Technical Manual PDF

PART NO.
TACG90-EN-00
ZX20U-5B
HYDRAULIC EXCAVATOR
Technical Manual
TECHNICAL MANUAL
ZX20U-5B
Hydraulic Excavator
URL:http://www.hitachi-c-m.com
TACG90-EN-00
Service Manual consists of the following separate Part No.

Technical Manual : Vol. No.TACG90-EN
Workshop Manual : Vol. No.WACG90-EN
PRINTED IN JAPAN (K) 2015, 04 Engine Manual : Vol. No.EACG-EN
INTRODUCTION
To The Reader
This manual is written for an experienced technician to  If you have any questions or comments, at if you found
provide technical information needed to maintain and any errors regarding the contents of this manual,
repair this machine. please contact using “Service Manual Revision Request
The machine specification and description according to Form” at the end of this manual. (Note: Do not tear off
destination may be explained on this manual. the form. Copy it for usage.):
 Technical Information Center Hitachi Construction
 Be sure to thoroughly read this manual for correct Machinery Co., Ltd.
product information and service procedures.  TEL: 81-29-832-7084
 FAX: 81-29-831-1162
 E-mail: [email protected]
Additional References
Please refer to the other materials (operator’s manual,
parts catalog, engine technical material and Hitachi
training material etc.) in addition to this manual.
Manual Composition
This manual consists the Technical Manual, the Workshop  Information included in the Workshop Manual:
Manual and the Engine Manual. Technical information needed for maintenance and
repair of the machine, tools and devices needed for
 Information included in the Technical Manual: maintenance and repair, maintenance standards, and
Technical information needed for redelivery and delivery, removal / installation and assemble / disassemble
operation and activation of all devices and systems, procedures.
operational performance tests, and troubleshooting
procedures.  Information included in the Engine Manual:
Technical information needed for redelivery and delivery
and maintenance and repair of the machine, operation
and activation of all devices and systems, troubleshooting
and assemble / 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:
 Technical Manual: T 1-3-5  Workshop Manual: W 1-3-2-5
T Technical Manual W Workshop Manual
1 Section Number 1 Section Number
3 Group Number 3 Group Number
5 Consecutive Page Number for Each Group 2 Sub Group Number
5 Consecutive Page Number for Each Group
IN-01
INTRODUCTION
Safety Alert Symbol and Headline Notations
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the potential dCAUTION:
for personal injury of machine damage. Indicates potentially hazardous situation which could, if
not avoided, result in personal injury or death.
d This is the safety alert symbol. When you see this IMPORTANT:
symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention to
component/part weights.
To avoid injury and damage, be sure to use appropriate
fNOTE:
Indicates supplementary technical information or know-
lifting techniques and equipment when lifting heavy
how.
parts.
Units Used
SI Units (International System of Units) are used in this Example: 24.5 MPa (250 kgf/cm2, 3560 psi)
manual. MKSA system units and English units are also
indicated in parentheses just behind SI units. A table for conversion from SI units to other system units
is shown below for reference purposes.
Quantity To Convert From Into Multiply By

Length mm in 0.03937
mm ft 0.003281
Volume L US gal 0.2642
L US qt 1.057
m3 yd3 1.308
Weight kg lb 2.205
Force N kgf 0.10197
N lbf 0.2248
Torque N·m kgf·m 0.10197
Pressure MPa kgf/cm 2
10.197
MPa psi 145.0
Power kW PS 1.360
kW HP 1.341
Temperature °C °F °C×1.8+32
Velocity km/h mph 0.6214
min -1
rpm 1.0
Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0
fNOTE: The numerical value in this manual might be

different from the above-mentioned table.
IN-02
SYMBOL AND ABBREVIATION
Symbol / Name Explanation

Abbreviation
TO Technical manual (Operational principle) Technical manual (Operational Principle).
TT Technical manual (Troubleshooting) Technical manual (Troubleshooting).
T/M Technical manual Technical manual.
W, W/M Workshop manual Workshop manual (Removal and Installation, Disassembly
and Assembly).
OP, OPT Option Optional component.
Li Low (Slow) Idle Slow idle engine speed.
ATT Attachment Attachment. Attachment is optional parts such as breaker,
crusher, and pulverizer in this manual.
HI, Hi High Travel fast position.
LO, Lo Low Travel slow position.
SY-1
SYMBOL AND ABBREVIATION
(Blank)
SY-2
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 personal injury.
 Follow recommended precautions and safe operating
practices.
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 do not use any of the designated signal
words above after the safety alert symbol are occasionally
used on this machine.
 CAUTION also calls attention to safety message in this

manual.
SA-1223
 To avoid confusing machine protection with personal
safety messages, a signal word IMPORTANT indicates a
situation which, if not avoided, could result in damage to
the machine.
 fNOTE: indicates an additional explanation for an

element of information.
SA-1
SAFETY
Follow Safety Instructions

 Carefully read and follow all safety signs on the machine
and all safety messages in operator's manual.
 Safety signs should be installed, maintained and replaced
when necessary.
 If a safety sign or operator's manual is damaged or
missing, order a replacement from your authorized dealer
in the same way you order other replacement 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 machine life.
 Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, function,
and/or service life. In addition, 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 attachments 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 authorized dealer before operating or performing
maintenance work on the machine.
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 attached 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, ambulance
service, hospital, and fire department posted near your
telephone. SA-437
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 SA-438
Wet weather gear
Respirator or filter mask
Be sure to wear the correct equipment and clothing for the
job. Do not take any chances.
 Avoid wearing loose clothing, jewelry, or other items that
can catch on control levers or other parts of the machine.
 Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones while
operating the machine.
SA-3
SAFETY
Protect Against Noise

 Prolonged exposure to loud noise can cause impairment or
loss of hearing.
 Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortably loud noises.
SA-434
Inspect Machine
 Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
 In the walk-around inspection be sure to cover all points
described in the "Inspect Machine Daily Before Starting"
section in the operator’s manual.
SA-435
SA-4
SAFETY
General Precautions for Cab
 Before entering the cab, thoroughly remove all dirt and/or
oil such as mud, grease, soil or stones that may mess up
the cab 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 mess up around the operator’s seat with parts,
tools, soil, stones, obstacles that may fold up or turn
over, cans or lunch box. The levers or pedals become
inoperable if obstacle jams in operation stroke of the
travel levers/pedals, pilot control shut-off lever or control
levers, which may result in serious injury or death.
 Avoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.
 Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
 Keep all flammable objects and/or explosives away from
the machine.
 After using the ashtray, always cover it to extinguish the
match and/or tobacco.
 Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.
 Use proper floor mat dedicated to the machine. If another
floor mat is used, it may be displaced and contact with
the travel pedals during operation, resulting in serious
injury or death.
SA-5
SAFETY
Use Handrails and Steps

 Falling is one of the major causes of personal injury.
 When you get on and off the machine, always use the
crawler instead of the step for safety. Also get on and off
from the position of the crawler that can secure your feet
space enough.
 When you get on and off the machine, always face the
machine.
 Maintain a three-point contact with the steps and
handrails.
 Do not use any controls as handholds.
 Never jump on or off the machine. Never mount or
dismount a moving machine.
SA-439
 In case adhered slippery material such as oil, grease,
or mud is present on steps, handrails, or platforms,
thoroughly remove such material.
Adjust the Operator's Seat

 A poorly adjusted seat for either the operator or for the
work at hand may quickly fatigue the operator leading to
misoperations.
 The seat should be adjusted whenever changing the
operator for the machine.
 The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
 If not, move the seat forward or backward, and check
again.
 Adjust the rear view mirror position so that the best rear SA-378
visibility is obtained from the operator’s seat. If the mirror
is broken, immediately replace it with a new one.
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 machine to unexpectedly move
when a body part unintentionally 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 position. 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. Additionally the
operator may be crushed by the overturning machine,
resulting in serious injury or death.
 Prior to operating the machine, thoroughly examine
webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine.
 Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation to SA-237
minimize the chance of injury from an accident.
 We recommend that the seat belt be replaced every three
years regardless of its apparent condition.
SA-7
SAFETY
Move and Operate Machine Safely

 Bystanders can be run over.
 Take extra care not to run over bystanders. Confirm the
location of bystanders before moving, swinging, or
 Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
 Use a signal person when moving, swinging, or operating
the machine in congested areas. Coordinate hand signals
before starting the machine.
 Use appropriate illumination. Check that all lights are
SA-1291
operable before operating the machine. If any faulty
illumination is present, immediately repair it.
 Ensure the cab door, windows, doors and covers are
securely locked.
 Check the mirrors for problems.
If there is, replace the problem part(s) or clean the mirror.
Operate Only from Operator's Seat

 Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury or
death.
 Start the engine only when seated in the operator's seat.
 NEVER start the engine while standing on the track or on
ground.
 Do not start engine by shorting across starter terminals.
 Before starting the engine, confirm that all control levers
are in neutral.
 Before starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders.
SA-444
SA-8
SAFETY
Jump Starting
 Battery gas can explode, resulting in serious injury.
 If the engine must be jump started, be sure to follow
the instructions shown in the “OPERATING THE ENGINE”
chapter in the operator’s manual.
 The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
 Never use a frozen battery.
 Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
SA-032
Keep Riders off Machine

 Riders on machine are subject to injury such as being struck
by foreign objects and being thrown off the machine.
 Only the operator should be on the machine. Keep riders
off.
 Riders also obstruct the operator’s view, resulting in the
machine being operated in an unsafe manner.
SA-1292
SA-9
SAFETY
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 operation and
machine movement. Do not permit persons other than
the operator to enter areas where there is danger such as
flying objects. Always beware of the surroundings while
operating. 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.
M586-12-012
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 conditions 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,
employ a signal person as required.
 Confirm that your machine is equipped with a FOPS cab
before working in areas where the possibility of falling SA-1293
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 becomes loose and
slippery.
 Beware the possibility of fire when operating the machine
near flammable objects such as dry grass.
SA-11
SAFETY
 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 positioned
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 machine on
it, possibly causing the machine to tip over. When working
on soft ground is required, be sure to reinforce the ground
first using large pieces of steel plates strong and firm
M586-05-021
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.
Install OPG Guard

In case the machine is operated in areas where the possibilities
of falling stones or debris exist, equip Hitachi OPG guard.
Consult your authorized dealer for installing the OPG guard.
The guard can be compliant with ROPS standards depending
on the machine specifications.
In order not to impair operator protective structure:
Replace damaged ROPS or OPG guard. Never attempt to repair
or modify the guard.
ROPS: Roll Over Protective Structure

OPG: Operator Protective Guard
SA-490
SA-12
SAFETY
Restriction of Attachment Installation

 Do not install an attachment which exceeds specified
weight for the machine structure.
Provide Signals for Jobs Involving Multiple

Machines
 For jobs involving multiple 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.
SA-481
Confirm Direction of Machine to Be Driven

 Incorrect travel pedal/lever operation may result in serious
injury or 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.
SA-1294
SA-13
SAFETY
Drive Machine Safely

 Before driving the machine, always confirm that the travel
levers/pedals direction corresponds to the direction you
wish to drive.
 Be sure to detour around any obstructions.
 Avoid traveling over obstructions. Soil, fragments of rocks, A
and/or metal pieces may scatter around the machine. Do
not allow personnel to stay around the machine while
traveling.
SA-1295
 Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or death.
 Never attempt to ascend or descend 25 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 200 to 300 mm (8 to
12 in) (A) above the ground.
 If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and stop.
 Driving across the face of a slope or steering on a
slope may cause the machine to skid or turnover. If
A
the direction must be changed, move the machine to SA-1296
level ground, then, change the direction to ensure safe
operation.
 Avoid swinging the upperstructure on slopes. Never
attempt to swing the upperstructure downhill. The
machine may tip over. If swinging uphill is unavoidable,
carefully operate the upperstructure and boom at slow
speed.
 If the engine stalls on a slope, immediately lower the
bucket to the ground. Return the control levers to neutral.
Then, restart the engine.
SA-441
SA-589
SA-14
SAFETY
 When the machine descends a slope at high speed,
machine weight accelerates descending speed. It may
cause collision accident due to misjudging of braking
distance or machine turnover due to running on an
unexpected obstacle.
Before descending a slope, always ensure that engine
control lever (1) is in the slow idle position, and then
reduce the engine speed. Turn the travel mode switch (2)
to slow speed for ZX26U-5A.
 Be sure to thoroughly warm up the machine before
ascending steep slopes. If hydraulic oil has not warmed
up sufficiently, sufficient performance may not be
obtained. MABA-04-003
1 2
 Use a signal person when moving, swinging or operating
the machine in congested areas. Coordinate hand signals
before starting the machine.
 Before moving machine, determine which way to move
travel pedals/levers for the direction you want to go.
When the travel motors are in the rear, pushing down
on the front of the travel pedals or 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 Travel Motor
and road shoulders, and reinforce if necessary. M104-05-008
 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
SA-673
possible damage to the machine.
 Avoid operations that may damage the track and
undercarriage components.
 During freezing weather, always clean snow and ice from
track shoes before loading and unloading machine, to
prevent the machine from slipping.
M586-05-002
SA-15
SAFETY
Avoid Injury from Rollaway Accidents

 Death or serious injury may result if you attempt to mount
or stop a moving machine.
To avoid rollaways:
 Select level ground when possible to park the machine.
 Do not park the machine on a grade.
 Lower the bucket and/or other work tools to the ground.
 Run the engine at slow idle speed without load for 5
minutes to cool down the engine.
 Stop the engine and remove the key from the key switch.
 Pull the pilot control shut-off lever to LOCK position.
 Block both tracks and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must park
on a grade.
 Position the machine to prevent rolling.
 Park at a reasonable distance from other machines.
SA-1297
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 MOVING INTO THE
WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
 USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW
IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN
VIEW. SA-383
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 markings used
on the job and confirm who has the responsibility for
signaling.
 Keep windows, mirrors, and lights clean and in good
condition.
 Dust, heavy rain, fog, etc., can reduce visibility. As visibility
decreases, reduce speed and use proper lighting.
 Read and understand all operating instructions in the SA-384
operator’s manual.
SA-17
SAFETY
Keep Person Clear from Working Area

 A person around the operating machine may be hit severely
by the swinging front attachment or counterweight, be
caught in other objects, and/or be struck by flying objects,
 Set up barriers and/or put a NO ADMISSION sign at the
machine operating site and areas exposed by flying
objects to prevent anyone from entering the work area.
 Check that all personnel or obstacles other than the
signal person are not present in the working area before
SA-667
Never Position Bucket Over Anyone

 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.
SA-668
SA-18
SAFETY
Avoid Undercutting
 In order to retreat from the edge of an excavation if the
footing should collapse, always position the undercarriage
perpendicular to the edge of the excavation 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.
SA-1300
Avoid Tipping
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE
--- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP
FREE
FASTEN YOUR SEAT BELT
 The danger of tipping is always present when operating on
a grade, possibly resulting in serious injury or death.
To avoid tipping:
 Be extra careful before operating on a grade.
 Prepare machine operating area flat.
 Keep the bucket low to the ground and close to the
machine.
 Reduce operating speeds to avoid tipping or slipping.
SA-1301
 Avoid changing direction when traveling on grades.
 NEVER attempt to travel across a grade steeper than 15
degrees if crossing the grade is unavoidable.
 Reduce swing speed as necessary when swinging loads.
 Be careful when working on frozen ground.

 Temperature increases will cause the ground to become
soft and make ground travel unstable.
SA-19
SAFETY
Never Undercut a High Bank

 The edges could collapse or a land slide could occur causing
SA-1302
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 severed, do
not look into the end. Doing so may result in serious eye
injury.
 Contact your local “diggers hot line” if available in your
area , and/or the utility companies directly.
Have them mark all underground utilities. SA-672
Operate with Caution

 If the front attachment or any other part of the machine 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-673
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 (10 ft) plus
twice the line insulator length.
 Check and comply with any local regulations that may
apply.
 Wet ground will expand the area that could cause any
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site. SA-1305
Precautions for Lightning

 Lightning may strike the machine.
If lightning comes close, immediately stop the operation,

and take the following action.
 When you are around the machine or operating cab-
less machine, evacuate to a safe place far away from the
machine.
 When you are in the cab, stay in the cab until lightning
has passed and safety is secured. Close the cab doors and
windows. Lower the bucket to the ground, and stop the
engine. Put your hands on your lap to avoid contact with
any metal surfaces. Never go out of the cab.
If lightning strikes the machine or near the machine,

check all of the machine safety devices for any failure after
lightning has passed and safety is secured. If any trouble is SA-1805
found, operate the machine only after repairing it.
SA-21
SAFETY
Object Handling
 If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed underneath it,
 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.
 Never attach a sling or chain to the bucket teeth. They
may come off, causing the load to fall.
SA-014
Protect Against Flying Debris

 If flying debris hit eyes or any other part of the body, serious
injury may result.
 Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
 Keep bystanders away from the working area before
striking any object.
SA-432
SA-22
SAFETY
Park Machine Safely

To avoid accidents:
 Park machine on a firm, level surface.
 Lower bucket to the ground.
 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.
 Lock all access doors and compartments.
SA-1306
Handle Fluids Safely−Avoid Fires

 Handle fuel with care; it is highly flammable. If fuel ignites,
an explosion and/or a fire may occur, possibly resulting in
 Do not refuel the machine while smoking or when near
open flame or sparks.
 Always stop the engine before refueling the machine.
 Fill the fuel tank outdoors.
 All fuels, most lubricants, and some coolants are flammable.

 Store flammable fluids well away from fire hazards.
 Do not incinerate or puncture pressurized containers. SA-018
 Do not store oily rags; they can ignite and burn
spontaneously.
 Securely tighten the fuel and oil filler cap.
SA-019
SA-23
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 machine to
be transported. SA-1307
 Be sure to use a signal person.
 Always follow the following precautions for loading or
unloading:
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to support the
machine weight.
3. Select the slow travel mode for loading or unloading the
machine.
Before descending a slope, always ensure that engine
control lever (1) is in the slow idle position, and then
reduce the engine speed. Turn the travel mode switch (2)
to slow speed for ZX26U-5A.
4. Never load or unload the machine onto or off a truck
or trailer using the front attachment functions when
driving up or down the ramp.
5. Never steer the machine while on the ramp. If the
traveling direction must be changed while the ramp,
unload the machine from the ramp, reposition the MABA-04-003
1 2
machine on the ground, then try loading again.
6. The top end of the ramp where it meets the flatbed is a
sudden bump. Take care when traveling over it.
7. Place blocks in front of and behind the tires. 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.
SA-24
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. Run the engine at slow idle speed without load for 5
minutes.
4. Turn the key switch to OFF to stop engine.
5. Relieve the pressure in the hydraulic system by moving
the control levers several times.
6. Remove the key from the key switch. SA-028
7. Attach a “Do Not Operate” tag on the control lever.

8. Pull the pilot control shut-off lever to the LOCK position.
9. Allow the engine to cool.
 If a maintenance procedure must be performed with the

engine running, do not leave the machine unattended.
 If the machine must be raised, maintain a 90 to 110˚ 90 to 110°
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 replace as
necessary. Refer to the section discussing that part in the
“MAINTENANCE” chapter of operator's manual. M1M7-04-006
 Keep all parts in good condition and properly installed.
 Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
 When cleaning parts, always use nonflammable
detergent oil. Never use highly flammable oil such as fuel
oil and gasoline to clean parts or surfaces.
 Disconnect battery ground cable (−) before making
adjustments to electrical systems or before performing
welding on the machine.
SA-527
SA-25
SAFETY
 Sufficiently illuminate the work site. Use a maintenance
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, antifreeze fluid, or
window washer fluid may catch fire.
SA-037
Warn Others of Service Work

 Unexpected machine movement can cause serious injury.
 Before performing any work on the machine, attach a “Do
Not Operate” tag on the control lever.
This tag is available from your authorized dealer.
SS2045102
SA-26
SAFETY
Support Machine Properly

 Never attempt to work on the machine without securing
the machine first.
 Always lower the attachment to the ground before you
work on the machine.
 If you must work on a lifted machine or attachment,
securely support the machine or attachment. Do not
support the machine on cinder blocks, hollow tires, or
props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
SA-527
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.
SA-026
SA-2294
SA-27
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, then gradually
loosen AIR RELEASE PLUG to release pressure.
Avoid Injury from Attachment Falling Accident

 Stored attachments such as buckets, hydraulic hammers,
and blades can fall and cause serious injury or death.
 To avoid possible personal injury from attachment falling
accident, use a platform when replacing an attachment.
 Securely store attachments and implements to prevent
falling.
 Keep children and bystanders away from storage areas.
SA-034
SA-28
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 removing the cap.
 The hydraulic oil tank is pressurized. Again, be sure to
release all pressure before removing the cap. SA-039
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 starting
any maintenance or inspection work.
SA-225
SA-29
SAFETY
Replace Rubber Hoses Periodically

 Rubber hoses that contain flammable fluids under pressure
may break due to aging, fatigue, and abrasion. It is very
difficult to gauge the extent of deterioration due to aging,
fatigue, and abrasion of rubber hoses by inspection alone.
 Periodically replace the rubber hoses. (See the page of
“Periodic replacement of parts” in the operator’s manual.)
 Failure to periodically replace rubber hoses may cause a fire,

fluid injection into skin, or the front attachment to fall on a
SA-019
person nearby, which may result in severe burns, gangrene,
or otherwise serious injury or death.
Avoid High-Pressure Fluids

 Fluids such as diesel fuel or hydraulic oil under pressure can
penetrate the skin or eyes causing serious injury, blindness
or death.
 Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
 Tighten all connections before applying pressure.
 Search for leaks with a piece of cardboard; take care to
protect hands and body from high-pressure fluids. Wear a
face shield or goggles for eye protection.
 If an accident occurs, see a doctor familiar with this
type of injury immediately. Any fluid injected into the SA-031
skin must be surgically removed within a few hours or
gangrene may result.
SA-292
SA-044
SA-30
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.
 Replace fuel hoses and hydraulic hoses periodically even
if there is no abnormality in their external appearance.
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.
 Never attempt to modify electric wirings.
SA-31
SAFETY
Clean up Flammable Materials:
 Spilled fuel and oil, and trash, grease, debris, accumulated
coal dust, and other flammable materials may cause fires.
 Prevent fires by inspecting and cleaning the machine
daily, and by removing adhered oil or accumulated
flammable materials immediately. Check and clean
high temperature parts such as the exhaust outlet and
mufflers earlier than the normal interval.
 Do not wrap high temperature parts such as a muffler or
exhaust pipe with oil absorbents.
 Do not store oily cloths as they are vulnerable to catching
fire.
 Keep flammable materials away from open flames.
 Do not ignite or crush a pressurized or sealed container.
 Wire screens may be provided on openings on the engine
compartment covers to prevent flammable materials
such as dead leaves from entering. However, flammable
materials which have passed through the wire screen
may cause fires. Check and clean the machine every
day and immediately remove accumulated flammable
materials.
Check Key Switch:

 If a fire breaks out, failure to stop the engine will escalate
the fire, hampering fire fighting.
Always check key switch function before operating the
machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key switch to the OFF position to confirm that
the engine stops.
 If any abnormalities are found, be sure to repair them
before operating the machine.
Check Heat Shields:

 Damaged or missing heat shields may lead to fires.
 Damaged or missing heat shields must be repaired or

replaced before operating the machine.
 If hydraulic hoses are broken while the engine cover is
open, splattered oil on the high temperature parts such
as mufflers may cause fire. Always close the engine cover
while operating the machine.
SA-32
SAFETY
Evacuating in Case of Fire

 If a fire breaks out, evacuate the machine in the following
way:
 Stop the engine by turning the key switch to the OFF
position if there is time.
 Use a fire extinguisher if there is time.
 Exit the machine.
 In an emergency, if the cab door or front window can not
be opened, break the front or rear window panes with
the emergency evacuation hammer to escape from the
cab. Refer to the explanation pages on the Emergency SA-393
Evacuation Method in the operator's manual.
SS4642980
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.
SA-016
SA-33
SAFETY
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 surrounding the welded
area still smoldering. SA-818
SA-34
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. Install temporary
fire-resistant guards to protect hoses or other materials
before engaging in welding, soldering, etc..
SA-030
Avoid Applying Heat to Lines Containing
Flammable Fluids
 Do not weld or flame cut pipes or tubes that contain
flammable fluids.
 Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.
Precautions for Handling Accumulator (ZX26U-

5A)
High-pressure nitrogen gas is sealed in the accumulator and
the gas damper. Inappropriate handling may cause explosion,
possibly resulting in serious injury or death.
Strictly comply with the following items:
 Do not disassemble the unit.

 Keep the units away from open flames and fire.
 Do not attempt to bore a hole or cut by torch.
 Avoid giving shocks by hitting or rolling the unit.
 Before disposing the unit, sealed gas must be released.
Consult your nearest Hitachi dealer.
SA-35
SAFETY
Remove Paint Before Welding or Heating

 Hazardous fumes can be generated when paint is heated by
welding, soldering, or using a torch. If inhaled, these fumes
may cause sickness.
 Avoid potentially toxic fumes and dust.
 Do all such work outside or in a well-ventilated area.
Dispose of paint and solvent properly.
 Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper with SA-029
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.
Beware of Asbestos and Silicon Dust and Other

Contamination
 Take care not to inhale dust produced in the work site.
Inhalation of asbestos fibers may be the cause of lung
cancer. Inhalation of silicon dust or other contamination
may cause sickness.
 Depending on the work site conditions, the risk
of inhaling asbestos fiber, silicon dust or other
contamination may exist. Spray water to prevent asbestos
fibers, silicon dust or other contamination from becoming
airborne. Do not use compressed air.
 When operating the machine in a work site where
asbestos fibers, silicon dust or other contamination SA-029
might be present, be sure to operate the machine
from the upwind side and wear a mask rated to
prevent the inhalation of asbestos, silicon dust or other
contamination.
 Keep bystanders out of the work site during operation.
 Asbestos fibers might be present in imitation parts. Use
only genuine Hitachi Parts.
SA-36
SAFETY
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 hydrometer.
 Do not charge a frozen battery; it may explode. Warm the
battery to 16 ˚C ( 60 ˚F ) first.
 Do not continue to use or charge the battery when
electrolyte level is lower than specified. Explosion of the
battery may result.
 Loose terminals may produce sparks. Securely tighten all
terminals. SA-032
 Connect terminals to the correct electrical poles. Failure
to do so may cause damage to the electrical parts or fire.
 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.
SA-37
SAFETY
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 Safety Data Sheet (SDS) provides specific details on
chemical products: physical and health hazards, safety
procedures, and emergency response techniques.
 Check the SDS before you start any job using a hazardous
chemical. That way you will know exactly what the risks
are and how to do the job safely. Then follow procedures
and use recommended equipment.
 See your authorized dealer for SDS’s (available only in SA-2579
English) on chemical products used with your machine.
Dispose of Waste Properly

 Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with HITACHI equipment includes such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
 Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
 Do not pour waste onto the ground, down a drain, or into
any water source.
 Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to SA-226
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.
SA-38
SAFETY
Never Ride Attachment

Never allow anyone to ride attachments or load. This is an
extremely dangerous practice.
Precautions for Communication Terminal

