Troubleshooting: Section 5

SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 General Group 4 Troubleshooting B
Introduction ..............................................T5-1-1 Troubleshooting B Procedure ...................T5-4-1
Diagnostic Procedures .............................T5-1-2 Relationship between Machine Trouble
Dr.EX Operation .......................................T5-1-4 Symptoms and Suspected Parts .............T5-4-2
Main Controller Fault Code List ................T5-1-5 Correlation between Trouble
Auto-MARCCINO Control Unit Symptoms and Part Failures ...................T5-4-6
Fault Code List (EX75UR-3) ....................T5-1-6 Engine System Troubleshooting .............T5-4-12
Main Controller Monitoring Function .........T5-1-8 All Actuator Control System
Auto-MARCCINO Control Unit Troubleshooting ....................................T5-4-24
Monitoring Function (EX75UR-3) .............T5-1-9 Front Attachment Control System
Dr.EX Special Function Troubleshooting ....................................T5-4-26
(Service Mode) (EX75UR-3)..................T5-1-10 Swing System Troubleshooting...............T5-4-32
Travel System Troubleshooting ..............T5-4-36
Group 2 Component Layout Blade System Troubleshooting ...............T5-4-39
Main Components ....................................T5-2-1
Electrical System
(Overview)..............................................T5-2-4
Electrical System
(Monitor and Switches) .........................T5-2-11
Pump Device ..........................................T5-2-15
Swing Device .........................................T5-2-15
Travel Device .........................................T5-2-16
Component in Control Valve ...................T5-2-18
Group 3 Troubleshooting A
Troubleshooting A Procedure ...................T5-3-1
Fault Code 01 (Abnormal EC Sensor).......T5-3-2
Fault Code 07
(Abnormal Engine Control Dial Angle).....T5-3-4
192T-5-1
Group 5 Troubleshooting C Group 7 Electrical System Inspection
Troubleshooting C Procedure Precautions for Inspection and
(Troubleshooting for Monitor)..................T5-5-1 Maintenance ...........................................T5-7-1
Malfunction of Coolant Temperature Instructions for Disconnecting
Gauge ....................................................T5-5-2 Connectors .............................................T5-7-3
Malfunction of Fuel Gauge........................T5-5-4 Fuse Continuity Test ................................T5-7-4
Malfunction of Indicator Light Fusible Link Inspection .............................T5-7-6
Check System ........................................T5-5-6 Battery Voltage Check ..............................T5-7-7
Malfunction of Alternator Indicator ............T5-5-8 How to Troubleshoot Alternator
Malfunction of Engine Oil Malfunctions ...........................................T5-7-8
Pressure Indicator ...............................T5-5-12 Continuity Check ......................................T5-7-9
Malfunction of Overheat Indicator ...........T5-5-16 Voltage and Current Check.....................T5-7-10
Malfunction of Fuel Level Indicator Check by False Signal ............................T5-7-15
(EX75UR-3, EX75URLC-3) ....................T5-5-20 Test Harness ..........................................T5-7-16
Malfunction of Air Filter Restriction
Indicator ..............................................T5-5-22
Malfunction of Electrolyte Level
Indicator(EX75UR-3, EX75URLC-3).......T5-5-26
Malfunction of Buzzer ............................T5-5-28
Malfunction of Hour Meter .....................T5-5-32
Group 6 Troubleshooting D
Troubleshooting D Procedure
(EX75UR-3) ............................................T5-6-1
Auto-Marccino Control Unit
System Fault Code List...........................T5-6-2
Fault Code 03...........................................T5-6-4
Fault Code 07...........................................T5-6-5
Fault Code 08...........................................T5-6-5
Fault Code 11, 12, 13 ...............................T5-6-6
Fault Code 14, 15, 16, 20 .........................T5-6-8
Fault Code 40, 41, 42, 44 .......................T5-6-10
Fault Code 43, 45, 47 .............................T5-6-11
Fault Code 50, 51, 52 .............................T5-6-12
Fault Code 60, 61, 62 .............................T5-6-14
Fault Code 80, 81, 82 .............................T5-6-15
Fault Code 90.........................................T5-6-16
192T-5-2
TROUBLESHOOTING / General
INTRODUCTION
Use the troubleshooting section to help you locate the • Troubleshooting D (troubleshooting of the front at-
source of any problems that may arise. Each trouble- tachment operational control using fault codes)
shooting section is presented in an orderly fashion so Use these charts when the self-diagnosing func-
as to make inspecting and troubleshooting easy. tion of Dr.EX shows any fault codes in diagnosing
the Auto-MARCCINO Control Unit. Some fault
The troubleshooting section consists of 7 groups: codes may be displayed on the system monitor.
General, the Component Layout, Troubleshooting A
(using fault codes), Troubleshooting B (starting with Example:
symptoms), Troubleshooting C (gauges and indica- Dr.EX : Fault Code 11 --- Arm Roll-Out
tors), Troubleshooting D (troubleshooting of the front Malfunction
attachment operational control using fault codes), Elec- System Monitor : Fault Code E11 --- Arm Roll-Out
trical System Inspection groups. Malfunction
• General • Electrical System Inspection

