Tt18ke00 Troubleshooting PDF

INTRODUCTION
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition The Engine Manual
to this manual. Parts Catalog of the Engine
Hitachi Training Material
The Operators Manual
The Parts Catalog
MANUAL COMPOSITION
This manual consists of three portions: the Techni- Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
Information included in the Technical Manual Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redelivery and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
PAGE NUMBER
Each page has a number, located on the center

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

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

signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
NOTE:
To avoid injury and damage, be sure to use appropri-
Indicates supplementary technical information or
ate lifting techniques and equipment when lifting
know-how.
heavy parts.
UNITS USED
SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
3 3
m yd 1.308 Temperature C F C 1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque Nm kgf m 1.0197 mL/rev cc/rev 1.0
Nm lbf ft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
These are the SAFETY ALERT SYMBOLS.
When you see these symbols on your machine or

in this manual, be alert to the potential for per-
sonal injury.
Follow recommended precautions and safe oper-
ating practices.
001-E01A-0001
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 desig-
nated signal words above after the safety alert
symbol are occasionally used on this machine.
To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT indi-
cates a situation which, if not avoided, could result in
damage to the machine. SA-1223
NOTE indicates an additional explanation for an

element of information.
002-E01A-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
Carefully read and follow all safety signs on the
machine and all safety messages in this manual.
Safety signs should be installed, maintained and
replaced when necessary.
If a safety sign or this manual is damaged or

missing, order a replacement from your author-
ized dealer in the same way you order other re-
placement parts (be sure to state machine model
and serial number when ordering).
Learn how to operate the machine and its controls
correctly and safely.
Allow only trained, qualified, authorized personnel to
operate the machine. SA-003
Keep your machine in proper working condition.
Unauthorized modifications of the machine may

impair its function and/or safety and affect ma-
chine life.
Do not modify any machine parts without au-
thorization. Failure to do so may deteriorate the
part safety, function, and/or service life. In addi-
tion, personal accident, machine trouble, and/or
damage to material caused by unauthorized
modifications will void Hitachi Warranty Policy.
Do not use attachments and/or optional parts or
equipment not authorized by Hitachi. Failure to do
so may deteriorate the safety, function, and/or
service life of the machine. In addition, personal
accident, machine trouble, and/or damage to
material caused by using unauthorized attach-
ments and/or optional parts or equipment will void
Hitachi Warranty Policy.
The safety messages in this SAFETY chapter are
intended to illustrate basic safety procedures of
machines. 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 au-
thorized dealer before operating or performing
maintenance work on the machine.
003-E01B-0003
SA-2
SAFETY
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-
lance service, hospital, and fire department
posted near your telephone. SA-437
004-E01A-0437
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
Respirator or filter mask.
Be sure to wear the correct equipment and clothing
for the job. Do not take any chances. SA-428
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 atten-
tion of the operator. Do not wear radio or music
headphones while operating the machine.
005-E01A-0438
SA-3
SAFETY
PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause im-
pairment or loss of hearing.
Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objec-
tionable 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 per-
sonal injury.
In the walk-around inspection be sure to cover all

points described in the "RE-START INSPEC-
TION" chapter in the operator's manual.
007-E01A-0435
SA-435
SA-4
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.
Do not leave parts and/or tools lying around the
operator's seat. Store them in their specified loca-
tions.
Avoid storing transparent bottles in the cab. Do
not attach any transparent type window decora-
tions 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.
Do not leave cigarette lighters in the cab. When
the temperature in the cab increases, the lighter
may explode.
524-E01A-0000
SA-5
SAFETY
USE HANDHOLDS AND STEPS
Falling is one of the major causes of personal injury.
When you get on and off the machine, 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.
Be careful of slippery conditions on platforms,
steps, and handrails when leaving the machine.
008-E01A-0439
SA-439
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 mis-operations.
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.
Adjust the rear view mirror position so that the
best rear visibility is obtained from the operator's
seat. If the mirror is broken, immediately replace it SA-462
with a new one.
009-E01A-0462
SA-6
SAFETY
ENSURE SAFETY BEFORE RISING FROM
OR LEAVING OPERATOR'S SEAT
Before rising from the operator's seat to open/close
either side window or to adjust the seat position, be
sure to first lower the front attachment to the ground
and then move the pilot control shut-off lever to the
LOCK position. Failure to do so may allow the ma-
chine to unexpectedly move when a body part un-
intentionally comes in contact with a control lever,
possibly resulting in serious personal injury or death.
Before leaving the machine, be sure to first lower

the front attachment to the ground and then move
the pilot control shut-off lever to the LOCK posi-
tion. Turn the key switch OFF to stop the engine.
Before leaving the machine, close all windows,
doors, and access covers and lock them up.
FASTEN YOUR SEAT BELT

If the machine should overturn, the operator may
become injured and/or thrown from the cab. Addi-
tionally the operator may be crushed by the over-
turning machine, resulting in serious injury or death.
Prior to operating the machine, thoroughly ex-

amine 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 se-
curely 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 SA-237
every three years regardless of its apparent con-

dition.
010-E01A-0237
SA-7
SAFETY
MOVE AND OPERATE MACHINE SAFELY
Bystanders can be run over.
Take extra care not to run over bystanders. Con-

firm 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. Coor-
dinate hand signals before starting the machine.
Use appropriate illumination. Check that all lights
are operable before operating the machine. If any
faulty illumination is present, immediately repair it.
SA-426
011-E01A-0398
HANDLE STARTING AIDS SAFELY

Starting fluid:
Starting fluid is highly flammable.
Keep all sparks and flame away when using it.

Keep starting fluid well away from batteries and
cables.
Remove container from machine if engine does
not need starting fluid.
To prevent accidental discharge when storing a
pressurized container, keep the cap on the con-
tainer, and store it in a cool, well-protected loca-
tion.
Do not incinerate or puncture a starting fluid con-
SA-293
tainer.
036-E01A-0293-3
SA-8
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
Inappropriate engine starting procedures may cause
the machine to runaway, possibly resulting in seri-
ous injury or death.
Start the engine only when seated in the opera-

tor's seat.
NEVER start the engine while standing on the
track or on ground.
Do not start engine by shorting across starter
terminals.
Before starting the engine, confirm that all control
levers are in neutral.
Before starting the engine, confirm the safety SA-444
around the machine and sound the horn to alert

bystanders.
012-E01B-0431
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 op-
eration.
Never use a frozen battery.
Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway
machine.
SA-032
S013-E01A-0032
SA-9
SAFETY
KEEP RIDERS OFF MACHINE
Riders on machine are subject to injury such as be-
ing 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.
014-E01B-0427
SA-379
PRECAUTIONS FOR OPERATIONS

Investigate the work site before starting operations.
Be sure to wear close fitting clothing and safety

equipment appropriate for the job, such as a hard
hat, etc. when operating the machine.
Clear all persons and obstacles from area of op-
eration and machine movement.
Always beware of the surroundings while operat-
ing. When working in a small area surrounded by
obstacles, take care not to hit the upperstructure
against obstacles.
When loading onto trucks, bring the bucket over
the truck beds from the rear side. Take care not to
swing the bucket over the cab or over any person.
M104-05-015
SA-10
SAFETY
INVESTIGATE JOB SITE BEFOREHAND
When working at the edge of an excavation or on a
road shoulder, the machine could tip over, possibly
resulting in serious injury or death.
Investigate the configuration and ground condi-
tions of the job site beforehand to prevent the
machine from falling and to prevent the ground,
stockpiles, or banks from collapsing.
Make a work plan. Use machines appropriate to
the work and job site.
Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
When working on an incline or on a road shoulder, SA-380
employ a signal person as required.
Confirm that your machine is equipped a FOPS
cab before working in areas where the possibility
of falling stones or debris exist.
When the footing is weak, reinforce the ground
before starting work.
When working on frozen ground, be extremely
alert. As ambient temperatures rise, footing be-
comes loose and slippery.
Beware the possibility of fire when operating the
machine near flammable objects such as dry
grass.
Make sure the worksite has sufficient strength to
firmly support the machine.
When working close to an excavation or at road
shoulders, operate the machine with the tracks po-
sitioned perpendicular to the cliff face with travel
motors at the rear, so that the machine can more
easily evacuate if the cliff face collapses.
If working on the bottom of a cliff or a high bank is
required, be sure to investigate the area first and
confirm that no danger of the cliff or bank collapsing
exists. If any possibility of cliff or bank collapsing
exists, do not work on the area.
Soft ground may collapse when operating the ma-
chine on it, possibly causing the machine to tip over.
When working on a soft ground is required, be sure
to reinforce the ground first using large pieces of
steel plates strong and firm enough to easily support
the machine.
Note that there is always a possibility of machine
tipping over when working on rough terrain or on
slopes. Prevent machine tipping over from occurring.
When operating on rough terrain or on slopes:
Reduce the engine speed.
Select slow travel speed mode.
Operate the machine slowly and be cautious with
machine movements.
SA-11
SAFETY
EQUIPMENT OF HEAD GUARD, ROPS,
FOPS
In case the machine is operated in areas where the
possibility of falling stones or debris exist, equip a
head guard, ROPS, or FOPS according to the poten-
tial hazardous conditions. (The standard cab for this
machine corresponds to ROPS and FOPS.)
ROPS: Roll-Over Protective Structure

FOPS: Falling Object Protective Structure
SA-490
PROVIDE SIGNALS FOR JOBS 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
position. 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.
017-E01A-0491
SA-491
SA-12
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.
Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or
death. SA-657
Never attempt to ascend or descend 35 degrees

or steeper slopes.
Be sure to fasten the seat belt.
When driving up or down a slope, keep the bucket
facing the direction of travel, approximately 0.5 to
1.0 m (A) above the ground.
If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop.
SA-658
SA-441
SA-442
SA-13
SAFETY
DRIVE MACHINE SAFELY
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 safe operation.
Avoid swinging the upperstructure on slopes.
Never attempt to swing the upperstructure down-
hill. The machine may tip over. If swinging uphill is
unavoidable, carefully operate the upperstructure
and boom at slow speed. Travel Motor
If the engine stalls on a slope, immediately lower
the bucket to the ground. Return the control lev-
M104-05-008
ers to neutral. Then, restart the engine.
Be sure to thoroughly warm up the machine be-
fore ascending steep slopes. If hydraulic oil has
not warmed up sufficiently, sufficient performance
may not be obtained.
Use a signal person when moving, swinging or
operating the machine in congested areas. Coor-
dinate hand signals before starting the machine.
Before moving machine, determine which way to
move travel pedals/levers for the direction you
Arrow-Mark
want to go. When the travel motors are in the rear,
pushing down on the front of the travel pedals or M178-03-001
pushing the levers forward moves the machine

forward, towards the idlers.
An arrow-mark seal is stuck on the inside surface
of the side frame to indicate the machine front
direction.
Select a travel route that is as flat as possible.
Steer the machine as straight as possible, making
small gradual changes in direction.
Before traveling on them, check the strengths of
bridges and road shoulders, and reinforce if nec-
essary.
SA-14
SAFETY
Use wood plates in order not to damage the road
surface. Be careful of steering when operating on
asphalt roads in summer.
When crossing train tracks, use wood plates in
order not to damage them.
Do not make contact with electric wires or
bridges.
When crossing a river, measure the depth of the
river using the bucket, and cross slowly. Do not
cross the river when the depth of the river is
deeper than the upper edge of the upper roller.
When traveling on rough terrain, reduce engine
speed. Select slow travel speed. Slower speed
will reduce possible damage to the machine.
Avoid operations that may damage the track and SA-011
undercarriage components.
During freezing weather, always clean snow and
ice from track shoes before loading and unloading
machine, to prevent the machine from slipping.
SA-15
SAFETY
AVOID INJURY FROM ROLLAWAY ACCI-
DENTS
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 ma-
chine.
Do not park the machine on a grade.
Lower the bucket and/or other work tools to the
ground.
Turn the auto-idle switch and the H/P mode
switch off.
Run the engine at slow idle speed without load for
5 minutes to cool down the engine. SA-391
Stop the engine and remove the key from the key
switch.
Pull the pilot control shut-off lever to LOCK posi-
tion.
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-E02A-0493
SA-16
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.
Keep the travel alarm in working condition (if
equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOV-
ING INTO THE WORK AREA. USE THE HORN SA-383
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.
No machine motions shall be made unless signals
are clearly understood by both signalman and
operator.
Learn the meanings of all flags, signs, and mark-
ings used on the job and confirm who has the SA-384
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.
021-E01A-0494
SA-17
SAFETY
KEEP PERSON CLEAR FROM WORKING
AREA
A person may be hit severely by the swinging front
attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.
Keep all persons clear from the area of operation

and machine movement.
Before operating the machine, set up barriers to
the sides and rear area of the bucket swing radius
to prevent anyone from entering the work area.
022-E01A-0386
SA-386
NEVER POSITION BUCKET OVER ANY-

ONE
Never lift, move, or swing bucket above anyone or a
truck cab.
Serious injury or machine damage may result due to
bucket load spill or due to collision with the bucket.
023-E01A-0487
SA-487
AVOID UNDERCUTTING
In order to retreat from the edge of an excavation if
the footing should collapse, always position the un-
dercarriage perpendicular to the edge of the exca-
vation with the travel motors at the rear.
If the footing starts to collapse and if retreat is not

possible, do not panic. Often, the machine can be
secured by lowering the front attachment, in such
cases.
024-E01A-0488 SA-488
SA-18
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING
MACHINE---SERIOUS OR FATAL CRUSHING IN-
JURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU
CAN JUMP FREE
FASTEN YOUR SEAT BELT
The danger of tipping is always present when oper-
ating on a grade, possibly resulting in serious injury
or death.
To avoid tipping:
Be extra careful before operating on a grade.
SA-012
Prepare machine operating area flat.

Keep the bucket low to the ground and close to
the machine.
Reduce operating speeds to avoid tipping or slip-
ping.
Avoid changing direction when traveling on
grades.
NEVER attempt to travel across a grade steeper
than 15 degrees if crossing the grade is un-
avoidable.
Reduce swing speed as necessary when swing-
ing loads.
SA-440
Be careful when working on frozen ground.
Temperature increases will cause the ground to

become soft and make ground travel unstable.
025-E03B-0463
NEVER UNDERCUT A HIGH BANK

The edges could collapse or a land slide could occur
causing serious injury or death.
026-E01A-0519
SA-489
SA-19
SAFETY
DIG WITH CAUTION
Accidental severing of underground cables or gas
lines may cause an explosion and/or fire, possibly
resulting in serious injury or death.
Before digging check the location of cables, gas

lines, and water lines.
Keep the minimum distance required, by law, from
cables, gas lines, and water lines.
If a fiber optic cable should be accidentally sev-
ered, do not look into the end. Doing so may re-
sult in serious eye injury.
Contact your local "diggers hot line" if available in
SA-382
your area, and/or the utility companies directly.
Have them mark all underground utilities.
027-E01A-0382
OPERATE WITH CAUTION

If the front attachment or any other part of the ma-
chine hits against an overhead obstacle, such as a
bridge, both the machine and the overhead obstacle
will be damaged, and personal injury may result as
well.
Take care to avoid hitting overhead obstacles with

the boom or arm.
SA-389
028-E01A-0389
SA-20
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 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
PRECAUTIONS FOR LIGHTENING

The machine is vulnerable to lighting strikes.
In the event of an electrical storm, immediately

stop operation, and lower the bucket to the
ground. Evacuate to a safe place far away from
the machine.
After the electrical storm has passed, check all of
the machine safety devices for any failure. If any
failed safety devices are found, operate the ma-
chine only after repairing them.
SA-1088
OBJECT HANDLING
If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed under-
neath 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 safely and securely situated on supporting
blocks or on the ground. SA-014
Never attach a sling or chain to the bucket teeth.

They may come off, causing the load to fall.
032-E01A-0132
SA-21
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.
031-E01A-0432
SA-432
PARK MACHINE SAFELY

To avoid accidents:
Park machine on a firm, level surface.
Lower bucket to the ground.
Turn auto-idle switch 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.
Close windows, roof vent, and cab door. SA-390
Lock all access doors and compartments.
HANDLE FLUIDS SAFELY-AVOID FIRES

Handle fuel with care; it is highly flammable. If fuel
ignites, an explosion and/or a fire may occur, possi-
bly 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 ma-
chine.
Fill the fuel tank outdoors.
All fuels, most lubricants, and some coolants are

flammable.
Store flammable fluids well away from fire haz- SA-018
ards.
Do not incinerate or puncture pressurized con-
tainers.
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-22
SAFETY
TRANSPORT SAFELY
Take care the machine may turn over when loading
or unloading the machine onto or off of a truck or
trailer.
Observe the related regulations and rules for safe

transportation.
Select an appropriate truck or trailer for the ma-
chine to be transported.
Be sure to use a signal person.
Always follow the following precautions for load-
ing or unloading:
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to
support the machine weight. SA-395
3. Turn auto-idle switch OFF.

4. Always select the slow speed mode with the
travel mode switch.
5. Never load or unload the machine onto or off a
truck or trailer using the front attachment func-
tions when driving up or down the ramp.
6. Never steer the machine while on the ramp. If the
traveling direction must be changed while the
ramp, unload the machine from the ramp, repo-
sition the machine on the ground, and then try
loading again.
7. The top end of the ramp where it meets the flat-
bed is a sudden bump. Take care when traveling
over it.
8. Place blocks in front of and behind the tracks.
Securely hold the machine to the truck or trailer
deck with wire ropes.
Be sure to further follow the details described in the

TRANSPORTING section in the operator's manual.
035-E07A-0454
SA-23
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
Understand service procedures before starting
work.
Keep the 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 switch off.
4. Run the engine at slow idle speed without load
for 5 minutes.
5. Turn the key switch to OFF to stop engine.
SA-028
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.
500-E02C-0520
SA-527
SA-24
SAFETY
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
100° angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
Inspect certain parts periodically and repair or re-
place as necessary. Refer to the section discuss-
ing that part in the "MAINTENANCE" chapter of
this manual.
SA-037
Keep all parts in good condition and properly in-
stalled.
Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or de-
bris.
When cleaning parts, always use nonflammable
detergent oil. Never use highly flammable oil such
as fuel oil and gasoline to clean parts or surfaces.
Disconnect battery ground cable (-) before mak-
ing adjustments to electrical systems or before
performing welding on the machine.
Sufficiently illuminate the work site. Use a main-
tenance work light when working under or inside
the machine.
Always use a work light protected with a guard. In
case the light bulb is broken, spilled fuel, oil, anti-
freeze fluid, or window washer fluid may catch
fire.
WARN OTHERS OF SERVICE WORK

Unexpected machine movement can cause serious
injury.
Before performing any work on the machine, at-

tach a "Do Not Operate" tag on the control lever.
This tag is available from your authorized dealer.
501-E01A-0287
T1J1-01-01-001
SA-25
SAFETY
SUPPORT MACHINE PROPERLY
Never attempt to work on the machine without se-
curing 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 attach-
ment, securely support the machine or attach-
ment. Do not support the machine on cinder
blocks, hollow tires, or props that may crumble
under continuous load. Do not work under a ma-
chine that is supported solely by a jack.
SA-527
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-26
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.
Never attempt to disassemble the track adjuster.
Inadvertent disassembling of the track adjuster
may cause the parts such as a spring to fly off,
possibly resulting in severe personal injury or
death.
SA-344
Travel reduction gears are under pressure.
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, and
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.
504-E01A-0034
SA-034
SA-27
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
stop. Allow all pressure to be released before
SA-039
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.
Wait for the oil and components to cool before SA-225

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

CALLY
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.)
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 SA-019
result in severe burns, gangrene, or otherwise

serious injury or death.
S506-E01A-0019
SA-28
SAFETY
AVOID HIGH-PRESSURE FLUIDS
Fluids such as diesel fuel or hydraulic oil under
pressure can penetrate the skin or eyes causing se-
rious 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-pressure fluids. Wear a face shield or gog-
gles 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 SA-031
few hours or gangrene may result.
507-E03A-0499
SA-292
SA-044
SA-29
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-cooler flange bolts.
Do not bend or strike high-pressure lines.
Never install bent or damaged lines, pipes, or
hoses.
SA-019
Check for Shorts:

Short circuits can cause fires.
Clean and tighten all electrical connections.
Check before each shift or after eight(8) to ten(10)
hours operation for loose, kinked, hardened or
frayed electrical cables and wires.
Check before each shift or after eight(8) to ten(10)
hours operation 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, ac-
cumulated coal dust, and other flammables may
cause fires.
Prevent fires by inspecting and cleaning the ma-
chine daily and by removing spilled or accumu-
lated 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 con-
firm that the engine stops.
If any abnormalities are found, be sure to repair
them before operating the machine.
508-E02B-0019
Check Heat Shields:

Damaged or missing heat shields may lead to fires.
Damaged or missing heat shields must be re-
paired or replaced before operating the machine.
508-E02A-0393
SA-30
SAFETY
EVACUATING IN CASE OF FIRE
If a fire breaks out, evacuate the machine in the fol-
lowing 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.
In an emergency, if the cab door or front window
cannot be opened, break the front or rear window
panes with the emergency evacuation hammer to
SA-393
escape from the cab. Refer the explanation pages
on the Emergency Evacuation Method in the op-
erator's manual.
18-E02B-0393
SS-1510
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
starting grinding.
After finishing welding and grinding, recheck that
there are no abnormalities such as the area sur- SA-818
rounding the welded area still smoldering.
523-E01A-0818
SA-31
SAFETY
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. In-
stall temporary fire-resistant guards to protect
hoses or other materials before engaging in
welding, soldering, etc..
SA-030
AVOID APPLYING HEAT TO LINES CON-

TAINING 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
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
dust.
Wear an approved respirator. SA-029
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
SA-32
SAFETY
BEWARE OF ASBESTOS DUST
Take care not to inhale dust produced in the work
site. Inhalation of asbestos fibers may be the cause
of lung cancer.
Depending on the wok site conditions, the risk of

inhaling asbestos fiber may exist. Spray water to
prevent asbestos from becoming airborne. Don't
use compressed air.
When operating the machine in a work site where
asbestos might be present, be sure to operate the
machine from the upwind side and wear a mask
rated to prevent the inhalation of asbestos.
Keep bystanders out of the work site during op-
eration. SA-029
Asbestos might be present in imitation parts. Use

only genuine Hitachi Parts.
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
object across the posts. Use a voltmeter or hy-
drometer.
Do not charge a frozen battery or start engine with
frozen battery.
There is fear of explosion. If battery electrolyte is
frozen, wait until it is liquefied completely in an
atmospheric temperature room.
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-E01B-0032
SA-33
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
If spilled onto skin, refrigerant may cause a cold
contact burn.
Refer to the instructions described on the con-

tainer for proper use when handling the refriger-
ant.
Use a recovery and recycling system to avoid
leaking refrigerant into the atmosphere.
Never touch the refrigerant.
513-E01A-0405
SA-405
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
hazardous chemical. That way you will know ex-
actly what the risks are and how to do the job
safely. Then follow procedures and use recom- SA-309
mended equipment.
See your authorized dealer for MSDS's (available
only in English) on chemical products used with
your machine.
515-E01A-0309
SA-34
SAFETY
DISPOSE OF WASTE PROPERLY
Improperly disposing of waste can threaten the en-
vironment 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
can damage the Earth's atmosphere. Govern-
ment regulations may require a certified air condi- SA-226
tioning 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, or from your authorized dealer.
516-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-35
SAFETY
(Blank)
SA-36
SECTION 4 OPERATIONAL
SECTION AND GROUP PERFORMANCE TEST
CONTENTS
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
TECHNICAL MANUAL SECTION 5 TROUBLESHOOTING
(Troubleshooting) Group 1 General
Group 2 Cross Reference Table
Group 3 Component Layout
Group 4 Troubleshooting A
Group 5 Troubleshooting B
Group 6 Troubleshooting C
Group 7 Electrical System Inspection
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Control Equipment
Group 1 Controller Group 5 DQR Valve
Group 2 Control System Group 6 Travel Device
Group 3 ELU System Group 7 Others (Upperstructure)
Group 4 Hydraulic System Group 8 Others (Undercarriage)
Group 5 Electrical System
WORKSHOP MANUAL
SECTION 1 GENERAL SECTION 3 UNDERCARRIAGE
Group 1 Precautions for Disassem- Group 1 Swing Bearing
bling and Assembling Group 2 Travel Device
Group 2 Tightening Group 3 Travel Brake Valve
Group 3 Painting Group 4 Drive Tumbler
Group 4 Bleed Air from Hydraulic Group 5 Center Joint
Oil Tank Group 6 Adjuster Cylinder
SECTION 2 UPPERSTRUCTURE Group 7 Front Idler
Group 1 Cab Group 8 Upper and Lower Roller
Group 2 Counterweight Group 9 Track
Group 3 Pump Device Group 10 Accumulator
Group 4 Control Valve Group 11 Welding Repair Procedure
Group 5 Swing Device SECTION 4 FRONT ATTACHMENT
Group 6 DQR Valve Group 1 Front Attachment
Group 7 Shuttle Valve Group 2 Cylinder
Group 8 EHC Valve Group 3 Bushing and Point
Group 9 Oil Cooler Fan Motor
Group 10 Compressor Drive Motor
Group 11 Air Conditioner
SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction Group 5 Component Test
Operational Performance Test .................. T4-1-1 Primary Pilot Pressure Check ................... T4-5-1
Preparation for Performance Tests ........... T4-1-2 EHC Valve Secondary Pilot Pressure ....... T4-5-2
DQR Valve Secondary Pilot Pressure ....... T4-5-4
Group 2 Standard
Main Relief Pressure, Relief Pressure ...... T4-5-6
Operational Performance Standard
Overload Relief Valve Set Pressure ........ T4-5-10
Table....................................................... T4-2-1
Main Pump Flow Rate Measurement ...... T4-5-12
Main Pump P-Q Diagram.......................... T4-2-5
Oil Cooler Fan Motor Drive Pump
Main Pump Pi-Q Diagram ......................... T4-2-5
Flow Rate Measurement ....................... T4-5-20
Swing Motor Drainage ............................ T4-5-28
P-Q Diagram........................................... T4-2-6
Travel Motor Drainage ............................ T4-5-30
Pi-Q Diagram .......................................... T4-2-6
Electric Lever............................................ T4-2-7
Group 3 Engine Test

Engine Speed ........................................... T4-3-1
Group 4 Excavator Test

Travel Speed ............................................ T4-4-1
Track Revolution Speed............................ T4-4-2
Mistrack .................................................... T4-4-3
Travel Parking Leakage............................ T4-4-4
Swing Speed ............................................ T4-4-5
Swing Function Drift ................................. T4-4-6
Swing Motor Leakage ............................... T4-4-8
Maximum Swingable Slant Angle.............. T4-4-9
Swing Bearing Play ................................ T4-4-10
Hydraulic Cylinder Cycle Time ................ T4-4-12
Dig Function Drift Check......................... T4-4-14
Control Lever Operating Force ............... T4-4-16
Control Lever Stroke............................... T4-4-17
Boom Raise/Swing Combined
Operation Check................................... T4-4-18
18KT-4-1
(Blank)
18KT-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TEST
Use operational performance test procedure to quan-

titatively check all system and functions on the ma-
chine.
Purpose of Performance Tests

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

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

rate as the working hours increase. However, the
machine performance is normally considered to re-
duce in proportion to the increase of the operation
hours. Accordingly, restoring the machine perform-
ance by repair, adjustment, or replacement shall con-
sider the number of the machines working hours.
Definition of Performance Standard

1. Operation speed values and dimensions of the
new machine.
2. Operational performance of new components
adjusted to specifications. Allowable errors will be
indicated as necessary.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out

performance tests accurately and safely.
THE MACHINE
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.
TEST AREA AND MEASURING EQUIPMENT

1. Select a hard and flat surface.
2. Secure enough space to allow the machine to
run straight more than 20 m (65 ft 7 in), and to
make a full swing with the front attachment ex-
tended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.
4. Prepare measuring instruments and apparatus
suitable to test requirements.
5. Arrange a test weight or an equivalent heavy T105-06-01-003
material.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among cowork-
ers. Once the test is started, be sure to commu-
nicate 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 escaping oil.
Pay special attention to this when removing hy-
draulic pipings. T105-06-01-004
MAKE PRECISE MEASUREMENT

1. Accurately calibrate test instruments in advance
to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.
T4-1-2
OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE STAN-
DARD TABLE
The standard performance values are listed in the The standard measurement conditions are as follows.
table below. Engine Control Lever: Fast Idle Position
Refer to the Groups 3 to 5 for performance test Hydraulic Oil Temperature: 50 5 C (122 9 F)
procedures. Values indicated in parentheses are
reference values.
The following switch positions shall be selected and

the hydraulic oil temperature shall be maintained as
indicated below as the preconditions of performance
tests unless otherwise instructed in each performance
test procedure:
Performance Reference
Performance Test Designation Remarks
Standard Page
ENGINE SPEED -1
(min ) T4-3-1
Fast Idle Speed 2000 50
Slow Idle Speed 700 50
Auto-Idle Speed 1400 50
TRAVEL SPEED (sec/20 m) T4-4-1
Fast Speed Mode 25.5 2.0
Slow Speed Mode 34.0 2.0
TRACK REVOLUTION SPEED (sec/3 rev) T4-4-2
Fast Speed Mode 58.0 2.0
Slow Speed Mode 77.0 2.0
MISTRACK (mm/20 m)
250 or less T4-4-3
(With fast and slow travel speed modes)
TRAVEL MOTOR DRIFT CHECK (mm/5 min) 0 T4-4-4
SWING SPEED (sec/3 rev) 38.0 1.0 T4-4-5
SWING FUNCTION DRIFT CHECK (mm/180) 1400 or less T4-4-6
SWING MOTOR LEAKAGE 0 T4-4-8
(mm/5 min)
MAXIMUM SWINGABLE SLANT ANGLE BH: 10 or possibly
(deg.) more, LD: 11 or T4-4-9
possibly more
SWING BEARING PLAY (mm) 2.0 or less T4-4-10
NOTE: BH : Backhoe (8.3 m Boom, 3.6 m Arm,