Electrical wave transmitted from the communication terminal
may cause malfunction of other electronic devices.
Inquire the device manufacturer for electrical wave
disturbance upon using an electronic device near the
communication terminal.
SA-39
SAFETY
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.
SA-435
SA-40
SECTION AND GROUP SECTION 1 GENERAL
CONTENTS Group 1 Specification
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Hydraulic System
TECHNICAL MANUAL Group 2 Electrical System
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Group 2 Swing Device
Group 3 Control Valve
Group 4 Pilot Valve
Group 5 Travel Device
Group 6 Others (Upperstructure)
Group 7 Others (Undercarriage)
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Machine Performance Test
Group 5 Component Test
Group 6 Adjustment
All information, illustrations and
specifications in this manual are based on SECTION 5 TROUBLESHOOTING
the latest product information available
at the time of publication. The right is
Group 1 Diagnosing Procedure
reserved to make changes at any time Group 2 Troubleshooting B
without notice.
Group 3 Troubleshooting C
COPYRIGHT(C)2015
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
WORKSHOP MANUAL
SECTION 1 GENERAL INFORMATION
Group 1 Precautions for Disassembling and Assembling
Group 2 Tightening Torque
Group 3 Painting
Group 4 Bleeding Air from Hydraulic Oil Tank
Group 5 Hydraulic Circuit Pressure Release Procedure
Group 6 Preparation
SECTION 2 MAINTENANCE STANDARD
Group 1 Upperstructure
Group 2 Undercarriage
Group 3 Front Attachment
SECTION 3 UPPERSTRUCTURE
Group 1 Canopy
Group 2 Counterweight
Group 3 Main Frame
Group 4 Pump Device
Group 7 Pilot Valve
Group 8 Solenoid Valve
SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track
Group 8 Blade Cylinder
SECTION 5 ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
SECTION 1
GENERAL
CONTENTS
Group 1 Specifications
Specifications........................................................................ T1-1-1
Working Ranges................................................................... T1-1-2
Main Component................................................................. T1-2-1
Electrical System (Overview)........................................... T1-2-2
Electrical System (Relays).................................................. T1-2-3
Electrical System (Monitor, Switches)........................... T1-2-4
Engine...................................................................................... T1-2-5
Swing Device......................................................................... T1-2-6
Control Valve......................................................................... T1-2-6
Travel Device......................................................................... T1-2-6
2-Spool Solenoid Valve...................................................... T1-2-7
Engine...................................................................................... T1-3-1
Engine Accessories.............................................................. T1-3-5
Hydraulic Component........................................................ T1-3-6
Electrical Component.......................................................T1-3-10
ACG90T-1-1
(Blank)
ACG90T-1-2
SECTION 1 GENERAL
Specifications
ZX20U-5B
A C
E
D
J I
H G MABA-12-004
Model ZX20U-5B
Specification 4-Pillars Canopy
Type of Front-End Attachment - Boom Swing Type
Bucket Capacity (Heaped) m3 (yd3) 0.070 (0.09)
Operating Weight kg (lb) 2230 (4920)
Base Machine Weight kg (lb) 1720 (3790)
3TNV80
Engine kW/min-1 12.8/2400
(PS/rpm) (17.4/2400)
A: Overall Width mm (ft·in) 1390 (4' 7'')
B: Overall Height mm (ft·in) 2390 (7' 10'')
C: Rear End Swing Radius mm (ft·in) 740 (2' 5")
D: Minimum Ground Clearance mm (ft·in) 290 (11'')
E: Counterweight Clearance mm (ft·in) 490 (1' 7'')
F: Engine Cover Height mm (ft·in) 1440 (4' 9'')
G: Undercarriage Length mm (ft·in) 1910 (6' 3'')
H: Undercarriage Width mm (ft·in) 1450 (4' 9")
I: Sprocket Center to Idler Center mm (ft·in) 1500 (4' 11")
J: Track Shoe Width mm (ft·in) 250 (10'')
Ground Pressure kPa (kgf/cm2, psi) 24.2 (0.25, 3.5)
Swing Speed min-1 (rpm) 9.2 (9.2)
Travel Speed (fast/slow) km/h (mph) 4.4/2.6 (2.7/1.6)
Gradeability 25° (tan θ = 0.47)
fNOTE:
 The dimensions do not include the height of the shoe lug. The dimensions of the machine equipped with rubber crawlers
are shown.
 The specifications include additional counterweight and extra attachment lines.
T1-1-1
SECTION 1 GENERAL
Working Ranges
ZX20U-5B
K (Left) K (Right)
G H
D
E
F
J
A
B
MABA-12-008
Category ZX20U-5B
Item 4-Pillars Canopy
A: Maximum Digging Reach mm (ft·in) 4190 (13' 9")
B: Maximum Digging Depth mm (ft·in) 2330 (7' 8")
C: Maximum Cutting Height mm (ft·in) 4080 (13' 5")
D: Maximum Dumping Height mm (ft·in) 2800 (9' 2")
E: Overall Height mm (ft·in) 2390 (7' 10")
F: Overall Length mm (ft·in) 2940 (9' 8")
G: Minimum Swing Radius mm (ft·in) 1760 (5' 9")
H: Boom Swing Pivot Offset Distance mm (ft·in) 85 (3")
I: Blade Bottom Highest Position mm (ft·in) 320 (1' 1")
J: Blade Bottom Lowest Position mm (ft·in) 310 (1')
K: Offset Distance mm (ft·in) L565 (1' 10") R690 (2' 3")
fNOTE:
 The dimensions do not include the height of the shoe lug. The dimensions of the machine equipped with rubber crawlers
are shown.
 L: Left R: Right
T1-1-2
SECTION 1 GENERAL
Main Component
2 3 4 5 6 7
30
1 9
10
11
31
12
13
29
14
28
15
27
16
26 18
25 19
20
21
24 22
23 TACD90-01-02-001
1- Bucket Cylinder 9- Front Attachment/Swing 16- Travel Device 25- Travel Pilot Valve
2- Arm Cylinder Pilot Valve 18- Control Valve 26- Boom Swing Cylinder
3- Fuel Tank 10- Air Cleaner 19- 2-Spool Solenoid Valve 27- Boom Swing Pilot Valve
4- Hydraulic Oil Tank 11- Water Separator Filter 20- Track Adjuster 28- Boom Cylinder
5- Swing Device 12- Engine 21- Lower Roller 29- Work Light
6- Blade Pilot Valve 13- Pump Device 22- Front Idler 30- Engine Control Lever
7- Swing Bearing 14- Center Joint 23- Auxiliary Pilot Valve 31- Fuel Filter
8- Radiator/Oil Cooler 15- Pilot Filter 24- Blade Cylinder
T1-2-1
SECTION 1 GENERAL
Electrical System (Overview)
1
3
11 5
6
10
9
8
7
TACC50-01-02-002
1- Electrical System (Monitor, 3- Pilot Shut-Off Switch 5- 2-Spool Solenoid Valve 9- Slow Blow Fuse
Switches) (Refer to T1-2-4.) 4- Components Related with 6- Horn 10- Glow Plug Relay
2- Electrical System (Relays) Control Valve (Refer to T1- 7- Fuel Sensor 11- Components Related with
(Refer to T1-2-3.) 2-6.) 8- Battery Engine (Refer to T1-2-5.)
T1-2-2
SECTION 1 GENERAL
Electrical System (Relays)
TABA50-01-02-003
6 7 8 9 1 2
TACC50-01-02-003
5 4 3
1- Starter Relay 2 4- Horn Relay 7- Light Relay

2- Power Relay 5- Pilot Shut-Off Relay 8- Starter Relay 1
3- Fuse Box 6- One-Second Timer 9- Travel Mode Selector Relay
T1-2-3
SECTION 1 GENERAL
Electrical System (Monitor, Switches)
12 1 2
MABA-01-003
3 13
TABA50-01-02-007
4 5 6 7 8
11 10 9
M1NC-01-005
1- Horn Switch 4- Coolant Temperature 7- Alternator Indicator 11- Overheat Indicator

2- Key Switch Indicator 8- Fuel Level Indicator 12- Travel Mode Pedal
3- Work Light Switch 5- Engine Oil Pressure Indicator 9- Preheat Indicator 13- Travel Alarm Deactivation
6- Fuel Gauge 10- Hour Meter Switch
T1-2-4
SECTION 1 GENERAL
Engine
1 2
7
3
4
5
6 TACC50-01-02-005 9 8 TACC50-01-02-006
1- Glow Plug 4- Governor Lever 7- Coolant Temperature Sensor

2- Overheat Switch 5- Engine Stop Solenoid 8- Starter
3- Fuel Pump 6- Engine Oil Pressure Switch 9- Alternator
T1-2-5
SECTION 1 GENERAL
Swing Device Travel Device
1 3 4
T1MW-01-02-008
TACC50-01-02-007
Control Valve
5 6 7 8 9
14 13 12 11 10 TACD90-01-02-002
a- Machine Front Side
1- Relief Valve 6- Overload Relief Valve (Boom 9- Main Relief Valve (Main Pump 12- Main Relief Valve (Main Pump
2- Make-Up Valve Lower) P3) P1)
3- Travel Mode Selector Valve 7- Main Relief Valve (Main Pump 10- Make-Up Valve (Boom Swing 13- Overload Relief Valve (Boom
4- Counterbalance Valve P2) (Left)) Raise)
5- Overload Relief Valve (Bucket 8- Overload Relief Valve (Arm 11- Overload Relief Valve (Arm 14- Make-Up Valve (Bucket
Roll-In) Roll-In) Roll-Out) Roll-Out)
T1-2-6
SECTION 1 GENERAL
2-Spool Solenoid Valve
1 2 3
TABA50-01-02-012
a- Machine Front Side
1- Pilot Relief Valve 3- Travel Mode Control Solenoid

2- Pilot Shut-Off Solenoid Valve Valve
T1-2-7
SECTION 1 GENERAL
(Blank)
T1-2-8
SECTION 1 GENERAL
Engine
Model 3TNV80
Type Diesel, 4-Cycle, Water-cooled, Vertical, Swirl Chamber Type
Cyl. No.- Bore × Stroke 3-80 mm × 84 mm (3.15 in × 3.31 in)
Piston Displacement 1266 cm3 (77.2 in3)
Rated Output 12.8 kW/2200 min-1 (17.4 PS/2200 rpm)
Compression Ratio 23.1
Dry Weight 120+50 kg (265+120 lb)
Firing Order 1-3-2-1
Rotation Direction Clockwise (Viewed from fan side)
T1-3-1
SECTION 1 GENERAL
COOLING SYSTEM Cooling Fan Dia. 335 mm (13.2 in), 7 Blades, Draw-In Type
Fan Pulley Ratio Belt Driven Rotation Ratio : 1.100
Thermostat Cracking Temperature at Atmospheric Pressure: 71 °C (160 °F)
Full Open : 85 °C (185 °F)
Water Pump Centrifugal Belt Driven Type
LUBRICATION SYSTEM Lubrication Method Pressure Lubrication Type
Lubrication Pump Type Trochoid Pump Type
Oil Filter Paper Element Type
STARTING SYSTEM Motor Magnetic Pinion Shift Reduction Type
Voltage/Output 12 V/1.4 kW
PREHEAT SYSTEM Preheating Method Glow Plug
ENGINE STOP SYSTEM Stop Method Fuel Shut-Off Electronic Solenoid Type
ALTERNATOR Type Alternating Current Type (with Built-In IC Regulator)
Voltage/Output 12 V/40 A
FUEL SYSTEM Type Row Type YPES-ML
Governor Centrifugal Type All Speed Control
Oil Filter Paper Element Type
Injection Nozzle Throttle Valve
T1-3-2
SECTION 1 GENERAL
IMPORTANT: This list shows design specifications, which are not servicing standards.
PERFORMANCE Fuel Consumption Ratio 286 g/kW·h (210 g/PS·h) or less (at Rated Point as New)
Maximum Output Torque 63.7±2.1 N·m (6.37±0.21 kgf·m 47±1.5 lbf·ft) at 1600±100
min-1
Compression Pressure 3.43 MPa (35 kgf/cm2, 495 psi) at 250 min-1
Valve Clearance (Inlet / 0.2/0.2 mm (when cool)
Exhaust)
No Load Speed Slow: 1400±25 min-1
Fast: 2380±25 min-1
T1-3-3
SECTION 1 GENERAL
Engine Performance Curve (3TNV80)

Test Condition:
1. In conformity with JIS D0006 (Performance Test
Method for Diesel Engine Used for Construction
Machinery) under standard atmospheric pressure.
2. Equipped with the fan and alternator (no load).
N·m
125 22
100
75
a
50
kW
25 35
0 30
g/kW·h
360 25
340 20
320 15
b
300 10
280 5
c
260 0
240
1200 1400 1600 1800 2000 2200 2400
min-1 (rpm)
TACD90-01-03-002
kW: Output g/kW·h: Fuel Consumption Ratio

N·m: Torque min-1 (rpm): Engine Speed
a- Torque b- Output c- Fuel Consumption Ratio
T1-3-4
SECTION 1 GENERAL
Engine Accessories
Radiator Oil Cooler

Air-Tight Test Pressure 177 kPa (1.8 kgf/cm , 26 psi)
2
981 kPa (10 kgf/cm 2, 140 psi)
Cap Opening Pressure 88.3±14.7 kPa (0.9±0.15 kgf/cm , 13±2.1 psi) −
2
BATTERY Type 55B24R-MF

Voltage 12 V
Capacity 36 Ah or more (5-Hour Rate), 38 Ah or more (20-Hour Rate)
BATTERY (Optional) Type 65B24R-MF
Voltage 12 V
Capacity 36 Ah or more (5-Hour Rate), 38 Ah or more (20-Hour Rate)
T1-3-5
SECTION 1 GENERAL
Hydraulic Component
MAIN PUMP 1, MAIN Type Swash Plate Type Variable Displacement Axial Plunger Pump
PUMP 2 Theoretical Displacement 12.0 cm3/rev (0.7 in3/rev)×2
MAIN PUMP 3 Type Gear Pump
Theoretical Displacement 6.5 cm3/rev (0.4 in3/rev)
PILOT PUMP Type Gear Pump
CONTROL VALVE Type Pilot Pressure Operated Type (10-Spool)
Main Relief Set-Pressure (P1,
20.6+10 MPa (210+100 kgf/cm2, 2990+1450 psi) at 25 L/min
P2)
Main Relief Set-Pressure (P3) 20.6+10 MPa (210+100 kgf/cm2, 2990+1450 psi) at 18 L/min
Overload Relief Set-Pressure
(Boom)
Overload Relief Set-Pressure
(Arm and Bucket)
T1-3-6
SECTION 1 GENERAL
SWING DEVICE Type One-Stage Reduction Planetary Gear

Reduction Gear Ratio 10.0
SWING MOTOR Type Swash Plate Type Fixed Displacement Axial Plunger Motor
VALVE UNIT Type Non Counterbalance Valve Type
Relief Set-Pressure 17.2±0.5 MPa (175±5 kgf/cm2, 2490±73 psi) at 15 L/min
SWING PARKING BRAKE Type Spring Set Hydraulic Released Wet-Type Single-Disk Brake
Release Pressure 2.5 MPa (25 kgf/cm2, 365 psi)
TRAVEL DEVICE Type Two-Stage Reduction Planetary Gear
Reduction Gear Ratio 39.0
TRAVEL MOTOR Type Swash Plate Type Variable Displacement Axial Plunger
Motor
Theoretical Displacement (Fast/ 9.5/17.2 cm3/rev (0.6/1.0 in3/rev)
Slow)
TRAVEL BRAKE VALVE Type Counterbalance Valve Type
TRAVEL PARKING BRAKE Type Spring Set Hydraulic Released Wet-Type Multi-Disk Brake
Release Starting Pressure 1.2 MPa (12 kgf/cm2, 175 psi)
T1-3-7
SECTION 1 GENERAL
CYLINDER Boom Arm Bucket

Rod Diameter 40 mm (1.57”) 40 mm (1.57”) 35 mm (1.38”)
Cylinder Bore 70 mm (2.76”) 70 mm (2.76”) 55 mm (2.17”)
Stroke 527 mm (1’8.7”) 380 mm (1’3.0”) 439 mm (1’5.3”)
Fully Retracted Length 830 mm (2’8.7”) 683 mm (2’2.9”) 694 mm (2’3.3”)
Plating Thickness 30 μm (1.18 μin) 30 μm (1.18 μin) 30 μm (1.18 μin)
CYLINDER Boom Swing Blade

Rod Diameter 35 mm (1.38”) 35 mm (1.38”)
Cylinder Bore 65 mm (2.56”) 65 mm (2.56”)
Stroke 415 mm (1’4.3”) 131 mm (5.16”)
Fully Retracted Length 698 mm (2’3.5”) 392 mm (1’3.4”)
Plating Thickness 30 μm (1.18 μin) 30 μm (1.18 μin)
T1-3-8
SECTION 1 GENERAL
FRONT ATTACHMENT Plunger Stroke Ports 1, 3: 6.6±0.5 mm (0.26±0.02 in)

PILOT VALVE Ports 2, 4: 8.0±0.5 mm (0.31±0.02 in)
TRAVEL PILOT VALVE Plunger Stroke Ports 1, 2, 3, 4: 3.4±0.3 mm (0.13±0.012 in)
BOOM SWING/BLADE/ Plunger Stroke Ports 1, 2: 3.7±0.3 mm (0.15±0.012 in)
AUXILIARY PILOT VALVE
2-SPOOL SOLENOID Relief Set-Pressure 4.1±0.2 MPa (42±2 kgf/cm2, 595±29 psi)
VALVE UNIT (2-Spool Rated Voltage DC 12 V
Solenoid Valve with Pilot Operating Voltage DC 10 to 15 V
Relief Valve) Coil Resistance 12.2±0.85 Ω
Solenoid Valve Port A Side: Pilot Shut-Off Solenoid Valve
Port B Side: Travel Mode Selector Solenoid Valve
OIL COOLER BYPASS Cracking Pressure 390 kPa (4 kgf/cm2, 57 psi) at 5 L/min
CHECK VALVE
T1-3-9
SECTION 1 GENERAL
Electrical Component
ENGINE OIL PRESSURE Operating Pressure 49±9.8 kPa (0.5±0.1 kgf/cm2, 7.1±1.4 psi)
SWITCH
OVERHEAT SWITCH Operating Temperature 110 °C (230 °F)
GLOW PLUG RELAY Voltage 12 V
FUEL SENSOR Resistance Empty: 87 Ω
Full: 10 Ω
HORN Specification 12 V/3 A
Sound Pressure 108+5-3 dB (A) at 2 m
ILLUMINATION Work Light Halogen 12 V, 55 W
T1-3-10
MEMO
MEMO
SECTION 2
SYSTEM
CONTENTS
Outline..................................................................................... T2-1-1
Pilot Circuit............................................................................. T2-1-2
Main Circuit............................................................................ T2-1-8
Others....................................................................................T2-1-14
Group 2 Electrical System
Outline..................................................................................... T2-2-1
Main Circuit............................................................................ T2-2-2
Electric Power Circuit (Key Switch: OFF)...................... T2-2-4
Electric Power Circuit (Key Switch: ON)........................ T2-2-6
Preheating Circuit (Key Switch: HEAT).......................... T2-2-8
Starting Circuit (Key Switch: START)............................T2-2-10
Charging Circuit (Key Switch: ON)...............................T2-2-12
Pilot Shut-Off Circuit (Key Switch: ON).......................T2-2-16
Engine Stop Circuit (Key Switch: OFF)........................T2-2-18
Monitor Circuit....................................................................T2-2-21
Indicator Circuit..................................................................T2-2-22
Work Light/Monitor Internal Light Circuit................T2-2-24
Gauge Circuit.......................................................................T2-2-26
Travel Alarm Circuit...........................................................T2-2-28
ACG90T-2-1
(Blank)
ACG90T-2-2
SECTION 2 SYSTEM
Outline
The hydraulic system mainly consists of the pilot circuit
and main circuit.
Pilot Circuit:
Power Source Related Device Supplied to
Pilot Pump Pilot Valve Operation Control Circuit
2-Spool Solenoid Valve Unit Travel Motor Displacement Angle Control Circuit
Swing Parking Brake Release Circuit
Main Circuit:
Power Source Related Device Supplied to
Main Pump Control Valve Motor
Cylinder
Attachment (OP)
T2-1-1
SECTION 2 SYSTEM
Pilot Circuit
Outline:
Pressure oil from the pilot pump is used in order to
operate the following circuits.
 Operation Control Circuit

 Travel Motor Displacement Angle Control Circuit
 Swing Parking Brake Release Circuit
T2-1-2
SECTION 2 SYSTEM
1 2 3 4 5 6
7
10 9 8
23 11
23
22
21
20 19 18 17 16 14 13
TACD90-02-01-001
1- Pilot Valve (Left) 7- Operation Control Circuit 14- Pilot Pump 20- Swing Motor
2- Pilot Valve (Right) 8- Flow Combiner Valve 16- Pilot Filter 21- Swing Parking Brake Release
3- Travel Pilot Valve 9- Control Valve 17- Pilot Relief Valve Circuit
4- Boom Swing Pilot Valve 10- Spool 18- Travel Mode Control Solenoid 22- Travel Motor Displacement
5- Blade Pilot Valve 11- Travel Motors (Left, Right) Valve Angle Control Circuit
6- Auxiliary Pilot Valve 13- Main Pump 19- Pilot Shut-Off Solenoid Valve 23- Travel Mode Selector Valve
T2-1-3
SECTION 2 SYSTEM
Operation Control Circuit

The operation control circuit controls the control valve
(11) operation.
In response to the control lever stroke, the pilot valve
regulates pressure oil supplied to the spool end in
control valve (11).
fNOTE: The boom raise operation is explained here.
1. When the pilot shut-off lever is set to the Unlock
position, the pilot shut-off switch which is located
under the pilot shut-off lever is turned ON and pilot
shut-off solenoid valve (15) is shifted.
2. When the control lever is moved to the boom
raise position, pressure oil from pilot pump (14) is
supplied to pilot valve (right) (4) through pilot shut-
off solenoid valve (15).
3. Pressure oil is reduced by pilot valve (right) (4) to
the pressure according to the control lever stroke
and is supplied to boom spool end (a) so that the
spool is moved in response to the control lever
stroke.
4. Pressure oil from main pump (13) is supplied to the
boom cylinder (12) bottom side through the boom
spool, extends boom cylinder (12), and raises the
boom.
T2-1-4
SECTION 2 SYSTEM
1 4
2 3 5 6 7 9 10 8
h gf e a bd c o p x y
l k j i n m
12
11
c b i k g y m e p
d a j l h x n f o
P1
P4 P3 P2
TACD90-02-01-002
15 14 13
a- Boom Raise f- Swing (Right) k- Travel (Right Forward) p- Blade Raise

b- Boom Lower g- Arm Roll-In l- Travel (Right Reverse) x- Auxiliary
c- Bucket Roll-In h- Arm Roll-Out m- Boom Swing (Right) y- Auxiliary
d- Bucket Roll-Out i- Travel (Left Forward) n- Boom Swing (Left)
e- Swing (Left) j- Travel (Left Reverse) o- Blade Lower
1- Pilot Valve (Left) 5- Boom 9- Boom Swing Pilot Valve 13- Main Pump
2- Arm 6- Bucket 10- Blade Pilot Valve 14- Pilot Pump
3- Swing 7- Travel Pilot Valve 11- Control Valve 15- Pilot Shut-Off Solenoid Valve
4- Pilot Valve (Right) 8- Auxiliary Pilot Valve 12- Boom Cylinder
T2-1-5
SECTION 2 SYSTEM
Travel Motor Displacement Angle Control Circuit (9)

The travel motor displacement angle control circuit
controls the travel mode.
It consists of travel mode control solenoid valve (2) and
travel mode selector valve (8).
In response to travel mode pedal position (fast/slow),
travel mode control solenoid valve (2) is shifted so
that the travel speed control oil pressure is supplied to
travel motor (7). (Refer to COMPONENT OPERATION /
Travel Device.)
Swing Parking Brake Release Circuit (6)

The swing parking brake release circuit releases the
swing parking brake.
It consists of the pilot shut-off lever, pilot shut-off
switch, and pilot shut-off solenoid valve (1).
When the pilot shut-off lever is set to the Unlock
position (pilot shut-off switch: ON), pilot shut-off
solenoid valve (1) is shifted so that the swing parking
release oil pressure is supplied to swing motor (4).
(Refer to COMPONENT OPERATION / Swing Device.)
T2-1-6
SECTION 2 SYSTEM
1 2
9
3
8
4
7 6 5
TACD90-02-01-003
1- Pilot Shut-Off Solenoid Valve 5- Swing Parking Brake 9- Travel Motor Displacement Angle Control
2- Travel Mode Control Solenoid Valve 6- Swing Parking Brake Release Circuit Circuit
3- Pilot Pump 7- Travel Motor
4- Swing Motor 8- Travel Mode Selector Valve
T2-1-7
SECTION 2 SYSTEM
Main Circuit
Outline
1. Main pumps (17) (P1, P2, P3) draw hydraulic oil from
hydraulic oil tank (18) and deliver it to control valve
(1).
2. Delivered pressure oil is supplied to the motors and
cylinders by shifting the control valve (1) spool.
(Refer to COMPONENT OPERATION / Control Valve.)
3. Returning oil from the cylinders and motors returns
to control valve (1) and is combined inside it
again. Returning oil from control valve (1) returns
to hydraulic oil tank (18) after being cooled in oil
cooler (20).
4. When oil temperature is low (high viscosity) and oil
flow resistance increases in oil cooler (20). Bypass
check valve (19) is opened and hydraulic oil directly
returns to hydraulic oil tank (18).
T2-1-8
SECTION 2 SYSTEM
24 1
12
2
3
23
4 13
22 14
6
15
7
21 9
10 16
11
20 19
P3 P2 P1
18
17 TACB-02-01-003
1- Control Valve 7- Arm Spool 13- Boom Swing Cylinder 19- Bypass Check Valve
2- Flow Combiner Valve 8- Travel (Right) Spool 14- Arm Cylinder 20- Oil Cooler
3- Blade Spool 9- Travel (Left) Spool 15- Travel Motor (Left) 21- Boom Cylinder
4- Swing Spool 10- Boom Spool 16- Bucket Cylinder 22- Travel Motor (Right)
5- Boom Swing Spool 11- Bucket Spool 17- Main Pump 23- Attachment
6- Auxiliary Spool 12- Blade Cylinder 18- Hydraulic Oil Tank 24- Swing Motor
T2-1-9
SECTION 2 SYSTEM
Neutral Circuit Single Operation Circuit

1. When the control lever is in neutral, pressure oil 1. Pressure oil from main pump (23) (P1) flows to travel
from main pump (23) returns to hydraulic oil tank (left) spool (17), boom spool (18), and bucket spool
(22) through control valve (9). (19) in control valve (9).
2. Pressure oil from main pump (23) (P2) flows to travel
Relief Circuit (right) spool (16), arm spool (15), and auxiliary spool
(14) in control valve (9).
1. Main relief valves (25, 26, 27) are provided in the
main circuit (between the pump and actuator). 3. Pressure oil from main pump (23) (P3) flows to flow
combiner valve spool (10), blade spool (11), swing
2. Main relief valves (25, 26, 27) prevent the pressure
spool (12), boom swing spool (13), and auxiliary
in the main circuit from exceeding the set pressure
spool (14) in control valve (9).
when the spool is operated (or when the control
lever is operated).
3. Overload relief valves (28, 29, 30, 31, 32) are
provided in the actuator circuit (between the
control valve and actuator) of the boom, arm, and
bucket.
4. Overload relief valves (28, 29, 30, 31, 32) prevent
the surge pressure caused by external force in the
actuator circuit from exceeding the set pressure.
5. In addition, overload relief valves (28, 29, 30, 31, 32)
have make-up function. When the pressure in the
actuator circuit decreases, overload relief valves (28,
29, 30, 31, 32) draw pressure oil from hydraulic oil
tank (22) and prevent cavitation from occurring.
T2-1-10
SECTION 2 SYSTEM
1 2 3 4 5 6 7 8
24
9
25 26
27
19 32 31 30 18 17 16 15 29 28 14 13 12 11 10
P3 P2 P1
TACD90-02-01-004
20 21 22 23
1- Swing Motor 12- Swing Spool 23- Main Pump 29- Overload Relief Valve (Arm:
2- Bucket Cylinder 13- Boom Swing Spool 24- Attachment Rod Side)
3- Boom Cylinder 14- Auxiliary Spool 25- Main Relief Valve (Main Pump 30- Overload Relief Valve (Boom:
4- Arm Cylinder 15- Arm Spool P1) Bottom Side)
5- Travel Motor (Left) 16- Travel (Right) Spool 26- Main Relief Valve (Main Pump 31- Overload Relief Valve (Boom:
6- Travel Motor (Right) 17- Travel (Left) Spool P2) Rod Side)
7- Blade Cylinder 18- Boom Spool 27- Main Relief Valve (Main Pump 32- Overload Relief Valve (Bucket:
8- Boom Swing Cylinder 19- Bucket Spool P3) Bottom Side)
9- Control Valve 20- Bypass Check Valve 28- Overload Relief Valve (Arm:
10- Flow Combiner Valve 21- Oil Cooler Bottom Side)
11- Blade Spool 22- Hydraulic Oil Tank
T2-1-11
SECTION 2 SYSTEM
Combined Operation Circuit (Combined Operation

of Travel and Front Attachment)
fNOTE: The combined operation of travel (left, right)

and boom raise is explained here.
1. When operating boom raise while traveling, pilot
signal circuit (5) is blocked by travel spools (13, 14)
and boom spool (15).
2. As pilot signal circuit (5) is blocked, the pressure in
pilot signal circuit (5) increases and flow combiner
valve (9) is shifted.
3. When flow combiner valve (9) is shifted, parallel
circuits (10) which are connected to boom spool
(15), arm spool (12), and bucket spool (16) from
main pump (18) (P3) are provided.
4. Therefore, pressure oil from main pump (18) (P3)
flows to each front attachment spool so that the
combined operation of travel and boom raise can
be operated.
5. Pressure oil from main pump (18) (P3) is supplied to
blade spool (8), swing spool (7), and boom swing
spool (6) through parallel circuit (10) bypassing flow
combiner valve (9).
T2-1-12
SECTION 2 SYSTEM
1 2 3
4 5 6 7 8
16 15 14 13 12 11 10 9
P3 P2 P1
17 18 TACD90-02-01-005
1- Boom Cylinder 6- Boom Swing Spool 11- Auxiliary Spool 16- Bucket Spool
2- Travel Motor (Left) 7- Swing Spool 12- Arm Spool 17- Pilot Pump
3- Travel Motor (Right) 8- Blade Spool 13- Travel (Right) Spool 18- Main Pump
4- Control Valve 9- Flow Combiner Valve 14- Travel (Left) Spool
5- Pilot Signal Circuit 10- Parallel Circuit 15- Boom Spool
T2-1-13
SECTION 2 SYSTEM
Others
AUX Function Lever (AFL) Control (Only Machine
with the Optional Parts Equipped)
Purpose:
The AUX function lever (AFL) control enables to operate 3
the function of slide switch (3) or switch (4) when using
the attachment such as a fork.
Operation:
1. When operating slide switch (3) or switch (4) of the 4
AUX function lever, current (a) from fuse #7 flows to
AUX function solenoid valve 1 (2) or AUX function
solenoid valve 2 (6) through AUX function lever
controller (5).
fNOTE: When operating slide switch (3) and switch