Refer to this group when precautions for electrical
• Component Layout system inspection or information on inspection
procedures is required.
• Troubleshooting A (using fault codes)
Use these charts when the self-diagnosing func- Example: Fuse Inspection
tion of Dr.EX shows any fault codes in diagnosing
the main controller (MC). (The controller auto-
matically diagnoses and memorizes malfunctions
that have occurred in the signal sending system.)
Example: Fault Code 01: EC Sensor Failure
• Troubleshooting B (starting with symptoms)

Use these charts when the machine is exhibiting
trouble and when Dr.EX does not indicate any
fault codes.
Example: Engine speed does not change even

when the engine speed control lever or
acceleration pedal is operated.
• Troubleshooting C (gauges and indicators)

Use these charts when any gauges or indicators
malfunction.
Example: The fuel gauge does not operate.
T5-1-1
DIAGNOSTIC PROCEDURES
These six basic steps are essential for efficient

troubleshooting:
1. Study the System

• Know the system configuration.
• Study what the construction, functions and
specifications of the system components are.
T107-07-01-001
2. Ask the Operator

Before inspecting, get the full story from the
operator.
• Operating Conditions: Check what kinds of work

the machine was doing and if the machine was
being operated correctly.
• Time of Trouble: Check when the trouble
occurred.
• Symptoms: What are the details ? Was the
trouble getting worse, or did it appear suddenly for
the first time ?
• Background Record: Check if the machine had
any other problems previously, if so, which parts
were repaired/replaced before ?
T107-07-01-002
3. Pre-Inspection
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 problems in the electrical system,
such as low battery voltage, loose connections
and blown fuses, will result in malfunction of the
controllers, causing total failure of the machine.
Cracked fuses are often very difficult to visually
check so inspecting with a tester is
recommended.
T107-07-01-003
T5-1-2
4. Check the Trouble Yourself
Try to identify the trouble by operating the ma-
chine yourself. If the symptoms are difficult to re-
produce, obtain detailed information on the cir-
cumstances when the trouble occurred from the
operator. In addition, check if a simple failure such
as a loose connection of the wire harness is pres-
ent by slightly moving the wire harness by hand.
5. Perform Troubleshooting
T107-07-01-004
CAUTION: Never attempt to disconnect har-

ness or hydraulic lines while the engine is
running. The machine malfunction may result
or pressure oil may spout, possibly resulting
in personal injury. Be sure to stop the engine
before disconnecting the wire harnesses or
hydraulic lines.
Connect Dr.EX to the MC to obtain malfunction

records.
If any fault codes are displayed, record them. After
deleting the fault codes (∗), run the self-
diagnosing function again. In case the fault codes T107-07-01-005
are displayed again, start checking following

Troubleshooting A in this section.
If no fault code is indicated, perform Troubleshoot-
ing B in this section and also check each compo-
nent performance using Dr.EX’s monitor function.
* Note that fault codes do not always indicate ma-

chine trouble. The controller, for example, stores
such records as a drop in battery output voltage
or disconnection of the sensors for inspection
purpose.
Before performing troubleshooting based on the

fault codes, delete the fault codes once and re- T107-07-01-006
check whether the fault codes are displayed again

(RETRIAL).
6. Recheck Possible Causes

Before reaching a conclusion, recheck the most
likely causes. Identify the fundamental causes by
making clear the reason why the trouble occurred.
Take appropriate corrective measures so that
consequent malfunction will not occur after repair-
ing.
T107-07-01-007
T5-1-3
DR.EX OPERATION
Dr.Ex is a diagnosing tool to be used for checking the

electronic system including the MC on the machine.
When Dr.EX is connected to the MC, malfunction

records in the MC and/or each sensor are indicated as
fault codes on the Dr.EX display. (Self-Diagnosing
Function)
Input signals from the sensors or switches that are

connected to the MC, or output signals from the MC to
actuators, such as solenoid valves, can be monitored
on a real-time basis while the machine is being
operated. (Monitor Function) T196-05-01-001
Dr.EX Connector
Operation
1. Connect Dr.EX’s harness to the diagnostic
connector in the cab.
2. Turn the key switch ON or start the engine. Start
3. Turn Dr.EX ON. The following screens will
successively appear on Dr.EX’s display.
3-1. Initial Screen
3-2. Model Code Screen Initial Screen
Example:
Model : EX60-5
Ver : 0100
Model Code
3-3. Function Selection Screen Communication
Confirmation
Failure
F1:Self-Diagnosing Results
F2:Monitor Data ・ Check
communication
F3:Special Functions NOT OK
harness
・ Check fuse OK ?
4. Select key F1. Then, proceed according to the in-
structions shown at the bottom of the screen. OK Replace Dr.EX
Software
NOTE: Refer to the Dr.EX Operator’s Manual for
detailed operation procedures.
Self- Monitor Special
Diagnosing Data Functions
Function
Selection Refer to
T5-1-6
Controller Record Monitor Data

Self-Diagnosing Selection
Results
Monitored Data
Retrial B Screen
Self-Diagnosing
Results
T5-1-4
MAIN CONTROLLER FAULT CODE LIST
Applicable Dr.EX Version: Dr.EX Ver 1.03
Fault Code Trouble Cause of Trouble

