) Ȁ
In boom lower / arm roll-in combined operation, Ȁ An orifice in the parallel passage of the 4-spool
the boom 1, arm 1 and 2 spools are shifted. Also, control valve block secures oil flow to the boom
the holding valve shift valve is shifted. cylinder so that the boom can be operated
Pressure oil from main pump 1 flows into the regardless of arm circuit pressure fluctuation.
bottom side of the arm cylinder via the neutral Return oil from the boom cylinder is routed to the
passage and arm 1 spool in the 5-spool control hydraulic oil tank via the holding check valve and
valve block. Since the boom 2 spool is not shifted boom 1 spool section. Return oil from the arm
during boom lower operation, no pressure oil cylinder is routed to the arm 1 section via the
flows to the boom cylinder from the 5-spool holding check valve. Return oil from the arm
control valve block. Pressure oil from main pump cylinder is restricted by an orifice in the arm 1
2 flows into the boom 1 spool and arm 2 spool spool and the arm regenerative valve. If the return
sections in the 4-spool control valve block via the oil pressure becomes higher than that of oil flow to
parallel passage. the arm cylinder bottom, return oil is supplied to
Ȁ Pressure oil from the boom 1 spool section flows the arm cylinder bottom via the check valve in the
into the rod side of the boom cylinder while that arm 1 spool. (For boom and arm holding check
from the arm 2 spool section flows into the bottom valves and arm regenerative valve, refer to the
side of the arm cylinder after combined with Control Valve group, the COMPONENT
pressure oil from the arm 1 spool section. OPERATION section.)
NOTE: ∗ In the case of loading shovel specification,

the operation is arm extend.
Hydraulic Oil Tank Holding Valve Shift Valve
Holding Valve Shift Valve
Arm
Holding Check Valve Regen-
erative
Valve Arm 1
Arm 2
Arm Cylinder
Boom Cylinder
Orifice Check Orifice
Valve Boom 2
Holding Check Valve

Boom 1
Parallel
Passage
Main Pump 2 Main Pump 1

T166-02-02-003
T2-2-4
• Swing/Boom Combined Operation (in the general
purpose mode, attachment mode, and precision
mode)
Pressure oil from main pump 2 flows into the
boom cylinder via the boom 1 spool.
Pressure oil from main pump 1 flows into the
swing motor via the swing spool. As the swing
circuit pressure becomes relatively high at the
start of upperstructure rotation, pressure oil from
the boom 2 spool section also flows into the boom
cylinder until the upperstructure speed becomes
constant.
6 Swing
5
Swing Motor
Parallel
Passage
Boom Cylinder
Boom 2
Boom 1 1B
1
1A
Parallel
Passage

T166-02-02-004
T2-2-5
• Travel/Swing Combined Operation
In travel/swing combined operation, the travel left Although pressure oil from main pump 1 flows into
and right spools and swing spool are shifted. The the swing spool and travel left spool sections via
shifted swing spool blocks the front att. pilot signal the 5-spool control block parallel passage, priority
circuit, raising the pilot pressure in that circuit, is given to the swing circuit due to a provided
which consequently shifts the flow combiner orifice. The orifice in the parallel passage also
valve. secures the priority to the swing circuit when the
pressure in the travel circuit becomes lower than
that in the swing circuit, i.e. when descending for
instance.
Pressure oil from main pump 2 flows into the right
travel motor via the travel right spool. It also flows to
the left travel motor via the flow combiner valve and
the travel left spool, securing straight travelability.
Front Att. Pilot

Signal Circuit
Swing
Swing Motor
Parallel
Passage
Orifice
Travel (L)
Check
From the Travel (R) Valve
Pilot Pump
Flow
Combiner
Valve

T166-02-02-005
T2-2-6
PILOT CIRCUIT
Pressure oil from the pilot pump is used as operating delivery rate control circuit, main relief pressure shift
pressure for the pilot circuit, travel speed mode shift circuit, and swing preference shift circuit.
circuit, swing parking brake release circuit, pump
Shuttle
Pilot Valve Valve
Control
Valve
Pilot Valve Shockless
Valve
Pilot Valve Shuttle Shockless Valve

Valve
Pilot
Shut-Off
Valve
Pilot Solenoid Valve

Accumulator Check (Swing Preference
Valve Circuit Shift)
Main Relief
Pressure Shift
Solenoid Valve
Swing Parking Brake

Release Solenoid Valve
Pilot
3-Spool Solenoid Valve Unit Relief
Valve
Swing Motor
Travel Speed Shift

Solenoid Valve Swing Motor
Right
Left Travel Travel Pilot Filter
Motor Motor
Pilot Pump
Regulator/Pump Regulator/Pump
Control Proportional Control Proportional
Solenoid Valve Solenoid Valve
(on Main Pump 2) (on Main Pump 1)
Hydraulic
Oil Tank
T166-02-02-006
T2-2-7
Pilot Circuit
Pressure oil from the pilot pump is routed to the pilot An accumulator is provided in the pilot circuit so that
valves via a pilot check valve and pilot shut-off valve. pressure oil can be supplied into the pilot circuit for a
When a pilot valve is operated, pressure oil is routed to limited period of time in case the engine stalls.
the control valve via a shockless valve and/or a shuttle
valve, shifting a spool in the control valve.
The machine cannot be moved by operating the
control levers while the pilot shut-off valve is closed
since the pilot oil pressure does not flow to the pilot
valves.
Accumulator
Pilot Shut-Off Valve Pilot Valves
Swing/Arm
P Control Lever
Pilot Pump Pilot Check Valve
Travel
Control Levers
Hydraulic Oil Tank

Boom/Bucket
Control Lever
Shuttle Valve Shockless Shuttle Valve

Valve
To the control To the control Shockless

valve. valve. Valve
To the control valve.
T166-02-02-007
T2-2-8
Pump Delivery Rate Control Circuit
• Refer to the heading Pump Control (Pump Flow

Rate Control) in the Control System group.
Travel Speed Mode Shift Circuit
• Refer to the heading Travel Motor in the Travel

Device group, COMPONENT OPERATION sec-
tion. Also, refer to the headings Valve Control
(Travel Speed Mode Shift Control) in the Control
System group.
Main Relief Pressure Shift Circuit
• Refer to the heading Main Relief Valve in the

Control Valve group, the COMPONENT OPERA-
TION section and to the headings Valve Control
(Main Relief Pressure Shift (Power Boost)
Control) in the Control System group.
Swing Preference Shift Circuit
• Refer to the headings Valve Control (Swing

Preference Control) in the Control System group.
Swing Parking Brake Release Control Circuit
• Refer to the headings Valve Control (Swing

Parking Brake Release Control) in the Control
System group.
T2-2-9
COUTERWEIGHT REMOVE/INSTALL CIR-
CUIT (Optional)
When the counterweight hoist/lower control lever When lowering the counterweight, pressure oil flows
(optional) is operated, pressure oil from the pilot pump into the cylinder rod side.
flows through the counterweight pilot valve and shifts The return oil flow from the cylinder bottom is regulated
the auxiliary spool in the 5-spool control valve to re- by the slow return valve and flows to the hydraulic oil
move/install the counterweight. tank via the holding valve.
Pressure oil from main pump 1 flows into the counter- The holding valve is opened by the pressure in the rod
weight remove/install cylinder via the parallel passage side, allowing the return oil from the bottom side to flow
and auxiliary spool in the 5-spool control valve. through.
When hoisting the counterweight, pressure oil flows The check valve is designed to open by the pressure in
into the cylinder bottom via the check valve in the slow the cylinder rod side circuit.
return valve.
Holding Lock
Valve Valve
Slow Return counterweight

Valve Removal Cylinder
Main Pump 1
T166-02-02-011
T2-2-10
SYSTEM / Electrical System
OUTLINE
The electrical circuit can be divided into three circuits:

main circuit, control circuit, and monitor circuit.
• Main Circuit
Engine / accessory circuit.
• Control Circuit
Engine / pump control circuit, consisting of
actuators (such as solenoid valves), controllers
(PVC and EC), sensors and switches.
• Monitor Circuit
Circuit that indicates machine operating
conditions, consisting of sensors and switches.
In this section, main constituents and their functions of

the main circuit are described.
• Power Circuit
The power source of all electrical circuits on this
machine.
• Bulb Check Circuit

The circuit to check if any indicator bulbs have
blown.
• Preheat Circuit
The circuit to aid in engine start in cold weather.
• Engine Start Circuit

The circuit to rotate the starter to start the engine.
• Charging Circuit
The circuit supplies electricity to the batteries to
replenish consumed (discharged) electricity.
• Accessory Circuit
The circuit for accessories which will be activated
when the key switch is turned to the ACC position.
• Surge Voltage Prevention Circuit

The circuit to protect electronic components, such
as the controller, from surge voltage.
• Engine Stop Circuit

The circuit to stop the engine using the engine
stop motor.
T2-3-1
POWER CIRCUIT
Since the negative terminal to the battery is grounded

to the vehicle frame, the battery supplies electricity to
the monitor, controller (PVC) and the radio as backup
power source, and to the controller (EC) and engine
stop motor as main power source while the key switch
is turned off.
Key Switch
Fusible Link
Battery
Battery
Relay
Fuse Box
Load Dump
Relay
39
Radio
Monitor
Fuse Box
39 48
Engine Stop
Motor
Controller (PVC)
EC Motor Relay
102
106
1 Controller (EC)
24
37
T166-02-03-001
T2-3-2
BULB CHECK CIRCUIT
When the key switch is turned to the ON position,

terminal B is connected to terminals ACC and M inside
the key switch.
Battery power flows to the monitor via the fuse box
since the electrical current from terminal M energizes
the battery relay. Then, all indicators on the monitor
come on for approximately 3 seconds. If any indicators
fail to come on, the bulbs have blown.
Key Switch
Fusible Link
Battery
Battery Relay
Fusible Link
Fuse Box
30 40
Monitor
29
Fuse Box
T166-02-03-002
T2-3-3
PREHEAT CIRCUIT
When the key switch is turned to the HEAT position,

terminal B is connected to terminal G1 in the key
switch. Electrical current from terminal G1 energizes
preheat relay 1 and also flows to the monitor, turning
on the preheat indicator.
Power source from the batteries is routed to the intake
heater via preheat relay 1, energizing the intake heater.
Approximately 14 seconds after the timer function of
the monitor is activated, the preheat indicator turns off,
indicating preheating has been completed.
Magnetic
Valve
Intake Heater 2 1 Key Switch
Preheat
Relay 1
2 1
Battery 2 1
Preheat
Relay 2
Battery Relay
Diode
31
Monitor
T166-02-03-003
T2-3-4
(Blank)
T2-3-5
ENGINE START CIRCUIT
When the key switch is turned to the START position, Because key switch terminal G2 is connected to key
terminal B is connected to terminals G2, M and ST in switch terminal G1, the preheat circuit is activated with
the key switch. Since electrical current from terminal M the key switch turned to the START position, routing
energizes the battery relay, the battery power is routed electrical current to the intake heater and opening the
to starter terminal B and starter relay terminal B via the magnetic valve to burn fuel so as to heat the incoming
battery relay. As key switch terminal ST is connected to air.
starter relay terminal S, current flows to the starter Electrical current from key switch terminal M also flows
relay coil, closing starter relay. Then, electrical current to the controller (EC), which signals that the key switch
is routed from starter relay terminal C to starter has been turned to the ON or START position.
terminal C, rotating the starter. Electrical current from the battery relay is the main
power source of the controller (PVC) and monitor.
Because the EC closes the EC motor relay's coil side
circuit, electrical current from the batteries flows to the
EC motor via the EC motor relay and the EC.
Magnetic
Intake Heater Valve Key Switch
Preheat
Fusible Link Relay 1
Battery
Preheat
Relay 2
Battery Relay
Fusible Link
Engine
Stop Fuse
Motor Box
Emergency
Relay
Starter Relay
Fuse Box
Engine Stop Relay

EC
Motor
Relay Controller (PVC)
Starter
Monitor
EC
Motor
Controller (EC)
T166-02-03-012
T2-3-6
Role of Engine Stop Motor in Engine Start
Electrical current from key switch terminal M Because of the electrical current flow described
energizes not only the battery relay but also the above, the engine stop motor rotates, opening the
engine stop relay. The flow of the electrical current fuel cut lever to make engine start possible.
when energizing the engine stop relay is as follows:
Battery→Fuse Box→Engine Stop Motor When the above occurs, the engine stop motor
Terminal B→Terminal P2→Emergency Relay rotates from the 0 degrees position to the 180
Terminal P2'→Terminal P2→Engine Stop Relay degrees position and is automatically held in that
Terminal #5→Terminal #3→Engine Stop Motor position.
Terminal A→E (Ground) Electrical current from switch terminal ST acts on
emergency relay terminal C, turning on the 10 second
timer immediately after the engine starts. If engine oil
pressure does not rise within 10 seconds, the
emergency relay is activated, stopping the engine.
Magnetic
Intake Heater Valve Key Switch
Preheat
Fusible Link Relay 1
Battery
Preheat
Relay 2
Battery Relay
Engine Fusible Link

Stop
Fuse
Motor
Box
Emergency
Relay
Starter Relay
Fuse Box
EC Engine Stop Relay

Motor
Relay Controller (PVC)
Starter
Monitor
Engine Stop Motor 180 Degrees Position EC

Motor
Controller (EC)
T166-02-03-005
T2-3-7
Operation of Starter Relay
• When the key switch is turned to the START • When the alternator starts generating as the
position, electrical current from key switch engine starts, some voltage is applied to starter
terminal ST flows to starter relay terminal S, then relay terminal N. When this voltage reaches 21 to
to coil (1) via contact P1 (normally closed), 22 V, coil (5) overcomes coil (4), opening contact
energizing coil (1). As coil (1) is energized, contact P1
P2 closes. As a result, electricity flows to starter
terminal C. • When contact P1 opens, contact P2 also opens,
deenergizing coils (2) and (3). Consequently, the
• Coils (2) and (3) in the starter are energized by starter pinion gear is retracted into the starter,
battery power from terminal C, extending the disengaging from the ring gear. Concurrently,
starter pinion gear to engage with the engine ring contact P3 opens, stopping the starter motor.
gear. At the same time, contact P3 closes to rout
electricity to the starter motor, rotating the starter Once the engine starts, the starter motor
motor to start the engine. automatically stops regardless of the key switch
position. In addition, the starter motor does not rotate
when the key switch is accidentally turned to the
START position while the engine is running.
Key Switch
Fusible Link
Battery
Battery Relay
Fusible Link
Fuse
1 Box
Starter Relay
5
4 Fuse Box
Starter
Alternator Terminal N
3 T166-02-03-006
T2-3-8
CHARGING CIRCUIT
The key switch automatically returns to the ON position Electrical current from alternator terminal L flows to the
upon releasing it after the engine starts. With the key monitor. In turn, the monitor turns off the alternator
switch in the ON position, terminal B is connected to indicator.
terminals ACC and M in the key switch.
Electrical current from alternator terminal B charges
the batteries via the fusible link and battery relay. Also,
electrical current from alternator terminal B flows to the
other circuits via the fuses.
Key Switch
Fusible Link
Battery
Battery Relay
Fusible Link
Fuse
Starter Relay Box
Fuse
Box
Starter
Monitor
Alternator
T166-02-03-007
T2-3-9
ACCESSORY CIRCUIT
When the key switch is turned to the ACC position,

terminal B is connected to terminal ACC in the key
switch.
Electrical current from terminal ACC is supplied to the
cigar lighter, radio, cab light and horn via fuses #16,
#17 and #18.
Key Switch
Fusible Link
Battery
Battery Relay
Fuse Box
Cigar Lighter
Radio
Cab Light
Horn T166-02-03-008
T2-3-10
SURGE VOLTAGE PREVENTION CIRCUIT
The surge voltage prevention circuit protects the

electronic components, such as the controllers (EC,
PVC), from surge voltage which may be generated
when the engine is stopped.
When the key switch is turned to the OFF position with
the engine running, battery-relay-energizing current
from key switch terminal M stops flowing. With the
main power OFF, the monitor outputs surge-voltage-
prevention signal, keep-energizing the load dump relay
for approximately 30 seconds after the key switch is
turned off.
Consequently, the battery relay is also energized for
the same period of time.
Key Switch
Fusible Link
Battery
Battery Relay
Load
Dump
Relay
Alternator
Fuse Box
Monitor
T166-02-03-009
T2-3-11
ENGINE STOP CIRCUIT
Engine Stop by Engine Stop Motor
When the key switch is turned to the OFF position, Because of the electrical current flow described
the signal circuit to the engine stop relay is above, the engine stop motor rotates, closing the fuel
disconnected so that the engine stop relay internal cut lever to stop the engine.
connection becomes the connection between
terminals #3 and #4. At this time, electrical current When the above occurs, the engine stop motor
flows as follows: rotates from the 180 degrees position to the 360
Battery→Fuse Box→Engine Stop Motor Terminal B→ degrees position and is automatically held in that
Terminal P1→Engine Stop Relay Terminal #4→ position.
Terminal #3→Engine Stop Motor Terminal A→E
(Ground)
Key Switch
Fusible Link
Battery
Battery Relay
Engine Stop Motor Fuse Box
Engine
Stop Relay
Fuse Box
Emergency Relay
EC Motor
Relay
Controller (PVC)
Engine Stop Motor 360 (0) Degrees Position
EC Motor
Controller (EC)
T166-02-03-011
T2-3-12
Engine Stop in Case of Excessive Engine Oil
Pressure Drop
If the engine oil pressure drops excessively while the Because of the electrical current flow described
engine is running, the engine pressure switch is above, the engine stop motor rotates, closing the fuel
turned on. Then, a signal from the engine pressure cut lever to stop the engine.
switch acts on emergency relay terminal T, changing
terminals P2'-P2 connection to terminals P1-P2 When the above occurs, the engine stop motor
connection. Approximately three seconds after the rotates from the 180 degrees position to the 360
occurrence of the excessive engine oil pressure drop, degrees position and is automatically held in that
the emergency relay is activated, stopping the engine. position.
At this time, electrical current flows as follows:
Battery→Fuse Box→Engine Stop Motor Terminal B→

Terminal P1→Emergency Relay Terminal
P1→Terminal P2→Engine Stop Relay Terminal
#5→Terminal #3→ Engine Stop Motor Terminal A→E
(Ground)
Key Switch
Fusible Link
Battery
Battery Relay
Engine Stop Motor
Fuse Box
Engine
Stop Relay
Engine oil pressure switch.
Fuse Box
Emergency Relay
Engine Stop Motor 360 (0) Degrees Position
T166-02-03-013
T2-3-13
(Blank)
T2-3-14
SECTION 3
COMPONENT OPERATION
—CONTENTS—
Group 1 Pump Device Group 4 Pilot Valve
Outline .....................................................T3-1-1 Outline .....................................................T3-4-1
Main Pump ...............................................T3-1-2 Operation .................................................T3-4-2
Regulator .................................................T3-1-4
Pilot Pump..............................................T3-1-12 Group 5 Travel Device
N Sensor (Engine Speed Sensor) ...........T3-1-12 Outline .....................................................T3-5-1
P Sensor Travel Reduction Gear..............................T3-5-2
(Pump Delivery Pressure Sensor) .........T3-1-12 Travel Motor .............................................T3-5-3
A Sensor Travel Brake Valve ...................................T3-5-5
(Pump Displacement Angle Sensor) ....T3-1-12 Travel Motor Displacement
Angle Shift ..............................................T3-5-7
Group 2 Swing Device Parking Brake...........................................T3-5-9
Outline .....................................................T3-2-1
Swing Motor .............................................T3-2-2 Group 6 Others (Upperstructure)
Valve Unit .................................................T3-2-4 Pilot Shut-Off Valve ..................................T3-6-1
Swing Parking Brake ................................T3-2-6 Shockless Valve .......................................T3-6-2
Swing Reduction Gear..............................T3-2-7 Solenoid Valve Unit ..................................T3-6-3
Accumulator .............................................T3-6-4
Group 3 Control Valve
Outline .....................................................T3-3-1 Group 7 Others (Undercarriage)
Hydraulic Circuit .......................................T3-3-6 Swing Bearing ..........................................T3-7-1
Flow Combiner Valve................................T3-3-8 Center Joint..............................................T3-7-2
Pump Control Valve..................................T3-3-9 Track Adjuster ..........................................T3-7-3
Main Relief Valve.................................... T3-3-11
Overload Relief Valve .............................T3-3-12
Make-Up Valve .......................................T3-3-12
Holding Valve .........................................T3-3-13
Arm Regenerative Valve .........................T3-3-14
Center Bypass Valve ..............................T3-3-16
166T-3-1
(Blank)
166T-3-2
COMPONENT OPERATION / Pump Device
OUTLINE
The pump device consists of a transmission, two main The pilot pump is a gear pump which supplies
pumps, and a pilot pump. pressure oil to the pilot circuit.
According to the gear ratio of each power train, the
transmission distributes the engine power to the output
shafts, driving the pumps. The gear speed ratio of the
engine to the main pump is 1:1 and that of the engine
to the pilot pump is 1:1.0810
The main pumps, which are variable displacement,
swash plate type plunger pumps, are positioned in
tandem in a single housing, supplying high pressure oil
to the hydraulic cylinders and motors via the main
circuit.
Main Pump 1
Transmission
Pilot Pump
Main Pump 2 T166-01-02-010
T3-1-1
MAIN PUMP
Shaft (1) is spline-connected to cylinder block (6),

while plungers (5) are inserted into the cylinder block
bores.
The engine power is transmitted to shaft (1) via the

transmission. Booster (7) connects shaft (1) of main
pump 1 to that of main pump 2. As shafts (1) rotate,
plungers (5) rotate along with cylinder blocks (6),
sliding along the surface of shoe plates (2). Because
swash plates (4) are placed at an angle against the
plungers, plungers (5) reciprocate in the bores of
cylinder blocks (6), drawing and discharging hydraulic
oil.
1 2 3 7 3 2 1

4 5 6 6 5 4
W111-02-04-001
1 - Shaft 3 - Servo Piston 5 - Plunger 7 - Booster

2 - Shoe Plate 4 - Swash Plate 6 - Cylinder Block
T3-1-2
Delivery Rate Increase/Decrease Operation
The main pump delivery rate is changed by changing

swash plate angle (displacement angle), thus
changing plunger stroke in the cylinder block bores.
Servo piston (2) is moved by pressure oil from the
regulator to control the swash plate angle
(displacement angle). As swash plate (3) is
connected to servo piston (2), swash plate (3) angle
is changed by the movement of servo piston (2).
6
5
4
3 T117-02-01-003
1 - Shaft 3 - Swash Plate 5 - Cylinder Block 6 - Valve Plate

2 - Servo Piston 4 - Plunger
T3-1-3
REGULATORS
The regulators are provided on the top of the main As pump control proportional solenoid valve (11) is
pumps to control the pump delivery rate. The pump activated, servo assist pressure Pi (delivery pressure
delivery (flow) rate is changed as the flow control from the pilot pump) is reduced, becoming pump flow
pressure from pump control proportional solenoid control pressure, which then acts on pilot piston (1) via
valve (11) increases or decreases. passage (a). Also, servo assist pressure Pi is
Main pump delivery pressure P1 is routed to spool (3) combined with main pump delivery pressure P1 via
via check valve (10), acting on spool (3). Main pump check valve (2) and passage (b).
delivery pressure P1 is also routed into the small
chamber of servo piston (8) via passage (d) all the
time.
2
a e
10
b
11
d
1 c
6
5
3
7
4
9
Pi
8 P1
Pilot Pump
Main Pump
T3-1-4
Pi b 1 2 3 c 4 5 6
a A
10
Small Chamber
Large Chamber 9 8 7
P1
Main Pump
Large Displacement Angle Small
T162-03-01-002
10 d 4 5 7
Cross b Cross Section B
Section A
11 e a b
Pi
Pilot Pump
P1
8
T162-03-01-004
T162-03-01-003
Main Pump
1 - Pilot Piston 4 - Sleeve 7 - Plug 10 - Check Valve

2 - Check Valve 5 - Pin 8 - Servo Piston 11 - Pump Control; Proportional
Solenoid Valve
3 - Spool 6 - Spring 9 - Feedback Lever
a - Passage for Pump Control Proportional Solenoid Valve e - Tank Port (Pump Control Proportional Solenoid Valve)
Output Pressure
b - Passage for Servo Assist Pressure to be Combined P1 - Main Pump Delivery Pressure
with Main Pump Delivery Pressure P1
c - Servo Piston Large Chamber Side Tank Port P2 - Servo Assist Pressure (Pilot Pump Delivery Pressure)
d - Passage to Servo Piston Small Chamber
T3-1-5
Regulator Operation with Flow Rate Control
Pressure 0 (Minimum Flow Rate)
When the flow rate control pressure from pump As servo piston (8) moves, feedback lever (9) rotates
control proportional solenoid valve (11) is 0, spool (3) counterclockwise around plug (7). Because the top
is pushed to the left by spring (6). As a result, main end of feedback lever (9) is connected to sleeve (4)
pump delivery pressure P1 is routed into the servo by pin (5), sleeve (4) moves to the left. Servo piston
piston (8) large chamber via check valve (10), sleeve (8) continues to move until the notch on spool (3) is
(4) and spool (3). Although main pump delivery closed completely.
pressure P1 is also routed into the small chamber, With the above operation, the pump displacement
servo piston (8) moves to the right due to the angle becomes the minimum, obtaining the minimum
difference in pressure receiving areas between the flow rate.
servo piston ends.
10
11
d
c
6
5
3
7
4
9
Pi
8 P1
Pilot Pump
Main Pump
T3-1-6
3 4 5 6
10
Small Chamber
Large Chamber 9 8 7
P1
Main Pump
T162-03-01-002
10 d 4 5 7
Cross Cross Section B
Section A
e
11
Pi
Pilot Pump
P1
8
T162-03-01-004
T162-03-01-003
Main Pump
3 - Spool 6 - Spring 8 - Servo Piston 10 - Check Valve

4 - Sleeve 7 - Plug 9 - Feedback Lever 11 - Pump Control; Proportional
Solenoid Valve
5 - Pin
d - Passage to Servo Piston Small Chamber P1 - Main Pump Delivery Pressure
e - Tank Port (Pump Control Proportional Solenoid Valve) Pi - Servo Assist Pressure (Pilot Pump Delivery Pressure)
T3-1-7
Pressure Increasing (Increasing Flow Rate)
When pump control proportional solenoid valve (11) As servo piston (8) is moved to the left, feedback
is actuated, flow control pressure, proportional to the lever (9) rotates clockwise around plug (7). Because
movement of pump control proportional solenoid the top end of feedback lever (9) is connected to
valve (11), acts on pilot piston (1) via passage (a), sleeve (4) by pin (5), sleeve (4) moves to the right.
moving spool (3) to the right until spool (3) balances Servo piston (8) continues to move until the notch on
with spring (6). spool (3) is closed completely.
When spool (3) moves to the right, the large chamber With the above operation, the pump displacement
of servo piston (8) is connected to the hydraulic oil angle is increased, increasing pump delivery rate.
tank via passage (c) in spool (3). Since the main Note that the rate of the increment is proportional to
pump delivery pressure P1 is routed into the small the increment of the flow rate control pressure.
chamber of servo piston (8) via passage (d) all the
time, servo piston (8) moves to the left and oil in the
large chamber is returned to the hydraulic oil tank.
a
10
11
d
c 3
1
6
5
7
4
9
Pi
8
P1
Pilot Pump
Main Pump
T3-1-8
Pi 1 3 c 4 5 6
a A
10
Small Chamber
Large Chamber 9 8 7
P1
Main Pump
T162-03-01-002
10 d 4 7
Cross Cross
Section A Section B
11 a
Pi
Pilot Pump
Pi
8
T162-03-01-004
T162-03-01-003
Main Pump
1 - Pilot Piston 5 - Pin 8 - Servo Piston 10 - Check Valve

3 - Spool 6 - Spring 9 - Feedback Lever 11 - Pump Control; Proportional
Solenoid Valve
4 - Sleeve 7 - Plug
a - Passage for Pump Control Proportional Solenoid Valve Output P1 - Main Pump Delivery Pressure
Pressure
c - Servo Piston Large Chamber Side Tank Port Pi - Servo Assist Pressure (Pilot Pump Delivery Pressure)
d - Passage to Servo Piston Small Chamber
T3-1-9
Pressure Decreasing (Decreasing Flow Rate)
When the flow control pressure from pump control As servo piston (8) moves, feedback lever (9) rotates
proportional solenoid valve (11) decreases, spool (3) counterclockwise around plug (7). Because the top
is returned to the left until it balances with spring (6). end of feedback lever (9) is connected to sleeve (4)
The pressure oil exerted on pilot piston (1) is returned by pin (5), sleeve (4) moves to the left. Servo piston
to the hydraulic oil tank via passages (a) and (e). (8) continues to move until the notch on spool (3) is
As spool (3) moves to the left, main pump delivery closed completely.
pressure P1 is routed into the large chamber of servo With the above operation, the pump displacement
piston (8) via check valve (10), sleeve (4), and spool angle is reduced, decreasing the pump flow rate.
(3). Although main pump delivery pressure P1 is also Note that the rate of the flow rate reduction is
routed into the small chamber, servo piston (8) moves proportional to the reduction of the flow rate control
to the right due to the difference in pressure receiving pressure.
areas between the servo piston ends.
a
e 10
11
6
5
7
1 3 4
9
Pi
8 P1
Pilot Pump
Main Pump
T3-1-10
Pi 1 3 4 5 6
a A
10
Small Chamber
Large Chamber 9 8 7
P1
Main Pump
T162-03-01-002
10 d 4 5 7
Cross
Section A Cross Section B
11 e a
Pi
Pilot Pump
P1
8
T162-03-01-004
T162-03-01-003
Main Pump
1 - Pilot Piston 5 - Pin 8 - Servo Piston 10 - Check Valve

3 - Spool 6 - Spring 9 - Feedback Lever 11 - Pump Control; Proportional
Solenoid Valve
4 - Sleeve 7 - Plug
a - Passage for Pump Control Proportional Solenoid Valve Output P1 - Main Pump Delivery Pressure
Pressure
d - Passage to Servo Piston Small Chamber Pi - Servo Assist Pressure (Pilot Pump Delivery Pressure)
e - Tank Port (Pump Control Proportional Solenoid Valve)
T3-1-11
PILOT PUMP
2 1
Drive gear (1) is rotated by the transmission, rotating
driven gear (2).
1 - Drive Gear 2 - Driven Gear
T137-02-03-005
N SENSOR (ENGINE SPEED SENSOR) 3
The N sensor detects engine speed. (This engine

speed data is used for various controls.)
The N sensor is installed close to the tips of the
flywheel gear teeth, detecting the number of gear teeth
passing under the N sensor tip. The detected number 4
is converted to electrical signals.
3 - N Sensor 4 - Gear (Teeth)
T162-03-01-009
P SENSOR (PUMP DELIVERY PRESSURE
SENSOR)
The P sensor detects pump delivery pressure. (This

data is used for various controls.)
Pump delivery pressure is exerted on diaphragm (8).
Electrical signals proportional to the extent of
diaphragm deformation are sent the controller.
5 - Ground Terminal 7 - Power Source (5 V) 5 6 7 8

6 - Output Terminal 8 - Pressure Receiving Area
(Diaphragm) T157-02-03-010
A SENSOR (PUMP DISPLACEMENT

ANGLE SENSOR)
9
The pump displacement angle is transmitted to A
sensor (9) via lever (10). The A sensor detects
displacement angle changes as changes in electrical
resistance.
10
9 - A Sensor (Pump
Displacement Angle Sensor)
10 - Lever
T162-03-01-010
T3-1-12
COMPONENT OPERATION / Swing Device
OUTLINE
The swing device consists of the valve unit, swing The reduction gear functions to reduce the rotation
motor and reduction gear. speed of swing motor and to increase its torque before
The swing motor is driven by pressure oil from the transmitting the rotational force from swing motor to
pump and transmits rotational force to the reduction the pinion shaft.
gear. The valve unit functions to protect the swing circuit.
Valve Unit
Swing Motor
Reduction Gear
T111-02-04-001
T3-2-1
SWING MOTOR
The swing motor is a swash-plate-type axial plunger The spherical end of plunger (5) is installed in shoe (2)
motor. by a ball-and-socket joint. The shaft part of plunger (5)
The swing motor consists of shaft (4), swash plate (3), is inserted into rotor (6). Rotor (6) is installed onto shaft
shoes (2), plungers (5), rotor (6), valve plate (9), (4) with a spline coupling.
housing (1), and parking brake. The parking brake is a wet-type multiple disc brake,
consisting of friction plates (7) and plates (8).
6 2
5
3
4
T166-03-02-002
1 - Housing 3 - Swash Plate 5 - Plunger 7 - Friction Plate

2 - Shoe 4 - Shaft 6 - Rotor 8 - Plate
9 - Valve Plate
T3-2-2
Operational Principle
Swing speed varies depending on the amount of oil The rotational force is then transmitted to the swing
delivered from the pump. reduction gear via the shaft. As the rotor is rotated,
When pressure oil is fed into the rotor bores via port the plungers are moved to port (B) side one by one,
(A), the plungers are pushed from the top to the returning oil to the hydraulic oil tank.
bottom causing the shoes to slide along the swash When pressure oil is fed via port (B), the motor
plate, developing rotational force. rotates in the opposite direction.
Plunger
Shoe
Shaft
T142-02-02-004
T3-2-3
VALVE UNIT
The valve unit consists of the make-up valve and the

relief valve.
Make-Up Valve Drain Port

When swing is stopped, the upperstructure tends to Make-Up Valve
keep rotating due to swing inertia force, causing the
Port M
swing motor to continue rotating further, and to begin (Make-Up Port)
drawing oil from the pump, developing cavitation the
motor.
Relief Valve
The make-up valve draws hydraulic oil through the
port M (make-up port) to compensate for the lack of
oil, and prevent cavitation.
Control Valve
T166-03-02-001
Port M
(Make-Up Port)
Port M
Make-Up Valve
Relief Valve
BV
AV
T166-03-02-003
T3-2-4
Relief Valve
When starting or stopping swing operation, oil
pressure in the swing circuit becomes high. The relief
valve prevents the circuit pressure from rising higher
than the specified pressure. Plunger is pushed to the
left by pressure Pp at port P and pressure-receiving
area A1.
However, plunger is also pushed back to the right by
spring force and pressure Pg at chamber (g) and
pressure-receiving area A2.
Chamber (g) is connected to port P through orifice
(m). When force acting to the left is higher than that Relief Valve
to the right, the relief valve operates.
Control Valve
T166-03-02-001
Spring Plunger
g n
Port P
T111-02-04-007
A2 m A1
T3-2-5
SWING PARKING BRAKE Brake is released (OFF).
The swing parking brake is a wet-type multiple disc

brake. 1
Also, the swing parking brake is a negative type, i.e. 2
the brake is released when brake release pressure is
routed into brake-piston chamber (b). b
The brake release pressure is supplied from the pilot
pump via a solenoid valve when a swing or front SC
attachment control lever is operated. (Refer to the
Valve Control in the Control System group, the
SYSTEM section.)
In cases other than above, the brake release pressure 3
is returned to the hydraulic oil tank and the swing 4
parking brake is automatically applied by spring (1). 5
6
• When the parking brake is released. (When a
swing or front attachment control lever is T111-02-04-020
operated.)
When a swing or front attachment control lever is
operated, the controller (PVC) actuates (shifts)
the solenoid valve. As the solenoid valve is shifted, Brake is applied (ON).
the brake release pressure from the pilot pump is
routed to the brake-piston chamber (b), acting on
1
brake piston (2). As a result, plates (3) and friction
plates (4) break contact, thus releasing the swing
2
parking brake.
• When the parking brake is applied. (When the b

swing or front attachment control levers are not
operated.)
When the swing or front attachment control levers
3
are not operated, the solenoid valve does not shift.
The brake release pressure is released to the
4
hydraulic oil tank port via the solenoid valve.
From the above, friction plates (4), which are 5
engaged with the outer circumference of rotor (6), 6
and plates (3), which in turn are engaged with the T111-02-04-021
inner wall of motor housing (5), are pushed by

spring (1), coming into tight contact with each
other. Consequently, rotor (6) is secured
immovable.
1 - Spring 4 - Friction Plate

2 - Brake Piston 5 - Motor Housing
3 - Plate 6 - Rotor
T3-2-6
SWING REDUCTION GEAR
The swing reduction gear is a planetary-gear-type two Motor output shaft (10) rotates first stage sun gear (9).
stage reduction gear. As the first stage reduction takes place between first
Both first stage ring gear (2) and second stage ring stage planetary gears (1) and first stage carrier (8),
gear (4) are immovable as they are fixed to the second stage sun gear (7) is rotated. Then, the second
housing. stage reduction takes place between second stage
planetary gears (3) and second stage carrier (6),
before the rotational force is transmitted to shaft (5).
10
1
3
8
7
4
T111-02-04-004
1 - First Stage Planetary Gear 4 - Second Stage Ring Gear 7 - Second Stage Sun Gear 9 - First Stage Sun Gear
2 - First Stage Ring Gear 5 - Shaft 8 - First Stage Carrier 10 - Motor Output Shaft
3 - Second Stage Planetary Gear 6 - Second Stage Carrier
T3-2-7
(Blank)
T3-2-8
COMPONENT OPERATION / Control Valve
OUTLINE
The control valve regulates oil flow rate, oil flow Right (4-spool) block: Travel (R), Bucket, Boom 1, and
direction, and oil pressure in the hydraulic circuit. The Arm 2 sections, in that order viewed from the front
main control valve consists of two blocks: the right (4- side.
spool) block and the left (5-spool) block, connected. Left (5-spool) block: Travel (L), ∗Aux., Boom 2, Arm 1,
The main control valve is a pilot-pressure operated and Swing sections, in that order viewed from the front
type. side.
The main control valve consists of main relief valve, The pump control valve is provided on each main
pump control valve, flow combiner valve, spools, arm control valve block downstream of each block's neutral
regenerative valve, and holding valve. passage. These pump control valves send pressure
The spool sections of the main control valve are signals to the DP sensor to control the main pump
arranged as follows : delivery rate.
Front Side Travel (R)
Travel (L) Boom 1
NOTE: ∗ In the case of load-
∗Aux. Arm 2
ing shovel specification
Arm Regenerative
Boom 2
(bottom dump), this valve is Valve
Arm 1
used for bucket’s opening DP Sensor
and closing. Swing
Pump Control Valve
Overload Relief (4-Spool Block Side)
Valve
Make-Up Valve 4-Spool
Block
Tank Port
T2
Holding Valve (Arm)
Overload Relief Valve Tank Port