(4) at the same time, priority is given to the switch (4)
operation. Then, the operation is similar to the operation
TACC50-02-01-002
when slide switch (3) reaches full stroke leftward.
2. When operating switch (4), AUX function lever
controller (5) activates AUX function solenoid valve
1 (2) or AUX function solenoid valve 2 (6). 3- Slide Switch 4- Switch
3. When operating slide switch (3), AUX function lever

controller (5) activates AUX function solenoid valve
1 (2) or AUX function solenoid valve 2 (6) according
to the slide switch (3) operation.
4. Pressure oil from pilot pump (9) is routed to
auxiliary spool (7) in the control valve through
AUX function solenoid valve 1 (2) or AUX function
solenoid valve 2 (6).
5. Consequently, pressure oil from main pump (8)
is supplied to each attachment through auxiliary
spool (7).
T2-1-14
SECTION 2 SYSTEM
10
3
11
7
9 8
TACB-02-01-006
a- Current from Fuse #7 b- To Attachment
1- Pilot Valve (Right) 4- Switch 7- Auxiliary Spool 10- Hydraulic Oil Tank
2- AUX Function Solenoid Valve 1 5- AUX Function Lever Controller 8- Main Pump 11- Pilot Relief Valve
3- Slide Switch 6- AUX Function Solenoid Valve 2 9- Pilot Pump
T2-1-15
SECTION 2 SYSTEM
(Blank)
T2-1-16
SECTION 2 SYSTEM
Outline
The electrical circuit is broadly divided into the main
circuit and monitor circuit.
 Main Circuit:
The main circuit operates the engine and the accessory
related circuits.
 Monitor Circuit:
The monitor circuit displays the machine operating
conditions. The monitor circuit consists of the monitor
controller, sensors, relays, and switches.
T2-2-1
SECTION 2 SYSTEM
Main Circuit
The major functions and circuits in the main circuit are as
follows.
 Electric Power Circuit: The electric power circuit

supplies all electric power to all electrical systems on
the machine.
{Key switch, Battery, Fuses (Fuse box, slow blow fuse
)}
 Preheating Circuit: The preheating circuit assists the
engine starting in cold weather. (Key switch, Glow
plug relay, Glow plug)
 Starting Circuit: The starting circuit starts the engine.
(Key switch, Starter, Starter relay 2)
 Charging Circuit: The charging circuit supplies
electric power to the battery and charges it.
(Key switch, Alternator, Battery)
 Pilot Shut-Off Circuit (Key switch: ON):
The pilot shut-off circuit supplies pressure oil from
the pilot pump to the pilot valve by the pilot shut-off
solenoid valve.
(Pilot shut-off solenoid valve, Pilot shut-off lever)
 Engine Stop Circuit (Key Switch: OFF):
The engine stop circuit stops the engine by using the
engine stop solenoid.
(Key switch, Engine stop solenoid, Alternator)
T2-2-2
SECTION 2 SYSTEM
(Blank)
T2-2-3
SECTION 2 SYSTEM
Electric Power Circuit (Key Switch: OFF)

The battery (1) minus terminal is grounded to the body.
Current from the battery (1) plus terminal flows as shown
below when key switch (3) is in the OFF position.
Battery (1) Starter (12) Terminal B

Slow Blow Starter Relay 2 (11) Terminal #1-A
Fuse (2) Glow Plug Relay (10)
Power Relay (9)
Alternator (13) Terminal B
Key Switch (3) Terminal B
Fuse Box (5) Terminal Horn Relay (7) Terminals #1 and #3
#1 Monitor Controller (4) Terminal M1-7
Terminal Work Light Relay (8) Terminal #3
#2
T2-2-4
SECTION 2 SYSTEM
1 2 4
B
5
B
12
1-A
1 2 M1-7
11
10
13 B
#3 #3 #1
8 7
TACD90-02-02-001
1- Battery 4- Monitor Controller 8- Work Light Relay 11- Starter Relay 2

2- Slow Blow Fuse 5- Fuse Box 9- Power Relay 12- Starter
3- Key Switch 7- Horn Relay 10- Glow Plug Relay 13- Alternator
T2-2-5
SECTION 2 SYSTEM
Electric Power Circuit (Key Switch: ON)

1. When key switch (1) is set to the ON position,
terminal B is connected to terminals BR, R2, and ACC
in key switch (1).
2. Current from terminals BR, R2, and ACC in key
switch (1) flows as shown below as a power source
respectively.
3. In addition, when current from terminal BR in
key switch (1) flows to terminal M2-2 in monitor
controller (4), monitor controller (4) lights the
indicator.
Key Switch (1) Terminal BR Fuse Box (2) Terminal Monitor Controller (4) Terminal M2-2
#3 Buzzer (3)
Alternator (8) Terminal IG
Key Switch (1) Terminal R2 Fuse Box (2) Terminal Auxiliary Power (c)
#5
Key Switch (1) Terminal Fuse Box (2) Terminal AUX Function Lever Power (OP) (b)
ACC #7 Travel Alarm Controller (b)
Buzzer (b)
Terminal Starter Relay 2 (9) Terminal #3-C
#8 One-Second Timer (7)
Engine Stop Solenoid (6)
Fuel Pump (5)
Travel Mode Selector Relay (d)
Travel Mode Pedal (d)
Diode Terminal #3 (e)
Terminal Pilot Shut-Off Switch (a)
#9 Pilot Shut-Off Relay (a)
Work Light Switch (a)
T2-2-6
SECTION 2 SYSTEM
ON
4
B R2 ACC
BR
+B
2 3
9
3-C
3 5 7 M2-2
9
8
8
IG
7 a
c
6
d
TACD90-02-02-002
a- Pilot Shut-Off Switch/Pilot b- AUX Function Lever Power c- Auxiliary Power e- Diode Terminal #3
Shut-Off Relay/Work Light (OP)/Travel Alarm Controller/ d- Travel Mode Selector Relay/
Switch Buzzer Travel Mode Pedal
1- Key Switch 4- Monitor Controller 7- One-Second Timer

2- Fuse Box 5- Fuel Pump 8- Alternator
3- Buzzer 6- Engine Stop Solenoid 9- Starter Relay 2
T2-2-7
SECTION 2 SYSTEM
Preheating Circuit (Key Switch: HEAT)

1. Current from battery (1) flows to terminal B in key
switch (3), fuse box (4), and terminal #3 in glow plug
relay (7) through slow blow fuse (2).
2. When key switch (3) is set to the HEAT position,
terminal B is connected to terminals BR and R1 in
key switch (3).
3. Current from terminal R1 in key switch (3) flows to
terminal M1-3 in monitor controller (5) and terminal
#2 in glow plug relay (7) through fuse box (4).
4. Therefore, as glow plug relay (7) is excited, the
circuit is connected to glow plug (6) and current
flows to glow plug (6).
5. When current flows to glow plug (6), glow plug (6)
heats intake air for the engine.
6. In addition, when current flows to terminal M1-3 in
monitor controller (5), monitor controller (5) lights
the preheat indicator for 15 seconds.
fNOTE: When key switch (3) is set to the START position,

current from terminal R1 in key switch (3) continues to
flow to glow plug (6). Therefore, the starter rotates with
glow plug (6) operated.
T2-2-8
SECTION 2 SYSTEM
HEAT 3
5
1 2 B R1
BR
1 3 4 M1-3
7 #2
#3
6
TACC50-02-02-003
1- Battery 3- Key Switch 5- Monitor Controller 7- Glow Plug Relay

2- Slow Blow Fuse 4- Fuse Box 6- Glow Plug
T2-2-9
SECTION 2 SYSTEM
Starting Circuit (Key Switch: START)

1. When key switch (3) is set to the START position, 9. When starter relay 1 (8) is OFF, the contact between
terminal B is connected to terminals BR, R1, C, and terminals #3 and #4 is turned ON. Therefore, current
ACC in key switch (3). from terminal C in key switch (3) flows to terminal
#1-E in starter relay 2 (15) through starter relay 1
2. Current from terminal ACC in key switch (3) flows
(8). Consequently, starter relay 2 (15) excites the coil
to terminal 3-C in starter relay 2 (15), terminal #1
inside and the contact between terminals #1-A and
(holding side) in engine stop solenoid (10), terminal
#2-B is turned ON.
#4 in one-second timer (12), fuel pump (9), and pilot
shut-off switch (7) through fuse box (4) as a power 10. Current from battery (1) flows to terminal S in
source respectively. starter (16) through starter relay 2 (15). Therefore,
the contact in starter (16) is turned ON.
3. Current from terminal BR in key switch (3) flows to
terminal IG in alternator (13) through fuse box (4) as 11. Current from battery (1) flows to the starter motor
a power source. through terminal B in starter (16) and the contact.
Therefore, the starter motor rotates.
4. When current from terminal ACC in key switch
(3) flows to terminal #4 in one-second timer (12), 12. When the engine has started, alternator (13) starts
current from terminal #2 in one-second timer generating electricity and voltage at terminals P
(12) flows to terminal #1 in one-second timer (12) and B in alternator (13) increase.
through terminals #2 and #1 in power relay (11) and
13. Alternating current in proportion to the alternator
excites power relay (11) for one second.
(13) rotating speed is sent from terminal P in
5. Therefore, current from slow blow fuse (2) flows to alternator (13) to terminal #4-H in starter relay
terminal #2 (attracting side) in engine stop solenoid 2 (15). When the alternator (13) rotating speed
(10) through power relay (11) for one second. reaches 1350±210 min-1, starter relay 2 (15) stops
exciting.
6. Consequently, engine stop solenoid (10) is moved
to the attracting position and the control rack is 14. Therefore, as the contact between terminals #1-A
operated. (The engine can start.) and #2-B in starter relay 2 (15) is turned OFF and no
current flows to terminal S in starter (16), the starter
7. Although current which flows to terminal #2
motor stops.
(attracting side) in engine stop solenoid (10) is
blocked by power relay (11) after one second,
current from fuse #8 flows to terminal #1 (holding
fNOTE: When the pilot shut-off lever is in the UNLOCK
position (pilot shut-off switch (7): ON), the engine does
side) in engine stop solenoid (10) and the engine not start. (Refer to Pilot Shut-Off Circuit.)
can run continuously.
8. Terminal L in alternator (13) is grounded inside
when alternator (13) slowly rotates or stops.
Therefore, terminal M1-1 in monitor controller (5) is
grounded through terminal L in alternator (13) and
the alternator indicator lights.
T2-2-10
SECTION 2 SYSTEM
5
START
1 2
B C ACC
BR 4
R1
B
16 S 2-B
1-A
3-C
15 1-E M1-1
1 3 4 8 9
4-H
14 6
13 B P
L IG
12 #1 #2
#4
11 #1
#2
10 #2
#1
9 #4
#3
8 7 6
TACC50-02-02-004
1- Battery 5- Monitor Controller 9- Fuel Pump 13- Alternator

2- Slow Blow Fuse 6- Pilot Shut-Off Relay 10- Engine Stop Solenoid 14- Glow Plug Relay
3- Key Switch 7- Pilot Shut-Off Switch 11- Power Relay 15- Starter Relay 2
4- Fuse Box 8- Starter Relay 1 12- One-Second Timer 16- Starter
T2-2-11
SECTION 2 SYSTEM
Charging Circuit (Key Switch: ON)

1. After the engine starts and key switch (4) is released,
key switch (4) is returned to the ON position. When
key switch (4) is in the ON position, terminal B is
connected to terminals BR, R2, and ACC in key
switch (4).
terminal IG in alternator (3) as a power source for
the regulator inside alternator (3).
3. When the engine runs, alternator (3) starts
generating electricity and terminal L in alternator
(3) is not grounded inside. Therefore, terminal M1-1
in the monitor controller is not grounded inside
alternator (3). Consequently, the alternator indicator
goes off.
4. Constant voltage is generated from terminal B
in alternator (3) regardless of the alternator (3)
rotating speed and current flows to battery (1) and
each circuit through slow blow fuse (2). Therefore,
battery (1) is charged.
T2-2-12
SECTION 2 SYSTEM
ON
5
1 2
B BR R2 ACC
M1-1
L IG
TACC50-02-02-005
1- Battery 3- Alternator 5- Monitor Controller

2- Slow Blow Fuse 4- Key Switch
T2-2-13
SECTION 2 SYSTEM
Alternator (1) Operation

Alternator (1) consists of regulator (2), field coil FC, 6. Initially, no current flows to field coil FC. When
stator coil SC, and diode D. In addition, regulator (2) the rotor in stator coil SC rotates due to the
consists of IC, transistor T1, and transistor T2. engine rotation, alternating voltage occurs in
stator coil SC by the remaining magnetism in the
1. Current from battery (4) flows to IC in regulator (2) rotor. (Alternating voltage from stator coil SC is
through terminal B in alternator (1). commutated into direct voltage by diode D.)
2. When key switch (3) is in the ON position, current 7. When current from stator coil SC flows to field
from battery (4) flows to IC in regulator (2) through coil FC, the rotor is further magnetized so that
key switch (3) and terminal IG in alternator (1). generating voltage increases. Therefore, current
flowing through field coil FC increases. Therefore,
3. At this time, current from IC in regulator (2) flows
generating voltage further increases.
to bases B in transistor T1 and transistor T2. Then,
collectors C are routed to emitter E respectively. 8. When generating voltage exceeds the battery (4)
voltage, current from stator coil SC flows to battery
4. Therefore, terminal L in alternator (2) is connected
(4) through terminal B in alternator (1), and battery
to terminal E in the ground through transistor T2.
(4) starts to be charged.
5. In addition, the ground side in field coil FC is
connected to terminal E in the ground through
terminal F in regulator (2) and transistor T1.
1 2
IG
3
D D D
L
SC F
IC
C C
D D D B B
E T1 T2 E 4
FC
T1MP-02-02-005
1- Alternator 2- Regulator 3- Key Switch 4- Battery
T2-2-14
SECTION 2 SYSTEM
Regulator (2) Operation

1. When the engine starts rotating and stator coil SC 6. When generating voltage decreases below set
starts generating, current from IC does not flow to voltage of IC, IC turns transistor T1 ON again.
base B in transistor T2. Then, transistor T2 is turned
7. Therefore, current flows to field coil FC and
OFF.
generating voltage of stator coil SC increases.
2. Therefore, terminal L in alternator (1) is not
8. The above operation is repeated so that alternator
grounded.
(1) generating voltage is kept constant.
3. When generating voltage of stator coil SC exceeds
set voltage of IC, current from IC does not flow to
base B in transistor T1. Then, transistor T1 is turned
OFF.
4. Therefore, the ground side in field coil FC is not
grounded.
5. Consequently, no current flows to filed coil FC and
generating voltage of stator coil SC decreases.
1 2
IG
3
D D D
L
SC F
IC
C
D D D B
E E 4
T1 T2
FC
T1MP-02-02-005
1- Alternator 2- Regulator 3- Key Switch 4- Battery
T2-2-15
SECTION 2 SYSTEM
Pilot Shut-Off Circuit (Key Switch: ON)

1. When the pilot shut-off lever is set to the UNLOCK
position, pilot shut-off switch (6) is turned ON.
2. Current from fuse #9 flows to the ground through
pilot shut-off switch (6) and pilot shut-off relay (5).
Pilot shut-off relay (5) is excited.
3. Therefore, current from fuse #9 flows to pilot shut-
off solenoid valve (4) and pilot shut-off solenoid
valve (4) is turned ON. Then, pressure oil from the
pilot pump is supplied to the pilot valve.
 Neutral Engine Start Circuit

position, pilot shut-off switch (6) is turned ON.
2. When pilot shut-off switch (6) is turned ON, current
from fuse #9 excites starter relay 1 (7) through pilot
shut-off switch (6). Then, starter relay 1 (7) is turned
ON.
3. When starter relay 1 (7) is turned ON, no current
from fuse #6 flows to starter relay 2 (8). Then, starter
relay 2 (8) stops exciting.
4. Therefore, the contact between terminals #1-A
and #2-B in starter relay 2 (8) is turned OFF and no
current flows to terminal S in starter (9).
5. Consequently, even if key switch (2) is set to the
START position with the pilot shut-off lever is in the
UNLOCK position, starter (9) does not rotate and the
engine does not start.
T2-2-16
SECTION 2 SYSTEM
ON
START
1
B C ACC
S
9 2-B
1-A
8 6 8 9
1-E
4 7 6 5
TACC50-02-02-007
1- Battery 4- Pilot Shut-Off Solenoid Valve 6- Pilot Shut-Off Switch (Pilot 8- Starter Relay 2
2- Key Switch 5- Pilot Shut-Off Relay Shut-Off Lever) 9- Starter
3- Fuse Box 7- Starter Relay 1
T2-2-17
SECTION 2 SYSTEM
Engine Stop Circuit (Key Switch: OFF)

1. When key switch (3) is turned from ON to OFF
position, terminal B in key switch (3) is disconnected
from terminals BR, R2, and ACC. Therefore, power is
shut off to each circuit.
2. When current which flows from terminal ACC in key
switch (3) to terminal #1 (holding side) in engine a
stop solenoid (5) is stopped, engine stop solenoid
(5) is turned OFF.
3. When engine stop solenoid (5) is turned OFF,
control rack (6) is moved to the STOP position by
the spring. 5 6
4. Therefore, as fuel is not supplied to the engine, the

engine stops.
fNOTE: As terminal B in alternator (2) is directly

T1M7-02-03-007
connected to battery (1), surge voltage is charged to
battery (1) until the engine stops.
a- Fuel Reduced Direction
5- Engine Stop Solenoid
6- Control Rack
T2-2-18
SECTION 2 SYSTEM
OFF
ON
1
B ACC
2 8
B
#1
TACC50-02-02-008
1- Battery 3- Key Switch 5- Engine Stop Solenoid

2- Alternator 4- Fuse Box
T2-2-19
SECTION 2 SYSTEM
(Blank)
T2-2-20
SECTION 2 SYSTEM
Monitor Circuit
The major functions and circuits in the monitor circuit are
as follows.
 Indicator Circuit: The indicator circuit turns the

indicator ON due to the signals from switches and
sensors. (Alternator Indicator, Fuel Level Indicator,
Overheat Indicator, Engine Oil Pressure Indicator,
Preheat Indicator)
 Work Light/Monitor Internal Light Circuit: The work
light/monitor internal light circuit is operated when
the work light switch is in the ON position. (Work
Light, Monitor Internal Light)
 Gauge Circuit: The gauge circuit operates the hour
meter. Also the gauge circuit controls the fuel gauge
and the coolant temperature indicator according to
the signals from sensors. (Hour Meter, Fuel Gauge,
Coolant Temperature Indicator)
T2-2-21
SECTION 2 SYSTEM
Indicator Circuit
Except Preheat Indicator Preheat Indicator
1. When key switch (3) is set to the ON position, 1. When key switch (3) is set to the HEAT or START
terminal B is connected to terminals BR, R2, and ACC position, terminal B is connected to terminals BR
in key switch (3). and R1 in key switch (3).
2. Current from terminal BR in key switch (3) flows to 2. Current from terminal R1 in key switch (3) flows to
terminal M2-2 in monitor controller (6) through fuse terminal M1-3 in monitor controller (6) through fuse
box (4) as a power source of alternator indicator (8), box (4).
fuel level indicator (9), overheat indicator (10), and
3. When current flows to terminal M1-3 in monitor
engine oil pressure indicator (11).
controller (6), it turns on preheat indicator (7) for 15
3. When the following condition exist, each switch or seconds.
sensor is grounded and the indicator lights.
4. In addition, current from terminal BR in key switch
(3) flows to terminal #2 in buzzer (5) through fuse
box (4).
5. When overheat indicator (10) or engine oil pressure
indicator (11) lights, terminal #1 in buzzer (5) is
grounded through monitor controller (6).
6. Overheat indicator (10) lights and buzzer (5) sounds
at the same time. Buzzer (5) sounds after three
seconds when engine oil pressure indicator (11) lit.
Indicator ON Condition:
Alternator Indicator (8) (Alternator (15)):
Engine: Stopped (Key Switch: ON)
 Fuel Level Indicator (9) (Fuel Sensor (12)):
Fuel Level: 6.3 L (1.66 US gal) or less
 Overheat Indicator (10) (Overheat Switch (14)):
Coolant Temperature: 110±3 °C (230±5.4 °F) or more
 Engine Oil Pressure Indicator (11) (Engine Oil
Pressure Switch (13)):
Engine Oil Pressure: 49±10 kPa (0.5±0.1 kgf/cm2,
7.1±1.5 psi) or less
T2-2-22
SECTION 2 SYSTEM
HEAT
ON
START
1 2 6
B ACC 7 8 9 10 11
R2
BR R1
4 5
#2 #1 M2-2
1 23 4 9
M1-3
15
14
13
#3
12
TACD90-02-02-003
1- Battery 5- Buzzer 9- Fuel Level Indicator 13- Engine Oil Pressure Switch
2- Slow Blow Fuse 6- Monitor Controller 10- Overheat Indicator 14- Overheat Switch
3- Key Switch 7- Preheat Indicator 11- Engine Oil Pressure Indicator 15- Alternator
4- Fuse Box 8- Alternator Indicator 12- Fuel Sensor
T2-2-23
SECTION 2 SYSTEM
Work Light/Monitor Internal Light Circuit

in key switch (3).
2. Current from terminal ACC in key switch (3) flows to
terminal #6 in work light switch (7) through fuse #9.
3. When work light switch (7) is turned ON, current
from fuse #9 flows to the ground through work light
switch (7) and work light relay (6). Then, work light
relay (6) is excited.
4. Therefore, current from fuse #2 flows to terminal
M2-9 in monitor controller (5), work light (8) (only
4-pillar canopy spec. machine), and work light (9).
5. Consequently, work light (8) (only 4-pillar canopy
spec. machine), work light (9), and the monitor
internal light are turned on.
T2-2-24
SECTION 2 SYSTEM
ON
1 2 5
B ACC
R2
BR
4
123 4 9
M2-9
#6
9 8 7 6
TACD90-02-02-003
1- Battery 4- Fuse Box 7- Work Light Switch 9- Work Light

2- Slow Blow Fuse 5- Monitor Controller 8- Work Light (Only 4-Pillar
3- Key Switch 6- Work Light Relay Canopy Spec. Machine)
T2-2-25
SECTION 2 SYSTEM
Gauge Circuit
1. Current from battery (1) flows to terminal M1-7 in
monitor controller (5) through fuse #1 as a power
source of the hour meter.
fNOTE: While current from battery (1) flows to terminal

M1-7 in monitor controller (5), the hour meter is
displayed on the monitor.
in key switch (3).
terminal M2-2 in monitor controller (5) through fuse
#3 as a power source of the fuel gauge and coolant
temperature indicator (6).
Fuel Gauge
1. Current from the fuel gauge flows to terminal #2 in
fuel sensor (7) through terminal M1-8 in monitor
controller (5).
2. The segment in the fuel gauge lights according to
the position of the float.
Hour Meter
1. When key switch (3) is set to the ON position and
current from terminal BR in key switch (3) flows to
terminal M2-2 in monitor controller (5), monitor
controller (5) recognizes that key switch (3) is in the
ON position.
2. When the engine runs and terminal M1-1 in monitor
controller is not grounded in alternator (9), the hour
meter counts.
Coolant Temperature Indicator (6)

1. Current from coolant temperature indicator (6)
flows to the terminal in coolant temperature sensor
(8) through terminal M2-10 in monitor controller (5).
2. When engine coolant temperature is lower than
30±10 °C (86±18 °F) and the engine starts, coolant
temperature indicator (6) lights.
3. When engine coolant temperature is 30±10 °C
(86±18 °F) or higher, coolant temperature indicator
(6) goes off.
T2-2-26
SECTION 2 SYSTEM
ON
1 2 5 6
B ACC
R2
BR
4
M1-1 M2-2 M2-10

123 4 9
M1-7
M1-8
#2
7
TACD90-02-02-003
1- Battery 4- Fuse Box 6- Coolant Temperature 8- Coolant Temperature Sensor

2- Slow Blow Fuse 5- Monitor Controller Indicator 9- Alternator
3- Key Switch 7- Fuel Sensor
T2-2-27
SECTION 2 SYSTEM
Travel Alarm Circuit

When travel alarm deactivation switch (5) is in the OFF 4. As long as travel alarm controller (7) receives
position, the travel alarm circuit sounds buzzer (6) during this signal, it connects terminal #6 to terminal #5
travel operation. (ground).
5. Therefore, buzzer (6) sounds.
in key switch (3).
fNOTE: Buzzer (6) can be deactivated by setting travel
alarm deactivation switch (5) to the ON position.
2. Current from terminal ACC in key switch (3) flows
to terminal #4 in travel alarm controller (7) and
terminal #2 in buzzer (6) through fuse #7.
3. When operate the travel, the signal from travel
pressure sensor (8) is sent to terminal #2 in travel
alarm controller (7).
ON
1 2 B ACC
R2
BR 4
#2 #4
#6 #5
7
#2
6
TACC50-02-02-009
1- Battery 4- Fuse Box 6- Buzzer

2- Slow Blow Fuse 5- Travel Alarm Deactivation 7- Travel Alarm Controller
3- Key Switch Switch 8- Travel Pressure Sensor
T2-2-28
MEMO
MEMO
SECTION 3
COMPONENT OPERATION
CONTENTS
Group 1 Pump Device
Outline..................................................................................... T3-1-1
Main Pump P1, Main Pump P2........................................ T3-1-2
Main Pump P3, Pilot Pump P4......................................... T3-1-3
Output Power Control Operation.................................. T3-1-4
Outline..................................................................................... T3-2-1
Swing Reduction Gear....................................................... T3-2-2
Swing Motor.......................................................................... T3-2-3
Parking Brake......................................................................... T3-2-4
Valve Unit................................................................................ T3-2-5
Outline..................................................................................... T3-3-1
Hydraulic Circuit.................................................................T3-3-10
Arm Regenerative Valve..................................................T3-3-14
Flow Combiner Valve........................................................T3-3-16
Main Relief Valve................................................................T3-3-18
Overload Relief Valve........................................................T3-3-20
Make-Up Valve....................................................................T3-3-24
Group 4 Pilot Valve
Outline..................................................................................... T3-4-1
Operation (Front Attachment/Swing and
Travel Pilot Valves).......................................................... T3-4-5
Operation (Boom Swing/Blade/Auxiliary Pilot
Valve)................................................................................T3-4-11
Shockless Function (Only for Travel Pilot Valve)......T3-4-16
Shuttle Valve........................................................................T3-4-17
Outline..................................................................................... T3-5-1
Travel Reduction Gear........................................................ T3-5-2
Travel Motor........................................................................... T3-5-4
Parking Brake......................................................................... T3-5-6
Travel Brake Valve................................................................ T3-5-8
2-Spool Solenoid Valve...................................................... T3-6-1
AUX Function Solenoid Valve (OP)................................ T3-6-5
Swing Bearing....................................................................... T3-7-1
Center Joint............................................................................ T3-7-2
Track Adjuster........................................................................ T3-7-4
ACG90T-3-1
(Blank)
ACG90T-3-2
Group 1 Pump Device
Outline
The pump device is a direct-engine-drive type and
consists of main pump P1 (1), main pump P2 (2), main
pump P3 (3), and pilot pump P4 (4). Main pump P1 (1)
and main pump P2 (2) are swash plate type variable
displacement axial plunger pumps. Main pump P3 (3) is a
gear pump. They supply pressure oil to the control valve.
Main pump P1 (1) and main pump P2 (2) have a dual
delivery port design. This allows one pump to function
like two pumps. Pilot pump P4 (4) is a gear pump and
supplies pressure oil to the pilot circuit.
1, 2 3 4
TACC-03-01-001
1- Main Pump P1 2- Main Pump P2 3- Main Pump P3 4- Pilot Pump P4
T3-1-1
Group 1 Pump Device
Main Pump P1, Main Pump P2

Shaft (5) is connected to cylinder block (1) by a spline There are suction and delivery ports on inside and outside
joint, and plunger (3) is inserted into cylinder block (1). of cylinder block (1) alternately. In addition, there are
The engine rotation drives shaft (5) directly, and shaft delivery ports on each side (inside and outside) of valve
(5) rotates cylinder block (1) and plunger (3) together. plate (2). Therefore, the dual delivery port design allows
Plunger (3) slides on swash plate (6) and oscillates in one pump to function like two pumps having equal oil
cylinder block (1) due to inclination of swash plate (6). displacement.
4 3 2 TACC-03-01-001
7
11
10
8
9
T1MW-03-01-002
1
1- Cylinder Block 5- Shaft 9- Suction, Delivery Port
2- Valve Plate 6- Swash Plate (Outside)
3- Plunger 7- Suction Port 10- Delivery Port (Outside)
4- Shoe 8- Suction, Delivery Port (Inside) 11- Delivery Port (Inside)
T3-1-2
Group 1 Pump Device
Main Pump P3, Pilot Pump P4

Drive gear (6) is installed to shaft (1). Drive gear (6)
engages driven gear (4). The engine rotation drives shaft
(1) directly, and shaft (1) rotates drive gear (6). When drive
gear (6) rotates, driven gear (4) also rotates. Hydraulic
oil from suction port (5) fills the spaces between gears,
flows along the inner surfaces of housing, and is delivered
through delivery port (8).
2 3
TACC-03-01-001
4 6
8 T137-02-03-005
1- Shaft 3- Pilot Pump P4 5- Suction Port 7- Housing

2- Main Pump P3 4- Driven Gear 6- Drive Gear 8- Delivery Port
T3-1-3
Group 1 Pump Device
Output Power Control Operation

The output power control controls delivery flow rate of 4. Therefore, as delivery flow rate of main pumps P1
main pumps P1 (1) and P2 (2) in order to prevent the (1) and P2 (2) varies depending on changes in load
total load of main pumps P1 (1), P2 (2), and P3 (4) from from main pump P3 (4), the total load of three main
exceeding the engine torque. pumps does not exceed the engine torque.
1. When delivery pressure from main pumps P1 (1)
and P2 (2) increases, plunger (6) pushes swash plate
(7). When the plunger (6) force exceeds the spring
(3) force, swash plate (7) reduces the angle at pivot
pin (8) and delivery flow rate of main pumps P1 (1)
and P2 (2) decrease.
2. In addition, delivery pressure from main pump P3
(4) is routed to rod G (9) through the inner passage
in the pump.
3. Therefore, rod G (9) pushes swash plate (7). When
the rod G (9) force exceeds the spring (3) force,
swash plate (7) reduces the angle at pivot pin (8)
and delivery flow rate of main pumps P1 (1) and P2
(2) decreases.
1,2 3 4 5
7 6 TACC-03-01-001
1- Main Pump P1 4- Main Pump P3 7- Swash 9- Rod G

2- Main Pump P2 5- Pilot Pump P4 Plate
3- Spring 6- Plunger 8- Pivot Pin
T3-1-4
Outline
The swing device consists of valve unit (1), swing motor
(2), and swing reduction gear (3). Valve unit (1) prevents
the cavitation and the overload in the swing circuit. Swing
motor (2) is a swash plate type axial plunger motor (with
built-in swing parking brake), which is driven by pressure
oil from the pump, and the rotation is transmitted to
swing reduction gear (3).
Swing reduction gear (3) converts swing motor (2) output
into slow large torque to rotate the shaft. Thereby, the
upperstructure is rotated.
1,2
TACC-03-02-001
1- Valve Unit 2- Swing Motor 3- Swing Reduction Gear
T3-2-1
Swing Reduction Gear

