SECTION 6 TROUBLESHOOTING

GROUP 1 HYDRAULIC AND MECHANICAL SYSTEM

1. INTRODUCTION

1) MACHINE IN GENERAL

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

(5) Check before troubleshooting.

‫ ڡ‬Check oil and fuel level.
‫ ڢ‬Check for any external leakage of oil from components.
‫ ڣ‬Check for loose or damage of wiring and connections.

6-1
2. DRIVE SYSTEM

1) UNUSUAL NOISE COMES OUT OF PUMP CONNECTION

Cause Remedy
YES Coupling element Disassemble and
is broken. repair.
Remove dust plug
under engine
flywheel and
check if rubber YES Replace hub or
pieces or particles
Coupling hub retighten setscrew.
are not present.
spline is worn or
hub fastening
NO setscrew is slack.

If hydraulic pump or engine is suspected

as a culprit refer also to shop manuals
NO
"hydraulic components" and"engine"

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

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

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

6-3
3. HYDRAULIC SYSTEM

1) HYDRAULIC OIL IS CLOUDY

Cause Remedy
YES Water is mixed. Put hydraulic oil
still, separate
Drop hydraulic oil water and dispose
sample on hot it or replace
plate and check if hydraulic oil.
foams come up. Check suction
Air is intruded.
NO
line and return
line and eliminate
the air intruding
source.

2) HYDRAULIC OIL TEMPERATURE HAS RISEN ABNORMALLY

Cause Remedy
NO Replenish
specified oil to the
Is hydraulic oil standard level.
volume proper?
YES Clean oil cooler.
In not oil cooler Secure air
clogged and is circulation route.
YES anything blocking YES
Is fan belt tension ‫ڇ‬
air circulation?
proper?
NO
Adjust belt tension
NO
or replace belt.
Is not the set
YES Readjust set
pressure of main
relief,port relief and pressure.
‫ڇ‬ Is main relief
travel relief valve
lower than the valve used very YES Reduce load.
NO
standard level? often?

6-4
 3) CAVITATION OCCURS WITH PUMP

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

4) HYDRAULIC OIL IS CONTAMINATED

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

6-5
4. SWING SYSTEM

1) BOTH LH AND RH SWING ACTIONS ARE IMPOSSIBLE

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

NO
Swing motor is Disassemble and
broken. repair.

YES
Pilot relief valve Disassemble and
Is gear pump
NO delivering oil? is faulty. repair or replace.

Gear pump is out Disassemble and

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

6-6
 2) SWING SPEED IS LOW

Cause Remedy
YES Swing port relief Disassemble and
Does swing control
YES valve spool move valve is faulty. repair or replace.

smoothly by hand?
Swing control Disassemble and
Is secondary pilot NO
valve spool is repair.
pressure same on
LH and RH sides? Clogged or oil stuck.
YES leak. Clean pilot piping
Is not pilot piping
Single direction interior or repair
clogged or is not it
NO piping.
leaking oil?
NO Pilot valve or Disassemble and
Is the trouble in
shuttle valve is repair.
one direction or in
faulty.
both direction? YES ‫ڞ‬
Does swing control
YES valve spool move
Both directions lightly by hand?
Is MCV pilot NO Swing control Disassemble
YES
pressure within valve spool is and repair.
Is Arm speed standard level? stuck.
within standard
‫ڟ‬
value? NO
‫ڠ‬
NO
Is swing motor's
‫ڞ‬ drain rate within NO Swing motor is Disassemble
standard value? broken. and repair.
Pilot valve or Disassemble
Check that pilot
YES shuttle valve is and repair.
piping is not clogged NO
faulty.
or oil is not leaking
from it? Clean pilot piping
interior or repair
Is gear pump pilot Clogged or piping.
‫ڟ‬ pressure within oil leak.
standard level? YES Pilot relief valve is Disassemble
Is gear pump
defective. and repair or
delivering oil?
NO replace.
NO Gear pump is
Disassemble
broken. and repair.
NO Main relief valve Main relief valve
faulty. pressure resetting
or repair
Is main relief YES
Does the symptom Hydraulic pump Disassemble
‫ڠ‬ valve setting
YES
change when front is broken. and repair.
pressure normal and rear pump
Is safety valve pilot discharge hoses
NO Shuttle v/v faulty.
Repair or replace.
pressure within
YES
standard level? YES Pilot relief faulty. Repair or replace.
Is gear pump
output pressure
NO
within standard level
NO Gear pump faulty. Repair or replace.

6-7
 3) SWING MOTION IS IMPOSSIBLE IN ONE DIRECTION

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

Clogged or oil leak. Clean pilot piping

interior or repair
piping.