T1
5-Spool
Block T166-03-03-001
DP Sensor
Pump Control Valve

5-Spool Block
Make-Up Valve
Overload Relief Valve
Front Side
Holding Valve (Boom)
Shuttle Valve Main Relief Valve

Flow Combiner
Valve 4-Spool Block
T162-05-02-012
T3-3-1
Control Valve Layout
1 2 3 43 4 5 6 7 8 9 10 11 12 13 14 15
42
41 Swing Motor
Boom Cylinder
Arm Cylinder
40
39
16
Bucket Cylinder
17
38 18
19
37
20
36 21
22
35
23
34
33

32 31 30 29 28 27 26 25 24 T166-01-02-019
Tandem Circuit)
T3-3-2
Swing Arm 1
Boom 2 32 33 24 23
∗Aux.
Left Travel
Am 2
Boom 1
Bucket
31
Right Travel
Front Side
T162-05-02-012 30 29 T162-05-02-009
44 28 45 37 48 35 49 21
22
20
34 26
25 21
T166-01-02-004
T162-05-02-004 37 51 6 27 50
47 46
T3-3-3
1 2 3 43 4 5 6 7 8 9 10 11 12 13 14 15
42
41 Swing Motor
Boom Cylinder
Arm Cylinder
40
39
16
Bucket Cylinder
17
38 18
19
37
20
36 21
22
35
23
34
33

32 31 30 29 28 27 26 25 24 T166-01-02-019
Tandem Circuit)
T3-3-4
56 5 57
52 53 Arm 2 Arm 1
7
Boom 1 Boom 2
17 41 16 13
39
8
2
36 18
12
1
19 4 9
15
40 55 38 54 T166-01-02-002 38 59 58 T166-01-02-003
14
42 3 60
Swing
15
43
10
14
T162-05-02-010
T162-05-02-008
40 61
T3-3-5
HYDRAULIC CIRCUITS
Main Circuit Pilot Signal Circuit
Oil flow from the main pumps is routed to the 4-spool Pressure oil from the pilot pump flows through the
block and 5-spool block of the control valve. A parallel control valve blocks, acting as pilot signals.
passage is provided on both control valve blocks, When the front attachment cylinders or swing motor
making combined operations possible. are operated, the pilot pressure in the front att. pilot
The main relief valve is provided in the main circuit to signal circuit in the main control valve increases,
set the main circuit pressure to a certain level. In shifting the flow combiner valve.
addition, an overload relief valve is provided in each
of the boom, arm, bucket, and swing circuits.
A pump control valve is provided downstream of each
control valve block's neutral passage.
T3-3-6
Pump Control Valve

(4-Spool Block Side) Front Att. Pilot Signal Circuit
Overload Relief
Valve
Overload Relief
Overload Valve
Relief Valve
From the pilot

pump
Travel Pilot
Signal Circuit
Main Relief 4-Spool
Valve Block
Side 5-Spool Block
Side
Main Main
Pump 2 Pump 1 Pump Control Valve T166-03-03-006
From the main (5-Spool Block Side)
relief pressure
shift solenoid valve.
T3-3-7
FLOW COMBINER VALVE
When a control lever, other than the travel levers, is If the travel control levers are operated with the above
operated, the front att. pilot signal circuit is restricted by mentioned control lever operated, oil flow from main
the movement of the main control valve spool, pump 2 is routed to both Travel (R) and Travel (L)
increasing the pilot pressure and shifting the flow spools, securing straight travelability in travel combines
combiner valve. operations.
Front Att. Pilot Signal Circuit
Boom Cylinder
Boom 1 Boom 2
Travel (L)
Travel (R)
Flow Combiner
Valve
4-Spool
Block 5-Spool Block Side
Side

T166-03-03-004
T3-3-8
PUMP CONTROL VALVE
A pump control valve is provided on the farthest

downstream part of the neutral passage in each 4-
spool and 5-spool control valve block.
The pump control valve routes pressures of neutral
passage before and after the pump control valve's
orifice to the DP sensor as pump flow control signals. If
the pressure difference is large, the pump flow rate is
decreased. If it is small, the pump flow rate is
increased.
Pump Control Valve (4-Spool Block Side)
Neutral
Passage
Pressure Difference
Sensor (DP Sensor)
Neutral
Passage
Pressure Difference
Sensor (DP Sensor)
4-Spool 5-Spool
Block Side Block Side
Pump Control Valve (5-Spool Block Side)
T166-03-03-005
T3-3-9
Pump control valve operation when control valve Pump control valve operation when control
spools are in neutral. levers are operated.
When the control valve spools are in neutral, all oil When a control lever is operated, a control valve
flowing from the main control valve goes through the spool is shifted to route oil flow to an actuator,
orifice before it is returned to the hydraulic oil tank. reducing the oil flow rate in the neutral passage. As a
The pressure difference between before and after the result, the pressure difference between before and
orifice becomes large, reducing the main pump flow after the orifice becomes small, increasing the main
rate to the minimum. pump flow rate.
DP Sensor
To the controller.
Orifice
(fp)
Neutral Passage
(rp)
Poppet Spring
T111-02-05-016
Return Line
Pump Control Valve Operation as a Relief Valve
Normally the pump control valve does not act as a

relief valve. However, if oil flow in the neutral passage
becomes excessive, a poppet opens to provide an
extra passage to the return line, in addition to the
orifice passage, to release excessive pressure.
Orifice Poppet
Neutral Passage
T111-02-05-017
Return Line
T3-3-10
MAIN RELIEF VALVE
Main relief valve set pressure can be shifted in two

stages using the pilot pressure from main relief
pressure shift solenoid valve (SA).
When traveling or when operating in the precision
mode, the main relief pressure is set in the high stage
(high relief pressure). In other cases, the main relief
pressure is set in the low stage (low relief pressure).
Main Relief Valve Operation in Low Main Relief

Pressure Setting
When the travel pressure switch is OFF or when the the main relief valve piston is not pushed to the left,
work mode is set in other than the precision mode, keeping the pilot poppet setting relatively low.
the main relief valve shift solenoid valve is not excited When pressure at port Hp rises to the set pressure,
and, as a result, no pilot pressure exerts on the the pilot poppet opens, routing oil at port Hp to port Lp
shuttle valve port pF2. At the same time, port pF1 is via passage A.
open to the hydraulic oil tank line. For this reason, The pressure in spring A chamber decreases as the
pilot poppet opens, causing the main poppet to open.
As a result, pressure oil at port Hp is directly routed to
port Lp.
Main Poppet Pilot Poppet Spring Piston
Lp
Hp
Lp
pF1 pF2 Shuttle Valve

Passage A
Spring A Chamber
Main Relief Valve Shift Solenoid Valve
T111-02-05-014
Main Relief Valve Operation in High Main Relief

Pressure Setting
When the travel pressure switch is ON or when the The valve operation is the same as the one in the low
work mode is set in the precision mode, the main main relief pressure setting.
relief valve shift solenoid valve is excited and, as a
result, a pilot pressure is routed to the shuttle valve
port pF2. This pilot pressure acts on the piston,
pushing it to the left. As a result, the spring is
compressed, increasing the pilot poppet setting force.
In other words, the main relief pressure setting is
shifted to the high stage.
T3-3-11
OVERLOAD RELIEF VALVE
(With Make-Up Function)
1 2 3 4
An overload relief valve is provided on each of swing,
boom, arm, and bucket actuator port, preventing
HP
excessive pressure from arising in each actuator
circuit if each actuator should be forcibly moved by an
external force.
When the pressure at port HP overcomes spring (4),
pilot poppet (3) opens, decreasing the pressure in
chamber (a). As a result, piston (1) is moved to the LP
right, opening main poppet (2), thus routing pressure
oil at port HP directly to port LP.
T111-02-05-019
In addition, the overload relief valve draws oil from the

hydraulic oil tank line to prevent cavitation from
occurring if the actuator circuit pressure becomes 2 a
negative.
HP
1 - Piston 3 - Pilot Poppet

2 - Main Poppet 4 - Spring LP
T111-02-05-021
MAKE-UP VALVE
A make-up valve is provided on the cylinder port of 5 6

boom 2 and arm 2 sections, reinforcing the overload d2 d1
relief valve's make-up function.
Poppet (5) is closed when the pressure at port HP is HP
higher than the pressure at port LP due to the
difference in pressure receiving areas of poppet ends
d1 and d2.
If the pressure at port HP becomes lower than the
pressure at port LP, port LP pressure for the area
difference between d1 and d2 is applied to poppet (5), LP
b
opening it.
T111-02-05-023
5 - Poppet 6 - Spring
HP
LP
T111-02-05-024
T3-3-12
HOLDING VALVE
A holding valve is provided on the boom raise side and

arm roll-out side cylinder ports, preventing the boom
and arm cylinders from retracting when the control
levers are in neutral.
• Holding valve operation when the control levers

are in neutral.
The cylinder holding pressure at cylinder port C acts Because of the difference in the sizes of pressure
on chamber (a) via orifice (b) in check valve (2). receiving areas d1 and d2, check valve (2) is
securely seated on cylinder port C, closing the
cylinder port.
1 External Force
g
2 a
a
d1
b Holding Pressure
g
c 3
b
d2
d
c 3
Pi
f
f d e
T111-02-05-025
• Holding valve operation when the boom lower or
arm roll-in control lever is operated.
Pilot pressure Pi acts on poppet (1), connecting As the pressure in chamber (a) decreases, check
chamber (a) and the hydraulic oil tank line. valve (2) opens. At the same time, spool (3) is
moved to form a circuit ( (c) → (d) → (f) ) so that the
actuating cylinder (boom or arm) can move.
a
a
2
d c 3
Pi
f
f d
T111-02-05-026
1 - Poppet 2 - Check Valve 3 - Spool
T3-3-13
ARM REGENERATIVE VALVE 1
The arm regenerative valve is provided to help smooth PB

arm operation and to prevent arm hesitation from PR
occurring. i
8
Return oil from cylinder rod side is restricted in two 3
stages at orifice (A) in spool (2) and at orifice (B) in 2
arm regenerative valve (7), increasing cylinder rod side h
pressure PR. A
When rod side pressure PR becomes higher than
bottom side pressure PB, check valve (3) opens,
C
routing the return oil from the rod side to supplement e
the pump oil flow to the bottom side. 7
9 b 6
a d B
T111-02-05-035
PR PB
8 9
A
h
f e a i d
e
7 B
d
c
6 5 4 T111-02-05-028
1 - Arm Cylinder 4 - Piston 6 - Spring 8 - Holding Valve

2 - Spool 5 - Spool 7 - Arm Regenerative Valve 9 - Load Check Valve
3 - Check Valve
T3-3-14
When bottom side pressure PB is higher than rod side 1
pressure PR, check valve (3) closes. Moreover, bottom
side pressure PB acts on piston (4) in arm PB
regenerative valve (7) via passage (b). As a result, PR
spool (5) is moved to the left, widening orifice (B), thus i
returning rod side oil faster to hydraulic oil tank 8
passage (d). 3
2
h
A
C
e
7
9 b 6
a d B
T111-02-05-035
1
PR PB
8 9
A
h
f e a i d
e
7 B
d
c
6 5 4 T111-02-05-029
1 - Arm Cylinder 4 - Piston 6 - Spring 8 - Holding Valve

2 - Spool 5 - Spool 7 - Arm Regenerative Valve 9 - Load Check Valve
3 - Check Valve
T3-3-15
Center Bypass Valve
The center bypass valve is operated by adding the

crusher selector valve (optional) to increase the
pressure oil flow to the auxiliary spool to operate the
crusher attachment (optional). (Therefore, the center
bypass valve on the standard specification machine
is inoperable.)
When the center bypass valve spool is moved to the
left by the pilot pressure oil from the crusher selector
valve, the main system pressure oil from the main
pump 2 is blocked at the front of the 4-spool side
pump control valve. Then the blocked main system
pressure oil flow is combined with the main system
pressure oil from the main pump 1 in the 5-spool
side control valve and routed to the auxiliary spool.
Pump Control Valve From the crusher selector
(4-Spool Block Side) valve (Optional)
Center Bypass Valve
Auxiliary Spool
(Attachment)
4-Spool Side
5-Spool Side
Main Main
Pump 2 Pump 1 T166-01-02-018
T3-3-16
COMPONENT OPERATION / Pilot Valve
OUTLINE
The pilot valve functions to control the pilot pressure oil, The machine is equipped with the front attachment
causing the control valve spools to move. When a /swing pilot valve, the travel pilot valve and the bucket
control lever is operated, the pilot valve sends a pilot open/close pilot valve (for loading shovel).
pressure, in proportion to the lever stroke, to the Construction and operation of all pilot valves are
control valve to move the respective control valve almost identical.
spool.
Front Attachment/Swing Pilot Valve Travel Pilot Valve Bucket Open/Close Pilot Valve
15
8
9 10 11
19 18 17 16
T142-02-04-002
7 2
6 3
14 13 12
T142-02-04-004
5 4
T142-02-04-003
1 - Left Pilot Valve 6 - Port T 11 - Left Travel Reverse Port 16 - Plug (Bucket Open)
(Right Pilot Valve)
2 - Left Swing Port 7 - BH: Arm Roll-Out Port 12 - Right Travel Reverse Port 17 - Port P
(Boom Raise Port) LD: Arm Retract Port
(Bucket Roll-In Port)
3 - Port P 8 - Travel Pilot Valve 13 - Port T 18 - Port T
4 - BH: Arm Roll-In Port 9 - Left Travel Forward Port 14 - Right Travel Forward Port 19 - Plug (Bucket Close)
LD: Arm Extend Port
(Bucket Roll-Out Port)
5 - Right Swing Port 10 - Port P 15 - Bucket Open/Close Pilot Valve
(Boom Lower Port)
NOTE: Ports in parentheses are the ones on the

right pilot valve.
BH: Backhoe
LD: Loading Shovel
T3-4-1
OPERATION
Spool (7) is held upward by return spring (6) via spring

guide (4). Spring guide (4) cannot be lifted further as it
is held by the lower neck of spacer (3) that is making
contact with bushing (2) which is immovable.
With spool (7) in this position, the output port is
connected to port T via a notch on spool (7).
In neutral Full Stroke Operation

(Pusher stroke: A to B in the output diagram) (Pusher stroke: E to F in the output diagram)
When the control lever is in the neutral position, spool When the control lever is moved further to the stroke
(7) completely blocks pressure oil from port P. Since end, pusher (1) is lowered until spring guide (4)
the output port is open to port T pressure at the comes in contact with the stepped part of the valve
output port equals that of the hydraulic oil tank. housing.
When the control lever is slightly moved, pusher (1), At the stroke point “D(E)”, pusher (1) comes in direct
spacer (3), and spring guide (4) move downward as a contact with spool (7) so that the lower notch does not
unit against return spring (6) and balance spring (5). close from this point on to the stroke end.
As the neck of spool (7) is pulled downward and held For this reason, the pressure at the output port rises
against spring guide (4) by balance spring (5), spool until it reaches port P pressure, and stays there.
(7) is also moved downward together with the above-
mentioned unit until clearance (A) of the spool notch
becomes zero.
Operation Corresponding to the control lever

stroke
(Pusher stroke: C to D in the output diagram)
As the control lever is moved further, the lower notch
on spool (7) reaches port P, routing pressure oil from E F
Output Port Pressure
port P to the output port, thus increasing pressure at (Pilot Pressure)
the output port. A part of the pressure oil at the output D
port is routed inside spool (7) via a passage on spool
(7), acting against spool (7) from the inside, pushing it
upward, and also acting against piston (8). As long as
the force of balance spring (5) is larger than this
upward pressure, the output port pressure rises C
continuously.
When the output port pressure overcomes balance
spring (5) force, spool (7) is moved upward,
compressing balance spring (5). As a result, the A B Pusher Stroke
lower notch is closed to block pressure oil from port P
to the output port, stopping pressure rise at the output Output Diagram
port.
If the control lever is further moved, spool (7) is
pushed downward again, opening the notch and
increasing the output port pressure. At this time,
balance spring (5) is compressed for the amount
equivalent to the movement of spool (7). For this
reason, the output pressure rises further until the
output pressure (pressure force to push spool (7)
upward) balances against balance spring (5) force.
T3-4-2
Pusher Stroke : A to B
5
Notched Part
7
Port T
Output Port
Port P
T142-02-04-006 T142-02-04-007
Pusher Stroke : C to D Pusher Stroke : E to F
Notched Part
5 4
7
7
Notched Part Output Port

Passage Notched Part
Output Port
Port P
Port P
8
T142-02-04-009
T142-02-04-008
1 - Pusher 3 - Spacer 5 - Balance Spring 7 - Spool

2 - Bushing 4 - Spring Guide 6 - Return Spring 8 - Piston
T3-4-3
(Blank)
T3-4-4
COMPONENT OPERATION / Travel Device
OUTLINE
The travel device consists of travel motor (1), the travel

reduction gear (parts (2) to (8), (10) and (14)), and
sprocket (9).
6
7
8
12
11
10
14 13
T111-03-02-001
1 - Travel Motor 5 - Second Stage Sun Gear 9 - Sprocket 12 - First Stage Carrier
2 - Housing 6 - Second Stage Carrier 10 - Third Stage Planetary 13 - Ring Gear
Gear
3 - Drum 7 - Third Stage Sun Gear 11 - Second Stage Planetary 14 - Shaft
Gear
4 - First Stage Planetary 8 - Third Stage Carrier
Gear
T3-5-1
TRAVEL REDUCTION GEAR
The travel reduction gear is a third stage planetary Third stage carrier (2) does not rotate as it is fixed to
gear type. When the travel motor rotates, shaft (7) travel motor housing (12). Ring gear (1) and sprocket
rotates, transmitting this motor-driving power to ring (11) are bolted to drum (13) and they rotate together.
gear (1) via first stage planetary gears (8), first stage
carrier (6), second stage sun gear (5), second stage
planetary gears (9), second stage carrier (4), third
stage sun gear (3), third stage planetary gears (10)
and third stage carrier (2).
11
12 13 2 3 4
5
㈍ 2 3 4 5 9 6
6
7
12
8
Third Second First
Stage Stage Stage
11 10
T111-03-04-011
10 1 9
T111-03-04-002
1 - Ring Gear 5 - Second Stage Sun Gear 8 - First Stage Planetary Gear 11 - Sprocket
2 - Third Stage Carrier 6 - First Stage Carrier 9 - Second Stage Planetary 12 - Housing (Travel Motor)
Gear
3 - Third Stage Sun gear 7 - Shaft 10 - Third Stage Planetary Gear 13 - Drum
4 - Second Stage Carrier
T3-5-2
TRAVEL MOTOR
The travel motor is a swash-plate-type axial plunger Tilt pistons (12) (4 provided) changes the displacement
motor, with a built-in hydraulically-released, wet-type angle of swash place (6); swash plate (6) is moved
multiple disc parking brake (3). (the angle is changed), having the contact point with
The travel motor consists of swash plate (6), rotor (17), ball (8) as the supporting point.
plungers (15) with shoes, valve plate (1), output shaft Rotor (17) is in tight contact with valve plate(1) by
(10), tilt pistons (12), and casing (7). spring (5).
1 2 3 4 5 6 7
10
18
11
17
16 14 13 12
15
T111-03-04-003
1- Valve Plate 6- Swash Plate 11 - Spring 15 - Plunger

2- Spring 7- Casing 12 - Tilt Piston 16 - Brake Piston
3- Parking Brake 8- Ball 13 - Ball 17 - Rotor
4- Retainer Plate 9- Roller Bearing 14 - Holder 18 - Valve Cover
5- Spring 10 - Output Shaft
T3-5-3
Pressure oil from the pump flows to port A of valve As output shaft (6) rotates, rotor (2) also rotates. Then,
plate (1), and enters into one-sided bores in rotor (2) when plungers (3) reach port B, oil is routed to the
located just behind the right-side crescent-shaped oil hydraulic oil tank.
port (port A side) of valve plate (1). Whether pressure oil from the pump is supplied to port
Then, plungers (3) in the right half side of rotor (2) are A or port B determines travel direction.
pushed out toward swash plate (5), and slide on the
swash plate to rotate rotor (2) and output shaft (6).
Port B Port A
Port B
Port A
2 1
4
Valve
6 5 Plate
T111-03-04-004
1 - Valve Plate 3 - Plunger 5 - Swash Plate 6 - Output Shaft

2 - Rotor 4 - Shoe
T3-5-4
TRAVEL BRAKE VALVE
The travel brake valve is located on the travel motor

head and consists of the following valves:
Counterbalance Valve: Check Valve:

ensures smooth starts and stops and prevents ensures smooth starts and stops, and prevents
overrunning when traveling down slopes. cavitation from occurring in the motor circuit by
functioning together with counterbalance valve.
Overload Relief Valve:
prevents overloads and surge pressure in the Travel Speed Shift Valve:
motor circuit. controls the tilt pistons when travel mode switch
is operated.
Check Valve
Counterbalance Valve
Travel Speed Shift Valve

T111-03-04-009
T3-5-5
Travel Operation Descending Operation
When supply oil from the control valve is routed to When the machine travels down a slope, the travel
port BV, supply oil flows around spool CB, opens motors are forcibly driven by the machine weight so
check valve BC and is led to motor port BM. However, that the motor sucks oil like a pump. When the motor
return oil from motor port AM is blocked by check sucks oil, oil pressure at port BV and chamber G
valve AC and spool CB. decreases, causing spool CB to move to the right.
As supply oil pressure at port BV increases, supply oil Then, the return oil flow from the motor is restricted
is routed to chamber G through orifice F in spool CB, by the spool, increasing pressure at port AM.
moving spool CB to the left against spring force. The increased pressure at port AM brakes the motor.
Consequently, return oil from motor port AM starts to Thus, the restricted return oil flow increases the
flow into port AV through notch H in spool CB, pressure at port BV again, moving spool CB back to
allowing the travel motor to rotate. the left. This repeat movement of the spool (hydraulic
brake action) prevents the machine from overrunning.
When the travel levers are returned to the neutral
position, the oil in both ports AV and BV are routed to Circuit Protectors
the hydraulic oil tank through the control valve. Thus,
oil pressure in chamber G decreases, and spool CB If pressure in the circuit increases over the setting
is moved back to the original position by spring force. pressure of overload relief valve, this valve opens to
Then, the oil flow circuit is blocked, causing the travel relieve peak pressure to the lower pressure side to
motors to stop rotating. protect the motor from overloading. This valve also
functions to release shock pressure caused by inertia
force developing when the motor stops.
When the motor draws oil because of pumping
operation, check valve BC opens to make up vacuum,
so that cavitation will not develop in the circuit.
Spool CB H Check Valve AC
Overload Relief Valve F
AV
AM
BV
Check Valve BC
BM
T111-03-04-010
T3-5-6
TRAVEL MOTOR DISPLACEMENT ANGLE
SHIFT
Travel speed mode shifts as the displacement angle of

swash plate (4) is changed by tilt pistons (5).
• Slow Speed Travel

(Maximum Displacement Angle)
With the travel mode switch is in the slow speed With the above, the displacement angle of swash
position, the controller (PVC) does not shift the plate (4) is held at the maximum angle, having the
travel speed mode shift solenoid valve SB so that maximum plunger (6) stroke. Accordingly the
pilot pressure (3) is not supplied to travel motor amount of oil required to rotate the travel motor
displacement angle shift valve (1) from the travel (per turn) becomes the maximum, resulting in
speed mode shift solenoid valve SB. Spool (7) in slow speed travel motor operation. (Refer to the
travel motor displacement angle shift valve (1) is Control System group in the SYSTEM section for
held in neutral by spring (2), blocking pressure oil the control circuit.)
from the control valve. At the same time, the line
to tilt pistons (5) is open to the hydraulic oil tank
line.
To the hydraulic 2 7 8 9 7 1
oil tank
10
10
From the control valve

T142-03-01-003
1 - Travel Motor Displacement 4 - Swash Plate 7 - Spool 9 - Spool

Angle Shift Valve
2 - Spring 5 - Tilt Piston 8 - Chamber A 10 - Ball
3 - Pilot Pressure (To the travel 6 - Plunger
speed mode shift solenoid
valve SB)
T3-5-7
Fast Speed Travel
(Minimum Displacement Angle)
When the travel mode switch is turned to the fast Consequently, tilt pistons (5) push swash plate (4),
speed position, the controller (PVC) shifts the changing the displacement angle to the minimum. As a
travel speed mode shift solenoid valve SB so result, the travel motor operates at fast speed. (Refer
that pilot pressure (3) is supplied to chamber A to the Control System group in the SYSTEM section for
(8) of travel motor displacement angle shift valve the control circuit.)
(1), shifting spool (7), thus routing pressure oil
from the control valve to tilt pistons (5).
5 6
From the travel motor 9 1

displacement angle
7 8
shift valve.
10 4
5
3
10
From the control valve.

T142-03-01-004
1 - Travel Motor Displacement 4 - Swash Plate 7 - Spool 9 - Spool

Angle Shift Valve
2 - Spring 5 - Tilt Piston 8 - Chamber A 10 - Ball
3 - Pilot Pressure (To the travel 6 - Plunger
speed mode shift solenoid
valve SB)
T3-5-8
PARKING BRAKE
The parking brake is a negative-type brake released Friction plates (4) are connected to rotor (6), and
when pressure oil from the control valve is applied to plates (3) to casing (5) via spline coupling respectively.
parking brake chamber M. Whenever the travel control When spring (1) pushes piston (2) to the right, friction
valve spools are in neutral, the parking brake is plates (4) come into contact with plates (3), applying
automatically applied. the parking brake.
M 2 3 4 5
1
6
T111-03-04-003
1 - Spring 3 - Plate 5 - Casing 6 - Rotor

2 - Piston 4 - Friction Plate
T3-5-9
Brake ON
1
When the travel levers are in the neutral position,
friction plates (4) and plates (3) are pressed down by
spring (1) force, braking the motor. Pressure oil in
brake chamber M is released to the hydraulic oil tank.
5
6
T111-03-04-007
Brake OFF
1
When the travel levers are operated, pressure oil
from the control valve is led to brake chamber M and
pushes brake piston (2) against spring (1) force.
Consequently, friction plates (4) are separated from
plates (3), releasing the parking brake.
M
5
6
T111-03-04-008
1 - Spring 3 - Plate 5 - Casing 6 - Rotor

2 - Piston 4 - Friction Plate
T3-5-10
COMPONENT OPERATION / Others (Upperstructure)
PILOT SHUT-OFF VALVE To Pilot Valve
The pilot control shut-off valve is a manually operated

switch valve. The valve spool is rotated when the pilot
control shut-off lever is operated, switching ON and
OFF the pilot pressure oil to the pilot valve.
From Pilot
Valve
To Hydraulic
Oil Tank
From Pilot
Valve
From Pilot
Pump
From Control
Valve T166-03-06-001
• Operation with Pilot Control Shut-Off Lever in

LOCK Position
When the pilot control shut-off lever is in the
LOCK position, the pilot shut-off valve is set in From Pilot Valve
neutral (OFF), blocking the pilot pressure oil from
the pilot pump to the pilot valve. The pilot pressure
oil in the pilot valve side is routed to the hydraulic
oil tank. As a result, the pilot valves become
inoperable with the control levers.
From Pilot Pump To Hydraulic Oil Tank

T162-03-06-002
• Operation with Pilot Control Shut-Off Lever in

UNLOCK Position To Pilot Valve
When the pilot control shut-off lever is moved to
the UNLOCK position, the pilot shut-off valve is
turned to the ON position, blocking the line to the
hydraulic oil tank and, at the same time, routing
the pilot pressure oil from the pilot pump to the
pilot valves. Thus, the pilot valves become
operable with the control levers.
From Pilot
Pump T162-03-06-003
T3-6-1
SHOCKLESS VALVE 5
The shockless valve regulates the pilot oil flow

between the pilot valve and control valve spools.
Shockless Valve (for Boom and Arm Functions) 2

The shockless valve consists of orifices (2) and (6),
1
check valve (3), restriction release shift valve (4),
heat circuit check valve (1) (used in the heating
circuit), and shuttle valve (5).
3
• When the boom raise control lever is operated,

the pilot valve is actuated, sending pilot pressure 4
oil to port A1. At the same time, port A2 is
connected to the hydraulic oil tank line. T105-02-09-001
At the start of pilot valve operation, pressure oil
from port A1 goes through orifice (2) only. The 5
1
pressure oil is regulated as it goes through orifice
(2), acting on the control valve spool from port B1 A1 A2 A3
side. As the pressure at port A1 rises, check valve
T1
(3) opens.
• Return oil from port B2 also goes through orifice

(6) only before it returns to the hydraulic oil tank in B1 B2 B3
the beginning of the pilot valve operation. As the T111-02-07-005
pressure at port A1 rises, restriction releasing shift
valve (4) is actuated, regulating the return oil in 2 3 4 6
proportional to the pressure value.
From Port A1 Side
4
B2
Heat Circuit A2
Hydraulic oil relieved from the pilot relief valve enters
port T1. Then, it flows to the pilot valve from each port
A via heat circuit check valve (1). 2 3 T105-02-09-005
Shuttle Valve 5 A4
A2
The shuttle valve outputs pilot pressures from port A2
(boom lower) and port A3 (arm roll-out) to port P2
(Pressure switch: Others).
To T1
To P2
1 - Heat Circuit Check Valve 4 - Restriction Releasing Shift
Valve
2 - Orifice 5 - Shuttle Valve
3 - Check Valve 6 - Orifice
A1 1 A3 T105-02-09-004
T3-6-2
SOLENOID VALVE
The 3-spool solenoid valve unit, swing preference
circuit shift solenoid valve, pump control proportional Swing Parking Travel Mode Main Relief
solenoid valve are provided on the machine. Brake Release Shift Solenoid Pressure Shift
Solenoid Valve Valve Solenoid Valve
• 3-Spool Solenoid Valve Unit
The solenoid valve unit consists of three solenoid
valves SA, SB, and SC and pilot relief valve.
Solenoid Valve SA:
Main Relief Pressure Shift Solenoid Valve. Pilot Relief Valve
The solenoid valve SA functions to raise the main SC SB SA
relief valve setting upon receiving a signal from
the controller (PVC).
Solenoid Valve SB:
Travel Mode Shift Solenoid Valve
The solenoid valve SB functions to shift the travel
motor displacement angle when the travel mode
switch is operated.
Solenoid Valve SC:
Swing Parking Brake Release Solenoid Valve
The solenoid valve SC functions to release the
swing parking brake when a swing or front
attachment function is operated upon receiving
signals from the cotroller (PVC). (Refer to the T111-02-07-002
heading “Pilot Circuit” in “Hydraulic System”

Group, “SYSTEM” Section.)
• Swing Preference Circuit Shift Solenoid Valve

Ȁ The swing preference circuit shift solenoid valve
regulates the control valve upon receiving signals
from the controller (PVC). (Refer to the “Hydraulic Spring Spool Solenoid
System” Group in “SYSTEM” Section.)
• Pump Control Proportional Solenoid Valve

The pump control proportional solenoid valve
regulates the pump flow rate upon receiving
signals from the controller (PVC). (Refer to the
heading “Regulator” in “Pump Device” Group,
“COMPONENT OPERATION” Section.)
T111-02-07-003
Solenoid Valve Operation
• In Neutral: P Output T2
The spool is pushed to the right by the spring. Port Tank Port
Pilot pressure P is blocked.
• When Excited:
The spool is pushed to the left by the excited Spool Spring
solenoid valve. Pilot pressure P is routed to the
output port.
Pilot Relief Valve

The pilot relief valve functions to set the pilot pressure
delivered to port P to a certain level. Relief port T1 is
connected to the heat circuit in the shockless valve.
T111-02-07-004
P
T1
T3-6-3
ACCUMULATOR
The accumulator is provided in the pilot circuit to buffer 6

fluctuations in oil pressure, and to maintain the pilot
1
pressure for a short time period after the engine is
stopped.
The accumulator mainly consists of body (5), holder 5 Nitrogen Gas
(4), bladder (2), which encloses nitrogen gas (N2), and (N2 ) 2
poppet (1).
4
• Pressure oil from the pilot pump enters into the

accumulator via port A. Pilot pressure com- Pilot Pressure Oil
presses the nitrogen gas in bladder (2) until they
3
balance against each other.
• When pressure supply is stopped due to engine

stall or any other reasons, bladder (2) starts
expanding, supplying accumulated oil into the pilot
circuit via port A.
A
T105-02-10-003
1 - Poppet 4 - Holder
2 - Bladder 5 - Body
3 - Oil Port 6 - Gas Plug
T3-6-4
COMPONENT OPERATION / Others (Undercarriage)
SWING BEARING
The swing bearing supports the upperstructure weight Outer race (1) is bolted to the upperstructure and inner
and functions to rotate the upperstructure smoothly. race (8) is bolted to the undercarriage. The internal
This bearing is a single-row shear ball-type bearing, gear of inner race (8) engages with the output shaft of
consisting of outer race (1), inner race (8), balls (5), the swing reduction gear.
supports (6), (7), seals (3)(9), and turn buckles (10). Seal (9) is securely tightened to inner race (8) by the
assembly of rods (11) and turn buckles (10).
4
3
8 5
10
11
W111-03-01-008
1 - Outer Race 4 - Bolt 7 - Support 10 - Turn Buckle

2 - Grease Fitting 5 - Ball 8 - Inner Race 11 - Rod
3 - Seal 6 - Support 9 - Seal
T3-7-1
CENTER JOINT
The center joint is a 360° rotating joint. The center joint Hydraulic oil flows to the right and left travel motors via
functions to allow hydraulic oil to flow smoothly to and the spindle and the oil ports of the body. Seals prevent
from the travel motors without twisting hoses while the oil leaks between the spindle and body into adjacent
upperstructure is rotated. passages.
The spindle is attached to the main frame, and the
body is bolted to the swing center of the undercarriage.
Spindle
Body
Seal
W142-03-03-001
T3-7-2
TRACK ADJUSTER
The track adjuster located on the side frame is

composed of spring (5) and adjuster cylinder (6).
Spring (5) absorbs loads applied to the front idler.
Adjuster cylinder (6) adjusts track sag.
• Grease is applied through grease fitting into

chamber “a” of adjuster cylinder (6) as illustrated
below. The pressure of the grease pushes piston 1
rod (8) out and decreases track sag.
• To increases track sag, loosen valve (1) 1 to 1.5 Grease Fitting
turns counterclockwise to release grease from the
track adjuster cylinder through the grease
discharge hole.
CAUTION: The adjusting cylinder is highly

pressurized. Loosening valve (1) quickly
and/or excessively may cause valve (1) to fly
off and the highly pressurized grease to
spout out, possibly resulting in personal Grease Discharge Hole
injury.
Be sure to loosen valve (1) slowly and M104-07-119
gradually, keeping face and body parts away
from valve (1). In addition, never attempt to
loosen the grease fitting.
1 2 3 4 a 5 6 7 8
T111-03-05-001
1 - Valve 3 - Washer 5 - Spring 7 - Flange
2 - Nut 4 - Spacer 6 - Adjuster Cylinder 8 - Piston Rod
T3-7-3
(Blank)
T3-7-4
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 Secondary Pilot Pressure ...................... T4-4-3
Test ..................................................... T4-1-2 Main Relief Pressure Shift Control
Pressure(SA Pressure) ........................ T4-4-4
Group 2 Engine Test Travel Mode Shift Control
Engine Speed........................................ T4-2-1 Pressure(SB Pressure) ........................ T4-4-5
Engine Compression Pressure .............. T4-2-3 Swing Parking Brake Release
Valve Clearance .................................... T4-2-4 Pressure(SC Pressure)........................ T4-4-6
Nozzle Check ........................................ T4-2-6 Main Relief Pressure ............................. T4-4-8
Injection Timing ..................................... T4-2-8 Overload Relief Valve Set Pressure
(Pressure in Power Boost Mode) ......... T4-4-12
Group 3 Excavator Test Main Pump Flow Test ............................ T4-4-14
Travel Speed ......................................... T4-3-1 Swing Motor Drainage ........................... T4-4-18
Track Revolution Speed ........................ T4-3-2 Travel Motor Drainage ........................... T4-4-20
Mistrack Check ..................................... T4-3-3
Travel Parking Function Check .............. T4-3-4 Group 5 Standard
Swing Speed ......................................... T4-3-5 Operational Performance
Swing Function Drift Check ................... T4-3-6 Standard Table .................................... T4-5-1
Swing Motor Leakage ............................ T4-3-7
Maximum Swingable
Slant Angle .......................................... T4-3-8
Swing Bearing Play ............................... T4-3-10
Hydraulic Cylinder Cycle Time ............... T4-3-12
Dig Function Drift Check ....................... T4-3-14
Control Lever Operating Force .............. T4-3-15
Control Lever Stroke ............................. T4-3-16
Boom Raise/Swing Combined
Operation Check ................................. T4-3-17
166T-4-1
(Blank)
166T-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedures to quan-

titatively check all systems and functions on the ma-
chine.
Purpose of Performance Tests Precautions for Evaluation of Test Data

1. To evaluate not only that the test data are correct,
1. To comprehensively evaluate each operational but also in what range the test data are.
function by comparing the performance test data
with the standard values. 2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
2. According to the evaluation results, repair, adjust, loads, and machine maintenance conditions.
or replace parts or components as necessary to
restore the machine's performance to the desired The machine performance does not always deteriorate
standard. as the working hours increase. However, the machine
performance is normally considered to reduce in pro-
3. To economically operate the machine under opti- portion to the increase of the operation hours.
mal conditions. Accordingly, restoring the machine performance by
repair, adjustment, or replacement shall consider the
Kinds of Tests number of the machine's working hours.
1. Base machine performance test is to check the Definition of “Performance Standards”

operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
1. Operation speed values and dimensions of the
2. Hydraulic component unit test is to check the op- new machine.
erational performance of each component such
as hydraulic pump, motor, and various kinds of 2. Operational performance of new components ad-
valves. justed to specification. Allowable errors will be in-
dicated as necessary.
Performance Standards
“Performance Standards” is shown in tables to evalu-

ate the performance test data.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out per-

formance tests accurately and safely.
1. THE MACHINE
Repair any defects and damage found, such as oil
or water leaks, loose bolts, cracks and so on, be-
fore starting to test.
2. TEST AREA
(1) Select a hard, flat surface.
(2) Secure enough space to allow the machine to
run straight more than 20 m (65 ft 7 inch),
and to make a full swing with the front at-
tachment extended.
(3) If required, rope off the test area and provide
signboards to keep unauthorized personnel
away. T105-06-01-003
3. PRECAUTIONS
(1) Before starting to test, agree upon the signals
to be employed for communication among
coworkers. Once the test is started, be sure
to communicate with each other using these
signals, and to follow them without fail.
(2) Operate the machine carefully and always
give first priority to safety.
(3) While testing, always take care to avoid acci-
dents due to landslides or contact with high-
voltage power lines. Always confirm that
there is sufficient space for full swings.
(4) Avoid polluting the machine and the ground
with leaking oil. Use oil pans to catch escap-
ing oil. Pay special attention to this when re-
moving hydraulic pipings.
T105-06-01-004
4. MAKE PRECISE MEASUREMENTS

(1) Accurately calibrate test instruments in ad-
vance to obtain correct data.
(2) Carry out tests under the exact test condi-
tions prescribed for each test item.
(3) Repeat the same test and confirm that the
test data obtained can be procured repeat-
edly.
Use mean values of measurements if neces-
sary.
T4-1-2
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED 2
1
Summary:
1. Use Dr.EX. If Dr.EX is not available, use an
engine tachometer.
2. Measure the engine speeds in each mode.
NOTE: Measure the engine speed to check that

the engine speed meets specification be-
fore performing other operational perform-
ance tests. If the engine speed is not cor-
rectly adjusted, all other performance test
data will be unreliable.
T111-06-02-002
5
Preparation:
3
1. Connect Dr.EX and select monitor function. When
using an engine tachometer, connect speed pick-
up (1) to injection pipe (2) as illustrated.
2. Warm up the engine until the engine coolant
temperature reaches 50 °C (122 °F) or more, and
hydraulic oil temperature reaches 50±5 °C (122±9
4
°F).
NOTE: Prior to the measurement, confirm that

governor lever (4) comes into contact with T166-04-02-001
stopper bolts (3) and (5) at the slow idle

and at the fast idle, respectively.
Be sure to turn on SP mode switch before
check governor lever movement.
SP Mode
Switch E Mode Switch
Measurement:
1. No Load Engine Speeds
1-1. Measure the slow and fast (standard) idle
speed.
1-2. Start the engine. Select the switch positions as
specified.
1-3. Set the engine control dial to the slow idle and Engine Control Dial M142-03-002
to the fast idle positions to measure engine idle

speeds.
Engine
E Mode SP Mode Auto-Idle Work Mode
Control
Switch Switch Switch Switch
Dial
General Purpose
Slow Idle OFF ON OFF
Mode
General Purpose Work Mode
Fast Idle OFF ON OFF
Mode Switch
Auto-Idle
Switch
M162-01-004
T4-2-1
2. No Load Auto-idle Engine speed
2-1. Start the engine. Select the switch position as

specified.
Engine Control E Mode SP Mode Auto-Idle Work Mode

Dial Switch Switch Switch Switch
General
Fast Idle OFF ON ON Purpose
Mode
Work Mode
2-2. Operate the bucket control lever. Switch
2-3. Return the bucket control lever to neutral.