The swing reduction gear is a one-stage planetary
reduction gear.
Ring gear (4) is monolithically built with the housing
and does not rotate. The swing motor shaft rotates shaft
(3) through planetary gear (1) and carrier (2). Shaft (3) is
engaged with the internal gear of the swing bearing fixed
to the undercarriage in order to swing the upperstructure.
4 1
3
TACC-03-02-001
1- Planetary Gear 2- Carrier 3- Shaft 4- Ring Gear
T3-2-2
Swing Motor
Shaft (1) is connected to rotor (2) by a spline joint, and
plunger (6) is inserted into rotor (2). When pressure oil
from the pump is supplied to plunger (6), it is pushed.
As plunger (6) is pushed, shoe (3) on the end of plunger
(6) slides along swash plate (4) and rotor (2) rotates. The
rotation of rotor (2) is transmitted to the swing reduction
gear through shaft (1).
TACC-03-02-001
1- Shaft 3- Shoe 5- Planetary Gear 7- Valve Plate

2- Rotor 4- Swash Plate 6- Plunger
T3-2-3
Parking Brake
The parking brake is a wet-type spring set hydraulic 1
released single-disc brake. The brake is released when the
brake release pressure is routed to brake piston chamber
(4).
2
When brake is released
1. When the pilot shut-off lever is in the UNLOCK 3
position, the pilot shut-off switch is turned ON. 7
Therefore, pilot shut-off solenoid valve (5) is turned
ON and the spool is shifted. 4
2. As the spool is shifted, the brake release pressure
from pilot pump (6) is routed to brake piston 9
chamber (4) through inner passage (8) in motor 8
housing (7).
3. The brake release pressure pushes brake piston (3)
downward. Brake piston (3) separates from disc
plate (1) which is connected to rotor (2) by a spline
6 5
joint. TACC-03-02-002
4. Consequently, as disc plate (1) becomes free and
rotor (2) can rotate, the brake is released.
1
When brake is applied

1. When the pilot shut-off lever is in the LOCK position, 2
the pilot shut-off switch is turned OFF. Therefore,
pilot shut-off solenoid valve (5) is turned OFF and
the spool returns. 3
7
2. As the spool returns, the brake release pressure
routed to brake piston chamber (4) is routed back
to the hydraulic oil tank through the spool in pilot 4
shut-off solenoid valve (5).
9
3. Brake piston (3) pushes disc plate (1) which is
connected to rotor (2) by a spline joint to motor
housing (7) due to spring (9).
4. Consequently, rotor (2) is secured and the brake is
applied.
6 5
TACC-03-02-003
1- Disc Plate 6- Pilot Pump

2- Rotor 7- Motor Hosing
3- Brake Piston 8- Inner Passage
4- Brake Piston Chamber 9- Spring
5- Pilot Shut-Off Solenoid Valve
T3-2-4
Valve Unit
The valve unit consists of make-up valve (2) and relief
valve (1). Make-up valve (2) prevents cavitation in the
circuit from occurring. Relief valve (4) prevents surge
pressure in the circuit from occurring and protects the
circuit from being overloaded.
Make-Up Valve
When the upperstructure is swung downward on a
slope, the upperstructure is accelerated by its own
weight and moves quicker than the swing motor drive
speed developed by the pump oil flow rate. Therefore,
cavitation can occur in the circuit. In order to prevent
cavitation, when pressure in the circuit is lower than
pressure at port T (4) (hydraulic oil tank), poppet
(3) opens, draws hydraulic oil into the circuit, and
compensates the lack of pump oil flow rate.
a b
2
3
4
TACC-03-02-004
a- To Control Valve b- From Control Valve

1- Relief Valve 2- Make-Up Valve 3- Poppet 4- Port T
T3-2-5
Relief Valve
When starting or stopping swing operation, the swing
circuit pressure becomes high. The relief valve prevents
the circuit pressure from rising higher than the set
pressure.
 Low-Pressure Relief Operation (Shockless Function)  High-Pressure Relief Operation (Overload Prevention)
1. When pressure in the circuit increases, pressure oil 1. After piston (3) reaches the stroke end, spring (5) is
at port HP is routed to piston (3) through orifice (2) compressed and the circuit pressure becomes the
of poppet (1), passage (4) of piston (3), and orifice normal relief set pressure.
(6). Then, piston (3) is moved to the left. 2. When pressure at port HP increases further and
2. Pressure in chamber A is kept low during movement the force applied to poppet (1) (Pressurized Area
of piston (3). (S1-S2)×Pressure at Port HP) exceeds the spring (5)
force, poppet (1) is opened and pressure oil flows to
3. Therefore, poppet (1) is pushed by only the spring port LP.
(5) force. Poppet (1) opens whenever pressure at
port HP is low. Therefore, hydraulic oil is relieved 3. When pressure at port HP is reduced to the
under low pressure. specified level, poppet (1) is closed by the spring (5)
force.
4. When piston (3) reaches the stroke end, the
pressure difference between the front and rear of 4. When pressure at port LP increases, piston (3) is
poppet (1) disappears and poppet (1) is closed. moved to the right.
1 2 3 6 1 3
LP LP
HP HP
A 5 4 S1 S2 5
TACC-03-02-005 TACC-03-02-006
HP- Port HP LP- Port LP
1- Poppet 3- Piston 5- Spring

2- Orifice 4- Passage 6- Orifice
T3-2-6
Outline
The control valve controls the pressure, flow rate, and flow The spools are operated by pilot oil pressure. Viewed from
direction in the hydraulic circuit. The main components the machine left side, the spools are arranged as follows:
are main relief valve, overload relief valve, flow combiner flow combiner valve (11), blade (10), swing (9), boom
valve (11), and spools. swing (8), auxiliary (6), arm (5), travel (right) (4), travel (left)
(3), boom (2), and bucket (1).
1 2 3 4 5 6 8 9 10 11
TACD90-03-03-001
a- Machine Front
1- Bucket 4- Travel (Right) 8- Boom Swing 11- Flow Combiner Valve
2- Boom 5- Arm 9- Swing
3- Travel (Left) 6- Auxiliary 10- Blade
T3-3-1
26 27
36
33
28
35
29
34
32
1 4 5 6 7 8 9 10 11 12 13 14 15 16 30 17
25 24 23 22 21 20 19 18
P3 P2 P1
31
TACD90-02-01-004
1- Load Check Valve (Bucket 11- Load Check Valve (Auxiliary 18- Make-Up Valve (Boom Swing: 25- Overload Relief Valve (Bucket:
Tandem Circuit) Tandem Circuit) Bottom Side) Bottom Side)
4- Load Check Valve (Boom 12- Check Valve (Orifice) (Auxiliary 19- Overload Relief Valve (Arm: 26- Travel Motor (Left)
Parallel Circuit) Parallel Circuit) Bottom Side) 27- Travel Motor (Right)
5- Load Check Valve (Boom 13- Load Check Valve (Main Pump 20- Overload Relief Valve (Arm: 28- Blade Cylinder
Tandem Circuit) P3 Tandem Circuit) Rod Side) 29- Boom Swing Cylinder
6- Main Relief Valve (Main Pump 14- Load Check Valve (Boom 21- Overload Relief Valve (Boom: 30- Flow Combiner Valve
P1) Swing Parallel Circuit) Bottom Side) 31- Main Pump
7- Main Relief Valve (Main Pump 15- Load Check Valve (Swing 22- Overload Relief Valve (Boom: 32- Attachment (OP)
P2) Parallel Circuit) Rod Side) 33- Swing Motor
8- Load Check Valve (Arm 16- Load Check Valve (Blade 23- Load Check Valve (Bucket 34- Bucket Cylinder
Tandem Circuit) Parallel Circuit) Parallel Circuit) 35- Boom Cylinder
9- Load Check Valve (Arm Parallel 17- Main Relief Valve (Main Pump 24- Make-Up Valve (Bucket: Rod 36- Arm Cylinder
Circuit) P3) Side)
10- Arm Regenerative Valve
T3-3-2
J I H 7 G F E D C B A 17
25 22 19
24 21 6 20 18
TACD90-03-03-001
a
a- Machine Front
fNOTE: Main relief valve (17), overload relief valves (19,

20, 21, 22, 25), and make-up valves (18, 24) are omitted
from the section view.
Section A (Flow Combiner Valve) Section B (Blade)
16
T1MS-03-03-002 TACD90-03-03-002
T3-3-3
26 27
36
33
28
35
29
34
32
1 4 5 6 7 8 9 10 11 12 13 14 15 16 30 17
25 24 23 22 21 20 19 18
P3 P2 P1
31
TACD90-02-01-004
Circuit) P3) Side)
T3-3-4
Section C (Swing) Section D (Boom Swing)
15 M
14
TACC-03-03-003 TACD90-03-03-003
Section E (Auxiliary) Section M-M
13
12 TACC-03-03-005
11
TACC-03-03-006
T3-3-5
26 27
36
33
28
35
29
34
32
1 4 5 6 7 8 9 10 11 12 13 14 15 16 30 17
25 24 23 22 21 20 19 18
P3 P2 P1
31
TACD90-02-01-004
Circuit) P3) Side)
T3-3-6
Section F (Arm) Section G (Travel (Right))
O
10
N N
TACC-03-03-007 TACC-03-03-009
Section H (Travel (Left)) Section O-O (Travel (Right))
8 TACC-03-03-010
Section P-P (Travel (Left))

P
5
TACC-03-03-012
Section N-N
TACC-03-03-011
TACC-03-03-008
T3-3-7
26 27
36
33
28
35
29
34
32
1 4 5 6 7 8 9 10 11 12 13 14 15 16 30 17
25 24 23 22 21 20 19 18
P3 P2 P1
31
TACD90-02-01-004
Circuit) P3) Side)
T3-3-8
Section I (Boom) Section J (Bucket)
4 1
23
TACD90-03-03-005
TACD90-03-03-004
T3-3-9
Hydraulic Circuit
The hydraulic circuit in control valve is divided into the
main circuit and pilot signal circuit.
Main circuit
Control Valve Hydraulic
Circuit
Pilot Signal Circuit
Main Circuit
Pressure oil from main pumps (26) (P1, P2, P3) flows
to the control valve respectively. When the spool is in
neutral (control lever is in neutral), pressure oil from
main pumps (26) returns to hydraulic oil tank (25)
through neutral circuits (6, 9, 10). When the spool is
operated (control lever is operated), pressure oil from
main pumps (26) flows to the actuator through the
spool. (When the combined operation of travel and
front attachment is done, flow combiner valve (12) is
shifted.) The main circuit has parallel circuits (13, 14,
16). The combined operation of actuators becomes
possible by using these circuits.
The pressure in the main circuit (between pump and

actuator) is controlled by main relief valves (11, 17) and
is prevented from exceeding the set pressure when the
spool (control lever) is operated. The pressure in the
actuator circuit (between control valve and actuator)
is controlled by overload relief valves (8, 20) and is
prevented from exceeding the set pressure by external
force when the spool (control lever) is in neutral.
T3-3-10
1 2
24
21
23 3
22 4
6 7 8 9 10 11
20 17 16 14 13 12
25 P3 P2 P1
18
26
19 TACD90-02-01-004
1- Travel Motor (Left) 8- Overload Relief Valve 16- Parallel Circuit 23- Boom Cylinder
2- Travel Motor (Right) 9- Neutral Circuit 17- Main Relief Valve 24- Arm Cylinder
3- Blade Cylinder 10- Neutral Circuit 18- Oil Cooler 25- Hydraulic Oil Tank
4- Boom Swing Cylinder 11- Main Relief Valve 19- Bypass Check Valve 26- Main Pump
5- Attachment (OP) 12- Flow Combiner Valve 20- Overload Relief Valve
6- Neutral Circuit 13- Parallel Circuit 21- Swing Motor
7- Arm Regenerative Valve 14- Parallel Circuit 22- Bucket Cylinder
T3-3-11
Pilot Signal Circuit

The pilot signal circuit is connected to hydraulic oil tank
(20) through each spool (travel (right) (14), travel (left)
(15), arm (13), boom (16), and bucket(17)). During the
combined operation of front attachment (boom, arm,
and bucket) and travel, the pilot signal circuit is blocked
so that pressure in the circuit increases. Consequently,
flow combiner valve (7) is shifted. During the combined
operation of travel and front attachment, pressure oil
from main pump (18) P3 flows to the front attachment
spool located at the downstream of the travel spool
so that the combined operation of travel and front
attachment can be operated. When operating the
swing, boom swing, and blade, flow combiner valve
(7) is not shifted. But, as pressure oil from main pumps
(18) P1 and P2 flows to travel (right) and travel (left)
respectively, the combined operation of swing, boom
swing, blade, and travel can be operated.
T3-3-12
1 2
24
21
23 3
22 4
17 16 15 14 13 12 11 10 9 8 7
20 P2 P1
P4 P3
19 18
TACD90-03-03-006
1- Travel Motor (Left) 7- Flow Combiner Valve 13- Arm Spool 19- Pilot Pump
2- Travel Motor (Right) 8- Blade Spool 14- Travel (Right) Spool 20- Hydraulic Oil Tank
3- Blade Cylinder 9- Swing Spool 15- Travel (Left) Spool 21- Swing Motor
4- Boom Swing Cylinder 10- Boom Swing Spool 16- Boom Spool 22- Bucket Cylinder
5- Attachment (OP) 11- Control Valve 17- Bucket Spool 23- Boom Cylinder
6- Pilot Signal Circuit 12- Auxiliary Spool 18- Main Pump 24- Arm Cylinder
T3-3-13
Arm Regenerative Valve

The arm regenerative valve supplies returning oil from the 4. Pressure oil which has pushed and has opened the
arm cylinder rod side to the arm cylinder bottom circuit poppet (arm regenerative valve) (4) flows to the arm
when the arm is rolled in. This control increases the arm cylinder (1) bottom side through passage F and port
roll-in speed and prevents the occurrence of cavitation. B5 so that cavitation is prevented.
5. In addition, pressure in the arm cylinder (1) bottom
1. When rolling in the arm with the arm raised, side becomes higher than that in the rod side
pressure in the arm cylinder (1) bottom side circuit during digging operation.
becomes lower than that in the rod side circuit
due to the arm and bucket weight while the arm is 6. In this case, the poppet (arm regenerative valve)
lowered. (4) is not opened. Therefore, the returning oil from
the arm cylinder (1) rod side does not flow to the
2. Pressure oil from the cylinder rod side flows to port bottom side, but returns to hydraulic oil tank (2).
A5 and is routed to the poppet (arm regenerative
valve) (4) through passage E.
3. Pressure oil from the cylinder rod side pushes and
opens the poppet (arm regenerative valve) (4).
fNOTE: Orifice (3) in passage E makes pressure oil easily

flow to the cylinder bottom side by restricting returning
oil from the cylinder rod side.
b
F A5
B5
4
c
E
3
2 TACC-03-03-016
a- Rod Side b- Bottom Side c- To Hydraulic Oil Tank

1- Arm Cylinder 3- Orifice 4- Poppet (Arm Regenerative
2- Hydraulic Oil Tank Valve)
T3-3-14
When Arm Spool is in Neutral

B5 A5
T1MS-03-03-024
When Operating Arm Roll-In

B5 A5
X
4
X
F
T1MS-03-03-025
Section X-X
T1MS-03-03-026
T3-3-15
Flow Combiner Valve

1. When operating the front attachment while 4. As parallel circuits (7) (passage G and passage E)
traveling, pilot signal circuit (5) is blocked by each are provided, pressure oil from main pump P3 is
spool (8, 9, 10, 11, 12, 13). supplied to each front attachment spool. Then, the
front attachment can be operated while traveling.
2. As pilot signal circuit (5) is blocked, pressure in
the circuit increases and flow combiner valve (6) is 5. Pressure oil from main pump P3 is supplied to to
shifted. spools of blade (4), swing (3) and boom swing (2)
through parallel circuit (7) (passage F) bypassing
3. When flow combiner valve (6) is shifted, parallel
flow combiner valve (6).
circuits (7) (passage G and passage E) to spools of
boom (12), arm (9), bucket (13), and auxiliary (8) are
provided.
e
1 g
2 3 4 5
a 13 12 11 10 9 8 7 E G F b
TACD90-03-03-007
a- From Main Pump P1 b- From Main Pump P3 e- From Main Pump P2 g- From Pilot Pump
1- Control Valve 5- Pilot Signal Circuit 9- Arm 13- Bucket

2- Boom Swing 6- Flow Combiner Valve 10- Travel (Right)
3- Swing 7- Parallel Circuit 11- Travel (Left)
4- Blade 8- Auxiliary 12- Boom
T3-3-16
When Flow Combiner Valve is in Neutral

E G
b
TACC-03-03-018
When Operating Flow Combiner Valve

b E G
TACC-03-03-019
i
b- From Main Pump P3 i- Flow Combiner Valve Spool

h- Pilot Signal Pressure
T3-3-17
Main Relief Valve

The main relief valve prevents that the pressure in the
main circuit exceeds the set pressure.
Operation
1. The pressure in port HP (actuator circuit) is routed
to pilot poppet (5) through orifices (2, 4) in main
poppet (1).
2. When the pressure in port HP reaches the set
pressure, pilot poppet (5) is opened and small
amount of pressure oil flows to port LP (hydraulic oil
tank) through passage (7).
3. At this time, the pressure difference between port
HP and spring chamber (8) occurs due to orifice (2).
4. When this pressure difference overcomes the spring
(3) force, main poppet (1) is opened and pressure oil
from port HP flows to port LP.
T3-3-18
During Normal Operation
1 2 3 4 5 6
HP
LP
8 7 TADB-03-03-010
During Relief Operation
1 2 3 4 5 6
HP
LP
8 7 T554-02-06-011
HP- Main Circuit LP- Hydraulic Oil Tank
1- Main Poppet 3- Spring 5- Pilot Poppet 7- Passage

2- Orifice 4- Orifice 6- Spring 8- Spring Chamber
T3-3-19
Overload Relief Valve

The overload relief valve prevents the actuator circuit
pressure from exceeding the set pressure (relief
operation) and prevents occurrence of cavitation (make-
up operation).
Relief Operation
Pressure oil is releaved to the hydraulic oil tank when
the pressure in the actuator increases due to external
force.
1. The pressure in port HP (actuator circuit) is routed
to pilot poppet (4) through orifice (8) in piston (9).
2. When the pressure in port HP reaches the set
pressure, pilot poppet (4) is opened and small
amount of pressure oil flows to port LP (hydraulic oil
tank) through passage (6) of seat (3).
3. At this time, the pressure difference between port
HP and spring chamber (7) occurs due to orifice (8).
When this pressure difference overcomes the spring
(2) force, main poppet (1) is opened and pressure oil
from port HP flows to the hydraulic oil tank through
port LP.
T3-3-20
During Normal Operation:
8 1 9 2 3 4 5
HP
LP
10 7 6 TADB-03-03-011
During Relief Operation:
8 1 9 2 3 4 5
HP
LP
10 7 6 TADB-03-03-012
1- Main Poppet 4- Pilot Poppet 7- Spring Chamber 10- Sleeve

2- Spring 5- Spring 8- Orifice
3- Seat 6- Passage 9- Piston
T3-3-21
Make-Up Operation
When lowering the boom suddenly, the actuator circuit
is lack of pressure oil from the pump. At this time, oil is
supplied to the actuator circuit from the hydraulic oil
tank.
When operating the relief operation due to external
force, which is explained on the previous page, the
pressure in the opposite side circuit decreases. At this
time, oil is supplied to the actuator circuit from the
hydraulic oil tank.
1. As the pressure in port HP is routed to spring

chamber (7) through the passage of piston (9), the
pressure in port HP and spring chamber (7) become
equal.
2. Therefore, when the pressure in port HP is high, the
force to close main poppet (1) [Pressure in Spring
Chamber (7) × Pressurized Area S2 + Spring (2)
Force] becomes larger than the force to open main
poppet (1) [Port HP × Pressurized Area S1] so that
main poppet (1) is closed.
3. When the pressure in port HP is lower than pressure
in port LP and the force to open main poppet (1)
[Pressure in Port LP x (Pressurized Areas S2 - S1)]
becomes larger than the force to close main poppet
(1) [Spring (2) Force], main poppet (1) is opened and
hydraulic oil is supplied to port HP from port LP.
4. Therefore, cavitation at the port HP side is
prevented.
T3-3-22
During Normal Operation:
8 1 9 2 3 4 5
HP
LP
10 7 6 TADB-03-03-011
During Make-Up Operation:
8 1 9 2 3 4 5
HP
LP
TADB-03-03-013
S1 10 S2 7 6
1- Main Poppet 4- Pilot Poppet 7- Spring Chamber 10- Sleeve

2- Spring 5- Spring 8- Orifice
3- Seat 6- Passage 9- Piston
T3-3-23
Make-Up Valve
The make-up valve prevents cavitation in the main circuit.
The make-up valves are provided in the bottom side
circuit in boom swing and the rod side circuit in bucket
cylinder.
1. As the pressure in port HP is routed to spring

chamber (4) through passage (1) in poppet (2), the 1 2 3 4
pressure in port HP and spring chamber (4) become
equal.
2. Therefore, when the pressure in port HP is high,
the force to close poppet (2) [Pressure in Spring
HP
Chamber (4) × Pressurized Area S2 + Spring (3)
Force] becomes larger than the force to open
poppet (2) [Port HP × Pressurized Area S1] so that
poppet (2) is closed. LP
3. When the pressure in port HP is lower than the
S1 S2
pressure in port LP and the force to open poppet T1LA-03-03-028
(2) [Pressure in Port LP x (Pressurized Areas S2 - S1)]
becomes larger than the force to close poppet 1- Passage 3- Spring
(2) [Spring (3) Force], poppet (2) is opened and 2- Poppet 4- Spring Chamber
hydraulic oil is supplied to port HP from port LP.
4. Therefore, cavitation at the port HP side is
prevented.
T3-3-24
Group 4 Pilot Valve
Outline
The pilot valve controls pilot pressure oil in order to move
the spool in the control valve.
The pilot valve outputs pressure according to the control
lever stroke by PPC (Pressure Proportional Control Valve)
function and moves the spool in the control valve.
The 4-port pilot valves for front attachment/swing and for
travel are standard.
The 2-port pilot valve is for boom swing, blade, and
auxiliary.
 Front Attachment / Swing Pilot Valve

Port No. ISO Control Pattern
Right 1 Bucket Roll-Out

2 Boom Raise
3 Bucket Roll-In
4 Boom Lower
Left 1 Swing (Right)
2 Arm Roll-In
3 Swing (Left)
4 Arm Roll- Out
TACC-03-04-001
A
View A
2
Hydraulic Symbol
3
P T
T
P
1 3 2 4 4 1
TADB-03-04-006 TACC-03-04-002
P- Port P (Pressure Oil from Pilot T- Port T (To Hydraulic Oil Tank)
Pump)
T3-4-1
Group 4 Pilot Valve
 Travel Pilot Valve

Port No.
1 Travel (Right Reverse)
2 Travel (Right Forward)
3 Travel (Left Forward)
4 Travel (Left Reverse) T
a Pressure Sensor
P
Hydraulic Symbol
P T a
T1M9-03-05-007
3 4
1 2 4 3
T1M7-03-04-020
a
a- Pressure Sensor
2 1
T1M9-03-05-008
P- Port P T- Port T
(Pressure Oil from Pilot Pump) (To Hydraulic Oil Tank)
a- Pressure Sensor
T3-4-2
Group 4 Pilot Valve
 Boom Swing/Blade/Auxiliary Pilot Valve

Port No.
Boom Swing 1 Right
2 Left
Blade 1 Lower
T
2 Raise
Auxiliary 1 - P
2 -
Hydraulic Symbol
P T
1 2 TADB-03-04-004
P- Port P (Pressure Oil from Pilot T- Port T (To Hydraulic Oil Tank)
Pump)
1 2
T1CF-03-04-001
T3-4-3
Group 4 Pilot Valve
(Blank)
T3-4-4
Group 4 Pilot Valve
Operation (Front Attachment/Swing and Front Attachment /

Travel Pilot Valves) Swing Pilot Valve
The spool (7) head comes in contact with the upper

surface of spring guide (4). Spring guide (4) is kept raised 1
by return spring (6).
2
fNOTE: Total lever strokes for front attachment and

swing controls are determined by stroke dimension 3
(E) of pusher (2). Total lever stroke for travel control is
determined by stroke dimension (E) of cam (1). 4
6
7
TACC-03-04-003
Travel Pilot Valve

1
2
3
4
5
6
TPPP-03-04-010
1- Cam 3- Casing 5- Balance Spring 7- Spool

2- Pusher 4- Spring Guide 6- Return Spring 8- Hole
T3-4-5
Group 4 Pilot Valve
Neutral (Output Curve: A to B): Front Attachment/

Swing Pilot Valve
1. When in neutral, spool (7) completely blocks
pressure oil from port P (pilot pump). In addition,
a
the output port is opened to port T (hydraulic oil
tank) through the inner passage in spool (7).
D
2. Therefore, the pressure in the output port is equal
to that in port T.
3. When the control lever is slightly tilted, cam (1) is
tilted and pusher (2) is pushed downward. Pusher C
(2) compresses return spring (6) along with spring
guide (4) together. A B b
4. At this time, as the pressure in the output port is T1F3-03-09-004
equal to that in port T, spool (7) moves downward a- Pilot Pressure b- Control Lever Stroke
due to the balance spring (5) force while keeping
the lower surface of the spool (7) head in contact Travel Pilot Valve
with spring guide (4).
E F
a
5. This status continues until hole (8) on spool (7) is
connected to port P. D
A B b
T523-02-05-001
a- Pilot Pressure b- Control Lever Stroke
T3-4-6
Group 4 Pilot Valve
Front Attachment/
Swing Pilot Valve
1
1
2 2
7 T
3 3
4 4
8 P
5 5
T T
6 6
7 7
P P
8
a TACC-03-04-003 a TACC-03-04-004
Travel Pilot Valve
1 1
2 2
T
3 7
3
P
4 4 8
5 5
6 6
a
T T
7 7
8 P P
8
a a
TPPP-03-04-016 TPPP-03-04-011
P- Port P T- Port T a- Output Port

T3-4-7
Group 4 Pilot Valve
During Metering or Decompressing (Output Curve: Front Attachment/

C to D) Swing Pilot Valve
1. When the control lever is further tilted and pusher

a
(2) is moved downward further, hole (8) on spool
(7) is connected to port P and pressure oil in port P D
flows to the output port.
2. The pressure in the output port acts on the bottom
surface of spool (7) so that spool (7) is pushed
upward. C
3. When the force to move spool (7) upward is smaller
than the balance spring (5) force, balance spring (5) A B b
is not compressed so that spool (7) is not raised and
T1F3-03-09-004
the pressure in the output port increases. a- Pilot Pressure b- Control Lever Stroke
4. As the pressure in the output port increases further,
the force to move spool (7) upward increases. When Travel Pilot Valve
this force overcomes the balance spring (5) force,
E F
spool (7) compresses balance spring (5) and moves a
upward.
D
5. As spool (7) is moved upward, hole (8) is closed so
that pressure oil from port P stops flowing to the
output port and the pressure in the output port
stops increasing. C
6. As spool (7) is moved downward and balance
spring (5) is compressed, the pressure acting on
A B b
the bottom surface of spool (7) increases until the
pressure balances with the increasing spring force. T523-02-05-001
This increasing pressure becomes the pressure in
the output port. a- Pilot Pressure b- Control Lever Stroke
T3-4-8
Group 4 Pilot Valve
Front Attachment/
Swing Pilot Valve
1
1
2 2
3 7 3
T 7
T
4 4
8
8
5 P 5 P
6 T 6 T
7 7
P P
8 8
a TACC-03-04-005 a TACC-03-04-006
Travel Pilot Valve
1 1
2 2
T T
7 7
3 3
4 P 4 P
5 8 5 8
6 6
a a
T T
7 7
P P
8 8
a a
TPPP-03-04-012 TPPP-03-04-013

T3-4-9
Group 4 Pilot Valve
Full Stroke (Output Curve: E to F) (Only for Travel

Pilot Valve)
1. When the control lever is fully stroked, cam (1)
moves downward until it comes in contact with E F
a
casing (3).
2. At this time, the bottom surface of pusher (2) D
directly pushes spool (7). Therefore, even if the
pressure in the output port increases further, hole
(8) on spool (7) is kept open.
C
3. Consequently, the pressure in the output port is
equal to that in port P.
A B b
T523-02-05-001
a- Pilot Pressure b- Control Lever Stroke
Travel Pilot Valve
4
5
6
T
7
8
a
TPPP-03-04-014

T3-4-10
Group 4 Pilot Valve
Operation (Boom Swing/Blade/Auxiliary Pilot

Valve)
The spool (7) head comes in contact with the upper
surface of spring guide (4). Spring guide (4) is kept raised 1
by return spring (6).
fNOTE: Total lever stroke is determined by stroke E

dimension (E) of cam (1).
2
3
4
5
6
7
8
TADB-03-04-007
1- Cam 3- Plate 5- Balance Spring 7- Spool

T3-4-11
Group 4 Pilot Valve
 Boom Swing/Blade/Auxiliary Pilot Valve
Neutral (Output Curve: A to B):

1. When the control lever is in neutral, spool (7)
a
completely blocks pressure oil from port P. In
addition, the output port is opened to port T D
(hydraulic oil tank) through the inner passage in
spool (7).
2. Therefore, the pressure in the output port is equal
to that in port T. C
3. When the control lever is slightly tilted, cam (1) is

moved and pusher (2) is pushed downward. Pusher A B b
(2) compresses return spring (6) along with spring
guide (4) together. T1F3-03-09-004
4. At this time, as the pressure in the output port is a- Pilot Pressure b- Pusher Stroke
equal to that in port T, spool (7) moves downward
due to the balance spring (5) force while keeping
the lower surface of the spool (7) head in contact
with spring guide (4).
5. This status continues until hole (8) on spool (7) is
connected to port P.
fNOTE: The pusher stroke while hole (8) on spool (7) is

connected to port P is play.
T3-4-12
Group 4 Pilot Valve
3 4
8 7
a
TADB-03-04-007
1
7 T
2
8
P
3
4
5 a
T
8 7
a TADB-03-04-008