4) MACHINE SWINGS BUT DOES NOT STOP

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

6-8
 5) THE SWING UNIT DRIFTS WHEN THE MACHINE IS AT REST ON A SLOPE

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

YES Swing relief valve Disassemble and

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

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

6-9
5. TRAVEL SYSTEM

1) TRAVEL DOES NOT FUNCTION AT ALL ON ONE SIDE

Cause Remedy
YES
‫ڇ‬
Does counterbalance
YES spool in travel brake
valve move lightly by
hand?
Is travel brake valve Counter spool in Disassemble and
YES pressure within NO
travel brake valve repair or replace.
standard level? Does the symptom is stuck.
change when relief YES Relief valve built Disassemble and
Has travel control NO valves in travel motor
YES are exchanged? in travel motor is repair.
valve spool changed
over positively? faulty.
YES
Control system is Disassemble
Does spool move
lightly when hand is defective. inspect and repair.
NO let free from control
cable?
NO Travel control Disassemble and
valve spool is repair.
Is bucket or arm stuck.
operation Do not metallic YES Travel reduction Disassemble and
particles come unit is faulty. repair.
possible? ‫ ڇ‬out of drain port
in travel
reduction unit? Travel motor is Disassemble and
NO
out of order. repair.
Does the symptom
change when front YES
and rear pump Hydraulic pump Disassemble and
NO
discharge hoses is broken. repair.
are exchanged?

6-10
 2) SPEED ON ONE SIDE FALLS AND THE MACHINE CURVES

Cause Remedy
YES Brake valve is Disassemble and
Do LH and RH travel defective. repair or replace.
speeds change
YES when LH and RH
YES Relief valve built Disassemble and
travel brake valves Does the symptom
are exchanged? change when relief in travel motor is repair.
valves in LH and RH
Has control valve NO travel motors are faulty.
YES spool changed over
exchanged? ‫ڇ‬
NO
positively?
YES
Control system is Disassemble,
Does spool move
lightly when it is faulty . inspect and repair.
NO cut off from
Is the lower speed
control spool? Control valve Disassemble and
(bucket or arm) within NO
standard level? spool is stuck. repair.

YES Travel relief valve is Disassemble and

Do LH and RH faulty. repair or replace.
travel speeds Does the symptom
change over when change when front
NO YES YES Hydraulic pump is Disassemble and
travel relief valves and rear pump
Is external pilot discharge hoses
are exchanged? broken. repair.
pressure within are exchanged?
NO
standard level?
External pilot Disassemble and
NO
piping is clogged or clean.
oil is leaking from it.
Does travel speed
change when
YES parking brake spring YES Travel motor's Disassemble and
Is leak rate of in the slower travel parking brake is not clean pilot piping.
‫ ڇ‬travel motor within motor is removed?
released properly.
standard level?
Travel motor is Disassemble and
NO
faulty. repair.

6-11
 3) MACHINE DOES NOT STOP ON A SLOPE
Machine is pulled forward as sprocket rotates during digging operation.

Is parking brake Cause Remedy

None friction plate worn? YES Friction plate is Disassemble and
Check if parking
YES brake pilot line is faulty. repair.
not clogged.
clogged Disassemble and
Is travel brake clean pilot piping.
pressure within Is drain rate of
standard level? travel motor within NO Travel motor is Disassemble and
standard value? defective. repair.

Brake valve is Disassemble and

NO
faulty. repair or replace.

4) LH AND RH TRAVEL MOTIONS ARE IMPOSSIBLE

Cause Remedy
YES Inspect according
to the procedure
"Travel does not
function at all on
one side."
However, a case
where both LH
and RH travel
motions are
disabled is
extremely seldom
Is bucket or arm statistically.
operation possible?
OK Hydraulic pump
Disassemble both Disassemble and
OK travel relief valves is faulty. repair.
Remove dust plug and inspect for
under engine any fault. Travel relief valve Disassemble and
OK flywheel and
check that there is Faulty is faulty. repair or replace.
no coupling
Check oil volume element particles. Particles present. Coupling at pump Disassemble and
NO
in hydraulic oil
connection is repair.
tank.
broken.
Short Replenish
hydraulic oil.

6-12
 5) TRAVEL ACTION IS POWERLESS(travel only)

Cause Remedy
YES
Is travel motor's ‫ڇ‬
YES drain rate within
standard level?
Is travel brake Travel motor is Disassemble and
YES pressure within NO
faulty. repair.
standard level?
Is travel relief valve
Travel brake Disassemble and
pressure within NO
standard level? valve is defective. repair or replace.

NO
Travel relief valve Disassemble and
is faulty. repair or replace.

YES Hydraulic circuit Disassemble and

that releases clean.
Does parking brake
Remove parking travel parking
Increases piston move lightly
brake spring in brake is clogged
by hand?
travel motor, draw with dirt.
out piston Disassemble and
‫ڇ‬
completely, refit NO Parking brake
cover and check if piston in travel repair.
travel power motor is stuck.
changes. Remains
Travel reduction Disassemble and
unchanged
unit is defective. repair.