Measure the engine speed after it Auto-Idle
automatically drops approximately 4 seconds Switch
later.
M162-01-004
Evaluation
Refer to the performance standard table in group
T4-5.
Remedy
Refer to the troubleshooting B in group T5-4.
Engine Control
Dial
M142-03-002
T4-2-2
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in each cylinder
to check for a decline in engine power.
2. Check exhaust color and the amount of blow-by
gas from the crankcase. Keep track of engine oil
consumption.
3. Check the intake system, including the air filter,
for any abnormalities.
Preparations:
1. Confirm that the valve clearances are correct.
2. Confirm that the batteries are sufficiently charged.
3. Warm up (run) the engine until the coolant
temperature reaches the operating range.
4. Stop the engine. Remove the nozzle holders and
injection lines from each cylinder. Adapter
5. Install an adapter and pressure gauge on the
nozzle holder mounting part. (Be sure to securely
tighten the adapter and pressure gauge to prevent
air leak.)
Measurement:
T111-06-02-003
1. Turn the starter. Record compression pressure for
each cylinder.
2. Repeat the measurement three times for each
cylinder and calculate the mean values.
Evaluation:
Refer to the Performance Standard Table in
Group T4-5.
Remedy:
Refer to the engine shop manual.
T4-2-3
VALVE CLEARANCE ADJUSTMENT
Summary:
1. Perform the measurement when the engine is
cold.
2. Clean the head cover mounting area to avoid any
foreign matter from getting into the engine
system.
Preparation:
1. Locate the top dead center (TDC) in the com-
pression stroke.
Remove the cover on the left bottom of the fly-
wheel housing.
Align the TDC mark on the flywheel periphery with
the pointer located on the flywheel housing by
rotating the ring gear using a bar.
Piston No. 1 (or piston No. 6) is now at TDC in its T111-06-02-008
compression stroke.
2. Remove the head cover.
3. Joggle the intake and exhaust side push rods of
cylinder No. 1 by hand. If they move a little, piston
No.1 is at TDC in its compression stroke. (If the
exhaust valve of cylinder No. 1 is pushed down,
piston No. 6 is at TDC in its compression stroke.)
Measurement:
1. Insert a feeler gauge between the rocker arm and
the valve stem to measure the valve clearance.
NOTE: The cylinders are positioned from No. 1 to

No. 6 in that order as viewed from the fan
side.
2. If the measurement is started from cylinder No. 1,

perform the same measurement for the valves
indicated with “{” mark in the table below.
Ȁ If the measurement is started from cylinder No. 6,
perform the same measurement for the valves
indicated with “X” mark.
Cylinder No. No.1 No.2 No.3 No.4 No.5 No.6

Valve Layout I E I E I E I E I E I E
When the measure-
ment is started from { { { { { {
cylinder No.1
When the measure-
ment is started from X X X X X X
cylinder No.6
3. Rotate the crank shaft 360 degrees.

Align the TDC mark with the pointer. Then, move
on to the next valve to be measured and perform
the measurement. Repeat the measurement for
the other valves.
T4-2-4
Evaluation:
Standard Valve Clearance (Cold Engine):
• Intake valve: 0.60 mm (0.024 in)
• Exhaust valve: 0.60 mm (0.024 in)
Adjustment:
If the measured valve clearances do not conform to
the standard value, adjust the valve clearance in the
same order of the measurement.
1. Completely loosen the adjusting screws on the

bridge and rocker arm. Insert a 0.6 mm (0.024 in)
feeler gauge. Adjust the valve clearance with the
adjusting screw on the rocker arm. Do not adjust Feeler Gauge (0.6 mm)
the clearance too tight at this stage. Leave a slight Rocker Arm
looseness. Securely lock the adjusting screw with Adjusting Screw
the lock nut. and Lock Nut
2. With the feeler gauge inserted, turn the adjusting
screw until the screw head comes into contact
with the valve head. Confirm that the feeler gauge
can be removed and inserted smoothly but with
Adjusting
some tightness. Securely lock the adjusting screw Screw and
with the lock nut. Lock Nut
3. Loosen the adjusting screw located on the other Bridge
side of the bridge. Insert the feeler gauge and
adjust the clearance. Securely lock the adjusting
screw with the lock nut.
T111-06-02-009
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 contaminating the engine
system.
Preparation
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 T107-06-02-006

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.
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.
NOTE: Use clean diesel oil.
T4-2-6
Evaluation Normal
1. Standard Injection Pressure:
2
19.6 MPa (200 kgf/cm , 2840 psi)
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.
T102-02-11-005
• There should be no drips found. Abnormal
• Injection spray angle must be normal.
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
1. Remove the flywheel timing mark cover. Align the
14° BTDC mark (before piston No.1 TDC) on the
flywheel or the crankshaft damper pulley to the
pointer, by turning the ring gear counterclockwise
(as seen from the flywheel side) using a metal bar.
Piston No.1 (or piston No.6) is now positioned in BTDC Mark on
its compression stroke. Flywheel
2. Check alignment of the injection pump flywheel

(or the timing advancer) notched line and injection T111-06-02-008
pump body notched line.

If the two notched lines are in alignment, the
injection timing is correct.
Adjustment
1. Loosen the two coupling bolts on the injection
pump flywheel (or the timing advanser). Pointer
Align the injection pump flywheel (or the timing
advanser) notched line and injection pump body
notched line.
Crankshaft T166-04-02-002
2. Tighten the timing adjusting bolt to specification. Damper
Pulley
: 13 mm
: 27 to 37 Nxm
(2.8 to 3.8 kgfxm, 20 to 27 lbfxft)
: 17 mm
: 42 to 52 Nxm
BTDC Mark
(4.3 to 5.3 kgfxm, 31 to 38 lbfxft) on Crankshaft
Damper Pulley
3. To advance the timing
Pointer
Turn the injection pump flywheel (or timing
advancer) toward out while the injection pump
coupling bolts are loosened condition. T166-04-02-003
Injection Pump Flywheel
Injection Pump
(Timing Advancer)
4. To retard the timing
Turn the injection pump flywheel (or timing
advancer) toward (cylinder block side) in the
injection pump coupling bolts loosened condition.
Notched
Lines
T166-04-02-004
Coupling Bolt
T4-2-8
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary:
Measure the time required for the excavator to travel
a 10 m (32.9 ft) test track to evaluate the travel
system (from the main pump to the travel motors).
Preparation:
Arm Rolled-In, Bucket Rolled-In End
1. Adjust the track sag of both tracks to be equal.
0.3 to 0.5 m (12 to 20 in)
2. Prepare a firm, level test track 10 m (32.8 ft) in
length, with an extra length of 3 to 5 m (9.8 to 16
Start
ft) on both ends for machine acceleration and
10 m 3 to 5 m
deceleration. (32.8 ft) (9.8 to 16 ft)
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above Deceleration
the ground with the arm and bucket rolled in. 3 to 5 m Zone
4. Maintain the hydraulic oil temperature at 50±5 °C (9.8 to 16 ft)
Acceleration
(122±9 °F). Zone
T105-06-03-001
Measurement:
1. Measure both the slow and fast travel mode
speeds.
2. Select the following switch positions:
Ȁ Engine Control Dial : Fast Idle

Ȁ SP Mode Switch : ON
Ȁ E Mode Switch : OFF
Ȁ Work Mode Switch : General Purpose Mode
Ȁ Auto-Idle Switch : OFF
3. Start traveling the machine in the acceleration

zone with the travel levers to full stroke.
4. Measure the time required to travel 10 m (32.8
ft).
After measuring the forward travel speed, turn the
upperstructure 180° and measure the reverse
travel speed.
5. 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 the ground to evaluate the travel system
(from the main pump to the travel motors).
Preparation:
1. Adjust the track sag of both side tracks to be
equal.
2. On the track to be measured, mark one shoe with T142-05-03-011
chalk.
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.
CAUTION: Securely support the reised track

using wooden blocks.
4. Maintain the hydraulic oil temperature at 50±5 °C

(122±9°F).
T142-05-03-012
Measurement:
Travel Mode Switch : Fast Speed Mode

Engine Control Dial : Fast Idle
SP Mode Switch : ON
E Mode Switch : OFF
Work Mode Switch : General Purpose Mode
Auto-Idle Switch : 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:
Refer to the performance standard table in group 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 10
m (32.8 ft) travel speed check described
before is more recommendable.
Remedy:
T4-3-2
MISTRACK CHECK
Summary:
1. Allow the machine to travel 20 m (65.5 ft).
Measure the maximum tread deviation from the
tread chord line drawn between the travel start
and end points to check the performance
equilibrium between both sides of the travel
device systems (from the main pump to the travel
motor).
2. If measured on a concrete surface, the tread
T145-05-03-005
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 (65.5 ft) in
length, with extra length of 3 to 5 m (9.8 to 16 ft)
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, position the front attachment as
follows:
Backhoe:
With the arm cylinder and the bucket cylinder fully
extended, raise the boom. T145-05-03-006
Loading Shovel:
With the arm cylinder fully retracted, and the
bucket cylinder fully extended, raise the boom.
(122±9 °F).
Maximum
Measurement: Distance
1. Measure the amount of mistracking in both fast,
and slow travel speeds.
3 to 5 m
Engine Control Dial : Fast Idle Extra Length
SP Mode Switch : ON 20 m for
E Mode Switch : OFF Deceleration
3. Start traveling the machine in the acceleration
zone with the travel levers at full stroke.
4. Measure the maximum distance between a T105-06-03-022
straight 20 m (65.5 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.
the average values.
Evaluation:
T4-5.
Remedy:
Refer to the Troubleshooting B in Group T5-4
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°).
2. Mark a white line on the travel device cover.
3. 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:
Position where the machine
Travel Mode Switch : Fast Speed Mode comes to a stop.
Position when the travel levers
Engine Control Dial : Fast Idle are in neutral.
SP Mode Switch : ON Displacement
E Mode Switch : OFF (Revolution
Angle)
Work Mode Switch : General Purpose Mode Mark
2. Measure the displacement (revolution angle) of

the travel device cover until the parking brake is
applied.
2-1. Climb the slope and place the travel levers in
T107-06-03-002
neutral.
2-2. Measure the displacement from the mark
position on the travel device cover when the
levers are placed in neutral to that position
when the machine stops moving.
3. Measure the travel parking brake slip amount

while parked.
3-1. Climb the slope and place the travel levers in
Alignment marks on the track side frame
neutral. and shoe when the machine comes to a stop.
3-2. Stop the engine. Displacement measured after 5 minutes.
3-3. After the machine stops, put alignment marks
on a track link or shoe, and the track side T105-06-03-006
frame.
3-4. After 5 minutes, measure the distance between
the marks on the track link or shoe and the
track side frame.
Evaluation:
T4-5.
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 T145-05-03-007
space for swinging. Do not conduct this test on

slopes.
3. With the bucket empty, position the front
attachment as follows:
Backhoe:
bucket cylinder fully extended, raise the boom so
that the arm tip pin height is flush with the boom
foot pin height.
Loading Shovel:
extended, raise the boom so that the arm tip pin
height is flush with the boom foot pin height. T145-05-03-008
(122±9 °F).
CAUTION: Prevent personal injuly. Always

make sure that the area is clear and that co-
workers are out of the swing area before
starting the measument.
Measurement:
SP Mode Switch : ON
E Mode Switch : OFF
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.
the 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 Two Chalk Marks
space for swinging. Do not conduct this test on a
T105-06-03-008
slope.
3. With the bucket empty, position the front
Backhoe:
With the arm cylilnder fully retracted, and the
bucket cylinder fully extended, raise the boom so
that the arm tip pin height is flush with the boom
foot pin height.
Loading Shovel:
extended, raise the boom so that the arm tip pin
height is flush with the boom foot pin height. T105-06-03-009
4. Make two chalk marks: one on the swing bearing
and one directly below it on the track frame.
5. Swing the upperstructure 180°.
6. Maintain the hydraulic oil temperature at 50±5 °C Measure Difference Between Marks
(122±9 °F).

starting the measument. Marking on the Track Frame
Measurement: Marking on the Swing Bearing

Engine Control Dial : Fast Idle T105-06-03-010
SP Mode Switch : ON
E Mode Switch : OFF
2. Operate the swing control lever fully and return it
to the neutral position when the mark on the
upperstructure aligns with that on the track frame
after swinging 180°.
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 %,
3. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used. T105-06-03-011
Backhoe: W=2400 kg (5290 lb)
Loading Shovel: W=3900 kg (8600 lb)
4. Positon the front attachment as described in the
following.
Backhoe:
With the arm cylinders fully retracted and the
bucket cylinders fully extended, position the arm
top pin height is flush with the boom foot pin
height.
Loading shovel:
With the arm cylinder fully extended and the
height.
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: Measure Difference Between Marks
SP Mode Switch : ON
E Mode Switch : OFF
2. Maintain the engine at slow idle. After five minutes, Marking on the Track Frame
measure the difference between the marks along
the swing bearing periphery and the track frame.
Marking on the Swing Bearing
3. Perform the measurement in both right and left
swing directions. T105-06-03-010
4. Perform the measurement three times in each

direction and calculate the average values.
Evaluation:
T4-5.
Remedy:
Refer to the Troubleshooting B in Group T5-4
T4-3-7
MAXIMUM SWINGABLE SLANT ANGLE
Summary:
With the upperstructure swung 90° to the slope,
check the maximum slant angle on which the
upperstructure can swing to the uphill side.
Preparation:
1. Check that the swing gear and bearing are well
lubricated.
used.
Backhoe: W=2400 kg (5290 lb) T105-06-03-011
following.
Backhoe:
height.
Loading shovel:
height.
4. Climp a slope and swing the upperstructure 90°
to the slope.
(122±9 °F).
Measurement:

SP Mode Switch : ON
E Mode Switch : OFF
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:
T4-3-8
(Blank)
T4-3-9
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
looseness.
2. Check the lubrication of the swing bearing.
Confirm that bearing rotation is smooth and
T105-06-03-014
without noise.
3. Install a dial gauge on the track frame as shown,
using a magnetic base.
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.
T105-06-03-015
T4-3-10
Measurement:
1. Position the front attachment as described in the
following.
Backhoe:
height.
Loading shovel:
height.
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
Evaluation:
T4-5.
Backhoe Front
Measurement : (h1 ) Measurement : (h2 )
Figure 1 Figure 2
T142-05-03-006
Loading Shovel Front

Measurement : (h1 ) Measurement : (h2 )
Figure 1 Figure 2
T142-05-03-005
T4-3-11
HYDRAULIC CYLINDER CYCLE TIME
Summary:
1. Check the overall operational performance of the
front attachment hydraulic system (between the
hydraulic pumps and each cylinder) by measuring
the cycle time of the boom, arm, bucket, and
bucket dump (open/close) cylinders with the
bucket emptied.
Preparation:
(122±9 °F).
Measurement:
E Mode Switch : OFF
SP Mode Switch : ON Backhoe
2. Position the front attachment as described in the Boom Cylinder
following. Then, measure the operating time until
the cylinder reaches the stroke end by fully
moving the control lever.
• Backhoe
Boom Cylinder: T145-05-03-012
With the bucket cylinder fully extended and the

arm cylinder fully retracted, lower the bucket to
the ground.
Arm Cylinder:
Adjust the boom cylinder stroke so that the bucket
bottom height is 0.5 m (20 in) above the ground
with the bucket cylinder fully extended while Arm Cylinder
positioning the center line between the arm and
bucket connection pin centers vertical with the
arm cylinder extended half stroke. T145-05-03-013
Bucket Cylinder:
Adjust the boom and arm cylinder so that the
center of full stroke movement of the bucket is
positioned vertically.
Bucket Cylinder
T145-05-03-014
T4-3-12
• Loading Shovel
Boom Cylinder: Loading Shovel
With the bucket cylinder and the arm cylinder fully
extended, lower the bucket to the ground.
Arm Cylinder:
Boom Cylinder
With the arm fully retracted, position the bucket so
that the rear bucket does not come in contact with
the arm stopper. Then, adjust the boom cylinder
stroke to position the bucket bottom 1 m (39 in)
above the ground. T145-05-03-015
Bucket Cylinder:
With the bucket closed and held in a load dump
position, adjust the boom cylinder stroke so that
bucket bottom height is approx. 1 m (39 in) above
the ground. Arm Cylinder
Bucket Open-Close Cylinder:
T145-05-03-016
With the bucket cylinder and arm cylinder fully
extended, adjust the boom cylinder stroke so that
the bucket bottom height approx. 1 m (39 in)
above the ground.
3. Repeat the measurement three times and Bucket Cylinder
T145-05-03-017
Evaluation:
Refer to T4-5 Operational Performance Standard.
Dump Cylinder
Remedy:
Refer to the T5-4 Troubleshooting B.
T145-05-03-018
T4-3-13
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.
Preparation: T145-05-03-020

used.
Backhoe: W=2400 kg (5290 lb)
following.
Backhoe:
With the arm cylinder with rod 50 mm (2 in)
extended from the fully retracted position, and
T145-05-03-021
bucket cylinder with the rod 50 mm (2 in) retracted
from the fully extended position.
Loading shovel: Boom and Bucket Cylinders Retraction
With the arm cylinder with the rod 50 mm (2 in) Mark
retracted from the fully extended position, and
Mark
bucket cylinder with the rod 50 mm (2 in) retracted
from the fully extended position.
3. With the arm rolled out and the bucket rolled in,
hold the bucket so that the height of the bucket
pin is the same as the boom foot pin.
(122±9 °F).
T110-06-03-002
5. Measurement:
Stop the engine.
Arm Cylinder Extension
6. 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.
7. Repeat step (2) three times and calculate the
average values. Mark
Evaluation:
T4-5.
Remedy:
T110-06-03-001
T4-3-14
CONTROL LEVER OPERATING FORCE
Summary:
Use a spring scale to measure the maximum
resistance of each control lever at the middle of the
grip.
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Start the engine.
T107-06-03-003

SP Mode Switch : ON
E Mode Switch : OFF

3. Operate each boom, arm, bucket and swing lever T107-06-03-004

to at full stroke and measure the maximum
operating force for each.
4. 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.

the average values.
Evaluation:
T4-5.
T4-3-15
CONTROL LEVER STROKE
Summary:
Measure each lever stroke at the lever top using a
ruler.
NOTE: When the lever has play, take a half of this

value and add it to the measured stroke.
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.
Evaluation:
T4-5.
T4-3-16
BOOM RAISE/SWING COMBINED OPERA-
TION CHECK
Summary:
Check boom raise and swing movement and speeds
while operating both functions simultaneously.
Preparation:
1. Start the engine and run it at fast idle. Operate the T142-05-03-007
boom raise function and check to be sure that the

cylinder movement is smooth, with out sticking.
2. Position the machine with front attachment
positioned as illustrated.
(122±9 °F).
CAUTION: Prevent personal injuly. Always T142-05-03-008

Measurement:
General Purpose Mode:

SP Mode Switch : ON
E Mode Switch : OFF
T107-06-03-010
Trenching Mode:
SP Mode Switch : ON
E Mode Switch : OFF
Work Mode Switch : Trenching Mode
2. Raise the boom and swing simultaneously, both at

full stroke. H
3. When the upperstructure rotates 90°, release the
control levers to stop both functions. Measure the
time required to swing 90° and the height (H) of
the bucket teeth.
4. Repeat steps (2 to 3) three times and calculate T107-06-03-011
the average values.
Evaluation:
T4-5.
Remedy:
T4-3-17
(Blank)
T4-3-18
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Properly shut down the engine.
CAUTION: The hydraulic oil tank cap may off

if turned quickly. Slowly turn it to release
internal pressure before removing it.
2. Move all control levers to release pressure

remaining in the system. Slowly turn the hydraulic
oil tank cap approximately 30 degrees counter-
clockwise to release remaining pressure from the
hydraulic oil tank.
: 4 mm
T111-06-04-001
3. Disconnect the hose end from the pilot filter outlet

port. Install adapter (ST 6477), fitting (ST 6069),
pressure gauge (ST 6315) and coupling (ST 6332).
: 24 mm, 27 mm
4. Start the engine. Confirm that no oil leakage is

observed at the pressure gauge connection.
(122±9 °F).
Measurement:

SP Mode Switch : ON
E Mode Switch : OFF
2. Measure the pilot pressure in specified setting

above.
3. Repeat the measurement three times and
Evaluation:
T4-5.
T4-4-1
Primary Pilot Pressure Adjustment Procedure
Adjustment:
Adjust the setting pressure of the pilot relief valve (the
primary pilot pressure).
: 22 mm
Pilot Relief
Valve
T166-01-02-011
1. Remove plug (1). 1
2
2. Install the estimated necessary numbers of shims
(2).
3. Tighten plug (1).
: 29.5 Nxm (3 kgfxm, 21.5 lbfxft)
4. Check the relief pressure of the relief valve.
Reference : Change in Pressure Setting

Shim Thickness 2
kPa kgf/cm psi
(mm)
0.25 78 0.8 11
0.5 147 1.5 21
1.0 294 3.0 42 T111-06-04-004
T4-4-2
SECONDARY PILOT PRESSURE
Preparation:
1. Properly shut down the engine. Connecting Port


oil tank cap approximately 30 degrees
counterclockwise to release remaining pressure
from the hydraulic oil tank.
: 4 mm
3. Install adapter (ST 6450), fitting (ST 6069), pres-
sure gauge (ST 6315) and coupling (ST 6332)
onto the pilot hose end of the measuring circuit.
: 19 mm, 22 mm T111-06-04-006

(122±9 °F).
Measurement:
CAUTION: Before starting measurement,

check that there are no bystanders and/or
obstructions within the swing radius.
When measuring the boom lower secondary
pilot pressure operate the machine carefully
as the base machine front will be raised off
the ground. This will cause the base machine
to become imbalanced and possibly allow the
rear of the machine to come in contact with
the ground.
Engine Control Dial : Fast Idle and Slow Idle
SP Mode Switch : ON
E Mode Swich : OFF
2. Measure the pilot pressure in each specified
setting above with the corresponding control lever
operated full stroke.
Evaluation:
T4-5.
Remedy:
T4-4-3
MAIN RELIEF PRESSURE SHIFT
CONTROL PRESSURE (SA Pressure) SA
Preparation:


hydraulic oil tank.
: 4 mm
3. Disconnect the hose end from the solenoid valve

SA output port. Install adapter (ST 6451), fitting (ST
6069), pressure gauge (ST 6315) and coupling (ST T166-01-02-011
6332).
: 19 mm, 22 mm


(122±9 °F).
Measurement:
1. Select the following switch and lever positions:
Engine Control SP mode E mode Auto-Idle Work Mode Power Boost
Control Dial Levers Switch Switch Switch Switch Switch
Fast Idle Travel lever General
ON OFF OFF OFF
operation Purpose
Fast Idle All in neutral ON OFF OFF Precision OFF
Fast Idle General
All in neutral ON OFF OFF *ON
Purpose
Fast Idle General
All in neutral ON OFF OFF OFF
Purpose
NOTE: ∗ The power boost functions only for 10

sconds.
2. Read the pressure gauge in each setting above.

Evaluation:
5.
Remedy:
T4-4-4
TRAVEL MODE SHIFT CONTROL PRES-
SURE (SB Pressure)
Preparation:
SB

hydraulic oil tank.
: 4 mm

SB output port. Install adapter (ST 6451), fitting (ST
6069), pressure gauge (ST 6315) and coupling (ST
6332).
: 19 mm, 22 mm
T166-01-02-011

(122±9 °F).
Measurement:
Engine Travel SP Auto-

E Mode Work Mode
Control Mode Mode Idle
Switch Switch
Dial Switch Switch Switch
Fast General
Fast Idle ON OFF OFF Purpose
Speed
Mode
Slow General
Speed
Mode
2. Read the pressure gauge in each setting above.

Evaluation:
5.
Remedy:
T4-4-5
SWING PARKING BRAKE RELEASE
PRESSURE (SC Pressure)
Preparation:
SC

hydraulic oil tank.
: 4 mm

SC output port. Install adapter (ST 6451), fitting (ST
6069), pressure gauge (ST 6315) and coupling (ST
6332).
: 19 mm, 22 mm
T166-01-02-011

(122±9 °F).
Measurement:
1. Select the following switch and lever positions:
SP
Engine E mode Auto-Idle Work Mode
mode
Control Dial Switch Switch Switch
Switch
General
Mode
2. Read the pressure gauge while operating a front

attachment (boom, arm, or bucket) or swing lever.
Also, read the pressure gauge with all control
levers in neutral.

Evaluation:
5.
Remedy:
T4-4-6
(Blank)
T4-4-7
MAIN RELIEF PRESSURE
Summary:
Measure the main relief valve setting pressure at the Pressure Gauge Mounting Port
main pump delivery port.
The main relief pressure can also be measured with
Dr. EX.
Preparation:


hydraulic oil tank.
: 4 mm
3. Remove the plug from the test port located on the T166-01-02-001
main pump delivery port. Install fitting (ST 6069)
and pressure gauge (ST 6934).
: 19 mm
Or, connect Dr. EX. Select the monitor function to

monitor main pump delivery pressure.
3. As for the swing function, secure the
4. Start the engine. Confirm that no oil leakage is upperstructure immovable. Slowly operate the
observed at the pressure gauge connection. swing lever to relieve the swing function.
5. Maintain the hydraulic oil temperature at 50±5 °C 4. As for the travel function, secure the tracks
(122±9 °F). against an immovable object. Slowly operate the
travel levers to relieve the travel function.
Measurement:
1. Select the following switch positions: Evaluation:
Engine Control Dial : Fast Idle 5.
SP Mode Switch : ON
E Mode Switch : OFF Reference:
Work Mode Switch : General Purpose Mode If the pressures for all functions measured are lower
Auto-Idle Switch : OFF than the specified range, the probable cause is a
decrease in the main relief valve setting pressure.
2. Relieve each actuator to measure main relief
pressure. If the relief pressure of a particular function is low, the
First, slowly operate bucket, arm, and boom probable cause is something other than the main
control levers to the stroke end to relieve each relief valve.
function one at a time.
T4-4-8
Main Relief Pressure Setting Adjustment
Procedure
Adjustment:
Adjust the main relief valve pressure settings using
plug (3) (for the low-side main relief pressure) and
sleeve (1) (for high-side main relief pressure) after
loosening lock nut (4).
• High-Side Main Relief Pressure Setting

Adjustment Procedure
1. Loosen lock nut (4). Tighten plug (3) until the

bottom of piston (5) comes into contact with
sleeve (1). Retighten lock nut (4).
: 22 mm, 30 mm
: Lock nut (4): 59 Nxm (6 kgfxm, 13 lbfxft)
Main Relief Valve
2. Loosen lock nut (2). Turn sleeve (1) to adjust the
relief pressure setting, referring to the table below. 3 T111-02-05-002
: 22 mm, 41 mm 4 1
2
• Low-Side Main Relief Pressure Setting
Adjustment Procedure
3. Loosen lock nut (4). Turn plug (3)

counterclockwise until the specified value is 5
obtained. Retighten lock nut (4).
: 22 mm, 30 mm
4. Recheck the set pressures.

Sleeve (1) and plug
1/4 1/2 3/4 1
(3) turns
MPa 4.4 8.8 13.2 17.7
2
kgf/cm 45 90 135 180
psi 640 1280 1920 2560 T162-04-04-010
Sleeve (1), Plug (3)
Pressure Increase Pressure Decrease
W107-02-05-127
T4-4-9
Swing Relief Pressure Setting Adjustment
Procedure
Swing Relief Valve
Adjustment:
Adjust the pressure setting of the swing relief valve
using adjusting screw (1) after loosening lock nut
(2).
1. Loosen lock nut (2).
: 19 mm
2. Turn adjusting screw (1) adjust the pressure

setting referring to the table below.
: 10 mm
3. Retighten lock nut (2).
: 19 mm
: 49 N⋅m (5 kgfxm, 36 lbfxft)

T166-01-02-012
4. Recheck the set pressure. 1 2
T111-02-04-007

Adjusting Screw (1)
Screw Turns 1/4 1/2 3/4 1
MPa 0.76 1.52 2.28 3.04
2
kgf/cm 7.75 15.5 23.3 31
psi 110 220 331 440
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-4-10
Travel Relief Pressure Setting Adjustment Travel Relief Valve
Procedure
Adjustment:
Adjust the pressure setting of the travel relief valve
using the adjusting screw after loosening the lock nut.
1. Loosen the lock nut.
: 17 mm
2. Turn the adjusting screw to adjust the pressure T142-01-02-012

setting, referring to the table below.
: 6 mm Lock Nut
3. Retighten the lock nut.
: 17 mm
: 49 Nxm (5 kgfxm, 36 lbfxft)
4. Recheck the set pressure. Adjusting Screw
T142-05-04-007
Reference : Change in Pressure Setting Adjusting Screw

MPa 1.96 3.92 5.88 7.85
2
kgf/cm 20 40 60 80
psi 280 570 850 1140
W107-02-05-129
T4-4-11
OVERLOAD RELIEF VALVE SET Pressure Gauge Mounting Port
PRESSURE (PRESSURE IN POWER
BOOST MODE)
Summary:
1. The circuit pressure must be increased by
applying an external force while blocking the
return circuit from the control valve. This
measuring 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 main pump delivery flow rate.
Accordingly, even if the main relief valve set
pressure can be reset higher than the overload
relief valve set pressure, the main pump supplies
too much oil to correctly measure the setting
pressure of the overload relief valve.
For this reason, in order to correctly measure the
set pressure of the overload relief valve, the
overload relief valve unit must be removed from T166-01-02-001
the machine and tested on a test stand.
3. If the overload relief valve performance must be 4. Start the engine. Confirm that no oil leakage is
checked on the machine, however, measure the observed at the pressure gauge connection.
main relief pressure while releasing each front 5. Maintain the hydraulic oil temperature at 50±5 °C
function respective to the measuring overload (122±9 °F).
relief valve. And, assume that the overload relief
valve is functioning correctly if the obtained main Measurement:
relief pressure is within the specified value range. 1. Select the following switch positions:
Measure the main relief pressure of the front Engine Control Dial : Fast Idle
functions as follows: SP Mode Switch : ON
The main relief pressure can also be measured E Mode Switch : OFF
with Dr. EX. Work Mode Switch : General Purpose Mode
Preparation: 2. Press the power boost switch while relieving each
1. Properly shut down the engine. actuator to measure main relief pressure.
First, slowly operate bucket, arm, and boom
control levers to the stroke end to relieve each
function one at a time.
4. Perform the measurement for the bucket, arm,
and boom, in that order.
calculate the average value for each front
function.
: 4 mm Evaluation:
3. Remove the plug from the test port located on the 1. Performance of each overload relief valve is
main pump delivery port. Install fitting (ST 6069) normal if the measured main relief pressure of the
and pressure gauge (ST 6934). concerned function is within the specified value
: 19 mm range.
Or, connect Dr. EX. Select the monitor function to
Refer to the Performance Standard Table in
monitor main pump delivery pressure.
Group T4-5.
T4-4-12
Overload Relief Valve Set Pressure Adjusting
Procedure
NOTE: In principle, adjust the overload relief valve

set pressure on a test stand.
Adjustment:
Adjust the pressure setting of the overload relief valve
using adjusting screw (2) after loosening lock nut (1).
1. Loosen lock nut (1).
: 19 mm
2. Turn adjusting screw (2) to adjust the pressure

setting referring to the table below.
: 6 mm T111-02-05-002
2
3. Retighten lock nut (1).
: 19 mm
: 98 Nxm (10 kgfxm, 72 lbfxft)
4. Recheck the set pressures.

1
MPa 4.9 9.8 14.7 19.6 T162-04-04-004
2
kgf/cm 50 100 150 200
Adjusting Screw (2)
psi 710 1420 2130 2840
W107-02-05-129
T4-4-13
MAIN PUMP FLOW TEST
Summary:
To check the main performance, measure the pump 2
flow rate by connecting a portable tester at the main
1 4
pump delivery port. Dr.EX or a pressure gauge is also
used. Test Port
3
Preparation:


from the hydraulic oil tank. Connect a vacuum
pump to the filter.
: 4 mm
NOTE: Be sure to keep the vacuum pump

operated while connecting the portable
tester to the main pump.
T166-01-02-001
3. Disconnect high-pressure hose (1) or (2),

depending on which main pump is to be
measured. 8. Connect Dr.EX. Or, remove the plug from the
Connect flange F18 (ST 6118) to the main pump test port. Install adapter (ST 6069)
disconnected hose end using split flange (Parts and pressure gauge (ST 6934) on the test port.
Number 4085560) and socket bolt (Parts Number : 19 mm
M341211).
: 10 mm 9. Disconnect the DP sensor and engine speed (N)
sensor connectors. (The pump displacement
4. Connect test hose (ST 6145) to flange F18 (ST angle will be the maximum.)
6118).
: 41 mm 10. Remove the P (delivery pressure) sensor from the
other main pump.
5. Install adapter (ST 6146) on portable tester (ST
6299). Connect the other end of test hose to 11. Disconnect the vacuum pump. Loosen drain hose
adapter (ST 6146). (3) or (4) connection on the top of the main pump
: 41 mm, 71 mm to bleed air from the casing (until oil comes out).
6. Install pipe (ST 6144) on the main pump delivery 12. Connect an engine tachometer to the injection
port using the split flanges and socket bolts pipe. Fully open the loading valve located on the
removed in step 3. portable tester.
: 10 mm
13. Start the engine. Check line connections for any
7. Connect test hose (ST 6145) between pipe (ST oil leaks.
6144) and portable tester (ST 6299).
T4-4-14
Measurement:
(122±9 °F).
Travel Mode Switch : Fast Speed Mode

SP Mode Switch : ON
E Mode Switch : OFF
-1
3. Adjust the engine speed to 2000 min with the
engine control dial.
4. Gradually close the loading valve on the portable

tester and measure (record) pump flow rate and
engine speed at each specified delivery pressure.