T3-4-13
Group 4 Pilot Valve
During Metering or Decompressing (Output Curve:

C to D)
1. When the control lever is further tilted and pusher
(2) is moved downward further, hole (8) on spool
a
(7) is connected to port P and pressure oil in port P
flows to the output port. D
2. The pressure in the output port acts on the bottom
surface of spool (7) so that spool (7) is pushed
upward.
C
3. When the force to move spool (7) upward is smaller
than the balance spring (5) force, balance spring (5)
is not compressed so that spool (7) is not raised and A B b
the pressure in the output port increases.
T1F3-03-09-004
4. As the pressure in the output port increases further,
the force to move spool (7) upward increases. When a- Pilot Pressure b- Pusher Stroke
this force overcomes the balance spring (5) force,
balance spring (5) is compressed so that spool (7) is
moved upward.
5. As spool (7) is moved upward, hole (8) is closed so
that pressure oil from port P stops flowing to the
output port and the pressure in the output port
stops increasing.
6. As spool (7) is moved downward and balance
spring (5) is compressed, the pressure acting on
the bottom surface of spool (7) increases until the
pressure balances with the increasing spring force.
This increasing pressure becomes the pressure in
the output port.
T3-4-14
Group 4 Pilot Valve
2 7
T
8
3
4
5 a
T
P
6
7
a TADB-03-04-009
1
2 7 T
8
3
4
5 a
T
6
P
7
8
a
TADB-03-04-010

T3-4-15
Group 4 Pilot Valve
Shockless Function (Only for Travel Pilot

Valve)
The travel pilot valve has damper (1) enabling damping of
the speed change shock by travel control lever (4).
Damper (1) is composed of support (5), gear 1 (9), gear 2
(8), and others. Gear 1 (9) is connected to support (5).
Support (5) is secure to bracket (6) by spring pin (2). Travel
1 2 3
control lever (4) and travel pedal (3) are secure to bracket
(6). Therefore, support (5) rotates transversely around pin A
(7) according to movement of travel control lever (4).
4
Operation
5
1. If travel control lever (4) is released while traveling,
spring force of the return spring returns travel
6
control lever (4) to the neutral position.
2. At this time, gear 1 (9) and gear 2 (8) inside damper 7
(1) receive resisting force due to friction. 8
3. Consequently, as travel control lever (4) gradually 9
returns to the neutral position, the shock of the A
sudden machine stop is reduced when travel
control lever (4) is suddenly released.
T1M7-03-04-002
Section A-A 2
5
1
7
T1M7-03-04-003
1- Damper 6- Bracket
2- Spring Pin 7- Pin
3- Travel Pedal 8- Gear 2
4- Travel Control Lever 9- Gear 1
5- Support
T3-4-16
Group 4 Pilot Valve
Shuttle Valve Travel Pilot Valve
The shuttle valves select the necessary pilot pressure for

traveling and lead pressure oil to the pressure sensor.
TADB-03-04-005
b a
a- Shuttle Valve b- To Pressure Sensor
T3-4-17
Group 4 Pilot Valve
(Blank)
T3-4-18
Outline
The travel device consists of travel motor (3), travel Travel reduction gear (2) is a two-stage planetary
reduction gear (2), and travel brake valve (1). reduction gear, converts the travel motor (3) rotation
Travel motor (3) is a swash plate type variable power to a slow-large torque, and rotates sprocket (4) and
displacement axial plunger motor and equipped with a the track.
parking brake (a wet-type spring set hydraulic released Travel brake valve (1) prevents the machine from running
multi-disc brake). Travel motor (3) is driven by pressure oil away.
from the pump and transmits the rotation power to travel
reduction gear (2).
2 1
4
TACD90-03-05-001
1- Travel Brake Valve 2- Travel Reduction Gear 3- Travel Motor 4- Sprocket
T3-5-1
Travel Reduction Gear

The travel reduction gear is a two-stage planetary As second stage carrier (4) and travel motor housing
reduction gear. is united into one part, the rotation of second stage
The travel motor rotates shaft (5) and the rotation is planetary gears (3) is transmitted to sprocket (9) via ring
transmitted to first stage sun gear (8). The rotation of gear (1).
first stage sun gear (8) is reduced by first stage planetary
gears (2) and first stage carrier (7), and is transmitted to
second stage sun gear (6). The rotation of second stage
sun gear (6) is reduced by second stage planetary gears
(3) and second stage carrier (4) (united with the travel
motor housing).
1 2 3 4 5
7 6
TACD90-03-05-001
1- Ring Gear 4- Second Stage Carrier 7- First Stage Carrier

2- First Stage Planetary Gear 5- Shaft 8- First Stage Sun Gear
3- Second Stage Planetary Gear 6- Second Stage Sun Gear 9- Sprocket
T3-5-2
(Blank)
T3-5-3
Travel Motor
The travel motor is a swash plate type variable When pressure oil is supplied from the pump, plungers (5)
displacement axial plunger motor, and consists of valve are pushed. As swash plate (4) is inclined, shoe (3) on the
plate (6), swash plate (4), rotor (2), plunger (5), and shaft end of plunger (5) slides along swash plate (4) and rotor
(1). (2) rotates.
Shaft (1) is connected to rotor (2) by a spline joint into
which plungers (5) are inserted.
1 2 6
4 3 5
T1MW-03-05-001
1- Shaft 3- Shoe 5- Plunger 6- Valve Plate

2- Rotor 4- Swash Plate
T3-5-4
Operation
1. Pressure oil flows to port B in valve plate (6), enters
one side in rotor (2), and pushes plunger (5).
2. This force and inclination of swash plate (4) make
shoe (3) slide on swash plate (4) in order to rotate
rotor (2) and output shaft (7).
3. As rotor (2) rotates, when plungers (5) reach port A,
pressure oil is returned to the hydraulic oil tank.
4. Whether forward travel or reverse travel depends on
whether pressure oil is supplied to port A or port B.
A B
A
B
7 6
4 3
T183-03-05-009
A- Port A B- Port B
(Pressure oil from main pump (Pressure oil from main pump
or returning oil to hydraulic oil or returning oil to hydraulic oil
tank) tank)
2- Rotor 4- Swash Plate 6- Valve Plate 7- Output Shaft

3- Shoe 5- Plunger
T3-5-5
Parking Brake
The parking brake is a wet-type spring set hydraulic
released multi-disc brake. The brake is released when
the brake release pressure oil is routed to brake piston
chamber (a).
The parking brake is automatically applied unless the
travel function is operated.
Friction plates (2) and plates (3) are connected to rotor
(4) and housing (1) of the travel motor by a spline joint
respectively.
When brake is released When brake is applied

1. When the travel control lever is operated, pressure 1. When the travel control lever is returned to neutral,
oil from the main pump is routed to port AV or BV in counterbalance valve spool (7) in the travel brake
the travel motor through the control valve. valve is returned to neutral.
2. This pressure oil shifts counterbalance valve spool 2. As pressure oil routed to brake piston (5) is returned
(7) in the travel brake valve and is routed to brake to the drain circuit, brake piston (5) is returned by
piston (5) through the notch on counterbalance spring (6).
valve spool (7).
3. Consequently, the spring force acts on friction
3. Consequently, as brake piston (5) is pushed, plates plate (2), which is engaged with the external
(3) and friction plates (2) become freed each other circumference of rotor (4), and on plate (3), which
so that the brake is released. is engaged with the inside of housing (1) of the
travel motor through brake piston (5). Therefore, the
external circumference of rotor (4) is secured with
friction force.
T3-5-6
When brake is applied: When brake is released:

2 3
1 5
T1MW-03-05-005 T1MW-03-05-006
Section A-A
AV BV
7
A
TACD90-03-05-003 TACD90-03-05-002
AV- Port AV BV- Port BV a- Brake Piston Chamber

(Pressure oil from main pump) (Pressure oil from main pump)
1- Housing 3- Plate 5- Brake Piston 7- Counterbalance Valve Spool

2- Friction Plate 4- Rotor 6- Spring
T3-5-7
Travel Brake Valve

The travel brake valve is located on the travel motor head
and consists of the following valves.
 Counterbalance Valve (2):

Counterbalance valve (2) ensures smooth start / stop
travel operation and prevents the machine from
running away when traveling on a down slope. In
addition, counterbalance valve (2) routes the travel
motor operating pressure oil in the high-pressure port
(AV or BV) to the parking brake.
 Travel Mode Selector Valve (3):

Travel mode selector valve (3) is switched by pressure
oil from the travel mode selector solenoid valve and
switches the travel speed by the control piston.
T3-5-8
A 1
TACD90-03-05-002
Section A-A 2
4 3 4
TACD90-03-05-003
1- Travel Brake Valve 2- Counterbalance Valve 3- Travel Mode Selector Valve
T3-5-9
Counterbalance Valve
 While Traveling
1. When pressure oil from the control valve enters
port BV (12), pressure oil flows through the inside
of spool (2), unseats check valve BC (9), and flows
further to motor port BM (8).
2. On the other hand, returning oil from the travel
motor is routed to motor port AM (7). However, its
passage is blocked by check valve AC (6) and spool
(2).
3. When pressure in port BV (12) increases further,
pressure oil is routed to chamber B (10) through
orifice (11) and moves spool (2) to the right.
4. Consequently, returning oil from the travel motor
flows to port AV (1) through notch (4) of spool (2).
As pressure oil starts flowing at this stage, the travel
motor starts rotating.
5. When the travel control lever is returned to neutral,
spool (2) is returned to the original position by the
spring force and blocks the oil passage so that the
travel motor rotation is stopped.
 While Descending a Slope

1. When the machine descends a slope, the travel
motors are forcibly rotated by the machine self
weight like a pump.
2. If the travel motor draws oil, oil pressure in port BV
(12) and chamber B (10) decrease. Spool (2) moves
to the left so that returning oil from the travel motor
is restricted.
3. Therefore, oil pressure in motor port AM (7)
increases and functions the travel motor brake.
4. Once post BV (12) is restricted by spool (2), pressure
oil in port BV (12) increases again and moves spool
(2) to the right.
By repeating this (hydraulic brake operation), the
machine is prevented from running away.
T3-5-10
During travel operation:
12 1
2
11
3
10
4
8 7
TACD90-03-05-004
1- Port AV 5- Chamber A 9- Check Valve BC
2- Spool (Counterbalance Valve) 6- Check Valve AC 10- Chamber B
3- Orifice 7- Motor Port AM 11- Orifice
4- Notch 8- Motor Port BM 12- Port BV
T3-5-11
Travel Mode Selector Valve

 Slow Speed Operation  When Engine Stops
1. When the travel is at slow speed, pressure oil 1. When the engine stops, pressure oil acting on
from travel mode selector solenoid valve (6) is not control piston (4) returns to the hydraulic oil tank
supplied to spool (1) of the travel mode selector through the travel mode selector valve.
valve. As spool (1) does not move to the right,
2. Consequently, surface (a) of the swash plate makes
pressure oil is not supplied to control piston (4).
contact with the housing by spring (5) force in the
2. Therefore, surface (a) of the swash plate makes rotor and the angle of swash plate increases.
contact with the housing by pressure oil acting on
plunger (2) and spring (5) force in the rotor.
3. Consequently, the angle of swash plate increases
and makes the stroke of plunger (2) longer.
4. As a consequence, the motor capacity becomes
larger and the travel motor rotates at slow speed.
 Fast Speed Operation

1. When the travel is at fast speed, pressure oil from
travel mode selector solenoid valve (6) flows
through the inner passage and switches spool (1) of
the travel mode selector valve.
2. Therefore, pressure oil in travel circuit A or B is
supplied to control piston (4) through notch (7) on
spool (1) and shuttle valve (8).
3. The swash plate is pushed by control piston (4) due
to pressure oil, which makes surface (b) contact with
the housing.
4. Consequently, the angle of swash plate decreases
and makes the stroke of plunger (2) shorter.
5. As a consequence, the motor capacity becomes
smaller and the travel motor rotates at fast speed.
T3-5-12
Slow Speed Operation:

1
A B
3
2
b
a
4 5 T1MW-03-05-010
Fast Speed Operation:

1
A B
6
7
8
3
b 2
a
4 5
T1MW-03-05-011
a- Surface (a) b- Surface (b)
1- Spool 3- Ball 5- Spring 7- Notch

2- Plunger 4- Control Piston 6- Travel Mode Selector Solenoid 8- Shuttle Valve
Valve
T3-5-13
(Blank)
T3-5-14
2-Spool Solenoid Valve

1 2
There are two kinds of solenoid valves in the 2-spool
solenoid valve; one is pilot shut-off solenoid valve (1) in
order to turn pilot pressure ON or OFF, the other is travel
mode selector solenoid valve (2) in order to shift travel
speed.
f NOTE: The structures of pilot shut-off solenoid valve (1)
and travel mode selector solenoid valve (2) are same.
TADB-03-06-001
1- Pilot Shut-Off Solenoid Valve 3- Pilot Relief Valve

2- Travel Mode Selector
Solenoid Valve
T3-6-1
 Pilot Shut-Off Solenoid Valve

 Pilot Shut-Off Lever: LOCK Position Pilot Shut-Off Lever: LOCK Position
1. When the pilot shut-off lever is set to the LOCK
position, the pilot shut-off relay is turned OFF and
the pilot shut-off solenoid valve is turned OFF. (Refer
to SYSTEM / Electrical System.)
2. Pressure oil from the pilot pump is blocked by spool
(1) in the pilot shut-off solenoid valve.
3. Therefore, even if the control/travel control lever is
operated, the pilot valve is not activated. P
1
 Pilot Shut-Off Lever: UNLOCK Position T
a
position, the pilot shut-off relay is turned ON and
the pilot shut-off solenoid valve is turned ON. (Refer
to SYSTEM / Electrical System.)
2. Therefore, spool (1) in the pilot shut-off solenoid
valve is pushed down and pressure oil from the pilot TADB-03-06-004
pump flows to the pilot valve.
3. Consequently, when the control/travel control lever
is operated, the pilot valve is activated. Pilot Shut-Off Lever: UNLOCK Position
P
1
a
TACC50-03-06-003
P- From Pilot Pump T- Returning Oil to Hydraulic Oil

a- To Pilot Valve Tank
1- Spool
T3-6-2
 Travel Mode Selector Solenoid Valve

 Slow Speed Position Slow Speed Position
1. When the travel mode switch is turned OFF (set to
slow speed position), the travel mode selector relay
is turned OFF and the travel mode selector solenoid
valve is turned OFF. (Refer to SYSTEM / Electrical
System.)
2. Pressure oil from the pilot pump is blocked by spool P
(1) in the travel mode selector solenoid valve.
3. Consequently, the travel mode selector valve in 1
travel motor is not shifted and the travel motor
rotates at slow speed. a
T
 Fast Speed Position
1. When the travel mode switch is turned ON (set to
fast speed position), the travel mode selector relay
is turned ON and the travel mode selector solenoid
valve is turned ON. (Refer to SYSTEM / Electrical
System.) TACC50-03-06-003
2. Therefore, spool (1) in the travel mode selector
solenoid valve is pushed down and pressure oil
from the pilot pump flows to both right and left
travel motors. Fast Speed Position
3. Consequently, the travel mode selector valve in

travel motor is shifted and travel motor rotates at
fast speed.
TACC50-03-06-004
P- From Pilot Pump T- Returning Oil to Hydraulic Oil

a- To Travel Motor Tank
1- Spool
T3-6-3
 Pilot Relief Valve

The pilot circuit of 2-spool solenoid valve has a pilot
relief valve which prevents the circuit pressure from
rising more than the set pressure.
1. Pressure oil from the pilot pump is always routed

to relief cap (1). When this pressure increases more 1
than the set pressure (spring (2) force), relief cap (1)
is moved and pressure oil is relieved.
2
TADB-03-06-003
a- From Pilot Pump b- To Hydraulic Oil Tank

1- Relief Cap 2- Spring
T3-6-4
AUX Function Solenoid Valve (OP)

The AUX function solenoid valve consists of AUX function
solenoid valve 1 (1) and AUX function solenoid valve 2
C
(2). AUX function solenoid valve 1 (1) and AUX function 1 2
solenoid valve 2 (2) are proportional solenoid valves.
They are controlled by the electric current signal from
the AUX function lever controller and output pressure in
proportion to the electric current.
A2 A1
P
C
T1ND-03-06-001
Operation
In neutral:
1. Spring (4) pushes spool (3) up and port A2 is Section C-C 1 2
connected to port T.
4
A1
A2
T
P
3
TACC50-03-06-001
A1- Port A1 T- Returning Oil to Hydraulic Oil

A2- Port A2 Tank
P- From Pilot Pump
1- AUX Function Solenoid 3- Spool

Valve 1 4- Spring
2- AUX Function Solenoid
Valve 2
T3-6-5
When excited:
1. Solenoid (5) pushes spool (3) down due to the 1 2
force in proportion to the electric current through
solenoid (5).
2. Pilot pressure oil flows to port A2 from port P and
5
pressure at port A2 increases.
3. This pressure at port A2 is routed to part (a) of spool
(3). Spool (3) is pushed up by the force [Pressure
in Port A2 x (Pressurized Areas S2 - S1)] due to 4
A1
difference in the pressure receiving area of part (a).
4. When pressure at port A2 increases and the force A2
to push spool (3) up overcomes the force to push T
spool (3) down by solenoid (5), spool (3) is moved
back up and the passage between port A2 and
P
port P is closed. Then, pressure at port A2 stops 3
increasing.
A TACC50-03-06-001
Detail A
a S2
S1
TACC50-03-06-002
A1- Port A1 P- From Pilot Pump

A2- Port A2 T- Returning Oil to Hydraulic Oil
S1- Pressurized Area S1 Tank
S2- Pressurized Area S2
1- AUX Function Solenoid 4- Spring

Valve 1 5- Solenoid
2- AUX Function Solenoid
Valve 2
3- Spool
T3-6-6
Swing Bearing
The swing bearing supports the upperstructure on the
undercarriage and allows the upperstructure to swing
smoothly.
This bearing is a single row type ball bearing and consists
of outer race (1), inner race (3), balls (6), supports (5), and
seals (2, 4).
Outer race (1) is bolted to the upperstructure. Inner race
(3) is bolted to the undercarriage. The internal gear of
inner race (3) meshes with the output shaft of the swing
reduction gear.
TADB-03-07-001
1- Outer Race 3- Inner Race 5- Support

2- Seal 4- Seal 6- Ball
T3-7-1
Center Joint
The center joint is a 360° rotating joint. When the
upperstructure swings, the center joint eliminates
twisting of the hoses and allows hydraulic oil to flow the
travel motors and the blade cylinder.
Spindle (1) and body (2) are secured to the upperstructure
and to the swing center of the undercarriage respectively.
Pressure oil flows from each oil port of body (2) to the
right and left travel motors and the blade cylinder
through spindle (1). Seals (3) prevent oil leaks between
spindle (1) and body (2).
h
c d
e f
b
g d
b
f
a
g
e
TACD90-03-07-001
a Blade Lower d- Travel (Right Reverse) g- Pilot Pressure for Travel Mode
b- Blade Raise e- Travel (Left Forward) Control
c- Travel (Left Reverse) f- Travel (Right Forward) h- Drain
1- Spindle 2- Body 3- Seal
T3-7-2
1
View A
f h a c
g
f
e
3
d g
2
b
g d b e T1MJ-03-07-002
a 3
T577-03-07-001
h
a Blade Lower d- Travel (Right Reverse) g- Pilot Pressure for Travel Mode
b- Blade Raise e- Travel (Left Forward) Control
c- Travel (Left Reverse) f- Travel (Right Forward) h- Drain
1- Spindle 2- Body 3- Seal
T3-7-3
Track Adjuster
The track adjuster supported on the side frame consists of
spring (3) and adjuster cylinder (1).
Spring (3) absorbs the loads applied to the front idler (4)
part. Track sag is adjusted by adjuster cylinder (1).
 When grease is supplied through grease fitting (5),

grease fills chamber (a) in adjuster cylinder (1), pushes
piston rod (2), and reduces track sag.
Detail A
M104-07-119
A 1 2 4
T577-03-07-002
a 3
1- Adjuster Cylinder 3- Spring 5- Grease Fitting
2- Piston Rod 4- Front Idler
T3-7-4
MEMO
MEMO
SECTION 4
OPERATIONAL PERFORMANCE TEST

CONTENTS
Operational Performance Tests....................................... T4-1-1
Preparation for Performance Tests................................ T4-1-2
Group 2 Standard
Operational Performance Standard Table.................. T4-2-1
Main Pump P1, Main Pump P2 P-Q Diagram............. T4-2-7
Group 3 Engine Test
Engine Speed........................................................................ T4-3-1
Travel Speed.......................................................................... T4-4-1
Track Revolution Speed..................................................... T4-4-2
Mistrack Check...................................................................... T4-4-3
Travel Parking Leakage...................................................... T4-4-4
Swing Speed.......................................................................... T4-4-5
Swing Function Drift Check............................................. T4-4-6
Swing Motor Leakage........................................................ T4-4-8
Maximum Swingable Slant Angle................................T4-4-10
Swing Bearing Play............................................................T4-4-12
Hydraulic Cylinder Cycle Time.......................................T4-4-14
Dig Function Drift Check.................................................T4-4-17
Control Lever Operating Force......................................T4-4-19
Control Lever Stroke.........................................................T4-4-21
Combined Operation of Boom Raise / Swing
Function Check.............................................................T4-4-22
Clearance of Front Attachment Connecting
Part....................................................................................T4-4-23
Primary Pilot Pressure......................................................... T4-5-1
Secondary Pilot Pressure................................................... T4-5-3
Main Relief Set Pressure.................................................... T4-5-4
Overload Relief Valve Set Pressure................................ T4-5-7
Pump Driving Torque......................................................... T4-5-9
Swing Motor Drainage.....................................................T4-5-10
Travel Motor Drainage.....................................................T4-5-12
Group 6 Adjustment
Engine Control Lever Adjustment................................. T4-6-1
ACG90T-4-1
(Blank)
ACG90T-4-2
Operational Performance Tests

Use operational performance test procedure to The machine performance does not always deteriorate
quantitatively check all system and functions on the as the working hours increase. However, the machine
machine. performance is normally considered to reduce in
proportion to the increase of the operation hours.
Purpose of Performance Tests Accordingly, restoring the machine performance by
repair, adjustment, or replacement shall consider the
1. To comprehensively evaluate each operational
number of the machine’s working hours.
function by comparing the performance test data
with the standard values.
Definition of “Performance Standard”
2. According to the evaluation results, repair, adjust, or
1. Operation speed values and dimensions of the new
replace parts or components as necessary to restore
machine.
the machine’s performance to the desired standard.
2. Operational performance of new components
3. To economically operate the machine under
adjusted to specifications. Allowable errors will be
optimal conditions.
indicated as necessary.
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
operational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
“Performance Standard” is shown in tables to evaluate
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.
T4-1-1
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
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run
straight more than 20 m (65 ft 7 in), and to make a
full swing with the front attachment extended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to be
employed for communication among coworkers.
Once the test is started, be sure to communicate
with each other using these signals, and to follow
them without fail.
2. Operate the machine carefully and always give first
priority to safety.
3. While testing, always take care to avoid accidents
due to landslides or contact with high-voltage
power lines. Always confirm that there is sufficient
space for full swings.
4. Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil. Pay
special attention to this when removing hydraulic T105-06-01-003
pipings.
MAKE PRECISE MEASUREMENT

1. Accurately calibrate test instruments in advance to
obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test data
obtained can be produced repeatedly. Use mean
values of measurements if necessary.
TABA50-04-01-001
T4-1-2
Group 2 Standard
Operational Performance Standard Table The following switch positions shall be selected and the
hydraulic oil temperature shall be maintained as indicated
The standard Performance values are listed in the table below as the preconditions of performance tests unless
below. otherwise instructed in each performance test procedure:
Refer to the Group T4-3 to T4-6 for performance test  Engine Control Lever: Fast Idle
procedures.  Hydraulic Oil Temperature : 50±5 °C (122±9 °F)
Values indicated in parentheses [ ] are reference values.
Performance Test Designation Unit Performance Remarks Reference Page

Standard
ENGINE SPEED min-1 T4-3-1
Slow Idle Speed 1350±50
Fast Idle Speed 2350±50
Fast Idle Speed (Main Pump P1 2270±50
Relief Operation)
Fast Idle Speed (Main Pump P2 2290±50
Relief Operation)
Fast Idle Speed (Main Pump P3 (2250±100)
Relief Operation)
ENGINE COMPRESSION PRESSURE MPa (kgf/cm2, 3.43±0.1 (35±1, Measure after warming up Refer to Engine
psi) 495±15) the engine. Manual.
VALVE CLEARANCE (IN, EX) mm 0.15 to 0.25 Measure with the engine Refer to Engine
cold. Manual.
NOZZLE INJECTION PRESSURE MPa (kgf/cm2, 11.8 to 12.8 (120 Refer to Engine
psi) to 130, 1710 to Manual.
1860)
INJECTION TIMING Before TDC 16±1° Refer to Engine
Manual.
T4-2-1
Group 2 Standard

Standard
TRAVEL SPEED sec/20 m T4-4-1
Fast Speed Mode 16.4±1.5
Slow Speed Mode 27.7±1.5
TRACK REVOLUTION SPEED sec/3 rev T4-4-2
Fast Speed Mode 9.3±1.5
Slow Speed Mode 16.8±1.5
MISTRACK (With fast and slow travel mm/20 m 300 or less T4-4-3
speed modes)
TRAVEL PARKING LEAKAGE mm/3 min about 0 T4-4-4
SWING SPEED sec/3 rev 18.8±1.5 T4-4-5
SWING FUNCTION DRIFT CHECK mm/90° 135 or less T4-4-6
SWING MOTOR LEAKAGE mm/5 min 0 Bucket: loaded T4-4-8
MAXIMUM SWINGABLE SLANT ANGLE deg 20 or more Bucket: loaded T4-4-10
SWING BEARING PLAY mm 0.3 or less Allowable limit: 1.5 T4-4-12
T4-2-2
Group 2 Standard

Standard
HYDRAULIC CYLINDER CYCLE TIME sec 0.97 m arm T4-4-14
0.07 m3 (PCSA heaped)
bucket
Bucket: empty
Boom Raise 2.6±0.3
Boom Lower 2.0±0.3
Arm Roll-In 2.7±0.3
Arm Roll-Out 2.2±0.3
Bucket Roll-In 2.4±0.3
Bucket Roll-Out 1.4±0.3
Boom Swing (Right) 3.6±0.5
Boom Swing (Left) 5.0±0.5
Blade Raise 1.2±0.3
Blade Lower 1.7±0.3
DIG FUNCTION DRIFT CHECK mm/5 min 0.97 m arm T4-4-17
bucket
Bucket: loaded
Boom Cylinder 10 or less
Arm Cylinder 8 or less
Bucket Cylinder 5 or less
Bucket Bottom 150 or less
Blade Cylinder 3 or less
Blade Cylinder (With track off the 10 or less
ground)
Boom Swing Cylinder 3 or less
T4-2-3
Group 2 Standard
Performance Test Designation Unit Performance Performance Reference Page

Standard
CONTROL LEVER/PEDAL OPERATING N(kgf, lbf ) T4-4-19
FORCE
Front and Rear at Right Side 14(1.4, 3.15) or
less
Right and Left at Left Side 14(1.4, 3.15) or
less
Right and Left at Right Side 14(1.4, 3.15) or
less
Front and Rear at Left Side 14(1.4, 3.15) or
less
Travel Control Lever 23(2.3, 5.18) or
less
Blade Control Lever 19(1.9, 4.28) or
less
Boom Swing Pedal 54(5.5, 12.2) or
less
CONTROL LEVER/PEDAL STROKE mm T4-4-21
Front and Rear at Right Side 90±10
Right and Left at Left Side 75±10
Right and Left at Right Side 75±10
Front and Rear at Left Side 90±10
Travel Control Lever 89±10
Blade Control Lever 60±10
Boom Swing Pedal 18±5
BOOM RAISE/SWING (Bucket: Empty) 0.97 m arm T4-4-22
bucket
Bucket: empty
Height mm 2000 or more
Time sec 2.0±0.3
T4-2-4
Group 2 Standard

Standard
CLEARANCE OF FRONT mm T4-4-23
ATTACHMENT CONNECTING PART
Swing Post and Boom Foot 1.0 or less Swing Post max 30.03
min 30.00
Boom Foot max 30.13 including Bushing
min 29.98 including Bushing
Pin max 29.98
min 29.93
Boom and Arm 1.0 or less Boom max 30.04
min 30.00
Arm max 30.13 including Bushing
min 29.98 including Bushing
Pin max 29.98
min 29.93
T4-2-5
Group 2 Standard
Performance Test Designation Unit Performance Remarks Reference

Standard Page
HYDRAULIC SYSTEM
PRIMARY PILOT PRESSURE MPa (kgf/cm2, 4.1±0.5(42±5, T4-5-1
psi) 595±73)
SECONDARY PILOT PRESSURE MPa (kgf/cm2, When the control lever is T4-5-3
psi) fully operated
Front, Swing, Boom Swing, Blade, 2.9±0.5(30±5,
Auxiliary 420±73)
Travel 4.1±0.5(42±5,
595±73)
MAIN RELIEF VALVE SET PRESSURE MPa (kgf/cm2, Measure at machine. T4-5-4
psi)
Main Pump P1, Main Pump P2 22.1±1.0(225±10,
3210±145)
Main Pump P3 21.6±1.0(220±10,
3130±145)
Travel 22.1±1.0(225±10, Pump
3210±145)
Swing 19.3±1.0(195±10, Pump
2800±145)
OVERLOAD RELIEF VALVE SET MPa (kgf/cm2, Measured at test stand. T4-5-8
PRESSURE psi)
Boom 27.5±1.0(280±10,
3990±145)
Arm, Bucket 23.5±1.0(240±10,
3410±145)
SWING MOTOR DRAINAGE L/min (gpm) T4-5-11
With constant speed [0.5 (0.13) or less] Reference Value
TRAVEL MOTOR DRAINAGE L/min (gpm) T4-5-13
With constant speed (With fast and [0.7 (0.18) or Reference Value
slow travel speed modes) less/0.7 (0.18) or
less]
PUMP DELIVERY PRESSURE (Control MPa (kgf/cm ,
2
Lever in Neutral) psi)