12.0 m3 (PCSA heaped) Bucket)
LD : Loading Shovel
T4-2-1
Performance Test Designation Remarks
Standard Page
HYDRAULIC CYLINDER CYCLE TIME (sec) T4-4-12
Backhoe
Boom Raise 6.9 0.5
Boom Lower 4.5 0.5
Arm Roll-In 5.9 0.5
Arm Roll-Out 4.5 0.5
Bucket Roll-In 4.3 0.5
Bucket Roll-Out 3.5 0.5
Loading Shovel
Boom Raise 7.5 0.6
Boom Lower 5.8 0.5
Arm Extend 3.4 0.5
Arm Retract 3.9 0.5
Bucket Tilt-In 3.4 0.5
Bucket Tilt-Out 3.2 0.5
Bucket Open 2.3 0.3
Bucket Close 1.8 0.3
DIG FUNCTION DRIFT CHECK (mm/5 min) T4-4-14
Backhoe
Boom Cylinder 30 or less
Arm Cylinder 30 or less
Bucket Cylinder 20 or less
Bucket Bottom 400 or less
Loading Shovel
Boom Cylinder 30 or less
Arm Cylinder 20 or less
Bucket Cylinder 20 or less
Bucket Bottom 400 or less
T4-2-2
Performance Test Remarks
Standard Page
CONTROL LEVER OPERATING FORCE T4-4-16
(ISO Control Pattern) N (kgf)
Boom Lever (Raise / Lower) 6.1 to 7.6 (0.6 to 0.8)
5.1 to 6.4 (0.5 to 0.7)
Arm Lever (Extend / Retract) 5.1 to 6.4 (0.5 to 0.7)
(HITACHI Control Pattern: Swing Lever (Right / Left)) 6.1 to 7.6 (0.6 to 0.8)
Bucket Lever (Tilt-in / Tilt-out) 5.2 to 6.5 (0.5 to 0.7)
5.9 to 7.4 (0.6 to 0.8)
Swing Lever (Right / Left)
5.2 to 6.5 (0.5 to 0.7)
(HITACHI Control Pattern:
5.9 to 7.4 (0.6 to 0.8)
Arm Lever (Extend / Retract))
Travel Lever 21.6 to 26.3
(2.2 to 2.7)
Bucket Open/Close Pedal 82 to 100
(8.4 to 10.2)
CONTROL LEVER STROKE T4-4-17
(ISO Control Pattern) mm
Boom Lever 90 10
Arm Lever
90 10
(HITACHI Control Pattern: Swing Lever)
Bucket Lever 90 10
Swing Lever
90 10
(HITACHI Control Pattern: Arm Lever)
Travel Lever 110 10
Bucket Open/Close Pedal 25 5
BOOM RAISE AND SWING COMBINED Bucket: Empty T4-4-18
OPERATION CHECK
Time (LD) sec/90 5.4 0.5
Time (BH) sec/90 5.6 0.5
Bucket Clearance H (LD) mm 4500 or more
Bucket Clearance H (BH) mm 4700 or more
NOTE: BH : Backhoe (8.3 m Boom, 3.6 m Arm,

3
12.0 m (PCSA heaped) Bucket)
LD : Loading Shovel
T4-2-3
Performance Test Remarks
Standard Page
HYDRAULIC SYSTEM MPa (kgf/cm2, psi)
PRIMARY PILOT PRESSURE 2
MPa (kgf/cm , psi) T4-5-1
Fast Idle 4.4 0.5
(45 5, 640 71)
Slow Idle 3.9 (40, 569)
or more
SECONDARY EHC VALVE PRESSURE
2 T4-5-2
MPa (kgf/cm , psi)
Fast Idle 4.4 0.5 With Lever Full
(45 5, 640 71) Stroke
Slow Idle 3.9 (40, 569) With Lever Full
or more Stroke
SECONDARY DQR VALUE PRESSURE
2 T4-5-4
MPa (kgf/cm , psi)
Fast Idle 4.3 0.5 With Lever Full
(43 5, 619 71) Stroke
Slow Idle 3.7 (37.5, 533) With Lever Full
or more Stroke
MAIN RELIEF PRESSURE 2
MPa (kgf/cm , psi) T4-5-6
Boom, Arm, Bucket, and Bucket Open 29.4 2.0 0
20 284
Circuit Relief Pressure (300 0, 4266 0)
Bucket Close Circuit Relief Pressure 16.7 1.5 0
15 213
(170 0, 2417 0)
RELIEF PRESSURE 2
MPa (kgf/cm , psi) 29.4 2.5 0
25 360 T4-5-6
(When relieving travel) (300 0, 4266 0)
RELIEF PRESSURE MPa (kgf/cm2, psi) 29.4 2.5 0
25 360
(When relieving swing) (300 0, 4266 0)
OVERLOAD RELIEF VALVE SET PRES- T4-5-10
SURE 2
MPa (kgf/cm , psi)
1.0
Boom, Arm, Bucket, and Bucket Open 31.4 0
10 142
Circuit Relief Pressure (320 0, 4550 0)
1.5
Bucket Close Circuit Relief Pressure 16.7 0
15 213
(170 0, 2417 0)
MAIN PUMP FLOW RATE MEASUREMENT T4-5-12
L/min
OIL COOLER FAN DRIVE PUMP FLOW T4-5-20
RATE MEASUREMENT L/min
SWING MOTOR DRAINAGE L/min
3.5 or less T4-5-28
(at Constant Swing Speed)
TRAVEL MOTOR DRAINAGE L/min
(While rotating at slow speed with the undercarriage 15 or less T4-5-30
raised off the ground.)
T4-2-4
MAIN PUMP P-Q DIAGRAM MAIN PUMP Pi-Q DIAGRAM
Hydraulic P-Q Control Hydraulic Pi-Q Control
Rated Pump Speed: 1892 min-1 (rpm) Rated Pump Speed: 1892 min-1 (rpm)
Pump Gear Reduction Ratio: 1.051 Pump Gear Reduction Ratio: 1.051
Hydraulic Oil Temperature: 50 5 C (122 9 F) Hydraulic Oil Temperature: 50 5 C (122 9 F)
NOTE: Refer to T4-5-12. NOTE: Refer to T4-5-14.
Main Pump P-Q Diagram Main Pump Pi-Q Diagram

Q P Q Pi
Location 2 Location 2
L/min (US gal/min) MPa (kgf/cm , psi) L/min (US gal/min) MPa (kgf/cm , psi)
A 307 (81) 3.9 (40, 569) A 70 (18) 0.2 0.1 (2.0 1.0,
B 235 (62) 7.9 (81, 1152) 28.4 14.2)
C 61 (16) 29.4 (300, 4266) B 335 (88) 2.7 0.2 (27.5 2.0,
D 327 (86) 15.1 (154, 2190) 391 28.4)
E 225 (59) 20.6 (210, 2986)
F 154 (41) 29.4 (300, 4266)
G 325 (85) 17.8 (182, 2588)
H 223 (59) 23.4 (239, 3399) Q (Flow
I 174 (46) 29.4 (300, 4266) Rate) 500
L/min
400 B
Q 300
(Flow
Rate) 200
L/min
400 100
A
D G Pf = 0 MPa 0 1 2 3 4
A Pz = 0.8 MPa
300 Pi (Flow Rate Control
Pilot Pressure)
B MPa
H
E
200
I
Pz
F Pz
100 Pf = 4.1 MPa

Pz = 0 MPa
C
0 T18C-04-05-001
5 10 15 20 25 30 P (Pressure)
MPa
NOTE: Pf: Power Decrease Pressure

Pf T18C-03-01-005
Pz: Power Increase Pressure
When measuring the power decrease con-
trol at points (A, B and C), supply the
pressure (4.1 MPa) to port Pf. Be sure to
measure at the test stand.
When measuring the power increase con-
trol at points (G, H and I), supply the pres-
sure (0.8 MPa) to port Pz. Be sure to
measure at the test stand.
T4-2-5
OIL COOLER FAN MOTOR DRIVE PUMP OIL COOLER FAN MOTOR DRIVE PUMP
P-Q DIAGRAM Pi-Q DIAGRAM
Hydraulic P-Q Control Hydraulic Pi-Q Control
Rated Pump Speed: 2176 min-1 (rpm) Rated Pump Speed: 2176 min-1 (rpm)
Pump Gear Reduction Ratio: 1.088 Pump Gear Reduction Ratio: 1.088
Hydraulic Oil Temperature: 50 5 C (122 9 F) Hydraulic Oil Temperature: 50 5 C (122 9 F)
NOTE: Refer to T4-5-20. NOTE: Refer to T4-5-22.
Oil Cooler Fan Motor Drive Pump P-Q Diagram Oil Cooler Fan Motor Drive Pump Pi-Q Diagram
Q P Q Pi
Location 2 Location 2
L/min (US gal/min) MPa (kgf/cm , psi) L/min (US gal/min) MPa (kgf/cm , psi)
A 175 (46) 13.4 (137, 1948) A 27 3 (7 0.8) 0.9 0.1 (9.2 1.0,
B 133 (35) 17.2 (175, 2489) 131 14.2)
C 106 (26) 22.5 (229, 3256) B 179 3 (47 0.8) 2.21 0.2 (22.4 2.0,
319 28.4)
Q (Flow
Rate)
L/min
200
Q (Flow
A
Rate)
L/min
200 B
150
B
C 100
100
A
50
0 1 2 3
Pi (Flow Rate Control
Pilot Pressure)
MPa
0 5 10 15 20 P (Pressure)
MPa
T18C-04-05-002
T4-2-6
ELECTRIC LEVER
When moving the electric lever, command current is

sent from the controller to ELU according to lever
stroke.
Boom, Arm, Bucket, Swing
15 to 20 15 to 20
-
+
Controller
To ELU X
T18G-03-04-001
Travel, Bucket Open/Close 12.4 1 12.4 1
Controller
To ELU
T18G-03-04-002
T4-2-7
Boom, Arm, Bucket, Swing
90 2
Short Zone
About 3
50 1.5
10 2
Center
15 to 20
Mechanical Control Angle
2 (Red)
1 (Yellow) 3 (Green)
Short Zone 4 (White) Short Zone
Resistor for Calibration Resistor for Calibration
30 5
Electrical Turning Angle
Total Resistance 2 k 15
+ Direction on XY Axis
T18G-03-04-003
T4-2-8
Travel
(Control Curve: 25±5 C)
Control Torque Output Voltage

Nm v
100
16.0 VOUT
15.3 2.3 80 7.5
Output
12.0 50 5
Voltage
Ratio
20 7.5
8.0 0
6.5 1.0 12.4 1 0 12.4 1 deg
4.0 T18M-03-04-004
Neutral Switch Voltage

0
12.4 1 0 12.4 1 deg
T18M-03-04-003
deg
T18G-03-04-006
Bucket Open/Close
(Control Curve: 25±5 C)
Control Torque Output Voltage

Nm 100 v
VOUT
16.0 80 7.5
Output
50 5
12.0 Voltage
Ratio
9.3 1.4 20 7.5
8.0 0
12.4 1 0 12.4 1 deg
T18M-03-04-004
4.0
3.9 0.6
Neutral Switch Voltage
0
12.4 1 0 12.4 1 deg
T18L-03-04-001
deg
T18G-03-04-006
T4-2-9
(Blank)
T4-2-10
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Performance Test Conditions:

Hydraulic Oil Temperature: 50 9 C (122 9 F)
Ground Conditions: Solid, level ground Engine Speed Sensor
Measurement:
1. Turn the key switch to the OFF position to stop
the engine.
2. Disconnect the engine speed sensor connector
(Lower side: For EC and MC). Connect the pulse
counter harness to engine speed sensor
harness.
3. Start the engine, run it at the specified speeds,
and read the pulse counter.
Calculate the engine speed using the following
formula:
-1
Engine speed (min ) = Pulse Number 60/142
Evaluation:
T141-04-02-001
Refer to T4-2 Operational Performance Standard
Table.
T4-3-1
OPERATIONAL PERFORMANCE TEST / Engine Test
(Blank)
T4-3-2
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary:
In order to check the performance of travel device
systems (from main pump to travel motor), measure
the time required for the excavator to travel a test
track.
Preparation:
1. Adjust the track sag (570 to 640 mm (22 to 25
in)) on both tracks equally.
2. Prepare a flat and solid test track 20 m (65.5 ft) in
length with extra length of 2 to 3 m (6.5 to 9.8 ft)
on both ends for machine acceleration and de- Track Sag:
celeration. 570 to 640 mm
(22 to 25 in)
3. Empty the bucket and roll in the arm.
4. Maintain the hydraulic oil temperature at 50 5 C
T145-05-03-001
(122 9 F).
Backhoe
Deceleration Zone: Travel Test Distance: Acceleration Zone:

2 to 3 m End 20 m Start 2 to 3 m T142-05-03-001
(6.5 to 9.8 ft) (65.5 ft) (6.5 to 9.8 ft)
Measurement:
1. Measure travel time at both fast and slow travel Loading Shovel
speeds.
2. Measure at the engine speed (fast idle).
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 (33 ft).
5. After measuring the forward travel speed, turn
the upperstructure 180 and measure the reverse
travel speed.
6. Repeat the measurement three times in each di- T145-05-03-006
rection and calculate the average values.
Evaluation:
Refer to Operational Performance Standard in T4-2.
Solution:
Refer to Troubleshooting B in T5-5.
T4-4-1
TRACK REVOLUTION SPEED
Summary:
In order to check the performance of travel device
systems (from main pump to travel motor), measure
the track revolution cycle time with the track raised 90 to 110
off ground.
Preparation:
1. Adjust the track sag (570 to 640 mm (22 to 25 T142-05-03-011
in)) of both side tracks equally.
2. On the track to be measured, put the mark on
one shoe by using a piece of chalk or cloth.
3. Jack up the track to be measured as illustrated.
CAUTION: Securely support the raised

machine by using the blocks. 90 to 110
4. Maintain the hydraulic oil temperature at 50 5

C(122 9 F).
T142-05-03-012
Measurement:
1. Measure the track rotation time at both fast and
slow travel speeds.
3. Operate the travel control lever of the track to be
measured to full stroke.
4. Measure the time required for 3 revolutions in
both directions after a constant track revolution
speed is obtained.
5. Measure on both tracks in both forward and
reverse.
Forward
6. Repeat the measurement three times and
calculate the average values. Reverse
Evaluation:
Refer to Operational Performance Standard in T4-2. Travel Device T145-05-03-001
Solution:
T4-4-2
MISTRACK
Summary:
1. In oredr to check the performance of travel
device systems (from main pump to travel motor),
allow the machine to travel 20 m (65.6 ft).
Measure the maximum tread deviation from the
tread chord line drawn between the travel start
and end points.
2. If measured on a concrete surface, the tread
deviation has a trend to decrease.
T145-05-03-005
Preparation:
1. Adjust the track sag (570 to 640 mm (22 to 25
in)) of both tracks equally.
2. Prepare a flat and solid test track 20 m (65.5 ft) in
length with extra length of 2 to 3 m (6.5 to 9.8 ft)
on both ends for machine acceleration and
deceleration.
3. Empty the bucket and set the front attachment in
the driving position as illustrated.
(122 9 F).
T145-05-03-006
Measurement:
1. Measure the amount of mistracking in both fast
and slow travel speeds.
3. Start traveling the machine in the acceleration
zone with the travel levers at full stroke.
4. Measure the maximum distance between a Deceleration Zone:
2 to 3 m
straight 20 m (65.6 ft) tread chord line and the (6.5 to 9.8 ft)
tread made by the machine.
5. After measuring the tracking in forward travel,
turn the upperstructure 180 and measure in
Maximum Distance (A)
reverse travel.
6. Repeat the measurement three times and 20 m (65.5 ft)
calculate the average values.
Evaluation:
Acceleration Zone:
2 to 3 m
Remedy: (6.5 to 9.8 ft)
Refer to Troubleshooting B in T5-5. T115-07-03-005
T4-4-3
TRAVEL PARKING LEAKAGE
Summary:
Measure the parking brake function on a specified
0.5 to 1.0 m
slope. (20 to 40 in)
Preparation:
1. The surface of test slope shall be even with a
gradient of 20 (11.31 ).
2. Put a white line mark on the drive tumbler.
T142-05-03-002
3. Empty the bucket. Position the front attachment
as follows:
Backhoe: With the arm and bucket cylinders fully
0.5 to 1.0 m
extended, hold the bucket 0.5 to 1.0 m (20 to 40 (20 to 40 in)
in) above the ground.
Loading Shovel: With the arm and bucket cylin-
ders fully extended, hold the bucket 0.5 to 1.0 m
(20 to 40 in) above the ground.
(122 9 C). T118-04-03-001
Measurement
1. Climb the slope and return the travel lever to
neutral.
2. Stop the engine.
3. After the machine stops, put the matching marks
on the shoe and the track side frame.
4. After five minutes, measure the distance between Matching
the marks on the shoe and the track side frame. Marks on Track
Side Frame and Shoe
When Machine Stops.
Evaluation
Displacement measured
Refer to Operational Performance Standard in T4-2. after 5 minutes.
T105-06-03-006
T4-4-4
SWING SPEED
Summary:
1. In order to check the performance of swing
device systems (from main pump to swing motor),
measure the time required to swing three
complete turns.
Preparation:
1. Check lubrication of the swing gear and swing
T145-05-03-007
bearing.
2. Place the machine on flat, solid ground with
ample space for swinging. Do not conduct this
test on slopes.
as follows.
Backhoe:
With the arm cylinders fully retracted and the
bucket cylinder fully extended, hold the bucket so
that the height of the arm tip pin is the same as
the boom foot pin.
Loading shovel: T145-05-03-008
With the arm cylinder fully extended and the

the boom foot pin.
(122 9 F).
CAUTION: Prevent personal injury. Always

make sure that the area is clear and that
co-workers are out of the swing area before
starting the measurement.
3 Turns
Measurement:
2. Operate the swing control lever fully.
3. After the swing attains to constant speed,
measure the time required to swing three turns in
one direction.
4. Operate swing control lever fully in the opposite
direction and measure the time required for three
turns.
calculate the average values. T145-05-03-009
Evaluation:
Solution:
T4-4-5
SWING FUNCTION DRIFT
Summary:
1. In oreder to check the performance of swing
brake valve, measure the swing drift on swing
bearing outer circumference when stopping after
a 180 full-speed swing.
2. The mechanical brake for swing parking brake is
equipped for the swing motor.
Preparation: T145-05-03-007

bearing.
2. Place the machine on flat, solid ground with
ample space for swinging. Do not conduct this
test on a slope.
as follows.
Backhoe:
With the arm cylinders fully retracted and the
the boom foot pin.
Loading shovel: T145-05-03-008

the boom foot pin.
4. Put the matching marks on the swing bearing
outer circumference (upperstructure side) and
the track frame.
5. Swing the upperstructure 180 .
(122 9 F).
T4-4-6
CAUTION: Prevent personal injury. Always Return the

make sure that the area is clear and that swing control
lever to the
co-workers are out of the swing area before neutral position.
Measurement:
1. Measure at the engine speed (fast idle). Drift
Amount
2. Operate the swing control lever fully and return it
to the neutral position when the mark on
upperstructure aligns with that on track frame
after swinging 180 .
3. Measure the distance between the two marks.
4. Align the marks again and swing 180 . Then test
in the opposite direction.
5. Repeat the measurement three times each and
Swing 180
Evaluation:
Solution:
Operate the swing T142-05-03-003
control lever fully.
T4-4-7
SWING MOTOR LEAKAGE
Summary:
Measure the upperstructure drift while suspending a
load on a specified slope and check the
performance of swing parking brake. (The
mechanical brake for swing parking brake is
equipped for the swing device.)
Preparation:
bearing.
2. Load the bucket fully. In lieu of loading the bucket,
weight (W) of the follwing specification can be
used.
W = 15900 kg (35100 lb): Backhoe
16500 kg (36400 lb): Loading shovel T142-05-03-004
3. Position the front attachment as follows.
Loading shovel: With the arm cylinder fully
extended and the bucket cylinder fully extended,
hold the bucket so that the height of the arm tip
pin is the same as the boom foot pin.
Backhoe: With the arm cylinder fully retracted
and the bucket cylinder fully extended, hold the
bucket so that the height of the arm tip pin is the
same as the boom foot pin.
4. Park the machine on a smooth slope with a
gradient of 26.8 % (15 ),
5. Climb a slope and swing the upperstructure to
position it 90 to the slope. Put the matching
marks on the outer circumference of swing
bearing (upperstructure side) and track frame by
using the tape.
(122 9 F).
Measure Distance Between Marks

Measurement:
1. Stop the engine. After five minutes, measure the
distance between the marks along the swing
bearing outer circumference and the track frame.
2. Perform the measurement in both right and left
swing directions.
3. Repeat the measurement three times in each Marking on Track Frame
direction and calculate the average values.
Marking on Swing Bearing
Evaluation:
T105-06-03-010
Solution:
T4-4-8
MAXIMUM SWINGABLE SLANT ANGLE
Summary:
1. With the upperstructure swung 90 to the slope,
check the maximum slant angle on which the
upperstructure can swing to the uphill side.
Preparation:
bearing.
weight (W) of the following specification can be
used.
W = 15900 kg (35100 lb): Backhoe
16500 kg (36400 lb): Loading shovel
Loading shovel: With the arm cylinder fully
extended and the bucket cylinder fully extended,
hold the bucket so that the height of the arm tip T142-05-03-004
pin is the same as the boom foot pin.

Backhoe: With the arm cylinder fully retracted
and the bucket cylinder fully extended, hold the
bucket so that the height of the arm tip pin is the
same as the boom foot pin.
4. Climb a slope and swing the upperstructure 90
to the slope.
(122 9 F).
Measurement:
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. When the machine can swing, increase the slant
angle. Repeat the test until the maximum swin-
gable angle is obtained. Check in both clockwise
and counterclockwise directions.
5. Repeat the measurement three times in each
direction and calculate the average values.
Evaluation:
Solution:
T4-4-9
SWING BEARING PLAY
Summary:
In order to check the wear of the bearing races and Dial Gauge
balls, measure the swing bearing play.
Preparation:
1. Check the swing bearing mounting bolts for
looseness.
2. Check lubrication of the swing bearing. Confirm
that bearing rotation is smooth and without noise.
Round Trunk
3. Secure a dial gauge on the round trunk of track
frame by using a magnetic base.
4. Position the upperstructure so that the boom
aligns with the tracks facing towards the front
Magnetic
idlers. Base
5. Position the dial gauge so that its needle point T105-06-03-015
comes into contact with the bottom surface of the

swing bearing outer race.
6. The bucket should be empty.
NOTE: The measured value will vary depending

on where the magnetic base is secured.
Secure the magnetic base onto the round
trunk or in a position as close to the round
trunk as possible.
T4-4-10
Measurement:
1. Measure the play at positions A, B, C and D.
Backhoe:
With the arm cylinder fully retracted and the A
bucket cylinder fully extended, hold the bucket so D B
that the height of the arm tip pin is the same as Measure the plays at
the boom foot pin. positions A, B, C and
C D.
Loading shovel:
the boom foot pin.
3. Lower the bucket to the ground and raise the
front idler 0.5 m (20 in) by using the front
attachment. Record dial gauge reading (h2).
4. Calculate bearing play (H) from these data (h1
and h2) as follows:
H=h2 - h1
Evaluation:
T145-05-03-023
Backhoe
Measurement : (h 1) Measurement : (h 2)
T142-05-03-006
Loading Shovel
Measurement : (h 1) Measurement : (h2 )
T142-05-03-005
T4-4-11
HYDRAULIC CYLINDER CYCLE TIME
Summary:
1. In order to check the performance of front
attachment systems (from main pump to each
cyliner), measure the cycle time of boom, arm,
bucket and dump cylinders.
2. Empty the bucket.
NOTE: When the bucket weight is increased by
welding wear-resist plates, cylinder cycle
time may become longer.
Preparation:
(122 9 F). Backhoe
2. Position the front attachment as followings.
Backhoe
When measuring the cycle time of the boom Boom Cylinder
cylinder:
With the bucket cylinder fully extended and the
arm cylinder fully retracted, lower the bucket to
the ground.
When measuring the cycle time of the arm
T145-05-03-012
cylinder:
With the bucket cylinder fully extended, adjust the
boom height so that the arm oscillation center
faces vertically to the ground while holding the
bucket bottom height at approx. 0.5 m above the
ground.
Set the arm so that the encter of arm operation is
vertical.
When measuring the cycle time of the bucket
Arm Cylinder
cylinder:
Adjust the boom and arm cylinder so that the
T118-04-03-003
bucket oscillation center faces vertically to the
ground.
Bucket Cylinder
T145-05-03-014
T4-4-12
Loading Shovel Loading Shovel
When measuring the cycle time of the boom
cylinder:
With the bucket cylinder and the arm cylinder
fully extended, lower the bucket to the ground.
When measuring the cycle time of the 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. Adjust the boom cylinder
stroke in order to position the bucket bottom 1 m
(39 in) above the ground. T145-05-03-015

cylinder:
With the bucket closed and held in a load dump
position, adjust the boom so that bucket bottom
height is approx. 1 m (39 in) above the ground.
open/close cylinder:
With the bucket cylinder and the arm cylinder Arm Cylinder
T145-05-03-016
fully extended, adjust the boom so that the
bucket bottom height is approx. 1 m (39 in) above
the ground.
3. Repeat the measurement three times and calcu-
late the average values.
Bucket Cylinder
Measurement:
T145-05-03-017
2. Measure the cylinder cycle times as follows:
(Cylinder full stroke includes cylinder cushioning
zone.)
2-1. Boom cylinder:
Operate the boom control lever to full stroke. Bucket Open/Close Cylinder
Measure the time to raise and lower the boom.
2-2. Arm cylinder:
Operate the arm control lever to full stroke. T145-05-03-018
Measure the time to roll in and roll out the
arm.
2-3. Bucket cylinder:
Operate the bucket control lever to full stroke.
Measure the time to roll in and roll out the
bucket.
2-4. Bucket Open/Close Cylinder (Loading Shovel)
Operate the bucket open/close control pedal
to full stroke. Measure the time to open and
close the bucket.
Evaluation:
Refer to Operational Performance Standard in T4-2
Remedy:
T4-4-13
DIG FUNCTION DRIFT CHECK
Summary:
1. Evaluate the internal oil leakage in the control
valve, boom, arm, and bucket cylinders by
measuring cylinder (dig function) drift with the
bucket loaded.
2. When checking soon after cylinder replacement,

T145-05-03-020
slowly operate each cylinder for ten minutes to its
stroke end and release any pressure.

welding wear-resist plates, cylinder drift
may increase.
Preparation:
weight (W) of the following specification can be T145-05-03-021
used.
W = 15900 kg (35100 lb): Backhoe
16500 kg (36400 lb): Loading shovel
Backhoe:
With the arm cylinder fully retracted, and the
the boom foot pin.
Loading shovel:
With the arm cylinder and the bucket cylinder
fully extended, hold the bucket so that the height
of the arm tip pin is the same as the boom foot
pin.
Position the arm cylinder with the rod 50 mm (2
in) extended from the fully retracted position.
Position the bucket cylinder with the rod 50 mm
(2 in) retracted from the fully extended position.
(122 9 F).
T4-4-14
Measurement:
1. Stop the engine. BH: Boom and Bucket Cylinders Retraction
LD: Boom, Arm and Bucket Cylinders Retraction
2. Five minutes after the engine has been stopped,
measure the change in position of bottom of the Mark Mark
arm tip, as well as the boom, arm and bucket
cylinders.
Evaluation:
Solution: T110-06-03-002

BH: Arm Cylinder Extension
Mark
T110-06-03-001
NOTE: BH: Backhoe

LD: Loading Shovel
T4-4-15
CONTROL LEVER OPERATING FORCE
Summary:
1. Measure a play, operating condition and
operating force of each control lever.
2. Measure the maximum operating force of the
front attachment control lever.
3. Measure the operating force at the grip top of
each control lever.
Measurement:
1. Stop the engine.
2. Measure all control levers.
Evaluation:
T18G-04-04-002
T107-06-03-004
T4-4-16
CONTROL LEVER STROKE
Summary:
1. Check a play and operating condition and
measure each control lever stroke.
2. Measure the lever stroke at the grip center of
each control lever.
3. In case lever stroke play is present in the neutral
position, add half (1/2) the play present to both
side lever strokes.
Measurement:
1. Stop the engine.
2. Measure each lever stroke from neutral to the
stroke end of each control lever of boom, arm, T107-06-03-005
bucket, swing and travel.

3. Measure the stroke straight from the neutral posi-
tion to the stroke end.
Evaluation:
T4-4-17
BOOM RAISE/SWING COMBINED OP-
ERATION CHECK
Summary:
1. Check the combined operation performance
while operating the boom raise and swing simul-
taneously.
2. Run the engine at full speed and check if the cyl-
inders move without hesitating. T142-05-03-007

welding wear-resist plates, boom may be-
come lower.
Preparation:
Empty the bucket.
T142-05-03-008
Backhoe:
With the arm cylinder fully retracted and the
bucket cylinder fully extended, lower the bucket
onto the ground.
Loading shovel:
With the arm and the bucket cylinders fully ex-
tended, lower the bucket onto the ground.
2. Maintain the hydraulic oil temperature at 50 5
C (122 9 F).

starting the measurement. T142-05-03-009
Measurement:
2. Raise the boom and roll the swing in full stroke at
the same time.
When the upperstructure rotates 90 , release the
control levers to stop both functions. Measure the
time required to swing 90 and height (H) of the H
bucket teeth.
Evaluation:
Refer to Operational Performance Standard in
T142-05-03-010
T4-2.
Solution:
T4-4-18
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE CHECK
Preparation:
1. Stop the engine.
CAUTION: Do not turn the air breather cap

on the hydraulic oil tank quickly. The air
breather cap may fly off by internal pressure.
Release any remaining pressure.
2. Loosen the air breather cap on the hydraulic oil

tank and release any pressure in the hydraulic oil
tank.
: 4 mm
3. Disconnect the pilot hose from the pilot relief
valve. Install tee (ST 6450) and a pressure
gauge.
: 19 mm, 22 mm
Pilot
4. Start the engine. Check for oil leakage at the Filter
pressure gauge connection.
(122 9 F).
Measurement: Pilot
1. The auto-idle is turned OFF. Hose
2. Measure the primary pilot pressure at the engine
speeds (fast and slow).
3. Repeat the measurement three times and calcu- Pilot Relief
late the average values. Valve
Evaluation: T18M-04-05-001
T4-5-1
EHC VALVE SECONDARY PILOT PRES-
SURE
Preparation: Measurement:
1. Stop the engine.
CAUTION: Do not turn the air breather cap make sure that the area is clear and that
on the hydraulic oil tank quickly. The air coworkers are out of the swing area before
breather cap may fly off by internal pressure. starting the measurement.
Release any remaining pressure. When measuring the boom lower secondary
pilot pressure, the machine should be raised
off the ground. Do not allow the machine to
2. Loosen the air breather cap on the hydraulic oil come in contact with the ground, and lay
tank and release any pressure in the hydraulic oil down the machine as the machine become
tank. unbalanced.
: 4 mm
3. Disconnect hoses (1 to 14) which corresponds to 1. Measure the secondary pilot pressure at the en-
the circuit to be measured. Install tee (ST 6450) gine speeds (fast and slow). Turn the auto-idle
between the EHC valve and DQR valve 1 or 2. switch OFF.
Install a pressure gauge to the tee. 2. Operate the control lever corresponding to the
: 19, 22 mm secondary pilot pressure to be measured. Meas-
4. Start the engine. Check for oil leakage at the ure the pressure with the control lever fully
pressure gauge connections. stroked.
5. Maintain the hydraulic oil temperature at 50 5 C 3. Repeat the measurement three times and calcu-
(122 9 F). late the average values.
Evaluation:
NOTE: In case the measurement data is abnormal,
measure the primary pilot pressure. When
the primary pressure is normal, the EHC
valve may be faulty.
T4-5-2
Pilot Panel (Left Side) Pilot Panel (Center Side)
1 8
2 9
3 10
4 11 EHC Valve
EHC Valve 5 12
6 13
7 14
DQR Valve 2
DQR Valve 1
T18K-03-05-001
1- BH: Bucket Roll-Out, 5 - Boom Raise 9- Left Travel Reverse 12 - Left Swing
LD: Bucket Tilt-Out
2 - BH: Bucket Roll-In, 6 - BH: Arm Roll In, 10 - Right Travel Forward 13 - Right Swing
LD: Bucket Tilt-In LD: Arm Retract
3 - BH: Arm Roll Out, 7 - Bucket Close (LD only) 11 - Right Travel Reverse 14 - Bucket Open (LD only)
LD: Arm Extend
4 - Boom Lower 8 - Left Travel Forward
BH: Backhoe
NOTE: LD: Loading Shovel
T4-5-3
DQR VALVE SECONDARY PILOT PRES-
SURE
Preparation: Measurement:
1. Stop the engine.
CAUTION: Do not turn the air breather cap make sure that the area is clear and that
on the hydraulic oil tank quickly. The air coworkers are out of the swing area before
breather cap may fly off by internal pressure. starting the measurement.
Release any remaining pressure. When measuring the boom lower secondary
pilot pressure, the machine should be raised
2. Loosen the air breather cap on the hydraulic oil off the ground. Do not allow the machine to
tank and release any pressure in the hydraulic oil come in contact with the ground, and lay
tank. down the machine as the machine become
: 4 mm unbalanced.
3. Disconnect hoses (1 to 14) which corresponds to
the circuit to be measured. Install a tee between 1. Measure the secondary pilot pressure at the en-
DQR valve 1 or 2 and the control valve. Install a gine speeds (fast and slow).
pressure gauge to the tee. 2. Operate the control lever corresponding to the
: 22, 27 mm secondary pilot pressure to be measured. Meas-
4. Start the engine. Check for oil leakage at the ure the pressure with the control lever fully
pressure gauge connections. stroked.
5. Maintain the hydraulic oil temperature at 50 5 C 3. Repeat the measurement three times and calcu-
(122 9 F). late the average values.
Evaluation:
NOTE: In case the measurement data is abnormal,
measure the EHC valve secondary pilot
pressure. When the EHC valve secondary
pilot pressure is normal, either DQR valve
1 or 2 may be faulty.
T4-5-4
Pilot Panel (Left Side) Pilot Panel (Center Side)
1 8
2 9
3 10
4 11 EHC Valve
EHC Valve 5 12
6 13
7 14
DQR Valve 2
DQR Valve 1
T18K-03-05-001
1- Right Travel Forward 5- Bucket Close (LD Only) 9 - Bucket Tilt-Out 12 - Right Swing
2- Right Travel Reverse 6- Bucket Open (LD Only) 10 - Boom Lower 13 - Left Swing
3- Left Travel Forward 7- Arm Retract (BH: Arm Out) 11 - Bucket Tilt-In 14 - Boom Raise
4- Left Travel Reverse 8- Arm Extent (BH: Arm In)
BH: Backhoe
T4-5-5
MAIN RELIEF PRESSURE, RELIEF
PRESSURE
Preparation
1. Stop the engine.

on the hydraulic oil tank quickly. The air Plug
1
2
tank and release any pressure in the hydraulic oil
tank.
: 4 mm 3
3. Remove the plug on top of the high-pressure

strainer. Install a pressure gange.
: 6 mm
4. Start the engine. Check for oil leakage at the

pressure gauge connections.