Evaluation:
1. Conversion
Convert the measured pump flow rate into the one
for the rated pump speed using the following Reference : Bench Test Result
formula. Point on Q P 2
Ȁ PQ curve (L/min) (kgf/cm )
Converted Pump Flow Rate (Qc)=(Np×Q) / (i×Ne)
A 360±20 100
Where: B 240±35 220
Qc : Converted Pump Flow Rate
Q : Measured Pump Flow Rate
i : Pump Reduction Ratio (= 1) 400
-1
Np : Rated Pump Speed (2000 min )
Ne : Measured Engine Speed 367 A
2
NOTE: 1 kgf/cm = 0.09807 MPa
2 300
1 kgf/cm = 14.22 psi
1 L/min = 0.2642 US gal Q (Flow Rate)
B
L/min
200
100
0 100 200 300 350
P (Pressure) kgf/cm 2
T166-04-04-003
T4-4-15
Adjustment:
Adjustment of Minimum and Maximum Flow Rate NOTE: Turn screw (1) clockwise to decrease the
maximum flow rate and counterclockwise to
Pump flow rate can be adjusted by changing the increase. Turning screw (1) one forth a turn
maximum stroke of the servo piston. changes flow rate approximately 7.6 L/min
To adjust the maximum flow rate, loosen nut (2) and (2.0 US gal/min).
turn screw (1) on the large chamber side end of the Turn screw (4) clockwise to increase the
servo piston. minimum flow rate and counterclockwise to
To adjust the minimum flow rate, loosen nut (3) and decrease. Turning screw (4) one forth a
turn screw (4) on the small chamber side end of the turn changes flow rate approximately 7.6
servo piston. L/min (2.0 US gal/min).
1 2 3 4
T162-04-04-007
Maximum Flow Rate Adjustment Minimum Flow Rate Adjustment
Q Q
I I
NOTE: “I” Means Proportional Solenoid Valve

Command Electrical Current Value
T4-4-16
Flow Rate Control Setting Adjustment
Because the flow rate is controlled by the proportional

solenoid valve command electrical current, it can be
adjusted by changing set force of spring (1).
Loosen nut (2) and turn screw (3) to adjust spring (1)
setting.
1 2 3
T162-04-04-007
Spring Setting Adjustment Flow Rate Control

Screw Turns 1/4 Q
26.5 L/min
Flow Rate
(7.0 US gal/min)
NOTE: “I” Means Proportional Solenoid Valve

Command Electrical Current Value.
T4-4-17
SWING MOTOR DRAINAGE
Summary:
To check swing motor performance, measure the
amount of oil draining from the swing motor while
swinging the upperstructure.
NOTE: The amount of drain oil from the swing

motor will change depending on the
hydraulic oil temperature. Be sure to
maintain hydraulic oil temperature at 50±5 2
°C (122±9°F). A
1
Preparation:
1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F). Rotate the swing motor to warm the
inside of the motor.
B

: 4 mm
3. To measure the left swing motor drainage, T166-04-04-001
disconnect left swing motor drain hose (1) at part

A. Install plug (ST 6491) on the tee side.
: 27 mm
: 93 Nxm (9.5 kgfxm, 70 lbfxft)
4. To measure the right swing motor drainage,

disconnect drain hose (2) at part B. Connect the
test drain hose (3/4-UN) to the motor side and
plug (ST 6637) to drain hose (2).
: 27 mm
CAUTION: Prevent personal injury. Always Preconditions for Measurement:

make sure that the area is clear and that co- 1. Select the following switch positions:
starting machine operation. Engine Control Dial : Fast Idle
Also, take care not to fall off the machine SP Mode Switch : ON
while the measurement. E Mode Switch : OFF
T4-4-18
Measurement:
1. Amount of Oil Drained While Swinging the
Upperstructure
(1) With the bucket empty, position the front
Backhoe:
bucket cylinder fully extended, raise the
boom so that the arm tip pin heigh is flush
with the boom foot pin height. T145-05-03-007
Loading Shovel:
With the arm cylinder and the bucket cylinder
fully extended, raise the boom so that the
arm tip pin height is flush with the boom foot
pin height.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start draining oil
measurement after the swing speed reaches
a constant maximum speed. The measuring
time should be more than 20 seconds.
(3) Repeat the measurement three times in both T145-05-03-008
clockwise and counterclockwise directions,
2. Amount of Oil Drained While Relieving Swing
Motor Circuit
(1) Thrust the bucket teeth into the ground as
illustrated so that the upperstructure does not
rotate when the swing lever is operated full
T107-06-06-005
stroke.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start drain oil measurement
when drain oil starts coming out of the drain
hose end. The measuring time should be
more than 20 seconds.
(3) Repeat the measurement three times in both
clockwise and counterclockwise directions,
NOTE: Because the left swing motor drain hose is
connected to the right swing motor drain
port, the total of the left and right swing
motor drainage will be measured when
measuring the right swing motor drainage
according to step 4 in Preparation. For this
reason, be sure to deduct the amount of left
swing motor oil drainage (step 3 in T107-06-05-008
Preparation) from that total amount.
Evaluation:
T4-5.
∗ Conversion of the amount of drain oil measured into ∆Q = 60 × q / t

the per-minute value Where:
First measure the amount of drain oil using a ∆Q : Amount of drain oil per minute (L/min)
calibrated container. Then, convert the measured t : Time measured (seconds)
drain oil into the per-minute value using the formula q : Total amount of drain oil (L)
below:
T4-4-19
TRAVEL MOTOR DRAINAGE
Summary:
To check travel motor performance, measure the
amount of oil draining from the travel motor, while
rotating the travel motor with the measuring side track
jacked up.
NOTE: The amount of drain oil from the travel

motor and the drain oil pressure will change
depending on hydraulic oil temperature.
Maintain hydraulic oil temperature within 50
±5°C (122±9°F).
Preparation: 2
1. Main hydraulic oil temperature at 50±5 °C (122±9
°F). Rotate the travel motor to warm the inside of
the motor.

2. Move all control levers to release pressure 1

hydraulic oil tank.
3. Disconnect the travel motor drain hose (1) at the

center joint end. Install plug (ST 6637) to the
disconnected end. Connect hose (2) (3/4-16UN)
to the center joint. T166-04-04-004
: 27 mm
Preconditions for Measurement:


SP Mode Switch : ON
E Mode Switch : OFF
Travel Mode Switch : Fast Mode
T4-4-20
Measurement:
(1) Start the engine. Jack up the measuring side

track using the front attachment, as illustrated.
CAUTION: Securely support the raised track

using wooden blocks.
(2) Rotate the raised track with the travel lever

operated full stroke. Start drain oil T142-05-03-011
measurement after the track rotation speed
reaches a constant maximum speed. The
measuring time should be more than 20
seconds.
(3) Repeat the measurement three times in both

forward and reverse directions and calculate
the average values.
Evaluation:
Refer to the Performance Standard Table in T142-05-03-012
Group T4-5.
∗ Conversion of the amount of drain oil measured

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

calibrated container. Then, convert the
measured drain oil into the paramount value
using the formula below:
∆Q = 60 × q / t
Where:
∆Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T166-04-04-004
T4-4-21
(Blank)
T4-4-22
OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE
STANDARD TABLE
The standard performance values are listed in the • The preconditions for measurement are as follows
table below. unless otherwise mentioned in each performance
Refer to the groups 2 to 4 for performance test test section:
procedures. Values indicated in parentheses are Engine Control Dial : Fast Idle
reference values. SP Mode Switch : ON
E Mode Switch : OFF
Work Mode : General Purpose
Mode
Hydraulic Oil Temperature : 50±5 °C
(122±9 °F)
Performance
Performance Test Remarks
Standard
-1
ENGINE SPEED (min )
Fast Idle (SP Mode Switch: ON) 2 200 ± 100 Dr.EX Value
Slow Idle 775 ± 100 Dr.EX Value
Auto-Idle 1 200 ± 100 Dr.EX Value
ENGINE COMPRESSION PRESSURE Limit of Use: 23
2 -1 29.0
(kgf/cm /220 min )
VALVE CLEARANCE (IN, EX) (mm) 0.6 With cold engine.
2
INJECTION PRESSURE MPa (kgf/cm ) 19.6 (200)
INJECTION TIMING (BTDC) (Degree) 14°
TRAVEL SPEED (sec/10 m)
Fast Speed Mode 6.5 ± 1.0
Slow Speed Mode 10.0 ± 1.0
TRACK REVOLUTION SPEED (sec/3 rev.)
Fast Speed Mode: 400-5 21.0 ± 2.0
400LC-5,450LC-5 23.0 ± 2.0
MISTRACK (Both Fast and Slow Speed 200 or less
Modes) (mm/20 m)
TRAVEL PARKING FUNCTION CHECK(rev.) 1/6 or less
TRAVEL MOTOR LEAKAGE (mm/5 min) 0
SWING SPEED (sec/3 rev.) 20.0 ± 1.5
SWING FUNCTION DRIFT CHECK 835 or less
(mm/180°)
SWING MOTOR LEAKAGE (mm/5 min) 0
3
MAXIMUM SWINGABLE SLANT ANGLE 21° or possibly more 3.4 m Arm, 1.8 m (PCSA
(deg.) heaped) bucket
SWING BEARING PLAY (mm) 1.5 or less Limit of Use: 5.0
2
NOTE: 1 kgf/cm = 98.07 kPa
T4-5-1
Performance
Standard
HYDRAULIC CYLINDER CYCLE TIME (sec)
3
3.4 m Arm, 1.8 m
Backhoe
(PCSA heaped) Bucket
Boom Raise 3.4 ± 0.3
Boom Lower 2.5 ± 0.3
Arm Roll-In 4.4 ± 0.3
Arm Roll-Out 3.2 ± 0.3
Bucket Roll-In 4.5 ± 0.3
Bucket Roll-Out (Up to Serial No.7046) 2.8 ± 0.3
(Serial No.7046 and over) 2.6 ± 0.3
3
Loading Shovel (Tentative) 2.6 m Bucket
Boom Raise 4.5±0.3
Boom Lower 3.6±0.3
Arm Extend 2.7±0.3
Arm Retract 2.0±0.3
Bucket Roll-in 3.1±0.3
Bucket Roll-out 2.6±0.3
Bucket Open 1.1±0.3
Bucket Close 1.0±0.3
DIG FUNCTION DRIFT CHECK (mm/5 min)
3
3.4 m Arm, 1.8 m
Backhoe
(PCSA heaped) Bucket
Boom Cylinder 10 or less
Arm Cylinder 10 or less
Bucket Cylinder 5 or less
Bucket Bottom 100 or less
3
Loadeng Shovel (Tentative) 2.6 m Bucket
Boom Cylinder 40 or less
Arm Cylinder 60 or less
Bucket Cylinder 40 or less
Bucket Bottom 100 or less
CONTROL LEVER OPERATING FORCE
(kgf)
Boom Lever 2.0 or less
Arm Lever 1.7 or less
Bucket Lever 1.7 or less
Swing Lever 2.0 or less
Travel Lever 2.5 or less
CONTROL LEVER STROKE (mm)
Boom Lever 105 ± 10
Arm Lever 83 ± 10
Bucket Lever 83 ± 10
Swing Lever 105 ± 10
Travel Lever 100 ± 10
3
Backhoe: 3.4 m Arm, 1.8 m
BOOM RAISE/SWING COMBINED
4.2 ± 0.3 (PCSA heaped) Bucket
OPERATION CHECK (sec) 3
Loading Shovel: 2.6 m Bucket
Bucket Teeth Height: H (mm) 7000 or more
NOTE: 1 kgf = 9.807 N
T4-5-2
Performance
Standard
2
COMPONENT TEST (kgf/cm )
PRIMARY PILOT PRESSURE +10
40 0
Fast Idle (SP Mode: ON)
SECONDARY PILOT PRESSURE more than 37
MAIN RELIEF PRESSURE SHIFT CONTROL
PRESSURE (SA Pressure)
more than 35
(Travel/precision mode and with power boost
2
switch ON) (kgf/cm )
(Operations other than the above) 0
TRAVEL MODE SHIFT CONTROL
PRESSURE (SB Pressure) more than 35
2
(Fast Speed Mode) (kgf/cm )
(Slow Speed Mode) 0
SWING PARKING BRAKE RELEASE
PRESSURE (SC Pressure)
more than 35
(When a front or swing function control lever is
2
operated.) (kgf/cm )
MAIN RELIEF PRESSURE (Power Boost Off) +15
2 300 -5
(Boom. Arm, Bucket) (kgf/cm )
OVERLOAD RELIEF PRESSURE (Power
+15
Boost ON) 325 -10
2
(Boom Raise, Arm Roll-In/Out) (kgf/cm )
+15
(Boom Lower, Bucket Roll-In/Out) 315 -10
TRAVEL/SWING RELIEF PRESSURE +10

2 275 0
(Swing Relief Pressure) (kgf/cm )
+20
(Travel Relief Pressure) 355 -5

2.0 or less
(With constant maximum speed) (L/min)
25 or less
(Having the upperstructure immovable)(L/min)
TRAVEL MOTOR DRAINAGE
5 or less
(With track jacked up) (L/min)
2
MAIN PUMP FLOW RATE (at 100 kgf/cm )
360 ± 20
(L/min)
2
MAIN PUMP FLOW RATE (at 220 kgf/cm )
240 ± 35
(L/min)
2
T4-5-3
INJECTION PUMP
Test Conditions:
1. Injection pump: PE6P 106067-0990
2. Governor: EP/RSV 105407-6090
3. Nozzle and nozzle holder assembly: 105780-8140 (Bosch No. EF8511/9A)
4. Nozzle: 105780-0000 (Bosch No. DN12SD12T)
5. Nozzle holder: 105780-2080 (Bosch No. EF8511/9)
2
6. Nozzle opening pressure: 17.2 MPa (175 kgf/cm )
7. Test fuel: ISO 4113 or SAE J967d
2
8. Transfer pump pressure: 157 kPa (1.6 kgf/cm )
9. Injection pipe: Inner Dia. 3 mm×Outer Dia. 8 mm-Length 600 mm (0.118×0.315-23.6 in)
10. Fuel temperature: 40+5 °C (104+9 °F)
2
11. Overflow valve opening pressure: 127 kPa (1.3 kgf/cm )
Injection rate adjustment

Average Injection Max. Var.
Adjusting Pump Speed Rack Position
Strokes Rate bet. Cyl Fixed Remarks
Point (mm-1) (mm)
(cm3/1000 Stroke) (%)
A 1000 9.8 177±2 ±3 Lever Basic Boost press. kPa (mmHg)
Above 90.6 (Above 680)
385 Approx.6.4 13.2±3.2 ±13 Rack Boost press. 0
Adjust max. var. bet. Cyl. At R=6.4
Adjust governor as per gov. adj. spec.
D 150 - Above 230±20 - Lever Boost press. 0
Rack limit
Governor adjustment
Above
Rack limit
Idle-sub spring setting
Governor spring setting

Boost compensator stroke: 0.8±0.1
Rack Position C
(mm)
Pump Speed min-1 (rpm) T166-01-03-003
T4-5-4
SECTION 5
TROUBLESHOOTING
—CONTENTS—
Group 1 Diagnosing Procedure Fault Code 13 (N Sensor Failure) .......... T5-3-8
Introduction .......................................... T5-1-1 Fault Code 14 (Overheat Switch
Diagnosing Procedure ........................... T5-1-2 L Failure, Hydraulic Oil Temperature
Dr. EX Sensor Failure) .................................... T5-3-9
Dr. EX Start-Up Procedure................... T5-1-4 Fault Codes 17, 18, 19, 21, 22
Clearing the Self-Diagnosing ................. T5-1-5 (PVC Failure)....................................... T5-3-10
EC Related Fault Codes ........................ T5-1-7 Fault Code 20 (Communication
PVC Related Fault Codes...................... T5-1-8 Failure between PVC and EC) ............. T5-3-11
Monitoring Function ............................... T5-1-9 Fault Codes 23, 24
(Pump Control Failure) ...................... T5-3-12
Group 2 Component Layout Fault Codes 26, 34
Main Components ................................. T5-2-1 (DP Sensor Failure) ............................. T5-3-14
Electrical System (1) ............................. T5-2-2 Fault Codes 27, 28, 35, 36
Electrical System (2) ............................. T5-2-3 (P Sensor Failure) ............................... T5-3-15
Electrical System (3) ............................. T5-2-4 Fault Codes 29, 30, 37, 38
Control Valve......................................... T5-2-6 (A Sensor Failure) ............................... T5-3-16
Others ................................................... T5-2-10 Sensor Operating Range List................. T5-3-17
Group 3 Troubleshooting A
Troubleshooting A Procedure ................ T5-3-1
EC Related Fault Codes ........................ T5-3-2
PVC Related Fault Codes...................... T5-3-3
Fault Codes 01, 02, 03, 04, 06
(EC Failure) ......................................... T5-3-4
Fault Code 05 (Communication
Failure between PVC and EC) ............. T5-3-5
Fault Codes 09, 10
(EC Sensor Failure) ............................. T5-3-6
Fault Codes 11, 12
(Engine Control Dial Failure) ............. T5-3-7
166T-5-1
Group 4 Troubleshooting B Malfunction of Fuel Level
Troubleshooting B Procedure ................ T5-4-1 Indicator .............................................. T5-5-17
Correlation between Part Failure and Malfunction of Air Filter
Abnormalities that Machine may Show .. T5-4-2 Restriction Indicator ............................. T5-5-18
Correlation between Troubles and Malfunction of Hour Meter ..................... T5-5-19
Part Failures ........................................ T5-4-6 Malfunction of Buzzer ............................ T5-5-20
Engine System Troubleshooting ............ T5-4-10 Malfunction of Work Light
Total Actuator System Indicator .............................................. T5-5-22
Troubleshooting................................... T5-4-18
Front Attachment System Group 6 Electrical System Inspection
Troubleshooting................................... T5-4-23 Precautions for Inspection and
Swing System Troubleshooting.............. T5-4-28 Maintenance ........................................ T5-6-1
Travel System Troubleshooting ............. T5-4-31 Instructions for Disconnecting
Troubleshooting for Other Connectors .......................................... T5-6-3
Functions............................................. T5-4-34 Fuse Continuity Test .............................. T5-6-4
EC Sensor Installation and Fusible Link Inspection and
Voltage Adjustment.............................. T5-4-39 Replacement ....................................... T5-6-5
Installation and Adjustment Battery Voltage Check ........................... T5-6-5
of the A Sensor.................................... T5-4-40 How to Troubleshoot Alternator
Malfunctions ........................................ T5-6-6
Group 5 Troubleshooting C Continuity Check ................................... T5-6-7
Troubleshooting C Procedure ................ T5-5-1 Voltage and Current Check.................... T5-6-8
Malfunction of Coolant Check using False Signal ...................... T5-6-11
Temperature Gauge............................. T5-5-2 Relay Replacing Procedure ................... T5-6-12
Malfunction of Fuel Gauge .................... T5-5-4
Malfunction of Indicator Bulb Group 7 Harness Check
Check System ..................................... T5-5-6 Circuit Check......................................... T5-7-1
Malfunction of Level Check
Switch ................................................. T5-5-6
Malfunction of Engine Oil Level
Indicator .............................................. T5-5-8
Malfunction of Coolant Level
Indicator .............................................. T5-5-10
Malfunction of Hydraulic Oil
Level indicator ..................................... T5-5-12
Malfunction of Alternator
Indicator .............................................. T5-5-14
Malfunction of Engine Oil
Pressure Indicator ............................... T5-5-15
Malfunction of Overheat
Indicator .............................................. T5-5-16
T166-5-2
TROUBLESHOOTING / Diagnosing Procedure
INTRODUCTION
Each troubleshooting section group is presented in an

orderly fashion so as to make the inspecting and
troubleshooting procedures easy to follow. Use the
troubleshooting section to guide you in locating the
source of any problems that may arise.
The troubleshooting section consists of 7 groups: the

diagnosing procedure, the component layout, the
troubleshooting A (using fault codes), troubleshooting
B (starting with symptoms), troubleshooting C (gauges
and indicators), the electrical system inspection
procedures, and harness check groups.
• Component Layout Drawing
• Troubleshooting A (using fault codes)

Use these charts when the self-diagnosing
function of Dr.EX shows any fault codes.
(The controller automatically diagnoses and
memorizes malfunctions that have occurred in the
signal sending system.)
Example: Fault Code 01: EC Failure (1)
• Troubleshooting B (starting with symptoms)

Use these charts when the machine is exhibiting
trouble and when Dr.EX does not indicate any
fault codes.
Example: Even if engine control dial is operated,

engine speed does not change.
• Troubleshooting C (Gauges and indicators)

Use these charts when any gauges or indicators
malfunction.
Example: The fuel gauge does not operate.
• Electrical System Inspection Procedure

Refer to this group for precautions and inspection
procedures of the electrical system when or
before performing inspections on the electrical
system.
Example: Fuse Inspection
• Harness Check
Refer to this group for information about the test
harnesses.
Example: ST 7129
T5-1-1
DIAGNOSING PROCEDURE
These six basic steps are essential for efficient

troubleshooting:
1. Study the system
Study the machine’s technical manuals. Know the

system and how it works, and what the construction,
functions and specifications of the system components
are.
T107-07-01-001
2. Ask the operator
Before inspecting, get the full story of malfunctions

from your star witness --- the operator.
(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.
Fuse failure is often caused by a fine crack in the fuse,
and such fine cracks are very hard to detect by visual
inspection.
T107-07-01-003
T5-1-2
4. Operate the machine yourself
Try to identify the trouble by operating the machine

yourself.
If the trouble cannot be confirmed, stop the engine and
obtain further details of the malfunction from the
operator.
Also, check for any incomplete connections of the wire
harnesses.
T107-07-01-004
5. Perform troubleshooting
CAUTION: Never attempt to disconnect har-

nesses 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.
Connect the diagnostic analyzer, Dr.EX, to the PVC

(Controller) to obtain malfunction records.
If any fault codes are displayed on the monitor, check T107-07-01-005
sensing signal circuits, referring to Troubleshooting A.
If no fault code is indicated on the monitor, go to the

troubleshooting B group.
Note that Dr.EX will be necessary in the
troubleshooting B procedures for monitoring real time
component performance.
∗ 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 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 T107-07-01-006
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
Dr.EX
The Dr.EX is a handy microcomputer used for Input signals from the sensors and switches that are
diagnosing malfunctions of the machine electronic connected to the controller, and output signals from the
control system, including the controllers. controller to the solenoid valves can be monitored in
When Dr.EX is connected to the controller, malfunc- real-time while the machine is operated. (Real-Time
tions recorded in the controller memory are indicated Monitoring Function)
as fault codes on the Dr.EX display.
(Self-Diagnosing Function) Dr.EX can also function to increase the pump
displacement angle to the maximum angle.
(Special Function)
Dr.EX START-UP PROCEDURE
1. Connect the Dr.EX harness end to the diagnosing Start

connector in the cab.
NOTE: Be sure to use the harness supplied with Model Selection

Dr.EX for connecting the Dr.EX to the Screen (Select
machine. Once Dr.EX is connected “40t~kg2”)
properly and switched on, the self-
diagnosing function will automatically start
up. Initial Pattern Communica-
(Dr. EX) tion Failure
2. Turn the key switch to the ON position, or start the ·Check the
engine. harness.
3. Turn the Dr.EX power switch on. The model ·Check the
Model Code
selecting screen will appear on the Dr.EX display. fuse.
Confirmation
On each step (screen), select an appropriate item Screen
and/or follow the instructions at the bottom of the Install the new-
NOT OK
screen to proceed to the next step. The other version soft-
screens shown below will appear, in the order OK ware.
shown. Function
1. Model Selection Screen (Select “40t∼kg2.”) Selection
2. Initial Pattern (Dr.EX) Screen
3. Model Code Confirmation Screen
Real-Time Special Function
Example: Controller Model :EX400-5 Monitoring (A sensor
PVC Version :1.01 Self-Diagnosing Function Function adjustment)
4. Function Selection Screen

F1: Self-Diagnosing Function Accumulated Monitor Item Fixing Pump
Fault Codes Selection Displacement
F2: Real-Time Monitoring Function Display Angle at
Screen
F3: Special Function Maximum
·Refer to the
4. When the Function Selection Screen appears, Retrial A or B Data Display page T5-4-40.
select the desired function, then proceed by
following the instructions at the bottom of the
display.
Fault Code Display
NOTE: For Dr.EX operating procedures, refer to
the Dr.EX Operator's Manual.
Failure Description
T5-1-4
CLEARING THE SELF-DIAGNOSING
FUNCTION
The PVC self-diagnosing function temporarily stores

information on any abnormality that occurs in the
electrical system. These include such things as a drop
in battery voltage or a sensor connector being
disconnected for inspection.
Therefore, when a fault code is displayed, it does not
necessarily mean that the machine has a problem.
To check the cause of a fault code, first erase the fault
code and check whether it is displayed again or not.
There are two ways to erase fault codes, depending on
the problem area.
1. Problems with controllers (PVC and EC)

(Retrial “A”)
2. Problems with sensors (Retrial “B”)
OFF
RETRIAL “A” (For problems with the

controller (PVC and EC) )
1. Turn the Dr.EX OFF, with its harness still

connected to the diagnosing connector of the
PVC.
T105-07-01-001
2. Turn the key switch OFF .
3. After 10 seconds or more have passed, turn the

key switch to the ON position or start the engine.
T107-07-06-005
4. Disconnect the harness from the diagnosing

connector.
T105-07-01-004
5. After one second or more has passed, reconnect

the harness to the diagnosing connector. More than
1 sec.
NOTE: If the harness of the Dr.EX is connected to
the diagnosing connector without an T105-07-01-002
interruption of at least one second, fault
codes may not be erased.
6. Check the fault code again, following the normal

method. If the fault code is displayed again, the
problem exists.
T105-07-01-001
T5-1-5
RETRIAL “B” (For problems with the
sensors)
ON
1. Leave the key switch in the ON position. (The
engine may be stopped or may be running.)
T105-07-01-004
2. Disconnect the harness from the diagnosing

connector.
More than
1 sec.
3. After one second or more has passed, reconnect T105-07-01-002
the harness to the diagnosing connector.
NOTE: If the harness of the Dr.EX is connected to

the diagnosing connector without an
interruption of at least one second, fault
codes may not be erased.
4. Then, check the fault code again, following the

normal method. If the fault code is displayed again, T105-07-01-001
the problem exists.
The fault code will be displayed with NO actual

problems existing in the following cases:
1. When a sensor connector was previously

disconnected with the key switch ON or the
engine running. (This may happen when replacing
a part.)
2. When the PVC or EC connector was previously

replaced or disconnected.
3. When the battery was removed, or when fuse No.

2 or No. 7 was previously replaced.
Be sure to perform Retrial “A” in order to erase the

fault codes in the above cases.
T5-1-6
EC-RELATED FAULT CODES
Fault Code Trouble Corrective Action

01 Failure (type-1) of EC 1) Retry diagnostic procedure A.
2) Replace EC if engine governor is
uncontrollable
uncontrollable
uncontrollable
uncontrollable with eight or more number
of errors indicated in self-diagnosis.
05 Signal from PVC is not transmitted 1) Retry diagnostic procedure B.
to EC 2) Check harness
3) If auto-idle is abnormal replace PVC or
EC.
06 Failure (type-6) of EC 1) Retry diagnostic procedure B.
uncontrollable
07∗ Short-circuit of auxiliary sensor 2 1) Retry diagnostic procedure B.
2) Check harness
3) Replace auxiliary sensor 2.
08∗ Discontinuity of auxiliary sensor 2. 1) Retry diagnostic procedure B.
2) Check harness
09 Short circuit of EC sensor 1) Retry diagnostic procedure B.
2) Check harness
3) Replace EC sensor
10 Discontinuity of EC sensor. 1) Retry diagnostic procedure B.
2) Check harness
11 Short-circuit of Eng. Governor 1) Retry diagnostic procedure B.
Dial/Lever angle sensor. 2) Check harness
12 3) Replace Eng. Governor Dial/Lever angle
sensor.
13 N sensor malfunction. 1) Retry diagnostic procedure B.
2) Check harness
3) Replace N sensor
14 Discontinuity of overheat switch 1) Retry diagnostic procedure B.
L and/or Hydraulic Oil 2) Check harness
Temperature sensor. 3) Replace overheat switch and/ or Hydraulic
Oil Temperature sensor.
15 Short-circuit of overheat switch 1) Retry diagnostic procedure B.
L and/or Hydraulic Oil 2) Check harness
Temperature sensor 3) Replace overheat switch and/ or Hydraulic
∗ No aux. sensors are used on this machine.
T5-1-7
PVC-RELATED FAULT CODES

17 Failure (type-17) of PVC 1) Retry diagnostic procedure A.
18 Failure (type-18) of PVC 2) If engine stalls or working speed is
19 Failure (type-19) of PVC abnormal replace PVC.
20 Signal from EC is not transmitted 1) Retry diagnostic procedure B.
to PVC 2) Check harness
3) If speed sensing control is abnormal
replace PVC and/or EC.
21 Failure (type-21) of PVC 1) Retry diagnostic procedure B.
22 Failure (type-22) of PVC 2) Replace PVC
23 Pump control malfunction (4-spool 1) Retry diagnostic procedure B.
side) 2) If engine stalls or working speed is
24 Pump control malfunction (5-spool abnormal refer to service manual.
side)
25 Short circuit of DP sensor (4-spool 1) Retry diagnostic procedure B.
side) 2) Check harness
26 Discontinuty of DP sensor (4- 3) Replace DP sensor (4-spool side)
spool side).
27 Short-Circuit of P sensor (4-spool 1) Retry diagnostic procedure B.
side). 2) Check harness
28 Discontinuity of P sensor (4-spool 3) Replace P sensor (4-spool side)
side)
29 Short circuit of A sensor (4-spool 1) Retry diagnostic procedure B.
30 Discontinuity of A sensor (4-spool 3) Replace A sensor (4-spool side)
side)
34 Discontinuity of DP sensor (5- 3) Replace DP sensor (5-spool side)
spool side)
35 Short circuit of P sensor (5-spool 1) Retry diagnostic procedure B.
side)
37 Short circuit of A sensor (5-spool 1) Retry diagnostic procedure B.
38 Discontinuty of A sensor (5-spool 3) Replace A sensor (5-spool side)
side)
40∗ Short-circuit of auxiliary sensor 3. 1) Retry diagnostic procedure B.
2) Check harness
T5-1-8
MONITORING FUNCTION
Dr.EX functions to monitor command signals from the

controllers (PVC, EC) and input signals to these (4) 4-Spool Control Valve Side
controllers from various switches and sensors. (5) 5-Spool Control Valve Side
Pat-
Key
tern Display Description Unit
No.
No.
2
1 F6 Differential Pressure (dP4) DP sensor output signal. (4P) kgf/cm
2
F7 Pump Delivery Pressure (Pd4) P sensor output signal. (4P) kgf/cm
F8 Approx. Pump Displacement (D4) Calculated pump displacement. (4P) cc/rev
2 F6 Desired Pump Displacement (Dr4) Pump displacement control signal. (4P) cc/rev
F7 Approx. Pump Displacement Calculated torque. (4P) kgfxm
Torque (T4)
F8 Potential Pump Displacement Pump driving torque control signal. (4P) kgfxm
Torque (Tr4)
2
3 F6 Differential Pressure (dP5) DP sensor output signal. (5P) kgf/cm
2
F7 Pump Delivery Pressure (Pd5) P sensor output signal. (5P) kgf/cm
F8 Potential Displacement (D5) Calculated pump displacement. (5P) cc/rev
4 F6 Desired Pump Displacement (Dr5) Pump displacement control signal. (5P) cc/rev
F7 Approx. Pump Displacement Calculated torque. (5P) kgfxm
Torque (T5)
F8 Desired Pump Displacement Pump driving torque control signal. (5P) kgfxm
Torque (Tr5)
5 F6 Pump Disp. Angle Control signal Control signal to pump displacement A
(I4) control solenoid valve. (4P)
F7 Pump Disp. Angle Control signal Control signal to pump displacement A
(I5) control solenoid valve . (5P)
F8 Relief Pressure Raise Signal (Sf) Control signal to solenoid valve (SA) On
6 F6 Travel High/Low Shift Signal (Sh) Control signal to solenoid valve (SB) On
F7 Swing Parking Brake Release Control signal to solenoid valve (SC) On
Signal (Sbs)
F8 Swing/Boom Operation Signal (Ssb) Control signal to swing/boom circuit On
solenoid valve.
7 F6 Power Boost Switch On
F7 Travel Mode Switch Lo,Hi
F8 Work Mode Selector G, T, P, A
8 F6 Pressure Switch Bm,
Am,Ot,
Sw,Tr
F7 Econ. Mode sig. On
F8 Sup. Pow. Mode Sig. On
T5-1-9
Pat-
Key
tern Display Description Unit
No.
No.
9 F6 Engine Control Angle (Aec) EC sensor output signal. V
F7 Engine Control Motor Position EC motor position control signal. Pulse
(Ecmp)
F8 Actual Engine Speed (Ea) Actual engine speed. rpm
10 F6 Selected Engine Speed Engine speed control signal. %
F7 Deviation engine speed (dE) rpm
11 F6 Auto-Idle Switch On
F7 Additional Pressure Switch On
12 F6 Engine Control Motor Signal (Ecms) Control signal to EC motor. Dn, St,
Up
F7 Engine Control Motor Relay Signal On

(Ecmr)
13 F6∗ Swing Dampener Valve (sdv) On

F7 Hydraulic Oil Temperature (To) °C
14 F6 Overheat Switch (L) (Ovh) On

F7 Counterweight Switch (Cw) On
15 F6 Dial Angle Sig. Signal from dial angle sig. V

F7∗ Auxiliary Sensor 2 (Aux2) Signal from auxiliary sensor 2 V
F8∗ Auxiliary Sensor 3 (Aux3) Signal from auxiliary sensor 3 V
∗ This item not used on this machine.
NOTE: UNIT ABBREVIATIONS

Lo : Slow Speed Bm : Boom
Hi : Fast Speed Am : Arm
G : General Purpose Mode Ot : Other
T : Trenching Mode Sw : Swing
P : Precision Mode Tr : Travel
A : Atttachment Mode
T5-1-10
TROUBLESHOOTING / Component Layout
MAIN COMPONENTS
2
3
1
4
36 5
6
7
8
9
10
11
12
13
14
15
35 16
34
33 17
18
32 19
31 20
30 21
29 22
28 23
27 24
26 T166-01-02-007
25
1 - Bucket Cylinder 10 - Fuel Tank 19 - Muffler 28 - Swing Shuttle Valve