1) Faulty Check harness
01 Abnormal EC sensor
2) Faulty EC sensor
1) Faulty harness
07 Abnormal engine control Dial sensor
2) Faulty engine control dial
T5-1-5
AUTO-MARCCINO CONTROL UNIT FAULT
CODE LIST (EX75UR-3)
Fault Code
System
System Buzzer Sound Problem
Dr. EX Indicator
Monitor
Continuously Abnormal RAM in CPU
03 E03 ON
sounds
Continuously Abnormal calibration value
07 E07 ON
sounds
Continuously Abnormal code selection
08 E08 ON
sounds
11 E11 Abnormal arm roll-out function
Continuously
12 E12 ON Abnormal right offset function
sounds
13 E13 Abnormal left offset function
14 − − Abnormal arm roll-out pilot pressure sensor
15 − − Abnormal right offset pilot pressure sensor
ON
16 − − Abnormal left offset pilot pressure sensor
20 − − Abnormal boom raise pilot pressure sensor
40 E40 Abnormal 7 spool-solenoid valve unit (boom raise deceleration)
Long beep
41 E41 Abnormal 7 spool-solenoid valve unit (arm roll-in deceleration)
sounds ON
42 E42 Abnormal 7 spool-solenoid valve unit (left offset deceleration)
intermittently
44 E44 Abnormal 7 spool-solenoid valve unit (boom lower decelera-
43 − − Abnormal 7 spool-solenoid valve unit (right offset acceleration)
45 − − ON Abnormal 7 spool-solenoid valve unit (arm roll-out accelera-
47 − − tion)
50 E50 Abnormal boom angle sensor
Continuously
51 E51 ON Abnormal arm angle sensor
sounds
52 E52 Abnormal offset angle sensor
60 E60 Faulty boom angle sensor initial setting

Continuously
61 E61 ON Faulty arm angle sensor initial setting
sounds
62 E62 Faulty offset angle sensor initial setting
80 E80 Boom angle sensor deviation
Continuously
81 E81 ON Arm angle sensor deviation
sounds
82 E82 Offset angle sensor deviation
Faulty hydraulic oil temperature sensor

90 − − ON
NOTE: * Unless the solenoid valve has failed,

boom raise operation is correctly con-
trolled in the range lower than boom foot
pin height.
T5-1-6
Trouble on the Machine Corrective Action Group
* Movement to the cab stops. 1) Replace the controller if the machine does not
G1
operate correctly.
G1
operate correctly.
* Movement to the cab stops. 1) Input the front and bucket codes again.
G1
All movement stops.(No pilot pressure) 1) Check harness.
2) Replace the pilot pressure sensor. G0
3) Replace the solenoid valve.
Cab collision prevention control stops 1) Check harness.
Offset movement by offset switch stops. 2) Replace pilot pressure sensor.
G4
Offset movement by offset switch stops
Cab collision prevention control stops.
Boom raise movement stops. 1) Check harness.
Arm roll-out movement stops. 2) Replace solenoid valve.
G3
Left offset movement stops.
Boom lower movement stops.
Movement by the right offset switch stops. 1) Check harness.
Cab collision prevention control stops 2) Replace the solenoid valve. G4
Movement by the left offset switch stops.
Interference prevention control system functions 1) Check harness.
as if boom is raised to the highest position (input 2) Replace the angle sensor.
value from sensor: 4.5 V).
Interference prevention control system functions
as if arm is fully rolled in (input value from sensor: G2
4.5 V).
as if the front attachment is fully offset to the left
side (input value from sensor: 4.5 V).
* Movement to the cab stops. 1) Perform initial setting again.
2) Replace angle sensor. G1

4.5 V).
as if oil temperature is lowest (input value from 2) Replace the hydraulic oil temperture sensor. G4
sensor: 4.5V).
NOTE: If two or more trouble occurs at the same

time, the system monitor displays the fault
code for the lower group number only.
T5-1-7
MAIN CONTROLLER MONITORING FUNC-
TION
Dr.EX has a function to monitor the command signals

from the MC and the input signals (to MC) from various
switches and sensors.
Monitor Item Descriptions Unit

Target engine speed Command signal value to EC motor rpm
EC angle Input from EC sensor V
Input from engine control dial/engine speed
Dial angle V
control lever/pedal
E mode switch ON/OFF signal from E mode switch *EP
Auto-idle switch ON/OFF signal from auto-idle switch *AI
Pressure switch ON/OFF signal from all pressure switches * Fr, Tr
Key switch ON/OFF signal from key switch *Ky
Engine learning control * Successful, EC
failed, Ky failed
Pump control solenoid valve ON/OFF signal from pump control solenoid ON, OFF
input valve
EC motor position step
NOTE: * White letters (or figures) are shown on the

black screen when the switches are ON
(connected).
T5-1-8
AUTO-MARCCINO CONTROL UNIT MONI-
TORING FUNCTION (EX75UR-3)
Dr.EX has a function to monitor the command signals

from the Auto-MARCCINO Control Unit and input sig-
nals from various switches and sensors.
Selected Function Key Data Unit