(122 9 F).
T18C-04-04-005
Measurement
1. Measure the pressure at the engine speed (fast). Connection of high-pressure strainer
High-Pressure
Main Pump Control Valve
2. Slowly operate the bucket, arm and boom control Strainer
levers to the stroke end and relieve each 1
2 2 (Center)
function. 2
3
1 1 (Left)
3. Measure the pressure when relieving each 4
function. 5
3 3 (Right)
6
4. Repeat the measarement three times and
Evaluation
NOTE: If relief pressures for all front attachment

circuits are lower than the specified range,
the probable cause is a decrease of main
relief valve pressure.
If relief pressure of a particular circuit is
lower, the probable cause is a decrease of
relief valve pressure corresponding to the
circuit or overload relief valve pressure.
T4-5-6
Main Relief Valve Pressure Adjustment Proce-
dure Lock Nut
IMPORTANT: Do not use these in this section in

order to customize the machine
without Hitachis recommendation.
For example, the machine perform-
ance is set beyond the specification.
Otherwise, the machine life includ-
ing the components and so on may
Adjusting
become short or be broken. Future Screw
in addition, a serious trouble may
T145-02-03-001
occur.
Adjustment:
1. Loosen the lock nut.
: 17 mm
2. Adjust the main relief valve set pressure by turn-

ing the adjusting screw.
: 6 mm
3. Tighten the lock nut.

: 17 mm
: 27.5 to 31.4 N m
(2.8 to 3.2 kgf m, 20 to 23 lbf ft)
4. After adjustment, check the set pressure.

Lock Nut Adjusting Screw
NOTE: Standard Change in Pressure
Adjusting Screw Turns 1/4 1/2 3/4 1
MPa 4.5 8.9 13.4 17.8
Change in
(kgf/cm2) (45) (90) (136) (181)
Pressure
(psi) (645) (1290) (1930) (2580)
Pressure Increase Pressure Decrease
W107-02-05-129
T4-5-7
Swing Relief Valve Pressure Adjustment Proce-
dure

become short or be broken. Future
occur.
Adjustment:
Loosen the lock nut and adjust the pressure by the M144-07-012
adjusting screw. Swing Relief Valve

: 41 mm
Lock Nut Adjusting
Screw
2. Adjust the swing relief valve set pressure by turn-
: 27 mm

: 41 mm
: 19.5 to 29.5 N m
(2 to 3 kgf m, 14.5 to 21.5 lbf ft)
T117-02-02-004
NOTE: Standard Change in Pressure Adjusting Screw

MPa 2.92 5.84 8.75 11.7
Change in
(kgf/cm2) (30) (59.5) (89) (119)
Pressure
(psi) (426) (846) (1270) (1690)
T157-05-04-023
T4-5-8
Travel Relief Valve Pressure Adjustment Proce-
dure
Travel Brake Valve
become short or be broken. Future
occur.
Travel Relief Valve
Adjustment: T144-03-05-002
Loosen the lock nut and adjust the pressure by the

adjusting screw.
1. Loosen the lock nut. Lock Nut
: 17 mm
2. Adjust the travel relief valve set pressure by turn-

: 6 mm

: 17 mm
Adjusting Screw
: 34 to 44 N m
(3.5 to 4.5 kgf m, 25.5 to 32 lbf ft)
T145-05-04-004
NOTE: Standard change in Pressure Lock Nut Adjusting Screw

MPa 1.96 3.92 5.88 7.85
Change in
(kgf/cm2) (20) (40) (60) (80)
Pressure
(psi) (284) (569) (853) (1140)
W107-02-05-129
T4-5-9
OVERLOAD RELIEF VALVE SET PRES-
SURE
Summary:
1. The circuit pressure must be increased by apply- 3. If the overload relief valve performance must be
ing an external force while blocking the return cir- checked on the machine, however, measure the
cuit from the control valve. This measuring main relief pressure while releasing each front
method is hazardous and the results obtained function respective to the measuring overload re-
with this method are unreliable. lief valve. And, assume that the overload relief
2. The oil flow rate used to set the overload relief valve is functioning correctly if the obtained main
pressure is far less than that used to set the main relief pressure is within the specified value range.
relief pressure. Therefore, measuring the over- Measure the main pressure of the front functions.
load pressure in the main circuit by increasing
the main relief set pressure more than the over-
load valve set-pressure is not a proper method.
In addition, in case a main relief valve designed
to leak a small quantity of oil before reliving is
used, its pre-leaking start pressure must be in-
creased more than the overload relief valve set
pressure. However, the pre-leaking start pressure
is not always increased more than the overload
relief valve set-pressure as the adjustable upper
limit of the main relief valve set-pressure is pro-
vided. Accordingly, the overload relief valve as-
sembly should be removed from the machine and
checked on a specified test stand at a correct oil
flow rate. Some overload relief valves come in
contact with the control valve body to block the oil
passage. When this type of overload relief valve
is checked, the control valve body must be pre-
cisely finished as the test unit. Provide one con-
trol valve other than that on the machine as a test
kit.
T4-5-10
Overload Relief Valve Pressure Adjustment
Procedure
Lock Nut
If necessary, loosen the lock nut and adjust
pressure with the adjusting screw.
IMPORTANT: In principle, adjust the overload

relief valve pressure by using a test
equipment.
Adjustment:
: 17 mm
Adjusting
Screw
2. Adjust overlood relief pressure by turning the
T145-02-03-001
adjusting screw.
: 6 mm

: 17 mm
: 27.5 to 31.4 N m
(2.8 to 3.2 kgf m, 20 to23 lbf ft)
4. After adjustment, check the travel relief set Lock Nut

pressure. Adjusting Screw
NOTE: Standard Change in Pressure

MPa 4.5 8.9 13.3 17.8
Change in 2)
(kgf/cm (45) (90) (136) (181) Pressure Pressure
Pressure Decrease
(psi) (645) (1290) (1930) (2580) Increase
W107-02-05-129
T4-5-11
MAIN PUMP FLOW RATE MEASUREMENT Front Side
Delivery Piping
P-Q Control (Torque Control)
Summary:
In order to check performance of the main pump,
measure the main pump flow rate by installing a
hydraulic tester to the delivery side of the main
pump.
Preparation:
1. Stop the engine.


tank and release any pressure in the hydraulic oil T18C-04-04-006
tank. Pi (Main Pump 1(Main Pump
: 4 mm 1, 3, 5) 2, 4, 6 to be measured)
3. Install a hydraulic tester to the delivery piping.
Hydraulic tester (ST 6299) Upper Side
Adapter (ST 6146)
Test hose (ST6145)
Bolt (M 341650, M341660)
Pipe (ST 6139) 1(Main Pump
Flange (ST 6141) 1, 3, 5 to be
measured) A
Split flange (4075854) 2
: 17 mm, 19 mm, 41 mm Split Flange
3 Pi (Main Pump 2, 4, 6)
: 14 mm (4075854)
4. Remove the plug from the pressure check port Test Hose (ST 6145)
on the main pump to be measured. Install a Adapter (ST 6146)
pressure gauge. Bolt Pipe
Hydraulic Tester (ST 6299) (M341650) (ST 6139)
Adapter
Adapter (ST 6146)
Pressure gauge assembly (ST 6934) Bolt Test Hose
Flange (ST 6141)
: 19 mm (M341660) (ST 6145)
5. Release any pressure in the main pump. Split Flange
T18C-04-04-007
(4075854) Delivery Hose
Pressure Check Port Pressure Gauge

(Main Pump2, 4, 6) Assembly (ST 6934)
Psv 2 3
View A
Adapter
Pressure Check Port (ST 6069)
(Main Pump 1, 3, 5)
T18C-04-04-008
Adapter Pressure Gauge
(ST 6069) Assembly (ST 6934)
T4-5-12
6. Disconnect the piping from ports Psv and Pi of Measurement:
the pump regulator in the main pump to be 1. Measure the maximum flow rate.
measured. Install tee (2) to port Psv of the regu- 2. Turn the auto-idle switch OFF.
lator. Connect hose (1) and hose (3) of the Psv 3. Set the fuel lever to the fast idle position.
circuit to tee (2). 4. Measure the pump flow rate and the engine
Install elbow (4) to port Pi. speed at each location on the P-Q diagram while
Connect hose (1) to elbow (4). gradually throttling the loading valve of the
Install the plug to the piping disconnected from hydraulic tester.
port Pi. 5. Repeat the measurement three times and calcu-
Connecting the pump servo assist pressure (Psv) late the average values.
circuit to port Pi allows the pump to be operated
by supplying the maximum pressure Pi with the Evaluation:
control lever operated full stroke. Convert the measured flow rates to those at the
: 17 mm, 19 mm specified pump speed by using the following for-
7. Disconnect the connectors from the power in- mulas:
crease solenoid valve and the power decrease Qc : Converted Flow Rate
solenoid valve. Q : Measured Flow Rate
8. Install the pulse meter to the engine speed Np : Specified Pump Speed: 1892 min-1
sensor. i : Pump Speed Ratio: 1.051
9. Fully open the loading valve of the hydraulic Ne : Measured Engine Speed
tester.
10. Start the engine and check for oil leakage at Qc= (Np Q) / (i Ne)
connection.
T4-5-13
Pi-Q Control by Flow Rate Control Pressure
(Pilot Pressure Characteristics)
Summary: Measurement:
In order to check performance of the main pump, 1. Measure the main pump flow rate controlled by
measure the main pump flow rate by installing a the external command pressure (flow rate control
hydraulic tester to the delivery side of the main pressure).
pump. 2. Turn the auto-idle switch OFF. Set the fuel lever
to the fast idle position.
Preparation: 3. Adjust the pressure reducing valve (8) set pres-
1. Refer to steps 1 to 3 on page T4-5-12. Install a sure to the specified pressure on the P-Q dia-
hydraulic tester to the main pump to be meas- gram of the main pump (Pilot Pressure Charac-
ured. teristics).
2. Disconnect the piping from port Pi of the regula- Measure the flow rate and engine speed at each
tor. Connect hose (5) to port Pi. Install the plug to pressure on the P-Q diagram.
the piping disconnected from port Pi. 4. Repeat the measurement three times and calcu-
3. Install pressure adapters (6)(2 used) and adapter late the average values.
(10) to reducing valve (8).
Remove plug (1) from manifold (13). Install and Evaluation:
adapter (4) connect hose (7). Connect hose (7) Convert the measured flow rates to those at the
to port P1 in pressure reducing valve (8). specified pump speed by using the following for-
: 19 mm mulas:
: 6 mm Qc = (Np Q)/(i Ne)
4. Install tee (9) to port P2 in pressure reducing Where:
valve (8). Qc : Converted Flow Rate
Install pressure gauge (3) and connect hose (5) Q : Measured Flow Rate
to tee (9). Np : Specified Pump Speed: 1892 min-1
: 19 mm i : Pump Speed Ratio: 1.051
5. Connect hose (5) to port T in pressure reducing Ne : Measured Engine Speed
valve (8).
Remove plug (2) from the hydraulic oil tank. In-
stall adapter (10). Connect hose (11).
: 19 mm, 22 mm
6. Release any pressure in the pump.
7. Fully open the loading valve on the hydraulic
tester.
T4-5-14
Main Pump: Pump Control Panel:
1
Pi
Manifold
Pi Front Side
T18C-03-01-005
Hydraulic Oil Tank:
T18K-04-05-001
2
T18C-04-04-009
Pressure Reducing Valve

Port Position To Plug (2) Hole
Pressure
on Hydraulic Oil Tank
Reducing
Valve (8)
10
3
P1 P2 11
10
5
To Port Pi in To Plug (1)

Regulator Hole on
Manifold
9 6 8 6 7 4
T118-04-04-014
1 - Plug G1/4 4 - Adapter UNF7/16 G1/4 7 - Hose UNF7/16 UNF7/16 10 - Adapter G3/8 G3/8
(4042037) (4042031)
2 - Plug G3/8 5 - Hose UNF7/16 UNF7/16 8 - Pressure Reducing Valve 11 - Hose G3/8 G3/8
(4325439) (ST6961)
3 - Pressure Gauge 6 - Adapter G3/8 UNF7/16 9 - Tee UNF7/16 UNF7/16
(ST 6931) (4200465) G1/4 (ST 6451)
T4-5-15
Adjustment of Maximum and Minimum Flow Rate
The pump flow rate can be adjusted by changing : 30 mm: Lock Nut (1), Lock Nut (3)
the maximum servo piston stroke. When adjusting : 13 mm: Adjusting Screw (2)
the maximum flow rate, loosen lock nut (1) and turn : 10 mm: Adjusting Screw (4)
adjusting screw (2) on the large chamber side in the
servo piston. When adjusting the minimum flow rate,
loosen lock nut (3) and turn adjusting screw (4) on
the small chamber in the servo piston.
NOTE: Turning adjusting screw (2) clockwise de-

creases the maximum flow rate, and turn-
ing adjusting screw (2) counterclockwise
increase the maximum flow rate. 1/4 turn
of adjusting screw (2) changes the flow
rate approx. 7.2 L/min.
Turning adjusting screw (4) clockwise in-
creases the minimum flow rate. Turning
adjusting screw (4) counterclockwise de-
creases the minimum flow rate. 1/4 turn of
adjusting screw (4) changes the flow rate
approx. 7.2 L/min.
4 3 1 2 2 1 3 4
T18C-03-01-005
Maximum Flow Rate Adjustment (Pump Minimum Flow Rate Adjustment

(Pump
Delivery Flow Delivery Flow
Rate) Rate)
Q Q
Pi (Flow Rate Pi (Flow Rate

Control Pressure) Control Pressure)
T4-5-16
Adjustment for Torque Constant Control
The torque constant control is performed by pump NOTE: When adjusting screw (4) is turned, the
own delivery pressure Pd. Therefore, the torque con- inner spring (2) set force varies. Therefore,
stant control is adjusted by changing the set force of turn adjusting screw (6) 2.06 times the
inner spring (2) and outer spring (1). turns of adjusting screw (4) in the opposite
(Before adjustment, mark the ends of adjust screws direction.
(4) and (6) by using a white marker for the record of
the original position.) : 36 mm: Lock Nut (3)
When adjusting inner spring (2), loosen nut (5) and : 24 mm: Adjusting Screw (4)
turn adjusting screw (6). : 13 mm: Lock Nut (5)
When adjusting outer spring (1), loosen nut (3) and : 4 mm: Adjusting Screw (6)
turn adjusting screw (4).
1 2
3
4
5
6
T117-05-04-005
Change in Flow Rate When Adjusting Outer Spring Change in Flow Rate When Adjusting lnner Spring
Adjusting Screw Turns 1/4 Adjust Screw Turn 1/4
Flow Rate 27.2 L/min Flow Rate 13.2 L/min
(7.19 US gal/min) (3.49 US gal/min)
Pressure 1.56 MPa Pressure 1.8 MPa
(15.9 kgf/cm2, 226 psi) (18.4 kgf/cm2, 262 psi)
Engine Torque 85.7 N m Engine Torque 62.7 N m
(8.7 kgf m, 63 lbf ft) (6.4 kgf m, 46.3 lbf ft)
(Pump (Pump
Delivery Q Delivery Q
Flow Rate) Flow Rate)
Pd (Pump Delivery Pd (Pump Delivery

Pressure) Pressure)
T4-5-17
Adjustment of Flow Rate Control
The flow rate control is performed by pump delivery NOTE: When the flow rate control is adjusted, the
flow rate control pressure Pi. Therefore, the flow relief flow rate minimizing control is also
rate control is adjusted by changing the set force of changed at the same time.
spring (1).
When adjusting, loosen nut (2) and turn adjusting : 13 mm: Nut (2)
screw (3). : 4 mm: Adjusting Screw (3)
2 3
T117-05-04-006
Change in Flow Rate When Adjusting Spring

Adjusting Screw Turns 1/4
Pressure (Pi) 0.26 MPa (2.7 kgf/cm2)
(38.4 psi)
Flow Rate 28.4 L/min (7.5 US gal/min)
(Pump (Pump
Delivery Flow Flow Rate Control Relief Flow Rate Minimizing Control
Delivery
Rate) Flow Rate)
Q
Q
Pi (Flow Rate Control

Pi (Pump Delivery
Pressure) Pressure)
T4-5-18
(Blank)
T4-5-19
OIL COOLER FAN MOTOR DRIVE PUMP
FLOW RATE MEASUREMENT
P-Q Control (Torque Control)
Summary:
In order to check performance of the oil cooler fan
motor drive pump, measure the oil cooler fan motor Front Side
drive pump flow rate by installing a hydraulic tester to
the delivery side of the oil cooler fan motor drive
pump. T18C-04-04-010
Pressure Delivery Piping
Check Port
Preparation: Split Flange
1. Stop the engine. (4506459) Test Hose
(ST 6145)
CAUTION: Do not turn the air breather cap Delivery Hose
on the hydraulic oil tank quickly. The air Flange
breather cap may fly off by internal pressure. Bolt (ST 6574)
Release any remaining pressure. (ST 6408)
Adapter Adapter
(ST 6146) (ST 6146)
2. Loosen the air breather cap on the hydraulic oil Hydraulic
Test Hose
tank and release any pressure in the hydraulic oil (ST 6145) Tester
tank. (ST 6299)
: 4 mm
3. Install a hydraulic tester to the delivery piping. Bolt (M341036)
Hydraulic tester (ST 6299) Pipe (ST6575)
Adapter (ST 6146)
Test hose (ST 6145)
Pipe (ST 6575)
Flange (ST 6574)
Split flange (4506459)
Bolt (M341036, ST 6408)
4. Install a pressure gauge to the pressure check
port. Split Flange
(4506459)
Adapter (ST 6069)
Pressure gauge assembly (ST 6934) Pressure Gauge Adapter (ST 6069) T18C-04-04-011
5. Release any pressure in the oil cooler fan motor Assembly (ST 6934)
drive pump.
6. Disconnect both side connectors in oil cooler fan
motor speed control solenoid valve.
NOTE: Both the left and right connectors on the oil
cooler fan speed control solenoid valve are
the same. Mark them before disconnecting
Oil Cooler Fan
for reassembling. Speed Control Front Side
Solenoid Valve
T18K-04-05-001
T4-5-20
7. Install a pulse meter to the engine speed sensor.
8. Fully open the loading valve of the hydraulic
tester.
9. Start engine and check for oil leakage at the
connections.
Measurement:
1. Measure the maximum flow rate.
2. Turn the auto-idle switch OFF.
3. Set the fuel lever to the fast idle position.
4. Measure the pump flow rate and the engine
speed at each location on the P-Q diagram while
gradually throttling the loading valve of the
hydraulic tester.
Evaluation:
Convert the measured flow rates to those at the
specified pump speed by using the following for-
mulas:
Qc : Converted Flow Rate
Q : Measured Flow Rate
Np : Specified Pump Speed: 2176 min-1
i : Pump Speed Ratio: 1.088
Ne : Measured Engine Speed
T4-5-21
Pi-Q Control by Flow Rate Control Pressure
(Pilot Pressure Characteristics)
Summary: Measurement:
In order to check performance of the oil cooler fan 1. Measure the main pump flow rate controlled by
motor drive pump, measure the oil cooler fan motor the external command pressure (flow rate control
drive pump flow rate by installing hydraulic tester to pressure).
the delivery side of the oil cooler fan pump. 2. Turn the auto-idle switch OFF. Set the fuel lever
to the fast idle position.
Preparation: 3. Adjust the pressure reducing valve (8) set pres-
1. Refer to steps 1 to 3 on page T4-5-20. Install a sure to the specified pressure on the P-Q dia-
hydraulic tester to the oil cooler fan motor drive gram of the main pump (Pilot Pressure Charac-
pump to be measured. teristics).
2. Disconnect the piping from port Pi of the regula- Measure the flow rate and engine speed at each
tor. Connect hose (5) to port Pi. Install the plug to pressure on the P-Q diagram.
the disconnected piping disconnected from port 4. Repeat the measurement three times and calcu-
Pi. late the average values.
3. Install adapters (6) (2 used) and adapter (10) to
pressure reducing valve (8). Evaluation:
Remove plug (1) from manifold (13). Install Convert the measured flow rates to those at the
adapter (4) and connect hose (7). Connect hose specified pump speed by using the following for-
(7) to port P1 in pressure reducing valve (8). mulas:
: 19 mm Qc = (Np Q)/(i Ne)
: 6 mm Where:
4. Install tee (9) to port P2 in pressure reducing Qc : Converted Flow Rate
valve (8). Q : Measured Flow Rate
Install pressure gauge (3) and connect hose (5) Np : Specified Pump Speed: 2176 min-1
to tee (9). i : Pump Speed Ratio: 1.088
: 19 mm Ne : Measured Engine Speed
5. Connect hose (5) to port T in pressure reducing
valve (8).
Remove plug (2) from the hydraulic oil tank. In-
stall adapter (10). Connect hose (11).
: 19 mm, 22 mm
6. Release any pressure in the pump.
7. Fully open the loading valve on the hydraulic
tester.
T4-5-22
Oil Cooler Fan Motor Drive Pump: Pump Control Panel:
1
Manifold
Regulator
Pi
Front Side
T118-05-02-026
Hydraulic Oil Tank:
T18K-04-05-001
2 T18C-04-04-009
Pressure
Reducing Valve
Port Position To Plug (2) Hole
Pressure on Hydraulic Oil Tank
Reducing Valve (8)
10
3
P1 P2 11
10
5
To Port Pi in To Plug (1)

Regulator Hole on
Manifold
9 6 8 6 7 4
T118-04-04-014
1 - Plug G1/4 4 - Adapter UNF7/16 G1/4 7 - Hose UNF7/16 UNF7/16 10 - Adapter G3/8 G3/8
(4042037) (4042031)
2 - Plug G3/8 5 - Hose UNF7/16 UNF7/16 8 - Pressure Reducing Valve 11 - Hose G3/8 G3/8
(4325439) (ST 6961)
3 - Pressure Gauge 6 - Adapter G3/8 UNF7/16 9 - Tee UNF7/16 UNF7/16
(ST 6931) (4200465) G1/4 (ST 6451)
T4-5-23
Adjustment of Maximum and Minimum Flow Rate
of Fan Motor Drive Pump
The pump flow rate can be adjusted by changing NOTE: Turning adjusting screw (2) clockwise de-
the maximum servo piston stroke. When adjusting creases the maximum flow rate, and turn-
the maximum flow rate, loosen lock nut (1) and turn ing adjusting screw (2) counterclockwise
adjusting screw (2) on the large chamber side in the increase the maximum flow rate. 1/4 turn
servo piston. When adjusting the minimum flow rate, of adjusting screw (2) changes the flow
loosen lock nut (3) and turn adjusting screw (4) on rate approx. 6.3 L/min.
the small chamber in the servo piston. Turning adjusting screw (4) clockwise in-
creases the minimum flow rate. Turning
adjusting screw (4) counterclockwise de-
creases the minimum flow rate. 1/4 turn of
adjusting screw (4) changes the flow rate
approx. 5.0 L/min.
: 30 mm: Lock Nut (1)

: 8 mm: Adjusting Screw (2)
4 3 1 2
T118-04-04-007
(Pump Maximum Flow Rate Adjustment (Pump Minimum Flow Rate Adjustment
Delivery Delivery
Q Q
Flow Rate) Flow Rate)
Pi (Flow Rate Pi (Flow Rate

Control Pressure) Control Pressure)
T4-5-24
Adjustment of Torque Constant Control
The torque constant control is performed by pump NOTE: When adjusting screw (4) is turned,the
own delivery pressure P. Therefore, the torque con- inner spring (2) set force varies. Therefore,
stant control is adjusted by changing the set force of turn adjusting screw (6) 2.24 times the
inner spring (2) and outer spring (1). turns of adjusting screw (4) in the opposite
(Before adjustment, mark the ends of adjust screws direction.
(4) and (6) by using a white marker for the record of
the original position.) : 36 mm: Lock Nut (3)
When adjusting inner spring (2), loosen nut (5) and : 24 mm: Adjusting Screw (4)
turn adjusting screw (6). : 13 mm: Lock Nut (5)
When adjusting outer spring (1), loosen nut (3) and : 4 mm: Adjusting Screw (6)
turn adjusting screw (4).
1 2
3 4
5 6
W117-02-02-017
Change in Flow Rate When Adjusting Outer Spring Change in Flow Rate When Adjusting Inner Spring
Adjusting Screw Turns 1/4 Adjusting Screw Turns 1/4
19.3 L/min Flow Rate 8.6 L/min (2.3 US gal/min)
Flow Rate
(5.1 US gal/min) 1.80 MPa (18.4 kgf/cm2)
Pressure
1.88 MPa (19.2 kgf/cm2) (262 psi)
Pressure
(273 psi) 13.0 N m (1.3 kgf m)
Engine Torque
24.5 N m (2.5 kgf m) (9.4 lbf ft)
Engine Torque
(18 lbf ft)
(Pump Delivery (Pump Delivery

Flow Rate) Q Flow Rate) Q
P (Pump Delivery Pressure) P (Pump Delivery Pressure)
T4-5-25
Adjustment of Flow Rate Control
The flow rate control is performed by external com-

mand pressure Pi. Therefore, the flow rate control is
adjusted by changing the set force of spring (1).
When adjusting, loosen lock nut (2) and turn adjust-
ing screw (3).

2 3
T117-05-04-006
Change in Flow Rate When Adjusting Spring

Adjusting Screw Turns 1/4 Flow Rate Control
0.18 MPa
Pressure (Pi) (Pump Delivery
(1.8 kgf/cm2, 25.6 psi) Flow Rate) Q
20.2 L/min
Flow Rate
(5.3 US gal/min)
Pi (External
Command
Pressure)
T4-5-26
(Blank)
T4-5-27
SWING MOTOR DRAINAGE
Summary:
1. In order to check the swing motor performance,
measure amount of oil draining from the swing
motor while swinging the upperstructure.
2. Always secure the test personnels safe during
the measurement. Before the measurement,
make sure there are no person or obstacles
within the test track.
3. The amount of drain oil from the swing motor will
change depending on hydraulic oil temperature.
4. Measure the swing motor dain oil one by one.
Front Side
Drain Hose
Preparation:
1. Rotate the swing motor in order to warm the
inside of the motor.

2. Stop the engine. Loosen the air breather cap on

the hydraulic oil tank and release any pressure in
the hydraulic oil tank.
3. Disconnect the swing motor drain hose at the
hydraulic oil tank end. Install plug (1-1/16-12UN)
to the disconnected end.
: 30 mm, 36 mm
: 176 N m (18 kgf m, 130 lbf ft)

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

1. Fuel Lever : Fast Idle Position Drain Hose
T18K-04-05-002
Auto-Idle Switch : OFF
T4-5-28
Measurement:
Amount of Oil Drained While Swinging the Upper-
structure
1. Fully retract the arm cylinder. Fully extend the
bucket cylinder. Hold the boom so that the arm tip
pin height is the same as the boom foot pin
height. The bucket must be empty.
2. Start the engine. Operate and hold the swing
lever full stroke. After the swing speed reaches a
constant maximum speed, start draining oil
measurement when drain oil starts coming out of
the drain hose end. T145-05-03-008
3. Repeat the measurement at least three times in
both clockwise and counterclockwise directions,
and calculate the average values.
4. The measuring time should be more than 20
seconds.
Amount of Oil Drained While Relieving Swing Motor

Circuit
1. Thrust the bucket teeth into the ground so that
the upperstructure does not rotate.
T145-05-03-007
2. Start the engine. Operate and hold the swing
lever full stroke. Start draining oil measurement
when drain oil starts coming out of the drain hose
end.
both clockwise and counterclockwise directions,
and calculate the average values.
seconds.
Evaluation:
* Conversion of the amount of drain oil measured

into the per-minute value
First measure the amount of drain oil by using a

calibrated container. Then, convert the measured
drain oil into the per-minute value using the
formula below:
Q = (60 / t) q
Where:
Q : Amount of drain oil per minute (L/min)
t : Measured time (seconds)
q : Total amount of drain oil (L)
T4-5-29
TRAVEL MOTOR DRAINAGE
Summary:
1. In order to check travel motor performance, while
rotating the travel motor with the track to be
measured jacked up, measure amount of oil
draining from the travel motor.
2. Always secure the test personnels safe during
the measurement. Before the measurement,
make sure there are no person or obstacles
within the test track.
3. Judge travel motor performance from the results
including travel speed, mistrack and so on over-
all.
4. The amount of drain oil from the travel motor will
change depending on hydraulic oil temperature.
Preparation:
1. Rotate the travel motor in order to warm the
inside of the motor.