2 - Arm 11 - Control Valve 20 - Drain Filter 29 - Shockless Valve (Front)
3 - Arm Cylinder 12 - Air Filter 21 - Solenoid Valve Unit 30 - Lower Roller
(3 Solenoid Valve Used)
4- Boom 13 - Engine 22 - Pump Device 31 - Travel Shuttle Valve
5- Boom Cylinder 14 - Radiator 23 - Pilot Filter 32 - Pilot Shut-Off Valve
6- Front/Swing Pilot Valve 15 - Oil Cooler 24 - Hydraulic Oil Tank 33 - Track Adjuster
7- Swing Bearing 16 - Counterweight 25 - Travel Device 34 - Front Idler
8- Center Joint 17 - Fuel Filter 26 - Shockless Valve (Travel) 35 - Travel Pilot Valve
9- Swing Device 18 - Engine Oil Filter 27 - Upper Roller 36 - Bucket
T5-2-1
ELECTRICAL SYSTEM(1) 2
3
(Overall System) 4
5 12
1 6 13
7
8 14
9 15
38 10 16
(Option) 11 17
37
18
19
36 20
35
21
34 22
33 23
32 24
31 25
30
29 T166-01-02-015
28
27
26
1 - Work Light (On Boom) 11 - Coolant Temperature Sensor 21 - Engine Stop Motor 30 - Hydraulic Oil Temperature
(For Monitor) Switch
2 - Monitor 12 - Overheat Switch H 22 - Engine Oil Pressure Switch 31 - Pressure Switch (Other)
3 - Pressure Switch (Travel) 13 - Alternator 23 - EC Motor 32 - Pressure Switch (Swing)
4 - Horn 14 - Starter Relay 24 - N (Engine Speed) Sensor 33 - Pressure Switch
(Arm Roll-In)
5 - Work Light 15 - Fusible Link 25 - Starter 34 - Pressure Switch
(on Right Side Frame) (Boom Raise)
6 - Fuel Sensor 16 - Battery Relay 26 - Coolant Level Switch 35 - Windshield Washer Motor
7 - Low Fuel Level Switch 17 - Emergency Relay 27 - DP Sensor (5-Spool Side) 36 - Fuse Box
8 - DP Sensor (4-Spool Side) 18 - Battery 28 - 3-Spool Solenoid Valve Unit 37 - ∗Outside Temperature Sensor
9 - Air Filter Restriction Switch 19 - Magnetic Valve 29 - Hydraulic Oil Level Switch 38 - ∗Work Light (on Cab)
(Option)
10 - Overheat Switch L 20 - Engine Oil Level Switch
NOTE: Electrical components marked with ∗ are
installed on the following machines:
T5-2-2
Relays
2
3
4
5
6
7
24
8 (Option)
9
10
11
12
23
13
22 14
15, 16
T166-01-02-016
21 20 19 18 17
1 - Power Boost Switch 7 - Wiper Relay BM 13 - Preheat Relay 2 19 - Blower Medium Position
Relay 1
2- Load Dump Relay 8- EC Motor Relay 14 - Preheat Relay 1 20 - Compressor Clutch Relay
3- Wiper Relay B1 9- Work Light Relay 1 15 - EC 21 - Blower Main Relay
4- Washer Relay 10 - Work Light Relay 2 16 - PVC 22 - Dr. EX Connector
5- Wiper Relay B2 11 - Horn Relay 17 - Blower Fast Position Relay 23 - Fuse Box
6- Engine Stop Motor Relay 12 - Wiper Relay A 18 - Blower Medium Position 24 - ∗Work Light Relay 3
Relay 2 (Option)
NOTE: Work light relay 3 marked with ∗ is installed
on the following machines:
EX400-5: Serial No. 007662 and after
EX450H-5: Serial No. 007662 and after
T5-2-3
Monitor and Switch Panels Monitor Panel
10 11 12
37
1 13
36
14
2 35
15
34 16
33 17
18
32
19
3
9
8 31
20
7 30
21
6 22
29
23
5 24
4 28
25
27 26 M166-01-013
T166-01-02-017
1- Monitor Panel 11 - Coolant Temperature Gauge 20 - Attachment Mode Indicator 29 - Washer Switch
2- Switch Panel 12 - Fuel Gauge 21 - Precision Mode Indicator 30 - Work Light Switch
3- Cigar Lighter 13 - SP Mode Indicator 22 - Trenching Mode Indicator 31 - Level Check Switch
4- Option Switch 14 - E Mode Indicator 23 - General Purpose Mode 32 - Overheat Indicator
Indicator
5 - Air Conditioner Control Panel 15 - Auto-Idle Indicator 24 - Work Mode Switch 33 - Engine Oil Pressure
Indicator
6- Engine Control Dial 16 - Hydraulic Oil Level Indicator 25 - Buzzer Stop Switch 34 - Alternator Indicator
7- E Mode Switch 17 - Preheat Indicator 26 - Travel Mode Switch 35 - Engine Oil Level Indicator
8- SP Mode Switch 18 - Air Filter Restriction Indicator 27 - Auto-Idle Switch 36 - Coolant Level Indicator
9- Key Switch 19 - Fuel Level Indicator 28 - Wiper Switch 37 - ∗ Solar Radiation Sensor
10 - Warm Up Complete Indicator
NOTE: Solar radiation sensor marked with ∗ is in-
stalled on the following machines:
T5-2-4
(Blank)
T5-2-5
Control Valve
1 2 3 43 4 5 6 7 8 9 10 11 12 13 14 15
42
41 Swing Motor
Boom Cylinder
Arm Cylinder
40
39
16
Bucket Cylinder
17
38 18
19
37
20
36 21
22
35
23
34
33

32 31 30 29 28 27 26 25 24 T166-01-02-019
Tandem Circuit)
T5-2-6
Swing Arm 1
Boom 2 32 33 24 23
∗Aux.
Left Travel
Arm 2
Boom 1
Bucket
31
Right Travel
Front Side
T162-05-02-012
30 29 T162-05-02-009
44 28 45
37 48 35 49 21
22
20
34 26
25
21
T166-01-02-004
T162-05-02-004
47 46 37 51 6 27 50
T5-2-7
1 2 3 43 4 5 6 7 8 9 10 11 12 13 14 15
42
41 Swing Motor
Boom Cylinder
Arm Cylinder
40
39
16
Bucket Cylinder
17
38 18
19
37
20
36 21
22
35
23
34
33

32 31 30 29 28 27 26 25 24 T166-01-02-019
Tandem Circuit)
T5-2-8
56 5 57
Arm 2 Arm 1
52 53
7
Boom 1 Boom 2
41 16 13
17
39 8
36 18 12
1
19 4 9
15
38 59 58 T166-01-02-003
40 55 38 54 T166-01-02-002
42 3 60
14
Swing
15
43
10
14
T162-05-02-010
40 61
T162-05-02-008
T5-2-9
OTHERS
Pump Device
4
3
2
9 8 T166-01-02-010
10 11 12 13
T166-01-02-011
1 - Pump Control Proportional 5- Main Pump 1 8 - P (Pressure) Sensor (Main Pump 2) 11 - Travel Mode Shift
Solenoid Valve (Main Pump 2) Solenoid Valve
2 - A (Displacement Angle) 6- Pilot Pump 9 - Main Pump 2 12 - Main Relief Pressure
Sensor (Main Pump 2) Shift Solenoid Valve
3 - Pump Control Proportional 7- A (Displacement Angle) 10 - Swing Parking Brake 13 - Pilot Relief Valve
Solenoid Valve (Main Pump 1) Sensor (Main Pump 1) Release Solenoid Valve
4 - P (Pressure) Sensor
(Main Pump 1)
T5-2-10
Swing Device Travel Device
1
T142-01-02-012
T166-01-02-012
1 - Swing Relief Valve 2 - Counterbalance Valve 3 - Travel Relief Valve
T5-2-11
(Blank)
T5-2-12
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Use troubleshooting A procedure when fault codes are

shown on Dr.EX.
• How to Read the Troubleshooting Flow Charts
YES (OK) (2)

• After checking or measuring item (1), select either YES
(1)
• (OK) or NO (NOT OK) and proceed to item (2) or (3), as
appropriate.
(3)
NO (NOT OK)
• Special instructions or reference item are indicated in the spaces under the box.
•
Incorrect measuring or checking methods will render troubleshooting impossible,
and may damage components as well.
·Key switch: ON
• Explanation of how to use lamp harness kit required. Refer to “Harness Check”
Group (Group 7) in this section.
•
• Use Dr. EX function.

•
Causes are stated in a thick-line box. Scanning through thick-line boxes, possibleC
•
going through the flow chart.
NOTE: For all connector drawings illustrated in this

group, harness end connector terminals
seen from the open end side are shown.
Wire Harness Side
Open End Side

Harness End Connector
T158-05-03-001
T5-3-1
EC-RELATED FAULT CODES

uncontrollable
uncontrollable
uncontrollable
uncontrollable with eight or more number of
errors indicated in self-deagnosis.
05 Signal from PVC is not transmitted 1) Retry diagnostic procedure B.
to EC 2) Check harness
3) If auto-idle is abnormal replace PVC or EC.
06 Failure (type-6) of EC 1) Retry diagnostic procedure B.
uncontrollable
07 ∗ Short-circuit of auxiliary sensor 2 1) Retry diagnostic procedure B.
2) Check harness
08 ∗ Discontinuity of auxiliary sensor 2. 1) Retry diagnostic procedure B.
2) Check harness
09 Short circuit of EC sensor 1) Retry diagnostic procedure B.
2) Check harness
10 Discontinuity of EC sensor. 1) Retry diagnostic procedure B.
2) Check harness
11 Short-circuit of Eng. Governor 1) Retry diagnostic procedure B.
Dial/Lever angle sensor. 2) Check harness
12 3) Replace Eng. Governor Dial/Lever angle
sensor.
13 N sensor malfunction. 1) Retry diagnostic procedure B.
2) Check harness
3) Replace N sensor
14 Discontinuity of overheat switch L 1) Retry diagnostic procedure B.
and/or Hydraulic Oil Temperature 2) Check harness
sensor. 3) Replace overheat switch and/ or Hydraulic
15 Short-circuit of overheat switch L 1) Retry diagnostic procedure B.
and/or Hydraulic Oil Temperature 2) Check harness
sensor 3) Replace overheat switch and/ or Hydraulic
T5-3-2
PVC-RELATED FAULT CODES

17 Failure (type-17) of PVC 1) Retry diagnostic procedure A.
18 Failure (type-18) of PVC 2) If engine stalls or working speed is
19 Failure (type-19) of PVC abnormal replace PVC.
20 Signal from EC is not transmitted 1) Retry diagnostic procedure B.
to PVC 2) Check harness
3) If speed sensing control is abnormal
replace PVC and/or EC.
21 1) Retry diagnostic procedure B.
22 Failure 2) Replace PVC
(type-21) of
PVC
Failure (type-
22) of PVC
23 Pump control malfunction (4-spool 1) Retry diagnostic procedure B.
side) 2) If engine stalls or working speed is
24 Pump control malfunction (5-spool abnormal refer to service manual.
side)
26 Discontinuty of DP sensor (4-spool 3) Replace DP sensor (4-spool side)
side).
27 Short-Circuit of P sensor (4-spool 1) Retry diagnostic procedure B.
side). 2) Check harness
side)
29 Short circuit of A sensor (4-Spool 1) Retry diagnostic procedure B.
30 Discontinuity of A sensor (4-spool 3) Replace A sensor (4-spool side)
side)
34 Discontinuity of DP sensor (5- 3) Replace DP sensor (5-spool side)
spool side)
35 Short circuit of P sensor (5-Spool 1) Retry diagnostic procedure B.
36 Discontinuity of P sensor (5-Spool 3) Replace P sensor (5-Spool side)
side)
37 Short circuit of A sensor (5-Spool 1) Retry diagnostic procedure B.
38 Discontinuty of A sensor (5-Spool 3) Replace A sensor (5-Spool side)
side)
40 ∗ Short-circuit of auxiliary sensor 3. 1) Retry diagnostic procedure B.
2) Check harness
T5-3-3
FAULT CODES 01, 02, 03, 04, 06
(EC Failure)
Precondition:
• Be sure inspect wiring connections prior to
troubleshooting.
Checking Instruction:
• Replace the EC if the machine shows any abnor- ∗ However, the machine can be used without
malities and if fault code(s) are still indicated after replacing the EC if the machine functions normally
performing applicable “Retrial. ” despite the fact that the fault code(s) are indicated
after performing applicable “Retrial. ”
Fault Codes 01, 02, and 03

YES Normal
Check if fault codes

disappear after Re-
Turn auto-idle YES ∗ EC failure
trial A.
switch ON and
·Perform Retrial A a OFF. Check if en-
few times if fault gine speed
NO
codes do not disap- changes when
pear after one trial. auto-idle switch is Replace EC.
operated. NO
Fault Code 04 YES Normal
Check if fault codes

disappear after Re- NO ∗ EC failure
trial A.
Check if the number
·Perform Retrial A a
of fault codes indi-
few times if fault NO cated is 8 or more.
code does not dis-
appear after one Replace EC.
trial. YES
Fault Code 06
YES Normal
Check if fault code

disappears after Re-
NO ∗ EC failure
trial B.
·Perform Retrial B a Check if engine

few times if fault speed changes with
NO engine control dial.
code does not dis-
appear after one Replace EC.
trial. YES
T5-3-4
FAULT CODE 05
(Communication Failure between PVC and
EC)
Precondition:
• Be sure inspect wiring connections prior to trou-
bleshooting.
• The PVC, EC, or the harness between the PVC ∗ However, the machine can be used without
and EC may have failed if the auto-idle does not replacing the EC or PVC if the machine functions
function normally and if fault code 05 is still normally despite the fact that the fault code is still
indicated after Retrial B. indicated after Retrial B.
YES Normal
Check if fault code

disappears after Re-
trial B. YES ∗ PVC or EC failure
·Perform Retrial B a
Check if auto-idle
few times if fault
code does not dis- NO functions normally.
appear after one Disconnect harness end connec- YES Replace PVC and
trial. tors from PVC and EC. EC.
Check if continuity exists between
terminals stated below:
NO • PVC harness end connector
terminal No. 4 and EC harness
Failure of harness
end connector terminal No. 9
NO between PVC and
• PVC harness end connector
EC.
·Key switch: OFF
Harness End Connector (Open End Side)
PVC EC
5 4 3 2
12 11 10 9
T5-3-5
FAULT CODES 09, 10
(EC Sensor Failure)
Precondition:
troubleshooting.
• Fault code 09 indicates the input voltage from the Fault code 10 indicates the input voltage from the EC
EC sensor is 4.75 V or more. sensor is 0.25 V or less.
YES Normal
Check if breakage
or short circuit ex- NO EC failure
Check if fault code ists in the line be-
disappears after Re- Disconnect EC tween EC connec-
Disconnect EC sen-
trial B. sensor connector. YES tor terminal No. 34
sor connector. Check
if resistance between Check if voltage be- and EC sensor
·Perform Retrial B
a few times if fault EC side connector YES tween harness end connector terminal
Harness failure be-
terminals No. 1 and connector terminals No.2.
code does not No. 1 and No. 3 is YES tween EC and EC
disappear after No. 3 is 1.7±0.4 kΩ. sensor.
Connect test harness 5±0.5 V. ·Fault code 09:
one trial. Check for short
NO (ST7129) to EC sen-
·Key switch: ON circuit.
sor. Check if voltage
varies as specified Fault code 10:
when engine control Check for break-
dial is operated. age.
·Specified voltage:
Refer to T5-3-17.
Harness failure be-

NO tween EC and EC
sensor.
EC sensor failure
NO
EC Harness End Connector (Open End Side)
34
EC Sensor Side Connector (Open End Side)
(Open End Side)
3 2 1 EC Sensor
(Red)
(Black)
1 2 3
(ST 7129)
T107-07-03-009
EC 21 34 35
T107-07-03-008 T162-05-03-005
T5-3-6
FAULT CODES 11, 12
(Engine Control Dial Failure)
Precondition:
troubleshooting.
YES Normal
Disconnect engine
control dial connec- Check if breakage
tor. Check if resis- or short circuit ex- YES Harness failure be-
Check if fault code tance between en- ists in the line be-
disappears after Re- Disconnect engine tween EC and en-
gine dial side connec- tween EC connec-
trial B. control dial connec- YES gine control dial.
tor terminals No. 5 tor terminal No. 23
and No. 7 is 5.0±0.5 tor. Check if voltage and engine control
·Perform Retrial B kΩ. between harness dial connector ter-
a few times if fault YES EC failure
Reconnect engine end connector terminal No.2.
code does not control dial connec- minals No. 5 and NO
disappear after tor. Insert test probes No. 7 is 5±0.5 V.
one trial. from the back of en-
NO gine control dial con- ·Key switch: ON
nector: (-) probe on
terminal No. 7 and
(+) probe on terminal
No. 5. Check if volt-
age varies as speci-
fied when engine
control dial is oper-
ated. Harness failure be-
NO tween EC and en-
·Specified voltage:
gine control dial.
0.3 to 1.0 V with en-
gine control dial at
slow idle
4.0 to 4.7 V with en- Engine control dial
gine control dial at NO failure
fast idle
EC Harness Side Connector (Open End Side)
23
Engine Control Dial Side Connector Engine Control Engine Control Dial
(Open End Side) Dial Side (Harness Side) Harness End Connector
(Open End Side)
7 6 5
5 6 7 7 6 5 EC 35 23 21
T162-05-03-006 T162-05-03-007 T162-05-03-008
T5-3-7
FAULT CODE 13 (N Sensor Failure)
Precondition: Checking Instruction:
• Be sure inspect wiring connections prior to • Check the engine speed using the Dr. EX
troubleshooting. monitoring function. If breakage exists in the
• Be sure to inspect N sensor installation harness between the N sensor and EC, EC
-1
condition. judges that the engine speed is 0 min (rpm), in
other words, that the engine is not running. For
this reason, no fault code will be displayed in the
case of a wire breakage between the N sensor
and EC.
YES Normal
Disconnect connec-
tors from the N sen-
sor and EC. Connect
YES EC failure
Check if fault code N sensor harness
disappears after Re- end connector termi-
trial B. YES nals No. 1 and No. 2
using a clip. Check if
Disconnect N sensor
·Perform Retrial B a continuity exists be-
connector. Check if Harness failure be-
few times if fault tween EC harness
resistance between N tween EC and N
code does not dis- end connector termi- NO
sensor side connec- sensor
appear after one NO nals No. 4 and No.
tor terminals No. 1
trial. 11.
and No. 2 is 810±240
Ω.
N sensor failure.
NO
N Sensor Installation:
1) While looking at the ring gear teeth through the
sensor installation hole, center a tooth in the hole.
2) Screw the sensor in until the sensor comes in
contact with the ring gear tooth.
Don’t use any tools tighten the sensor at this time.
3) Turn the sensor back 2 full turns plus approxi-
mately a quarter turn from contacting the ring gear
teeth. (The gap between the sensor and ring gear
should be 3.1 mm (0.12 in). The thread pitch is
1.5 mm. (0.06 in)) N Sensor
4) While holding the sensor, tighten the lock nut. (Open End Side)
(Tightening torque: 24.5 to 34 N⋅m (2.5 to 3.5 1 2
kgf⋅m, 18 to 25.5 lbf⋅ft))
N Sensor
Lock Nut
4
11
EC
3.1 mm (0.12 in) Harness End
Connector
(Open End Side)
Ring Gear T166-05-03-001 T162-05-03-009
T5-3-8
FAULT CODE 14
(Overheat Switch L Failure, Hydraulic Oil
Temperature Sensor Failure)
Precondition:
troubleshooting.
• Fault code 14 indicates that the input voltage from If the harness between the EC and the overheat switch
the sensor is 4.75 V or more. In this case, harness L / hydraulic oil temperature sensor short-circuits, Dr.
breakage between the EC and the overheat EX indicates 120 °C (248 °F).
switch L / the hydraulic oil temperature sensor However, if the coolant temperature exceeds 98 °C
may be the cause. In addition, Dr.EX indicates -45 (208 °F) causing overheat switch L to turn on, Dr. EX
°C (-49 °F) in this case. also indicates 120 °C (248 °F).
Connect hydraulic oil

temperature sensor har- YES EC failure
ness end connector ter-
minals No. 1 and No. 2
using a clip.
YES Disconnect 48P connec- Harness breakage
Ground 48P harness between EC and
tor from the EC. Check if end connector terminals YES
continuity exists between hydraulic oil tem-
No. 33 to vehicle frame. perature sensor
48P harness end con- Check if continuity ex-
Disconnect hydraulic nector terminals No. 33 terminal No. 2.
ists between hydraulic
oil temperature sen- and No. 35.
NO oil temperature sensor
sor connector. Check
harness end connector
if resistance at hy- Harness breakage
terminal No. 1 and ve-
draulic oil tempera- between EC and hy-
hicle frame.
ture sensor side con- draulic oil tempera-
nector is within stan- NO ture sensor terminal
dard value range. No. 1.
·Standard value:
Refer to the table Hydraulic oil tem-
below. NO perature sensor
failure
Hydraulic Oil Temperature Sensor Overheat Switch L
Hydraulic Oil Resistance Coolant Temperature Switch Operation

Temperature °C kΩ °C (°F)
(°F) 96 to 100 (205 to 212) ON
-20 (-4) 16.2±1.6 89 to 100 (192 to 212) OFF
0 (32) (5.88)
20 (68) 2.45±0.24
40 (104) (1.14)
60 (140) (0.534)
80 (176) 0.322
EC Hydraulic Oil Temperature Sensor
1 2
35 33
T5-3-9
FAULT CODES 17, 18, 19, 21, 22
(PVC Failure)
Precondition:
troubleshooting.
• Replace the PVC if the machine shows any
abnormalities and if fault code (s) are still
indicated after performing applicable “Retrial.”
∗ However, the machine can be used without

replacing the PVC if the machine functions
normally despite the fact that the fault code (s) are
indicated after performing applicable “Retrial.”
Fault Codes 17, 18, 19
YES Normal
Check if fault codes disappear

after Retrial A. YES ∗ PVC failure
·Perform Retrial A a few times Check if engine stalls or if op-
if fault codes do not disappear erating speed is abnormal.
after one trial. NO
Replace PVC.
NO
Fault Codes 21, 22
YES Normal
Check if fault codes disappear

after Retrial B.
·Perform Retrial B a few times

if fault codes do not disappear Replace PVC.
after one trial. NO
T5-3-10
FAULT CODE 20
(Communication Failure between PVC and
EC)
Precondition:
troubleshooting.
• If the fault code still appears after Retrial B, check
the harness between the PVC and EC.
∗ Since it is practically impossible to determine

whether the PVC or EC has failed, replace both if
a failure occurs in the PVC/EC.
YES Normal
Check if fault code disappears

after Retrial B. OK ∗ Failure of PVC/EC
·Perform Retrial B a few times
if fault code does not disap- Check the harness between
pear after one trial. NO PVC and EC.
·Refer to page T5-3-5. Harness failure between PVC
NOT OK and EC
T5-3-11
FAULT CODES 23, 24
(Pump Control Failure)
Precondition:
troubleshooting.
• Fault codes 23 and 24 are indicated when the One of the following may be the cause:
target pump displacement does not match with 1. Pump control solenoid valve failure.
the actual pump displacement. 2. A sensor failure
3. PVC failure
If any other codes are also indicated, troubleshoot
those codes first.
PVC
37 3 106
10 114
OK
1
Pump Control Solenoid Valve Check harness
NOT OK between fuse No.
8 and PVC termi-
nal No. 37.
Troubleshoot us-
1 2 2
ing indicated fault YES Check fuse No. 8. ·Be sure to re-
YES codes (other than NOT OK
place failed fuse
Check if any fault 23 and 24). (No. 8) after the
NO codes other than cause is found. OK
23 and 24 are in- 3
dicated. Check if fault
code 23 is indi- OK 4
NO cated. NOT OK
OK
5
Check if fault YES Check fuse No. 8.
codes disappear
after Retrial B. Check if fault 6
code 24 is indi- NOT OK
NO cated.
·Perform Retrial Normal
B a few times if YES Normal
NO
fault codes do
not disappear
after one trial. Disconnect one A
Check if machine sensor. Check if A sensor failure
and engine oper- machine and en- or loose or incor-
YES ate normally. gine operate nor- YES rect connection of
mally. Reconnect A sensor.
A sensor and
check if machine
NO and engine oper-
ate normally. Re- Failure of PVC or
peat the same pump.
NO
procedure for the
other A sensor.
·If machine and engine

operate normally when
one of A sensors is dis-
connected, the discon-
nected A sensor has
failed.
T5-3-12
NOTE: (4) : 4-Spool Control Valve Side OK Failure of PVC or

(5) : 5-Spool Control Valve Side Check swing/ pump (4).
OK boom circuit shift
Check if continuity exists be- Check resistance solenoid valve line. Failure of the line
tween pump control solenoid between pump con- between PVC ter-
valve (4) harness end con- YES trol solenoid valve minal No. 112 and
nector terminals No. 1 and (4) connector termi-
No. 2. NOT OK swing/boom circuit
nals No. 1 and No. Pump control valve shift solenoid
Connect PVC side harness
end connector terminal No. 3 2. solenoid valve (4) valve.
(No. 10) to vehicle frame us- NOT OK failure.
·Standard value:
1 ing a clip. Check if continuity
exists between pump control 14±3 Ω at 20 °C
solenoid valve (4) harness (68 °F)
end connector terminal No. 1 Harness failure be-
(No. 2) and vehicle frame.
tween pump control
NO solenoid valve (4)
Harness failure between fuse and PVC.
2 No. 8 and PVC terminal No.
37. OK Failure of PVC or
Check resistance
between pump con- pump (4).
Check if continuity exists be- trol solenoid valve
tween pump control solenoid YES
(4) connector termi-
valve (4) harness end conec- nals No. 1 and No.
tor terminals No. 1 and No. 2. Pump control valve
Connect PVC side harness 2.
NOT OK solenoid valve (4)
end connector terminal No. 3 ·Standard value: failure.
3 (No. 10) to vehicle frame us- 14±3 Ω at 20 °C
ing a clip. Check if continuity
exists between pump control (68 °F)
solenoid valve (4) harness
end connector terminal No. 1 Harness failure be-
(No. 2) and vehicle frame. NO tween pump control
solenoid valve (4)
and PVC.
Harness failure between fuse Check resistance OK Failure of PVC or

4 No. 8 and PVC terminal No. between pump con- pump (5).
37.
trol solenoid valve
YES (5) connector termi-
Check if continuity exists be- nals No. 1 and No.
tween pump control solenoid 2.
valve (5) harness end con- Pump control valve
nector terminals No. 1 and · Standard value: NOT OK solenoid valve (5)
No. 2. ·14±3 Ω at 20 °C failure.
OK Connect PVC side harness
end connector terminal No. (68 °F)
114 (No. 106) to vehicle
frame using a clip. Check if Harness failure be-
continuity exists between
pump control solenoid valve tween pump control
5 (5) harness end connector solenoid valve (5)
terminal No. 1 (No. 2) and ve- NO and PVC.
hicle frame.
Check if continuity exists be-
Harness failure between fuse tween pump control solenoid Check resistance OK Failure of PVC or
No. 8 and PVC terminal No. valve (5) harness end connector between pump con- pump (5).
NOT terminals No. 1 and No. 2. trol solenoid valve
37.
OK Connect PVC side harness end YES (5) connector termi-
connector terminal No. 114 (No. nals No. 1 and No.
106) to vehicle frame using a
clip. Check if continuity exists 2. Pump control valve
OK solenoid valve (5)
between pump control solenoid
valve (5) harness end connector ·Standard value: NOT OK failure.
Check harness terminal No. 1 (No. 2) and vehi- 14±3 at 20 °C
between fuse cle frame. (68 °F)
6 No. 8 and PVC
terminal No. 37. Harness failure be-
NO tween pump con-
Harness failure between fuse trol solenoid valve
NOT OK No. 8 and PVC terminal No. 37. (5) and PVC.
T5-3-13
FAULT CODES 26, 34
(DP Sensor Failure)
Precondition: • If input voltage from the DP sensor is 1.0 V or
• Be sure inspect wiring connections prior to trou- higher with the engine stopped, the probable
bleshooting. cause is a faulty DP sensor or broken harness be-
tween the DP sensor and PVC.
• Fault codes 26 and 34 indicate input from the DP Check harness NO PVC failure
sensor is 0.25 V or less. Harness breakage lines between
between DP sensor and PVC may be the cause. PVC connector
YES terminal No. 44
(No. 32) and DP Harness break-
sensor terminal age between
No. 2 for harness PVC and DP
breakage. YES sensor terminal
Disconnect DP ·Fault codes 26 No.2.
sensor connector. and 34:
Check if voltage Check for harness
YES between harness breakage.
end connector
terminals No. 1
and No. 3 is
5±0.5 V. Harness break-
NO age between
·Key switch: ON PVC and DP
Attach test har-
Check if voltage sensor terminal
ness (ST 7129)
between the har- No.1.
NO between DP sen-
ness end connec-
sor and harness
NO tor terminal No.1 Harness break-
end. Check if in-
and vehicle frame
dicated voltage is age between
+0.15 is 5±0.5 V.
0.4 –0.1 or less. PVC and DP
·Key switch: ON YES sensor terminal
Check if fault code ·Key switch: ON No.3.
disappears after ·Fault code 26: 4-
Retrial B. spool side DP
sensor DP sensor failure.
·Perform Retrial B a Fault code 34: 5-
few times if fault spool side DP NO
codes does not sensor
disappear after one Normal
trial.
YES
PVC
(5-Spool Side)
32
44
Black (4-Spool Side)
Red
ST 7129 DP Sensor
ȑ Ȓ ȓ
T162-05-03-004
T5-3-14
FAULT CODES 27, 28, 35, 36
(P Sensor Failure)
Precondition:
troubleshooting.
• Fault codes 27 and 35 indicate the input from the Fault codes 28 and 36 indicate the input from the P
P sensor is 4.75 V or more. Short circuit between sensor is 0.25 V or less. Harness breakage between
the P sensor and PVC may be the cause. the P sensor and PVC may be the cause.
Check harness NO PVC failure

lines between the
PVC connector
YES terminal No. 42
(No. 31) and P Harness failure
Disconnect P sensor terminal between PVC
sensor connector. No. 2 for harness and P sensor.
Check if voltage breakage (short YES
NO between harness circuit).
Switch pump 1 end connector
side P sensor terminals No. 1
with pump 2 side and No. 3 is
NO P sensor. Check 5±0.5 V. Harness failure
if indicated fault between PVC
·Key switch: ON
code changes to NO and P sensor.
the one for the
other P sensor.
P sensor failure
·Fault codes 27
Check if fault code and 28: Fault YES
disappears after codes for pump
Retrial B. 1 side P sensor
·Fault codes 35
·Perform Retrial B and 36: Fault
a few times if fault codes for pump
codes does not 2 side P sensor
disappear after Normal
one trial.
YES
PVC P Sensor
(5-Spool Side)
31
42 1 2 3
(4-Spool Side)
T5-3-15
FAULT CODES 29, 30, 37, 38
(A Sensor Failure)
Precondition:
troubleshooting.
• Fault codes 29 and 37 indicate the input from the Fault codes 30 and 38 indicate the input from the A
A sensor is 4.75 V or more. Short circuit between sensor is 0.25 V or less. Harness breakage between
the A sensor and PVC may be the cause. the A sensor and PVC may be the cause.
Check the harness

lines between PVC NO Failure of PVC or
connector terminal A sensor
Disconnect the A sen- YES
sor connector. Check if No. 30 (No. 22) and A ·Refer to T5-4-40.
voltage between the sensor terminal No. 2
NO for harness breakage Harness failure be-
harness end connector
(short circuit). tween PVC and A
terminals No. 1 and No. YES sensor.
3 is 5±0.5 V.
Check if fault code ·Key switch: ON

·Fault codes 29 and 30: Harness failure be-
disappears after tween PVC and A
Retrial B. Fault codes for pump 1 NO
side A sensor sensor.
·Perform Retrial B a Fault codes 37 and 38:
few times if fault Fault codes for pump 2
codes does not side A sensor
disappear after one
trial. Normal
YES
PVC A Sensor
(5-Spool Side)
22
30 1 2 3
(4-Spool Side)
T5-3-16
SENSOR OPERATING RANGE LIST
1. Measurement Preconditions SP Mode E

Switch Mode
• Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
• Unless otherwise instructed, set the switches as
follows:
E Mode
Engine Switch and Work Mode Auto-Idle Slow Fast
Control Dial SP Mode Switch Switch
Switch
General
Fast Idle
ON Purpose OFF
(Max.)
Mode
• Monitor using the Dr.EX. Engine Control

M142-01-047
Dial
2. Sensor Operating Range
Item Required Control/Switch Operation Specified Range
Engine Control Slow Idle (Minimum Speed) 0.3 to 1.0 V

Dial Fast Idle (Maximum Speed) 4.0 to 4.7 V
Engine Control Dial at Slow Idle 2.5 to 2.7 V
EC Sensor
Engine Control Dial at Fast Idle 3.9 to 4.3 V
Pump Delivery
Pressure Sensor Boom Raise: Full Stroke, Relieved 300+15
–5 kgf/cm2
Control Levers: Neutral 49 cc/rev.

A Sensor One Track Jacked-Up,
Travel Lever (Raised Track Side): 183 cc/rev.
Full Stroke
Control Levers: Neutral 26 kgf/cm2
Pump Control
Pressure Sensor
One Track Jacked-Up,
Travel Lever(Raise Track Side): Full
Stroke 0 kgf/cm2
NOTE: 1 kgf/cm2=0.09807 MPa
T5-3-17
(Blank)
T5-3-18
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault code Start the troubleshooting with more probable causes
is displayed on the Dr.EX although the machine’s selected by referring to these tables.
operation is abnormal.
On the front section pages of this group T5-4, are
tables indicating the correlation between part failure
and abnormalities that the machine may show.
• How to Read the Troubleshooting Flow Charts

YES (OK)
(2)
• After checking or measuring item (1), select either YES

• (1)
(OK) or NO (NOT OK) and proceed to item (2) or (3), as
appropriate.
(3)
NO (NOT OK)
• Incorrect measuring or checking methods will render troubleshooting
impossible, and may damage components as well.
·Key switch: ON
• Explanation of how to use lamp harness kit required. Refer to “Harness Check”
• Group (Group 7) in this section.
• Use Dr. EX function.

•
• Causes are stated in a thick-line box. Scanning through thick-line boxes,

• possible causes can be seen without going through the flow chart.

Harness Side

T158-05-03-001
One End Side
T5-4-1
CORRELATION BETWEEN PART FAILURE

AND ABNORMALITIES THAT MACHINE
MAY SHOW
The table below shows abnormalities that the machine

may show and the effects in the control system if the
listed parts have failed. Also, troubleshooting
procedures are shown to find out if the listed parts
have failed in case the indicated abnormalities are
found.
Pump and Valve Controller Engine Controller Differential Pressure Sensor

(PVC) (EC) (DP Sensor)
Designated Function • Controls main hydraulic • Controls engine • Senses differential pressure
pump and main control speed. for pump displacement angle
valve. control.
Effects in Control • Loss of pump and/or valve • Loss of engine speed • Loss of main pump
System control. (Loss of pump control. displacement angle control.
control has resulted more
often than loss of valve
control.)
Abnormalities that the • Slow actuator speed. (Pump • Loss of engine speed • Correct metering may not be
machine may show. fixed to the minimum control. obtained.
displacement angle.) • Abnormal sound is heard from
• Engine may stall. (Pump the control valve with control
fixed to the maximum levers in neutral.
displacement angle.) • Excessively high oil and
• Actuator speed may vary coolant temperature.
unstably. (Displacement • Slow actuator speed.
angle varies unstably.) • Machine mistracks.
Dr.EX Self- • Dr.EX may display “Can not • Dr.EX displays fault • Dr.EX displays fault code 26 or
Diagnosing communicate with PVC” or code 01, 02, 03, 04, 34.
Function one or more of the following 05, or 06.
fault codes may be
displayed: 17, 18, 19, 20, 21,
and 22.
Dr.EX − − • Check the DP sensor pressure

Monitor with 2-F8.
Function
Trouble-
Test Harness − − −
shooting
Check
Pro-
cedures Other − − −
Note • Check fuse No. 8 (for PVC) • Check fuse No. 2 −
output side for wire (for EC) output side
breakage. for wire breakage.
• Be sure that the bolt on the • Be sure that the bolt
PVC connector is tight. on the PVC
connector is tight.
T5-4-2
Engine Speed Sensor Pump Displacement Pressure Sensor Engine Control Sensor
(N Sensor) Angle Sensor (A Sensor) (P Sensor) (EC Sensor)
• Senses engine (pump) • Senses main hydraulic • Senses main hydraulic • Senses governor lever
speed. pump displacement pump delivery pressure. position.
angle.
• Loss of speed sensing • Loss of pump control. • Loss of horsepower • Loss of learning control for
control. (This happens control. governor lever maximum
when engine speed speed position.
signal is not sent to the
EC due to harness
breakage, etc.)
• Engine stalls when • Machine mistracks. (It • Actuator maximum speed • Engine speed cannot be
operating under severe may be noticed when will decrease. controlled from slow idle to
conditions, such as traveling straight.) • Engine may stall. fast idle with engine speed
when operating at high • Engine overload or control dial. (Engine can be
altitude. decrease in speed may started.)
result. • EC motor moves beyond the
control range.
• Dr. EX displays fault • Dr. EX displays fault code • Dr. EX displays fault code • Dr. EX displays fault code 09
code 13 when engine 23, 24 ,29, 30, 37, or 38. 27, 28, 35 or 36. or 10.
speed is not within
specification. No fault
code is displayed if
circuit between N
sensor and EC is open.
• Monitor engine speed. • Monitor and compare the • Monitor pump delivery −
pump displacement target pressure. If P sensor
2
angle and the pump harness is open, 0 kgf/cm
displacement angle. will be indicated.
− − − −
− − − −
− − − If EC sensor fails, the fast idle
speed is set using the
previous learning value or the
backup value. For this reason,
the machine can still operate
almost normally. However,
after the EC is replaced, the
machine may show
abnormalities described as no
fast idle values are stored in a
new EC.
T5-4-3
Overheat Switch L,
Pump Control Solenoid Swing Preference Circuit Shift
Hydraulic Oil Temperature
Valve Solenoid Valve
Sensor
Designated Function • Senses hydraulic oil and • Shifts the pump • Turns on/off the pilot
coolant temperatures. displacement angle. pressure to shift (turn
on/off) the swing
preference circuit.
Effects in Control System • Loss of overheat • Loss of pump control. • Loss of swing preference
prevention control. circuit shifting (turning
• Loss of auto warm-up on/off) control.
function.
Abnormalities that the • Slow actuator speed may • Pump flow rate becomes • Priority is given to swing
machine may show. result if sensor signal line minimum if the harness in swing/boom raise
is short-circuited. has an open circuit. combined operation.
• Auto warm-up function is • In the trenching mode,
not operating. priority is not given to
swing in swing/boom raise
combined operation.
Dr.EX Self- • Dr.EX displays fault code • Dr.EX displays fault code −
Diagnosing 14. 23 or 24.
Function
Dr.EX − − • Check signals from the
Monitor swing and boom raise
Function pressure switches and from
the work mode switch for
any abnormalities.
Trouble- Test Harness
shooting − − −
Check
Proce-
dure Other − − −
Note − − −
T5-4-4
Travel Mode Shift Main Relief Pressure Shift

EC Motor Engine Control Dial
Solenoid Valve Solenoid Valve
• Shifts travel motor • Temporarily raises the main • Operates governor • Controls engine speed.
displacement angle. relief pressure. lever.
• Travel motor • Main relief pressure cannot • Governor lever does • Engine speed does not
displacement angle is be raised. not move. change with engine
fixed to the maximum control dial.
(slow speed).
• Travel speed mode • Travel steering power • Turning engine control • Engine speed stays at
around 1000 min− with
1
does not shift to the decreases. dial, engine speed
fast speed mode with • Main relief pressure cannot stays at slow idle. no load applied.
the travel mode be raised even in the
switch. precision work mode.
− − − • Dr.EX displays fault code

11 or 12.
− • Operate and return the − • Monitor the input signal

travel lever, and confirm that for engine control dial
the travel code on Dr. EX angle. (If it is 1.0 to 4.0 V,
goes to the reverse video engine control dial is
and returns to the normal normal.)
− − − −
− • The solenoid valve function • EC motor is

is considered normal if the considered normal if
main relief pressure rises governor lever moves
temporarily when a front when key switch is
function, i.e. boom, arm, or turned to ON position.
bucket, is relieved in the
precision mode.
− − − −
T5-4-5
CORRELATION BETWEEN TROUBLES
AND PART FAILURES
Engine Control Electrical Parts

Eng. EC EC EC Emerg. Eng. Eng. Pres. Pres. Pres.
Cont. Motor Sensor Motor Relay Stop Stop Sw. Sw. Sw.
Dial Relay Motor Relay (Travel) (Swing) (Boom
Raise)
E-1 Starter does not rotate.
E-2 Starter rotates but engine

does not start.
E-3 Engine is hard to start in cold
weather.
E-4 Engine stalls 12 seconds
{
after engine starts.
E-5 Auto-Idle does not function.
{ { { { { {
E-6 Engine stalls with engine
control dial turned to fast idle
position.
With engine control dial
turned to fast idle position
{
and auto-idle switched turned
ON, engine sometimes stalls
while operating.
Slow idle speed is
excessively slow or fast.
E-7 Engine speed does not
change with engine control { { {
dial.
E-8 Engine does not stop.
{ {
Pump Control Valve Cont. Electrical Parts

Pump P DP A Swing Swing Hyd. Work SP E
Cont. Sensor Sensor Sensor Pref. Park. Temp. Mode Mode Mode
Prop. Sol. Brake Sensor Sw. Sw. Sw.
Sol. Valve Sol. /Over-
Valve Valve hert
Sw. L
A-1 All cylinders and motors
{ { { { { {
move slowly or do not move
A-2 Cylinders and motors, which
are hydraulically connected to
{ { { { {
one particular main pump,
move slowly or do not move.
A-3 Cylinders and motors do not
stop moving with control
levers returned to neutral.
A-4 Boom is slow in swing/boom
{ {
raise combined operation.
A-5 SP mode cannot be activated
{
with SP mode switch.
A-6 E mode cannot be activated
{
with E mode switch.
A-7 Cylinder or motor
{ {
responsiveness is slow.
NOTE: The above table shows the correlation between machine operation trouble and related parts which may
cause trouble. However, the correlations in this table are described based on the condition supposing
that each trouble occurs independently. If any other trouble occur at the same time, find out the faulty
parts causing the trouble by checking all suspected parts in each symptom.
T5-4-6
Electrical Parts Engine

Pres. Pres. Key Pre- Bat- Starter Starter Monitor EC Eng. Gover Fuel Gauze EC
Sw. Sw. Sw. Heat tery Relay /Auto- nor Filter Filter Monit
(Arm (Other Relay Relay Idle or
Roll- s) Sw. Link
In)
{ { { {
{ { { { { {
{ {
{ { { {
{ { { { { {
{ {
{ { {
Pump Cont. Valve Others

PVC Pump Servo Pilot Main Main Shock Pilot Pilot Pilot
Unit Piston Pump Spool Relief less Shut- Valve Relief
Valve Valve Off Valve
Valve
{ { { { { { {
{ { {
{ {
{ { { {
T5-4-7
Pump Control Valve Control Electrical Parts

P DP A Swing Main Travel Power Pres. Monitor PVC
Sensor Sensor Sensor Pref. Relief Speed Boost Sw. /Auto-
Sol. Pres. Sol. Sw. Travel idle
Valve Sol. Valve Sw.
Valve
F-1 Front attachment cylinder(s)

{
move slowly or do not move.
F-2 Bucket drops excessively.
F-3 In the beginning of front

attachment operation, bucket
drops slightly.
F-4 Power does not increase with
power boost switch turned on. { {
S-1 Upperstructure does not

rotate, rotates slowly, or { {
swing power is weak.
S-2 Upperstructure coasts
excessively when stopping
swing operation or when
machine is parked on a slope.
T-1 Both tracks move slowly.
{ {
T-2 Travel mode does not shift.
{ { { {
T-3 Machine mistracks.
{ { { { {
Pump Control Valve Cont. Pressure Switch Electrical Parts

P DP A Swing Main Swing Boom Arm Work Monitor
Sensor Sensor Sensor Pref. Relief Raise Roll- Mode /Auto-
Sol. Pres. In Sw. Idle
Valve Sol. Sw.
Valve
O-1 Work mode does not shift.