Screen
1 F6 Boom angle sensor voltage V
F7 Arm angle sensor voltage V
F8 Offset angle sensor voltage V
F9 − −
F10 Oil temperature °C
2 F6 Boom raise deceleration solenoid valve current mA
F7 Boom lower deceleration solenoid valve current mA
F8 Arm roll-in deceleration solenoid valve current mA
F9 Left offset deceleration solenoid valve current mA
F10 − −
3 F6 Right offset acceleration solenoid valve current mA
F7 Left offset acceleration solenoid valve current mA
F8 Arm roll-out acceleration solenoid valve current mA
F9 − −
F10 − −
2
4 F6 Boom raise pilot pressure kgf/cm
F7 − −
2
F8 Right offset acceleration pilot pressure kgf/cm
2
F9 Left offset acceleration pilot pressure kgf/cm
2
F10 Arm roll-out acceleration pilot pressure kgf/cm
5 F6 ON/OFF signal from right offset switch *Sor
F7 ON/OFF signal from left offset switch *Sol
F8 ON/OFF signal from range limit release switch *Sav
F9 Bucket selection 2/1
F10 ON/OFF signal from emergency release switch *Sem
6 F6 ON/OFF signal from interference prevention mode switch *Sin
F7 ON/OFF signal from emergency evacuation switch *Spr
F8 ON/OFF signal from initial setting switch *Scl
F9 ON/OFF signal from service switch *Ssv
F10 − −
7 F6 Buzzer Output *Dbz
F7 Lock/Unlock signal of pilot pressure *Dpi
F8 − −
F9 − −
F10 − −
8 F6 Boom angle sensor correction value V
F7 Arm angle sensor correction value V
F8 Offset angle sensor correction value V
F9 − −
F10 − −
9 F6 Boom angle sensor standard value V
F7 Arm angle sensor standard value V
F8 Offset angle sensor standard value V
F9 − −
F10 − −
10 F6 Monitored height m
F7 Monitored reach m
F8 Monitored offset amount m
F9 − −
F10 − −
NOTE: * White letters (or figures) are shown on the
black screen when the switches are ON
(connected).
T5-1-9
Dr.EX SPECIAL FUNCTION (Service Mode)
(EX75UR-3)
When the optional front attachment or bucket is used,

the bucket may contact with the cab depending on the
size and shape of the bucket. To prevent contact, in-
putting the size of the optional front attachment or
bucket into the Auto-MARCCINO Control Unit is re-
quired.
Procedures
1. Turn the key switch to the OFF position and wait
for 10 seconds. Then, connect Dr.EX to the Auto-
MARCCINO Control Unit.
2. Connect the service switch (plug type).
3. Start the engine.
4. Select the service mode on Dr.EX to input the
front and bucket data.
5. When using the optional front attachment, per-
form the initial setting of the angle sensor (when
using the optional bucket, this step is not re-
quired).
6. After completing the data input, stop the engine
and disconnect the service switch (plug type).
Then, start the engine again.
7. Confirm that the cab collision prevention control
and Auto-MARCCINO Control correctly operate.
NOTE: After completing the data input in the serv-

ice mode, be sure to disconnect the service
switch. Failure to do so may cause the fol-
lowing trouble to occur:
• Self-diagnosing by Dr.EX doesn’t operate.

• Fault codes are not stored in the Auto-
MARCCINO Control Unit memory.
• Initial setting of the angle sensor cannot be made.
• The switches in the system monitor (limiting range,
indicating distance) becomes inoperative.
T5-1-10
Dr. EX Operation Procedure
Start
Start-Up Screen
Machine Model Menu
Select the displayed No. for the ”Medium Size UR.”
Program Version Confirmation
Execute (F1) after confirming.
EX
HITACHI
Dr.
(C) Hitachi Construction
UR V1.03
Machinery Co., Ltd. 1996

F1: Start F10: Machine Model Menu
F1
C/U Classification
Designed by : Medium Size Design
Group
Base Machine : EFCT
Variation : EFCT-UR
ELC Program Version : 01.03
F1: Next F5: Exit
F1
Front Attachment Compatibility
Base Machine and Front Attachment:
EX75UR-3, STD Front Attachment
Bucket:
EX75UR-3 STD
Control System:
EFCT-UR
F1: Next F5: Exit
F1
Select operation mode.
F1: Self-Diagnostic Result Screen

F2: Monitor Screen
F3: Service Mode
F5: Exit
F1 F2 F3
1 To T5-1-12 2 To T5-1-13 3 To T5-1-13
T5-1-11
Self-Diagnostic Result Screen
1 From T5-1-11
Trouble exists. No trouble exists.
Following fault codes are detected by No trouble exists or trouble beyond

self-diagnostic function. the scope of Dr. EX. Check by moni-
41 2 3 4 5 6 tor function hereafter referring to
789 troubleshooting manual.
F1: Details F2: Retrial F5: Exit F5: Exit
F1 F2
Fault Code: 41 Retrial successful.