2. Stop the engine. Loosen the air breather cap on

the hydraulic oil tank and release any pressure in
the hydraulic oil tank.
3. Disconnect the travel motor drain hose at the
hydraulic oil tank end. Install plug (1-1/16-12UN)
to the disconnected end.
: 30 mm, 36 mm Drain Hose
: 176 N m (18 kgf m, 130 lbf ft)
Preconditions for Measurement:

1. Fuel Lever : Fast Idle Position
Auto-Idle Switch : OFF
M144-12-002
T4-5-30
Measurement:
1. Start the engine. Jack up the track to be
measured.
CAUTION: When working around moving

parts is unamoidable, pay special attention to
ensure that hands, feet, and clothing do not
become entangled. Securely support the
raised macnine by using wooden blocks.
90 to 110
2. Rotate the track to be measured. Start drain oil

measurement when drain oil starts coming out of
the drain hose end. T142-05-03-011

both forward and reverse directions, and calcu-
seconds.
Evaluation:
Refer to Operational Performance Standard in T4-2. 90 to 110
* Conversion of the amount of drain oil measured

into the per-minute value
T142-05-03-012
First measure the amount of drain oil by using a

calibrated container. Then, convert the measured
drain oil into the per-minute value using the
formula below:
Q = (60 / t) q
Where:
Q : Amount of drain oil per minute (L/min)
t : Measured time (seconds)
q : Total amount of drain oil (L)
T4-5-31
(Blank)
T4-5-32
MEMO
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SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 General Group 3 Component Layout
Introduction .............................................. T5-1-1 Main Components (Overview)................... T5-3-1
Diagnosing Procedure .............................. T5-1-2 Around Pump ............................................ T5-3-3
Starting Check Indication .......................... T5-1-4 Pilot Panel (Operation Circuit) .................. T5-3-4
Alarm Indication........................................ T5-1-6 Pilot Panel (Back of Control Valve) ........... T5-3-5
Fault Diagnosis Indication ........................ T5-1-8 Undercarriage ........................................... T5-3-6
Automatic Snapshot Indication ............... T5-1-10 Fast-Filling Panel ...................................... T5-3-7
Monitor And Manual Snapshot Electrical System (Overview) .................... T5-3-8
Indication .............................................. T5-1-12 Engine .................................................... T5-3-20
Recorded Data ....................................... T5-1-14 Around Radiator...................................... T5-3-21
Maintenance History Display .................. T5-1-16 Water Tank.............................................. T5-3-22
Life Data Display .................................... T5-1-18 Air Cleaner.............................................. T5-3-22
Machine Information Indication............... T5-1-20 Oil Cooler................................................ T5-3-23
Various Setup Indication ......................... T5-1-22 Around Pump .......................................... T5-3-24
Maintenance Setup................................. T5-1-24 Swing Device .......................................... T5-3-25
Control Valve .......................................... T5-3-26
Group 2 Cross Reference Table
Travel Device .......................................... T5-3-29
Electrical Circuit Diagram (1/3) ................. T5-2-1
Center Joint ............................................ T5-3-29
EHC Valve (Main Pump Control) ............. T5-3-30
EHC Valve (Electric Lever Control) ......... T5-3-31
Hydraulic Circuit ....................................... T5-2-9
Sliding Fold-In Ladder............................. T5-3-32
Auto-Lubrication Device.......................... T5-3-33
Group 4 Troubleshooting A
Troubleshooting A Procedure .................... T5-4-1
Fault Diagnosis Indication......................... T5-4-2
Fault Code List.......................................... T5-4-4
Group 5 Troubleshooting B
Troubleshooting B Procedure ................... T5-5-1
How to Read Fault Codes ......................... T5-5-2
Fault Code for Engine ............................... T5-5-4
18KT-5-1
Group 6 Troubleshooting C
Troubleshooting C Procudure ................... T5-6-1
Diagnosis by blinking of Indicator ........... T5-6-14
Group 7 Electrical System Inspection

Precautions for Inspection and
Maintenance ........................................... T5-7-1
Instructions for Disconnecting
Connectors ............................................. T5-7-3
Battery Voltage Check .............................. T5-7-4
Fusible Link Inspection ............................. T5-7-6
Fuse Inspection ........................................ T5-7-8
Alternator Check..................................... T5-7-15
Voltage Check ........................................ T5-7-16
Check by False Signal ............................ T5-7-24
Continuity Check .................................... T5-7-25
Circuit Check by Lamp Harness ............. T5-7-26
18KT-5-2
TROUBLESHOOTING / General
INTRODUCTION
Refer to the inspection and troubleshooting procedures

after any machine trouble has occurred. The inspection
and troubleshooting procedures are presented in an
orderly fashion in this section to help you quickly find
the cause and solution of the machine trouble.
The troubleshooting section in this manual consists of

7 groups; General, Cross Reference Table of circuit
Diagram / Component Layout, Component Layout,
Troubleshooting A (base machine diagnosis indicated
in the monitor display fault codes), Troubleshooting B
(engine diagnosis indicated by the flashing pattern of
indicator lights), Troubleshooting C (Air conditioner
diagnosis) and Electrical System Inspection.
General
Cross Reference Table of Circuit Diagram / Com-

ponent Layout
Component Layout
Troubleshooting A (base machine diagnosis indi-

cated in the monitor display fault codes)
Troubleshooting B (engine diagnosis relies on the

flashing pattern of indicator lights)
The engine is diagnosed by referring to the flash-
ing patterns of the engine stop indicator and the
engine warning indicator.
Troubleshooting C (Air conditioner diagnosis)

Refer to these procedures when troubleshooting
by inspecting abnormal air conditioner operational
status.
Example Air conditioner malfunction.
Electrical System Inspection

Refer to this group when required to obtain pre-
cautions and/or information for the electrical sys-
tem inspection.
Example Fuse Inspection
T5-1-1
DIAGNOSING PROCEDURE
These six basic steps are essential for efficient

troubleshooting:
1. Study the system

Study the machines 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.
How is the machine being used? (Find out if the
machine is being operated correctly)
When was the trouble noticed, and what types of
work the machine doing at that time?
What are the details of the trouble? Is the trouble
getting worse, or did it appear suddenly for the
first time?
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 machines daily maintenance points, as
shown in the operator's manual.
Also, check the electrical system, including the

batteries, as troubles in the electrical system such
as low battery voltage, loose connections and
blown fuses will result in malfunction of the
controllers, causing total operational failure of the
machine.
If troubleshooting is started without checking for

blown fuses, a wrong diagnosis may result, wast-
ing time. Be sure to check for blown fuses before
troubleshooting. Even if a fuse looks normal by
visual inspection, a fine crack is difficult to find.
Always use a tester when checking the fuses.
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: If a harness or pipe is discon-
nected with the engine running, the machine
may operate incorrectly, or high pressure oil
may spray, causing personal injury. Be sure
to disconnect harnesses or pipes after stop-
ping the engine.
Perform self-diagnosis by operating the monitor

display. In case any fault code has been displayed
by diagnosis using the monitor display, check the
cause of the trouble by referring to Troubleshoot-
ing A in this section. After the machine trouble has
been corrected, the fault code will be deleted. If
the engine stop indicator and the engine warning
indicator in the electrical equipment box start
flashing by the ECM diagnosis system, check the
cause of the trouble by referring to Troubleshoot-
ing B in this section. Therefore, in case problems
which are not easily repredicable are encountered,
T107-07-01-006
use the built-in self-diagnosing system and ECM
diagnosis system to display the fault code.
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
STARTING CHECK INDICATION
IDU displays the starting check information on the

monitor display in response to the level sensor signals
received from each controller by using CAN.
IMPORTANT: The monitor display can be switched

by the keypad.
Indication Keypad T18G-02-01-108
Starting Screen
1. When the engine is not running and the Meter
Screen appears on the monitor display, push
key ? the Starting Check Screen is displayed on
the monitor display.
Return to the Meter Screen, by pushing key .
Automatic Transition T18M-05-01-003
Meter Screen
T18M-05-01-001
Starting Check Screen
T18M-05-01-002
T5-1-4
(Blank)
T5-1-5
ALARM INDICATION
IDU displays the alarm information on the monitor dis-

play in response to the alarm signals received from
each controller by using CAN.

by the keypad.
Starting Screen
1. When the Meter Screen appears on the monitor
display, push key and display the Current
Alarms List Screen on the monitor display.
In order to return to the Meter Screen, push key .
2. Select the required item from the list by pushing Meter Screen
keys and , and push key . The Alarm Expla-
nation Screen will appear. (Refer to the next
page.)
In order to return the Current Alarms List Screen,
push key .
T18M-05-01-001
Current Alarm List Screen
T18M-05-01-004
T5-1-6
3. In order to display the Detailed Circuit Diagram
Screen, push key . Alarm Explanation Screen
In order to return to the Alarm Explanation Screen,
push key .
T18G-05-01-004
Detailed Circuit Diagram Screen
T18G-05-01-005
T5-1-7
FAULT DIAGNOSIS INDICATION
IDU displays the fault diagnosis results on the monitor

display in response to the fault signals received from
each controller by using CAN.

by the keypad.
Starting Screen
display, push key and display the Current
Faults Code List Screen on the monitor display.
2. Select the required item from the list by pushing Meter Screen
keys and , and push the key . The Faults Ex-
planation Screen of the selected item will appear.
(Refer to the next page.)
In order to return the Current Fault Code List
Screen, push key .
T18M-05-01-001
Current Fault Code List Screen
T18M-05-01-005
T5-1-8
3. In order to display the Detailed Circuit Diagram
Screen, push key . Fault Explanation Screen
In order to return to the Fault Explanation Screen,
push key .
T18G-05-01-007
Detailed Circuit Diagram Screen
T18G-05-01-027
T5-1-9
AUTOMATIC SNAPSHOT INDICATION
IDU displays the related snapshot lists on the monitor

display on time-series basis in response to event log
received from DLU by using CAN.

by the keypad.
Starting Screen
display, push key . The Service Menu Screen will
appear.
2. Select Automatic Snapshot from the menu by Meter Screen

pushing keys and , and push key . The
Automatic Snapshot List Screen will appear. (Re-
fer to next page.)
In order to return to the Service Menu Screen,
push key .
T18M-05-01-001
Service Menu Screen
T18M-05-01-008
T5-1-10
3. Select the required item from the list by pushing
keys and , and push key . The Snapshot Automatic Snapshot List Screen
Screen of the selected item will appear.
In order to return the Automatic Snapshot List
Screen, push key .
IMPORTANT: If there is no auto snapshot data, the

snapshot screen cannot appear on
the display.
T18M-05-01-011
Snapshot Screen
T18M-05-01-015
T5-1-11
MONITOR AND MANUAL SNAPSHOT IN-
DICATION
IDU receives the operating status of the component

used for the corresponding control from DLU, MC or
ELU by using CAN. IDU indicates it on the monitor
display, records and replays it.

by the keypad.
Monitor/Record/Replay
Starting Screen
appear.

2. Select Monitor and manual snapshot from the
Meter Screen
menu by pushing keys and , and push key .
The Monitor and Manual Snapshot Menu Screen
will appear. (Refer to the next page.)
push key .
T18M-05-01-001
Service Menu Screen
T18M-05-01-008
T5-1-12
3. Select Monitor/Record/Replay from the menu by
pushing keys and , and push key . The Moni- Monitor and Manual Snapshot Menu Screen
tor/Record/Replay List Screen will appear.
In order to return to the Monitor and Manual
Snapshot Menu Screen, push key .
T18G-05-01-011
4. Select the required item from the list by pushing Monitor / Record / Replay List Screen
keys , , and , and push key . The Snap-
shot Screen of the selected item will appear.
In order to return to the Monitor/Record/Replay
List Screen, push key .
T18M-05-01-006
Snapshot Screen
5. Select the item to be recorded from the Snapshot.
Screen by pushing keys and , and push key .
Data on the selected item will be recorded.
T18M-05-01-014
T5-1-13
RECORDED DATA
REPLAY

by the keypad.
Keypad T18G-02-01-108
Indication
1. Display The Monitor and Manual Snapshot Menu Monitor and Manual Snapshot Menu Screen
Screen. (Refer to T5-1-12.)
T18G-05-01-011
Replay List Screen

2. Select Replay from the menu by pushing keys
and , and push key . The Replay List Screen
will appear.
In order to return to the Monitor and Manual
Snapshot Menu Screen, push the key .
3. Select the item to be displayed from the list by

pushing keys and , and push key . The Re-
corded Data Replay Screen of the selected item
will appear.
In order to return to the Replay List Screen, push
key . T18G-05-01-013
Recorded Data Replay Screen

4. Select the data replay item from the Recorded
Data Replay Screen by pushing keys , , and
, and push key . Data on the selected item will
be replayed.
T18G-05-01-014
T5-1-14
(Blank)
T5-1-15
MAINTENANCE HISTORY DISPLAY
IDU displays the log (maintenance history) at the re-

placement of air filter, engine oil and hydraulic oil in
terms of hourmeter reading, number of replacement
and time length until the next replacement.
Replacement items are shown in the list. Select the
required item from the list and record replacement his-
tory.

by the keypad.
Starting Screen
appear.
2. Select Maintenance History from the menu by Meter Screen

pushing keys and , and push key . The Main-
tenance History List Screen will appear. (Refer to
the next page.)
push key .
T18M-05-01-001
Service Menu Screen
T18M-05-01-008
T5-1-16
3. Select the required maintenance name from the
list by pushing keys and , and push key . Maintenance History List Screen
Maintenance Name, Hourmeter Hours and Main-
tenance Date will appear on the monitor display.
In order to return to the Maintenance History List
Screen, push key .
T18G-05-01-015
Maintenance History Screen
T18G-05-01-016
T5-1-17
LIFE DATA DISPLAY
IDU receives cumulative information, including cumu-

lative engine running hours and machine operating
hours, from DLU by using CAN. IDU indicates it on the
monitor display.

by the keypad.
Starting Screen
appear.
2. Select Life from the menu by pushing keys and , Meter Screen
and push key . The Life Data Screen will appear.
push key .
T18M-05-01-001
Service Menu Screen
T18M-05-01-008
T5-1-18
Life Data Screen
T18G-05-01-017
T5-1-19
MACHINE INFORMATION INDICATION
IDU displays controller configuration as well as hard-

ware and software (version) used in the respective
controllers on the monitor display.

by the keypad.
Starting Screen
appear.
2. Select Machine Information from the menu by Meter Screen

pushing keys and , and push key . The Ma-
chine Information Screen will appear.
push key .
T18M-05-01-001
Service Menu Screen
T18M-05-01-008
T5-1-20
Machine Information Screen
T18M-05-01-007
T5-1-21
VARIOUS SETUP INDICATION
Maintenance Setup, Event Display Setup, Time Adjust

and Setting Put-out Lights Delay Time can be set on
the Various Setup Screen.

by the keypad.
Starting Screen
appear.
2. Select Various Setup from the menu by pushing Meter Screen

keys and , and push key . The Setup Menu
Screen will appear. (Refer to the next page.)
push key .
T18M-05-01-001
Service Menu Screen
T18M-05-01-008
T5-1-22
Setup Menu Screen
T18M-05-01-009
T5-1-23
MAINTENANCE SETUP
Replacement intervals of air filter, engine oil, hydrau-

lic oil, etc. can be set.

by the keypad.
1. Display the Setup Menu Screen (Refer to Setup Menu Screen

T5-1-22.)
T18M-05-01-009
Maintenance Setup List Screen

2. Select Maintenance Setup from the menu by
pushing keys and , and push key . The Main-
tenance Setup List Screen will appear.
In order to return to the Setup Menu Screen, push
key .
3. Select the item to be changed from the list by

pushing keys , , and , and push key . The
selected item will blink and can be changed.
4. Select the number, by using keys , and , and

push key . Setup is completed. T18M-05-01-012
: Increase Maintenance Setup Screen

: Decrease
: Cancellation
T18M-05-01-013
T5-1-24
Snapshot Setup
Manual snapshot data can be initialized.

by the keypad.
Keypad
Indication T18G-02-01-108
1. Display the setup Menu Screen. (Refer to

Setup Menu Screen
T5-1-22.)
T18M-05-01-009
2. Select Snapshot Setup from the menu by pushing Snapshot Setup Screen
keys and , and push key . The Snapshot
Setup Screen will appear.
In order to return to the Setup Menu Screen,
pushing key .
3. Push key and initialize the snapshot data.
T18M-05-01-010
T5-1-25
Time Adjust
Set the world standard time, local standard time and

time difference.

by the keypad.
IMPORTANT: If DLU setting is incorrect, reset the

Greenwich Mean Time, Local Stan-
dard Time and Time Difference.
When DLU setting is correct, adjust
time difference only.
Keypad T18G-02-01-108
Indication
1. Display the Setup Menu Screen. (Refer to Setup Menu Screen
T5-1-22.)
T18M-05-01-009
Time Adjust Screen

2. Select Time Adjust from the menu by pushing
keys and , and push key . The Time Adjust
Screen will appear.
key .
T18G-05-01-022
Adjust Screen
3. Push key to and display the Adjust Screen.
4. Select the required item by using keys and

keys, and adjust time or time difference by push-
ing keys , and . After adjustment, push key .
Time or time difference is set up.
: Increase
: Decrease
: Cancellation
T18G-05-01-023
T5-1-26
Setting Put-out Lights Delay Time
Select and set up the put-out delay time of light from

the setting time.

by the keypad.
Keypad T18G-02-01-108
Indication
Setup Menu Screen
1. Display the Setup Menu Screen. (Refer to
T5-1-22.)
T18M-05-01-009
2. Select Setting Put-out Lights Delay Time from the Setup Put-out Lights Delay
menu by pushing keys and , and push key . Time Setting Screen
The Setting Put-out Lights Delay Time Setting
Screen will appear.
key .
3. Select the required time from the list by pushing

keys and , and push key . Delay time is set
up.
T18G-05-01-024
T5-1-27
(Blank)
T5-1-28
TROUBLESHOOTING / Cross Reference Table
ELECTRICAL CIRCUIT DIAGRAM (1/3)
IMPORTANT: The No. indicates the component

number in the circuit diagram.
The position indicates the compo-
nents position in the circuit diagram.
The number at left side is horizontal
lines of drawing frame, the alphabet
at right side is vertical lines of
drawing frame.
Refer to the page and item number
in the following group.
Item
No. Position Component Name Page Note
Number
001 E13 Sliding Fold-In Ladder Emergency Stop Switch - - OP
002 E14 Limit Switch (Storage Slowdown) - - OP
003 E14 Limit Switch (Expansion Slowdown) - - OP
004 F14 Sliding Fold-In Ladder Isolation Switch - - OP
005 I15 Lift Pump Drive Solenoid Valve - -
006 I15 Fuel Sensor (WATER IN) - -
007 B18 Ladder Limit Switch T5-3-8, 32 28, 2
008 E18 Sliding Fold-In Ladder Beacon/Alarm - - OP
009 E20 Limit Switch (Storage Detection) - - OP
010 D20 Limit Switch (Lock Lever) - - OP
011 D21 Sliding Fold-In Ladder Relay 3 - - OP
012 C21 Sliding Fold-In Ladder Relay 1 - - OP
013 B21 Sliding Fold-In Ladder Relay 4 - - OP
014 C23 Solenoid Valve - - OP
015 D23 Sliding Fold-In Ladder Relay 2 - - OP
016 E23 Sliding Fold-In Ladder Work Light - - OP
017 E22 Motor Pump Unit - - OP
018 J18 LTA Coolant Temperature Sensor (IN) T5-3-21 3
019 J18 LTA Coolant Temperature Sensor (OUT) T5-3-21 5
020 J18 Coolant Temperature Sensor (IN) T5-3-21 4
021 K18 Coolant Temperature Sensor (OUT) T5-3-21 6
022 K18 Fresh Air Temperature Sensor (Radiator Front) T5-3-21 7
023 K19 Ether Solenoid Valve - - OP
NOTE: OP: Optional
T5-2-1
Item
Number
024 J19 Air Cleaner Restriction Switch 2 T5-3-22 4
025 J19 Air Cleaner Restriction Switch 1 T5-3-22 4
026 J19 Maintenance Light (Engine Space) T5-3-8 18
027 I19 Engine Stop Switch (For Pump Space Rear Side) T5-3-8 19
028 I19 Engine Stop Switch (Engine Space Front Side) T5-3-8 22
029 I22 Entrance Light T5-3-8 3
030 I22 Coolant Level Sensor T5-3-22 2
031 J22 Coolant Level Switch 1 (Level Indicator) T5-3-8, 22 23, 1
032 J22 Coolant Level Switch 2 (Level Indicator) T5-3-8, 22 23, 1
033 J22 Work Light (Rear Left) T5-3-8 21
034 K22 Camera 3 (R-L) - -
T5-2-2
Item
Number
001 B2 Contamination Sensor (Main Pump 1) T5-3-19 1
002 B2 Contamination Sensor (Main Pump 2) T5-3-19 2
003 C2 Contamination Sensor (Main Pump 3) T5-3-19 3
007 B4 Pump 1 Drain Pressure Sensor T5-3-24 1
008 B4 Pump 2 Drain Pressure Sensor T5-3-24 1
009 C4 Pump 3 Drain Pressure Sensor T5-3-24 3
013 D4 Pump Transmission Level Switch T5-3-24 2
014 D4 Pump Transmission Oil Temperature Sensor T5-3-24 6
015 E3 Engine Stop Switch (For Pump Space Front Side) T5-3-8 12
016 F3 Valve Limit Switch R (Delivery Circuit) T5-3-8 14
017 F3 Valve Limit Switch F (Delivery Circuit) T5-3-8 14
018 G4 Engine Stop Switch (For Pump Space Rear Side) T5-3-8 16
019 G4 Maintenance Light (Pump Space) T5-3-8 13
020 G4 Work Light (Rear Right) T5-3-8 15
021 H4 Camera 4 (R-R) - -
022 G2 Auxiliary T5-3-30 9
024 H2 Power Decrease Control Solenoid Valve T5-3-30 11
025 H2 Main Pump Displacement Angle Control Solenoid Valve T5-3-30 13
(Main Pump No.5)
026 H2 Main Pump Displacement Angle Control Solenoid Valve T5-3-30 8
(LD: Main Pump No.1, 2, BH: Main Pump No.1)
027 I2 Power Increase Control Solenoid Valve T5-3-30 6
028 I2 Main Pump Displacement Angle Control Solenoid Valve T5-3-30 4
(LD: Main Pump No.3, 4, 6, BH: Main Pump No.2, 3, 4, 6)
T5-2-3
Item
Number
029 I2 Oil Cooler Fan Speed Control Solenoid Valve T5-3-30 2
030 J2 Pressure Sensor (SE) T5-3-30 12
031 J2 Pressure Sensor (SD) T5-3-30 14
032 J2 Pressure Sensor (SH) T5-3-30 7
033 K2 Pressure Sensor (SB) T5-3-30 5
034 K2 Pressure Sensor (SA) T5-3-30 3
035 K2 Pressure Sensor (SC) T5-3-30 1
036 K7 Coolant Pressure Sensor 2 T5-3-23 3
037 K7 Coolant Pressure Sensor 1 T5-3-23 3
038 J7 Fresh Air Temperature Sensor 2 (Oil Cooler Front) - - OP
039 J7 Fresh Air Temperature Sensor 1 (Oil Cooler Front) T5-3-23 1
040 J7 Hydraulic Oil Temperature Sensor (Delivery Circuit) - - OP
041 I7 Hydraulic Oil Temperature Sensor (Oil Cooler Fan Motor T5-3-23 2
Rotation Control)
042 B10 Engine Oil Coolant Reservoir Level Sensor - - OP
043 C10 Engine Oil Coolant Reservoir Level Switch - - OP
044 D10 Engine Oil Coolant Reservoir Pump Unit - - OP
045 D10 Engine Oil Coolant Reservoir Valve Switch - - OP
046 E10 PRELUB Motor - -
047 E10 Alternator (Cummins) T5-3-20 7
048 E12 Starter (Cummins) (Upper) T5-3-20 6
049 F12 Starter (Cummins) (Lower) T5-3-20 6
050 E14 Prelub Pressure Switch T5-3-20 3
051 E14 Engine Speed Sensor T5-3-20 2
052 F14 Engine Oil Level Sensor - -
053 F18 Engine Oil Coolant Reservoir Filling System Power Switch T5-3-7 5 OP
054 F19 Engine Oil Coolant Reservoir Filling System Operation T5-3-7 6 OP
Switch
055 F20 Engine Oil Coolant Reservoir Full Indicator T5-3-7 3 OP
056 G19 Engine Oil Coolant Reservoir Shut-Off Valve Open Lamp T5-3-7 4 OP
NOTE: OP: Optional
T5-2-4
Item
Number
058 H18 (BH: Bucket Roll-Out / LD: Bucket Tilt-Out) Solenoid Valve T5-3-31 2
059 H18 (BH: Bucket Roll-In / LD: Bucket Tilt-In) Solenoid Valve T5-3-31 3
060 H18 (BH: Arm Roll-Out / LD: Arm Extend) Solenoid Valve T5-3-31 4
061 I18 LD: Bucket Close Solenoid Valve T5-3-31 8
BH: Auxiliary
062 I18 Boom Lower Solenoid Valve T5-3-31 7
063 I18 Boom Raise Solenoid Valve T5-3-31 6
064 I18 (BH: Arm Roll-In / LD: Arm Retract) Solenoid Valve T5-3-31 5
065 J18 Pressure Sensor (SF) T5-3-31 17
066 J18 Pressure Sensor (SE) T5-3-31 18
067 J18 Pressure Sensor (SD) T5-3-31 19
068 K18 Pressure Sensor (SH) T5-3-31 23
069 K18 Pressure Sensor (SB) T5-3-31 22
070 K18 Pressure Sensor (SA) T5-3-31 21
072 J19 Travel Alarm T5-3-8 20
073 I19 Fuel Cooler Bypass Solenoid Valve - - OP
074 H19 Proximity Switch - - OP
075 G19 Fuel Full Indicator T5-3-7 8
076 I23 Air Bleeding Solenoid Valve T5-3-8 9
077 I24 Hydraulic Oil Level Switch 1 (Level Indicator) T5-3-8 7
078 I24 Hydraulic Oil Level Switch 2 (Alarm Light) T5-3-8 8
079 J24 Hydraulic Oil Temperature Sensor 1 (Hydraulic Oil Tem- T5-3-8 10
perature Gauge, Oil Cooler Fan Motor Control)
080 J24 Valve Limit Switch (Suction Circuit) T5-3-8 11
081 K24 Frame Center Work Light R - - OP
082 F26 Travel Right Forward Solenoid Valve T5-3-31 9
083 G26 Travel Left Reverse Solenoid Valve T5-3-31 10
084 G26 Travel Left Forward Solenoid Valve T5-3-31 11
NOTE: OP: Optional