6) MACHINE RUNS RECKLESSLY ON A SLOPE

Travel brake valve Cause Remedy

(counterbalance Disassemble and
valve) is faulty. repair or replace.

6-13
 7) MACHINE MAKES A CURVED TRAVEL OR DOES NOT TRAVEL AT ALL WHEN TRAVEL AND
ATTACHMENT OPERATIONS ARE EXECUTED AT THE SAME TIME

Does logic valve

function normally
Cause Remedy
Is logic valve
YES when boom is NO spring normal? NO Replace spring.
Is select valve
YES normal? executed at the
same time?

NO Select valve is Repair or replace

Is pilot pressure
faulty
for travel select
valve within YES Remove dirt on
standard level? Is filter in pilot
pilot line filter
piping between
gear pump and Is pilot relief
NO YES valve normal? NO Pilot relief valve is Disassemble
control valve not Is gear pump
clogged? defective. and repair or
delivering oil?
NO replace.
NO Gear pump is Disassemble
broken. and repair.

6-14
6. ATTACHMENT SYSTEM

1) BOOM OR ARM ACTION IS IMPOSSIBLE AT ALL

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

YES Cylinder interior is Disassemble and

Does control
broken. repair.
‫ڇ‬ valve spool move
lightly by hand?
Control valve Disassemble and
NO
spool is stuck. repair.

6-15
 2) BOOM, ARM OR BUCKET SPEED IS LOW

Cause Remedy
YES Normal
YES
Are other ‫ڇ‬
YES attachment
speeds within
Is speed low only Is combination of standard levels?
oil streams normal NO ‫ڈ‬
in composite
YES at boom hoisting
operation? YES
and at arm Logic valve is Repair or replace.
extrusion? Logic valve
faulty
normal.
Are LH/RH travel NO
speeds within Replace spring.
NO NO
standard levels?
YES
Hydraulic pump is Disassemble and
Are both LH/RH faulty. repair.
travel speeds low? YES
NO ‫ډ‬
Is MCV pilot
NO
pressure within
standard?
NO ‫ڊ‬
Does the YES
Port relief valve is Disassemble and
symptom change faulty. repair or replace.
YES
when port relief
valve is replaced
Does control Disassemble and
YES valve spool move
with other valve? NO Cylinder is faulty.
repair.
lightly by hand?

Is MCV pilot NO Control valve Disassemble and

‫ڇ‬ pressure within spool is stuck. repair.
standard level?
Is not secondary YES Clean pilot
pilot pressure piping interior or
piping clogged or
NO repair piping.
is not there oil
leakage? NO Pilot valve is Disassemble
defective. and repair.
YES
Is primary pilot Pilot relief valve is Disassemble and
Is gear pump
pressure within NO delivering oil? faulty. repair or replace.
‫ڈ‬
standard level?
NO Gear pump is Disassemble
broken. and repair.
Is engine
revolution within NO Adjust engine
‫ډ‬
standard level? revolution.

YES Clean orifice in

Is not orifice in control valve.

‫ڊ‬ control valve

YES Clean pilot
clogged? Is pilot piping not
clogged or is oil piping interior or
NO not leaking from Is pilot valve repair piping
the piping? NO
normal? Pilot valve is Disassemble
NO
faulty. and repair.

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

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

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

4) BOOM, ARM OR BUCKET POWER IS WEAK

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

Main relief valve Adjust pressure,

NO
is defective. repair or replace.

6-17
 5) ONLY BUCKET OPERATION IS TOTALLY IMPOSSIBLE

Cause Remedy
YES
Port relief valve is Disassemble and
Does the repair or replace.
defective.
symptom change
YES when port relief
valve is replaced YES Cylinder interior is Disassemble and
with other valve? Does control valve broken. repair.
Is secondary pilot spool move
NO
YES pressure within smoothly by hand?
standard level? Control valve Disassemble and
NO
spool is stuck. repair.
Is RH travel
possible? NO Pilot valve is Disassemble and
faulty. repair.

Does the YES

Main relief valve Adjust pressure,
symptom change
Does the symptom is faulty. repair or replace.
NO
when LH/RH
main relief valves change when
YES
are exchanged? NO hydraulic pump's Hydraulic pump is Disassemble and
discharge hoses broken. repair.
are exchanged?

6-18
 6) BOOM MAKES A SQUEAKING NOISE WHEN BOOM IS OPERATED

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

Boom foot pin has Supply grease to

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

6-19
Ɠ HOW TO CHECK INTERNAL BOOM
CYLINDER LEAKAGE

1. Lower the bucket teeth to the ground with

bucket cylinder fully retracted and arm
cylinder rod retracted almost in full.

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

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

3. Raise bucket OFF the ground by

retracting the arm cylinder rod.

If off leaks from piping side and boom

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

6-20