Slow Arm Roll-in Speed
Abnormal Proportional Valve Self-diagnostic function will operate
Output again when key F1 is pushed.
F3: Next F5: Exit F1:Self Diagnostic Operation

F1
Trouble exists. No trouble exists.
T5-1-12
Monitor Screen
2 From T5-1-11
F2
Select data to be monitored.

F6: Boom Angle Sensor Voltage NOTE: Refer to the table on
F7: Arm Angle Sensor Voltage page T5-1-9 in the Moni-
F8: Offset Angle Sensor Voltage tor Function Group for
F9: the monitor data items.
F10:
F1: START
F2: CLEAR ( Selected Data No.: 0)
F3: NEXT↓ F4: PREV.↑ F5: EXIT.
Touch F1 after selecting the item to be monitored.
Boom Angle Voltage V
Arm Angle Voltage V
Offset Angle Voltage V
F1: FREEZE F5:PREV.

F5
Service Mode 3 From T5-1-11,

T5-1-15
F3
Select Item
F1:Front Attachment Var. Code
Setting
F2:C/U Memory Check
F3:
F4:
F5: EXIT
F1 F2
Bucket Switch Setting C/U Memory Check

Select the switch.
Socket EPROM = Normal
F1: Switch 1 7 From T5-1-15
F2: Switch 2 MPU/EPROM = Error
F5: EXIT F5: EXIT
F2 (Touch only F2 key)

4 To T5-1-14
T5-1-13
4 From T5-1-13, 15
SW2 Current Data Setting
Front Attachment: EX75UR-3 STD

Bucket: EX75UR-3 STD
Control System: EFCT-UR
F1: SETTING (Table)
F2: SETTING (Input)
F5: EXIT
Use when inputting the code No.
F1 F2
Bucket Switch Setting Bucket Switch Setting

Select front attachment code. Select front attachment code.
Code 90: EX75UR-3 Code :EX75UR-3
Refer to the Front

Attachment Code Table.
Touch F1 to change
F1: NEXT the code No.
F3: SELECT F5: EXIT ENT: End of Input
F3 Touch ENT
after inputting.

Select front attachment code. Select front attachment code.
Code 90: EX75UR-3 Code 90: EX75UR-3
STD Bucket STD Bucket
F1: NEXT Touch F1 to change

the code No.
F3: SELECT F5: EXIT F3: SELECT F5: EXIT
F3 F3
5 To T5-1-15 6 To T5-1-15
Front Attachment Code Table Bucket Code Table

Code No. Variation of Front
Code No. Bucket Variation
Attachment
90 STD Front 90 0.25 (STD)
Attachment 91 0.20
91 Slide Arm 92 0.25 (Level finishing plate)
92 Long Arm 93 0.10
94 Slope-Finishing Blade
95 Slope-Finishing Blade
T5-1-14
6 From T5-1-14
Bucket Switch Setting

Select bucket code.
Code :
Refer to the Bucket
Code Table.
3 To T5-1-13 4 To T5-1-14 ENT: END OF INPUT

Touch ENT after
F1 F5 inputting the code.

Select bucket code.
Operation will end without setting To T5-1-14 4 Code 90: EX75UR-3
switch 2. STD Bucket
F5
F1: RESET F5: EXIT F3: SELECT F5: EXIT

From T5-1-14
5 F3

Do you want to store the front at-
tachment/bucket code data ?
Code 90: EX75UR-3
F5
(Bucket) STD Bucket
Code 90: EX75UR-3
(Front Attachment)
STD Front Attachment
F1: STORE F5: Exit
F1
Successful Failed

To T5-1-13 7
Switch 2 setting has been com- To T5-1-13 F1
pleted. Transaction in controller failed.
3
F5 F5
F5: EXIT F1: RETRY F5: EXIT
T5-1-15
(Blank)
T5-1-16
TROUBLESHOOTING / Component Layout
MAIN COMPONENTS
EX60-5
3
4
5
6
7
8
9
10
19
11
12
18
13
17 14
16
15 T152-01-02-001
1- Bucket Cylinder 6- Control Valve 11 - Pump Device 16 - Swing Bearing

2- Arm Cylinder 7- Fuel Tank 12 - Engine 17 - Shockless Valve
3- Boom Cylinder 8- Hydraulic Oil Tank 13 - Radiator 18 - Pilot Shut-Off Vale
4- Center Joint 9- Air Cleaner 14 - Oil Cooler 19 - Front/Swing Pilot Valve
5- Swing Device 10 - Muffler 15 - Travel Device
T5-2-1
EX75UR-3
8
3
7
1
4
5
23 6
22
9
10
11
21
20
19
18
17
16
15 12
14 13
T192-01-02-001
1- Bucket Cylinder 7- Hydraulic Oil Tank 13 - Radiator 19 - Pilot Shut-Off Valve

2- Arm Cylinder 8- Fuel Tank 14 - Oil Cooler 20 - Blade Pilot Valve
3- Boom Cylinder 9- Control Valve 2 15 - Travel Device 21 - Blade Cylinder
4- Control Valve 1 10 - Swing Device 16 - Center Joint 22 - Front/Swing Pilot Valve
5- Swing Mode Selection 11 - Pump Device 17 - Swing Bearing 23 - Offset Pilot Valve
Valve
6 - Pilot Filter 12 - Engine 18 - Shockless Valve
T5-2-2
EX75URLC-3
4 8
5
6 7
20 9
10
11
19
18
17
16
15
12
13 T195-01-02-001
14
1- Bucket Cylinder 6- Pilot Filter 11 - Pump Device 16 - Center Joint