Fast Idle [1.6(16.3, 230)] Reference Value
Slow Idle [0.7(7.1, 100)] Reference Value
T4-2-6
Group 2 Standard
Main Pump P1, Main Pump P2 P-Q Diagram

 P-Q Control (Torque Control) (Air Conditioner: OFF)
(Reference: Calculated Valve)
 Rated Pump Speed: 2200 min-1 (rpm)
 Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
 Pilot Pump Pressure: 4.1 MPa (42 kgf/cm2, 595 psi)
 Points on P-Q Line (P3=0.98 MPa (1.0 kgf/cm2, 140  Points on P-Q Line (P3=20.6 MPa (210 kgf/cm2, 2990
psi)) psi))
Delivery Pressure Flow Rate Delivery Pressure Flow Rate
MPa (kgf/cm2, psi) L/min (gpm) MPa (kgf/cm2, psi) L/min (gpm)
A 0 (0, 0) 26.4 (6.97) A 0 (0, 0) 26.4 (6.97)
B 10.1 (105, 1460) 25.9 (6.84) E 2.9 (30.0, 420) 26.3 (6.95)
C 17.5 (180, 2540) 12.1 (3.20) F 11.6 (120, 1680) 12.1 (3.20)
D 20.6 (210, 2990) 9.9 (2.62) G 18.3 (185, 2650) 6.4 (1.69)
H 20.6 (210, 2990) 6.3 (1.66)
L/min
Q
35
30
A E B
25
20
15
F C
D
10
G H
5
0 P
0 5 (51) 10 (102) 15 (153) 20 (204) 25 (255)
MPa (kgf/cm2)
TACD90-04-02-001
P- Delivery Pressure Q- Flow Rate
T4-2-7
Group 2 Standard
 Auxiliary Section P-Q Control (Torque Control)

(Reference: Calculated Valve)
 Rated Pump Speed: 2200 min-1 (rpm)
 Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
 Pilot Pump Pressure: 4.1 MPa (42 kgf/cm2, 595 psi)
 Points on P-Q Line

Delivery Pressure Flow Rate
MPa (kgf/cm2, psi) L/min (gpm)
A 0 (0, 0) 39.5 (10.4)
B 12.3 (125, 1780) 39.3 (10.4)
C 20.6 (210, 2990) 27.2 (7.19)
L/min
Q
50
45
A B
40
35
30
C
25
20
15
10
0 P
0 5 (51) 10 (102) 15 (153) 20 (204) 25 (255)
MPa (kgf/cm2)
TACD90-04-02-002
P- Delivery Pressure Q- Flow Rate
T4-2-8
Group 3 Engine Test
Engine Speed
Summary:
1. Measure the engine speed. 1 2
fNOTE: If the engine speed is not adjusted correctly, all

other performance data will be unreliable. Therefore,
measure the engine speed before performing all other
tests in order to check that the engine speed meets
specification.
Preparation:
1. Warm up the machine until coolant temperature
reaches 50 °C or more, and hydraulic oil
temperature is 50±5 °C.
2. Confirm that governor lever (1) of the fuel injection
pump comes in contact with stopper (2) at the fast-
idle and slow-idle positions according to the engine
control lever operation. T1MS-04-06-002
3. Put a reflection mark onto the crank pulley (3) side

by using a non-contact type engine speed meter.
3
(Reference Tool: ONO SOKKI HT-4200)
T1ND-04-03-001
a- Reflection Mark Position

1- Governor Lever 3- Crank Pulley
2- Stopper
T4-3-1
Group 3 Engine Test
Measurement: Remedy:
1. Measure the items as shown in the table below. Refer to Troubleshooting B.
2. When measuring, set test condition as shown in the
table below in response to the engine speed to be
measured.
Evaluation:
Refer to Operational Performance Standard.
Item Engine Control Test Conditions

Lever
Slow Idle Min. Speed Set the pilot shut-off lever to the UNLOCK position. Measure engine speed with
the control lever in neutral.
Fast Idle Max. Speed Set the pilot shut-off lever to the UNLOCK position. Measure engine speed with
the control lever in neutral.
Fast Idle (Relief Max. Speed Measure engine speed while relieving the boom raise circuit.
operation)
T4-3-2
Group 3 Engine Test
TABA50-04-03-001
1- Engine Control Lever
T4-3-3
Group 3 Engine Test
(Blank)
T4-3-4
Travel Speed
Summary:
1. Measure the time required for the machine to travel
a test track and check the performance of the travel
device system (from the main pump to the travel
motor).
Preparation:
c
1. Adjust track sag of both tracks equally. b
2. Provide a flat, solid test yard 20 m (65.6 ft) in length,
with extra length of 3 to 5 m (10 to 16 ft) on both
ends for machine acceleration and deceleration. a d
e
3. With the arm and the bucket cylinders fully d
extended, hold the bucket 0.3 to 0.5 m (12 to 20 in) TADB-04-04-001
above the ground.
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F). a- Bucket Height: 0.3 to 0.5 m d- Acceleration/Deceleration
(12 to 20 in) Zone: 3 to 5 m (10 to 16 ft)
b- Start e- 20 m (65.6 ft)
Measurement: c- End
1. Measure in both fast and slow travel modes.

2. Select the following conditions.
Travel Mode Switch Engine Speed

Slow Mode Fast Idle
Fast Mode Fast Idle
3. Start traveling the machine in the acceleration zone

with the travel levers to full stroke.
4. Measure the time required to travel 20 m (65.6 ft).
5. After measuring the forward travel speed, swing the
upperstructure 180° and measure the reverse travel
speed in the same way.
6. Repeat the measurement three times and calculate
the mean values.
Evaluation:
Remedy:
Refer to Troubleshooting B.
T4-4-1
Track Revolution Speed

Summary:
1. Measure the track revolution cycle time with the
track raised off ground and check the performance
of the travel device system (from the main pump to
the travel motor).
a
Preparation:
1. Adjust track sag of both tracks equally.
2. Put a mark on one shoe for side being measured by
TADB-04-04-002
using a piece of chalk or cloth.
3. Raise track off the ground for side being measured a- 90 to 110°
as illustrated.
dCAUTION: Securely support the raised machine

using blocks.
(122±9 °F).
Measurement:
1. Measure on both tracks at slow and fast travel
modes during forward and reverse travel.

Slow Mode Fast Idle
Fast Mode Fast Idle
3. Operate the travel control lever of the track to be
measured to full stroke.
4. Measure the time required for 3 revolutions after a
constant track revolution speed is obtained.
the mean values.
Evaluation:
f NOTE: The measurement data obtained through the
raised track revolution test may have wide variations.
Therefore, the evaluation based on the results obtained
from the 20 m (65.6 ft) travel speed check described
before is more recommendable.
Remedy:
T4-4-2
Mistrack Check
Summary:
1. Allow the machine to travel 20 m (65.6 ft). Measure
the maximum tread deviation from the tread chord
drawn between the travel start and end points and
check the performance of travel device system
(from the main pump to the travel motor).
2. If measured on a concrete surface, the tread
deviation has a trend to decrease.
Preparation:
1. Adjust track sag of both tracks equally.
a
2. Provide a flat, solid test yard 20 m (65.6 ft) in length,
with extra length of 3 to 5 m (10 to 16 ft) on both
ends for machine acceleration and deceleration.
c b
3. With the arm and bucket cylinders fully extended, TADB-04-04-003
hold the bucket 0.3 to 0.5 m (8 to 12 in) above the
ground. a- Maximum Distance c- 20 m (65.6 ft)
b- Acceleration Zone: 3 to 5 m
4. Maintain the hydraulic oil temperature at 50±5 °C (10 to 16 ft)
(122±9 °F).
Measurement:
1. Measure in both fast and slow travel modes.

Slow Mode Fast Idle
Fast Mode Fast Idle
3. Start traveling the machine in the acceleration zone
with the travel levers to full stroke.
4. Measure maximum distance between a straight 20
m (65.6 ft) tread chord and the tread made by the
machine.
5. After measuring the tracking in forward travel,
swing the upperstructure 180° and measure in
reverse travel.
the mean values.
Evaluation:
Remedy:
T4-4-3
Travel Parking Leakage

Summary:
1. Measure the parking brake function on a specified
slope.
Preparation:
1. Measure on a flat slope with a gradient of 20 %
(11.31°).
2. With the arm and bucket cylinders fully extended,
hold the bucket 0.2 to 0.3 m (8 to 12 in) above the
a
ground.
(122±9 °F). TADB-04-04-004
a- 0.2 to 0.3 m (8 to 12 in)
Measurement:
1. Measure the travel parking brake slip amount while
parked.
2. Climb the slope and set the travel lever in neutral.
3. Stop the engine.
4. After the machine stops, put matching marks on the
track link or the shoe, and the track frame.
5. After 3 minutes, measure the distance between
marks on the track link or the shoe and the track
frame.
Evaluation:
T505-06-03-005
b- Displacement measured after
3 minutes.
T4-4-4
Swing Speed
Summary:
1. Measure the time required to swing three complete
turns and check the performance of the swing
device system (from the main pump to the swing
motor).
Preparation:
1. Check lubrication of the swing gear and the swing
bearing.
2. Place the machine on a flat and solid ground with
a
ample space for swinging. Do not conduct this test
on a slope.
3. Fully retract the arm cylinder. Fully extend the TADB-04-05-007
bucket cylinder. Hold the boom so that the arm end
pin height is the same as the boom foot pin height. a- The height as boom foot pin height
Empty the bucket.
fNOTE: In case a sufficient space for the measurement

is difficult to find, carry out the measurement with the
boom fully raised and the arm fully rolled-in.
(122±9 °F).
dCAUTION: Prevent personal injury. Always make

sure that the area is clear and that coworkers
are out of the swing area before starting the
measurement.
Measurement:
1. Set the engine to the fast idle speed.
2. Operate the swing control lever fully.
3. Measure the time required to swing 3 turns in one
direction.
4. Check in both clockwise and counterclockwise
directions.
TADB-04-04-018
the mean values.
Evaluation:
Remedy:
T4-4-5
Swing Function Drift Check

Summary:
1. Measure the swing drift on the swing bearing outer
circumference when stopping after a 90° full-speed
swing and check the performance of the swing
brake valve.
2. The mechanical brake for the swing parking brake is
equipped in the swing motor.
Preparation: TADB-04-04-015

bearing.
2. Place the machine on a flat and solid ground with
sufficient space for swinging. Do not conduct this
test on a slope.
3. With the arm cylinder fully retracted and the bucket
cylinder fully extended, hold the bucket so that
height of the arm end pin is the same as the boom
foot pin. Empty the bucket.
4. Put matching marks on the swing bearing outer
circumference (upperstructure side) and the track
frame. TADB-04-04-016
5. Swing the upperstructure 90°.
(122±9 °F).

measurement.
T4-4-6
Measurement:
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 a
swinging the upperstructure 90°.
3. Measure the distance between the two marks.
4. Check in both clockwise and counterclockwise
directions.
5. Repeat the measurement three times and calculate b
the mean values.
c T1MP-04-04-009
Evaluation:
a- Measure distance between c- Mark on Swing Bearing
marks.
Remedy: b- Mark on Track Frame
T4-4-7
Swing Motor Leakage
Summary:
1. Measure the upperstructure drift while suspending
a load on a specified slope and check the
performance of the swing parking brake.
(The mechanical brake for the swing parking brake
is equipped in the swing device.)
Preparation:
bearing.
2. Load the bucket with either soil or a weight
equivalent to the specification.
Weight: 80 kg (180 lb)
3. With the arm cylinder fully retracted and the bucket TADB-04-04-006
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 matching marks
on the outer circumference of the swing bearing
(upperstructure side) and track frame by using the
tape.
(122±9 °F).
T4-4-8
Measurement:
1. Maintain the engine at slow idle. After five minutes,
measure the difference between the marks on the
swing bearing outer circumference and the track a
frame.
2. Measure the difference respectively when the brake
is applied (pilot shut-off lever: LOCK position) and
when the brake is released (pilot shut-off lever:
UNLOCK position).
3. Check in both clockwise and counterclockwise b
directions.
c T1MP-04-04-009
the mean values.
a- Measure difference between c- Mark on Swing Bearing

Evaluation: marks.
b- Mark on Track Frame
Remedy:
T4-4-9
Maximum Swingable Slant Angle
Summary:
1. With the upperstructure swung 90° to a slope,
check the maximum slant angle on which the
upperstructure can swing to a uphill side.
Preparation:
bearing.
2. Load the bucket with either soil or a weight
equivalent to the specification.
Weight: 80 kg (180 lb)
TADB-04-04-006
foot pin.
4. Climb a slope and swing the upperstructure 90° to
the slope.
(122±9 °F).
T4-4-10
Measurement:
2. Operate the swing control lever to full stroke to
swing the upperstructure to a uphill side.
3. If the machine can swing, measure the cab floor
slant angle.
4. When the machine can swing, increase the
slant angle. Check in both clockwise and
counterclockwise directions.
5. Repeat the measurement three times.
Evaluation:
Remedy:
T4-4-11
Swing Bearing Play

Summary:
1. Measure the swing bearing play and check the wear
of the swing bearing races and the balls.
Preparation
1. Check the swing bearing mounting bolts for 1 2
looseness. T105-06-03-014
1- Magnetic Base 2- Dial Gauge
2. Check lubrication of the swing bearing. Confirm
that bearing rotation is smooth without noise.
3. Secure dial gauge (2) on round trunk (3) of the track
frame by using magnetic base (1).
4. Position the upperstructure so that the boom aligns
with the tracks facing towards the front idlers.
5. Position dial gauge (2) so that its needle point
comes in contact with the bottom surface of the
swing bearing outer race. 3
6. The bucket should be empty.
fNOTE: The measured value will vary depending on

T1MP-04-04-019
where magnetic base (1) is secured. Secure magnet base
(1) onto round trunk (3) or in a position as close to the 3- Round Trunk
swing bearing as possible.
T4-4-12
Measurement:
cylinder fully extended, hold the bucket at the
height as boom foot pin height. Record dial gauge
reading (h1).
TADB-04-05-007
2. Lower the bucket to the ground and raise the front a- The height as boom foot pin height
idler 0.5 m (20 in) by using the front attachment.
Record dial gauge (2) reading (h2).
3. Calculate bearing play (H) from these data (h1 and
h2) as follows:
H=h2-h1
Evaluation:
b
TADB-04-04-021
b- 0.5 m (20 in)
T4-4-13
Hydraulic Cylinder Cycle Time
Summary:
1. Measure the cycle time of boom, arm, bucket,
boom swing, and blade cylinders and check the
performance from main pumps to each cylinder.
2. The bucket should be empty.
Preparation:
1. Measurement is made for the following positions.
 Measurement of the cycle time of the boom cylinder:
With the bucket cylinder fully extended and the arm TADB-04-04-008
cylinder fully retracted, lower the bucket onto the
ground.
 Measurement of the cycle time of the arm 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 (20 in) above the
ground.
 Measurement of the cycle time of the bucket

cylinder:
Adjust the boom and arm cylinders so that the a
bucket oscillation center faces vertically to the
ground. TADB-04-04-009
a- 0.5 m (20 in)
T105-06-03-020
T4-4-14
 Measurement of the cycle time of the boom swing

cylinder:
With the arm cylinder fully retracted and the bucket
cylinder fully extended, hold the bucket at the
height as boom foot pin height. Set the boom swing
cylinder in either the right or left swing stroke end
position.
TADB-04-04-010
 Measurement of the cycle time of the blade cylinder:

Raise the machine off the ground by using the front
attachment in order to be able to move the blade
cylinder to fully stroke.
TADB-04-04-019
T4-4-15
Measurement:
2. Measure the cylinder cycle times as follows:
(Cylinder full stroke includes cylinder cushioning
zone.)
 Measurement of the cycle time of the boom cylinder:
Operate the boom control lever to full stroke.
Measure the time to raise and lower the boom.
 Measurement of the cycle time of the arm cylinder:
Operate the arm control lever to full stroke. Measure
the time to roll in and roll out the arm.
 Measurement of the cycle time of the bucket
cylinder:
Operate the bucket control lever to full stroke.
Measure the time to roll in and roll out the bucket.
 Measurement of the cycle time of the boom swing
cylinder:
Operate the boom swing pedal to full stroke.
Measure the time to swing the front attachment
from right to left or vice versa.
 Measurement of the cycle time of the blade cylinder:
Operate the blade control lever to full stroke.
Measure the time to raise and lower the blade.
the mean values.
Evaluation:
Remedy:
T4-4-16
Dig Function Drift Check
Summary:
1. Measure the dig function drift, which can be caused
by oil leakage in the control valve and boom, arm,
bucket, boom swing, and blade cylinders, with the
bucket loaded. b
a
2. Measure the dig function drift for the blade cylinder
a
by using only blade weight.
3. When measuring the drift just after cylinder
replacement, slowly operate the cylinder for ten
minutes and bleed air from the cylinder. d
c
Preparation:
TADB-04-04-011
1. Load the bucket with either soil or a weight b
equivalent to the specification. a- Retracted Distance d- The height is the same as
b- Extended Distance boom foot pin.
Weight: 80 kg (180 lb) c- Dig Function Drift Amount
foot pin. Fully retract the blade cylinder.
3. When measuring the boom swing cylinder, climb a
slope with a gradient of 26.8 % (15°) and swing the
upperstructure 90° to the slope.
4. Position each cylinder with the rod 50 mm (2 in)
away from the full stroke end position.
(122±9 °F).
TADB-04-04-006
T4-4-17
Measurement:
1. Stop the engine. a
b b
2. When five minutes pass after the engine has been
stopped, measure the change in position of bottom
of the bucket and the blade, as well as the boom,
arm and bucket cylinders.
Boom and Bucket Cylinders: Retraction: a
a=A-B
Arm Cylinder: Extension: c
c=B-A T110-06-03-002
Blade Drift Amount: e a- Boom and Bucket Cylinders: b- Mark
e=A-B Retraction
3. When measuring the boom swing cylinder, measure

the boom swing cylinder retraction and extension
in left and right direction to a slope. c
d d
the mean values.
Evaluation:
Remedy:
TDCY-04-04-001
c- Arm Cylinder: Extension d- Mark
A B
e- Blade Drift Amount TDAD-04-04-001
T506-06-03-001
f- Boom Swing Cylinder:
Extension and Retraction
T4-4-18
Control Lever Operating Force
Summary:
1. Measure a play and operating condition of each
control lever.
2. Measure the maximum operating force of the front
attachment control lever.
3. Measure the lever stroke along the control lever
operation from the grip center of each control lever.
Preparation:
(122±9 °F). TABA50-04-04-001

measurement.
Measurement:
1. Measure the force of each control lever.
3. In case of boom (raise), arm, and bucket control
lever, measure the maximum operating force for
each with each actuator relieved.
4. In case of boom (lower) control lever, measure the
maximum operating force with the boom (lower)
relieved by raising the machine in a stable area.
5. In case of swing control lever, measure the TABA50-04-04-003
maximum operating force with swing relieved after
securing the front attachment to prevent turning.
6. In case of travel control lever, raise the track to be
measured. Measure the maximum operating force
required.
7. In case of blade control lever, raise the machine off
the ground by using the front attachment. Measure
the maximum operating force to be required.
TABA50-04-04-002
T4-4-19
8. In case of boom swing pedal, fully extend the boom

cylinder and arm cylinder. Measure the maximum
operating force to be required.
the mean values.
Evaluation:
TABA50-04-04-004
T4-4-20
Control Lever Stroke
Summary:
1. Check a play and operating condition of each
control lever and boom swing pedal, and measure
their strokes.
2. Measure the lever stroke at the grip center of each
control lever. As for the boom swing pedal, measure
the stroke from the center position to the stopper.
3. In case the lever stroke play is present in the neutral
position, add half (1/2) the play present to both side
lever strokes.
Preparation: T107-06-03-005
Blade Control Lever
(122±9 °F).
Measurement:
1. Stop the engine.
2. Measure each lever stroke from neutral to the stroke
end of each control lever of boom, arm, bucket,
swing, travel, and blade.
3. As for the boom swing pedal, measure the straight
distance between the center and fully depressed
positions at tip of the pedal.
4. Measure the chord length from neutral to the stroke
end. TADB-04-04-017

the mean values.
Evaluation:
T4-4-21
Combined Operation of Boom Raise / Swing

Function Check
Summary:
1. Check the boom raise and swing speeds while
operating both functions simultaneously.
2. Check if the cylinders do not hesitate while
operating the cylinder with the engine running at
fast idle.
TADB-04-04-012
Preparation:
cylinder fully extended, lower the bucket onto the
ground. Lower the bucket onto the ground. Empty
the bucket.
(122±9 °F).

measurement.
TADB-04-04-013
Measurement:
2. Raise the boom and swing the upperstructure in full
stroke at the same time. Measure the time required
to swing the upperstructure 90° and height (H) of
the bucket teeth. (The bucket should be empty.)
3. Repeat the measurement three times and calculate H
the mean values.
Evaluation:
Remedy: T107-06-03-011
T4-4-22
Clearance of Front Attachment Connecting 1 2

Part
Summary:
1. Measure the clearance of pin and pin hole, and
check the clearance of pins and bushings in each
connecting part of swing post (5), boom (1), and
arm (6).
Preparation:
1. Secure dial gauge (3) on the side surface of boom 5 4 3
TDCK-04-04-001
(1) or arm (6) by using magnetic base (2).
1- Boom 4- Needle Point
2. Position the upperstructure so that the boom aligns 2- Magnetic Base 5- Swing post
with the tracks facing towards the front idlers. 3- Dial Gauge
3. Position dial gauge (3) so that needle point (4)

comes into contact with the upper surface of swing 1 3 4
post (5) or the arm (6) connecting part of boom (1) 6
tip.
Measurement:
1. Set arm (6) so that the center of arm (6) operation is
vertical. Hold the bucket 50 mm (1.97 in) above the
ground. Record reading (h1) of dial gauge (3).
2. Rraise the front idler off the ground with arm (6) set
in vertical position. Raise the machine 50 mm (1.97 2 TDCK-04-04-002
in) as illustrated. Record reading (h2) of dial gauge 1- Boom 4- Needle Point
(3). 2- Magnetic Base 6- Arm
3- Dial Gauge
3. Calculate clearance (H) from these data (h1 and h2)
as follows:
Measurement of (h1)
H=h2-h1
Evaluation:
TADB-04-04-020
a- 50 mm (1.97 in)
Measurement of (h2)
a
TADB-04-04-021
a- 50 mm (1.97 in)
T4-4-23
(Blank)
T4-4-24
Primary Pilot Pressure

Preparation:
1. Stop the engine.
2. Slowly loosen the cap of the hydraulic oil tank and
bleed air.
3. Remove hose (9/16-18UNF) (3) at the pilot filter (2)
connection part. Install tee (ST 6450), adapter (ST
6069), and pressure gauge assembly (ST 6932) to 1
the pressure check port.
j : 19mm, 22 mm
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
2
(122±9 °F)
4
Measurement:
1. Measure the pilot pressure with the engine speed 3
set at the fast idle speed without load by using the
pressure gauge.
TACC50-04-05-001
the mean values.
1- Pump Device 3- Hose (9/16-18UNF)
2- Pilot Filter 4- 2-Spool Solenoid Valve
Evaluation:
T4-5-1
Primary Pilot Pressure Adjustment Procedure
Adjustment:
Adjust the relief valve set pressure of the 2-spool
solenoid valve if necessary.
1. Loosen lock nut (1).
j : 17 mm
2. Turn adjusting screw (2) in order to adjust the
pressure.
l : 6 mm
3. Tighten lock nut (1).
j : 17 mm
m : 15 to 20 N·m (1.5 to 2.0 kgf·m, 11 to 15

lbf·ft)
4. After the adjustment, check the set pressures.
fNOTE: Standard Change in Pressure (Reference)

1
Adjusting Screw (2) Turns 1/4 1/2 3/4 1 2 TADB-03-06-003
Change in kPa 182 363 545 726
Pressure (kgf/cm ) (1.85) (3.70) (5.55) (7.40)
2
1- Lock Nut 2- Adjusting Screw

(psi) (26) (53) (79) (105)
T4-5-2
Secondary Pilot Pressure

Preparation:
1. Stop the engine.
bleed air.
3. Install tee (5) (ST 6451), adapter (7) (ST 6069), and
pressure gauge (6) (ST 6942) to the pilot port for the
spool operation in the circuit to be measured.
j : 17mm, 19 mm
observed at the pressure gauge (6) connection.
(122±9 °F).
Measurement:
dCAUTION: Always make sure that the area is

clear and that co-workers are out of the swing
5 7 6
area before starting the measurement. When

measuring the boom lower secondary pilot
pressure, the machine should be raised off the 5- Tee 7- Adapter
6- Pressure Gauge
ground. Do not allow the machine to come in
contact with the ground or lay down the machine
as the machine becomes unbalanced.
2. Measure the pilot pressure by using pressure gauge
(6) with the corresponding control lever operated to
the full stroke.
the mean values.
Evaluation:
Remedy:
T4-5-3
Main Relief Set Pressure

Main Circuit
Summary:
Measure the main relief valve set pressure at the
delivery port in the main pump.
1 2 3
Preparation:
1. Stop the engine.
bleed air.
3. Remove plug (2) from the port to be measured.
Install adapter (ST 6069) and pressure gauge
assembly (ST 6933).
j : 19 mm
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50±5 °C 2 4
(122±9 °F). TACC50-04-05-002
1- Port P2 3- Port P1
2- Plug 4- Port P3
T4-5-4
Measurement:
2. Operate the control levers or pedals slowly to the 2 3
stroke end and relieve the pressure.
3. When measuring the set pressure of main relief
valve (P1) (1), operate the bucket control lever and
relieve the pressure.
valve (P2) (2), operate the arm control lever and
valve (P3) (3), operate the blade control lever and
valves (P1) (1) and (P2) (2) at the same time, operate TACD90-01-02-002
the arm and bucket control levers and relieve the 1
pressure. 1- Main Relief Valve (P1) 3- Main Relief Valve (P3)
2- Main Relief Valve (P2)
valves (P1) (1), (P2) (2), and (P3) (3) at the same time,
operate the arm, bucket, and blade control levers
and relieve the pressure.
8. As for the swing, secure the upperstructure so it is
immovable. Slowly operate the swing control lever
and relieve the pressure. Measure the relief pressure
of swing by using the pressure gauge at main pump
P3.
9. As for the travel, secure the tracks against an
immovable object. Slowly operate the travel control
lever and relieve the pressure.
the mean values.
Evaluation:
T4-5-5
Adjustment:
Adjust the main relief valve set pressure if necessary.
The main relief valves are installed on the position as 3
2
illustrated.
j : 17 mm
IMPORTANT: Adjust the pressure so that the
pressure does not exceed the upper limit of the
standard.
pressure.
l : 6 mm
j : 17 mm TACD90-01-02-002
1
m : 28 to 32 N·m (2.8 to 3.2 kgf·m, 20.5 to 23.5
lbf·ft)
4. After the adjustment, check the set pressures.
fNOTE: Standard Change in Pressure (Reference) 4

5
Adjusting Screw (5) Turns 1/4 1/2 3/4 1
MPa 4.45 8.9 13.35 17.8
Change in (kgf/cm2) (45.4) (91) (136) (182)
Pressure
(psi) (645) (1290) (1940) (2580)
TACC50-04-05-004
4
5
a
b
T505-06-04-007
a - Pressure Increase b - Pressure Decrease
1- Main Relief Valve (P2) 4- Lock Nut

2- Main Relief Valve (P1) 5- Adjusting Screw
3- Main Relief Valve (P3)
T4-5-6
Overload Relief Valve Set Pressure

Summary:
1. The circuit pressure must be increased by applying
an external force while blocking the return circuit
of the control valve. This measuring method is
hazardous and the results obtained with this
method are unreliable.
2. The oil flow rate used to set the overload relief
pressure is far less than that used to set the main
relief pressure. Therefore, measuring the overload
pressure in the main circuit by increasing the main
relief set pressure more than the overload valve
set-pressure is not a proper method. In addition the
main relief valve may be designed to leak a small
quantity of oil before reliving. In this case, its pre-
leaking start pressure must be increased 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 provided.
Accordingly, the overload relief valve assembly
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 the overload relief valve is
checked, the control valve body must be precisely
finished as the test unit. Provide one control valve
other than that on the machine as a test kit.
3. If the overload relief valve performance must be
checked on the machine, assume that the overload
relief valve is functioning correctly if the obtained
main relief pressure is within the specified value
range.
T4-5-7
Overload Relief Valve Pressure Adjustment

Procedure 1 2 3
fNOTE: In principle, adjust the overload relief valve

pressure on a test stand.
Loosen lock nut (7) and adjust the pressure by using
adjusting screw (8).
j : 17 mm
pressure.
l : 6 mm
3. Tighten lock nut (7). TACD90-01-02-002
5 4
j : 17 mm
m : 28 to 32 N·m (2.8 to 3.2 kgf·m, 20.5 to 23.5

lbf·ft)
4. After the adjustment, check the set pressures. 7
fNOTE: Standard Change in Pressure (Reference) 8
Adjusting Screw (8)