{ { { { { { {
O-2 Pump emits abnormal sound
{ { { {
or vibration.
O-3 Wiper does not operate or
does not retract.
O-4 Counter weight removal
cylinder moves slowly or does
not move.
NOTE: The above table shows the correlation between machine operation trouble and related parts which may
cause trouble. However, the correlations in this table are described based on the condition supposing
that each trouble occurs independently. If any other trouble occur at the same time, find out the faulty
parts causing the trouble by checking all suspected parts in each symptom.
T5-4-8
Pump Control Valve Others

Pump Main Main Over- Load Hold- Swing Travel Center Shut- Shock Lock Pilot Pilot Cylin-
Unit Spool Relief load Check ing Device Device Joint tle -less Valve Shut- Valve der
Valve Relief Valve Valve Valve Valve Off
Valve Valve
{ { { { { { {
{ { { {
{ { { {
{ { { { { { {
{ { {
{ {
{ { { { { {
Electrical Parts Pump Control Valve Others

Wiper PVC Pump Main Main Over- Pilot Lock Holding Slow Return
Sw. Unit Spool Relief load Valve Valve for Valve for Valve for
Valve Relief Counter Counter Counter
Valve Weight Weight Weight
Removal Removal Removal
Device Device Device
{
{ { { { { { {
T5-4-9
ENGINE SYSTEM TROUBLESHOOTING

E-1 Starter does not rotate.
Precondition:
troubleshooting.
YES
Checking Instructions:
• Measure each voltage by referring to the table
below.
• Electronic control system, i.e. EC, etc., is not
related with the fact that the starter does not
rotate.
Voltage at terminal B is 0 V in
both key switch positions: ON
Check if voltage values at and START.
starter and starter relay termi-
YES nals shown in the table are as ·Key switch: ON↔START
specified, key switch in ON
and START positions.
Unit: V
ON START
Starter B 24 24
Check if battery voltage and Voltage at starter relay termi-
Starter C 0 24 nal S is not 24 V with key
electrolyte specific gravity are
normal. Starter Relay S 0 24 switch in START position.
NO
Voltage: ·Key switch: START
Starter Relay
24 V or more
Specific gravity:
1.26 or larger
S
Voltage values at starter relay
terminal S, at starter terminals
B and C are not 24 V with key
T166-05-04-002 switch in START position.
·Key switch: START
·NO (Battery also has failed if voltage at terminal B is less than 18 V with key switch in
START position.)
B C
• Starter Terminal Voltage Check
1. Turn the key switch to the ON or START position.
2. Connect the negative probe of a circuit tester to

the vehicle frame (unpainted surface such as a
bolt head). Connect the positive probe to starter
terminals B and C and to starter relay terminal S.
Measure voltage at each terminal.
T166-05-04-001
T5-4-10
Starter Failure.
YES Harness failure between bat-

Check if a click sound is heard tery relay and starter.
from the battery relay when
key switch is turned OFF from
ON position.
Check if battery relay func-
·Key switch: ON↔START NO tions.
NO Harness failure between fusi-

ble link and key switch.
Terminal No. 1: 0 V
Check if fusible link
(45A) has blown.
Measure voltage at key
Blown fusible link.
switch terminals No. 1 ·Visual check
and No. 6. Terminal No. 1: 24 V YES
Terminal No. 6: 0 V
Key switch failure.
·Key switch: START
Terminal No. 1: 24 V
Terminal No. 6: 24 V Harness failure between key
switch terminal No. 6 and
starter relay terminal S.
Starter relay failure.
Battery failure.
• Key Switch Voltage Check
1. Remove the key switch from the console.
2. Turn the key switch to the ON position. ST G1 ACC

V
3. With the key switch connected to the harness,
measure voltage at terminals No. 1 and No. 6. View A
(Insert the probe from the back of the connector.)
B G2 M
T105-07-04-002
T5-4-11
E-2 Starter rotates but engine does not start.
Precondition::
troubleshooting.
• Check the governor lever and fuel cut lever
position while cranking the engine. If the both
levers position are normal, the engine unit or fuel
system may have failed.
YES Engine Unit Failure.
·Refer to the engine shop

manual.
Check if fuel cut lever moves
YES to start position when key
switch is turned to START
position.
·Key switch: START

Check if governor lever moves
to start position when key
Check the engine stop motor
switch is turned to ON posi-
NO actuating circuit.
tion.
·Refer to page T2-3-7
·Key switch: ON
(Electrical System Group,
SYSTEM SECTION).
Check the EC motor actuating

NO circuit.
·Refer to page T2-3-6
(Electrical System Group,
SYSTEM SECTION).
T5-4-12
E-3 Engine is hard to start in cold weather. (Fails
to preheat.)
Precondition: Preheat relay 1 harness end Connector

• Be sure inspect wiring connections prior to (Open end Side)
troubleshooting.
2
1
• Check if electricity reaches the intake heater and
magnetic valve. Also, test the intake heater and
magnetic valve units.
Disconnect the har- YES Magnetic valve failure.
ness end plug from
YES magnetic valve.
Check if voltage at
Measure resis- harness end plug is Harness breakage be-
tance value at in- 20 to 24 V. tween key switch termi-
YES nal No. 3 and magnetic
take heater. NO
Check if it is valve.
2.23±0.2 Ω.
Disconnect har-
ness end terminal ·Key switch: OFF Intake heater failure.
from intake ·Disconnect the NO
heater. harness end be-
Check if voltage fore the measure-
at harness end ment. Harness breakage be-
YES
terminal is 20 to tween register and in-
24 V. take heater.
Disconnect har-
·Key switch: HEAT ness end terminal
from register.
NO Check if voltage at YES Preheat relay 1 failure.
harness end termi- Disconnect preheat
nal is 20 to 24 V. relay 1 connector.
Check if voltage at
·Key switch: HEAT connector terminal
NO Harness breakage be-
No. 1 on harness is tween key switch ter-
20 to 24 V. minal No. 1 and pre-
·Key switch: HEAT NO
heat relay 1.
E-4 Engine stalls 12 seconds after engine starts.
Precondition:
troubleshooting.
• Emergency relay functions to stop the engine if it
judges that engine oil pressure is excessively low.
YES Emergency relay failure.
Check if engine oil is up to the

specified level.
·Engine oil: 50 liters Add engine oil.
(13.2 US gal.) NO
T5-4-13
E-5 Auto-idle does not function.
Precondition:
troubleshooting.
NOTE: EC motor and EC sensor are functioning

normally.
• If E-1 to E-4 has occurred, troubleshoot them first.
• Refer to “Auto-Idle Control” in the Control System
Group, the SYSTEM section, the Operation
Principle book.
• If the auto-idle function has failed after EC had
been replaced, increase the engine speed to the
maximum (fast idle) speed.
Pressure switch (travel, swing,

boom raise, arm roll-in, and/or
others) failure.
NO
Harness failure between PVC
and pressure switches.
Restriction of filter in pilot sig-
nal circuit.
Monitor pressure switches
(travel, swing, boom raise,
arm roll-in, and others). NOTE: Pressure switch location:
ȹȥȳ Check if letters “Tr”, “Sw”, Pressure switch (travel): Travel shuttle valve
“Bm”, “Am”, and ”Ot” turn re- Pressure switch (swing): Swing shuttle valve
verse video when respective Pressure switch (boom raise): Shockless valve
control lever is operated. Pressure switch (arm roll-in): Shockless valve
Pressure switch (others): Swing shuttle valve
Monitor auto-idle switch.
Check if letters “On” turn re- ·Monitor items #8-F6
verse video. EC failure.
YES
·Monitor item #11-F6
Auto-idle switch failure, or

harness breakage between
NO auto-idle switch and EC.
T5-4-14
E-6 Engine stalls with engine control dial turned
to fast idle position.
With engine control dial turned to fast idle
position and auto-idle switch turned ON,
engine sometimes stalls while operating.
Engine speed is slow in general.
Slow idle speed is excessively slow or fast.
Related Fault Codes: 09, 10
Precondition:
troubleshooting.
• If the EC sensor has failed, the governor lever fast Moreover, because the fast idle position may vary
idle position learning will not be performed when depending on the governor lever position when
the key switch is turned to the ON position. (The the key switch is turned to the ON position, the
slow idle position learning will be performed.) For trouble may not appear constantly.
this reason, the fast idle is set referring to the
previously performed fast idle position learning or
the preset fast idle.
YES EC sensor failure.
·Refer to page
T5-4-39.
YES End
Check if fault code
09 or 10 is indi-
cated.
YES
Check if governor Failure of engine
lever comes into unit and fuel sys-
contact with stop- tem.
Restart engine. per when the key
Check if the trouble
NO disappears. YES switch is turned to
the ON position Control cable fail-
(when the slow idle ure. Incorrect en-
position learning is gine governor
Turn engine control performed). lever adjustment.
dial and monitor EC NO
Torque limiter fail-
angle. Check if EC ure.
angle changes as
NO engine speed ·Refer to T5-4-36.
changes.
EC failure, harness
·Monitor items #9-F6
failure between EC
#10-F6
motor and EC, or
NO blown fuse No. 2
or No. 3.
T5-4-15
E-7 Engine speed does not change with engine
control dial.
• If the above phenomenon occurs after the EC is
replaced, EX sensor failure may be the cause.
Related Fault Codes: 11, 12
Precondition:
troubleshooting.
Engine control dial failure, or

YES harness breakage between
engine control dial and EC.
Check if fault code 11 or 12 is

indicated.
YES EC motor failure.
Connect test harness
(ST7125) to EC motor. Turn ·Refer to page T5-4-39.
NO engine control dial and check
if test harness lamp comes on. EC failure, or harness break-
NO age between EC and EC mo-
tor.
T5-4-16
E-8 Engine does not stop.
If the engine does not stop with the key switch,

manually move the fuel cut lever to the engine stop
position to stop the engine. Be sure to troubleshoot
after stopping the engine.
Precondition:
troubleshooting.
• The engine is stopped by the engine stop motor.
• If the engine does not stop, failure of the engine
stop motor or the key switch may be the cause.
(Note that the key switch sends engine stop signal
to the engine stop motor. Also note that 24 V is
routed to key switch terminal No. 5 even when the
key switch is turned to the OFF position, allowing
the key switch to send engine stop signal to the
engine stop motor.)
YES Fuel injection pump failure.
·Refer to the engine shop

manual.
Check if both the governor
lever and fuel cut lever are in
the engine stop position. YES Engine stop motor failure.
·Key switch: OFF
Check if voltage at fuse No. 5
NO output side is 0 V.
·Key switch: OFF Key switch failure.

NO
(24V)
• How to Stop Engine Manually Fuel Cut Lever (Engine Stop

Position)
Fuel Cut Lever (Engine
Manually pull the fuel cut lever to the engine stop Start Position)
(fuel cut) position. The engine will stop.
T166-04-02-001
T5-4-17
TOTAL ACTUATOR SYSTEM TROUBLE-
SHOOTING
A-1 All cylinders and motors move slowly or do
not move.
Precondition:
troubleshooting.
• Pilot system (pilot pump, pilot relief valve, pilot
shut-off valve), relief valve circuit, work mode
select switch circuit, or overheat switch
L/hydraulic oil sensor circuit may have failed.
Move pilot control
NO shut-off lever to
UNLOCK position.
Check if pilot con-

trol shut-off lever is NO Work mode selec-
in UNLOCK posi- tor failure.
tion.
Remove, disas- NO End

Check if work semble, clean,
mode can be NO and reassemble
YES shifted. pilot relief valve.
Check if trouble Pilot pump failure.
·Key switch: ON still exists.
·Monitor Item #7-F8 YES
Check if primary
pilot pressure is
YES normal. NO Main relief valve
failure.
·Engine speed: SP
mode Check if main
·Refer to Opera- relief pressure is
YES normal. Check if letters
tional Performance
Test section for “ON” for over-
·Monitor items #1-F7 heat switch L A
pressure meas- #3-F7 YES turn reverse
urement proce- ·Refer to Operational
dure. video.
Performance Test sec-
tion for pressure ·Key switch: ON
measurement proce- ·Monitor item
dure. #14-F6
YES Overheat of coolant

Check if coolant and/or hydraulic oil.
temperature exceeds
98 °C (208 °F) or if
A
hydraulic oil tempera-
ture exceeds 120 °C
Check overheat
(248 °F).
switch L / hydraulic oil
NO temperature sensor
circuit.
T5-4-18
A-2 Cylinders and motors, which are hydraulically
connected to one particular main pump, move
slowly or do not move.
Precondition:
troubleshooting.
• Switching part(s) in 4-spool control valve side with
those in 5-spool side, it can be judged that
switched part(s) have failed if the trouble appears
on the other side.
• Pump control sensors (DP sensor, A sensor),
pump control solenoid valve circuit, or main pump
have failed.
2
NO DP sensor failure.
Monitor DP sensor
pressure again
NO with engine
stopped. Is it 4
kgf/cm2 or less?
Operate one con-
trol lever and moni- ·Key switch: ON DP sensor circuit har-
tor the correspond- ·Monitor items #1-F6 YES ness failure.
ing DP sensor Ȁ #3-F6
pressure. Is it 4
2 DP sensor failure.
kgf/cm or less? YES
·Engine: Running Switch DP sensors

·Monitor items #1-F6 with each other.
#3-F6 Check if slower
YES side becomes YES Insecure or incorrect A
normal. sensor installation, or A
Remove A sensor.
Check if slower sensor failure
NO side becomes ·Refer to T5-4-40

normal.
A
NO
Check if target pump

flow rate is the minimum Insecure A sensor
value with control levers YES installation or the cor-
in neutral. responding main
Also, check if target pump failure.
pump flow rate is the
A maximum when one ·Refer to T5-4-40
travel lever is operated
full stroke while the cor- Pump control sole-
responding track is noid valve circuit fail-
NO ure
jacked up.
·Control levers in neutral:

Minimum value: 48±10 L/rev.
Travel lever full stroke:
Maximum value: 183±10 L/rev.
·Monitor Items #2-F6
#4-F6
T5-4-19
A-3 Cylinders and motors do not stop moving
when control levers are returned to neutral.
• Sticking of spools in pilot valve and/or control
valve may be the cause.
YES Pilot valve failure.
·Pilot pressure has been

Pull up pilot control shut-off falsely routed to the control
lever and check if cylinders valve.
and motors stop moving.
Control valve failure.
NO
·Although pilot pressure was
not routed to the control valve,
control valve spool(s) were
open due to sticking.
A-4 Boom is slow in swing/boom raise combined

operation.
Precondition:
troubleshooting.
• If operations other than swing/boom raise are
normal, the swing preference circuit may have
failed.
2
NO Swing preference circuit shift

solenoid valve failure (Sticking
or seizure).
Check if boom speed changes Check if the swing preference
in swing/boom raise combined circuit shift solenoid valve indi-
operation when general pur- cation (On) turns reverse video
pose mode and trenching when swing/ boom raise func-
mode are selected. tions are operated simultane-
ously.
Harness breakage between
·Monitor item; #6-F8 the PVC and swing prefer-
YES ence circuit shift solenoid
valve.
T5-4-20
A-5 SP mode cannot be activated with SP mode
switch.
(Other controls are normal.)
Precondition:
troubleshooting.
• If only SP mode is the one does not function,
related switches or controller may have failed.
• Refer to “SP Mode Control” in the Control System
Principle book.
NO SP mode switch failure, or

harness breakage between
SP mode switch and PVC.
Monitor SP mode switch. Op-
erate SP mode switch and
check if the letters “On” turn
reverse video.
PVC failure.
YES
A-6 E mode cannot be activated with E mode

switch.
Precondition:
troubleshooting.
• Refer to “E Mode Control” in the Control System
Principle book.
NO E mode switch failure, or har-

ness breakage between E
mode switch and PVC.
Monitor E mode switch. Oper-
ate E mode switch and check
if the letters “On” turn reverse
video.
PVC failure.
YES
T5-4-21
A-7 Cylinder or motor responsiveness is slow.
More than 1 second. Pump servo piston mecha-

nism failure.
While monitoring pump dis-
placement angle value, oper-
ate corresponding control More than 1 Pilot system failure (Excessive
lever and measure time lag second. drop in pilot pressure, pilot
between lever operation and valve failure, etc.)
change in displacement angle Operate the slow responding
value. lever and measure time lag
between lever operation and
·Monitor items #1-F8 the moment the correspond-
#3-F8 Less than 1 ing pressure switch letters
second. turn into reverse video.
Less than 1
·Monitor items #8-F6 second.
T5-4-22
FRONT ATTACHMENT SYSTEM
TROUBLESHOOTING
F-1 Front attachment cylinder(s) move slowly or
do not move.
Precondition:
troubleshooting.
• The corresponding pilot valve, overload relief
valve, or pressure switches may have failed.
• If only boom raise in swing/boom raise combined
operation is slow, go to troubleshooting A-4.
NO Pilot valve failure.
Check if corresponding
secondary pilot pressure
is normal. NO Corresponding over-
load relief valve failure.
·Refer to Operational
Performance Test sec- Check if corresponding
tion for pressure meas- overload relief pressure
urement procedure. YES is normal.
·Refer to Operational Per- Control valve failure
formance Test section for (sticking, etc.)
pressure measurement YES
procedure.
T5-4-23
F-2 Bucket drops excessively.
YES Normal.
Damaged control
NO valve spool, bro-
Remove holding ken spring, or
check valve and Check if excessive loose spool end.
Check if cylinders holding check YES cylinder internal
for drift quantity. valve shift valve leakage exists.
Are drift values from control valve. Cylinder sealing
within the specifica- YES Disassemble, YES failure.
tions? clean, reassemble,
·Refer to Opera- and reinstall them.
Replace the over- Check if bucket still Failure of holding
tional Perform- load relief valve(s)
ance Test section drops excessively. check valve or
for cylinder(s) holding valve shift
for cylinder drift NO
which shown ex- valve.
measurement cessive drift, with
procedure. one(s) from other ·If holding valve shift valve is sticking:
NO function(s). Check Arm cylinder: Roll-out: Operable (Backhoe)
if excessive cylin- Roll-in: Inoperable (Backhoe)
der drift is still ob- Extend: Inoperable (Loading Shovel)
served. Retract: Operable (Loading Shovel)
Boom cylinder: Raise: Operable
Lower: Inoperable
·If holding check valve has failed, responsiveness of
both the arm and boom becomes slow.
Overload relief
NO valve failure.
F-3 In the beginning of front attachment operation

(boom raise, arm roll-out or bucket open),
bucket drops slightly.
NO Damaged control valve spool,

broken spring, or loose spool
end.
YES Check if excessive cylinder
internal leakage is found.
Cylinder sealing failure.
Check if load check valve lo- YES
cated in control valve is nor-
mal.
·Disassemble and visually

check. Load check valve failure.
NO
T5-4-24
• Boom Cylinder Internal Leakage Check
Backhoe
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.
Then, drain oil from hoses and cylinders. (Plug the
disconnected hose ports.)
T142-05-03-014
3. Retract the arm cylinder to lift the bucket above
the ground.
Loading Shovel
1. With the arm cylinder retracted a short a short dis-
tance from the stroke end, lower the bucket teeth
onto the ground a illustrated to the right.
2. Disconnect the hydraulic hoses from the boom
cylinder rod side. Drain hydraulic oil from the cyl-
inders and hoses. (Plug the disconnected hose
ends.)
3. Extend the bucket cylinder to raise the bucket
above the ground.
T142-05-03-014
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.
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 (B)
malfunctioning, the oil in the bottom side
of the boom cylinder flows back into the When the load check
circuit through the load check valve, valve is malfunctioning:
(A)
causing the boom cylinder to
temporarily retract.
2. If the clearance between the piston and
the cylinder barrel is poor, oil pressure in
the bottom side (A) leaks to rod side (B).
As oil pressure and flow rate from the
pump is low during the initial stage of
operation, and if the amount of oil leak-
ing through the gap between the piston T105-07-04-012
and the barrel is large, the cylinder is
temporarily retracted. In addition, cylin-
der force is reduced. In this case, the
cylinder drift is also increased
T5-4-25
F-4 Power does not increase with power boost
switch turned on.
Precondition:
troubleshooting.
• Refer to the heading “Power Boost” in the Control
System group, the SYSTEM section, the
Technical Manual (Operating Principle).
2
Pressure increases
2
from 300 kgf/cm or
2
less to 325 kgf/cm .
Normal
Power boost
switch failure or
NO harness breakage
Monitor delivery
between power
pressure for
boost switch and
pumps 1 and 2.
PVC.
·Monitor items #1-F7
#3-F7 Monitor power
·Push the power boost Disconnect the
boost switch.
switch to monitor harness end from YES Solenoid valve SA
Check if the let-
change in pressure. Pressure solenoid valve SA. failure.
ters “ON” turn
does not Connect test har-
reverse video
Pressure when the power change. ness (ST7123)
does not boost switch is between solenoid
increase. pressed. valve SA and the
harness end. Harness failure
Measure the pilot Check if the test between solenoid
·Monitor items
pressure at sole- harness lamps NO valve SA and PVC.
#7-F6
noid valve SA port come on.
in the solenoid
YES valve unit (3 sole- ·Power boost switch: ON
noid valves used).
·Push the power

boost switch to ob- Main relief valve
serve pressure Pressure changes from 0 failure.
2
change. to max. 40 kgf/cm .
·Refer to the PER-
FORMANCE TEST
section for the
measurement pro-
cedure.
T5-4-26
(Blank)
T5-4-27
SWING SYSTEM TROUBLESHOOTING
S-1 Upperstructure does not rotate, rotates
slowly, or swing power is weak.
Precondition:
troubleshooting.
• If other functions (front attachment and travel)
operate normally, the pilot pump is considered to
be normal. If the pilot system has failed, the
trouble exists in the pilot circuit after the pilot
pump (the pilot valve and thereafter).
YES Check if swing relief

pressure is normal.
Performance Test sec-
Check if oil quantity tion for swing relief
YES draining from pressure measurement
swing motor is procedure.
normal.
Monitor DP sensor ·Refer to Opera-
pressure. Operate tional Performance
control lever slowly Test section for Swing motor failure.
YES
to the stroke end swing motor drain- NO
and check if DP ing oil quantity
sensor pressure measurement pro-
changes smoothly. cedure.
Check if secondary Control valve spool
pilot pressure is NO sticking.
normal.
Performance Test NO Pilot valve failure.
section for secon-
dary pilot pressure
measurement pro- Disassemble, clean,
cedure. and reassemble the
NO pilot valve. Check if
the trouble still exists.
Check if sticking or sei-
zure exists in swing
YES shuttle valve.
T5-4-28
2
Failure of swing over-

YES load relief valve located
in control valve.
Switch swing motor
NO relief valve with the
other swing relief
valve. Check if the
trouble still exists.
Corresponding swing
relief valve failure.
NO
Swing reduction gear

YES failure.
YES Swing shuttle valve

failure.
Swing preference circuit

Check if the swing NO shift solenoid valve fail-
preference circuit shift ure (sticking or seizure).
solenoid valve indica-
tion (On) turns reverse
video when
NO swing/boom raise
functions are operated
simultaneously. Harness breakage be-
tween the PVC and
·Monitor item: #6-F8 swing preference circuit
YES
shift solenoid valve.
T5-4-29
S-2 Upperstructure coasts excessively when
stopping swing operation or when machine is
parked on a slope.
• If upperstructure jerks when coasting, valve
related failure is suspected. If it coasts smoothly
(but excessively), spool related failure is
suspected.
YES Swing motor failure.

Monitor DP sensor
pressure. Operate
control lever slowly
YES
to the stroke end
and check if DP
sensor pressure
changes smoothly. Swing spool failure.
Check if swing sec-
ondary pilot pres- ·Monitor item #3-F6 NO
YES sure is 0 kgf/cm
2
with swing lever in

neutral.
Performance Test Pilot valve failure.
Check if swing re- section for swing NO
lief pressure is secondary pilot pres-
normal. sure measurement
procedure.
·Refer to Opera-
tional Perform-
ance Test section Failure of overload relief
for swing relief valve in control valve, or
pressure meas- swing relief valve failure.
NO
urement proce-
dure.
T5-4-30
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Both tracks move slowly.
• It is unlikely that both sides (left and right) of the Note, however, that the front attachment operation
pilot valves, travel motors, or travel control valve will also have difficulty if the primary pilot pressure
spools fail simultaneously. If both tracks are slow, is abnormal. (Refer to troubleshooting A-1.)
the pilot system which is commonly used for left
and right travel motors may have failed. 2
NO Restriction of filter located at
outlet of pilot shut-off valve.
Check if pilot valve inlet pres-
NO Travel pilot valve failure.
sure is normal.
·Engine: Running Check if secondary travel pilot
·In SP mode: more than 40 YES pressure is normal.
2 Go to Troubleshooting A-1.
kgf/cm ·Engine: Running YES
·In SP mode: more than 35
2
kgf/cm
T-2 Travel mode does not shift.
Precondition:
troubleshooting.
• The switch circuit may have failed if the travel If the indicator shifts but actual travel mode (speed)
mode indicator does not shift in accordance to the does not shift, the travel motor displacement angle
travel mode switch operation. shift circuit may have failed.
2
Switch failure, or har-

NO ness breakage be-
tween switch and
PVC.
Check if monitor
indicates Hi and Lo NO PVC failure.
alternately when
travel mode switch
is operated.
Check if travel Travel mode shift
·Monitor items #7-F7 mode shift solenoid solenoid valve failure,
·Key switch: ON valve shifts as travel NO or harness failure
YES mode switch is op- between PVC and
erated. travel mode shift so-
lenoid valve.
·Monitor items #6-F6 Check if travel mode
shift pressure (SB) is
YES normal. YES Travel motor dis-
Check if sticking or placement angle shift
·SP mode valve failure.
·Auto-idle: OFF seizure exists in
·Refer to Operational Per- travel motor dis-
YES placement angle Failure of travel mo-
formance Test section for
SB pressure measure- shift valve. tor or travel reduction
ment procedure. gear.
NO
T5-4-31
T-3 Machine mistracks.
Precondition: Checking Instruction:

• Be sure inspect wiring connections prior to • Refer to troubleshooting A-2 if swing or bucket
troubleshooting. function is slow in addition.
• The flow combiner valve may have failed if
machine mistracks only during front attachment
function combined operations.
NO Shuttle valve failure.

Disassemble, clean,
NO and reassemble travel
shuttle valve. Check if
the trouble still exists. Pilot valve failure.
YES
Check if secondary
travel pilot pres-
sure is normal. Operate left and right NO DP sensor failure.
travel levers the
·SP mode same distance and
·Travel lever: full check if pump target
stroke displacement angle YES P sensor failure.
·Refer to Opera- on 5-spool side is the
tional Perform- Switch the P sen-
YES same as that on 4-
ance Test section sor on 5-spool side
spool side. with that on 4-
for travel secon-
dary pilot pres- spool side. Check Switch the left and right
sure measure- Ȁ #4-F6 YES if machine mis- travel hoses with each
ment procedure. tracks in the oppo- other at the upper side
site direction. of center joint. Check if
NO machine mistracks to
Seal Location
Relation between Faulty Seal Position
and Mistrack Direction 1
Seal 2
Traveling Pivot Turn
NO.
1 External oil leakage ←
2 Right Travel
(Reverse)
Left Travel
(Forward)
3
3 Right Travel
(Forward)
Left Travel
(Reverse)
4
4 5
6
7
6
7 External oil leakage ←
T142-06-04-017
T5-4-32
Disassemble, NO Control valve spool

clean, reassemble sticking.
YES corresponding
spool in control Control valve fail-
valve. Check if the ure (internal leak),
trouble still exists. A sensor failure, or
YES main pump failure.
YES Travel relief valve

Switch the right and left travel
NO relief valves with each other. failure.
Check if machine mistracks in Center joint failure.
NO
Check if slower-
NO Travel motor fail-
side travel relief
NO pressure is normal. ure.
Check if quantity
of oil draining from
·Refer to Opera- YES Travel brake valve
tional Perform- YES travel motor is Disassemble failure.
normal. travel motor
ance Test section
·Refer to Operational brake valve
for travel relief Remove travel YES Travel motor tilt
pressure meas- Performance Test YES and check if
any abnormali- motor tilt pistons piston failure.
urement proce- section for travel mo-
ties are found. and check if any
dure. tor drain oil quantity NO abnormalities are Travel reduction
measurement proce-
dure.
found. NO gear failure.
Travel Hose Connections

2
1
3
4
1- Left Travel Reverse

2- Left Travel Forward
3- Right Travel Reverse
4- Right Travel Forward
5- Pilot Hose (Travel Mode Shift)
6 6- Drain Hose
M162-07-071
T5-4-33
TROUBLESHOOTING FOR OTHER FUNC-
TIONS
O-1 Work mode does not shift.
Precondition:
troubleshooting.
• The work mode switch may have failed if the work
mode indicators do not shift with the work mode
switch. The pressure switch or solenoid valve may
have failed if the work mode indicators shift but
actual work mode does not shift.
Disconnect the harness

end from swing prefer- YES
ence circuit shift solenoid Solenoid valve failure.
valve, solenoid valve,
and main relief pressure
YES shift solenoid valve one
by one. Connect test
Monitor pressure
harness (ST 7123) be-
switches (travel, Harness breakage be-
tween each solenoid
swing, boom raise, tween solenoid valve
valve and harness end,
arm roll-in, and oth- NO and PVC.
and check if harness
YES ers). lamp comes on.
Check if letters “Bm”,
“Tr”, “Sw”, “Am”, and
“Ot” turn reverse YES Pressure switch failure.
video when respec- end from each pressure
tive control lever is switch one by one. Con-
Monitor work mode
operated. nect test harness (ST
switch. Check if work
mode letters turn ·Monitor item #8-F6 NO 7123) between each
reverse video when pressure switch and har-
work mode switch is ness end, and check if Harness breakage be-
operated. harness lamp comes on. tween PVC and pres-
NO sure switch.
Work mode switch fail-

NO ure.
NOTE:
Work Mode Designed Application
General Purpose Mode Designed for general digging and truck loading.
Attachment Mode Select this mode when using breakers.
Precision Mode All front functions are slow for easy load lifting work.
Trenching Mode Swing is given priority in swing/boom raise combined operation.
T5-4-34
O-2 Pump emits abnormal sound or vibration.
Precondition:
troubleshooting.
YES Main pump failure.
YES Main pump failure.

Check if indicated
pump displace-
ment angle value Check if indicated
stays stable. pump differential
YES pressure and pump
pressure values NO DP sensor or P sen-
·Monitor items #1-F8 stay stable. Replace the sensor failure.
#3-F8 sor obtained un-
·Monitor items stable values and
Check if A sensor #1-F6, F7 NO check if the trouble
is installed se- #3-F6, F7 still exists.
NO curely. Main pump failure.
·Replace DP sen- YES
·Refer to T5-4-40. sor and/or P sen-
sor.
Insecure A sensor
NO installation.
·Refer to T5-4-40
T5-4-35
O-3 Wiper does not operate or does not retract.
Precondition:
troubleshooting.
• Wiper is operated by battery power via the relay
circuit. The relay circuit is closed/opened at the
monitor assembly. For this reason, if wiper does
not move, check if wiper motor and link functions
using the auxiliary power source and test harness.
YES Wiper relay failure.

Remove test harness
and reconnect the har-
ness end. Replace re-
YES lays one by one with
new ones. Check if
wiper operates each YES End.
time a relay is replaced.
Replace monitor as-
Connect test harness ·Key switch: ON sembly. Check if wiper
(Parts Number 3073259) NO operates.
between auxiliary power
Cab harness failure.
source (fuse box #20)
and wiper motor as illus- NO
trated on the next page.
Check if wiper operates.
·Key switch: ON
Wiper motor or link fail-
No or lamps does not light as indicated in the note. ure.
NOTE: If wiper motor is normal, lamp S comes

on while wiper operates in wiping range.
In addition, lamps B and S come on
momentary when wiper comes to inter-
mittent stop position.
T5-4-36
Electrical Circuit When Test Harness is Connected.
Fuse Box #20
Lamp S
Lamp B Wiper Motor
Ground
T157-07-04-002
Wiper's Operating Range

Intermittent Stop Position
Retracted Position
Wiping Range
T157-07-04-003
Test Harness Connection
Wiper Motor Lamp B
Lamp S
Test Harness Fuse Box
T157-07-04-004
T5-4-37
O-4 Counter Weight removal cylinder moves
slowly or does not move.
NO Move lock valve to UN-

LOCK position.
Check if lock valve is

UNLOCK position. NO
Pilot valve failure.
Check if secondary pilot NO Holding valve or slow

YES pressure is normal. Remove holding valve return valve failure.
·Refer to OPERATIONAL and slow return valve.
PERFORMANCE TEST Disassemble, clean, reas-
section for pressure YES semble, and reinstall then.
measurement procedure. Check if failure phenome-
non happens again.
YES
2
3
4 1- Counter Weight Removal Cylinder

2- Lock Valve
3- Holding Valve
4- Slow Return Valve
M116-06-022
T5-4-38
EC SENSOR INSTALLATION AND
VOLTAGE ADJUSTMENT
1. Install M8 bolt into the T link positioning hole. Note Control Cable
that this position will be the idle position.
2. Temporarily connect EC sensor at the middle of
the EC sensor mounting slit. Connect the
connector.
3. Connect Dr. EX to the monitor terminal. Install test
harness (ST 7129) between EC sensor and har-
ness.
4. Turn the key switch to the ON position. Turn the
engine control dial to the slow idle position.
Measure the EC sensor output voltage using Dr.
EX or a digital type tester.
5. Adjust EC sensor position so that the output
voltage is within the specified range. Secure EC
sensor.
Specified Voltage: 2.50±0.05 V
T Link Positioning Hole T Link
T107-04-05-013
T5-4-39
INSTALLATION AND ADJUSTMENT OF
THE A SENSOR
1
Removal
1. Put matching mark on the A sensor and pump
housing. Remove the A sensor connector from its
harness.
2. Remove two A sensor mounting bolts (1) and

washers (2).
3. Remove the A sensor. Take care not to lose

internal spacer (3) and fastener spring (4). O-ring
(5) is provided on the A sensor side.
Installation and Adjustment

1. Apply a film of grease to the surface of fastener T111-04-05-001
spring (4) and install it into the cavity on the
feedback shaft end. 3
2. With the key switch turned OFF, connect the

4
connector of the A sensor. Then, connect the Dr.
EX to the diagnosing connector located in the
operator's cab.
3. Start the engine and operate it in the slow idle

speed. Maintain hydraulic oil temperature at 50±5
°C (122±9 °F).
4. Operate the Dr. EX. Select information for “A

Sensor Mounting Angle Adjustment” (Push F3
key). Then, increase displacement angle to the T107-04-05-010
maximum by pushing F1 key on the next display.