2- Arm Cylinder 7- Hydraulic Oil Tank 12 - Engine 17 - Swing Bearing
3- Boom Cylinder 8- Fuel Tank 13 - Radiator 18 - Shockless valve
4- Control Valve 1 9- Control Valve 2 14 - Oil Cooler 19 - Pilot Shut-Off Valve
5- Swing Mode Selection 10 - Swing Device 15 - Travel Device 20 - Front / Swing Pilot Valve
Valve
T5-2-3
ELECTRICAL SYSTEM (Overview)
EX60-5 1 2 3 4 5 6 7 8 9 10 11
12
26
25
24
13
14
23
15
22 21 20 19 18 17 16 T152-01-02-002
1 - MC(Main Controller) 8 - Work Light Relay(R3) 15 - Pump Control Solenoid 22 - Battery Relay
Valve
2 - QHS Controller 9 - Load Dump Relay(R1) 16 - Engine Oil Pressure Switch 23 - Battery
3 - Wiper Relay(R9) 10 - Pressure Switch 17 - Coolant Temperature 24 - Learning Plug Connector
(Front/Swing) Sensor(QHS Controller)
4 - Wiper Relay(R8) 11 - Pressure Relay(Travel) 18 - Overheat Switch 25 - Dr.EX Connector
5 - Wiper Relay(R7) 12 - Fuel Sensor 19 - Coolant Temperature 26 - Fuse Box
Sensor(Coolant Tempera-
ture Gauge)
6 - Wiper Relay(R6) 13 - EC Motor･EC Sensor 20 - Starter Relay
7 - Horn Relay(R5) 14 - Air Restriction Switch 21 - Air Heater Relay
T5-2-4
(Blank)
T5-2-5
EX75UR-3
2
1 3
4
5 7
6 8
9
10
A 11
12
13
24 25
View A
24
23
Relay
22
21
27 14
15
16
17
18 19
T192-01-02-002
26
T192-01-02-008
1 - Arm Angle Sensor 8 - Starter Relay 15 - Engine Oil Pressure Switch 22 - Auto-MARCCINO Control
Unit
2 - Offset Angle Sensor 9 - Intake Air Heater Relay 16 - Coolant Temperature 23 - Engine Speed Control
Sensor Sensor
(For Engine Preheat)
3 - Work Light 10 - Fuel Sensor 17 - Overheat Switch 24 - Pressure Switch
(Front⋅Swing)
4 - Boom Angle Sensor 11 - Emergency Stop Solenoid 18 - Coolant Temperature 25 - Pressure Switch (Travel)
Valve Sensor (For Coolant
Temperature Gauge)
5 - Electrolyte Level Switch 12 - EC Motor, EC Sensor 19 - Alternator 26 - Solenoid Valve
(For Precise Swing Mode)
6 - Battery 13 - Horn 20 - MC (Main Controller) 27 - Pressure Switch (Swing)
7 - Battery Relay 14 - Pump Control Solenoid 21 - Heater
Valve
T5-2-6
Relay and QHS Controller
1
2
3
4
9
8
7
6
5
T192-01-02-007
1 - Horn Relay 4 - Swing Relay 6 - Work Light Relay 8 - Load Dump Relay
2 - Wiper Relay 5 - Solenoid Valve Relay 7 - IC/U Relay 9 - QHS Controller
3 - Washer Relay
T5-2-7
EX75URLC-3
4
2
3 5
6
7
A
8
9
18
Relay
17
16
10
11
12, 13, 14
15
T195-01-02-002
1 - Work light 6 - Intake Air Heater Relay 11 - Engine Oil Pressure Switch 16 - MC(Main Controller)
2 - Electrolyte Level Switch 7 - Fuel Sensor 12 - Coolant Temperature 17 - Heater
Sensor (For Engine Pre-
heat): Pump Side
3 - Battery 8 - EC Motor, EC Sensor 13 - Overheat Switch 18 - Engine Speed Control
: middle Sensor
4 - Battery Relay 9 - Horn 14 - Coolant Temperature
Sensor (For Coolant
Temperature Gauge)
: Radiator Side
5 - Starter Relay 10 - Pump Control Solenoid 15 - Alternator
Valve
T5-2-8
19 20
View A
21
22
T192-01-02-008
Relay and QHS Controller
23
24
25
26
30
29
28
27
T195-01-02-003
19 - Pressure Switch 22 - Pressure Switch (Swing) 25 - Washer Relay 28 - Work Light Relay
(Front ⋅ Swing)
20 - Pressure Switch (Travel) 23 - Horn Relay 26 - Swing Relay 29 - Load Dump Relay
21 - Solenoid Valve 24 - Wiper Relay 27 - Solenoid Valve Relay 30 - QHS Controller
(For Precise Swing Mode)
T5-2-9
(Blank)
T5-2-10
ELECTRICAL SYSTEM (Monitor and
Switches)
EX60-5
2
3
4
5
6
7
2 8
M152-01-014
Monitor Panel (5) Switch Panel (6)
11 12 13 14 15
18 19 20 21 22 23 24 25 26 27 28 29
10
M152-01-016 M152-01-002
17 16
1 - Radio 9 - Coolant Temperature 16 - Hour Meter 23 - Slow Speed Mode Indicator

