GROUP 2 HYDRAULIC AND MECHANICAL SYSTEM

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

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

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

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

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

Is primary pilot
pressure within ‫ڞ‬
NO standard level?

YES
Clean pilot piping
Is not pilot piping interior or repair
YES clogged or is not piping.
oil leakage present
on pilot piping?
Pilot valve is faulty. Disassemble and
NO
‫ڞ‬ repair.
YES
Pilot relief valve is Repair or replace.
faulty.
Is gear pump
NO delivering oil?

Gear pump is Disassemble and

NO broken. repair.

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

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

Air is intruded. Check suction

NO
line and return
line and eliminate
the air intruding
source.

2) HYDRAULIC OIL TEMPERATURE HAS RISEN ABNORMALLY

Cause Remedy
NO
Replenish
specified oil to the
standard level.
Is hydraulic oil YES
volume proper? Clean oil cooler.
Is not oil cooler Secure air
clogged and is circulation route.
YES anything blocking YES ‫ڞ‬
Is fan belt tension
NO proper?
Adjust belt
NO
tension or
replace belt.

Is not the set YES Readjust set

pressure of main
pressure.
‫ڞ‬ relief,port relief and
travel relief valve
lower than the Is main relief valve YES
Reduce load.
standard level? used very often?
NO

6-7
 3) CAVITATION OCCURS WITH PUMP

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

4) HYDRAULIC OIL IS CONTAMINATED

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

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

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

YES
Pilot relief valve is Disassemble and
NO Is gear pump faulty. repair or replace.
delivering oil?
Gear pump is out Disassemble and
Is gear pump pilot NO
of order. repair.
‫ڠ‬ pressure within
standard level? YES
Is not there oil Clean pilot piping
leakage from pilot interior or repair
YES piping or is not it piping.
clogged?
Pilot valve is Disassemble and
NO
broken. repair.

6-9
 2) SWING SPEED IS LOW

Does swing control
YES
valve spool move
smoothly by hand?
Is MCV pilot
pressure same on
LH and RH sides?
Is not pilot piping
Single direction clogged or is not it
NO
leaking oil?
Is the trouble in
one direction or in
both direction?
Both directions
Is MCV pilot
YES
pressure within
Is Dozer speed
standard level?
within standard
value?
NO
Cause Remedy
YES
Swing port relief Disassemble and
valve is faulty. repair or replace.
NO
Swing control valve Disassemble and
spool is stuck. repair.
YES
Clogged or oil leak. Clean pilot piping
interior or repair
piping.
Pilot valve or shuttle Disassemble and
NO
valve is faulty. repair.
YES
‫ڞ‬
Does swing control
YES
valve spool move
Disassemble and
lightly by hand?
Swing control valve repair.
NO
spool is stuck.
‫ڟ‬
NO
‫ڠ‬

Is swing motor's
NO
‫ڞ‬ drain rate within Swing motor is Disassemble and
standard value? broken. repair.
Check that pilot
YES piping is not NO
clogged or oil is not Pilot valve or shuttle Disassemble and
leaking from it? valve is faulty. repair.

Clogged or oil leak. Clean pilot piping

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

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

Cause Remedy
YES
Does symptom Swing port relief Disassemble and
change when LH valve is faulty. repair.
YES
and RH port relief
valves are
Does swing Shuttle valve is Disassemble and
YES exchanged? NO
control valve spool faulty. repair.
move smoothly by
Is MCV pilot Swing control valve Disassemble and
pressure same for NO
spool is stuck. repair.
LH and RH? Check if pilot piping
is not clogged or YES
Pilot valve is faulty. Disassemble and
NO does not have oil
leakage. repair.

Clogged or oil
Clean pilot piping
leak.
interior or repair
piping.

4) MACHINE SWINGS BUT DOES NOT STOP

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

Return spring is Disassemble and

NO
faulty. replace.

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

Cause Remedy
NO
Shuttle valve is Disassemble and
YES Is swing shuttle faulty. replace.
valve normal?
YES Is brake spring
‫ڞ‬
YES
normal?
Is return spring of
swing control Brake spring is Disassemble and
valve normal? NO
faulty replace.

Return spring of Disassemble and

NO
swing control valve replace.
is faulty.

YES
Swing relief valve Disassemble and
YES Is drain rate of is faulty. repair or replace.
swing motor within
standard value?
Is swing relief Swing motor is Disassemble and
NO
‫ڞ‬ pressure within broken. repair.
standard level?

NO
Adjust swing relief
valve pressure or
replace swing
relief valve.