BH: Backhoe
LD: Loading Shovel
T5-2-5
Item
Number
085 G26 Auxiliary T5-3-31 12
086 H26 Swing Right Solenoid Valve T5-3-31 16
087 H26 Swing Left Solenoid Valve T5-3-31 15
088 H26 Travel Right Reverse Solenoid Valve T5-3-31 14
089 I26 LD: Bucket Open Solenoid Valve T5-3-31 13
BH: Auxiliary
090 I26 Pressure Sensor (SI) T5-3-31 24
091 I26 Pressure Sensor (SF) T5-3-31 25
092 I26 Pressure Sensor (SE) T5-3-31 26
093 J26 Pressure Sensor (SH) T5-3-31 30
094 J26 Pressure Sensor (SB) T5-3-31 29
095 J26 Pressure Sensor (SA) T5-3-31 28
097 K26 Pressure Sensor (PH) (Gate Lock) T5-3-31 31
098 F29 Fuel Level Switch H (Indicator) T5-3-8 24
099 F29 Fuel Level Switch L (Indicator) T5-3-8 24
100 G29 Fuel Level Sensor (Fuel Gauge) T5-3-8 25
101 G29 Pressure Sensor (Travel) T5-3-5 2
102 H29 Travel Mode Selector Solenoid Valve T5-3-4 8
103 I29 Pilot Shut-Off Solenoid Valve T5-3-4 10
T5-2-6
Item
Number
001 F4 Camera 2 (F-R) - -
002 F4 Work Light L (Front Right) T5-3-8 5
003 F4 Work Light R (Front Right) T5-3-8 5
004 G3 Horn (Right) - - OP
005 G3 Horn Air Compressor (R1) - - OP
006 G3 Horn Air Compressor (R2) - - OP
007 H4 Horn Pressure Switch (R1) - - OP
008 H4 Horn Pressure Switch (R2) - - OP
009 I4 Auto-Lubrication Solenoid Valve T5-3-33 6
010 D11 Pressure Switch (Auto-Lubrication) T5-3-9, 33 16, 2
011 D11 Pressure Switch (Manual-Lubrication) T5-3-9, 33 17, 1
012 D12 Auto-Lubrication Selection Switch T5-3-9, 33 15, 3
013 E11 Prelub Timer T5-3-9 5
014 F11 Fusible Link (5 A) (PRELUB Signal) T5-3-10 3
015 F12 Prelub Relay T5-3-9 13
016 F11 Starter Relay 1 (Upper) T5-3-9 7
017 G11 Starter Relay 1 (Lower) T5-3-9 8
018 H11 Alternator Relay T5-3-9 4
019 I10 Starter Relay 2 T5-3-9 6
020 I12 Engine Oil Filling Relay (1) T5-3-9 2
021 I12 Engine Oil Filling Relay (2) T5-3-9 3
022 G13 Fusible Link (400 A) (PRELUB Relay) T5-3-10 2
023 G13 Circuit Breaker T5-3-9 11
024 G14 Battery Relay (3) T5-3-9 14
025 G14 Battery Relay (2) T5-3-9 9
026 F14 Battery Relay (1) T5-3-9 10
027 F13 Fusible Link (10 A) (Engine Oil Coolant Reservoir Valve) T5-3-10 5
028 G12 Fusible Link (30 A) (Zener Diode) T5-3-10 4
029 E13 Fusible Link (75 A) (Engine Starter Relay) T5-3-10 13
NOTE: OP: Optional
T5-2-7
Item
Number
030 E13 Fusible Link (75 A) (Fuse Box) T5-3-10 7
036 E14 Fusible Link (45 A) (Optional) T5-3-10 12 OP
037 E15 Fusible Link (45 A) (ECM Power) T5-3-10 14
038 E15 Fusible Link (75 A) (Sliding Fold-In Ladder Relay) (Op- T5-3-10 15
tional)
039 E16 Fusible Link (250 A) (Sliding Fold-In Ladder Motor) (Op- T5-3-10 1 OP
tional)
040 E16 Fusible Link (250 A) (Sliding Fold-In Ladder Motor) (Op- - -
tional)
041 E16 Battery T5-3-9 12
042 F17 Cover Switch T5-3-9 1
043 F22 Pressure Sensor (Arm Cylinder Bottom Side) T5-3-28 1
044 F22 Pressure Sensor (Arm Cylinder Rod Side) T5-3-28 2
045 H23 Drain Pressure Sensor 1 (Swing Motor) T5-3-25 4
046 H23 Contamination Sensor (Swing Motor Front Side) T5-3-8, 19 29, 7
047 I23 Travel Stop Pressure Detection Sensor T5-3-29 4
048 I23 Contamination Sensor (Travel Motor) T5-3-8, 19 28, 9
049 J23 Drain Pressure Sensor 2 (Swing Motor) T5-3-25 5
050 J23 Engine Stop Switch (Engine Space Rear Side) T5-3-8, 19 27, 8
NOTE: OP: Optional
T5-2-8
HYDRAULIC CIRCUIT
Item
Number
001 2B Accumulator (Pilot Circuit) T5-3-1, 4 25, 1
002 2B EHC Valve (Electrical Lever) (Left Side of Main Frame) T5-3-4, 31 4
003 3B DQR Valve 2 (Left Side of Main Frame) T5-3-4 5
004 3B Shuttle Valve (Travel) T5-3-5 1
005 3B DQR Valve 1 (Center Side of Main Frame) T5-3-4 6
006 4B EHC Valve (Electrical Lever) (Center Side of Main Frame) T5-3-4, 31 7
007 4C Pilot Shut-Off Solenoid Valve T5-3-4 10
008 4D Travel Mode Selector Solenoid Valve T5-3-4 8
009 4D Pressure Reducing Valve (Travel Speed Change) T5-3-4 9
010 3D Engine T5-3-1, 21 24
011 2D Pump Transmission T5-3-3 6
012 2E Transmission Oil Filter T5-3-24 5
013 2E 4-Unit Pump (Oil Cooler Fan Drive Pump) T5-3-3 8
014 2E 4-Unit Pump (Pilot Pump) T5-3-3 8
015 2E 4-Unit Pump (Compressor Pump) T5-3-3 8
016 2E 4-Unit Pump (Pump Transmission Oil Pump) T5-3-3 8
017 3E Main Pump 5 T5-3-3 7
018 3E Main Pump 6 T5-3-3 7
019 3E Main Pump 3 T5-3-3 5
020 3E Main Pump 4 T5-3-3 5
021 4E Main Pump 1 T5-3-3 4
022 4E Main Pump 2 T5-3-3 4
023 5E High Pressure Strainer T5-3-1 15
024 2F Transmission Oil Circulation Pump Bypass Check Valve T5-3-24 7
025 2G Pilot Filter T5-3-1, 3 22, 2
026 2G Pilot Relief Valve T5-3-3 1
027 2G Check Valve (Pilot Circuit) T5-3-4 3
028 3G EHC Valve (Main Pump Control) T5-3-3, 30 3
029 4G Oil Cooler Fan Motor T5-3-1 17
030 4G Pump Transmission Cooler T5-3-1 16
T5-2-9
Item
Number
031 4G Oil Cooler T5-3-1 19
032 4G Fuel Cooler T5-3-1 18
033 5D Compressor Pump Relief Valve T5-3-4 2
034 6B Control Valve (Left) T5-3-1, 26 23
035 6D Control Valve (Center) T5-3-1, 26 23
036 6F Control Valve (Right) T5-3-1, 26 23
037 6G Bypass Filter T5-3-1 14
038 6G Hydraulic Oil Tank T5-3-1 13
039 7G Air Bleeding Solenoid Valve T5-3-8 9
040 7A Compressor Motor T5-3-1 35
041 7A Motor Pump Unit (Sliding Fold-In Ladder) - - OP
042 8A Valve Unit (Sliding Fold-In Ladder) - - OP
043 9A Sliding Fold-In Ladder Cylinder - - OP
044 9A Holding Valve - - OP
045 7B Travel Motor (Left) T5-3-29 2
046 8B Brake Valve T5-3-29 1
047 7E Swing Motor (Rear) T5-3-25 1
048 8E Center Joint T5-3-1, 6 11, 5
049 8E Pilot Pressure Selector Valve T5-3-6 4
050 9E Relief Valve T5-3-6 3
051 9D Accumulator (Adjuster Cylinder) T5-3-1, 6 33, 7
052 10E Swing Motor (Front) T5-3-25 1
053 7G Travel Motor (Right) T5-3-29 2
054 8G Travel Brake Valve T5-3-1, 29 29, 1
055 7G Accumulator (Adjuster Cylinder) T5-3-1, 33 10
056 10F Adjuster Cylinder T5-3-1, 6 34, 1
057 9C Adjuster Cylinder T5-3-1 34
058 10B ELU T5-3-12 8
059 10B Electrical Lever (Left) T5-3-12 1
060 10C Electrical Lever (Right) T5-3-12 5
T5-2-10
Item
Number
061 11B Electrical Lever (Travel) T5-3-12 3
062 11D Bucket Cylinder T5-3-1, 2 1, 3
063 11D Arm Cylinder T5-3-1, 2 5, 4
064 11E Boom Cylinder T5-3-1, 2 8, 5
065 11B Electrical Lever (Bucket Open/Close) T5-3-12 2, 4 LD
Only
066 11C Dump Cylinder T5-3-1 2 LD
Only
067 11E Level Cylinder T5-3-1 6 LD
Only
NOTE: OP: Optional

LD: Loading Shovel
T5-2-11
(Blank)
T5-2-12
TROUBLESHOOTING / Component Layout
MAIN COMPONENTS (OVERVIEW)
Loading Shovel
7 8
6
5
9
4
10
3 11
12
13 14
15
16
17
18
1 19
2
20
37
36
21
35 22
23
34
24
33 25
32 26
31
30 27
29
28 T18K-01-02-001
1- Bucket Cylinder 11 - Center Joint 21 - Counterweight 31 - Lower Roller

2- Dump Cylinder 12 - Fuel Tank 22 - Pilot Filter 32 - Upper Roller
3- Bucket 13 - Hydraulic Oil Tank 23 - Control Valve 33 - Accumulator (Adjuster
Cylinder)
4- Arm 14 - Bypass Filter 24 - Engine 34 - Adjuster Cylinder
5- Arm Cylinder 15 - High Pressure Strainer 25 - Accumulator (Pilot Circuit) 35 - Compressor Motor
6- Level Cylinder 16 - Pump Transmission Cooler 26 - Engine Radiator 36 - Front Idler
7- Boom 17 - Oil Cooler Fan Motor 27 - LTA Radiator 37 - Window Washer Tank
8- Boom Cylinder 18 - Fuel Cooler 28 - Travel Device
9- Swing Device 19 - Oil Cooler 29 - Travel Brake Valve
10 - Auto-Lubrication Device 20 - Pump Device 30 - Swing Bearing
T5-3-1
Backhoe
4
5
3
2 6
M18L-01-005
1- Bucket 3- Bucket Cylinder 5- Boom Cylinder 6- Boom

2- Arm 4- Arm Cylinder
T5-3-2
AROUND PUMP
3 4 5
1 7
8
T18K-01-02-003
1- Pilot Relief Valve 3- EHC Valve (Main Pump 5- Main Pump 3 7- Main Pump 5
Control) (Transmission Side) (Transmission Side)
Main Pump 4 (Pump End Main Pump 6 (Pump End
Side) Side)
2- Pilot Filter 4- Main Pump 1 6 - Pump Transmission 8 - 4-Unit Pump
(Transmission Side)
Main Pump 2 (Pump End
Side)
T5-3-3
PILOT PANEL (OPERATION CIRCUIT)
Machine Front
2
B
1
3
T18K-01-02-004
View A
4 5 View B
6 7 8 9
10
T18K-03-05-001
1- Accumulator (Pilot Circuit) 4- EHC Valve (Electrical 7- EHC Valve (Electrical 9- Pressure Reducing Valve
(2 Used) Lever) (Left Side of Main Lever) (Center Side of Main (Travel Speed Change)
Frame) Frame)
2- Compressor Pump 5 - DQR Valve 2 (Left Side of 8 - Travel Mode Selector 10 - Pilot Shut-Off Solenoid
Relief Valve Main Frame) Solenoid Valve Valve
3 - Check Valve (Pilot Circuit) 6 - DQR Valve 1 (Center Side
of Main Frame)
T5-3-4
PILOT PANEL (BACK OF CONTROL VALVE)
T18K-01-02-002
2 1
1- Shuttle Valve (Travel) 2- Pressure Sensor (Travel)
T5-3-5
UNDERCARRIAGE
Machine
Front
1
7 8 2
4 3 T18C-01-02-013
1- Adjuster Cylinder 3- Relief Valve 5- Center Joint 7- Accumulator (Adjuster

Cylinder)
2- Pressure Reducing Valve 4- Pilot Pressure Selector 6- Relief Valve 8 - Manifold
Valve
T5-3-6
FAST-FILLING PANEL
3 4 5 6 7 8 9 10 11
17 16 15 14 13 12 M18K-01-007
1- Engine Oil In (Reserve 6- Engine Oil Coolant 10 - Pump Transmission Oil 14 - Fuel
Tank) (Optional) Reservoir Filling System
Operation Switch (Optional)
2- Engine Oil Out (Reserve 7 - Fuel Filling System 11 - Grease 15 - Engine Oil (Engine Oil
Tank) (Optional) Operation Switch Pan)
3 - Engine Oil Coolant 8 - Fuel Full Indicator 12 - Gear Oil (Rear Side Swing 16 - Coolant (Radiator Engine
Reservoir Full Indicator Device) Side)
(Optional)
4 - Engine Oil Coolant 9- Hydraulic Oil 13 - Gear Oil (Front Side Swing 17 - Coolant (Radiator Outside)
Reservoir Shut-Off Valve Device)
Open Lamp (Optional)
5 - Engine Oil Coolant
Reservoir Filling System
Power Switch (Optional)
T5-3-7
ELECTRICAL SYSTEM (OVERVIEW)
1
2
3 6
7
4 8
36 9
10
5 11
12
13
14
15
35
34
33
16
17
32 18
31 19
30 20
29
28 21
27
22
26
25 23
24 T18K-01-02-028
1 - Work Light (on the Cab) 10 - Hydraulic Oil Temperature 19 - Engine Stop Switch 28 - Contamination Sensor
Sensor (Hydraulic Oil (Engine Space Rear Side) (Travel Motor)
Temperature Gauge, Oil
Cooler Fan Motor Control)
2- Horn 11 - Valve Limit Switch (Suction 20 - Travel Alarm 29 - Contamination Sensor
Circuit) (Swing Motor Front Side)
3- Entrance Light 12 - Engine Stop Switch 21 - Work Light (Rear Left) 30 - Maintenance Light (Under
(For Pump Space Front Cab Space)
Side)
4- Air Conditioner 13 - Maintenance Light 22 - Engine Stop Switch 31 - Electrical Equipment Box
(Pump Space) (Engine Space Front Side)
5- Work Light (Front Right) 14 - Valve Limit Switch (Delivery 23 - Coolant Level Switch 32 - Work Light (Front Left)
Circuit) (Level Indicator)
6- Battery Space 15 - Work Light (Rear Right) 24 - Fuel Level Switch (Indicator) 33 - Air Horn Compressor
7- Hydraulic Oil Level 16 - Engine Stop Switch 25 - Fuel Level Sensor (Fuel 34 - Condenser with Fan
Switch 1 (Level Indicator) (For Pump Space Rear Side) Gauge) Motor
8 - Hydraulic Oil Level 17 - Pump Transmission Coolant 26 - Ladder Limit Switch 35 - Receiver-Dryer
Switch 2 (Alarm Light) Level Switch Condenser Fan Control
Pressure Switch
9- Air Bleeding Solenoid 18 - Maintenance Light 27 - Contamination Sensor 36 - Wiper Motor
Valve (Engine Space) (Swing Motor Rear Side)
T5-3-8
Battery Space
1 2 3 4 A
5 6 7 8 B
9
14
10
13
11
12
Section A Section B T18K-01-02-029
16
15
17
M18L-07-042
1- Cover Switch 6- Starter Relay 2 10 - Battery Relay (1) 14 - Battery Relay (3)
2- Engine Oil Filling Relay (1) 7- Starter Relay 1 (Upper) 11 - Circuit Breaker (200A) 15 - Auto-Lubrication Mode Switch
3- Engine Oil Filling Relay (2) 8- Starter Relay 1 (Lower) 12 - Battery 16 - Pressure Switch
(Auto-Lubrication)
4- Alternator Relay 9- Battery Relay (2) 13 - Prelub Relay 17 - Pressure Switch
(Manual-Lubrication)
5- Prelub Timer
T5-3-9
Battery Space (Fusibel Link)
Section A A B Section B
3 4
1
5
T18K-01-02-030
Section C
6 7 8 9 10 11
12 13 14 15
T18L-01-02-046
1- Fusible Link (250 A) 5- Fusible Link (10 A) 9- Fusible Link (75 A) 13 - Fusible Link (75 A)
(Sliding Fold-In Ladder (Engine Oil Coolant (Fuse Box) (Engine Starter Relay)
Motor) (Optional) Reservoir Valve)
2 - Fusible Link (400 A) 6 - Fusible Link (75 A) 10 - Fusible Link (75 A) 14 - Fusible Link (45 A) (ECM
(Prelub Relay) (Fuse Box) (Fuse Box) Power)
3 - Fusible Link (5 A) 7 - Fusible Link (75 A) 11 - Fusible Link (75 A) 15 - Fusible Link (75 A)
(Prelub Signal) (Fuse Box) (Fuse Box) (Sliding Fold-In Ladder
Relay) (Optional)
4- Fusible Link (30 A) 8- Fusible Link (75 A) 12 - Fusible Link (45 A)
(Zener Diode) (Fuse Box) (Optional)
T5-3-10
Inside Cab
2
1
T18G-01-02-053
T18M-01-02-004
29 3 4 5
28 6
27 7
8
26 9
25 10
24
11
23
22 12
21 13
20
14
T18M-01-02-005
19 18 17 16 15 13
1- Monitor Display 9- Dome Light Switch 16 - Travel Mode Selector 23 - Air Conditioner Operation
Switch Part (Front)
2- Hour Meter 10 - Entrance Light Switch 17 - Maintenance Light Switch 24 - Wiper/Window Washer
Switch
3- Left Control Lever/Horn 11 - Auto-Idle Switch 18 - Work Light Switch 25 - Wiper Interval Switch
Switch
4 - Right Control Lever/Horn 12 - Fast-Filling System Switch 19 - Engine Stop Switch 26 - Monitor Contrast Switch
Switch
5 - Pilot Control Shut-Off 13 - Auxiliary 20 - Radio 27 - Monitor Operation Part
Lever
6 - Emergency Switch 14 - Key Switch 21 - Air Conditioner Operation 28 - Engine Warning Indicator
Part (Rear) (Yellow)
7- Engine Control Dial 15 - Buzzer Stop Switch 22 - Air Conditioner Operation 29 - Engine Stop Indicator
Part (Side) (Red)
8- Engine Start Switch
T5-3-11
1 2 3 4 5
M18M-01-006
8 T18M-01-02-006
1- Electrical Lever (Left) 3 - Electrical Lever (Travel) 5 - Electrical Lever (Right) 7 - IDU
2- Electrical Lever (Bucket 4 - Electrical Lever (Bucket 6 - Monitor Display 8 - ELU
Close) (LD only) Open) (LD only)
T5-3-12
T18G-01-02-030
1
M18M-01-007
2 3 4 5 6 7
10
T18G-01-02-026
12 11
Power Source Terminal T146-01-03-023
1- Fuse Box (Cab) 4- ORBCOMM (Optional) 7- Data Link Connector (DLU) 10 - Power Terminal
2- DC-DC Converter 5- Data Link Connector 8- Buzzer 11 - DLU
(Unused)
3- Cigar Lighter 6 - Data Link Connector 9- DC-DC Converter 12 - Data Link Connector
(ECM) (MMS)
T5-3-13
Electrical Equipment Box
T18M-01-02-003
10 11 12 13
5
Relay Layout
Refer to
T5-3-16.
4
3
T18M-01-02-007
1- Fuse Box 2 5 - Auto-Lubrication Interval 8- Engine Troubleshooting 11 - CSU
Switch Switch (Contamination Sensing
Unit)
2- Fuse Box 1 6 - Engine Fault Code Display 9- Engine Fault Code Display 12 - Limit Switch
Lamp Selection Switch (Box Light Switch)
3- Fuse Box 4 7 - MC 10 - HMU 13 - Box Light
4- Fuse Box 3
T5-3-14
(Blank)
T5-3-15
Electrical Equipment Box Relay Layout
1 2 3 4 5 6
7
8
9
10
40 11
39 12
13
38
14
37 15
36 16
35 17
18
34
19
33
20
21
22
23
24
25
26
32 31 30 29 28 27 T18M-01-02-007
T5-3-16
1- Wiper Relay 3 for Slow 11 - Work Light Relay (Front on 21 - Washer Motor Relay (21) 31 - ELU PWM Power Relay 1
Speed Control (L5) Cab) (3) (Key ON Signal Monitoring)
(26)
2- Air Conditioner Main Relay 12 - Work Light Relay (Both 22 - Air Conditioner Fan Motor 32 - ELU Gate Lock Solenoid
(Front) (L6) Front of Right Frame) (4) Relay (Front) (22) Valve Relay (25)
3- Air Horn Compressor (L1) 13 - Work Light Relay (Engine 23 - Air Conditioner Fan Motor 33 - Air Horn Compressor
Relay (L1) Frame Rear) (5) Relay (Side) (23) Relay (L2) (17)
4- Air Horn Compressor (L2) 14 - Work Light Relay (Both 24 - Air Conditioner Fan Motor 34 - Air Horn Compressor
Relay (R1) (Optional) Frame Sides) (6) Relay (Rear) (24) Relay (R2) (Optional) (18)
5- Wiper Relay 1 (Slow Speed 15 - Entrance Light Relay (7) 25 - Folding-Ladder 35 - Horn Relay (19)
Control) (L3) Alarm/Blinking Light Realy
2 (32)
6- Wiper Realy 2 (Slow Speed 16 - Maintenance Light Relay 26 - Folding-Ladder 36 - Wiper Realy 4 (Fast Speed
Control) (L4) (Engine Space) (8) Alarm/Blinking Light Realy Control) (20)
1 (31)
7- Air Conditioner Main Relay 17 - Fast-Fiiling System Folding 27 - Engine Oil Coolant 37 - Maintenance Light Relay
(Side) (L7) Position Relay (Folding Resevoir Pump Unit Relay (Pump Space and Radiator
Monitoring) (30) Space) (9)
(13)
8- Air Conditioner Main Relay 18 - Illumination OFF Dilay 28 - Sliding Fold-In Ladder 38 - Maintenance Light Relay
(rear) (L8) Relay Operation Relay (29) (Cab Bed) (10)
(14)
9- Work Light Relay (Left 19 - Travel Mode Selection 29 - ELU PWM Power Relay 3 39 - Maintenance Light Relay
Frame Front Left Side) (1) Relay (Emergency Switch ON (around Control Valve and
(15) Signal Monitoring) (28) Oil Coller Space) (11)
10 - Work Light Relay (Left 20 - Fast-Filling System 30 - ELU PWM Power Relay 2 40 - Alternator Signal Relay (12)
Frame Front Right Side) Operation Relay (Gate Lock Switch ON
(2) (16) Signal Monitoring) (27)
NOTE: The alphabet and number inside parenthesis indicate the relay No. on the electrical circuit.
T5-3-17
Contmination Sensor Amplifier Led Layout
2 4 6
1 3 5
Auxiliary
Auxiliary
7 9
8
T146-05-02-049
T18M-01-02-007
1- Main Pump 1 4 - Main Pump 4 6- Main Pump 6 8- Rear Swing Motor

2- Main Pump 2 5 - Main Pump 5 7- Front Swing Motor 9- Travel Motor
3- Main Pump 3
T5-3-18
Contamination Sensor Layout
4
1 Machine Front
2 Pump Device
T18K-01-02-007
Swing Device
Machine Front
Center Joint
T18K-01-02-009
1- Contamination Sensor 4 - Contamination Sensor 6- Contamination Sensor 8- Contamination Sensor

(Main Pump 1) (Main Pump 4) (Main Pump 6) (Swing Motor Rear)
2 - Contamination Sensor 5 - Contamination Sensor 7 - Contamination Sensor 9 - Contamination Sensor
(Main Pump 2) (Main Pump 5) (Swing Motor Front) (Travel Motor)
3 - Contamination Sensor
(Main Pump 3)
T5-3-19
ENGINE
2 3
1
T18K-01-02-011
5 4
T18K-01-02-012
1- Coolant Filter 3 - Prelub Pressure Switch 5 - Fuel Filter (3 Used) 7 - Alternator (Cummins)
2- Engine Speed Sensor 4 - Oil Filter (3 Used) 6 - Starter (2 Used) (Cummins)
T5-3-20
AROUND RADIATOR
3 4
6 5
T18K-01-02-010
View A
7
T18L-01-02-044
1- After Cooler (LTA Radiator) 3 - LTA Coolant Temperature 5 - LTA Coolant Temperature 7 - Fresh Air Temperature
Sensor (IN) Sensor (OUT) Sensor (Radiator Front)
2- Engine Radiator 4 - Coolant Temperature 6 - Coolant Temperature
Sensor (IN) Sensor (OUT)
T5-3-21
WATER TANK
T18K-01-02-017
AIR CLEANER
3 View A
4
A T18K-01-02-018
T18K-01-02-019
1- Coolant Level Switch 2- Coolant Level Sensor 3- Air Cleaner 4- Air Cleaner Restriction
(Level Indicator) Switch
T5-3-22
OIL COOLER
T18K-01-02-025
2
View A
Machine Front
View B
3
T18K-01-02-024
B B
1- Fresh Air Temperature 2- Hydraulic Oil Temperature 3- Coolant Pressure Sensor

Sensor 1 (Oil Cooler Front) Sensor (Oil Cooler Fan
Motor Rotation Control)
T5-3-23
AROUND PUMP
1 2 A
T18K-01-02-023
View A View B
7
B
T18K-01-02-022
T18K-01-02-021
1- Pump 1 Drain Pressure 3 - Pump 3 Drain Pressure 5- Transmission Oil Filter 7- Transmission Oil
Sensor (Transmission Sensor (Transmission Circulation Pump Bypass
Side) Side) Check Valve
Pump 2 Drain Pressure Pump 4 Drain Pressure
Sensor (Pump End Side) Sensor (Pump End Side)
2 - Pump Transmission Level 4 - Pump 5 Drain Pressure 6- Pump Transmission Oil
Switch Sensor (Transmission Temperature Sensor
Side)
Pump 6 Drain Pressure
Sensor (Pump End Side)
T5-3-24
SWING DEVICE
1 2 3
Machine Front
T18K-01-02-026
5 4
1- Swing Motor 3- Relief Valve 4- Drain Pressure Sensor 1 5- Drain Pressure Sensor 2
(Swing Motor) (Swing Motor)
2- Make-Up Valve
T5-3-25
CONTROL VALVE
Control Valve 3 Right Control Valve 2 Center Control Valve 1 Left
1 2 3 4 16 17 18 29 30 31
Machine
Front
7 6 5 21 20 19 34 33 32 T18C-01-02-006
22
8
35
T18C-01-02-005
11 10 9 25 24 23 37 36 41
T18C-01-02-007
12 13 14 15 26 27 28 38 39 40
T5-3-26
Control Valve 1 (Left)

29 - Overload Relief Valve (Arm Roll-In)
30 - Overload Relief Valve (Boom Raise)
31 - Overload Relief Valve (BH: Bucket
Roll-Out, LD: Bucekt Open)
32 - Make-Up Valve Boom Raise (BH: Bucket
Roll-Out, LD: Bucket Open)
33 - Make-Up Valve (Boom Raise)
34 - Make-Up Valve (Arm Roll-In)
35 - Main Relief Valve
36 - Make-Up Valve (BH: Boom Lower, LD:
Bucket Roll-In)
37 - Make-Up Valve (Arm Roll-Out)
38 - Overload Relief Valve (Arm Roll-Out)
39 - Overload Relief Valve (BH: Boom Lower,
LD: Bucket Roll-In)
40 - Overload Relief Valve (BH: Bucket Roll-In,
LD: Bucket Close)
41 - Overload Relief Valve (LD: Bucket Close)
Control Valve 2 (Center)

17 - Overload Relief Valve (Arm Roll-Out)
18 - Overload Relief Valve (BH: Bucket Roll-In, LD: Bucket Tilt-In)
19 - Make-Up Valve (BH: Bucket Roll-In, LD: Bucket Tilt-In)
20 - Make-Up Valve (Arm Roll-Out)
21 - Make-Up Valve (Boom Raise)
22 - Main Relief Valve
23 - Make-Up Valve (BH: Bucket Roll-Out, LD: Bucket Tilt-Out)
24 - Make-Up Valve (Arm Roll-In)
25 - Make-Up Valve (Boom Lower)
26 - Overload Relief Valve (Boom Lower)
27 - Overload Relief Valve (Arm Roll-In)
28 - Overload Relief Valve (BH: Bucket Roll-Out, LD: Bucket Tilt-Out)
Control Valve 3 (Right

1- Overload Relief Valve (Boom Lower)
2- Make-Up Valve (BH: Bucket Roll-In, LD: Bucket Tilt-In)
3- Overload Relief Valve (Arm Roll-Out)
4- Overload Relief Valve (Swing Right)
5- Make-Up Valve (Arm Roll-Out)
6- Make-Up Valve (BH: Bucket Roll-In, LD: Bucket Tilt-In)
7- Make-Up Valve (Boom Lower)
8- Main Relief Valve
9- Make-Up Valve (BH: Arm Roll-In)
10 - Make-Up Valve (LD: Bucket Roll-Out)
11 - Make-Up Valve (Boom Riase)
13 - Overload Relief Valve (LD: Bucket Roll-Out)
14 - Overload Relief Valve (BH: Arm Roll-In)
15 - Overload Relief Valve (Swing Left)

BH: Backhoe
T5-3-27
1 2
Control Valve
Machine Front
T18K-01-02-027
1- Pressure Sensor (Arm 2- Pressure Sensor (Arm

Cylinder Bottom Side) Cylinder Rod Side)
T5-3-28
TRAVEL DEVICE
Machine Front
Travel Forward Pipe
Travel Reverse Pipe
Travel Speed Selection Pipe
Drain Pipe
T117-03-01-001
Machine Rear
3 3
CENTER JOINT
T18K-01-02-020
1- Brake Valve 2- Travel Motor 3- Travel Reduction Gear 4- Travel Stop Pressure
Detection Sensor
T5-3-29
EHC VALVE (MAIN PUMP CONTROL)
8
7 9
6
10
5
4 11
3 12
2 13
1 14
T18K-03-07-004
1- Pressure Sensor (SC) 5 - Pressure Sensor (SB) 9 - Auxiliary 12 - Pressure Sensor (SE)
2- Oil Cooler Fan Speed 6 - Power Increase Control 10 - Auxiliary 13 - Main Pump Displacement
Control Solenoid Valve Solenoid Valve Angle Control Solenoid
Valve (Main Pump No.5)
3- Pressure Sensor (SA) 7 - Pressure Sensor (SH) 11 - Power Decrease Control 14 - Pressure Sensor (SD)
Solenoid Valve
4- Main Pump Displacement 8 - Main Pump Displacement
Angle Control Solenoid Angle Control Solenoid
Valve (LD: Main Pump Valve (LD: Main Pump
No.3, 4, 6, BH: Main Pump No.1, 2, BH: Main Pump
No.2, 3, 4, 6) No.1)
T5-3-30
EHC VALVE (ELECTRICAL LEVER
CONTROL)
Solenoid Valve
EHC Valve (Left) EHC Valve (Center)
1 2 3 4 9 10 11 12
8 7 6 5 T178-03-04-017 16 15 14 13 T18L-01-02-023
Pressure Sensor
EHC Valve (Left) EHC Valve (Center)
17 18 19 24 25 26
23 22 21 20 T178-03-04-017 30 29 28 27 31 T18L-01-02-023
1- Auxiliary 9- Travel Right Forward Solenoid 17 - Pressure Sensor (SF) 25 - Pressure Sensor (SF)
Valve
2- (BH: Bucket Roll-Out / LD: 10 - Travel Left Reverse Solenoid 18 - Pressure Sensor (SE) 26 - Pressure Sensor (SE)
Bucket Tilt-Out) Solenoid Valve Valve
3 - (BH: Bucket Roll-In / LD: 11 - Travel Left Forward Solenoid 19 - Pressure Sensor (SD) 27 - Pressure Sensor (SC)
Bucket Tilt-In) Solenoid Valve Valve
4 - (BH: Arm Roll-Out / LD: Arm 12 - Auxiliary 20 - Pressure Sensor (SC) 28 - Pressure Sensor (SA)
Extend) Solenoid Valve
5 - (BH: Arm Roll-In / LD: Arm 13 - LD: Bucket Open Solenoid 21 - Pressure Sensor (SA) 29 - Pressure Sensor (SB)
Retract) Solenoid Valve Valve
BH: Auxiliary
6- Boom Raise Solenoid Valve 14 - Travel Right Reverse Solenoid 22 - Pressure Sensor (SB) 30 - Pressure Sensor (SH)
Valve
7- Boom Lower Solenoid Valve 15 - Swing Left Solenoid Valve 23 - Pressure Sensor (SH) 31 - Pressure Sensor (PH)
(Gate Lock Pressure)
8- LD: Bucket Close Solenoid 16 - Swing Right Solenoid Valve 24 - Pressure Sensor (SI)
Valve
BH: Auxiliary

BH: Backhoe
T5-3-31
SLIDING FOLD-IN LADDER
T18K-01-02-014
View A
T18K-01-02-015
1- Lock Lever 2- Ladder Limit Switch
T5-3-32
AUTO-LUBRICATION DEVICE
Battery Space Lubricator Tank 4

2
1
M18L-07-015
T146-01-03-026
T18K-03-07-003
T18M-03-07-006
1- Pressure Switch 3 - Auto-Lubrication Selection 5 - Auto-Lubrication Pump 7 - Auto-Lubrication Interval

(Manual-Lubrication) Switch Switch
2 - Pressure Switch 4 - Vent Valve 6 - Auto-Lubrication Solenoid
(Auto-Lubrication) Valve
T5-3-33
(Blank)
T5-3-34
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Refer to troubleshooting A procedure in case any fault

codes are displayed after diagnosing the controller
using Monitor Display.
Cummins Code is the fault code HCM Code is the fault code of Hitachi Construction
of Cummins Inc.. Machinery Co.,Ltd.
T18M-05-01-005
T5-4-1
FAULT DIAGNOSIS INDICATION
IDU indicates the fault diagnosis results on the monitor

display in response to fault signals received from each
controller through CAN.
IMPORTANT: Monitor display window can be

switched by the keypad.
IMPORTANT: Only when malfunction or alarm oc-

curs, Fault or Alarm is displayed on
the Meter Window by blinking.
Item Abnormal Not abnormal