Gauge
2 - Horn Switch 10 - Warm Up Complete Indi- 17 - Fuel Gauge 24 - Travel Mode Switch
cator
3 - Key Switch 11 - Alternator Indicator 18 - Auto-Idle Indicator 25 - Buzzer Deactivation Switch
4 - Engine Control Dial 12 - Engine Oil Pressure Indi- 19 - Auto-Idle Switch 26 - Work Light Indicator
cator
5 - Monitor Panel 13 - Preheat Indicator 20 - Ｅ Mode Indicator 27 - Work Light Switch
6 - Switch Panel 14 - Overheat Indicator 21 - Ｅ Mode Switch 28 - Wiper Indicator
7 - Optional Switch 15 - Air Filter Restriction Indi- 22 - Fast Speed Mode Indicator 29 - Wiper Switch
cator
8 - Optional Switch
T5-2-11
EX75UR-3
Left Console Right Console

1
8 9
System
Monitor
2
23
22
21 10
3
20
4 19
11
5
18 12
6
17 13
16 14
M192-01-001
15
M192-01-002
System Monitor
Seat Rear Side
24
25
26
35 36
27 37
28
34
29
33
M191-01-052
32 31 30 T191-01-02-008
T5-2-12
Seat Right-Front Side Seat Left-Rear Side
40
38
39
M191-01-037 T191-02-02-001
1 - Horn Switch 11 - Alternator Indicator 21 - Auto-Idle Switch 31 - Offset Limit Switch

2 - Hour Meter 12 - Preheat Indicator 22 - Wiper Switch 32 - System Failure Indicator
3 - E Mode Switch 13 - Air Filter Restriction Indi- 23 - Work Light Switch 33 - Monitor Selection Switch
cator
4 - Precise Swing Mode 14 - Battery Level Indicator 24 - Liquid Crystal Display 34 - Monitor Selection Indicator
Switch
5 - Auto-MARCCINO Mode 15 - Overheat Indicator 25 - Absolute/Relative Distance 35 - Zero-Point Set Switch
Switch Selector
6 - Radio 16 - Fuel Gauge 26 - Height Limit Indicator 36 - Cab Heater Control Panel
7 - Work Range Restriction 17 - Fuel Level Indicator 27 - Height Limit Switch 37 - Fuse Box
Cancel Switch
8 - Left Offset Switch 18 - Coolant Temperature 28 - Depth Limit Indicator 38 - Collision Prevention Sys-
Gauge tem Emergency Deactiva-
tion Switch
9 - Right Offset Switch 19 - Engine Oil Pressure Indi- 29 - Depth Limit Switch 39 - Engine Stop Handle
cator
10 - Key Switch 20 - Washer Switch (Optional) 30 - Offset Limit Indicator 40 - Emergency Redundant
Switch
T5-2-13
EX75URLC-3
Left Console Right Console
1 7
8
9
10
11
14
2
12 15
16
3 17
13
4 18
19
5
20
6
T195-01-02-004
M192-01-001
Seat Rear Side
T191-01-02-008
21 22
1 - Horn Switch 7 - Key Switch 13 - Fuel Gauge 19 - Overheat Indicator

2 - Hour Meter 8 - Work Light Switch 14 - Engine Oil Pressure Indi- 20 - Battery Level Indicator
cator
3 - E Mode Switch 9 - Wiper Switch 15 - Alternator Indicator 21 - Cab Heater Control Panel
4 - Precise Swing Mode 10 - Auto-Idle Switch 16 - Fuel Level Indicator 22 - Fuse Box
Switch
5 - Auxiliary Switch 11 - Washer Switch (Optional) 17 - Preheat Indicator
6 - Radio 12 - Coolant Temperature 18 - Air Filter Restriction Indi-
Gauge cator
T5-2-14
PUMP DEVICE SWING DEVICE
EX60-5 EX60-5
5 7
1 2
T152-01-02-003
T152-01-02-003
EX75UR-3, 75URLC-3 EX75UR-3, 75URLC-3