Wait about one second. The pump displacement
angle is set to the maximum.
5. Select information for “Monitor Data”. Then, push

F8 key to indicate the approx. Pump displacement
(D4 or D5) on the next display.
5
6. Before installing the A sensor to the pump, turn
the punch mark on the A sensor shaft towards the 3
opposite side of the harness so that the reading of Punch Mark FeedbackShaft
Feedback Shaft
the Dr.EX display indicates 180 mL/rev. 4 T107-04-05-011
7. Insert the A sensor shaft into the feedback shaft Front

and tentatively tighten bolts (1). The bolt holes of Harness Side
the A sensor are made in a ellipse form. Adjust
the A sensor position using ellipse holes so that
the reading of 1-F8 (D4) and/or 3-F8 (D5) on the
Dr. EX display indicates 183±3 mL/rev. Engine
8. Tighten bolts (1) and washers (2) to 9.8 Nxm (1.0 4-Spool Side 5-Spool Side
kgf⋅m, 7.2 lbf⋅ft).
Main Pump
T111-04-05-002
T5-4-40
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 checking or measuring item (1), select either YES
• (OK) or NO (NOT OK) and proceed to item (2) or (3), as
(1) appropriate.
(3)
NO (NOT OK)
•
Incorrect measuring or checking methods will render troubleshooting impossible,
and may damage components as well.
·Key switch: ON
• Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
•
causes can be seen without going through the flow chart.

Harness Side
Open End
Side
T158-05-03-001
T5-5-1
MALFUNCTION OF COOLANT TEMPERA-
TURE GAUGE
Precondition:
• Be sure to inspect wiring connections prior to
troubleshooting.
YES
Disconnect coolant tempera-
Gauge pointer does not move ture sensor terminal. Ground
at all. (It does not rise from harness end terminal to vehi- With coolant temperature sen-
zero.) cle frame. Does pointer swing sor terminal disconnected,
to the (H) side? disconnect 20P connector
NO from monitor. Check if continu-
·Key switch: ON ity exists between terminal No.
47 and sensor terminal.
YES
Gauge pointer swings over ture sensor terminal. Does With coolant temperature
scale. pointer swing back to zero? sensor terminal disconnected,
disconnect 20P connector
from monitor. Check if continu-
·Key switch: ON NO ity exists between harness
end terminal and vehicle
frame.
YES
ture sensor terminal. Ground
Gauge pointer swings over harness end terminal to vehi-
scale. cle frame. Does pointer swing
to the (H) side?
·Key switch: ON NO
T5-5-2
Approximate temperature on
Coolant temperature sensor Coolant Temperature Gauge
failure
105 °C (221 °F)
YES Monitor failure 101 °C (214 °F)
70 °C (158 °F)
NO monitor and sensor
T162-05-05-003
Coolant Temperature Sensor
Coolant temperature sensor Coolant Resistance

failure
Temperature Ω
YES Short circuit between monitor °C (°F)
and sensor 50 (122) 153.9
80 (176) 51.9±10
Monitor failure 100 (212) 27.4±4
NO 120 (248) 16.1
Connector
(Harness end connector terminals seen from the open
Coolant temperature sensor end side)
failure
Monitor (20P)
29 30 31 32 33 34 35 36 37 38
Monitor failure 39 40 41 42 43 44 45 46 47 48
T5-5-3
MALFUNCTION OF FUEL GAUGE
Precondition:
troubleshooting.
Disconnect connector from YES

fuel level sensor. Connect
Gauge pointer does not move harness end connector termi-
at all. (It does not rise from nals No. 1 and No. 2 using a With sensor connector dis-
zero.) clip. Does pointer swing to the connected, disconnect 20P
(F) side? connector from monitor.
NO Check if continuity exists be-
·Key switch: ON tween monitor terminal No. 46
and sensor terminal No. 2.
YES
Disconnect the connector from

Gauge pointer swings over fuel level sensor. Does pointer With sensor connector dis-
scale. swing back to zero? connected, disconnect 20P
connector from monitor.
·Key switch: ON Check if continuity exists be-
NO
tween sensor terminal No. 2
and vehicle frame.
Disconnect connector from YES

fuel level sensor. Connect
Gauge pointer swings unstably. harness end connector termi-
nals No. 1 and No. 2 using a
clip. Does pointer swing to the
(F) side?
NO
·Key switch: ON
T5-5-4
Fuel Level Sensor
Float
FULL
Fuel level sensor failure
257
YES Monitor failure mm
53°
R381.9
70.5
mm
NO monitor and sensor
1/2 51°
338
mm
EMPTY

T162-05-05-001
YES Short circuit between monitor

and sensor
Resistance
Float Position
Monitor failure Ω
NO FULL
+0
10 –4
3/4 26
1/2 38±5
1/4 53
+10
EMPTY 90 –0
Connector
Monitor failure (Harness end connector terminals seen from the open
end side)
Monitor (20P) Fuel Level Sensor
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48 1 2
T5-5-5
MALFUNCTION OF INDICATOR BULB
CHECK SYSTEM
Precondition:
troubleshooting.
YES Check power line:

·Check fuse.
·Disconnect 20 P connector
from monitor. Check if conti-
nuity exists between harness
Indicators do not come on end 20P connector terminal
when key switch is turn to ON Check if all indicators fail to
No. 30 and fuse No. 8 termi-
position. come on.
nal.
Troubleshoot individual indica-

NO tors which failed to come on.
Connector
end side)
Monitor (20P)
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48
MALFUNCTION OF LEVEL CHECK

SWITCH
• This troubleshooting flow chart can be applied to a

level check switch malfunction only. If power is not
supplied at all when the key switch is turned ON,
or if any level indicators fail to light during the bulb
check, troubleshoot these failures first.
Precondition:
• Park the machine on a level surface.
troubleshooting. YES
Level check switch
failure or harness
breakage.
YES Check if oil and
coolant levels are
normal. Add engine oil,
Level indicators do hydraulic oil,
not come on when Check if all level and/or coolant as
NO
level check switch indicators do not necessary.
is pressed. come on.
Troubleshoot each
NO failed indicator (s).
T5-5-6
(Blank)
T5-5-7
MALFUNCTION OF ENGINE OIL LEVEL
INDICATOR
Precondition:
• The engine oil level indicator bulb has not blown.
• Other indicators are functioning normally.
troubleshooting.
Reconnect engine YES

oil level switch
connector. Discon-
nect 12P connector
YES from monitor.
Disconnect engine Check if continuity
oil level switch exists between
Engine oil level harness end 12P
connector. Check if
indicator does not connector terminal
continuity exists
come on when No. 7 and vehicle
between engine oil NO
level check switch frame.
level switch con-
is pressed.
nector and vehicle
frame.
NO
With engine oil

level switch con-
nector discon-
nected, disconnect
Disconnect engine YES 12P connector
oil level switch from monitor.
Check if continuity
3 mm or more connector. Press exists between
level check switch.
Check if engine oil harness end 12P
Although engine oil Check engine oil connector terminal
level on the dip- level indicator
is insufficient, en- comes on. No. 7 and vehicle
gine oil level indica- stick. How many frame.
tor comes on when millimeters is the
level check switch oil level higher than
is pressed. the LOW mark line NO
on the dipstick?
Less than 3 mm
T5-5-8
Engine Oil Level Switch
Monitor failure
H (Indicator
ON)
L
Harness breakage 3 mm (Indicator

(0.12 in) OFF)
Engine oil level switch failure T166-05-05-001
Connector
YES end side)
Short circuit between engine
oil level switch and monitor
Monitor (12P)
1 2 3 4 5 6
7 8 9 10 11 12
Monitor failure
NO
Engine oil level switch failure
Normal
T5-5-9
MALFUNCTION OF COOLANT LEVEL
INDICATOR
Precondition:
• The bulb of the coolant level indicator has not
blown.
troubleshooting.
Re-connect coolant YES

level switch 3P con-
nector. Disconnect
12P connector from
YES monitor. Check if
continuity exists
between harness
end 12P connector
Disconnect coolant terminal No. 8 and
Coolant level indi- level switch 3P vehicle frame. NO
cator does not connector. Check if
come on when continuity exists ·Be sure that
level check switch between coolant coolant level
is pressed. level switch 3P switch 3P con-
connector termi- nector is re-
nals. connected.
NO
With coolant level

switch connector
disconnected, dis-
connect 12P con-
Disconnect coolant YES nector from monitor.
level switch connec- Check if continuity
tor. Press level exists between har-
YES check switch. ness end 12P con-
Check if coolant nector terminal No.8
Although coolant level indicator and vehicle frame.
is insufficient, cool- Check if coolant comes on.
ant level indicator level on reservoir is
comes on when lower than LOW
level check switch mark.
is pressed. NO
NO
T5-5-10
Coolant Level Switch
Reservoir
Monitor failure
ON
FULL
LOW
Radiator
OFF
Harness breakage
T107-04-03-012
Coolant level switch failure
Connector (harness end connector terminals seen

from the open end side)
YES Short circuit between coolant
level switch and monitor
Monitor (12P)
1 2 3 4 5 6
7 8 9 10 11 12
Monitor failure
NO Coolant Level Switch
Coolant level switch failure

3
1 2
Normal
T5-5-11
MALFUNCTION OF HYDRAULIC OIL
LEVEL INDICATOR
Precondition:
• The bulb of the hydraulic oil level indicator has not
blown.
troubleshooting.
Reconnect hydraulic YES

oil level switch 2P
connector. Discon-
nect 12P connector
YES from monitor. Check
Disconnect hydrau- if continuity exists
Hydraulic oil level lic oil level switch between harness
indicator does not 2P connector. end 12P connector
come on when Check if continuity terminal No. 9 and
level check switch exists between vehicle frame. NO
is pressed. hydraulic oil level
switch 2P connec-
tor terminals.
NO
With hydraulic oil

level switch connec-
tor disconnected,
disconnect 12P
connector from
Disconnect hydrau- YES
monitor. Check if
lic oil level switch continuity exists
NO connector. Press between harness
level check switch. end 12P connector
Although hydraulic Check if hydraulic terminal No.9 and
oil is insufficient, Check oil level on oil level indicator vehicle frame.
hydraulic oil level the level gauge. comes on.
indicator comes on Check if oil can be
when level check seen on the level
switch is pressed. gauge. NO
YES
T5-5-12
Hydraulic Oil Level Switch
Monitor failure
ON
6.2 mm
(0.24 in)
Harness breakage
OFF
Hydraulic oil level switch fail-

ure
T137-04-04-001
YES Short circuit between hydrau-

lic oil level switch and monitor
Connector
end side)
Monitor failure Monitor (12P)

NO
1 2 3 4 5 6
Hydraulic oil level switch fail- 7 8 9 10 11 12
ure
Normal
Hydraulic Oil Level Switch
1 2
T5-5-13
MALFUNCTION OF ALTERNATOR INDICA-
TOR
Precondition:
troubleshooting.
Less than 1V Alternator failure
Alternator indicator Check voltage at alter-

does not go out after nator terminal L.
engine is started. YES Monitor failure
·Engine: Running
·Engine: Running ·Measure from con-
nector reverse face Check if voltage at
without disconnecting monitor 20P con-
connector. nector terminal
More than No. 42 is more
15V than 15 V.
Harness breakage
·Key switch: ON between the moni-
·Engine: Running NO tor and alternator.
More than 10 V Regulator failure
Check voltage YES

YES Monitor failure
at alternator
terminal L.
·Engine: Stopped Check if voltage at
·Measure from con- monitor 20P con-
Check if alternator nector reverse face nector terminal No.
Although alternator Less
indicator comes without disconnect- than 42 is less than 10 V.
output is low, alter- Harness breakage
on when key ing connector. 10 V
nator indicator does ·Key switch: ON between the alter-
switch is turned
not come on. ·Engine: Stopped NO nator and monitor.
ON.
·Key switch: ON
·Engine: Stopped
Blown alternator
NO indicator bulb.
Connector
end side)
Monitor (20P) Alternator
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48 1 2 3
T5-5-14
MALFUNCTION OF ENGINE OIL PRES-
SURE INDICATOR
Precondition:
troubleshooting.
YES Engine oil pres-

Disconnect engine
oil pressure switch sure switch failure
terminals. Ground
the harness end (+) Harness breakage
YES terminal (white line YES between monitor
with blue stripe) to and engine oil
vehicle frame. Connect the monitor
12P connector ter- pressure switchϔ
Check if engine oil
pressure indicator minal to vehicle
comes on. NO frame. Check if en-
gine oil pressure
·Key switch: ON indicator comes on. Monitor failure
Although engine oil ·Reconnect engine
Check if engine oil ·Key switch: ON NO
pressure is insuffi- oil pressure switch
pressure indicator ·Insert a clip from the
cient, engine oil terminals after the
comes on when key back of 12P connec-
pressure indicator checking.
switch is turned ON. tor to reach the ter-
does not come on.
minal. Ground the
·Key switch: ON
other end of the clip
·Engine: Stopped
to vehicle frame.
·Engine oil pressure
may remain 1 to 2
minutes after en- Blown indicator
gine stops. This is bulb
normal. NO
Engine oil pres-

YES sure switch failure,
engine oil system
failure, or oil filter
clogging.
Engine oil pressure Disconnect engine oil

pressure switch. Check if Short circuit be-
indicator does not
engine oil pressure indica- YES tween monitor and
go off after engine is
tor goes off. engine oil pressure
started.
Reconnect engine oil switch.
·Check oil filter for ·Key switch: ON pressure switch. Discon-
clogging. ·Engine: Stopped nect 12P connector from
monitor. Check if continu-
NO ity exists between har-
ness end 12P connector
terminal No. 10 and vehi- Monitor failure
cle frame.
NO
Connector
(Harness end connector terminals seen from the open Engine Pressure Switch
end side)
Approximate ON/OFF
Indicator
Threshold Pressure
Monitor (12P)
2
Less than 29.4 kPa (0.3 kgf/cm ) ON
1 2 3 4 5 6 2
7 8 9 10 11 12 More than 29.4 kPa (0.3 kgf/cm ) OFF
T5-5-15
MALFUNCTION OF OVERHEAT INDICA-
TOR
Precondition:
troubleshooting.
YES Overheat switch H

failure.
Disconnect over-
heat switch H termi- Harness breakage
nal. Ground the YES between monitor
YES
harness end termi- Reconnect overheat and overheat
nal to vehicle frame. switch H terminal. switch H.
Check if overheat Connect the monitor
indicator comes on. 12P connector ter-
·Key switch: ON NO minal No. 1 to vehi-
·Engine: Stopped cle frame. Check if
overheat indicator Monitor failure.
comes on. NO
Although engine Check if overheat
overheats, overheat indicator comes on ·Key switch: ON
indicator does not when key switch is ·Engine: Stopped
come on. turned ON. ·Insert a clip from the
back of 12P connector
·Key switch: ON
to reach the terminal.
·Engine: Stopped
Ground the other end
of the clip to vehicle
frame.
Blown indicator
NO bulb.
YES
Overheat switch H
failure.
Overheat indicator Disconnect overheat

comes on even switch H. Check if over- Short circuit be-
YES
when coolant tem- heat indicator goes off. tween monitor and
perature is low. overheat switch H.
·Key switch: ON With overheat switch H
·Engine: Stopped disconnected, disconnect
12P connector from moni-
tor. Check if continuity
NO exists between 12P con-
nector terminal No. 1 and
vehicle frame. Monitor failure
NO
Connector
(Harness end connector terminals seen from the open Overheat Switch
end side)
ON/OFF Threshold Coolant
Indicator
Temperature
Monitor (12P)
Lower than 101 °C (214 °F) OFF
1 2 3 4 5 6
7 8 9 10 11 12 101°C (214 °F) or higher ON
T5-5-16
MALFUNCTION OF FUEL LEVEL INDICA-
TOR
Precondition:
troubleshooting.
YES Fuel level switch

failure.
Disconnect the har-
ness end plug from
the fuel level switch YES Monitor failure
YES harness. Ground the Re-connect the har-
harness end termi- ness end plug.
nal to vehicle frame. Disconnect 12P
Check if fuel level connector from
indicator comes on. monitor. Check if
NO continuity exists be-
·Key switch: ON Harness breakage
Although fuel gauge Check if fuel level ·Engine: Stopped tween 12P connec-
indicates “E”, fuel between monitor
indicator comes on tor terminal No. 2
level indicator does NO and fuel level
when key switch is and vehicle frame.
not come on. switch.
turned ON.
·Key switch: ON
·Engine: Stopped
Blown indicator
NO bulb.
YES
Fuel level switch
failure.

Fuel level indicator end plug from the fuel Short circuit be-
comes on even level switch harness. YES tween monitor and
when fuel is suffi- Check if fuel level indica- fuel level switch.
cient. tor goes off. With fuel level switch
(harness end plug) dis-
·Key switch: ON connected, disconnect
·Engine: Stopped 12P connector from moni-
NO tor. Check if continuity
exists between 12P con-
nector terminal No. 2 and Monitor failure
vehicle frame.
NO
Connector Fuel Level Switch

end side) Magnet
OFF Float
Fuel Level
Monitor (12P)
1 2 3 4 5 6 112.5±5 mm ON
(4.4±0.2 in) M22×1.5
7 8 9 10 11 12
T107-04-03-019
T5-5-17
MALFUNCTION OF AIR FILTER RESTRIC-
TION INDICATOR
Precondition:
troubleshooting.
Disconnect the har- YES Air filter restriction

ness end plug from switch failure.
the air filter restric-
tion switch. Ground
the harness end (+) YES Monitor failure
YES Re-connect the har-
terminal (Blue line
ness end plug.
with green stripe) to
Disconnect 12P
vehicle frame.
connector from
Check if air filter
monitor. Check if
restriction indicator NO continuity exists
comes on. Harness breakage
Although air filter is Check if air filter re- between 12 connec-
·Key switch: ON tor terminal No. 3 between monitor
clogged, air filter striction indicator
·Engine: Stopped and vehicle frame. NO and air filter restric-
restriction indicator comes on when key
tion switch.
does not come on. switch is turned ON.
·Key switch: ON
·Engine: Stopped
Blown indicator
NO bulb.
YES Air filter restriction

switch failure.

Although air filter is end plug from the air filter Short circuit be-
not clogged, air filter restriction switch. Check if YES tween monitor and
restriction indicator air filter restriction indica- air filter restriction
comes on. tor goes off. With air filter restriction switch.
switch disconnected, dis-
·Remove and visu-
·Key switch: ON connect 12P connector
ally check the air fil-
·Engine: Stopped from monitor. Check if con-
ter.
tinuity exists between har-
·Confirm that the air NO ness end 12P connector
filter is not damp.
terminal No. 3 and vehicle
Monitor failure
frame.
NO
Connector
(Harness end connector terminals seen from the open Air Filter Restriction Switch
end side)
Indicator ON/OFF Pressure Indicator
Monitor (12P)
5.1 kPa (520 mm H2O) OFF
1 2 3 4 5 6 6.2 kPa (630 mm H2O) ON
7 8 9 10 11 12
T5-5-18
MALFUNCTION OF HOUR METER
Precondition:
troubleshooting.
Harness breakage
between monitor
0V terminal No. 29
and fuse No. 8.
Check voltage at
NO the monitor 20P
connector terminal
No. 29.
Monitor failure
24V
Hour meter does not
count operating Check if alternator
hours with engine indicator is on.
running. More than 20V
Monitor failure
·Engine:Running
Check voltage at
the monitor 20P Harness failure
connector terminal between alternator
YES No. 42. YES
terminal L and
·Key switch: ON monitor terminal
·Engine: Stopped No. 42.
Check if voltage at
alternator terminal L
Less is more than 20 V.
than
1V ·Engine: Running Alternator failure
·Measure from con- NO
nector reverse face
without disconnect-
ing connector.
Connector
(Harness end connector terminals seen from the open end side)
Monitor (20P) Alternator
29 30 31 32 33 34 35 36 37 38
1 2 3
39 40 41 42 43 44 45 46 47 48
T5-5-19
MALFUNCTION OF BUZZER
Precondition:
troubleshooting.
More than 20 V Monitor failure

Buzzer starts sound-
Check voltage at
ing when key switch
monitor 20P connec-
is turned to ON posi-
tor terminal No. 42.
tion.
Alternator failure
·Key switch: ON
·Engine: Running Less than
1V
Engine oil pres-

YES sure system failure
Buzzer starts sound-

Check if engine oil
ing when engine
pressure indicator is
starts. YES Engine overheat
on.
Check if overheat
NO indicator is on. Check if buzzer
stops when buzzer
stop switch is
NO pressed.
NO Normal
Although engine oil

pressure indicator or Check if engine is run-
overheat indicator -1
ning at 800 min (rpm)
has turned on, NO Normal
or higher.
buzzer does not
sound.
Check if alternator
YES indicator is on. Check voltage at
monitor 20P con-
nector terminal
YES No.42.
·Key switch: ON
·Engine: Running
T5-5-20
Connector
end side)
Monitor (20P)
29 30 31 32 33 34 35 36 37 38
39 40 41 42 43 44 45 46 47 48
YES
Normal
Monitor failure
NO
20 V or more
Monitor failure
Alternator failure or
harness failure
between alternator
Less than 20 V terminal L and
monitor terminal
No. 42.
T5-5-21
MALFUNCTION OF WORK LIGHT INDICA-
TOR
Precondition:
troubleshooting.
Harness breakage
YES between work light
Check if work lights switch and moni-
YES turn on when work tor.
light switch is
turned on.
Work light indicator Check if work light Work light switch
does not come on indicator comes on NO failure.
when work light when key switch is
switch is turned on. turned to ON posi-
tion. Blown indicator
bulb or monitor
NO failure.
T5-5-22
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source. 3. Precautions for connecting and disconnecting

Be sure to remove the negative terminals from the terminal connectors.
batteries first when taking wire harnesses and 1) When disconnecting harnesses, grasp them
connectors off for repair or replacement work. by their connectors. Do not pull on the wire
Failure to do so can result in damage to the wire itself. Be sure to release the lock first before
harnesses, fuses, and fusible links and, in some attempting to separate connectors, if a lock is
cases, cause fire due to short circuiting. provided. (Refer to “Instructions for
2. Color coding of wire harnesses. Disconnecting Connector" on page T5-6-3.)
The color codes of the wire harnesses in the 2) Water-resistant connectors keep water out so
electrical system are shown below. that if water enters them, water will not easily
In cases on the design sheet where two colors are drain from them. When checking water-
indicated for one wire, the left initial stands for the resistant connectors, take extra care not to
base color, while the right initial stands for the allow water to enter the connectors. In case
marking color. water should enter the connectors, reconnect
only after the connectors are thoroughly dried.
Codes Color Codes Color 3) Before connecting terminal connectors, check
R Red W White that no terminals are bent or coming off. In
L Blue G Green addition, check that no terminals are rusting.
Or Orange Lg Light green 4) When connecting terminal connectors
Y Yellow B Black provided with a lock, be sure to insert them
Br Brown P Pink together until the lock “clicks."
Gr Gray V Violet
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 T107-07-06-001
not to confuse them with color coded
wires.
Right
Rust
Wrong
(Bent)
Wrong
(Coming of, Separation)
T107-07-06-002
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. Wind a Piece of Wire Tester Probe
Then, set the circuit tester to meet the object
to be measured, voltage range and current
polarity.
2) Before starting the connector test, always Sharpen the End of the Wire
T107-07-06-003
check the connector terminal numbers,
referring to the circuit diagram.
When the connector size is very small, and the
standard probe size is too large to be used for
testing, wind a fine piece of sharpened wire or
a pin around the probe to make the test easier.
T5-6-2
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
• Push the lock to disconnect
NOTE: 1) Connector may not separate if the lock

is pushed while the connector is being
pulled. Be sure to push the lock first
before pulling the connector.
2) The lock is provided on the female
connector side (the harness end).
T107-04-05-002
Locations of this Type Connector
Fuel Sensor Swing Preference Solenoid Harness Connections in Cab Thermoguard Switch
Valve
A Sensor General Purpose Relay Pressure Switch Diode Box
(Displacement Angle Sensor)
EC Sensor P Sensor Wiper
EC Motor Monitor Speaker Diode
Coolant Level Switch Starter Relay 2 Radio Lubricator
Pump Control Pressure Air Conditioner Blower Motor Starter Relay 1 Motion Alarm
Sensor
Engine Oil level Switch Air Conditioner Controller Key Switch Power Line between
Engine/Cab
Hydraulic Oil Level Switch Engine Control Dial Buzzer Fusible Link
N Sensor
• Pull to disconnect
Locations of This Type Connector
Hydraulic Oil Temperature Sensor

Dr.EX
T107-04-05-004
• Remove screw to disconnect Projection

Use a 10 mm wrench and a ratchet wrench.
When connecting, tighten until the torque mark (a
projection) is seen.
Locations of This Type Connector
EC
PVC
Connections between Cab/Engine
T107-04-05-005
T5-6-3
FUSE CONTINUITY TEST
Fuse failure is often caused by a fine crack in the fuse, (3) Connect the negative probe to the vehicle
and such fine cracks are very hard to detect by visual ground, and touch the outside terminal of each
inspection. fuse with the positive probe of the tester.
Checking fuse continuity with a tester is far superior to When normal continuity of a fuse is intact, the
sight inspection. tester will indicate 20 to 25 volts.
(1) Turn the key switch ON NOTE: (a) All the inside terminals of the fuses in
In doing so, the battery relay is activated by the the fuse box are connected to the
current from key switch terminal M and power is power source, while the outside
supplied to all circuits except the ether relay and terminals are connected to the
starter relay 1 circuits. (Refer to the electrical accessories.
circuit diagram.) Test all fuses using the above
mentioned method, except the starter
(2) Remove the fuse box cover and set the correct relay circuits.
voltage measurement range of the tester.
(b) To check the fuses for the starter relay
(Measurement range: 0 to 30 V)
circuit, perform step (3) while turning
the key switch to the START position.
Power Source (Inside) For Starter Relay
Accessories (Outside)
T162-05-06-002
T5-6-4
FUSIBLE LINK INSPECTION AND RE-
PLACEMENT
Inspection
1. Visually check if fusible links have blown.
Replacement
Fusible Link
1. Remove the negative cable from the battery.
2. Push (to unlock) and pull to disconnect fusible link

connector. Replace the fusible link.
T111-04-05-015
3. Reconnect the negative cable to the battery.
BATTERY VOLTAGE CHECK

To Battery Relay
1. Turn the key switch OFF. Check voltage between
the battery positive terminal and the vehicle.
Normal Voltage: 24 V
NOTE: If voltage is abnormal, recharge or replace

the battery.
V
2. Start the engine. Check voltage between the
battery positive terminal and the vehicle frame.
Normal Voltage: 26 to 28 V
T162-05-06-005
NOTE: If voltage is abnormal, check the charging
system.
T5-6-5
HOW TO TROUBLESHOOT ALTERNATOR
MALFUNCTIONS
The alternator indicator remains off if the alternator is

generating power. If the alternator indicator comes on
while the engine is running, the alternator may have
failed.
How to check the alternator circuit

1. Turn the key switch to the ON position. Confirm
that the alternator indicator comes on.
2. Measure voltage between alternator terminal B

and the alternator body. If the measured voltage is
approximately 24 V, the alternator circuit can be B
considered normal. If it is low, insufficient battery
capacity or a loose connection between the
battery and the alternator may be the cause.
If it is 0V, disconnection or wire breakage between
the battery relay and the alternator or in alternator
ground line may be the cause.
3. Next, start the engine. Measure alternator

generating voltage (voltage between alternator
terminals B and the alternator body). If the
measured voltage is approximately 28V, the V
alternator is normal. If it is the same as the one
measured in step 2 (around 24 V), the alternator
or the regulator may have failed.
T111-04-05-016
L N R
T5-6-6
CONTINUITY CHECK
Harness
Single Line Breakage Check a
A
Disconnect both harness end connectors and check

continuity (resitance) between both ends.
0 Ω : Continuity (Normal)
∞ Ω : Discontinuity (Breakage) Ω
NOTE: When harness end connectors are far apart Connect to Vehicle
from each other, connect harness end Frame A a
terminal A to the vehicle frame. Then,
check continuity through the vehicle as
illustrated.
0 Ω : Continuity (Normal) Connect to Vehicle Ω
Frame
∞ Ω : Discontinuity (Breakage)
Single Line Short Circuit Check A a

(Short Circuit to Vehicle Frame) Short Circuit to
Disconnect both harness end connectors and check Vehicle
continuity between one harness end and the vehicle
frame. Ω
0 Ω : Short Circuit
∞ Ω : Normal
T107-07-05-003
Connect with a Clip (First Check)
Multi-Line Breakage Check
Disconnect both harness end connectors and
connect one harness end connector terminals (A) A a
B b
and (B) using a clip. Then, check continuity between C c
the other harness end terminals (a) and (b). If the
Connect
ohm meter reading is ∞ Ω, either line (A) - (a) or (B) - with a Clip
(b) has an open (wire breakage). (Second
To find out which line is open, perform the single line Check)
breakage check on both lines, or perform the multi- Ω
line breakage check lines (A) - (a) and (C) - (c). Be
sure to connect terminals (A) and (C) using a clip
before checking continuity between the other T107-07-05-004
harness end terminals (a) and (c).

0 Ω : an open in line (B) - (b) (Wire breakage)
∞ Ω : an open in line (A) - (a) (Wire breakage)
Short Circuit between Lines
A a
Multi-Line Short Circuit Check B b
C c
(Short Circuit between Lines)
Disconnect both harness end connectors and check
continuity between terminal (A) and (B) or (C).
0 Ω : Short Circuit
∞ Ω : Normal Ω
T107-07-05-005
T5-6-7
VOLTAGE AND CURRENT CHECK
Turn the key switch and engine control dial as 24 Voltage Circuit
specified, so as to apply specified voltage (current) to Start checking in order from either the power source
the point to be measured before starting or actuator side. Thereby, the faulty part in the circuit
measurements. Check if the specified voltages can be located, if any.
(current) are obtained.
Black (Negative) Tester Probe : To Vehicle
Red (Positive) Tester Probe : To the Point to be
Measured
Specified
Engine Key Switch Check Points Voltage
(Current)
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: Power Source 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link 20 to 25 V
Stopped OFF Between (1) and Ground: Backup Current ∗ 5 mA
Preheating Circuit
Stopped HEAT Between (3) and Ground: Batteries (2 used) 20 to 25 V
Stopped HEAT Between (5) and Ground: Fusible Link 20 to 25 V
Stopped HEAT Between (6) and Ground: Key Switch 20 to 25 V
Stopped HEAT Between (7) and Ground: Intake Heater 20 to 25 V
Starting Circuit
Cranking START Between (8) and Ground: Key Switch 20 to 25 V
Cranking START Between (9) and Ground: Fuse 20 to 25 V
Cranking START Between (10) and Ground: Battery Relay (Coil) 20 to 25 V
Cranking START Between (11) and Ground: Battery Relay (Switch) 20 to 25 V
Cranking START Between (12) and Ground: Starter Relay (S) 20 to 25 V
Cranking START Between (13) and Ground: Starter (B) 20 to 25 V
Cranking START Between (14) and Ground: Starter (C) 20 to 25 V
Charging Circuit
Fast Idle ON Between (15) and Ground: 26 to 30 V
Alternator Generating Voltage (B)
Alternator Generating Voltage
Alternator Generating Voltage (L)
Fast Idle ON Between (17) and Ground: Monitor 26 to 30 V
Accessory Circuit
Stopped ON Between (18) and Ground: Cigar Lighter 20 to 25 V
Stopped ON Between (19) and Ground: Cab Light, Radio 20 to 25 V
Stopped ON Between (20) and Ground: Horn 20 to 25 V
Surge Voltage Prevention
Circuit
Slow Idle ON Between (21) and Ground: Load Dump Relay 26 to 30 V
∗ Be sure to disconnect the negative cable from the

battery before starting the measurements.
T5-6-8
Intake Heater
7
Fusible Link
1 2 3 4 5 Key Switch
10
Preheat Relay 1
Battery
Preheat Relay 2
Battery
Relay 8
11 6
21
Fuse Box
Load Dump Relay
Fuse Box
Starter
Relay
18 19 20
Starter
17
12
13 42
14
15 Monitor
Alternator
18
16
T166-02-03-014
T5-6-9
5 Voltage Circuit
Power Source Signal or Ground
• Voltage between terminal No. 1 and the vehicle
1 2
frame (ground).
Two-Wire System Connector
With the key switch turned OFF, disconnect the
sensor connector. Measure voltage between
harness side connector terminal No. 1 and vehicle
under the following conditions:
V
• Key switch: ON
• Black (negative) tester probe: Touching the vehi-
cle (ground)
• Red (positive) tester probe: Touching terminal T107-07-05-006
No. 1 Power Source Signal Ground

1 2 3
Evaluation:
If the measured voltage is 5±0.5 volts, the circuit up Three-Wire System Connector
to terminal No. 1 is normal.
T107-07-05-007
• Voltage between terminal No. 1 and the ground
terminal.
1 2
With the key switch turned OFF, disconnect the Two-Wire System Connector
sensor connector. Measure voltage between
harness side connector terminal No. 1 (5 V power
source) and the ground terminal (terminal No. 2 for V
two-wire system connector, or terminal No. 3 for
three-wire system connector) under the following
conditions:
• Key switch: ON
• Black (negative) tester probe:
Ȁ Touching the ground terminal (terminal No. 2 or T107-07-05-008
3)
1 2 3
• Red (positive) tester probe:
Ȁ Touching terminal No. 1 Three-Wire System Connector
Evaluation:
If the measured voltage is 5±0.5 volts, the lines up to
terminal No. 1 and to the ground terminal (terminal V
No. 2 or 3) are normal.
T107-07-05-009
T5-6-10
Check Using False Signal
With the key switch turned OFF, disconnect the sensor Two-Wire System Connector 1 2
connector. Connect machine side connector terminal
No.1 (power source) and terminal No.2. The power
source voltage is supplied to the controller as a false
signal. Monitor this false signal with Dr.EX. If the
(Pressure Switch)
maximum value is indicated, the EC, PVC, and the (Hydraulic Oil Temperature Sensor)
circuit up to the machine side connector are normal. (N Sensor)
When checking on a pressure switch circuit, Dr.EX Connect
displays ON if it is normal.
IMPORTANT: On three-wire system connectors,

never connect terminals No. 1 and/or T107-07-05-010
No. 2 to terminal No. 3 or to vehicle.
Three-Wire System Connector

1 2 3
(A Sensor)
(Pump Delivery Pressure Sensor)
(EC Sensor)
(DP Sensor)
Connect
T107-07-05-011
T5-6-11
RELAY REPLACEMENT PROCEDURE
1. Remove screw (1) under the right console to

detach cover (2).
2. Remove bolt (3) and turn the console up side

down around pin (4). Then, remove lock pin (5).
Push pin (4) to remove spacer (6).
: 17 mm
5 2 3 1
3. Move the console to the seat side.
View a
4. Using a sharp-pointed tool, remove cap (9) from 4 6 T157-07-06-004
cover (7) and duct cover (8) located under the

monitor.
5. Remove cover (7) and duct cover (8). 7 10 11
6. Remove ashtray (10) and the ashtray screw.

Remove aux. switch panel (11).
7. Remove relay cover (12).

9 8 12 T157-07-06-005
8. Replace the relay.
1 - Screw 4 - Pin 7 - Cover 10 - Ashtray

2 - Cover 5 - Lock Pin 8 - Duct Cover 11 - Aux. Switch Panel
3 - Bolt 6 - Spacer 9 - Cap 12 - Relay Cover
T5-6-12
TROUBLESHOOTING / Harness Check
CIRCUIT CHECK
Connect the lamp harness kit between connectors.