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

Cause Remedy
YES
‫ڞ‬
Travel motor relief
YES
valve within
standard pressure
YES Is the travel speed NO
Travel relief valve Disassemble and
solenoid valve is faulty repair or replace.
normal?
Travel speed Disassemble and
NO
Is the travel pilot solenoid valve is repair or replace.
YES
pressure within faulty
standard?
YES
Accelerator pedal Disassemble and
or travel forward/ repair or replace.
Travel pilot Reverse solenoid
NO
solenoid valve
valve is faulty
normal?

Travel pilot Disassemble and

NO
solenoid valve is repair or replace.
Is bucket operation
faulty
possible?
YES
Transmission Disassemble and
unit is faulty. repair.
‫ڞ‬ Does travel motor
rotate?

Travel motor is out Disassemble and

NO
of order. repair.
Does the symptom
change when front
YES
and rear pump Hydraulic pump is Disassemble and
NO
discharge hoses broken. repair.
are exchanged?

6 - 13
 2) TRAVEL ACTION IS POWERLESS(TRAVEL ONLY)

Cause Remedy
YES
‫ڞ‬
Travel motor relief
YES
valve within
standard pressure
YES Is the travel speed NO
Travel relief valve Disassemble and
solenoid valve is faulty repair or replace.
normal?
Travel speed Disassemble and
NO
Is the travel pilot solenoid valve is repair or replace.
YES
pressure within faulty
standard?
YES
Accelerator pedal Disassemble and
or travel forward/ repair or replace.
Travel pilot Reverse solenoid
NO
solenoid valve
valve is faulty
normal?

Travel pilot Disassemble and

NO
Is the travel action solenoid valve is repair or replace.
powerless in both faulty
direction?
YES
Transmission Disassemble and
unit is faulty. repair.
‫ڞ‬ Does travel motor
rotate?

Travel motor is out Disassemble and

NO
of order. repair.

YES
The travel relief Disassemble and
Does the symptom valve is faulty. repair or replace.
change when
YES
NO travel relief valve Travel motor is out Disassemble and
are exchanged? Does the symptom
change when of order. repair.
travel motor
NO
suction hoses are
exchanged? Travel motor Disassemble and
NO
suction valve is repair or replace.
faulty.

6 - 14
6. ATTACHMENT SYSTEM
1) BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL

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

YES
Cylinder interior is Disassemble and
Does control valve
‫ڞ‬ broken. repair.
spool move lightly
by hand?
Control valve spool Disassemble and
NO
is stuck. repair.

6 - 15
 2) BOOM, ARM OR BUCKET SPEED IS LOW
Cause Remedy
YES
Normal

Does the symptom OK Port relief valve is Disassemble and

YES change when port faulty. repair or replace.
relief valve is
Is speed low only replaced with other
in composite Does control valve valve? Cylinder is faulty. Disassemble and
YES NO
operation? spool move lightly repair.
by hand?
Control valve spool Disassemble and
NO
is stuck. repair.

Is MCV pilot
pressure within YES
NO Clean pilot piping
standard level? Is not MCV pilot
interior or repair
YES pressure piping
clogged or is not piping.
there oil leakage?
Pilot valve is Disassemble and
Is gear pump pilot NO
pressure within defective. repair.
NO
standard level?
YES
Pilot relief valve is Disassemble and
Is gear pump faulty. repair or replace.
NO delivering oil?
Gear pump is Disassemble and
NO
broken. repair.

6 - 16
 3) BOOM, ARM OR BUCKET CYLINDER EXTENDS OR CONTRACTS ITSELF AND ATTACHMENT FALLS

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

Replace with
NO
genuine hydraulic
oil or equivalent.
OK
Pressure tightness Disassemble and
Disassemble and between control repair.
inspect check
YES valve in hydraulic valve casing and
circuit and check spool is poor.
for any fault.
Is cylinder internal Abnormal Contact surface Disassemble and
‫ڞ‬ leakage within between poppet repair.
standard level? and seat is poor.

Cylinder is faulty. Disassemble and

NO
repair.

4) BOOM, ARM OR BUCKET POWER IS WEAK

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

Main relief valve is Adjust pressure,

NO
defective. repair or replace.

6 - 17
 5) BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED

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

Boom foot pin has Supply grease to

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

6 - 18
Ɠ HOW TO CHECK INTERNAL BOOM CYLINDER LEAKAGE

1. Lower the outrigger and / or dozer blade at

ground.
2. Lower the bucket teeth to the ground with
bucket cylinder fully retracted and arm
cylinder rod retracted almost in full.

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

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

4. Raise bucket OFF the ground by retracting

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

6 - 19