Alarm ( ) Blinking Not displayed
Fault ( ) Blinking Not displayed
Menu ( ) Always displayed
Key Pad T18G-02-01-108
Meter Window
Indication
1. When the Meter Window appears on the monitor

display, press the (or ) key to display the
Current Faults (or Alarm) List Window on the
monitor display.
To return to the Meter Window, press the key.
T18M-05-01-001
Current Faults (or Alarm) List Window
T18M-05-01-005
T5-4-2
2. Select the required item from the list, using the Current Faults (or Alarm) List Window
and keys, and press the key. The Fault (or
Alarm) Explanation Window of the selected item
will appear.
To return the Current Faults (or Alarm) List Win-
dow, press the key.
T18M-05-01-005
3. To display the Detailed Circuit Diagram Window, Faults (or Alarm) Explanation Window
press the key.
To return to the Fault (or Alarm) Explanation
Window, press the key.
T18G-05-01-007
Detailed Circuit Diagram
T18G-05-01-027
T5-4-3
FAULT CODE LIST
HCM Cummins Warning Related

Description
CODE CODE Buzzer Controller
00006-000 00151 High Coolant Temperature Yes ECM
00006-003 00144 Coolant Temperature Sensor Failed High No ECM
00006-004 00145 Coolant Temperature Sensor Failed Low No ECM
00006-016 00146 Coolant Temperature Above Normal Yes ECM
00007-001 00235 Low Coolant Level Yes ECM
00007-003 00195 Coolant Level Sensor Failed High No ECM
00007-004 00196 Coolant Level Sensor Failed Low No ECM
00007-018 00197 Coolant Level Below Normal No ECM
00008-001 00228 Very Low Coolant Pressure Yes ECM
00008-003 00231 Coolant Pressure Sensor Failed High No ECM
00008-004 00232 Coolant Pressure Sensor Failed Low No ECM
00009-000 00266 High Fuel Temperature (Most Sever Level) Yes ECM
00009-003 00263 Fuel Temperature Sensor Failed High No ECM
00009-004 00265 Fuel Temperature Sensor Failed Low No ECM
00009-016 00261 High Fuel Temperature (Moderate Level) Yes ECM
00011-001 00415 Very Low Oil Pressure Yes ECM
00011-003 00135 Oil Pressure Sensor Failed High No ECM
00011-004 00141 Oil Pressure Sensor Failed Low No ECM
00011-018 00143 Low Oil Pressure No ECM
00012-003 00212 Engine Oil Temperature Sensor Failed High No ECM
00012-004 00213 Engine Oil Temperature Sensor Failed Low No ECM
00012-016 00421 Engine Oil Temperature Above Normal Yes ECM
00014-016 01362 High Lube Oil Filter Restriction No ECM
00015-000 00556 High Crankcase Pressure Yes ECM
00015-003 01843 Crankcase Pressure Sensor Failed High No ECM
00015-004 01844 Crankcase Pressure Sensor Failed Low No ECM
00021-000 00155 High Inlet Manifold Temperature 1 Yes ECM
00021-003 00153 Inlet Manifold Temperature 1 Sensor Failed High No ECM
00021-004 00154 Inlet Manifold Temperature 1 Sensor Failed Low No ECM
00021-010 00783 Rapid Rise Inlet Manifold Temperature 1 No ECM
00021-016 00488 High Intake Manifold Temperature Yes ECM
00022-016 01984 Inlet Manifold Temperature 2 Above Normal Yes ECM
T5-4-4

Description
00041-000 00449 High Rail Pressure No ECM
00041-003 00451 Rail Pressure Sensor Failed High No ECM
00041-004 00452 Rail Pressure Sensor Failed Low No ECM
00041-018 00559 Rail Pressure 1 Below Normal No ECM
00043-003 00221 Ambient Air Pressure Failed High No ECM
00043-004 00222 Ambient Air Pressure Failed Low No ECM
00046-000 00234 Engine Overspeed No ECM
00046-002 00689 Engine Crankshaft Speed Erratic No ECM
00048-003 01358 Axel Pedal Sensor 1 Sensor Failed High No ECM
00048-004 01359 Axel Pedal Sensor 1 Sensor Failed Low No ECM
00048-008 01514 Axel Pedal Position Sensor 1 Freq Issue No ECM
00096-003 Temperature Sensor Fault (Inlet Air) High No MC
00096-004 Temperature Sensor Fault (Inlet Air) Low No MC
00097-003 Temperature Sensor Fault (Radiator Outlet) High No MC
00097-004 Temperature Sensor Fault (Radiator Outlet) Low No MC
00098-003 Pressure Sensor Fault (Cooler Fan Motor Inlet) High No MC
00098-004 Pressure Sensor Fault (Cooler Fan Motor Inlet) Low No MC
00100-003 Pressure (Cooler Fan Motor Negative Control) High No MC
00100-004 Pressure (Cooler Fan Motor Negative Control) Low No MC
00120-016 02121 High Exhaust Temperature Cylinder 1 No ECM
00188-003 Level Sensor Fault (Fuel) High No MC
00188-004 Level Sensor Fault (Fuel) Low No MC
00227-005 EHC Valve Current Low (Radiator Fan) No MC
00227-006 EHC Valve Current High (Radiator Fan) No MC
T5-4-5

Description
00233-016 01987 Inlet Manifold Temperature 5 Above Normal No ECM
00234-016 01988 Inlet Manifold Temperature 6 Above Normal No ECM
00239-003 Temperature Sensor Fault (Radiator Inlet) High No MC
00239-004 Temperature Sensor Fault (Radiator Inlet) Low No MC
00249-003 Temperature Sensor Fault (LTA Radiator Inlet) High No MC
00249-004 Temperature Sensor Fault (LTA Radiator Inlet) Low No MC
00250-003 Temperature Sensor Fault (LTA Radiator Outlet) High No MC
00250-004 Temperature Sensor Fault (LTA Radiator Outlet) Low No MC
01001-003 Pressure Sensor Fault (Positive Control 1) High No ELU
01001-004 Pressure Sensor Fault (Positive Control 1) Low No ELU
01003-000 EHC Valve Stick/High Pressure (Positive Control 1) No ELU
01003-001 EHC Valve Stick/Low Pressure (Positive Control 1) No ELU
01003-005 EHC Valve Current Low (Positive Control 1) No ELU
01003-006 EHC Valve Current High (Positive Control 1) No ELU
T5-4-6

Description
01050-000 Contamination Alarm (CH1) No CSU
01066-000 Contamination Alarm (Travel Motor CH21) No CSU
01068-003 Pressure Sensor Fault (Power Increase) High No MC
01068-004 Pressure Sensor Fault (Power Increase) Low No MC
01070-005 EHC Valve Current Low (Power Increase) No MC
01070-006 EHC Valve Current High (Power Increase) No MC
01072-003 Pressure Sensor Fault (Power Reduction) High No MC
01072-004 Pressure Sensor Fault (Power Reduction) Low No MC
01074-005 EHC Valve Current Low (Power Reduction) No MC
01074-006 EHC Valve Current High (Power Reduction) No MC
T5-4-7

Description
02001-003 Pressure Sensor Fault (Travel) High No MC
02001-004 Pressure Sensor Fault (Travel) low No MC
02003-003 Pressure Sensor Fault (Adjuster Cylinder) High No ELU
02003-004 Pressure Sensor Fault (Adjuster Cylinder) Low No ELU
03006-000 Contamination Alarm (Swing Motor CH17) No CSU
05006-013 Boom Raise Cylinder End Memory Error No ELU
05008-013 Arm Roll-In Cylinder End Memory Error No ELU
05009-013 Arm Roll-Out Cylinder End Memory Error No ELU
05010-013 Bucket Roll-In Cylinder End Memory Error No ELU
05011-013 Bucket Roll-Out Cylinder End Memory Error No ELU
07000-003 Temperature Sensor Fault (Hydraulic Oil) High No MC
07000-004 Temperature Sensor Fault (Hydraulic Oil) Low No MC
08008-003 Pressure (Cooler Fan Motor Negative Control) High No MC
08008-004 Pressure (Cooler Fan Motor Negative Control) Low No MC
08011-005 EHC Valve Current Low (Oil Cooler Fan) No MC
08011-006 EHC Valve Current High (Oil Cooler Fan) No MC
10017-012 Temperature Sensor Fault (Radiator Inlet) High No ELU
10018-012 Travel Operation Signal to MC Fault No ELU
11001-003 Pressure Sensor Fault (Boom Raise) High No ELU
11001-004 Pressure Sensor Fault (Boom Raise) Low No ELU
11003-000 EHC Valve Stick/High Pressure (Boom Raise Operation) Yes ELU
11003-001 EHC Valve Stick/Low Pressure (Boom Raise Operation) Yes ELU
11003-005 EHC Valve Current Low (Boom Raise Operation) No ELU
11003-006 EHC Valve Current High (Boom Raise Operation) Yes ELU
11006-003 Pressure Sensor Fault (Boom Lower) High No ELU
11006-004 Pressure Sensor Fault (Boom Lower) Low No ELU
11008-000 EHC Valve Stick/High Pressure (Boom Lower Operation) Yes ELU
11008-001 EHC Valve Stick/Low Pressure (Boom Lower Operation) Yes ELU
11008-005 EHC Valve Current Low (Boom Lower Operation) No ELU
11008-006 EHC Valve Current High (Boom Lower Operation) Yes ELU
11011-003 Pressure Sensor Fault (Bucket Roll-In) High No ELU
11011-004 Pressure Sensor Fault (Bucket Roll-In) Low No ELU
11013-000 EHC Valve Stick/High Pressure (Bucket Roll-In Operation) Yes ELU
11013-001 EHC Valve Stick/Low Pressure (Bucket Roll-In Operation) Yes ELU
11013-005 EHC Valve Current Low (Bucket Roll-In Operation) No ELU
11013-006 EHC Valve Current High (Bucket Roll-In Operation) Yes ELU
T5-4-8

Description
11016-003 Pressure Sensor Fault (Bucket Roll-Out) High No ELU
11016-004 Pressure Sensor Fault (Bucket Roll-Out) Low No ELU
11018-000 EHC Valve Stick/High Pressure (Bucket Roll-Out Operation) Yes ELU
11018-001 EHC Valve Stick/Low Pressure (Bucket Roll-Out Operation) Yes ELU
11018-005 EHC Valve Current Low (Bucket Roll-Out Operation) No ELU
11018-006 EHC Valve Current High (Bucket Roll-Out Operation) Yes ELU
11021-003 Pressure Sensor Fault (Bucket Open) High No ELU
11021-004 Pressure Sensor Fault (Bucket Open) Low No ELU
11023-000 EHC Valve Stick/High Pressure (Bucket Open Operation) Yes ELU
11023-001 EHC Valve Stick/Low Pressure (Bucket Open Operation) Yes ELU
11023-005 EHC Valve Current Low (Bucket Open Operation) No ELU
11023-006 EHC Valve Current High (Bucket Open Operation) Yes ELU
11026-003 Pressure Sensor Fault (Bucket Close) High No ELU
11026-004 Pressure Sensor Fault (Bucket Close) Low No ELU
11028-000 EHC Valve Stick/High Pressure (Bucket Close Operation) Yes ELU
11028-001 EHC Valve Stick/Low Pressure (Bucket Close Operation) Yes ELU
11028-005 EHC Valve Current Low (Bucket Close Operation) No ELU
11028-006 EHC Valve Current High (Bucket Close Operation) Yes ELU
11031-003 Pressure Sensor Fault (Arm Roll-Out) High No ELU
11031-004 Pressure Sensor Fault (Arm Roll-Out) Low No ELU
11033-000 EHC Valve Stick/High Pressure (Arm Roll-Out Operation) Yes ELU
11033-001 EHC Valve Stick/Low Pressure (Arm Roll-Out Operation) Yes ELU
11033-005 EHC Valve Current Low (Arm Roll-Out Operation) No ELU
11033-006 EHC Valve Current High (Arm Roll-Out Operation) Yes ELU
11036-003 Pressure Sensor Fault (Arm Roll-In) High No ELU
11036-004 Pressure Sensor Fault (Arm Roll-In) Low No ELU
11038-000 EHC Valve Stick/High Pressure (Arm Roll-In Operation) Yes ELU
11038-001 EHC Valve Stick/Low Pressure (Arm Roll-In Operation) Yes ELU
11038-005 EHC Valve Current Low (Arm Roll-In Operation) No ELU
11038-006 EHC Valve Current High (Arm Roll-In Operation) Yes ELU
11041-003 Pressure Sensor Fault (Right Swing) High No ELU
11041-004 Pressure Sensor Fault (Right Swing) Low No ELU
11043-000 EHC Valve Stick/High Pressure (Right Swing Operation) Yes ELU
11043-001 EHC Valve Stick/Low Pressure (Right Swing Operation) Yes ELU
11043-005 EHC Valve Current Low (Right Swing Operation) No ELU
11043-006 EHC Valve Current High (Right Swing Operation) Yes ELU
11046-003 Pressure Sensor Fault (Left Swing) High No ELU
11046-004 Pressure Sensor Fault (Left Swing) Low No ELU
T5-4-9

Description
11048-000 EHC Valve Stick/High Pressure (Left Swing Operation) Yes ELU
11048-001 EHC Valve Stick/Low Pressure (Left Swing Operation) Yes ELU
11048-005 EHC Valve Current Low (Left Swing Operation) No ELU
11048-006 EHC Valve Current High (Left Swing Operation) Yes ELU
11051-003 Pressure Sensor Fault (Right Travel Forward) High No ELU
11051-004 Pressure Sensor Fault (Right Travel Forward) Low No ELU
11053-000 EHC Valve Stick/High Pressure (Right Travel Forward) Yes ELU
11053-001 EHC Valve Stick/Low Pressure (Right Travel Forward) Yes ELU
11053-005 EHC Valve Current Low (Right Travel Forward) No ELU
11053-006 EHC Valve Current High (Right Travel Forward) Yes ELU
11056-003 Pressure Sensor Fault (Right Travel Reverse) High No ELU
11056-004 Pressure Sensor Fault (Right Travel Reverse) Low No ELU
11058-000 EHC Valve Stick/High Pressure (Right Travel Reverse) Yes ELU
11058-001 EHC Valve Stick/Low Pressure (Right Travel Reverse) Yes ELU
11058-005 EHC Valve Current Low (Right Travel Reverse) No ELU
11058-006 EHC Valve Current High (Right Travel Reverse) Yes ELU
11061-003 Pressure Sensor Fault (Left Travel Forward) High No ELU
11061-004 Pressure Sensor Fault (Left Travel Forward) Low No ELU
11063-000 EHC Valve Stick/High Pressure (Left Travel Forward) Yes ELU
11063-001 EHC Valve Stick/Low Pressure (Left Travel Forward) Yes ELU
11063-005 EHC Valve Current Low (Left Travel Forward) No ELU
11063-006 EHC Valve Current High (Left Travel Forward) Yes ELU
11066-003 Pressure Sensor Fault (Left Travel Reverse) High No ELU
11066-004 Pressure Sensor Fault (Left Travel Reverse) Low No ELU
11068-000 EHC Valve Stick/High Pressure (Left Travel Reverse) Yes ELU
11068-001 EHC Valve Stick/Low Pressure (Left Travel Reverse) Yes ELU
11068-005 EHC Valve Current Low (Left Travel Reverse) No ELU
11068-006 EHC Valve Current High (Left Travel Reverse) Yes ELU
11100-003 Right Lever (F/R) Signal Fault (High) Yes ELU
11100-004 Right Lever (F/R) Signal Fault (Low) Yes ELU
11100-013 Right Lever (F/R) Interlock Yes ELU
11101-003 Right Lever (F/R) Center Signal Fault (High) Yes ELU
11101-004 Right Lever (F/R) Center Signal Fault (Low) Yes ELU
11101-013 Right Lever (F/R) Center Signal Out of Range Yes ELU
11103-003 Right Lever (L/R) Signal Fault (High) Yes ELU
11103-004 Right Lever (L/R) Signal Fault (Low) Yes ELU
11103-013 Right Lever (L/R) Interlock Yes ELU
11104-003 Right Lever (L/R) Center Signal Fault (High) Yes ELU
11104-004 Right Lever (L/R) Center Signal Fault (Low) Yes ELU
11104-013 Right Lever (L/R) Center Signal Out of Range Yes ELU
T5-4-10

Description
11106-003 Left Lever (F/R) Signal Fault (High) Yes ELU
11106-004 Left Lever (F/R) Signal Fault (Low) Yes ELU
11106-013 Left Lever (F/R) Interlock Yes ELU
11107-003 Left Lever (F/R) Center Signal Fault (High) Yes ELU
11107-004 Left Lever (F/R) Center Signal Fault (Low) Yes ELU
11107-013 Left Lever (F/R) Center Signal Out of Range Yes ELU
11109-003 Left Lever (L/R) Signal Fault (High) Yes ELU
11109-004 Left Lever (L/R) Signal Fault (Low) Yes ELU
11109-013 Left Lever (L/R) Interlock Yes ELU
11110-003 Left Lever (L/R) Center Signal Fault (High) Yes ELU
11110-004 Left Lever (L/R) Center Signal Fault (Low) Yes ELU
11110-013 Left Lever (L/R) Center Signal out of range Yes ELU
11112-003 Bucket Pedal (Open) Signal Fault (High) Yes ELU
11112-004 Bucket Pedal (Open) Signal Fault (Low) Yes ELU
11112-013 Bucket Pedal (Open) Interlock Yes ELU
11114-013 Bucket Pedal (Open) Center Signal Fault Yes ELU
11115-003 Bucket Pedal (Close) Signal Fault (High) Yes ELU
11115-004 Bucket Pedal (Close) Signal Fault (Low) Yes ELU
11115-013 Bucket Pedal (Close) Interlock Yes ELU
11117-013 Bucket Pedal (Close) Center Signal Fault Yes ELU
11118-003 Travel Pedal (Right) Signal Fault (High) Yes ELU
11118-004 Travel Pedal (Right) Signal Fault (Low) Yes ELU
11118-013 Travel Pedal (Right) Interlock Yes ELU
11120-013 Travel Pedal (Right) Center Signal Fault Yes ELU
11121-003 Travel Pedal (Left) Signal Fault (High) Yes ELU
11121-004 Travel Pedal (Left) Signal Fault (Low) Yes ELU
11121-013 Travel Pedal (Left) Interlock Yes ELU
11123-013 Travel Pedal (Left) Center Signal Fault Yes ELU
11124-013 Multi-Lever Selection Abnormalities Yes ELU
11125-013 Front Attachment Selection Abnormalities Yes ELU
11126-013 Machine Selection Abnormalities Yes ELU
11126-019 Machine Information Reception Failure No ELU
12037-003 Pressure Sensor Fault (Pilot Shut-Off Valve) High No ELU
12037-004 Pressure Sensor Fault (Pilot Shut-Off Valve) Low No ELU
12037-018 Below Normal Operation Pressure (Pilot Shut-Off Valve) No ELU
12038-012 Pilot Shut-Off Signal Output Fault Yes ELU
12039-019 Communication Error ELU-MC No ELU
T5-4-11

Description
13011-003 Temperature sensor fault (Pump Lube Oil) High No MC
13011-004 Temperature sensor fault (Pump Lube Oil) Low No MC
13015-001 Pump Transmission Oil Level Low Yes MC
14000-000 Alternator Charge Fault No MC
14005-000 Hydraulic Oil Level Low Yes MC
14009-001 Auto-Lubrication OFF No MC
14009-002 Manual-Lubrication No MC
14009-003 Auto-Lubrication Alarm No MC
14013-000 Emergency Switch ON No MC
14015-000 Air Cleaner Restriction No MC
14017-000 Hydraulic Oil Temperature High No MC
14049-000 Fast Fill Panel Low Yes MC
14051-000 Ladder Limit Switch Yes MC
14052-000 Tension Indicator No ELU
14053-000 Valve Close (Suction Piping) Yes MC
14055-000 Valve Close (Return Piping) Yes MC
15038-031 Control Box Door Open No MC
20000-019 MC Communication Error No MC
20600-019 ELU Communication Error No ELU
20610-012 ELU Internal Memory Error Yes ELU
20611-003 ELU 5V Output (Travel/Bucket) High Yes ELU
20611-004 ELU 5V Output (Travel/Bucket) Low Yes ELU
20612-003 ELU 5V Output (Front/Swing) High Yes ELU
20612-004 ELU 5V Output (Front/Swing) Low Yes ELU
20613-003 ELU 5V Output (Angle Sensor/Pressure Sensor) High No ELU
20613-004 ELU 5V Output (Angle Sensor/Pressure Sensor) Low No ELU
20614-003 ELU PWM Power High Yes ELU
20614-004 ELU PWM Power Low Yes ELU
20615-003 ELU SOL Power High No ELU
20615-004 ELU SOL Power Low No ELU
20616-003 ELU Sensor 24V Output High No ELU
20616-004 ELU Sensor 24V Output Low No ELU
20618-003 ELU Main Power High Yes ELU
20618-004 ELU Main Power Low Yes ELU
20800-019 DLU Communication Error No DLU
21000-019 HMU Communication Error No HMU
21200-019 CSU Communication Error No CSU
21800-019 ECM Communication Error (Parent) No ECM
23000-019 ECM Communication Error (Child 1) No ECM
23200-019 ECM Communication Error (Child 2) No ECM
T5-4-12

Description
30001-004 01361 Remote Accelerator Pedal 1 Circuit Failed High No ECM
30002-016 01852 Water Indicator Above Normal No ECM
30003-003 00224 Sentinel Burn Valve Above Normal No ECM
30003-004 00223 Sentinel Burn Valve Below Normal No ECM
30006-013 00342 Calibration Incompatibility Error No ECM
30007-009 00781 J1939 Data Link 2 cannot Transmit No ECM
30010-003 02377 Fan Control Circuit Failed High No ECM
30010-004 00245 Fan Control Circuit Failed Low No ECM
30011-002 01257 Module ID Input State Error No ECM
30012-002 00431 Idle Validation Invalid No ECM
30015-009 00285 J1939 PGN Timeout Error No ECM
30015-013 00286 J1939 Configuration Error No ECM
30020-003 02265 Lift Pump Supply Circuit Failed High No ECM
30020-004 02266 Lift Pump Supply Circuit Failed Low No ECM
30021-003 00272 Fuel Pump Pressure 1 Circuit Failed High No ECM
30021-004 00271 Fuel Pump Pressure 1 Circuit Failed Low No ECM
30022-003 00546 Fuel Del Pressure Circuit Failed High No ECM
30022-004 00547 Fuel Del Pressure Circuit Failed Low No ECM
30022-018 02215 Fuel Pump Pressure Below Normal No ECM
30100-012 00351 Injector Power Supply Failed No ECM
30101-031 02311 Fuel Injection Valve Circuit Error No ECM
30102-005 00322 Injector Solenoid Driver Cylinder 1 Below Normal No ECM
T5-4-13
(Blank)
T5-4-14
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Troubleshooting B is used for executing troubleshoot-

ing of the engine by use of the Engine Fault Indicator
inside the electrical equipment box below the cab.
In case the engine control system suffers a fault, the

Engine Fault Indicator is lit.
Each warning lamp means the following.

Engine Stop Lamp (Red)
Stop the engine immediately, and repair the de-
fective portion.
Engine Warning Lamp (Amber)

Working can be continued for a while, but repair T18L-01-02-038
the defective portion within 24 hours.
Engine Maintenance Lamp (Yellow)

Electrical
Further operation can be allowed, but repair the Equipment Box
defective portion in the next periodic maintenance.
NOTE: Fault codes related to the Engine Stop

Lamp (Red) and the Engine Warning Lamp Engine Fault
(Amber) can be confirmed by the monitor Indicator
display also. Therefore, in case the monitor
display is functioning normally, execute
troubleshooting utilizing Troubleshooting A.
NOTE: Fault codes related to the Engine Mainte-

nance Lamp (Yellow) cannot be confirmed
by the monitor display. Therefore, periodi-
cally examine whether the Engine Mainte-
nance Lamp (Yellow) is lit or not, and in T18M-05-04-002
case it is lit, read the fault code(s), and re-

pair the portion(s) needing remedy in the Engine Stop Lamp
next periodic maintenance. (Red)
T18M-05-04-003
Engine Maintenance Engine Warning
Lamp (Yellow) Lamp (Amber)
T5-5-1
HOW TO READ FAULT CODES
Engine Diagnostic
Switch
1. Stop the engine, and turn the key switch ON.
2. In case a fault code exists, the Engine Warning
Lamp (Amber) alone is lit, but in case no fault
code exists, none of the lamps are lit.
3. Turn the Engine Diagnostic Switch ON. Fault Code
INC/DEC
4. The Engine Warning Lamp (Amber) flickers once, Switch
and in a second, the Engine Stop Lamp (Red) in-
dicates the fault code at stake twice consecutively,
which is repeated.
5. A Fault code has four digits at the maximum. A
numeral is indicated by the number of times of Engine Stop
Lamp (Red) T18M-05-04-003
flickering of the Engine Stop Lamp (Red) for each
digit, and remains unlit for 1 second between digit Engine Maintenance Engine Warning
Lamp (Yellow) Lamp (Amber)
change.
6. When the key switch is turned off, indication of the
fault code is finished.
Example: Flickering of Engine Stop Lamp (Red)
NOTE: In case a plural number of fault codes are in in case of Fault Code 132
existence, the Engine Warning Lamp (Am-
ber) flickers once each time indication of a 100s digit 10s digit 1s digit
fault code is over, and a second later, the
Engine Stop Lamp (Red) indicates the next Lit
fault code twice, which is repeated.
NOTE: When indication of all the fault codes is over,

the Engine Warning Lamp (Amber) flickers
once, and a second later, the Engine Stop Unlit
Lamp (Red) repeats indication of the fault 1 second 1 second T141-05-03-004
codes from the first one.
NOTE: IN case the Fault Code INC/DEC Switch is

moved toward INC once, indication of the
next fault code begins. In case the Fault
Code INC/DEC Switch is moved toward
DEC once, indication is changed to the
previous fault code.
T5-5-2
(Blank)
T5-5-3
FAULT CODE FOR ENGINE
Cummins Warning HCM

Description Effect On Engine
Code Lamp Color Code
115 Red 30036-002 Speed Signal Lost Fueling to the injectors is disabled and the
engine cannot be started.
122 Amber 00016-003 Intake Manifold Pressure 1 Circuit

Failed High
123 Amber 00016-004 Intake Manifold Pressure 1 Circuit
Failed Low
124 Amber 00016-016 High Intake Manifold Press 1
135 Amber 00011-003 Oil Press Circuit Failed High None on performance. No engine protection
for oil pressure.
141 Amber 00011-004 Oil Press Circuit Failed Low None on performance. No engine protection
for oil pressure.
143 Amber 00011-018 Low Oil Pressure Calibration dependent progressive power
derate and calibration dependent engine
shutdown with increasing time after alert.
144 Amber 00006-003 Coolant Temperature Circuit Failed Possible white smoke. No engine protection
High for engine coolant temperature.
145 Amber 00006-004 Coolant Temperature Circuit Failed Possible white smoke. No engine protection
Low for engine coolant temperature.
146 Amber 00006-016 Coolant Temperature Above Normal Progressive power derate increasing in se-
verity from time of alert.
151 Red 00006-000 High Coolant Temperature Calibration dependent progressive power
153 Amber 00021-003 Intake Manifold Temperature 1 Circuit Possible white smoke.
Failed High No engine protection for intake manifold air
temperature.
Failed Low No engine protection for intake manifold air
temperature.
155 Red 00021-000 High Intake Manifold Temperature 1 Calibration dependent progressive power
156 Amber 00022-003 Intake Manifold Temperature 2 Circuit Possible white smoke. No engine protection
Failed High for intake manifold air temperature.
temperature.
T5-5-4
Instruction 1 Instruction 2
Inspect the engine harness connectors for correct connec- If the warning continues to be on afterward, report
tions. Make sure the engine crankshaft speed/position sensor it to your local Cummins dealer along with all ex-
and engine camshaft speed/position sensor are connected to isting Cummins fault codes and any symptoms.
the engine wiring harness correctly.
Fix it as soon as possible within 12 hours. Make sure engine

oil level is optimal and re-fill if not.
Fix it as soon as possible within 12 hours. Make sure engine
oil level is optimal and re-fill if not.
Shut the engine off. Call your local Cummins dealer along with all ex-
isting Cummins fault codes and any symptoms
Fix them as soon as possible within 12 hours. And monitor

radiator inlet temperature if the operation continues under this
condition
Fix them as soon as possible within 12 hours. And monitor
radiator inlet temperature if the operation continues under this
condition
Run the engine at High idle speed or auto idle speed to cool
down the engine.
Stop the engine after cooling down and check radiator for re-
striction and clean fins.
Run the engine at high idle speed or auto idle speed to cool If the warning continues to be on afterward, report
down the engine. it to your local Cummins dealer along with all ex-
Stop the engine after cooling down and check radiator for re- isting Cummins fault codes and any symptoms.
striction and clean fins.
Check also coolant level.
Fix it as soon as possible within 12 hours. Make sure LTA
outlet temperature is at optimal. Keep an eye on other three.

Check LTA radiator for restrictions. Clean the radiator thor- If the warning continues to be on afterward, report
oughly. it to your local Cummins dealer along with all ex-
If all four temperatures are high, there may be restrictions on isting Cummins fault codes and any symptoms.
radiators, If a single one is high, internal problem may exist.
Check LTA radiator for restrictions. If the warning continues to be on afterward, report
Clean the radiator thoroughly. it to your local Cummins dealer along with all ex-
T5-5-5
Cummins Warning HCM

temperature.
temperature.
temperature.
temperature.
187 Amber 21812-004 Sensor Supply 2 Circuit Failed Low Multiple sensor faults possible.
Loss of sensor functionality.
195 Amber 00007-003 Coolant Level Circuit Failed High None on performance.
196 Amber 00007-004 Coolant Level Circuit Failed Low None on performance.
197 Amber 00007-018 Coolant Level Below Normal None on performance.