1/4 1/2 3/4 1
Turns
MPa 7.1 14.2 21.3 28.4
Change in (kgf/cm ) (72)
2
(145) (217) (290)
Pressure
(psi) (1030) (2060) (3090) (4120)
TADB-04-05-004
7
8
a
b
T505-06-04-007
a - Pressure Increase b - Pressure Decrease
1- Overload Relief Valve (Bucket: 5- Overload Relief Valve (Boom:

Bottom Side) Bottom Side)
2- Overload Relief Valve (Boom: 7- Lock Nut
Rod Side) 8- Adjusting Screw
3- Overload Relief Valve (Arm:
Bottom Side)
4- Overload Relief Valve (Arm:
Rod Side)
T4-5-8
Pump Driving Torque

Summary:
The adjustment of the pump driving torque is not 2
recommended. If the adjustment of the pump driving
torque is necessary, perform the following procedures.
However, do not increase the torque.
Adjustment:
j : 13 mm
pressure. 1
l : 4 mm
T1MS-04-05-006
fNOTE: Replace the washer of lock nut (2) after every
adjustment. If not, oil leaks may occur.
j : 13 mm
m : 10 to 14 N·m (1 to 1.4 kgf·m, 7.4 to 10 lbf·ft) 2 1

f NOTE: Standard Change in Pressure (Reference)
Adjusting Screw (1) Turns 1/4 1/2 3/4 1
Change in kPa 123 245 368 490 a
Pressure (kgf/cm ) (1.25) (2.5)
2
(3.75) (5)
(difference
from point A) (psi) (18) (36) (53) (71)
TABA50-04-05-005
b
a - Torque Decrease c- Flow Rate (Q1 = Q2)
b - Pressure ((P1 + P2)/2)
1- Adjusting Screw 2- Lock Nut
T4-5-9
Swing Motor Drainage

Summary:
1. Measure the amount of oil draining from the swing
motor while swinging the upperstructure and check
the swing motor performance.
2. Secure safety for the measuring persons as well as
for the surrounding while measuring.
a
3. The amount of drain oil from the swing motor
will change depending on the hydraulic oil
temperature.
Preparation:
(122±9 °F). Rotate the swing motor and warm the
inside of the motor. TACC50-04-05-003
2. Stop the engine. Slowly loosen the cap of the a- Drain Port
hydraulic oil tank and bleed air.
3. Disconnect the drain hose of the swing motor at
the motor end. Install the plug (9/16-18UNF) to the
disconnected hose. Connect the hose to drain port
(a) of the swing motor.
j : 17 mm, 22 mm
m : 30 N·m (3 kgf·m, 22 lbf·ft)
Preconditions for Measurement:

1. Set the engine speed to the fast idle speed before
the measurement.
T4-5-10
Measurement:
dCAUTION: Always make sure that the area is

clear and that co-workers are out of the swing area
before starting the measurement. Also, take care
not to fall off the machine while the measuring.
 Amount of Oil Drained While Swinging the
Upperstructure
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
control lever in the full stroke. After the swing
speed reaches a constant maximum speed, start
the draining oil measurement when drain oil starts
coming out from the drain hose end.
a
3. Repeat the measurement at least three times in
both clockwise and counterclockwise directions,
and calculate the mean values. TADB-04-05-007
4. The measuring time should be more than 45 a - The same height as boom
seconds. foot pin height
 Amount of Oil Drained While Relieving Swing Motor

Circuit
1. Thrust the bucket teeth into the ground so that the
upperstructure does not swing.
2. Start the engine. Operate and hold the swing
control lever in the full stroke. Start the draining oil
measurement when drain oil starts coming out from
the drain hose end.
both clockwise and counterclockwise directions,
and calculate the mean values.
4. The measuring time should be more than 45
seconds.
Evaluation:
* Conversion of 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 by using the
formula below:
∆Q =60×q/t
∆Q : Amount of drain oil per minute (L/min)

t : Measured time (seconds)
q : Total amount of drain oil (L)
T4-5-11
Travel Motor Drainage

Summary:
1. While rotating the travel motor with the track to
be measured raised off the ground, measure the
amount of oil draining from the travel motor and
check the travel motor performance.
2. Secure absolute safety for the measuring persons as
well as for the surrounding while measuring.
3. Judge the travel motor performance from the
results including the travel speed, mistrack and so
on overall.
4. The amount of drain oil from the travel motor
will change depending on the hydraulic oil
temperature.
1
Preparation:
(122±9 °F). Rotate the travel motor and warm the
inside of the motor.
2. Stop the engine. Slowly loosen the cap of the
hydraulic oil tank and bleed air.
3. Disconnect drain hose (1) of the travel motor at the
travel motor end. Install plug (7/16-20UNF) to the
disconnected hose.
Connect drain hose (7/16-20UNF) to the drain port
of the travel motor.
j : 17 mm
m : 25 N·m (25 kgf·m, 18.5 lbf·ft)
T571-04-04-004
Preconditions for Measurement:
1. Set the engine speed to the fast idle speed before
the measurement. 1- Drain Hose
T4-5-12
Measurement:
dCAUTION: When the working around moving

parts is unavoidable, pay special attention to
ensure that hands, feet, and clothing do not
become entangled. Securely support the raised
track off the by ground using the blocks.
1. Start the engine. Raise the track to be measured off a
the ground.
2. Rotate the track to be measured. Start the drain oil
measurement when drain oil starts coming out from
TADB-04-04-002
the drain hose (1) end.
a - 90 to 110°
both forward and reverse directions, and calculate
the mean values.
4. The measuring time should be more than 45
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
1
calibrated container. Then, convert the measured
drain oil into the per-minute value by using the
formula below:
T1MW-04-05-005
∆Q =60×q/t
1- Drain Hose
∆Q : Amount of drain oil per minute (L/min)
t : Measured time (seconds)
q : Total amount of drain oil (L)
T4-5-13
(Blank)
T4-5-14
Group 6 Adjustment
Engine Control Lever Adjustment

IMPORTANT: Do not adjust slow idle stopper bolt Engine Control Lever Side
(7) and fast idle stopper bolt (5) of governor lever
(6). These are sealed in advance by the engine
manufacturer. 1
Procedure
1. Loosen nuts (4) (2 used). Loosen fast idle stopper 2
bolt (2) and slow idle stopper bolt (3).
2. Adjust the bottom end length of slow idle stopper 4
bolt (3) to the specification. Secure it with nut (4).
3. Operate engine control lever (1) until it touches
slow idle stopper bolt (3).
At this time, check that governor lever (6) touches b
slow idle stopper bolt (7). In case it does not touch
slow idle stopper bolt (7), adjust the length of
3
engine control cable (8). a
TAEBJ0-04-06-003
4. Operate engine control lever (1) until governor lever
(6) touches fast idle stopper bolt (5).
Engine Side
Tighten fast idle stopper bolt (2) of engine control
5 6
lever (1) until the clearance between engine control
lever (1) and fast idle stopper bolt (2) is 1 to 2 mm.
Then, secure them.
8 T1MS-04-06-002
a- Specification: 25+10 mm b- Specification: 28.8+10 mm
1- Engine Control Lever 5- Fast Idle Stopper Bolt

2- Fast Idle Stopper Bolt 6- Governor Lever
3- Slow Idle Stopper Bolt 7- Slow Idle Stopper Bolt
4- Nut 8- Engine Control Cable
T4-6-1
Group 6 Adjustment
(Blank)
T4-6-2
MEMO
MEMO
SECTION 5
TROUBLESHOOTING
CONTENTS
Introduction........................................................................... T5-1-1
Diagnosis Procedure........................................................... T5-1-2
Electric System Inspection................................................ T5-1-4
Precautions for Inspection and Maintenance............ T5-1-5
Instructions for Disconnecting Connectors............... T5-1-7
Fuse Inspection..................................................................... T5-1-8
Slow Blow Fuse Inspection.............................................T5-1-10
Battery Voltage Check......................................................T5-1-11
Alternator Check................................................................T5-1-12
Continuity Check...............................................................T5-1-13
Voltage Inspection Method...........................................T5-1-14
Group 2 Troubleshooting B
Troubleshooting B (Machine Diagnosis by Using
Troubleshooting Symptom) Procedure.................. T5-2-1
Engine System Troubleshooting.................................... T5-2-4
All Actuator System Troubleshooting........................... T5-2-9
Front Attachment System Troubleshooting.............T5-2-14
Swing System Troubleshooting....................................T5-2-19
Travel System Troubleshooting....................................T5-2-21
Blade System Troubleshooting.....................................T5-2-26
Boom Swing System Troubleshooting.......................T5-2-27
How to Lowering Boom in Case of Emergency
and When Engine Stops.............................................T5-2-28
Troubleshooting C (Monitor Diagnosis)
Procedure.......................................................................... T5-3-1
Malfunction of Monitor Buzzer....................................... T5-3-3
Malfunction of Coolant Temperature Indicator........ T5-3-4
Malfunction of Fuel Gauge............................................... T5-3-5
Malfunction of Hour Meter............................................... T5-3-7
Indicator Operation Check............................................... T5-3-8
Malfunction of Fuel Level Indicator............................... T5-3-9
Malfunction of Overheat Indicator..............................T5-3-11
Malfunction of Engine Oil Pressure Indicator..........T5-3-12
Faulty Alternator Indicator.............................................T5-3-13
Malfunction of Preheat Indicator.................................T5-3-14
ACG90T-5-1
(Blank)
ACG90T-5-2
SECTION 5 TROUBLESHOOTING
Introduction
Refer to the inspection and troubleshooting procedures
after any machine trouble has occurred. The inspection
and troubleshooting procedures are presented in an
orderly sequence in this section to quickly find the cause
of machine trouble and solution.
The troubleshooting section in this manual consists of

three groups; Diagnosing Procedure, Troubleshooting
B (base machine diagnosis starting with inspection of
abnormal operational status), and Troubleshooting C
(monitor diagnosis).
 Diagnosing Procedure  Troubleshooting B (base machine diagnosis starting

This group explains procedures of troubleshooting with inspection of abnormal operational status)
and precautions and/or information for the electrical Refer to troubleshooting B for diagnosis by using
system inspection. trouble symptom.
Example: Fuse Inspection Example: Starter does not rotate.
 Troubleshooting C (monitor diagnosis)

This procedure is used when there are malfunctions
on components regarding monitor, such as gauges
or indicators.
Example: The fuel gauge is not operated.
T5-1-1
Diagnosis Procedure
These six basic steps are essential for efficient
troubleshooting:
1. Study the system

 Study the machine's technical manuals.
 Know the system and how it works, and what the
construction, functions and specifications of the
system components are.
(Construction and functions)
2. Ask the operator
Before inspecting, get the full story of malfunctions
T107-07-01-001
from the operator below.
 Operating condition: How is the machine being
used? (Find out if the machine is being operated
correctly.)
 Trouble identification: When was the trouble noticed,
and what type of work was the machine doing at
that time?
 Trouble symptom: What are the details of the
trouble? Did the trouble slowly get worse, or did it
appear suddenly for the first time?
 Trouble history: Did the machine have any other
troubles previously? If so, which parts were repaired
before?
3. Inspect the machine
Before starting the troubleshooting procedure,
check the machine's daily maintenance points, as
shown in the operator's manual.
Also, check the electrical system, including the
batteries, as troubles in the electrical system such
as low battery voltage, loose connections and T107-07-01-002
blown fuses will result in malfunction of controllers,
causing total operational failure of the machine.
If troubleshooting is started without checking for
blown fuses, a wrong diagnosis may result, wasting
time. Check for blown fuses before troubleshooting.
Even if a fuse looks normal by visual inspection, a
fine crack may exist and it is difficult to find.
Always use a circuit tester when checking the fuses.
4. Operate the machine yourself
Reproduce the trouble on the machine and make
sure the actual phenomenon.
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 corresponding to
the trouble.
T107-07-01-003
T5-1-2
5. Perform troubleshooting
dCAUTION: Do not disconnect wire harnesses

or hydraulic lines while the engine is running.
The machine may malfunction or pressurized
oil may spout out, possibly resulting in personal
injury. Stop the engine before disconnecting wire
harnesses or hydraulic lines.
Check operating condition of each component by
referring to Troubleshooting B and Troubleshooting C
in this section.
6. Trace possible causes
Before reaching a conclusion, check the most
suspect causes again.
Try to identify the actual cause of the trouble.
Based on your conclusion, make a plan for
appropriate repairs to avoid consequent T107-07-01-007
malfunctions.
T5-1-3
Electric System Inspection

The precautions and information for the electrical system
inspection are explained here. The electrical system
inspection contains as follows.
 Precautions for Inspection and Maintenance

 Instructions for Disconnecting Connectors
 Fuse Inspection
 Slow Blow Fuse Inspection
 Battery Voltage Check
 Alternator Check
 Continuity Check
 Voltage Inspection Method
T5-1-4
Precautions for Inspection and Maintenance

1. Disconnect the power source.
Disconnect the wire 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 slow blow
fuses and, in some cases, cause fire due to short
circuiting. In addition, even when the key switch is
turned OFF, the controller may be operated for a
specified time. Therefore, disconnect the harness
from the negative terminal side in battery after
setting the key switch to the OFF position and
waiting one minute or more.
2. Color coding of wire harnesses.
As for the color codes of wire harnesses in the
electrical system, refer to the table. 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
Color Orange Light Brown Pink Gray Violet
green
fNOTE:
 Code BW indicates a black base wire with white fine-
line marking.
 Initials "O" and "Or" both stand for the color orange.
 Longitudinal stripes printed on wires are not color
coded, indicate the kinds of wires.
T5-1-5
3. Precautions for connecting and disconnecting

terminal connectors.
 When disconnecting wire harnesses, grasp them
by their connectors. Do not pull on wire harness
itself. Release the lock first before attempting to
separate connectors, if a lock is provided. (Refer to
Instructions for Disconnecting Connector on T5-1-7.)
 Water-resistant connectors keep water out. If water
enters them, water will not easily drain from them. TDAA-05-08-002
When checking water-resistant connectors, take
extra care not to allow water to enter the connectors.
In case water enter the connectors, reconnect only
after the connectors are thoroughly dried. 1
 Before connecting connectors, check that no
terminal is bent (3) or coming off (4). In addition, 2
as most terminals of connector are made of brass,
check that no terminal is rusting (2). 3
 When connecting connectors provided with a lock,
insert them together until the lock "clicks."
 Pull wires near the connector in order to check if they 4
are correctly connected. TDAA-05-08-003
1- Correct
4. Precaution for using a circuit tester.

 Before using a circuit tester, refer to the instructions
in the circuit tester manual. Then, set the circuit
tester to meet the object to be measured, voltage TDAA-05-08-004
range and current polarity.
 Before starting the connector test, always check
connector terminal numbers, referring to the circuit
diagram. When connector size is very small, and
the standard probe size is too large to be used for
testing, wind a fine piece of sharpened wire or a pin
around the probe to make the test easier.
 When checking connector by using a circuit tester,
insert a tester probe from the wire harness end
of connector in order not to damage the terminal
inside connector.
T5-1-6
Instructions for Disconnecting Connectors
 Push, Unlock, and Separate Type
 Connectors will not be easily separated even if the

lock is pushed while being pulled.
 The lock is located on female side connector (wire
harness end side).
T107-04-05-002
 Raise Lock, Pull, and Separate Type
T107-04-05-003
T5-1-7
Fuse Inspection
Cracks in a fuse are so fine that it is very difficult or
impossible to find by visual inspection. Use a circuit tester
in order to correctly inspect fuse continuity. Use a circuit
tester in order to correctly inspect fuse continuity by
following the instructions described below.
1. Set the key switch to the ON position. When the key

switch is in the ON position, current from key switch
terminal BR, R2, and ACC is supplied to all circuits
except fuses #4, #6. (Refer to the circuit diagram.)
2. Remove the fuse box cover. Set a circuit tester.
(Measurement Range: 0 to 14.5 V)
3. Ground the negative probe of the circuit tester to
the body. Touch the terminals located away from
center of the fuse box with the positive probe of the
circuit tester one at a time. When the circuit tester
indicates around 12 V (battery voltage), the fuse is
normal.
6 1
7 2
8 3
9 4
10 5
TACC50-05-01-002
T5-1-8
Fuse No. Capacity Connected to

1 5A Horn Relay, Monitor Controller (Backup Power)
2 20 A Work Light Relay
3 5A Alternator, Buzzer, Monitor Controller (Power)
4 5A Monitor Controller, Glow Plug Relay
5 20 A Auxiliary Power
6 5A Starter Relay 1
7 10 A Travel Alarm Controller, Buzzer, AUX Function Lever Power (Optional)
8 5A Starter Relay 2, One-Second Timer, Engine Stop Solenoid, Fuel Pump, Travel Mode Selector Relay,
Travel Mode Pedal, Diode Terminal #3
9 5A Pilot Shut-Off Switch, Pilot Shut-Off Relay, Work Light Switch
10 - -
T5-1-9
Slow Blow Fuse Inspection

Inspection
1. Visually inspect slow blow fuse (1).
Replacement
1
1. Disconnect the negative cable from the battery.
2. Pull out slow blow fuse (1). Replace fusible link (1).
3. Connect the negative cable to the battery.
TACC50-05-01-001
T111-04-05-015
1- Slow Blow Fuse
T5-1-10
Battery Voltage Check

1. Turn the key switch OFF. Check the voltage between
the battery positive terminal and the body (ground).
Normal Voltage: 12 V
fNOTE: If the voltage is abnormal, recharge or replace

the battery.
2. Start the engine. Check the voltage between the
battery positive terminal and the body (ground).
Normal Voltage: 14.5 V
fNOTE: If the voltage is abnormal, check the charging

system.
T505-07-01-002
T5-1-11
Alternator Check
Generally, if the alternator has generated electricity,
alternator indicator (1) will disappear. If alternator 1
indicator (1) is displayed while the engine is running, the
alternator might be defective.
How to Check Alternator

1. Set the key switch to the ON position. Confirm that
alternator indicator (1) is displayed.
2. Measure the voltage between terminal IG of the
alternator and the body. If the measured voltage is
around 12 V, the alternator circuit can be considered
normal. If the measured voltage is low, a shortage M1NC-01-005
in battery capacity or looseness of the wire harness
connectors of the alternator circuit might be the 1- Alternator Indicator
cause of the malfunction. When the voltage is 0 V,
the wire harness between fuse box and alternator B
might be loose or disconnected.
3. Next, start the engine and measure the voltage
generated while the alternator rotates. As described
above, measure the voltage between terminal B on
the alternator side and the body.
If the voltage is around 13.5 V, the alternator is
operating normally. If the measured voltage is same
as the battery voltage (around 12 V), there is some
trouble with the alternator.
TABA50-05-01-003
T5-1-12
Continuity Check
IMPORTANT: Before the continuity check, set the key
switch to the OFF position. A a
 Single-line continuity check

Disconnect both end connectors of the wire harness and
check the continuity between both ends:
 If the ohm-meter reading is: ∞ Ω = Discontinuity
 0 Ω = Continuity
A a
 When the one end connector is far apart from the
other, connect one end of connector (A) to the body
by using a clip. Then, check the continuity of the wire
harness through the body as illustrated.
 If the ohm-meter reading is: ∞ Ω = Discontinuity
 0 Ω = Continuity
A a
 Single-line short-circuit check

Disconnect both end connectors of the wire harness and
check the continuity between one end connector of the
wire harness and the body:
 0 Ω = Short-circuit is present.
 ∞ Ω = No short-circuit is present.
T107-07-05-003
 Multi-line continuity check

Disconnect both end connectors of the wire harness,
and short-circuit two terminals, (A) and (B), at one end
connector, as illustrated. Then, check the continuity A a
between terminals (a) and (b) at the other connector. B b
C c
If the ohm-meter reading is ∞ Ω, either line (A) - (a),
or (B) - (b) is in discontinuity. To find out which line is
discontinued, conduct the single line continuity check on
both lines individually, or, after changing the short-circuit
terminals from (A) - (B) to (A) - (C), check the continuity
once more between terminals (a) and (c). By conducting
the multi-line continuity check twice, it is possible to find T107-07-05-004
out which line is discontinued. With connecting terminals
(A) and (C), check the continuity between terminals (a)
and (c).
 0 Ω = Line (B) - (b) has discontinuity.
 ∞ Ω = Line (A) - (a) has discontinuity.
A a
B b
C c
 Multi-line short-circuit check
Disconnect both end connectors of the wire harness, and
check the continuity between terminals (A) and (B) or (C).
 0 Ω = Short-circuit exists between the lines.
 ∞ Ω = No short-circuit exists between the lines.
T107-07-05-005
T5-1-13
Voltage Inspection Method

Turn switches ON so that the specified voltage is supplied Key Switch: ON (check point (4) to check point (8))
to the check point. Measure the voltage. Diagnose the Relay: ON (check point (9), check point (10))
circuit between power source and the check point by Black (negative) probe terminal of circuit tester: To the
checking that the specified voltage is supplied or not. body (to ground)
Red (Positive) probe terminal of circuit tester: To check
Start checking the circuit in order up to the location to point
be measured from either power source or actuator side. Power source: Batteries (12 V)
Thereby, the faulty location in the circuit will be found. * If the measured voltage is 0.5 V less than the battery
voltage, some incorrect contacts may exist at
connectors.
TAEBJ0-05-01-002
a- Key Switch e- Battery

d- Relay f- Check Order (Horn Circuit)
T5-1-14
5-Volt Circuit
 Voltage between terminal #1 and the body Three Polarities
Disconnect the connector with the key switch OFF.
Measure the voltage between terminal #1 on the body 1 2 3
wire harness end connector and the body (ground).
 Key Switch: ON
 Black (negative) probe terminal of circuit tester: To
the body (to ground)
 Red (Positive) probe terminal of circuit tester: To
terminal #1
Evaluation: If the measuring voltage is within 5 ± 0.5 volts, T107-07-05-007

the circuit up to terminal #1 is normal.
 Voltage between terminal #1 and the ground terminal Three Polarities

Turn OFF the key switch, and disconnect the sensor
connector. Measure the voltage between terminal #1 (5 1 2 3
V power supply) on the body wire harness end connector
and the ground terminal (terminal #3 for three-polarities
connector) under the following conditions.
 Key Switch: ON
 Black (negative) probe terminal of circuit tester: To
ground terminal (Terminal #3)
 Red (Positive) probe terminal of circuit tester: To
terminal #1 T107-07-05-009
Evaluation: If the measuring voltage is within 5 ± 0.5 volts,

the circuit up to terminal #1 and the ground terminal
(terminal #3) is normal.
T5-1-15
(Blank)
T5-1-16
Troubleshooting B (Machine Diagnosis by

Using Troubleshooting Symptom) Procedure
Refer to troubleshooting B procedures for diagnosis by
using trouble symptom.
 Diagnosis Procedure
 The diagnosis procedures for the displayed fault
codes are explained in this group.
f NOTE: All connector images in this section are viewed
from the open end side of wire harness end.
1
2
T6L4-05-03-001
1- Wire Harness End Connector 2- Wire Harness
T5-2-1
Contents of Diagnosis
Trouble Symptom
Preparation
Viewpoints for a diagnosis and contents

needing inspection beforehand are
explained.
How to Read Table

Inspection
Procedure Condition Evaluation Cause
Method
(A) (B) (C) (D) (E)
(F) (G) (H) (I) (J)
 A, F: Inspection order
 B, G: Inspection method for trouble cause
 C, H: Conditions for inspection
 D, I: Evaluation specification of check results
 E, J: Trouble cause for trouble symptom
Procedure:
1. Perform inspection according to Inspection Method (B) and Condition (C) of
Procedure (A).
2. In case the results are applied to Evaluation (D), the trouble cause becomes Cause
(E).
In case the results are not applied to Evaluation (D), go to the next procedure,
Procedure (F).
T5-2-2
(Blank)
T5-2-3
Engine System Troubleshooting

E-1 Starter does not rotate.
Preparation
 The engine unit may be faulty. Refer to Engine OFF ON START
Manual. Starter Terminal B 12 V or 12 V or 12 V or
 Check the wiring connections first. more more more
Starter Terminal S 0 0 12 V or
more
Procedure Inspection Method Condition Evaluation Cause

1 Measure battery voltage - The value is not within Faulty battery
and electrolyte density. the specification.
(Specification:
Voltage: 12 V or more,
Electrolyte density: 1.25
to 1.28)
2 Switch start relay 1 with Set the key switch The symptom Faulty starter relay 1
other general relay. to START after disappears
switching relays.
3 Check continuity in wire Key Switch: START ∞ Ω Faulty key switch
harness between key switch
#1 and #5 and between key
switch #1 and #6.
4 Measure voltage at key - 0V Open circuit in wire harness
switch terminal B. between battery and key switch
5 Measure voltage at starter Key Switch: ON 0V Faulty pilot shut-off circuit (Refer
relay 1 harness end #1. Pilot Shut-Off to A-2.)
Lever: UNLOCK
6 Measure voltage at starter Key Switch: START 0 V Open circuit in wire harness
relay 1 harness end #3. between starter relay 1 and key
switch
relay 2 harness end #1-E. between starter relay 1 and
starter relay 2
8 Check continuity in wire - ∞Ω Open circuit in wire harness of
harness between starter starter relay 2 #5-G
relay 2 #5-G and the body.
9 Measure voltage at starter - 0V Open circuit in wire harness
terminal B. between battery and starter
terminal S. between starter and starter relay
2
11 - - Normal in above check Faulty starter
T5-2-4
Connector (Wire harness end)

 Starter Relay 2  Starter Relay 1
TDEB-05-06-006
TAEBJ0-05-04-001
 Starter
B TABA50-05-02-001
B- Terminal B S- Terminal S
T5-2-5
E-2 Even if starter rotates, engine does not start.
Preparation
 The engine unit and the electrical circuit system may
be faulty. Perform troubleshooting of the electrical
circuit system (fuel pump, engine stop solenoid)
here. As for trouble of the engine unit, refer to
Engine Manual.
 Check the wiring connections first.

1 Check that fuel filter is - There is abnormality. Clogged fuel filter
clogged.
2 Check continuity between - ∞Ω Faulty fuel pump
fuel pump #1 and #2.
3 Measure voltage at fuel Key Switch: ON 0V Open circuit in wire harness
pump harness end #2. between fuse box and fuel
pump
4 Check continuity between - ∞Ω Open circuit in fuel pump
fuel pump harness end #1 harness end #1
and the body.
5 Measure voltage at one- Key Switch: ON 0V Open circuit in wire harness
second timer harness end #4. between one-second timer and
fuse box
6 Check continuity between - ∞Ω Open circuit in one-second
one-second timer harness timer harness end #3
end #3 and the body.
7 Measure voltage at power - 0V Open circuit in wire harness
relay harness end #3. between battery and power
relay
8 Check continuity between - ∞Ω Open circuit in wire harness
power relay #4 and engine between power relay and
stop solenoid #2. engine stop solenoid
9 Measure voltage at engine Key Switch: ON 0V Open circuit in wire harness
stop solenoid harness end between engine stop solenoid
#1. and fuse box
T5-2-6

10 Check continuity between - ∞Ω Open circuit in engine stop
engine stop solenoid harness solenoid harness end #3
end #3 and the body.
11 Check continuity in wire - ∞Ω Open circuit in wire harness
harness between one- between one-second timer and
second timer and power power relay
relay.
12 Remove engine stop Key Switch: START The pin of engine stop Faulty engine stop solenoid
solenoid from engine unit. solenoid end does not
Disconnect lead wire of move.
starter motor.
13 - - Normal in above check Faulty one-second timer or
faulty power relay
 One-Second Timer  Power Relay
T25N-05-06-020
TAEBJ0-05-04-002
 Engine Stop Solenoid  Fuel Pump
 Starter TAEBJ0-05-04-003 T2BC-05-04-031
TABA50-05-02-001
a- Lead Wire
T5-2-7
E-3 Engine is difficult to start at low temperature.

(During cold weather or in cold districts, engine
is difficult to start or does not start even if pre-
heated.)
Preparation
 The engine unit or the electrical circuit system may
be faulty. Refer to Engine Manual.
 Check the battery.

1 Check continuity between Key Switch: HEAT ∞ Ω Faulty key switch
key switch #1 and #3.
2 Switch glow plug relay with Key Switch: The engine does not Faulty glow plug relay
power relay. START start.
3 Measure voltage at glow - 0V Open circuit in wire harness
plug relay harness end #3. between glow plug relay and
battery
4 Measure voltage at glow Key Switch: 0V Open circuit in wire harness
plug relay harness end #2. START between glow plug relay and
fuse box
5 - - Normal in above check Open circuit in glow plug relay
harness end #1

 Glow Plug Relay
TAEBJ0-05-04-002
T5-2-8
All Actuator System Troubleshooting

A-1 All actuator speeds are slow and power is
weak.
Specification Remark
Primary Pilot 4.1±0.5 Engine Control Lever:
Pressure (MPa) Max.Speed
Preparation
 In case the trouble occurs only when the hydraulic
oil temperature is low, high viscosity of hydraulic oil
may be the cause.
 As the main circuit consists of 3 systems (3 main
relief valves are located), all main relief valves are
unlikely to be faulty at the same time.
 In case more than one actuators are abnormal, the
load check valves in the related circuits may be
faulty.

1 Measure engine speed. Refer to The value is not within Faulty engine unit
OPERATIONAL the specification.
PERFORMANCE TEST/
Engine Test.
2 Measure primary pilot - The value is not within To Procedure No. 3
pressure. the specification.
Correct Find out cause of trouble by
tracing other trouble symptoms.
3 Check that pilot filter is - There is abnormality. Clogged pilot filter
clogged.
4 - - Normal in above check Faulty pilot relief valve or faulty
pilot pump
T5-2-9
A-2 All actuators do not work.
Preparation
 As the main circuit consists of 3 systems (3 main
relief valves are located), all main relief valves are
unlikely to be faulty at the same time.
 Refer to SYSTEM / Electrical System.