Then, check if the circuit is normal or abnormal
depending on whether the lamp comes ON or goes
OFF during operation.
Parts Number 4283594 (ST 7126)

Use when checking the conditions (discontinuity) of
a single wire.
To check point. To ground.
During Operation: Lamp comes ON. Parts Number 4283594 (ST 7126)
T107-07-05-012

Use when checking EC motor circuit.
(Refer to page T5-4-16)
5
6
• EC Motor Circuit 50
When the engine control dial is rotated,
When both lamps come ON: Normal 1 2 150 50 2 1
If only one lamp come ON: Check continuity of the 50
3 4 4 3
circuit connecting to the lamp going OFF.
If both lamps go OFF: Check the harness together 7 50
with the relay. 8
Parts Number 4274589 ( ST 7125) T107-07-06-024

Use when measuring the signal cable voltage
(Red)
(between terminal No.2 and 3) in the EC sensor or A
sensor (Pump displacement angle) circuit.
(Black)
V
Parts Number 4284347 (ST 7129) T107-07-03-009
Parts Number 3073259

Use when checking the wiper circuit.
2
5 4
1 2
1
Parts Number 3073259 T157-07-07-001
T5-7-1
TROUBLESHOOTING / Harness Check
Use when checking the solenoid valve unit (3
solenoid valves used).
The lamp comes on when the applicable control 4

lever or switch is operated. 3
50
(Refer to page T5-4-26.)
150 50 50
1 2 2 1
Parts Number 4274587 ( ST7123)

T107-07-06-015
T5-7-2
Hydraulic Circuit Diagram
Technical Manual,Vol.No. TT166E-01
EX400-5 EX400LC-5 EX450LC-5 HYDRAULIC CIRCUIT DIAGRAM (BACKHOE)
CAUTION: Authorized Hitachi Dealer Use Only
Control Valve
Swing Motor
Pilot Valve
Roll-Out Swing Shuttle Valve

Bucket
( )
Swing 24.5MPa
( )
Roll-In
Others
Raise Boom Cylinder
Boom
( ) 26.5MPa
Lower
Boom Raise ( )
26.5MPa
( )
24.5MPa
( ) ( )
Shockless Valve
( ) 30.9MPa
30.9MPa
( ) Arm Cylinder
Roll-Out
Bucket Cylinder
Arm
30.9MPa
( )
Roll-In 30.9MPa
30.9MPa (315K)
( )
30.9MPa
(315K)
Shockless Valve
Right
Swing
Left
34.3MPa 29.4MPa
Arm Roll-In ( ) ( )
Travel Shuttle Valve

Travel Right
Forward
Center Joint
Reverse 147KPa
Travel 343KPa ( )
( )
Forward Oil Cooler

Travel Left
Reverse 36.8MPa ( ) 36.8MPa ( )

Main Pump Engine
Accumulator ( ) ( )
Pilot Shut-Off Valve Hydraulic Oil Tank
Pilot Filter
Check Valve Pilot Pump
Solenoid Valve Unit

Travel Motor
Main Relief Travel Speed Swing

Pressure Shift Parking
Shift Brake
Release
Solenoid Valve
Swing Prefarence Circuit

EX400-5 EX400LC-5 EX450LC-5 HYDRAULIC CIRCUIT DIAGRAM (BACKHOE: C / W REMOVE / INSTALL DEVICE)
Parts numbers on the drawing are provided only for reference purpose.
To order parts on the drawing, be sure to consult the Parts Catalog.
Counterweight Remove/Install Cylinder
Control Valve Swing Motor

Pilot Valve
Swing Shuttle Valve
Roll-Out
Bucket
Swing 24.5MPa
Roll-In
Others
Raise Boom Cylinder
Boom
Lower
Boom Raise
24.5MPa
30.9MPa
Shockless Valve
Arm Cylinder
Roll-Out
Arm
Bucket Cylinder
Roll-In
30.9MPa
(315K)
Shockless Valve
30.9MPa
(315K)
Right
Swing
Left
Arm Roll-In
Center Joint
Travel Right
Forward
Reverse
Travel
Forward Oil Cooler

Travel Left
Engine
Reverse 36.8MPa
36.8MPa
Main Pump
Pilot Shut-Off Valve Accumulator Hydraulic Oil Tank

Pilot Filter
Solenoid Valve Unit

Travel Motor
Main Relief Travel Speed Swing

Pressure Shift Parking
Shift Brake
Release Counterweight Remove/Instal Device
Solenoid Valve
Counterweight
Remove/Instal

EX400-5 EX400LC-5 EX450LC-5 HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL: BOTTOM DUMP)

Pilot Valve
Swing Shuttle Valve
Tilt-Out
Bucket
Swing
Tilt-In
Level Cylinder
Others
Raise
Boom
Boom Cylinder
Lower
Boom Raise
Shockless Valve
Arm Sylinder
Retract
Arm
Extend
Shockless Valve
Right
Bucket Open/Close Cylinder
Swing
Bucket Cylinder
Left
Arm Extend
Forward Center Joint

Travel Right
Reverse
Travel
Oil Cooler
Forward
Travel Left
Engine
Reverse
Main Pump
Pilot Shut-Off Valve Accumulator Hydraulic Oil Tank

Pilot Filter
Pilot Pump
Check Valve
Solenoid Valve Unit Travel Motor
Main Relief Travel Swing

Pressure Speed Parking
Shift Shift Brake
Release
Solenoid Valve Open/Close
Bucket Open Prefarence Valve
(Right Pedal)
Bucket Close
(Left Pedal)
EX400-5 EX400LC-5 EX450LC-5 HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL: TILT DUMP)

Pilot Valve
Swing Shutle Valve
Tilt-Out
Bucket
Swing
Tilt-In
Level Cylinder
Others
Raise
Boom
Boom Cylinder
Lower
Boom Raise
Shockless Valve
30.9Mpa
Arm Cylinder
Retract
Arm
30.9Mpa
Extend
30.9Mpa
Shockless Valve
Right
Swing
Bucket Cylinder
Left
34.3 Mpa 29.4 Mpa

Arm Extend
Forward Center Joint

Travel Right
Reverse
Travel
Forward Oil Cooler

Travel Left
Engine
Reverse 36.6 Mpa
36.6 Mpa
Main Pump
Pilot Shut-Off Valve Accumulator

Hydraulic
Pilot Filter Oil Tank
Solenoid Valve Unit

Travel Motor
Main Relief Travel Swing

Pressure Speed Parking
Shift Shift Brake
Release
Solenoid Valve
Prefarence Valve

( )
EX400-5:Serial No.007661 or earlier
EX400-5 EX400LC-5 EX450LC-5 ELECTRICAL CIRCUIT DIAGRAM 1 EX400LC-5:Serial No.007703 or earlier
EX450LC-5:Serial No.007703 or earlier
Preheat Relay 1
Key SW
Outside Cab Inside Cab
Resistor A K
Preheat Sig.
Magnetic Valve Alternator + Inside Cab Outside Cab
Intake Heater(on Eng. ) (on Eng. ) Motion Alarm
Lubricator
Sol.Power
Eiectrical Component Layout in the Relay Box Preheat Relay 2 PVC Main Pow.
K
Fusible Link 45A PVC Back up Pow. Motion Alarm
Monitor Back up Pow. (Opt.)
Monitor Main Pow.
A
K
Motion Alarm
Cancel SW(Opt.)
Disconect from SMJ
A
Battery Relay
Interior Light Lubricator
BatteryFuel Pump
Back up EN Input
Lub.Component
Starter Relay
Back up
Batt.+
Main Power Power
K
Eng.Stop Motor Coolant Temp. Gauge
Fusible Link Pow.ON
A
Fuel Gauge
Glow Input
Fuel Pump(Opt.) Indicator
Load Dump Relay
Warm Up Ind.
Emergency Relay G Lowpass Filter
Eng.Stop Motor
Alternator Load
G Alternator Vol.Input
ACC Load
G
Eng. Oil Level OK G Coolant Temp. Sensor(Eng.)
EC Main/PVC Back up Pow.
Radio/Monitor Back up Pow.
Monitor/PVC Main Pow.

Eng.Stop Relay
A/C OFF Relay

EC Motor Pow.
Starter Relay
Coolant Level OK G Fuel Sensor(Fuel Tank)
Sol.Power
Lubricator
Pow.ON
Eng.Stop Relay
Starter Relay
Hyd. Oil Level OK G
Eng.Oil Level SW(Eng)
Voltage
Operating(V)
Charge R Coolant Level SW(Reservoir)
Eng.Oil Press R Hyd.Oil Level SW(Hyd.Oil Tank)
Stater Coolant O/H R Eng.Oil Press.SW(Eng.)
Low Fuel R O/H SW(H)

ENG Direct BODY GROUND 101 (214 F)
Air Filter Clogg. R Fuel SW(Fuel Tank)
Alternator Light Relay
Output (V) (A) Glow O Monitor Air Filter SW
Auto-Lub R
Wiper(H Cab 5A)
Eng.Stop Motor
Work Light
Light(Opt.)
Radio/Room Lamp
Cig. Lighter
Motion Alarm
Light Relay Aux.1
Wiper/Washer SW
Horn
Aux.
A/C
Back up Power Main Power Sol. Power
Aux.2 1 Speed Swing Preference
Wiper SW Intermit. Contorol GND Swing Preference Sol. Sol.
Buzzer
Regulator Press.SW(Others)
Load dump Relay Output
Sol.GND Pressure SW Input Press.SW(Travel)
Light 70W Boom Hour Meter
Light Pow.(Opt.) Washer SW
Press.SW(Swing)
Barister
Wiper Relay Output A Power Boost SW Press.SW(Boom Raise)
Auto - Idle SW
Light 70W Fender(R) Aux.Current Cont.Output
Level Check SW (SW GND) Press.SW(Arm Roll-In)
Wiper Relay Output B
K
Box GND Spare Buzzer Cancel SW Aux.ON/OFF Output
Waiper Relay A (4 - Spool)
Wiper Relay Output C (4 - Spool)
A
Power Boost Input
Mode SW Aux.GND
Wiper Relay Output BM
(5 - Spool)
(5 - Spool)
Swing Parking Brake Release
Waiper Relay B-1 Washer Relay Output Checker SW Input
Serial Output 1 Travel Speed Travel Speed Shift (SB)
Serial Input 1
Serial GND Main Relief Press. Shift Main Relief Press.Shift (SA) Sol.Valve Unit
Aux.: Serial GND
Light SW Travel ModeSW Travel Swing Parking
Fast
K
Aux.:A/I Brake Release

Waiper Relay B-2 Light 1+2 Fast Output
Cig. Lighter
Light Relay Output 2
Wiper(H Cab) Light 1 Slow Travel Mode Input P/D(4 - Spool)
A
Horn Horn Relay Travel

K A
Light Relay Output 1 Slow
Output P/S(4 - Spool) (4 - Spool)
Wiper/Washer Move Output

Power Mode SW 1 Output
(4 - Spool)
Power Mode SW 1 Input

Mode Output 1
Wiper/Washer EN Input
Horn Waiper Relay BM
Mode Output 2 Mode SW Input A/S(4 - Spool)
Outo - Idle Output

(4 - Spool)
Horn SW
Serial Output 2 P/D(5 - Spool)
Serial Input 2
Serial GND P/S(5 - Spool)
Radio Serial GND (5 - Spool)
Waiper Relay A,B-1,B-2,BM in the Cab Wall Antenna
(5 - Spool)
for STD Cab
Washer Relay A/S(5 - Spool)
(5 - Spool)
Speaker(R )
K
Connector
Waiper Motor Serial GND
N Sensor
Washer Motor Speaker(L ) Serial GND
A
Waiper Relay(H Cab) Room Lamp Eng.Control Dial Unit Limit SW Serial Output
Wired Serial Input
Interior Light EC Motor 1
Dial Motor EC
W/U Input EC Motor 2
Heater
Auto-Idle Input EC Sensor
Blower Mid.Relay 1
Blower Mid.Relay 2
Blower Motor Blower Resist.

Comp.Clutch Relay
Blower Main Relay

Blower Hi.Relay
Power Mode Input

Eng.Control Dial Input
Vent.Servo Motor A/M Servo Motor
EC Motor Relay
M M
Power ON EC Sensor Pow.
Dual Press. SW O/H(L) O/H SW(L)
EC Motor Pow. Sensor GND
Aux. A/I
EC Motor Relay Hyd.Oil Tem.Sensor
Main Power
C/W SW Input Counterweight Removal and Installation SW
A/C Controller
Control GND
Eng.Direct Attachment SW Input
K
A/C Unit Attachment Press. SW

Circ.Servo Motor(MRF) Motor GND
A

Thermister
Cab Floor Cab Floor
Inside Cab Outside Cab
( )
EX400-5:Serial No.007661 or earlier
EX400-5 EX400LC-5 EX450LC-5 ELECTRICAL CIRCUIT DIAGRAM 2 EX400LC-5:Serial No.007703 or earlier
EX450LC-5:Serial No.007703 or earlier
HARNESS CIRCUIT NO.

CONNECTORS (These connectors are the herness end connectors,unless otherwise specified)
HARNESS
PARTS TERMINAL NO. CIRCUIT NO.
Lock
MITSUBISHI MITSUBISHI MITSUBISHI YAZAKI MITSUBISHI MITSUBISHI MITSUBISHI YAZAKI
EC Z Type Z Type Z Type Econ.Seal(Mark 2) MWP Type L Type JFC Type CN Type With Lock
Sol.Valve Unit EC MOTOR Motion Alarm Lubricator Hyd.Oil Tem.Sensor Coolant Level SW
Press.SW Wiper Motor
Swing Preference Sol.
Hyd.Oil Level SW
Fuel Sensor
PVC
EQUIPMENTS
RELATED TO
CONTROLLER
MONITOR YAZAKI MITSUBISHI YAZAKI MITSUBISHI MITSUBISHI MITSUBISHI YAZAKI MITSUBISHI YAZAKI
CN Type With Lock C Type(White) CN Type With Lock L Type L Type CN Type With Lock M Type CN Type With Lock
Or
Or
OTHERS MITSUBISHI Limit SW MITSUBISHI Fusible Link Fusible Link Diode Alternator Relays Starter SW
Motion Alarm SW
Starter Relay Washer Motor

Preheat Relay 1,2
Speaker
A/C Blower Motor
Thermister
K 9 7 5 3 1
1 2
A 10 8 6 4 2
Fuel Sensor Battery Relay SUMITOMO YAZAKI YAZAKI YAZAKI MITSUBISHI MITSUBISHI
Starter Relay Hyd.Oil Level SW
With Lock With Lock
Emergency Relay Air Filter SW (Water Proof)

Detail 1 A/C Press.SW A/C Comp.Clutch Blower Resist Circu.Servo Motor Preheat Relay 1 Eng.Oil Level SW Diode Box 1 Diode Box
Coolant Level SW Eng. Stop Motor (A/C) A/C Blower Relay Vent. Servo Motor Preheat Relay 2 Diode Box 2
Blower Main Relay A/M Servo Motor
Blower Hi.Relay (A/C)
Blower Mid.Relay 1
Blower Mid.Relay 2
A/C Comp.Clutch Relay
Cig.Lighter
Others GND Line
Monitor Wiper
MITSUBISHI MITSUBISHI
C Type(White) Multi-Lock Multi-Lock Multi-Lock Z Type
Control Pow. Eng.Control Dial Unit Monitor Eng. Stop Motor

GND Line
Cab Floor
YAZAKI
Control GND
Line Radio A/C Controller
Cab(View from open end side)

Detail 2
MITSUBISHI
Cover 64 Poles
Detail 2
Cab Wall
Black
Black Cover 48 Poles 84 Poles SMJ Type
J04-FL(N)
Cab Floor
Frame
1 2 3 4 5 6 7 1 2 3 4 5 1 2 3 4 5
8 9 10 11 12 13 14 15 16 6 7 8 9 10 11 12 6 7 8 9 10 11 12
YAZAKI MITSUBISHI MITSUBISHI MITSUBISHI MITSUBISHI

C Type(Black) C Type(Brown) C Type(Black) C Type(White)
Emergency Relay Wiper(H Cab)

Water Proof
Receptacles
Ring Terminal
Screw Terminal Ring Terminal with Lock

APM 172320-2 1 2 3 4
5 6 7 8
YAZAKI MITSUBISHI MITSUBISHI

M Type(Black) CN Type With Lock C Type(Black)
Light Pow.(Opt.) Heater

EX400-5:Serial No.007662 or after
EX400-5 ELECTRICAL CIRCUIT DIAGRAM 1
CAUTION : Parts numbers on the drawing are provided only for reference purpose.
( EX400LC-5:Serial No.007704 or after
EX450LC-5:Serial No.007704 or after
)
Preheat Relay1
Key SW
Resistor A K
Preheat Sig.
Alternator+
Magnetic Valve Inside Cab Outside Cab
Intake Heater(on Eng.) (on Eng.) Motion Alarm
Lubricator
Sol.Power
Electrical Component Layout in the Relay Box Preheat Relay1 PVC Main Pow.
K
Fusible Link PVC Back up Pow. Motion
Monitor Back up Pow. Alarm
Monitor Main Pow. (Opt.)
A
K
Motion Alarm
Disconnect Cancel SW
from SMJ (Opt.)
A
Battery Relay
Interior Light Lubricator
Batteryfuel Pump
Buck up EN Input
or less
Lub.Component
Starter Relay
Buck up
Batt.+
Main Power
K
Power
Pow.ON Coolant Temp. Gauge
Eng.Stop Motor Fusible Link
A
Fuel Gauge
Glow Input
Fuel Pump Indicator
Load Dump Relay
Warm Up Lnd.
Alternator
Emergency Relay G Vol.Input
Lowpass Filter
Eng.Stop Motor
G
Aternator Load
ACC Load
G
E/C Main/PVC Back up Pow.
Radio/Monitor Back up Pow.

Eng.Oil Level OK G Coolant Temp. Sensor(Eng.)
Monitor/PVC Main Pow.

Eng.Stop Relay
Eng.Stop Relay
A/C OFF Relay

EC Motor Pow.
Coolant Level OK G Fuel Sensor(Fuel Tank)
Starter Relay
Sol.Power
Lubricator
Pow.ON
Starter Relay
Hyd. Level OK G
Eng.Oil Level SW(Eng.)
Voltage
Operating(V) Charge R Coolant Level SW(Reservoir)
Eng.Oil Press R Hyd.Oil Level SW(Hyd.Oil Tank)
Starter Eng.Oil Press.SW(Eng.)

Coolant O/H R
Low Fuel R O/H SW(H)

ENG Direct BODY GROUND 101°C(214°F)
Air Filter Clogg. R Fuel SW(Fuel Tank)
Light (on H Cab)(Opt.)
Alternator
Light Relay1
Output(V)
Output(A)
Glow O Monitor Air Filter SW
Auto-Lub R
Wiper(H Cab 5A)

Work Light
Light(Opt.)
Eng.Stop Motor
Radio/Room Lamp
Cig. Lighter
Motion Alarm
Light Pow.
Horn
Aux.
A/C
Light Relay2 (Opt.) Aux.1
Wiper/Washer SW
(on Cab)(Opt.) Back up Main Sol. Power
Light 1 Speed Power Power Swing Preference
Aux.1 Sol.
Wiper SW
Intermit Control GND Swing Preference
Light (on Cab)(Opt.) Buzzer
Regulator Press.SW(Other)
Light Relay3
Load dump Relay Output
Sol.GND Pressure SW Input Press.SW(Travel)
Hour Meter
Washer SW
Press.SW(Swing)
Barister
Power Boost SW Press.SW(Boom Raise)
Wiper Relay Output A Auto Ldle SW
Aux.Current Cont.Output
Light (on Cab)(Opt.) Press.SW(Arm Roll-in)
Wiper Relay Output B Level Check SW (SW GND)
K
Light 70W Boom
Spare Buzzer Cancel SW Aux.ON/OFF Output 4-Spool
4-Spool
Wiper Relay Output C
A
Power Boost Input

Mode SW Aux.GND
Light 70W Fender(R) Wiper Relay Output BM
5-Spool 5-Spool
G Swing Parking Brake Release
Box GND Checker SW Input
Wiper RelayA Washer Relay Output G
Serial Output 1 Travel Speed Travel Speed Shift
G Serial Input 1 (SB)
Serial GND Main Relief Press. Sol.Valve Unit
G Main Relief Press.Shift
Aux.:Serial GND Shift(SA)
Light SW Travel Mode SW Swing Parking
Travel
Brake Release
K
Slow Aux.:A/I
Light 1+2 Slow Output
Light Relay Output 2
Wiper RelayB-1 Wiper(H Cab) Cig.Lighter Light 1 Travel Mode Input
Fast 4-Spool
A
Horn Travel
Horn Relay
Wiper Washer Move Output

Fast

Wiper Washer EN Output

Light Relay Output 1 Output

4-Spool 4-Spool
Mode Output 1 4-Spool

Horn
Auto Idle Output

Wiper RelayB-2 Mode Output 2 Mode SW Input 4-Spool 4-Spool
K A
Horn SW
Monitor Serial Output 2 5-Spool
Serial Input 2
Serial GND 5-Spool 5-Spool
Wiper RelayBM in the Cab Wall Radio Antenna Serial GND
5-Spool
Washer Relay 5-Spool

5-Spool
K
Speaker(R)
Connector
Washer Motor Wiper Motor Serial GND
N Sensor
A
Wiper Relay A,B-1,B-2,BM Speaker(L) Serial GND

Wiper Relay(H Cab) Limit SW
for STD Cab Room Lamp Eng.Control Dial Unit Serial Output
Wired Serial Input
EC Motor 1
Interior Light Motor
Dial
Input EC Motor 2
A K Heater
Auto-Idle Input EC Sensor
Blower Motor Blower Resist.
Comp.Clutch Relay
Blower Mid.Relay1
Blower Mid.Relay2
Blower Main Relay
Power Mode Input

Blower Hi.Relay
M Eng.Control
Vent.Servo Motor A/M Servo Motor Dial Input
EC Motor Relay
Power ON EC Sensor Pow.
O/H(L) O/H SW(L)
Dual Press. SW Sensor GND
HI LO
EC Motor Pow.
Comp. Clutch AX.A/I
EC Motor Relay Hyd.Oil Tem.Sensor
Eng.Direct Main Power

A/C Controller Inside Tem. C/W SW Input
Sensor Frost Sensor Counterweight Removal Installation SW
Water Tem.
Outside Tem. Sensor
Disconnect A/C Unit Sensor Solar Radiation
Sensor
Control GND
Attachment SW Input
from SMJ
Circ.Servo Motor
Attachment Press.SW
M Motor GND
Outside Cab Inside Cab Cab Floor Cab Floor

EX400-5:Serial No.007662 or after
EX400-5 ELECTRICAL CIRCUIT DIAGRAM 2
( EX400LC-5:Serial No.007704 or after
EX450LC-5:Serial No.007704 or after
)
HARNESS CIRCUIT NO.
CONNECTORS (These connectors are the harness end connectors,unless otherwise specified)
HARNESS
PARTS TERMINAL NO. CIRCUIT NO.
MITSUBISHI MITSUBISHI MITSUBISHI YAZAKI MITSUBISHI MITSUBISHI MITSUBISHI YAZAKI

EC Z Type Z Type Z Type Econ.Seal(Mark 2) MWP Type L Type JFC Type CN Type With Lock
Sol.Valve Unit Motion Alarm Lubricator Hyd.Oil Tem.Sensor Coolant Level SW

Press.SW
Wiper Motor Eng. Harness
Swing Preference Sol. Cab. Harness
Hyd.Oil Level SW
PVC Fuel Sensor
EQUIPMENTS
RELATED TO
CONTROLLER
MONITOR YAZAKI MITSUBISHI YAZAKI MITSUBISHI MITSUBISHI MITSUBISHI YAZAKI SUMITOMO YAZAKI
CN Type With Lock C Type(White) CN Type With Lock L Type L Type CN Type With Lock CN Type With Lock
or
or
OTHER MITSUBISHI Limit SW MITSUBISHI Fusible Link Fusible Link Diode Alternator Relay Starter SW
Motion Alarm SW
Starter Relay Washer Motor

Preheat Relay 1,2
Wiper Harness(H Cab) Eng. Harness
Air.Con. Speaker
A/C Blower Motor
Thermistor
K 9 7 5 3 1
1 2
A 10 8 6 4 2
Fuel Sensor Battery Relay SUMITOMO YAZAKI YAZAKI YAZAKI MITSUBISHI MITSUBISHI
Starter Relay With Lock With Lock
Hyd.Oil Level SW
Emergency Relay Air Filter SW (Water Proof)
A/C Press.SW A/C Comp.Clutch Blower Resist Circu.Servo Motor Preheat Relay 1 Diode Box 1 Diode Box
Detail 1 (A/C) A/C Blower Relay Vent.Servo Motor Preheat Relay 2 Eng.Oil Level SW Diode Box 2 Connector
Coolant Level SW Eng. Stop Motor
Blower Main Relay A/M Servo Motor
Blower Hi Relay (A/C)
Blower Mid.Relay 1
Blower Mid.Relay 2
A/C Comp.Clutch Relay
Cig.Lighter
Others GND Line
Monitor Wiper
C Type(White) Multi-Lock Multi-Lock Multi-Lock Z Type
Eng.Control Dial Unit Monitor Eng.Stop Motor

Control Pow. Radio Harness
Cab Floor
GND Line
YAZAKI
Control GND
Line Radio A/C Controller
Cab(View from open end side)

Detail 2
MITSUBISHI
Cover 64 Poles
Detail 2
Cab Wall
Black
Black Cover 48 Poles 84 Poles SMJ Type
Cab Floor
Frame
1 2 3 4 5 6 7 1 2 3 4 5 1 2 3 4 5
8 9 10 11 12 13 14 15 16 6 7 8 9 10 11 12 6 7 8 9 10 11 12
YAZAKI MITSUBISHI MITSUBISHI MITSUBISHI MITSUBISHI

C Type(Black) C Type(Brown) C Type(Black) C Type(White )
Water Emergency Relay Wiper(H Cab) Relay Harness 1 (in the cab) Relay Harness 2 (in the cab) Relay Harness 3 (in the cab)
Proof
Receptacles
Ring Terminal
Ring Terminal with Lock

Screw Terminal
APM 172320-2 1 2 3 4
5 6 7 8
YAZAKI MITSUBISHI MITSUBISHI MITSUBISHI YAZAKI

M Type(Black) CN Type With Lock C Type(Black) CN Type With Lock Type
Light Pow.(Opt.) Heater Light Pow.(on Cab) Water Tem. Sensor

Relay Harness
(in the cab)
YAZAKI YAZAKI YAZAKI

Type Water Proof CN Type With Lock
Solar Radiation Outside Tem. Light(on Cab) Relay Harness

Sensor Sensor
Blower Mid.Relay1(RLBM1)
EX400-5 EX400LC-5 EX450LC-5 CAB HARNESS (STD) 1 Speaker

Blower Mid.Relay2(RLBM2) Compressor Clutch Relay(RLEC)
Thermister Blower Hi.Relay(RLBH)

Blower Main Relay(RLBM)
YAZAKI
Speaker
Dual Press.SW
SUMITOMO
A/M Servo Motor(MAM)
Preheat Relay2 Preheat Relay1 Preheat Relay1

YAZAKI YAZAKI YAZAKI
Circu.Servo Motor(MRF)
Preheat Relay2
YAZAKI
OPT.Light
1
Commect
N-SLC-3M Secure with Tape
2 3
Terminal Cap Limit SW(WWES)
Room Lamp
Label
Resistor
Secure with Tape
Air Cnditioner(Controller)
Blower Motor(MB)
Air Cnditioner(Controller) YAZAKI
Heater
Secure with Tape
Key SW
Blower Resister
Eng.Control Dial
Power Boost SW
Harness
Diode Box 2 (5 Spool)
Diode Box1(5 Spool)
Set.
Button
Set.
Install Clip(255) Screw
Install Clip(255) MITSUBISHI PP021-54120(Black)
MITSUBISHI Measure Point
PP021-54120(Black)
Vent.Servo Motor(MV)
Secure with Tape Assem.Cover

SJD J04-FL(N)
PJ015-12000
Connect
Horn SW Assem.Cover
SJD J06-FL(N)
PJ015-10000 (Equipped Fuse Puller)
Secure with Tape Connect
Assem.Cover
SDJ PF211-20000-C01
Equipped Aux.
Fuses 5A,10A,20A,30A
Secure with Tape
Motion Alarm Cancel SW Secure with Tape

Label
70
Connct Femail Sleeve
50
Assem.PJ014-08000
Waterproof Sleeve
CN Type
Measure Point
EX400-5 EX400LC-5 EX450LC-5 CAB HARNESS (STD) 2
AV Seald
Motion Alarm SW
Motion Alarm SW
AV Seald Aux . +
Aux . -
Light 1
Limit SW 1
Eng.Control Dial 9
Seald Wire
Floor GND
Eng.Control Dial 4 S t a t e r S W 2 Preheat Relay 1 - 1

Limit SW 2 Eng.Control Dial 6 S t a t e r S W 3 Preheat Relay 2 - 1
Eng.Control Dial 7 Preheat Relay 1
Eng.Control Dial 8 Preheat Relay 2
Eng.Control Dial 10 Preheat Relay 1 - 2
Blower Main Relay 1 Preheat Relay 2 -2
Blower Main Relay 2 Air Con./C 2 Preheat Relay 1 R e s i s t o r 1
Blower Main Relay 3 Blower Motor 2 Preheat Relay 2
Pow.Boost SW Eng.Control Dial 1 Blower Main Relay 4 Resistor 2
Eng.Control Dial 3 Blower Hi.Relay 3
Eng.Control Dial 2 Blower Hi.Relay 4 Blower Motor 1 Light 3
Floor GND Blower Hi.Relay 1
Blower Hi.Relay 2 Air Con./C 5
Blower Mid.Relay 2 - 3
Blower Mid.Relay 2 - 4 Blower Resistor 2
Floor GND Blower Mid.Relay 2 - 1
Blower Mid.Relay 2 - 2 Air Con./C 4
Blower Mid.Relay 1 - 3
Stater SW 1 Blower Mid.Relay 1 - 4 Blower Resistor 3
Stater SW 4 Blower Mid.Relay 1 - 1
Stater SW 5 Blower Mid.Relay 1 - 2 Air Con./C 3
Stater SW 6 Compress.Relay 3
Compress.Relay 4
Compress.Relay 1
Compress.Relay 2 Dual Press. SW 2
Air Con./C 6 Dual Press. SW 1
Air Con./C 21 Sircu.Servo Motor 1
Air Con./C 22 Sircu.Servo Motor 2
Air Con./C 14
Blower Resistor 4
Blower Resistor 1
Light 2 Bent.Servo Motor 5 Air Con./C 13
Bent.Servo Motor 3 Air Con./C 11
Horn SW(Fe.) Bent.Servo Motor 4 Air Con./C 23
Horn SW(Fe.) Bent.Servo Motor 2 Air Con./C 18
Bent.Servo Motor 1 Air Con./C 17
A/M Servo Motor 5
A/M Servo Motor 3 Air Con./C 10
Room Lamp A/M Servo Motor 4 Air Con./C 16
Speaker R + A/M Servo Motor 2 Air Con./C 20
Pow.Boost SW Speaker R - A/M Servo Motor 1 Air Con./C 19
Speaker L + Thermister 1
Speaker L - Thermister 2 Air Con./C 9
Air Con./C 1
Diver.from 8
Diver.from 8
Diver.from 8
EX400-5 EX400LC-5 EX450LC-5 RELAY HARNESS (STD)
EC Motor Relay 2 Horn Relay 2

Horn Relay 5
Wiper Motor D
Wiper Relay A 1
EC Motor Relay 5 Wiper Relay B1 - 1
Wiper Relay B2 - 1
Wiper Relay BM - 1
Wiper Motor B Wiper Relay A 3 Wiper Motor
Wiper Relay A 4
EC Motor Relay 1 Wiper Relay A 5
EC Motor Relay 3 Wiper Relay B1 - 3 Wiper Motor A
Wiper Relay B1 - 4 Wiper Relay BM - 3
Wiper Relay B1 - 5
Wiper Relay B2 - 2
Wiper Relay B2 - 3
Wiper Relay B2 - 5
Wiper Motor C
Wiper Relay BM 5
Washer Relay 3
Load Dump Relay2 Washer Relay 1
Light Relay 1 - 2 Washer Relay 5
Light Relay 2 - 2 Cig.Lighter(Fe.)
Wiper Relay BM 2 Eng.Stop Relay 1
Washer Relay 2 Eng.Stop Relay 2
Wiper Relay A 2 Eng.Stop Relay 3
Wiper Relay B 1 - 2 Eng.Stop Relay 4
Eng.Stop Relay 5
Label Label Label Label Label Label Label Label
Cig.Lighter
Load Dump Relay 1
Load Dump Relay 3
Label Label Label
Load Dump Relay 5
Light Relay 2 - 3
Light Relay 1 - 1
Light Relay 1 - 3
Light Relay 2 - 1
Light Relay 1 - 5
Light Relay 2 - 5
Horn Relay 3
Horn Relay 1
Cig.Lighter
EX400-5 EX400LC-5 EX450LC-5 ENGINE HARNESS (STD)
Motion Alarm-B
Motion Alarm-C
Lubricator +
Box GND Lubricator -
Emer.Relay P1 Horn
Light(Boom )
Overheat SW(L) Emer.Relay P2' Eng.Stop Motor P2
Emer.Relay E Waterproof Sleeve Light(Fender R)
Waterproof Sleeve
Emer.Relay T Cab GND
Pressure SW Pressure SW
A/S(5-Spool)-1 Emer.Relay C YAZAKI YAZAKI Lubricator
A/S(5-Spool)-3 Connect BOX GND
Alternator N YAZAKI 7322-9327
EC Motor 1 Starter C Travel Aux. (With Seald Pin) Connect L02-MB
Assem.Cover PJ015-06000 Floor GND
EC Motor 2 Magnetic Valve(Male)
EC Motor 3 Alternator R
EC Motor 4 Alternator B
Compressor
PD Sol.(4-Spool)-1 Connect PM054-02071
Light(Fender R)
Overheat SW(L)
PD Sol.(4-Spool)-2 Hyd.Oil Tem.Sensor 2
Press.SW B-1 Hyd.Oil Tem.Sensor 1 Fuel Pump
P/S(5-Spool)-3 Waterproof Sleeve
Press.SW S-1
Press.SW A-2 DP/S(5-Spool)-1 Frame GND Fuel SW
A/S(5-Spool)-2 DP/S(5-Spool)-3 Waterproof Sleeve Coolant Level SW
Pressure SW Arm Swing Others
YAZAKI
Press.SW T-1 YAZAKI
Press.SW A-1
Press.SW O-1 Pressure SW Y-1 Fuel Gauge
A/S(4-Spool)-2 Washer
Pressure SW Y-2 YAZAKI
P/S(5-Spool)-2 Boom Fusible Link
DP/S(5-Spool)-2 Air filter SW
Waterproof Sleeve Connect SL129-00010
A/S(4-Spool)-1
P/S(4-Spool)-1 DP/S(5-Spool)
DP/S(4-Spool)-1
A/S(4-Spool)-3 Hyd.Oil Tem.Sensor Fusible Link
P/S(4-Spool)-3 Two Polarities(Female)
P/S(4-Spool)-2 Connect SL280-00010
DP/S(4-Spool)-3 Red Label Swing Preference

Hyd.Oil Level SW
DP/S(4-Spool)-2
Main Relief Press.Shift
PD Sol.(5-Spool)-1
Emergency Relay
Swing Preference Sol.2
Waterproof Sleeve
PD Sol.(5-Spool)-2
Travel Speed Shift SUMITOMO

P/S(5-Spool)-1 Solenoid Valve Emergency Relay
Press.SW O-2 YAZAKI
White Label
Press.SW T-2
Press.SW S-2 DP/S(4-Spool) SUMITOMO
Press.BM -2
Swing Preference Sol.1
Wire Wire N/S Connector Around Seald4,11
Swing Parking Brake Release
Alternator L Motion Alarm
Eng.Oil Level SW Alternator
Compressor Alternator
Coolant Level SW 1 Connect PH801-04020 Terminal Cap
Hyd.Oil Level SW 1 (With Seald Pin)
YAZAKI
Eng.Oil Level SW Or
YAZAKI Overheat SW(H)
Eng.Oil Press.SW YAZAKI MITSUBISHI Terminal Cap
Overheat SW(H) Connect X01M-GY
(YAZAKI 7322-6214-40,
Fuel SW MITSUBISHI PH621-01320)
Coolant Temp.Gauge
Air Filter SW (Fe.)
Coolant Temp.Gauge PD Sol.(4-Spool) Terminal Cap
Fuel Gauge 1 A/S(5-Spool) Starter
Fuel Gauge 2 Terminal Cap
Hyd.Oil Level SW 2 P/S(4-Spool)
AMP EJ( ) Three Polarities C/W Remov.and Insta.Device SW
Coolant Level SW 2 (Female) YAZAKI
Connect
Air Filter SW (Male) YAZAKI 7322-9327 Magnetic Valve
White Label Red Label (With Seald Pin)
Eng.Stop Motor B P/S(5-Spool) White Label

AMP EJ( ) Three Polarities
Emer.Relay(Fe.Receptacles) (Female)
Eng.Stop Motor A
Eng.Stop Motor P1 Red Label
Emer.Relay P2 J08-MW Intake Heater
Button
Eng.Stop Motor E Seald Pin Terminal Cap
EC Motor Secure with Heatproof Tape Overheat SW(L)
Terminal Cap
Fuel Pump(Fe.) White Label
A/S(4-Spool)
Eng.Stop Motor
Light(Fender R)
Light(Boom )
Horn Lo Red Label
Horn Hi
Washer 1 Measurement Starting Point
PD Sol.(5-Spool)
Washer 2
Cab GND Frame GND Harness Direction
Magnetic Valve(Fe.) Secure with Tape
Floor GND Frame GND Eng.Oil Press.SW
Intake Heater
Motion Alarm-A Terminal Cap
Assm. Cover PJ015-06000
Motion Alarm-D

Technical Manual

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EX400-5, EX400LC-5, EX450LC-5

• 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-

• For jobs involving multiple numbers of machines,

CONFIRM DIRECTION OF MACHINE TO

• Incorrect travel pedal/lever operation may result in