212 Amber 00012-003 Oil Temperature Circuit Failed High No engine protection for engine oil tempera-
ture.
213 Amber 00012-004 Oil Temperature Circuit Failed Low No engine protection for engine oil tempera-
ture.
221 Amber 00043-003 Ambient Air Pressure Failed High Power derate may occur.
222 Amber 00043-004 Ambient Air Pressure Failed Low Power derate may occur.
223 Amber 30003-004 Sentinel Burn Valve Below Normal ECM turns off the engine oil burn valve so-
lenoid driver supply voltage and the system is
disabled.
224 Amber 30003-003 Sentinel Burn Valve Above Normal ECM turns off the engine oil burn valve so-
lenoid driver supply voltage and the system is
disabled.
227 Amber 21812-003 Sensor Supply 2 Circuit Failed High Multiple sensor faults possible.
228 Red 00008-001 Very Low Coolant Pressure Calibration dependent progressive power
231 Amber 00008-003 Coolant Press Circuit Failed High No engine protection for coolant pressure.
232 Amber 00008-004 Coolant Press Circuit Failed Low No engine protection for coolant pressure.
T5-5-6


Call your local Cummins dealer along with all ex-
isting Cummins fault codes and any symptoms.
Check on wires for damages and connections. Fix them as

soon as possible within 12 hours.
Check on wires for damages and connections. Fix them as
soon as possible within 12 hours.
Check for wire damages and connections. Call your local Cummins dealer along with all ex-
Fix them as soon as possible. isting Cummins fault codes.
Check for wire damages and connections. Call your local Cummins dealer along with all ex-
Fix them as soon as possible. isting Cummins fault codes.
Look for damages on wiring and connectors. If there are no damages, call your Cummins
Look for damages on wiring and connectors. d l
If there are no damages, call your Cummins
Check for wire damages and connections. d l
Call your Cummins dealer to fix them as soon as possible.
Check for wire damages and connections.


Check coolant level add coolant water if it is at low level. If the warning continues to be on afterward, report
it to your local Cummins dealer along with all ex-
T5-5-7
Cummins Warning HCM

234 Red 00046-000 Engine Over speed Fuel injection disabled until engine speed
falls below the over speed limit.
235 Red 00007-001 Low Coolant Level Calibration dependent progressive power
237 Amber 30008-002 Multi Unit Synchronization Error
245 Amber 30010-004 Fan Control Circuit Failed Low The fan can possibly stay on continuously or
not run at all.
261 Amber 00009-016 High Fuel Temperature Calibration dependent progressive power
(Moderate Level) derate and calibration dependent engine
263 Amber 00009-003 Fuel Temperature Circuit Failed High ECM will set a default value for fuel tem-
perature. No other action taken by ECM.
265 Amber 00009-004 Fuel Temperature Circuit Failed Low ECM will set a default value for fuel tem-
perature. No other action taken by ECM.
266 Red 00009-000 High Fuel Temperature Calibration dependent progressive power
(Most Sever Level) and speed derate and calibration dependent
engine shutdown with increasing time after
alert.
271 Amber 30021-004 Fuel Pump Pressure 1 Circuit Failed Engine will run poorly at idle. Engine will
Low have low power.
Fuel pressure will be higher than com-
manded.
272 Amber 30021-003 Fuel Pump Pressure 1 Circuit Failed Engine will not run or engine will run poorly.
High
285 Amber 30015-009 J1939 PGN Timeout Error One or more multiplexed devices will not
operate properly.
One or more symptoms will occur.
286 Amber 30015-013 J1939 Configuration Error At least one multiplexed devices will not op-
erate properly.
296 Red 21822-014 Aux Pressure 1 Exception
319 Yellow 30016-002 Real Time Clock Data Erratic None on performance.
Data in the ECM will not have accurate time
and date information.
322 Amber 30102-005 Injector Solenoid Driver Cylinder 1 Engine can misfire or possibly run rough.
Below Normal
Below Normal
Below Normal
Below Normal
Below Normal
Below Normal
342 Red 30006-013 Calibration Incompatibility Error Hard to start or no start.
T5-5-8
Check on operating conditions. If the condition has not changed, report it to your
local Cummins dealer along with all existing
Cummins fault codes and any symptoms.
Look for any external leaks and fix them if there are any. If you cannot find any leaks, report it your Cum-
And fill up coolant water. mins dealer along with all existing Cummins fault
codes and any symptoms.

Wiring problem should be fixed.
Monitor coolant temperature.
Check for fuel cooler restrictions and clean it.
Shut down engine as soon as possible. If the warning continues to be on afterward, report
Check for fuel cooler restrictions and clean it. it to your local Cummins dealer along with all ex-


Call Hitachi Dealer for investigation.
Let your Cummins dealer set dates and time.

T5-5-9
Cummins Warning HCM

343 Amber 21800-012 ECM Hardware Issue Non Mission Possible none on performance, or severe
Disabling derate.
349 Amber 30035-016 Trans Output Shaft Speed Above Engine will run off of a default auxiliary
Normal speed.
351 Amber 30100-012 Injector Power Supply Failed
386 Amber 21811-003 Sensor Supply 1 Circuit Failed High Multiple sensor faults possible.
415 Red 00011-001 Very Low Oil Pressure Calibration dependent progressive power
418 Yellow 30002-015 WIF Indicator Warning Possible white smoke, loss of power, or hard
starting.
421 Amber 00012-016 Engine Oil Temperature Above Nor- Severity based torque derate.
mal
426 Yellow 30015-002 J1939 Data link Can Not Transmit
431 Amber 30012-002 Idle Validation Invalid Engine will run at idle.
432 Red 30012-013 Idle Validation Calibration Error Engine will run at idle.
441 Amber 21817-018 Low Battery Voltage ECM voltage supply approaching level at
which unpredictable operation will occur.
442 Amber 21817-016 High Battery Voltage Possible electrical damage to all electrical
components.
449 Red 00041-000 High Rail Pressure Fuel injection noise.
451 Amber 00041-003 Rail Press Circuit Failed High Power and or speed derate.
452 Amber 00041-004 Rail Press Circuit Failed Low Power and or speed derate.
487 Amber 30000-018 Ether Bottle Empty Ether Injection is disabled.

488 Amber 00021-016 High Intake Manifold Temperature Calibration dependent progressive power
489 Amber 30005-018
AXG Speed Low Error
497 Amber 30033-002
Multi Unit Synchronization Error
527 Amber 21920-003
Dual Output A Failed High
529 Amber 21921-003
Dual Output B Failed High
546 Amber 30022-003
Fuel Delivery Pressure Circuit Failed No action taken by the ECM.
High
547 Amber 30022-004 Fuel Delivery Pressure Circuit Failed No action taken by the ECM.
Low
555 Amber 00015-016 Crankcase Pressure Above Normal
556 Red 00015-000 High Crankcase Pressure Ramps to full derate in 20 seconds.
559 Amber 00041-018 Rail Pressure 1 Below Normal Low Power, possible shutdown, or no start.
T5-5-10

Shut the engine off immediately. Call your local Cummins dealer along with all ex-
Drain the water from the fuel filter.
Make sure coolant water is not overheating. Call your local Cummins dealer along with all ex-
Check OEM wirings for any damages. Call your local Cummins dealer along with all ex-
If these damages are not causes, call your Cummins dealer. isting Cummins fault codes and any symptoms if
there is no damage to the OEM wiring.
Check on alternator and battery capacity.
Check battery voltage on the display.

It must be below 32VDC.
Change alternator.
Replace ether bottle.
Inspect the following item:
-Plugged LTA radiator fins
-Coolant level

T5-5-11
Cummins Warning HCM

599 Red 30009-014 Aux Commanded Dual Output Shut-
down
611 Yellow 30032-031 Engine Hot Shutdown
621 Yellow 00120-017 Low Power Cylinder 1 Possible power loss.
671 Yellow 00120-004 Exhaust Temperature Circuit Failed Loss of exhaust gas temperature meas-
Low Cylinder 1 urement.
T5-5-12

T5-5-13
Cummins Warning HCM

689 Amber 00046-002 Engine Crankshaft Speed Erratic Engine can run rough.
Possibly poor starting capability.
Engine runs using backup speed sensor.
Engine power is reduced.
697 Amber 30013-003 ECM Temperature Circuit Failed
698 Amber 30013-004 ECM Temperature Circuit Failed Low
731 Amber 30036-007 Engine Speed Cam/Crank Mis- Engine will run derate.
alignment Excessive smoke, hard start, and rough idle
possible.
781 Amber 30007-009 J1939 Data link 2 Can Not Transmit Engine will lose power or stop running.
783 Red 00021-010 Rapid Rise Intake Manifold Tem- Calibration dependent progressive power
perature 1 and speed derate and calibration dependent
alert.
1117 Yellow 30100-002 Power Lost with Ignition On
1135 Red 30007-009 J1939 Data link 2 Can Not Transmit Engine will lose power or stop running.
1256 Amber 30011-002 Module ID Input State Error Low Power, possible shutdown, or no start.
1257 Red 30011-002 Module ID Input State Error Hard to start or no start.
Lose power.
1357 Amber 30027-018 Remote Oil Level Below Normal No action taken by ECM.
Possible damage to engine if left unresolved
(SENTINEL application only).
1358 Amber 00048-003 Accelerator Pedal Sensor 1 Sensor Calibration dependent power and speed
Failed High derate.
Engine speed will be locked to 1000 min-1
1359 Amber 00048-004 Accelerator Pedal Sensor 1 Sensor Calibration dependent power and speed
Failed Low derate.
Engine speed will be locked to 1000 min-1
1361 Amber 30001-004 Remote Accelerator Pedal 1 Circuit Calibration dependent power and speed
Failed High derate.
T5-5-14



Look for any damage on the throttle dial and its stopper. Also
look for any worn on harness.
Look for any damage on the throttle dial and its stopper. Also
look for any worn on harness.

Fix them as soon as possible.
T5-5-15
Cummins Warning HCM

1362 Amber 00014-016 High Lube Oil Filter Restriction Calibration dependent progressive power
derate and engine shutdown with increasing
time after alert.
1363 Yellow 00016-017 Intake Manifold Pressure 1 Below Possible low power.
Normal
1367 Yellow 30026-003 Pre Filter Oil Press Circuit Failed None on performance.
High
1368 Yellow 30026-004 Pre Filter Oil Press Circuit Failed None on performance.
Low
1369 Yellow 21820-003 Aux Temperature Input 1 Circuit None on performance.
Failed High
1371 Yellow 21822-003 Aux Press Input 1 Circuit Failed High None on performance.
1372 Yellow 21822-004 Aux Press Input 1 Circuit Failed Low None on performance.
1373 Yellow 30004-011 Ether Injection Circuit Failed Ether injection feature is disabled.
Hard to start in cold temperatures.
1374 Yellow 30037-003 Turbo Speed Sensor Circuit Failed Possible performance influence.
High
1375 Yellow 30037-004 Turbo Speed Sensor Circuit Failed Possible performance influence.
Low
1376 Yellow 30036-002 Engine Speed Cam/Crank data Er- Possible poor starting.
ratic Engine power derate.
1377 Yellow 30031-003 Post Filter Oil Press Circuit Failed None on performance.
High
1378 Yellow 30031-004 Post Filter Oil Press Circuit Failed None on performance.
Low
1381 Yellow 21820-014 Aux Temperature Input 1 Circuit Ex- Calibration-dependent progressive power
ception and speed derate and engine shutdown with
increasing time after alert. (Not included in
HCM application?)
1383 Yellow 00016-003 Intake Manifold Pressure 1 Failed Possible performance influence.
High
Low
High
Low
1387 Yellow 30017-031 J1939 Engine Commanded Shut-
down
1411 Amber 30031-003 Gen Output Freq Circuit Failed High
1412 Amber 30031-003 Droop Adjust Circuit Failed High
1418 Amber 30031-003 Gain Adjust Circuit Failed High
1427 Amber 30031-031 Over Speed Shutdown Relay Driver
Error
1428 Amber 30031-031 Low Oil Pressure Shutdown Relay
Driver Error
T5-5-16
Replace filters and at the same time cut open filters and in- If there are coolant or metals, do not start engine
spect for coolant and metals. and all your local Cummins dealer along with all
Do not start engine until the inspection is made. existing Cummins fault codes and any symptoms.
Check air filters for restrictions and replace them if they are
clogged.
Check ether injection system. If there is no external problem, call your local
Cummins dealer along with all existing Cummins
fault codes and any symptoms.

T5-5-17
Cummins Warning HCM

1429 Amber 30031-031 High Engine Temperature Shutdown
Relay Driver Error
1431 Amber 30031-031 Oil Pressure Relay Driver Error

1432 Amber 30031-031 High Engine Temperature Relay
Driver Error
1435 Amber 30030-031 Engine Cold Potential Starting Issue
1514 Amber 00048-008 Accelerator Pedal Position Sensor 1 Engine operates at idle.
Frequency Issue
1516 Yellow 00046-015 Engine Crankshaft Speed Above

Normal
1517 Red 21800-031 ECM Detects Most Severe Fault Dependent on particular faults from ECM 1
and/or ECM 2 that triggered Fault Code
1517.
1518 Amber 21800-031 ECM Detects Moderately Severe Dependent on particular faults from ECM 1
Fault and/or ECM 2 that triggered Fault Code
1518.
1519 Yellow 21800-031 ECM Detects Least Severe Fault Dependent on particular faults from ECM 1
and/or ECM 2 that triggered Fault Code
1518.
High Cylinder 3 urement.
T5-5-18
Check OEM wirings for any damages. Call your local Cummins dealer along with all ex-
If these damages are not causes, call your Cummins dealer. isting Cummins fault codes and any symptoms if
there is no damage to the OEM wiring.

Look if any other faults are apparent. Call your local Cummins dealer along with all ex-
Look if any other faults are apparent. Call your local Cummins dealer along with all ex-

T5-5-19
Cummins Warning HCM

1544 Yellow 21821-014 Aux Pressure Sensor Input 1 Excep- Possible engine power derate.
tion
1548 Amber 30108-005 Injector Solenoid Driver 7 Below Engine can misfire or possibly run rough.
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
Normal
1595 Amber 30001-003 Remote Accelerator Pedal 1 Circuit
Failed High
1596 Yellow 21820-004 Aux Temperature Sensor Input 1 Cir- None on performance.
cuit Failed Low
1597 Yellow 21800-012 ECM Critical Internal Failure Engine will possibly not start.
Normal
1634 Amber 00017-016 Intake Manifold Pressure 2 Above
Normal
1638 Yellow 00017-017 Intake Manifold Pressure 2 Below Possible low power.
Normal
1843 Amber 00015-003 Crankcase Press Circuit Failed High No engine protection.
1844 Amber 00015-004 Crankcase Press Circuit Failed Low No engine protection.
1845 Yellow 30002-003 WIF Indicator Circuit Failed High None on performance.
No water in fuel warning available.
1846 Yellow 30002-004 WIF Indicator Circuit Failed Low None on performance.
No water in fuel warning available.
1847 Red 00006-014 Engine Coolant Temperature Excep-
tion
1852 Amber 30002-016 WIF Indicator Above Normal Possible white smoke, loss of power, or hard
starting.
1888 Yellow 00048-019 J1939 Accelerator Pedal Error Engine could possibly only idle or engine will
not accelerate to full speed.
T5-5-20


Check air filters for restrictions and replace them if they are
clogged.
Check wires and connections from a filter to the engine con-

nection.
Check wires and connections from a filter to the engine con-
nection.
Drain water from all filters.
Check pedals for any damages. Call your local Cummins dealer along with all ex-
T5-5-21
Cummins Warning HCM

1889 Yellow 30001-019 J1939 Remote Accelerator Pedal Engine will not respond to the remote throt-
Error tle.
Engine could possibly only idle.
The primary or cab accelerator could possi-
1891 Amber 30025-031 Engine Oil Change Interval Ex-
ceeded
1911 Amber 00041-000 Injector Rail Pressure Above Normal Engine performance derate.
1978 Amber 30014-003 Load Bias Circuit Failed High

1979 Amber 30014-004 Load Bias Circuit Failed Low
1984 Amber 00022-016 Intake Manifold Temperature 2 Calibration dependent progressive power
Above Normal derate and calibration dependent engine
1992 Red 00046-016 Engine Speed Above Normal
2121 Amber 00120-016 High Exhaust Temperature Cylinder Possible engine smoke and engine damage.
1
3
5
7
9
11
T5-5-22
Shut the engine off. Call your local Cummins dealer along with all ex-

- Plugged LTA radiator fins
- Coolant level
- Coolant level
- Coolant level
Inspect the following items: Call your local Cummins dealer along with all ex-
- Restricted air flow through the exhaust isting Cummins fault codes and any symptoms.
manifold or exhaust system
- Air Cleaner Restriction Warning
- LTA output temperature
T5-5-23
Cummins Warning HCM

13
15
2131 Amber 00121-016 High Exhaust Temperature Cylinder 2 Possible engine smoke and engine damage.
10
12
14
16
T5-5-24
T5-5-25
Cummins Warning HCM

alert.
alert.
alert.
2185 Amber 21820-003 Sensor Supply 4 Circuit Above Nor- Multiple sensor faults possible.
mal Loss of sensor functionality.
It may cause throttle problem.
2186 Amber 21820-004 Sensor Supply 4 Circuit Below Nor- Multiple sensor faults possible.
mal Loss of sensor functionality.
It may cause throttle problem.
2215 Amber 30022-018 Fuel Pump Pressure Below Normal Low power.
2261 Yellow 30022-015 Fuel Pump Delivery Pressure Above Low power or engine smoke.
Normal
2262 Yellow 30022-017 Fuel Pump Delivery Pressure Below Low power.
Normal
2265 Amber 30020-003 Lift Pump Supply Circuit Failed High Engine can be difficult to start.
2266 Amber 30020-004 Lift Pump Supply Circuit Failed Low Engine can be difficult to start.
2311 Amber 30101-031 Fuel Injection Valve Circuit Error Possible low power.
2321 Yellow 00046-002 Engine Crankshaft Speed - Data Er-

ratic
2322 Yellow 30036-002 Engine Camshaft Speed Data Erratic
2377 Amber 30010-003 Fan Control Circuit Failed High The fan can possibly stay on continuously or
not run at all.
2557 Amber 21960-003 Aux PWM Driver 1 Circuit Failed
2558 Amber 21960-004 Aux PWM Driver 1 Circuit Failed Low
2963 Yellow 00006-015 Engine Coolant Temperature Above
Normal
2964 Yellow 00021-015 Intake Manifold Temperature 1
Above Normal
T5-5-26


Check for fuel restriction and high 1st stage filter restriction. If no restriction is found, call your local Cummins
dealer along with all existing Cummins fault codes
and any symptoms.
- Stage 2 fuel filter restriction isting Cummins fault codes and any symptoms.
- Fuel quality
If there are restrictions, change all filters.
- High stage 1 fuel filter restriction isting Cummins fault codes and any symptoms
- High fuel inlet restriction
- Fuel quality
If there are restrictions, change all filters.
Look for any wiring damages. If there are no damages or mis-connection, call
your local Cummins dealer along with all existing
Cummins fault codes and any symptoms.
Look for any wiring damages. Call your local Cummins dealer along with all ex-
Wiring problem should be fixed.

Monitor coolant temperature.
T5-5-27
(Blank)
T5-5-28
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C PROCEDURE
Fault Diagnosis C is used for the failure of the air con-

ditioner.
T5-6-1
Air conditioner malfunction.
When the air conditioner system control panel in-

dicator flashes, see T5-6-14.
When reporting the malfunction of the air condi-
tioner to HITACHI, use the Air Conditioner Trou-
ble Report form shown on page T5-6-16.
Cooling Circuit
Piping and/or parts are stained
Refrigerant pressure in Bubbles can be seen
with oil, respond to gas detector.
both high and low in sight glass.
pressure sides is low. No oil stain is found or gas de-
tector doesnt respond. Refrig-
erant has not been refilled for
longer than one season.
No bubbles are seen in sight
glass.
After cooling at fast speed con-

tinuously, cooling power is re-
duced. Air flow volume remains
unchanged.
Air flow volume is reduced.

Refrigerant pressure Bubbles can be seen in sight Compressor cylinder is not hot.
in low pressure side glass. (Refrigerant returns into com-
is high. pressor in liquid form.)
Insufficient
Cooling
Power Refrigerant pressure in high pres- Compressor cylinder is ex-
sure side is low. tremely hot, emitting a smell.
Heater unit emits hot air.
Refrigerant pressure Bubbles can be seen in sight Refrigerant pressure in low

in high pressure side glass. pressure side is low.
is high.
Condenser is stained and clogged.
Even if condenser is sprayed with water, few bubbles appear. Receiver dryer
temperature is low.
After cooling at fast speed continu- Frost

ously, cooling power is reduced. Air Thermistor doesnt cool.
forms.
flow volume is reduced.
Thermistor cools.
T5-6-2
Gas leaks from pipe joints and/or parts. Re-tighten or replace parts.
Normal leakage of refrigerant from hoses. Refill refrigerant.
Improper adjustment (excessive restriction) of ex- Readjust or replace expansion valve.

pansion valve.
Remove clog, or replace receiver and/or expansion
Clogged expansion valve. valve.
Clogged low pressure circuit and/or evaporator. Remove clog, or replace parts.
After evacuation, refill refrigerant and/or replace re-

Frozen expansion valve or water in circuit. ceiver dryer.
Gas leaks from case. Seal gaps using vinyl tape or packing compound.
Poor contact of expansion valve temperature sen- Make good contact. Replace temperature sensing
sor. stay.
Improper adjustment (excessive open) of expan-
sion valve. Readjust or replace.
Insufficient compressor discharge (faulty gasket Replace.

and/or valve).
Improper water stop valve wire adjustment and/or

faulty stop valve. Check and readjust or replace.
Poor airtight fitting of outside air damper (outside Repair.

air induction type).
Remove clog, or replace parts.
Clogged high pressure circuit before receiver Clean Condenser.

dryer.
Excessive refrigerant. Remove excessive refrigerant to proper level.
After evacuation, refill refrigerant and/or replace re-

Air is mixed in system. ceiver dryer.
Incorrect thermistor location. Correct thermister location.
Gas leaks from case. Seal gaps using vinyl tape or packing compound.
Faulty thermistor (stays ON). Disconnected thermister cord.
Even if function and performance are normal,

Instruct user correct air-conditioner operation. (Re-
when air-conditioner is kept operated for a long
set thermistor to either minimum or middle cooling
time with thermistor in max. cooling position and
position or increase air flow.)
air flow in M or L mode, frost may form.
T5-6-3
Cooling Circuit
Case connection. Louver resonance.
Fan contacts case, or foreign matter enters case.

Blower fan connection.
Brush friction noise, metal and/or thrust washer contact
noise.
Gas vibration noise (compressor discharge and/or suc-

Gas blowing sound (roaring). tion gas noise).
Expansion valve connection, whistle Abnormal noise from expansion valve (Expansion
Noise sound, gas blowing sound. valve is normally functioning.).
Faulty clutch bearing, and/or idle pulley bearing.

Clutch disengaging sound.
Contact of clutch amature due to resonance, or loose
belt and/or screws.
Noisy compressor.
Compressor rotating sound.

Vibration and/or loose screws due to excessive drive
belt looseness.
Broken heater core and/or hose.

Water leak and/or splash.
Clogged case drain port and/or drain hose.

Others
Abnormal smell. Absorbed cigarette and dust smell on evaporator fins.
T5-6-4
Repair or replace.
Remove foreign matter. Readjust fan motor location.
Slight noise is unavoidable. Replace if loud.
No functional problem exists. Provide silencer if intolerable.
Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.
Replace.
Repair or replace clutch. Re-tighten screws.
Repair or replace.
Re-adjust drive belt.
Replace.
Clean.
Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min-1 in L
mode for more than 10 minutes, flush smell out by condensed water.
T5-6-5
Electrical Circuit
Both
clutch and Not blown.
blower Check fuses.
dont op-
erate. Blown.
Not drawn.
Only
clutch Directly connect bat-
is not ac- tery to clutch termi-
tivated. nal.
Directly connect battery only to ther-
Drawn. mostat (relay), and clutch circuit.
Blower doesnt rotate.

Only Directly connect bat-
blower tery to blower motor
doesnt positive terminal.
rotate.
Connect blower switch terminals L, M,
Blower rotates.
and H directly to terminal B.
Fan doesnt rotate.
Electric
Directly connect bat-
fan Check for voltage between fan motor
tery to fan motor posi-
doesnt relay connectors terminal #1 and #2.
tive terminal.
rotate.
Fan rotates. 24 V (12 V)
Short circuit between relay connec-

tors terminal #3 and #5.
Check air gap.
Clutch Measure clutch drawing voltage (16 v on 24

slips. V-system circuit).
Check if compressor shaft rotates smoothly.
T5-6-6
Move to steps
(2 and 3).
Short-circuited clutch and/or blower circuit (In-
Repair.
correct power input terminal)).
Follow instructions.
Faulty clutch. Replace.
Clutch is drawn. Faulty parts (thermostat and/or relay). Replace.
Clutch is not drawn. Broken clutch system harness. Repair.
Faulty blower motor. Replace.
Blower rotates. Faulty blower switch. Replace.
Broken blower system harness. Repair.

Blower doesnt ro-
tate.
Faulty resister. Replace.
Faulty motor. Replace.
0V Broken signal circuit harness. Repair.
Fan rotates. Faulty relay. Replace.
Fan doesnt rotate. Broken fan motor power circuit harness. Repair.
T5-6-7
Electronic Thermo
Clutch stays ON. Short-circuited thermistor. Check thermistor connector resistance with tester.
Short-circuited thermo volume. Thermo volume is turned OFF.
Poor relay contact and/or faulty am- Disconnect thermistor.

plifier.
Clutch stays OFF. Faulty thermistor. Check for thermistor connector resistance with tester.
Broken circuit in thermo volume. Check for thermo volume terminal resistance with
tester.
Faulty thermostat (or broken harness Check for resistance with tester after turning switch
to thermo volume). ON (continuity check).
Poor relay contact and/or faulty am- Disconnect thermistor. Ground amplifier connector.
plifier.
Clutch chatters. Poor thermostat contact. Check for continuity at volume switch terminal with
tester.
Faulty soldering in amplifier. Disconnect thermistor. Ground amplifier side connec-

tor.
Poor connector contact. Vibrate connectors.
Temperature is not suf-

ficiently cooled (clutch Faulty thermistor. Replace thermistor.
operates ON/OFF).
Improper thermistor location. Locate thermistor in evaporator center.
Failure in amplifier. Replace thermistor.
Temperature is not suf- Trouble exists outside electronic Standard Thermistor Temperature Characteristics:
ficiently cooled (clutch thermo. (Refer to the troubleshooting 0 C (32 F): approx. 7.2 k
stays ON). tables on previous pages.) 25 C (77 F): approx. 2.2 k
Noisy relay (chattering) Poor ground line contact. Check for ground line contact.
T5-6-8
Resistance is small. Replace thermistor.
(When resistance is approx. 2 k at 25 C (77 F), thermistor is normal.)
Clutch is turned OFF. Replace thermo volume.
Clutch is not turned OFF. Replace amplifier.
Replace thermistor. Check ampli-

Resistance is 7 k or more.
fier.
Resistance is infinite. Replace thermo volume.
Normal when resistance is 0. Replace thermo volume.
Abnormal when resistance is infinite.

Clutch stays OFF. Replace amplifier.
Tester needle moves when thermo volume is vibrated. Replace thermo volume.
Normal if tester needle is unmoving when thermo volume is vibrated.
Clutch chatters when amplifier is vibrated. Replace amplifier.
Clutch chatters. Faulty connector. Repair connector.
Temperature is cooled. Faulty thermistor. Replace thermistor.
Temperature is not cooled. Faulty thermistor. Replace thermistor.
Faulty cooling function.

Normal when cooled.
Temperature is not cooled. Faulty amplifier. Replace amplifier.
Normal. Faulty amplifier. Replace.
Poor connection. Repair.
T5-6-9
Compressor
Compressor doesnt rotate. Clutch terminal voltage is normal 24 V.
Clutch terminal voltage is low.
Clutch terminal voltage is 0 V.

Inoper-
able
cooling Bubbles exist even after refrigerant is refilled.
system
Both high and low side Check for oil and refrigerant leaks from parts other than
pressures are low. compressor and pipe joints using gas detector.
Both
Check for oil and refrigerant leaks from com-
com-
pressor (no leaks from parts other than com-
pressor
pressor) using gas detector.
and
blower
motor
rotate. Refer to NOTE 1 and 2 on page T5-6-13.
Stain
on Refrigerant has not been refilled for longer
exterior than one season.
Refrigerant is discharged within 1 to 2
months after being recharged. Check for
refrigerant leaks using gas detector.
Refrigerant is kept charged for longer than

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

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

Table on page T5-6-4.
Temperature is not cooled when compressor is
operated at fast speed continuously.
Air flow from blower is insufficient.
Compressor rotation is abnormally draggy.

Over-hea
ting is
suscep-ti
ble to
occur.
Trouble other than compressor Refer to the Cooling Circuit Troubleshooting Table on page
T5-6-4.
T5-6-10
Seized clutch. Replace.
Improper gap between am

Replace.
Broken or short-circuited core cable.
Shaft doesnt rotate (internally locked). Replace.
Refer to the Electrical Circuit Troubleshooting Table on page T5-6-6.
Refer to the Cooling Circuit Troubleshooting Table on page T5-6-4.
Faulty mechanical seal, gasket, and/or charge valve.

Replace.
Oil leaks from oil plug.
Oil and refrigerant leaks from front housing, and/or cylinder block joint. Replace.
Normal leaks from hoses. Charge

refrigerant.
No leaks (normal).
Refer to the Cooling Circuit Troubleshooting Table on page T5-6-4.
Broken valve (See NOTE 3 on page T5-6-13.).
Replace.
Blown gasket (See NOTE 3 on page T5-6-13.).
Check and
Excessive oil. adjust oil level.
Broken clutch bearing due to overly tightened belt. Replace.
Shaft doesnt rotate.

Replace.
Shaft rotates draggy.
T5-6-11
Compressor
Noise is heard when clutch is OFF.
Abnormal
noise
Noise is heard when clutch is ON.
T5-6-12
Broken clutch bearing.

Replace
Contact or slip due to poor air gap.
Faulty idle pulley bearing.
Saggy belt. Refer to the Cooling Circuit

Troubleshooting Table on
page T5-6-4.
Loose screws.
Broken valve.
Replace
Blown gasket.
Abnormal internal noise. Replace
Vibration due to saggy belt.

Refer to the Cooling Circuit
Loose screws. Troubleshooting Table on
page T5-6-4.
NOTE:
1. Dont quickly decide that oil is leaking when a stain around the clutch and/or gasket is found. A
slight oil seepage will appear due to the seal construction. However, this oil seepage will not
cause malfunction. Be sure to accurately check whether oil is leaking or seeping only.
2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose
surface may be detected. As long as the specified rubber hoses are used, the problem should
not occur. (In case a large leaks is detected, the hose may be broken.)
3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between
2
high pressure side and low pressure side is 0.49 MPa (5 kgf/cm , 71 psi) or less. When the
clutch is turned OFF, the pressure difference between high pressure side and low pressure side
will disappear within about 10 seconds.
T5-6-13
DIAGNOSIS BY BLINKING OF INDICATOR
The air conditioner system has a function to detect the

abnormality of the system by blinking of the indicator
IMPORTANT: Once abnormality is detected, the

detection state remains even after
normal state resumes. To release
this detection state, turn OFF the
key switch, or stop the air condi-
tioner with ON/OFF switch on the
control panel. Notice that the limita-
tion of M/A (motor actuator) can be
released only when the key switch
is OFF.
Open-Circuit Detection Abnormal Communication

Blinking of HOT Mark Blinking of Temperature Control Bar Frame
When the power is ON, HOT mark blinks if the har- 1. If communication between control panel and con-
ness of the air mix M/A disconnects or shorts. The trol amplifier fails, thus disabling reception, the
air mix M/A remains disabled until the power is control panel makes the temperature control bar
turned ON again. frame blink about 30 seconds later.
Blinking of Inside/Outside Air Mark 2. At this time, the control amplifier makes all out-
When the main key power is ON, the inside/outside puts turn OFF.
air mark blinks if the harness of the inside/outside
air selection M/A disconnects or shorts. The in- 3. Even when is blinking, the control panel receives
side/outside air selection M/A remains disabled until all switch inputs.
the power is turned ON again.
4. When reception resumes, the temperature con-
Blinking of A/C Mark (Open- or Short-Circuit of trol bar frame is turned ON instead of blinking
Evaporation Sensor and Its Input Circuit) state, and the control panel and control amplifier
The A/C mark blinks if the harness disconnects or resume.
shorts.
At this time, compressor control is not made, and
the compressor clutch is always turned OFF. Notice
that anti-fretting control is made.
T5-6-14
Control Panel
ON/OFF Switch
A/C Mark
Inside/Outside
Air Mark
HOT Mark
Temperature Control
Bar Frame
T18G-05-06-001
T5-6-15
Please fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to the related post / after experiencing a problem with your
machines air conditioning system.
AIR CONDITIONER TROUBLE REPORT File No.