1 Check continuity between - ∞Ω Faulty pilot shut-off switch
pilot shut-off switch #1 and
#2.
2 Measure voltage between Key Switch: ON 0V Open circuit in wire harness
pilot shut-off switch harness between fuse box and pilot
end #1 and the body. shut-off switch
3 Switch the pilot shut-off Pilot Shut-Off Lever: The symptom Faulty pilot shut-off relay
relay with other general relay UNLOCK disappears.
except starter relay 1. Key Switch: ON
4 Measure resistance between - ∞ Ω (Specification: Faulty pilot shut-off solenoid
pilot shut-off solenoid valve 12.2±0.85 Ω) valve
#1 and #2.
5 Measure voltage between Pilot Shut-Off Lever: 0 V Open circuit in wire harness
pilot shut-off solenoid valve UNLOCK between pilot shut-off relay and
harness end #1 and the body. Key Switch: ON pilot shut-off solenoid valve
6 - - Normal in above Faulty ground circuit in pilot
check shut-off solenoid valve

 Pilot Shut-Off Switch, Pilot Shut-Off Solenoid Valve
T2BC-05-03-031
T5-2-10
A-3 Actuator does not stop even if control lever is

set to neutral.
Preparation
 Stuck spool in the pilot valve or stuck main spool in
the control valve is suspected.
 Refer to T5-2-12 in case the actuator does not stop
even if control lever is returned to neutral.

1 Set the pilot shut-off lever to - The actuator stops. Faulty pilot valve (stuck spool)
the LOCK position.
2 - - Normal in above check Faulty control valve (stuck spool)
T5-2-11
A-4 Actuator does not stop even if control lever is

set to neutral.
Boom, Arm, Bucket, Boom Swing

1 Switch corresponding - The actuator stops. Faulty overload relief valve or
overload relief valve and faulty make-up valve
make-up valve with normal
ones.
or faulty pilot valve (stuck spool)
Swing

1 Measure relief pressure when When relieving The value is not within Faulty swing relief valve
relieving swing. swing the specification.
(Specification: 19.3±1.0
MPa (pump))
Travel

1 Disassemble and inspect - There is abnormality. Faulty counterbalance valve
counterbalance valve in travel
device.
T5-2-12
A-5 Front attachment is not operated during

combined operation of travel and front
attachment.
Preparation
 Pressure oil from main pump P1 flows to each spool
of travel (left), boom, and bucket. Pressure oil from
main pump P2 flows to each spool of travel (right),
arm, and auxiliary. As the travel spool is located in
upstream of other spools in each circuit, pressure oil
does not flow to other spools when travel operation
is made. Therefore, pressure oil from main pump P3
is supplied to the front attachment spool located
downstream of the travel spool through the flow
combiner valve, so that the front attachment can be
operated when travel operation is made. In case the
front attachment can not be operated when travel
operation is made, the flow combiner valve may be
faulty (stuck spool). Therefore, pressure oil from main
pump P3 is not supplied to the front attachment
spool.
T5-2-13
Front Attachment System Troubleshooting

F-1 All front attachment actuator power are weak.
Preparation
 Not only the front attachment but also other
functions will have the problem. In case the travel
function is also abnormal, refer to "All actuator
speeds are slow and power is weak" on T5-2-9. In
case only the front attachment is abnormal, check
the pilot valve.
T5-2-14
F-2 Some cylinders are not operated or speeds

are slow.
Secondary Pilot 2.9±0.5 When the control

Pressure (MPa) lever is fully
operated
Overload Relief Specification Remark

Pressure (MPa)
Boom 27.5±1.0
Arm, Bucket 23.5±1.0
Preparation
 The main circuit consists of 3 systems (3 main relief
valves are located). Incase one of main relief valves is
faulty, it may lead to failure in the actuator operation
of the corresponding system.
Main Pump P1: Travel (Left), Boom, Bucket

Main Pump P2: Travel (Right), Arm, Auxiliary
Main Pump P3: Swing, Blade, Boom Swing

1 Measure secondary pilot Fully operate the The value is not within Faulty pilot valve of
pressure of corresponding control lever of the specification. corresponding cylinder
cylinder. corresponding (Specification: 2.9±0.5
cylinder. MPa)
2 Measure relief pressure of - The value is not within Faulty overload relief valve of
corresponding cylinder. the specification. corresponding cylinder
3 - - Normal in above check Stuck control valve spool or
faulty cylinder (faulty seal kit)
T5-2-15
F-3 Arm roll-in operation speed is slow.
Arm Roll-In (sec) (2.7±0.3)
Preparation
 The arm regenerative valve is provided in the arm
roll-in circuit so that the arm roll-in speed increases.
In case only the arm roll-in speed is slow, the arm
regenerative valve may be faulty.
T5-2-16
F-4 Front attachment drifts remarkably.
 Boom Cylinder Internal Leakage Check

1. With the bucket cylinder fully retracted and the arm
cylinder slightly extended from the fully retracted
position, lower the bucket tooth tips onto the
ground.
2. Disconnect the hose from the boom cylinder rod
side. Drain oil from the hose and cylinder. (Plug the
disconnected hose ends.)
3. Retract the arm cylinder and lift the bucket off the
ground. If oil flows out of the hose disconnected
piping ends and the boom cylinder is retracted at
this time, oil leaks in the boom cylinder. If no oil
flows out of the hose disconnected piping ends TADB-05-04-003
but the boom cylinder is retracted, oil leaks in the
control valve.

1 Set the pilot shut-off lever to - The symptom Faulty pilot valve
the LOCK position. disappears.
2 Disassemble and inspect the - There is abnormality. Faulty cylinder (seal kit)
cylinder.
3 - - Normal in above check Scored control valve spool,
broken spring, or loose spool
end
T5-2-17
F-5 When boom raise or arm roll-out is operated,

boom or arm starts to move after moving
slightly down.
When the load check valve is faulty:
Preparation
(B)
 During the initial stage of operation, oil pressure and
flow rate from the pump is low. Therefore, if the load
check valve is faulty, the oil in the bottom side of the (A)
boom cylinder flows back into the circuit through
the load check valve. Therefore, the boom cylinder is
temporarily retracted.
 As oil pressure and flow rate from the pump is low, if
oil leaks from bottom side (A) to rod side (B) due to
faulty boom cylinder piston or cylinder barrel, the
boom cylinder is temporarily retracted during the
initial stage of operation. In addition, cylinder force
is reduced. The boom cylinder drift increases in this T105-07-04-012
case.

1 Disassemble and inspect load - There is abnormality. Faulty load check valve
check valve.
2 - - Normal in above check Faulty cylinder (seal kit)
T5-2-18
Swing System Troubleshooting

S-1 Swing is slow or unmoving.
Swing Speed 18.8±1.5 The bucket
(sec/3 rev) should be empty.
Preparation
 In case the blade and boom swing cylinders, along  When the control valve spool sticks other than the
with the swing function move slowly, their power are neutral position, other trouble will occur.
weak, or they are not operated, the main relief valve
for main pump P3 may be faulty.

1 Measure secondary pilot When fully operating The value is not within Faulty pilot valve
pressure of swing. swing the specification.
MPa)
2 Measure delivery pressure of When fully operating Approx. 1.6 MPa Faulty control valve (stuck
main pump P3. swing spool)
Engine Control Lever:
Max. Speed
3 Measure relief pressure of When relieving swing The value is not within Faulty swing relief valve
swing. the specification.
MPa (pump))
4 Measure swing motor With constant speed The value is not within Faulty swing motor
drainage. the specification.
(Specification: 0.5 L/min
or less)
5 - - Normal in above check Faulty swing parking brake
T5-2-19
S-2 Swing drifts remarkably when swinging is

stopped.
Specification Remarks
Swing Function 135 or less The bucket
Drift (mm/90 °) should be empty.
Preparation
 In case pressure oil does not flow smoothly, valves
may be faulty. In case pressure oil flows smoothly,
spools may be faulty.

1 Measure relief pressure of When relieving swing The value is not within Faulty swing relief valve
swing. the specification.
MPa (pump))
2 Disassemble and inspect the - There is abnormality. Stuck control valve spool
control valve spool.
3 - - Normal in above check Faulty swing device
T5-2-20
Travel System Troubleshooting

T-1 Machine does not travel, travels slowly, or
power is weak.
 Both right and left travel motors and control valve
spool are unlikely to be faulty at the same time.
 This is used when both right and left travel motors
are faulty. In case only one travel motor is faulty,
refer to Machine mistracks.
 In case travel speed does not become fast, refer to
Fast travel is not selected or Travel mode does not
change from slow mode to fast mode. Refer to Travel
mode does not change from slow mode to fast
mode.
 Refer to "All actuators do not work" when the
machine does not travel.
 Refer to "All actuator speeds are slow and power is
weak" when power is weak.
T5-2-21
T-2 Fast travel is not selected. Travel mode does

not change from slow mode to fast mode.
Preparation

1 Measure voltage at travel Key Switch: ON 0 V (Specification: 12 V) Open circuit in wire harness
mode switch harness end between travel mode switch
#1. and fuse #8
mode selector relay harness between travel mode selector
end #3. relay and fuse #8
3 Measure voltage at travel Key Switch: ON 0 V (Specification: 12 V) Faulty travel mode switch or
mode selector relay harness Travel Mode open circuit in wire harness
end #1. Switch: Fast Speed between travel mode switch
Position and travel mode selector relay
4 Switch travel mode selector Key Switch: ON The symptom Faulty travel mode selector
relay with horn relay or work Travel Mode disappears. relay
light relay. Switch: Fast Speed
Position
mode control solenoid valve Travel Mode between travel mode selector
harness end #1. Switch: Fast Speed relay and travel mode control
Position solenoid valve
6 Measure resistance between - ∞ Ω (Specification: Faulty travel mode control
travel mode control 12.2±0.85 Ω) solenoid valve
solenoid valve #1 and #2.
7 - - Normal in above check Open circuit in wire harness #2
of travel mode control solenoid
valve

 Travel Mode Control Solenoid Valve, Travel Mode  Travel Mode Selector Relay
Switch
TADB-05-04-005
T2BC-05-03-031
T5-2-22
T-3 Slow travel is not selected. Travel mode does

not change from fast mode to slow mode.
Preparation

1 Disconnect connector of the - The symptom does not Faulty travel mode control
travel mode control solenoid disappear. solenoid valve (stuck spool)
valve.
2 Disconnect connector of the Key Switch: ON The symptom Faulty travel mode switch
travel mode switch. disappears.
3 Disconnect travel mode Key Switch: ON The symptom Faulty travel mode selector relay
selector relay. disappears.
4 - - Normal in above check Shorted circuit in wire harness
between travel mode control
solenoid valve and travel mode
selector relay
T5-2-23
T-4 One side track does not rotate or rotates

slowly. Machine mistracks.
Track Revolution Speed (sec/3 rev) Hydraulic Cylinder Cycle Time (sec)
Specification Remark Specification Remark
Fast Mode 9.3±1.5 Boom Raise 2.6±0.3
Slow Mode 16.8±1.5 Boom Lower 2.0±0.3
Arm Roll-In 2.7±0.3
Arm Roll-Out 2.2±0.3
Bucket Roll-In 2.4±0.3
Bucket Roll-Out 1.4±0.3
Preparation
 In case the machine mistracks to the right (only the  In case the machine mistracks to the left (only the
travel (right) operation is slow, power is weak, or travel (left) operation is slow, power is weak, or
machine does not move), the main relief valve of machine does not move), the main relief valve of
main pump P2 may be faulty. main pump P1 may be faulty.

1 Measure cycle time of - The value is not within Faulty main pump P1
boom or bucket cylinders. the specification.
2 Measure cycle time of arm - The value is not within Faulty main pump P2
cylinder. the specification.
3 Measure secondary pilot Operate the control The value is not within Faulty travel pilot valve
pressure of travel. lever alternately. the values.
MPa)
4 Switch right and left travel - Symptom is reversed Faulty center joint or faulty
line hoses each other at control valve (stuck spool)
the bottom of center joint.
5 - - Normal in above check Faulty travel motor or faulty
travel motor displacement angle
control mechanical part
T5-2-24
Relationship between Faulty Seal Location and

Mistrack Direction
Serial No. When traveling When pivot turn is

straight performed
d 1
1
2
c
3
2
b
4
a 5
3
TACC50-05-02-001
a- Travel (Left Reverse) c- Travel (Left Forward)

b- Travel (Right Reverse) d- Travel (Right Forward)
T5-2-25
Blade System Troubleshooting

Blade is not operated or moves slowly.
 As each actuator of blade, swing, and boom swing  When the control valve spool is stuck in the position
is operated by pressure oil from main pump P3, the other than the neutral position, other trouble will
main relief valve of main pump P3 may be faulty. occur.

1 Measure secondary pilot Fully operate the blade The value is not within Faulty blade pilot valve
pressure of blade. control lever. the specification.
MPa)
2 Measure delivery pressure of Fully operate the blade Approx. 1.6 MPa Faulty control valve (stuck
main pump P3. control lever. spool)
Max. Speed
3 Remove the rod pin of blade When operating blade Oil leaks from the Faulty seal of cylinder
cylinder. Retract the blade raise bottom side port of
cylinder fully. Remove the blade cylinder.
cylinder bottom side hose.
Plug the disconnected hose
ends.
4 - - Normal in above check Faulty center joint
TACC50-05-02-001
a- Blade Lower c- Travel (Left Forward)

b- Blade Raise
T5-2-26
Boom Swing System Troubleshooting

Boom swing is not operated or moves slowly.
 As each actuator of blade, swing, and boom swing  When the control valve spool is stuck in the position
is operated by pressure oil from main pump P3, the other than the neutral position, other trouble will
main relief valve of main pump P3 may be faulty. occur.

1 Measure secondary pilot Fully operate the boom The value is not within Faulty boom swing pilot
pressure of boom swing. swing pedal. the specification. valve
MPa)
2 Measure delivery pressure of Fully operate the boom Approx. 1.6 MPa Faulty control valve (stuck
main pump P3 swing pedal. spool)
Max. Speed
3 - - Normal in above check Faulty seal of cylinder
T5-2-27
How to Lowering Boom in Case of Emergency

and When Engine Stops
dCAUTION: Prevent personal injury. Confirm

that no one is under the front attachment before
starting the procedure below.
Lower the boom in the following procedures in case the
engine stops with the boom raised and is impossible to
restart by some reason.
In case the front attachment is not loaded:
dCAUTION: Loosen overload relief valve (1)

slowly. In case it is loosened rapidly, the boom
may lower rapidly. Do not loosen it more than 3/4
turns as hydraulic oil may spout.
1. Loosen overload relief valve (1) slowly by checking TACD90-01-02-002
the movement of the boom.
1
j : 24 mm 1- Overload Relief Valve (Boom Raise)
2. After checking that boom has been lowered
completely, tighten overload relief valve (1).
j : 24 mm
m : 70 to 80 N·m (7 to 8 kgf·m, 52 to 59 lbf·ft)
T5-2-28
In case the front attachment is loaded:

1. Put matching marks on lock nut (2), adjusting screw
(3), and body (4) of overload relief valve (1) at the
boom raise side (cylinder bottom side).
dCAUTION: Loosen adjusting screw (3) slowly. In

case it is loosened rapidly, the boom may lower
rapidly.
2. Loosen lock nut (2). Loosen adjusting screw (3)
slowly by checking the movement of the boom.
j : 17 mm (Lock Nut)
l : 6 mm (Adjusting Screw)
TACD90-01-02-002
3. After checking that boom has been lowered
completely, fit the matching marks and tighten lock 1
nut (2). 1- Overload Relief Valve (Boom Raise)
j : 17 mm (Lock Nut)
m : 28 to 32 N·m (2.8 to 3.2 kgf·m, 20.5 to 23.5

lbf·ft)
l : 6 mm (Adjusting Screw) 4
2
IMPORTANT: After completing the work, check the
set pressure of overload relief valve (1). (Refer to 3
OPERATIONAL PERFORMANCE TEST / Standard.)
TADB-04-05-004
2- Lock Nut 4- Body

3- Adjusting Screw
T5-2-29
(Blank)
T5-2-30
Troubleshooting C (Monitor Diagnosis)

Procedure
This procedure is used when there are malfunctions
on components regarding monitor, such as gauges or
indicators.
 Diagnosis Procedure
 The diagnosis procedures for components regarding
monitor, such as gauges, or indicators are explained
in this group.
f NOTE: All connector images in this section are viewed
from the open end side of wire harness end.
1
2
T6L4-05-03-001
1- Wire Harness End Connector 2- Wire Harness
T5-3-1
Contents of Diagnosis
Trouble Symptom
Preparation
Viewpoints for a diagnosis and contents

needing inspection beforehand are
explained.
How to Read Table

Procedure Inspection Condition Evaluation Cause
Method
(A) (B) (C) (D) (E)
(F) (G) (H) (I) (J)
 A, F: Inspection order
 B, G: Inspection method for trouble cause
 C, H: Conditions for inspection
 D, I: Evaluation specification of check results
 E, J: Trouble cause for trouble symptom
Procedure:
1. Perform inspection according to Inspection Method (B) and Condition (C) of
Procedure (A).
2. In case the results are applied to Evaluation (D), the trouble cause becomes Cause
(E).
In case the results are not applied to Evaluation (D), go to the next procedure,
Procedure (F).
T5-3-2
Malfunction of Monitor Buzzer

 Check the wiring connections first.
f NOTE: Operating Conditions of the Buzzer: The engine
oil pressure indicator or overheat indicator lights.
The buzzer continues to sound even when the
engine oil pressure indicator or overheat indicator
goes OFF with the engine running.

1 Disconnect monitor controller Key Switch: ON The buzzer Faulty buzzer
harness end terminal M1-6. continues to sound.
2 - - Normal in above Shorted circuit in wire
check harness between buzzer
and monitor controller or
faulty monitor controller
The buzzer does not sound even when the engine

oil pressure indicator or overheat indicator lights
with the engine running.

1 Check continuity in wire harness - ∞Ω Faulty buzzer
between buzzer #1 and #2.
2 Measure voltage between buzzer Key Switch: ON 0V Open circuit in wire
harness end #1 and the body. harness between fuse
box and buzzer
3 Measure voltage at monitor Key Switch: ON 0V Open circuit in wire
controller harness end terminal harness between buzzer
M1-6. and monitor controller
4 - - Normal in above Faulty monitor controller
check

 Monitor Controller M1  Buzzer
T2BC-05-04-031
TACC50-05-03-001
T5-3-3
Malfunction of Coolant Temperature

Indicator
 Only malfunction of the coolant temperature indicator
is explained here. Refer to T5-3-11 for malfunction of
the overheat indicator.
The coolant temperature indicator is not turned off.

1 Connect coolant temperature Key Switch: ON The symptom Faulty coolant
sensor harness end terminal to the Disconnect coolant disappears. temperature sensor
body. temperature sensor
terminal.
2 Check continuity between monitor Connect the coolant ∞Ω Open circuit in wire
controller harness end terminal temperature harness between
M2-10 and the body. sensor harness end monitor controller
terminal to the and coolant
body. temperature sensor
3 - - Normal in above check Faulty monitor
controller
The coolant temperature indicator does not light.

1 Disconnect coolant temperature - The symptom Faulty coolant
sensor terminal. Set the key switch disappears. temperature sensor
to the ON position.
2 Check continuity between monitor Key Switch: ON 0Ω Shorted circuit in wire
controller harness end terminal Disconnect coolant harness between
M2-10 and the body. temperature sensor monitor controller
terminal. and coolant
temperature sensor
controller

 Monitor Controller M2 Coolant Coolant
Temperature (°C) Temperature
Sensor (kΩ)
30 6.08
TABA50-05-03-003
T5-3-4
Malfunction of Fuel Gauge

 Check the wiring connections first.  When all segments in the fuel gauge blink, the wire
 Only malfunction of the fuel gauge is explained as an harness between monitor controller terminal M1-8 and
example here. Refer to T5-3-9 for malfunction of the fuel sensor may be open or shorted.
fuel level indicator.
Even when fuel is sufficient, all segments in the fuel

gauge do not light.

1 Short-circuit in wire harness Key Switch: ON All segments in the Faulty fuel sensor
between fuel sensor harness end Disconnect fuel fuel gauge blink.
#1 and #2. sensor connector.
2 - - Normal in above Faulty monitor controller
check
Even when fuel is reduced, all segments in the fuel

gauge light.

1 Disconnect fuel sensor connector. Key Switch: ON All segments in the Faulty fuel sensor
fuel gauge blink.
2 - - Normal in above Faulty monitor
check controller
The segments in fuel gauge unstably light.

1 Short-circuit in wire harness Key Switch: ON All segments in the Faulty fuel sensor
between fuel sensor harness end Disconnect fuel fuel gauge blink.
#1 and #2. sensor connector.
check controller

 Monitor Controller M1
TACC50-05-03-001
 Fuel Sensor
T6LE-05-05-017
T5-3-5
Fuel Sensor
Unit: mm
a 3 2 1
(55°
103 R12 )
6
M1NC-01-007
b
(55°)
103
Lighting Segment Float Position Fuel Sensor (Ω)
1 Upper Limit 10±0.5
(FULL)
c
2 1/2 32±1
3 Lower Limit 87±1.5
TABA50-05-03-001 (EMPTY)
fNOTE: When the float is in EMPTY, segment (3) blinks.

a- Float Position: Upper Limit c- Float Position: Lower Limit
(FULL) (EMPTY)
b- Float Position: 1/2
T5-3-6
Malfunction of Hour Meter

The hour meter does not count with the engine

running.

1 Check the alternator indicator. Engine: Running The alternator Faulty alternator
indicator is ON.
controller
The hour meter counts operation hours while the

key switch is ON (the engine is stopped).

1 Check continuity between - ∞Ω Open circuit in wire
alternator harness end #1 and harness between
monitor controller harness end monitor controller
terminal M1-1. and alternator
controller

 Monitor Controller M1  Alternator
TACC50-05-03-001 TABA50-05-03-004
T5-3-7
Indicator Operation Check

 Check that fuse #3 is normal.
 When there is an indicator which does not light
at the indicator operation check, perform the
troubleshooting of each indicator.
All indicators do not light.

1 Check continuity between monitor Key Switch: ON ∞Ω Open circuit in wire
controller harness end terminal harness between
M2-2 and the body. monitor controller
and key switch
controller

TABA50-05-03-003
T5-3-8
Malfunction of Fuel Level Indicator

Even when the fuel tank is empty, the indicator

does not light.

1 Measure resistance between fuel - Refer to the table. Faulty fuel sensor
sensor #1 and #2.
2 Check continuity between monitor Key Switch: ON ∞Ω Open circuit in wire
controller harness end terminal Disconnect fuel harness between
M1-8 and fuel sensor terminal #2. sensor connector. monitor controller and
fuel sensor
check controller
Even when fuel is sufficient, the indicator lights.

1 Disconnect fuel sensor connector. Key Switch: ON Indicator: OFF Faulty fuel sensor
2 Disconnect monitor controller Key Switch: ON Indicator: OFF Shorted circuit in wire
connector. Connect only harness between
monitor controller monitor controller and
terminal M2-2. fuel sensor
check controller
Fuel Sensor
Unit: mm
a 3 2 1
(55°
103 R12 )
6
M1NC-01-007
b
(55°)
103
Lighting Segment Float Position Fuel Sensor (Ω)
1 Upper Limit 10±0.5
(FULL)
c
2 1/2 32±1
3 Lower Limit 87±1.5
TABA50-05-03-001 (EMPTY)
a- Float Position: Upper Limit c- Float Position: Lower Limit
(FULL) (EMPTY)
b- Float Position: 1/2
T5-3-9

 Monitor Controller M2  Fuel Sensor
TABA50-05-03-003
T6LE-05-05-017
T5-3-10
Malfunction of Overheat Indicator

Even when the engine overheats, the indicator does

not light.

1 Disconnect overheat switch Key Switch: ON Indicator: ON Faulty overheat
terminal (orange). Connect the switch
wire harness end terminal to the
body.
2 After connecting overheat switch Key Switch: ON ∞Ω Open circuit in wire
harness end terminal to the body, harness between
check continuity between monitor monitor controller
controller harness end terminal and overheat switch
M2-3 and the body.
controller
Even when coolant temperature is low, the indicator

lights.

1 Disconnect overheat switch Key Switch: ON Indicator: OFF Faulty overheat
terminal. switch
2 Disconnect monitor controller Key Switch: ON 0Ω Shorted circuit in wire
connector M2. Check continuity Disconnect harness between
between wire harness end terminal overheat switch monitor controller
M2-3 and the body. terminal. and overheat switch
controller
Overheat Switch
Coolant Temperature Operation
 Monitor Controller M2 110±3 °C (230±5.4 °F) ON
or more
TABA50-05-03-003
T5-3-11
Malfunction of Engine Oil Pressure Indicator

f NOTE: The pressure may remain in the circuit for one to
two minutes after the engine stops. If the engine starts in
this condition, the indicator may not light.
Even when the engine oil pressure is insufficient,
the indicator does not light.

1 Connect engine oil pressure switch Key Switch: ON Indicator: ON Faulty engine oil
harness end connector terminal #1 pressure switch
(white and red cable) to the body.
2 After connecting engine oil Key Switch: ON ∞Ω Open circuit in wire
pressure switch connector #1 harness between
to the body, check continuity monitor controller
between monitor controller and engine oil
terminal M2-4 and the body. pressure switch
controller
Even when the engine runs, the indicator is not

turned off.

1 Disconnect engine oil pressure Key Switch: ON Indicator: OFF Faulty engine oil
switch connector. pressure switch, faulty
engine oil system, or
clogged oil filter
2 Disconnect monitor controller Key Switch: ON 0Ω Shorted circuit in wire
connector M2. Check continuity Disconnect engine harness between
between wire harness end terminal oil pressure switch monitor controller
M2-4 and the body. connector. and engine oil
pressure switch
controller
Connector (Wire harness end) Engine Oil Pressure Switch

 Monitor Controller M2 Pressure Operation
Approx. 49±9.8 kPa ON
(0.5±0.1 kgf/cm2,
7.1±1.4 psi) or less
Approx. 49±9.8 kPa OFF
(0.5±0.1 kgf/cm2,
TABA50-05-03-003 7.1±1.4 psi) or more
T5-3-12
Faulty Alternator Indicator

Even when the engine runs, the alternator indicator

is not turned off.

1 Disconnect alternator connector. Key Switch: ON The symptom Faulty alternator
Engine: Stopped disappears.
2 Disconnect monitor controller Key Switch: ON 0Ω Shorted circuit in wire
connector M1. Check continuity Disconnect harness between
between wire harness end terminal alternator monitor controller
M1-1 and the body. connector. and alternator
controller
Even when charging is low, the alternator indicator

does not light.

1 Connect alternator harness end Key Switch: ON The symptom Faulty alternator
terminal #1 to the body. Engine: Stopped disappears.
2 After connecting alternator harness Key Switch: ON ∞Ω Open circuit in wire
end terminal #1 to the body, harness between
check continuity between monitor monitor controller
controller harness end terminal and alternator
M1-1 and the body.
controller

 Monitor Controller M1  Alternator
TACC50-05-03-001
TABA50-05-03-004
T5-3-13
Malfunction of Preheat Indicator

 The preheat indicator lights for 15 seconds after setting
the key switch to the HEAT or START position.
 If the preheat indicator does not go off, the monitor
controller may be faulty.
The preheat indicator does not light.

1 Measure voltage at monitor Key Switch: HEAT 0V Open circuit in wire
controller harness end terminal harness between
M1-3. monitor controller
and key switch

TACC50-05-03-001
T5-3-14
MEMO
MEMO
Hitachi Construction Machinery Co., Ltd. Hitachi Ref. No.
Attn: Technical Information Center
Tel: 81-29-832-7084
Fax: 81-29-831-1162
E-mail: [email protected]
SERVICE MANUAL REVISION REQUEST FORM
COMPANY NAME: MODEL:

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

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

The Attached Diagram List
The following diagrams are attached to this manual.
1. ELECTRICAL CIRCUIT DIAGRAM
2. ELECTRICAL CIRCUIT DIAGRAM (TRAVEL ALARM)

TRAVEL ALARM HARNESS
3. FLOOR HARNESS
MAIN HARNESS
4. LIGHT HARNESS
5. HYDRAULIC CIRCUIT DIAGRAM

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PART NO.

Service Manual consists of the following separate Part No.

Quantity To Convert From Into Multiply By

fNOTE: The numerical value in this manual might be

Symbol / Name Explanation

Recognize Safety Information

Understand Signal Words

 CAUTION also calls attention to safety message in this

 fNOTE: indicates an additional explanation for an

Follow Safety Instructions

Prepare for Emergencies

Wear Protective Clothing

You may need:

Protect Against Noise

Use Handrails and Steps

Adjust the Operator's Seat

Fasten Your Seat Belt

Move and Operate Machine Safely

Operate Only from Operator's Seat

Keep Riders off Machine

Precautions for Operations

Investigate Job Site Beforehand

Install OPG Guard

ROPS: Roll Over Protective Structure

Restriction of Attachment Installation

Provide Signals for Jobs Involving Multiple

Confirm Direction of Machine to Be Driven

Drive Machine Safely

 Driving on a slope may cause the machine to slip or

Avoid Injury from Rollaway Accidents

Avoid Injury from Back-Over and Swing

Keep Person Clear from Working Area

Never Position Bucket Over Anyone

 Be careful when working on frozen ground.

Never Undercut a High Bank

Dig with Caution

Operate with Caution

Avoid Power Lines

Precautions for Lightning

If lightning comes close, immediately stop the operation,

If lightning strikes the machine or near the machine,

Protect Against Flying Debris

Park Machine Safely

Handle Fluids Safely−Avoid Fires

 All fuels, most lubricants, and some coolants are flammable.

Be sure to further follow the details described in the

Practice Safe Maintenance

Before servicing the machine:

7. Attach a “Do Not Operate” tag on the control lever.

 If a maintenance procedure must be performed with the

Warn Others of Service Work

Support Machine Properly

Stay Clear of Moving Parts

Prevent Parts from Flying

 Travel reduction gears are under pressure.

Avoid Injury from Attachment Falling Accident

 After operation, engine coolant is hot and under pressure.

Hot fluids and surfaces:

Replace Rubber Hoses Periodically