(1) What
Model (Serial No. )
Operation Type Manual Semi-Auto Full-Auto
Delivery Date Year Month
(2) When
Date Year Month Day Operating Hour ( h)
Time Morning Daytime Evening Night
Frequency Every Day Once a Week Once a Month Times per
(3) Where
Job Site Address State County Town
Access Road Condition Paved Not Paved (Gravel Sand Soil)
(4) How (Operating Conditions)
Weather Fine Cloudy Rain Snow
Atmospheric Temperature Very Hot Hot Cold Very Cold
Operating Conditions Parking Traveling Working
Temperature Control Paint blanks equal to red indicators. / Fill in
set-temperature when full-auto operation
A/C ON OFF
Air Induction Re-Circulation Fresh Air Circulation
Control
Panel AUTO ON OFF Not Available
Fill following items when operated in manual mode or when manual control type
unit is used.
Vent Position Front Front / Rear Foot Front / Rear and Foot
Fan First Second Third Fourth Fifth Sixth
(5) How (Problem Symptom)
Abnormal Compressor Operation
Symptom Not turned ON
Not turned OFF (1)
Others
Uncontrollable air temperature
Symptom No cool air (1)
No warm air
Others
Uncontrollable air volume
Symptom Air flows in Hi mode only
No air flows (1)
Small air volume
Others
Uncontrollable vent hole
Symptom Vent hole isnt selected
Others
Abnormal panel indication
Faulty Indi- Vent Hole
cator A/C
AUTO
Fresh Air Circulation
Fan OFF
Fan (Lo Hi)
Temperature Control
Symptom Stays OFF
Stays ON
Blinks
Others
T5-6-16
Refrigerant Quantity....................... 1400 50 g

Compressor Oil Quantity ............... 320 cm3
T5-6-17
(Blank)
T5-6-18
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source.

Disconnect the harness from the negative terminal
side in battery first when taking wire harnesses
and connectors off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses and fusible links and, in some
cases, cause fire due to short circuiting.
2. Color coding of wire harnesses.
As for the color codes of wire harnesses in the
electrical system, refer to the table below.
In cases on the design sheet where two colors are
indicated for one wire, the left initial stands for
base color, while the right initial stands for marking
color.
Code R W L G Y B
Color Red White Blue Green Yellow Black
Code Or Lg Br p Gr V
Light
Color Orange Brown Pink Gray Violet
Green
NOTE: Code BW indicates a black base wire

with white fine-line marking.
Initials O and Or both stand for the
color orange.
Wires with longitudinal stripes printed
on them are not color coded. Do not
confuse them with color coded wires.
T5-7-1
3. Precautions for Connecting and Disconnecting
Terminal Connectors
Correct Incorrect
When disconnecting the harnesses, grasp them
by their connectors. Do not pull on the wire itself.
Release the lock first before attempting to
separate the connectors, if a lock is provided.
The water-resistant connectors keep water out. If
water enters them, water will not easily drain from T107-07-06-001
them. When checking the water-resistant
connectors, take extra care not to allow water to
enter the connectors. In case water should enter
the connectors, reconnect only after thoroughly
drying the connector. Correct
Before connecting terminal connectors, check Rust
that no terminals are bent or coming off. In Bending
addition, as most connectors are made of brass,
check that no terminals are rusting.
Separation
When connecting terminal connectors provided
with a lock, insert them together until the lock
T107-07-06-002
clicks.
4. Precaution for Using a Circuit Tester

Before using a circuit tester, refer to the Wind a piece of wire
around the probe. Tester Probe
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object to be
measured, voltage range and current polarity.
Before starting the connector test, always check
the connector terminal numbers by referring to the Sharpen the end of the wire.
circuit diagram. When the connector size is very T107-07-06-003
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 in order
to make the test easier.
When checking the connector by using a tester,
insert a tester probe from the harness end of
connector in order not to damage the terminal
inside connector.
T5-7-2
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
Push, Unlock and Separate Type
NOTE: 1. Connectors will not be easily separated

even if the lock is pushed while being
pulled. Push the lock first before pulling the
connectors.
2. The lock is located on female side
connector (harness end side).
T107-04-05-002
Pull and Separate Type
IMPORTANT: Before pulling and separating,

release the lock of connector by
using a pair of pincers.
T107-04-05-004
Pull and Separate Type After Removing Screw

Use a 10 mm wrench and a ratchet. Tighten the Screw
screw until the torque mark (convex) appears.
Convex
T107-04-05-005
T5-7-3
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between

the battery positive terminal and the vehicle frame.
Normal Voltage:Between 24 to 26 V
NOTE: If voltage is abnormal, recharge or replace

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

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

system.
T157-07-06-007
T5-7-4
(Blank)
T5-7-5
FUSIBLE LINK INSPECTION
Fusible Link 1
Pull out the fusible link and visually inspect it.
T18K-01-02-030
Section C
1 2 3 4 5 6
7 8 9 10
T18L-01-02-046
No. Part Name Capacity Connected to

1 Fusible Link 1 75A Fuse Boxes 1,3 (Fuses No.1,2,4 to 12,55)
2 Fusible Link 2 75A Fuse Boxes 2,4 (Fuses No.31 to 33,69,70)
3 Fusible Link 3 75A Fuse Boxes 2,3,4 (Fuses No.30,34 to 36,48 to 50,73)
4 Fusible Link 4 75A Fuse Boxes 2,3,4 (Fuses No.37 to 39,44 to 47,53,59,60,67,68,77 to 79)
5 Fusible Link 5 75A Fuse Box 4 (Fuses No.61 to 66)
6 Fusible Link 6 75A Fuse Boxes 3,4 (Fuses No.41,51,52,75,76)
7 Fusible Link 7 45A Optional
8 Fusible Link 8 75A Engine Starter Relay
9 Fusible Link 9 45A ECM Power Source
10 Fusible Link 10 75A Sliding Fold-In Ladder Relay (Optional)
T5-7-6
Fusible Link2
Check continuity between both ends of the fusible link.
T18K-01-02-030
T183-05-08-001

1 Fusible Link 250A 250A Sliding Fold-In Ladder Motor (Optional)
2 Fusible Link 400A 400A Engine PRELUB Relay
T5-7-7
FUSE INSPECTION
Cracks in a fuse are so fine that it is very difficult or

impossible to find by visual inspection. Use a tester in
order to correctly inspect fuse continuity by following
the instructions described below.
1. Turn the key switch ON.

When the key switch is turned ON, current from
key switch terminal M activates the battery relay
so that electric power is supplied to all circuits
except the glow plug relay circuit. (Refer to the
circuit diagram.)
2. Remove the fuse box cover. Set the tester.
(Measurement Range: 0 to 30 V)
3. Ground the negative probe of tester to the vehicle
frame. Touch the terminals located away from Power Source Side
center of the fuse box with the positive probe of (Positive)
tester one at a time. When normal continuity of a
fuse is intact, the tester will indicate 20 to 25 V
(battery voltage).
NOTE: 1.The inside terminals of the fuses in fuse

boxes 1 and 2 are connected to the
power source, while the outside terminals
are connected to the loads (accessory)
side.
2.The left side terminals of the fuses in fuse
box 3 are connected to the power source,
while the right side terminals are Loads (Accessory)
Side (Negative)
connected to the loads (accessory) side.
3.The upper side terminals of the fuses in
the fuse box (cab) are connected to the
power source, while the lower side T105-07-01-008
terminals are connected to the loads
(accessory) side.
T5-7-8
Fuse Box (Cab)
20 19 18 17 16 15 14 13 12 11
T18G-01-02-030
10 9 8 7 6 5 4 3 2 1
T18G-01-02-028
Fuse Box (Cab)

1 Main Power Key SW 20A Key Switch Terminal B
2 ELU Power Source 5A ELU
3 IDU Power Source 5A IDU
4 DLU Power Source 5A DLU
5 ORBCOMM Battery Power 5A ORBCOMM Unit (Optional)
6 Radio Backup 5A Radio
7 ELU Key ON Sig. 5A ELU
8 IDU Key ON Sig. 5A IDU
9 DLU Key ON Sig. 5A DLU
10 Buzzar 5A BUZZAR
11 Key ON Sig. (Control Box) 5A Fuse Box 1 (Fuse No.13)
12 ECM Key ON Sig. 5A ECM
13 Radio (ACC) 5A Radio
14 Air Horn Comp. ACC Sig. 5A Air Horn Compressure Relay, Horn Relay
15 Lighter 10A Radio, Ciger Lighter
16 Terminal (ACC) 10A Terminal 1
17 Terminal (12V) 15A Terminal 1
18
19 Monitor Controller 5A Monitor Display
20 Pilot Shut-Off Lever SW. 5A Pilot Shut-Off Lever Switch
T5-7-9
Fuse Box 1
1 2 3 4 5 6 7 8 9 10
T18G-05-07-001
11 12 13 14 15 16 17 18 19 20
T18M-05-06-002
Fuse Box 1
1 MC Main Power 5A MC
2 Delayed Power OFF Relay 5A Delayed Power OFF Relay
3
4 MMS Backup 5A MMS (Optional)
5 HMU Power Source 5A HMU
6 Air Horn Compressor (L) 30A Air Horn Compressor Relay (L)
7 Air Horn Compressor (R) 30A Air Horn Compressor Relay (R)
8 Sliding Fold-In Ladder Sol. (A) 10A Sliding Fold-In Ladder Solenoid (A) (Optional)
9 Box Light 5A Box Light
10 Cab Battery Power 30A Fuse Box (Cab) Fuse #1, 2, 3, 4, 5 ,6
11 C/U Power Source (Optional) 10A Option Controller
12 C/U Power Source (Optional) 10A Option Controller
13 C/U Key ON Sig. (Optional) 5A Option Controller
14 C/U Key ON Sig. (Optional) 5A Option Controller
15 MC Key ON Sig. 5A MC
16 ELU PWM Power Relay 5A ELU PWM Power Relay
17 DLU Key SW ON Sig. 5A DLU
18
19 ECM Light Power Source 5A Engine troubleshooting Switch
20 HMU Key ON Sig. 5A HMU
T5-7-10
Fuse Box 2
21 22 23 24 25 26 27 28 29 30
T18G-05-07-001
31 32 33 34 35 36 37 38 39 40
T18M-05-06-002
Fuse Box 2
21 Washer Motor Relay 5A Washer Motor Relay
22 Travel Mode Selection Relay 5A Travel Mode Selection Relay
23 A/C Main Relay (Front) 5A A/C Relay (Front)
24 A/C Main Relay (Side) 5A A/C Relay (Side)
25 A/C Main Relay (Rear) 5A A/C Relay (Rear)
26 Battery Relay 5A Battery Relay
27 A/C Control AMP (Front) 5A A/C Control AMP (Front)
28 A/C Control AMP (Side) 5A A/C Control AMP (Side)
29 A/C Control AMP (Rear) 5A A/C Control AMP (Rear)
30 Motion Alarm 5A Motion Alarm
31 A/C Main Power (Front) 15A A/C (Front)
32 A/C Main Power (Side) 15A A/C (Side)
33 A/C Main Power (Rear) 15A A/C (Rear)
34 A/C Condenser Fan (Front) 20A Air Compressure Fan Relay (Front)
35 A/C Condenser Fan (Side) 20A Air Compressure Fan Relay (Side)
36 A/C Condenser Fan (Rear) 20A Air Compressure Fan Relay (Rear)
37 DLU Service Tool 5A DLU
38 ORBCOMM Power Source 5A ORBCOMM Unit (Optional)
39 MMS Power Source 5A MMS (Optional)
40 Alternator Signal 5A Alternator
T5-7-11
Fuse Box 3
41 42 43 44 45 46 47 48 49 50
T18G-05-07-001
51 52 53 54 55 56 57 58 59 60
T18M-05-06-002
Fuse Box 3
41 Suspention Seat Air Compressor 15A Suspention Seat Air Compressure
42
43
44 Travel Mode Selector Sol. 5A Travel Mode Selection Relay
45 Sliding Fold-In Ladder Hold Sol. 5A Sliding Fold-In Ladder Solenoid Valve B (Optional)
46 Dome LED Light 5A Dome LED Light in the Cab
47 Air Breather Sol. 5A Air Breather Solenoid Valve
48 Terminal (24V) 15A Terminal
49 DC/DC Converter1 15A DC-DC Converter 1
50 DC/DC Converter2 15A DC-DC Converter 2
51 MC Sol. Power Source 10A MC
52 MC PWM. Power Source 10A MC
53 ELU Sol. Power Source 15A ELU PWM.Power Relay, ELU
54
55 ECM Data Link 15A ECM
56
57
58
59 Engine Oil Reserve Tank Pump 15A Engine Oil Reserve Tank Pump
60 Oil Pump 20A Air Bleed Solenoid Valve
T5-7-12
Fuse Box 4
61 62 63 64 65 66 67 68 69 70
T18G-05-07-001
71 72 73 74 75 76 77 78 79 80
T18M-05-06-002
Fuse Box 4
61 Wark Light (1) 10A Work Light Relay (1)
67 Maintenance Light (1) 10A Maintenance Light Relay (1)
71
72
73 Entrarce Light 10A Entrarce Light Relay
74
75 Wipir Motor (Slow Speed) 30A Wipir Motor Relay (Slow Speed)
76 Wipir Motor (Fast Speed) 30A Wipir Motor Relay (Fast Speed)
77 Washer Motor 10A Washer Motor Relay
78 Fast Filling System Sol. 5A Fast Filling System Relay
79 CSU Power Source 5A CSU
80
T5-7-13
Fuse
Pull out the fuse. Inspect the fuse by using a tester.
1 2
T18K-01-02-030
No. Part Name Connected to

1 Fuse 5A IDU (PRELUB Signal)
2 Fuse 30A Zener Diode
3 Fuse 10A Engine Oil Reserve Tank Valve
T5-7-14
ALTERNATOR CHECK
In general, the alternator indicator remains off when

Terminal B
the alternator is generating power.
Terminal R
If the alternator indicator comes on while the engine is
running, the alternator might be defective.
Measurement of Generating Voltage

1. Start the engine. Measure voltage at terminals R
and B.
If the voltage at terminal R is 14 V or higher, and if
that at the terminal B is approximately 28 V, the
alternator is normal.
T18M-05-06-001
T5-7-15
VOLTAGE CHECK
The voltage check is performed not only for
determination of the voltage values at the
measurement point, but also for the confirmation of the
electrical validity between the measurement point and
power supply.
24-Volt Circuit
Before voltage check, turn the appropriate switch ON

and supply voltage at the measurement line. Measurement Example 1: When current is not flowing
Black Negative (-) Probe: Vehicle Frame

Red Positive (+) Probe: Each Measurement Point
If the rated voltage (battery voltage) is measured,

probably the circuit from the battery (alternator) to the
Measurement Point
measurement point is normal. However, if the current
flowing through the circuit, the voltage may not be
reached the rated value (this voltage drop is caused by T141-05-06-002
resistance of electrical components).
Measured Voltage
If the rated voltage is not measured, faulty power 24 V: The circuit from power source to the
supply, short-circuited circuit and/or open line on circuit measurement point is normal.
may be suspected. In this case, the faulty parts in the 0 V: There is open or short circuit between power
circuit can be found out by checking each parts in supply and the measurement point.
order of the circuit from the upstream (or downstream).
Measurement Example 2: When current flows
Rated Voltage (with normal power source):
When engine is not running: Battery voltage 2
approx. 25.5 V
When engine is running: Alternator generated
voltage
approx. 28 V
1 3
T141-05-06-003
Measurement Point Measured Value

1 24 V
2 20 V
3 0V
The measurement voltage does not become same to
the power supply value because of voltage drops by
resistance of the electrical components.
However, if the voltage is measured, it can be decided
that there are no open wires in the upstream circuit
from measurement point.
T5-7-16
Engine Key Switch Check Point Standard

Power Source Circuit
Stopped OFF Between (1) and (2): One Battery 10 to 12.5 V
Stopped OFF Between (2) and (3): One Battery 10 to 12.5 V
Stopped OFF Between (1) and (3): 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 1 20 to 25 V
Accessory Circuit
Stopped ACC Between (6) and Ground: Radio, Cigarette Lighter 20 to 25 V
Stopped ACC Between (7) and Ground: Air Horn Compressor Relay 20 to 25 V
Stopped (L2)
Stopped ACC Between (8) and Ground: Air Horn Compressor Relay 20 to 25 V
Stopped (R2)
Stopped ACC Between (9) and Ground: Horn Relay 20 to 25 V
Starting Circuit
Engine Start Switch: ON
Started ON Between (10) and Ground : PRELUB Timer Relay (#2) 20 to 25 V
Started ON Between (11) and Ground : PRELUB Timer Relay (#5) 20 to 25 V
Started ON Between (12) and Ground : Starter Relay (Upper) 20 to 25 V
(Switch)
Started ON Between (13) and Ground : Starter Relay (Upper) 20 to 25 V
(Coil)
Started ON Between (14) and Ground : Starter Relay (Lower) 20 to 25 V
(Switch)
Started ON Between (15) and Ground : Starter Relay (Lower) 20 to 25 V
(Coil)
Started ON Between (16) and Ground : Starter Relay 2 (Switch) 20 to 25 V
Started ON Between (17) and Ground : Starter Motor (Upper) (S) 20 to 25 V
Started ON Between (18) and Ground : Starter Motor (Lower) (S) 20 to 25 V
Charging Circuit
Running ON Between (19) and Ground: Alternator Generating 26 to 30 V
Voltage (B)
Running ON Between (20) and Ground: Battery Relay (B) 20 to 25 V
Surge Voltage Prevention
Circuit
Running Stopped ON OFF Between (21) and Ground: Delayed Power OFF 20 to 25 V
Relay (Coil)
Running Stopped ON - OFF Between (22) and Ground: Battery Relay (Coil) 20 to 25 V
T5-7-17
Power Source Circuit LED Fuse Box
Limit Switch
(Cab)
(Box Light Switch)
To MC Delayed Power OFF

Relay Terminals Sliding Fold-In Ladder To ELU
#1 and #3 Relay (1) Terminal #3 To IDU
MMS
Communication Sliding Fold-In Ladder Relay Alarm/ To DLU
Unit (Optional) Flash Light (1) Terminal #12 ORBCOMM
To HMU C/U Main Power Terminal #2 (Optional)
Air Horn Compressor Source Terminal #1
Relay (L1) Terminal #3 (Optional)
Air Horn Compressor To Radio
Relay (R1) Terminal #3
C/U (Ke-CAN)
Terminal #A Key Switch
(Optional)
Fuse Box 1
ECM
(Data Link)
Fuse Box 3
Sliding Fold-In Ladder Relay (2) (Optional)
Sliding Fold-In Ladder Relay

(3) (Optional) Fusible Link #9
Fusible Link 1
Fusible Link #10
Fusible Link (250A)

(Optional)
Battery Relay (1)

4
Battery Relay (2)

4
Battery Relay (3) 3

4
Battery
Sliding Fold-In 1
Ladder Motor
(Optional)
T18K-02-05-001
T5-7-18
Accessory Circuit
Fuse Box 1
Fuse #7
Fuse #6 Fuse Box
(Cab)
Fuse Box 1
Fuse #10
Air Horn Key Switch

Compressor Relay (L2) To Radio
Air Horn
Compressor Relay (L1)
Cigarette Lighter
Fusible Link 1
7
Power Source
Terminal (1)
6
8
Air Horn Air Horn
Compressor Relay (R2) Compressor Relay (R1)
9
Horn Relay
Horn Switch
Horn (R) (Optional) Horn (L)
Air Horn
Compressor (R) Air Horn
(Optional) Compressor (L1)
Battery
Horn Pressure
Horn Pressure Switch (L1)
Switch (R1) (Optional)
Horn Pressure
Horn Pressure Switch (L2)
Switch (R2) (Optional)
T18M-02-05-002
T5-7-19
Starting Circuit
From Key Switch
Engine Start Terminal M
Switch (L)
PRELUB Timer Relay

11 10
Charge SIG Relay
Starter Relay (Upper)

12
13
Engine Oil Reserve
Fuse Box 3 Pump Unit Relay
Starter Relay (Lower)
14 Fuse #59
15
Alternator Relay Engine Oil Reserve

Starter Relay 2 Pump Unit Switch
16 From
EHU
Fusible
Link 4 Fuse Box 2
Fuse #40
Alternator ECM Fuse Box 2

Battery Relay (1)
Fuse #26
Battery Relay (2)
Battery Relay (3)

17
Crank Speed
Sensor
Fuse Box
(Cab)
18
Starter (1)
(Upper) From Battery
Key Switch
Starter (2)
(Lower)
T18M-02-05-006
T5-7-20
Charging Circuit
T2-5-15, 17, 19, 21
Fusible Link
Terminal (Main)
Fusible Link 9
Terminal (Sub)
Circuit
Braker
(200A) 20
Battery Relay (1)
20
Battery Relay (2)
20
Battery Relay (3)
19
From Alternator
Terminal B
From Key Switch
Terminal M
Sliding Fold-In Ladder

Relay (2) (Optional)
Sliding Fold-In Ladder

ECM Relay (3) (Optional)
Battery
Sliding Fold-In
Ladder Motor
(Optional)
T18K-02-05-002
T5-7-21
Surge Voltage Prevention Circuit
Fuse Box (Cab)
Fuse #11
Fuse #1
Key Switch
Fuse Box 1
Fuse #2
Delayed Power OFF

Relay Fuse Box 2 Fuse #15
Fuse #26 Fuse #10
21 MC Fusible Link 1
Battery Relay (1)
22 Battery Relay (2)
22 Battery Relay (3)
22
Alternator (L)
Battery
T18M-02-05-016
T5-7-22
5-Voltage Circuit
Power Signal or
Voltage between terminal No.1 and the vehicle Two Polarities Source Ground
frame 1 2
Disconnect the connector with the key switch OFF.
Measure voltage between terminal No.1 on the
machine harness end connector and the vehicle
frame (ground).
Key switch: ON V
Tester black terminal (negative):
Connected to the vehicle frame (ground)
Tester red terminal (positive):
Connected to terminal No.1
T107-07-05-006
Power
Evaluation: Three Polarities
Source Signal Ground
If the measuring voltage is within 5 0.5 volts, the 1 2 3
circuit up to terminal No.1 is normal.
Voltage between terminal No.1 and the ground

terminal T107-07-05-007
Disconnect the sensor connector with the key switch

OFF. Two Polarities
1 2
Measure voltage between terminal No.1 on the
machine harness end connector and the ground
terminal (terminal No.2 for two polarities, or terminal
No.3 for three polarities).
V
Key switch: ON
Tester black terminal (negative):
Connected to the ground terminal
(terminal No.2 or No.3)
Tester red terminal (positive):
Connected to terminal No.1 T107-07-05-008
Evaluation: Three Polarities

If the measured voltage is within 5 0.5 volt, the 1 2 3
circuit up to terminal No.1 or the ground terminal
(terminal No.2 or No.3) is normal.
T107-07-05-009
T5-7-23
CHECK BY FALSE SIGNAL
Turn the key switch OFF. Disconnect the sensor

connector. Turn the key switch ON. Connect terminal Two Polarities 1 2
No.1 (power source) of machine harness end
connector to terminal No.2 (signal). (Power voltage is
used as a false signal.)
This makes it to create the same situation as the
extreme situation on the sensor input signal. If the
machine and/or gauge actuate with the maximum Connect
signal accordingly, the related harness is considered to
be normal. As for the pressure switch, the switch
indicates "ON" status.
T107-07-05-010
IMPORTANT: As for three-polarity connectors, do

not connect terminals No.1 and No.2
to No.3 or the vehicle frame
(ground). Three Polarities 1 2 3
Connect
T107-07-05-011
T5-7-24
CONTINUITY CHECK
Harness
Single-line continuity check A a
Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is: 0 Continuity
Discontinuity
NOTE: When the one end connector is far apart

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

T107-07-05-004
check twice, it is possible to find out which Short-circuit between harnesses.
line is discontinued. With terminals (A) and
(C) short-circuited, check continuity A a
between terminals (a) and (c). B b
If the ohm-meter reading is: C c
0 Line (B) - (b) has discontinuity.
Line (A) - (a) has discontinuity.
Multi-line short-circuit check

Disconnect both end connectors of the harness, and
check continuity between terminals (A) and (B) or
(C).
If the ohm-meter reading is:
T107-07-05-005
0 Short-circuit exists between the lines.
No short-circuit exists between the lines.
T5-7-25
CIRCUIT CHECK BY LAMP HARNESS
Check the current at the measurement point by using
a lamp harness.
#4283594 (ST 7126)

Use in order to check a single-line (discontinuity and/or
voltage).
During Operation: Lamp is ON.
NOTE: As for the PWM signal circuit, the lamp To Measurement Point
does not light if the ON signal duration ratio To Ground
#4283594(ST 7126) T107-07-05-012
is too small.
Connect an end of the lamp harness to the

measurement point, and connect the other end to the
ground.
Turn the circuit to be measured ON.
Check the circuit condition depending on whether the
test harness lamp lights or extinguishes during
operation.
T5-7-26
MEMO
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Many thanks for your purchase.
Happy every day.
QIWEN YE
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INTRODUCTION

Each page has a number, located on the center

Consecutive Page Number for Each Group

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

 When you see these symbols on your machine or

UNDERSTAND SIGNAL WORDS

 DANGER indicates an imminently hazardous

To avoid confusing machine protection with personal

NOTE indicates an additional explanation for an

 If a safety sign or this manual is damaged or

Keep your machine in proper working condition.

 Unauthorized modifications of the machine may

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

WEAR PROTECTIVE CLOTHING

You may need:

 Avoid wearing loose clothing, jewelry, or other

 Wear a suitable hearing protective device such as

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

 When you get on and off the machine, always

ADJUST THE OPERATOR'S SEAT

 The seat should be adjusted whenever changing

with a new one.

 Before leaving the machine, be sure to first lower

FASTEN YOUR SEAT BELT

 Prior to operating the machine, thoroughly ex-

every three years regardless of its apparent con-

 Take extra care not to run over bystanders. Con-

HANDLE STARTING AIDS SAFELY

Starting fluid is highly flammable.

 Keep all sparks and flame away when using it.

 Start the engine only when seated in the opera-

around the machine and sound the horn to alert

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

 Only the operator should be on the machine.

PRECAUTIONS FOR OPERATIONS

 Be sure to wear close fitting clothing and safety

ROPS: Roll-Over Protective Structure

PROVIDE SIGNALS FOR JOBS INVOLV-

CONFIRM DIRECTION OF MACHINE TO

 Before driving the machine, confirm the position

 Be sure to detour around any obstructions.

Driving on a slope may cause the machine to slip or

 Never attempt to ascend or descend 35 degrees

pushing the levers forward moves the machine

To avoid back-over and swing accidents:

OR OTHER SIGNAL TO WARN BYSTANDERS

 Keep all persons clear from the area of operation

NEVER POSITION BUCKET OVER ANY-

 If the footing starts to collapse and if retreat is not

 Prepare machine operating area flat.

 Temperature increases will cause the ground to

NEVER UNDERCUT A HIGH BANK

 Before digging check the location of cables, gas

OPERATE WITH CAUTION

 Take care to avoid hitting overhead obstacles with

 When operating near an electric line, NEVER

PRECAUTIONS FOR LIGHTENING

 In the event of an electrical storm, immediately

 When using the machine for craning operations,

 Never attach a sling or chain to the bucket teeth.

 Guard against injury from flying pieces of metal or

PARK MACHINE SAFELY

 Lock all access doors and compartments.

When you see these symbols on your machine or

DANGER indicates an imminently hazardous

If a safety sign or this manual is damaged or

Unauthorized modifications of the machine may

Keep a first aid kit and fire extinguisher on hand.

Avoid wearing loose clothing, jewelry, or other

Wear a suitable hearing protective device such as

In the walk-around inspection be sure to cover all

When you get on and off the machine, always

The seat should be adjusted whenever changing

Before leaving the machine, be sure to first lower

Prior to operating the machine, thoroughly ex-

Take extra care not to run over bystanders. Con-

Keep all sparks and flame away when using it.

Start the engine only when seated in the opera-

If the engine must be jump started, be sure to

Only the operator should be on the machine.

Be sure to wear close fitting clothing and safety

Before driving the machine, confirm the position

Be sure to detour around any obstructions.

Never attempt to ascend or descend 35 degrees

Keep all persons clear from the area of operation

If the footing starts to collapse and if retreat is not

Prepare machine operating area flat.

Temperature increases will cause the ground to

Before digging check the location of cables, gas

Take care to avoid hitting overhead obstacles with

When operating near an electric line, NEVER

In the event of an electrical storm, immediately

When using the machine for craning operations,

Never attach a sling or chain to the bucket teeth.

Guard against injury from flying pieces of metal or

Lock all access doors and compartments.

Do not refuel the machine while smoking or when

Store flammable fluids well away from fire haz- SA-018

Observe the related regulations and rules for safe

Before performing any work on the machine, at-

Always lower the attachment to the ground before

To prevent accidents, care should be taken to

Do not attempt to remove GREASE FITTING or

As pieces may fly off, be sure to keep body and

Securely store attachments and implements to

To avoid possible injury from hot spraying water.

Wait for the oil and components to cool before SA-225

Periodically replace the rubber hoses. (See the

Failure to periodically replace rubber hoses may

Avoid this hazard by relieving pressure before

Stop the engine by turning the key switch to the

If you must operate in a building, be sure there is

Be sure to perform welding in a well ventilated

Do not heat by welding, soldering, or using a torch

Avoid potentially toxic fumes and dust.

Remove paint before welding or heating:

Depending on the wok site conditions, the risk of

Asbestos might be present in imitation parts. Use

Keep sparks, lighted matches, and flame away

Be sure to wear eye protection when checking

Refer to the instructions described on the con-

A Material Safety Data Sheet (MSDS) provides

Use leakproof containers when draining fluids. Do

The machine is functioning properly, especially

Definition of Performance Standard