4 2
1 5
7
3
T192-01-02-005
T192-01-02-004
1 - Main Pump 3 - Pump Control Solenoid 5 - Make-Up Valve 7 - Swing Relief Valve
Valve
2 - Pilot Pump 4 - Main Pump 2 6 - Parking Brake Switch Valve
T5-2-15
TRAVEL DEVICE
9
T192-01-02-003
8 - Control Balance Valve 9 - Travel Relief Valve
T5-2-16
(Blank)
T5-2-17
COMPONENT IN CONTROL VALVE
EX60-5: 1 2 3 4 5 6
Left Travel Motor Right Travel Motor
22
7
21 8
20
Bucket
Cylinder
9
19 10
11
Arm Boom
Cylinder Cylinder
18
17
12
13
Swing Motor
Control Valve
16 15 14
Main Pump Pilot Pump T152-03-03-002
1 - Main Relief Valve 7 - Load Check Valve 13 - Load Check Valve 19 - Overload Relief Valve
(Bucket Circuit) (Arm 1 Circuit) (Arm Circuit)
2 - Check Valve 8 - Overload Relief Valve 14 - Check Valve (Arm Roll-In 20 - Check Valve
(Bucket) Flow Combining Circuit) (Auxiliary Parallel Circuit)
3 - Check Valve 9 - Load Check Valve 15 - Check Valve (Arm Roll-Out 21 - Check Valve (Travel Left
(Boom 2 Circuit) Flow Combining Circuit) Parallel Circuit)
4 - Check Valve (Bucket Flow 10 - Boom Anti-Drift Valve 16 - Check Valve 22 - Load Check Valve
Combining Circuit) (Check Valve) (Swing Parallel Circuit) (Travel Left Circuit)
5 - Flow Combiner Valve 11 - Boom Anti-Drift Valve 17 - Load Check Valve
(Switch Valve) (Arm 2 Tandem Circuit)
6 - Check Valve 12 - Overload Relief Valve 18 - Check Valve
(Boom Circuit) (Arm 2 Parallel Circuit)
T5-2-18
Section A
1
G
B
A
T152-05-04-004
2 3
View
T152-03-03-003
Section B Section C
6 5
21, 22
T152-03-03-004
T152-03-03-005
T5-2-19
EX60-5: 1 2 3 4 5 6
Left Travel Motor Right Travel Motor
22
7
21 8
20
Bucket
Cylinder
9
19 10
11
Arm Boom
Cylinder Cylinder
18
17
12
13
Swing Motor
Control Valve
16 15 14
Main Pump Pilot Pump T152-03-03-002
1 - Main Relief Valve 7 - Load Check Valve 13 - Load Check Valve 19 - Overload Relief Valve
(Bucket Circuit) (Arm 1 Circuit) (Arm Circuit)
2 - Check Valve 8 - Overload Relief Valve 14 - Check Valve (Arm Roll-In 20 - Check Valve
(Bucket) Flow Combining Circuit) (Auxiliary Parallel Circuit)
3 - Check Valve 9 - Load Check Valve 15 - Check Valve (Arm Roll-Out 21 - Check Valve (Travel Left
(Boom 2 Circuit) Flow Combining Circuit) Parallel Circuit)
4 - Check Valve (Bucket Flow 10 - Boom Anti-Drift Valve 16 - Check Valve 22 - Load Check Valve
Combining Circuit) (Check Valve) (Swing Parallel Circuit) (Travel Left Circuit)
5 - Flow Combiner Valve 11 - Boom Anti-Drift Valve 17 - Load Check Valve
(Switch Valve) (Arm 2 Tandem Circuit)
6 - Check Valve 12 - Overload Relief Valve 18 - Check Valve
(Boom Circuit) (Arm 2 Parallel Circuit)
T5-2-20
Section D Section E
10
8
11
20
9
12
T152-03-03-007 T152-03-03-006
8
Section F Section G
12 19
14
17, 18 16
13
15
19
T152-03-03-009
T152-03-03-008
T5-2-21
EX75UR-3, EX75URLC-3:
1 2 3 4 5 6 7
25 26 27
10
24
23 11
12
22
28 13
21
14
20
19 18 17 16 15
T192-03-03-003
1 - Main Relief Valve 8 - Load Check Valve 15 - Check Valve 22 - Load Check Valve
(Front Attachment/Swing) (Travel Parallel Circuit) (EX75UR-3:
Offset Parallel Circuit)
(EX75URLC-3:
Auxiliary Tandem Circuit)
2 - Main Relief Valve (Travel) 9 - Check Valve 16 - Check Valve 23 - Overload Relief Valve
(Flow Combining Circuit) (EX75UR-3: Offset)
(EX75URLC-3: Auxiliary)
3 - Relief Set Pressure 10 - Load Check Valve (Bucket 17 - Check Valve 24 - Load Check Valve
Change Valve Circuit) (Travel Tandem Circuit)
4 - Check Valve 11 - Overload Relief Valve 18 - Load Check Valve 25 - Main Relief Valve (Precise
(Bucket) (Arm 1 Parallel Circuit) Swing)
5 - Check Valve 12 - Load Check Valve (Boom 1 19 - Load Check Valve 26 - Load Check Valve
Parallel Circuit) (Swing Parallel Circuit) (Swing Circuit)
6 - Flow Combiner Valve 13 - Overload Relief Valve 20 - Load Check Valve 27 - Load Check Valve
(Boom) (Arm 1 Tandem Circuit) (EX75UR-3:
Blade Parallel Circuit)
(EX75URLC-3:
Auxiliary Parallel Circuit)
7 - Check Valve 14 - Load Check Valve 21 - Overload Relief Valve 28 - Overload Relief Valve
(Arm 2 Tandem Circuit) (Arm) (EX75UR-3: Blade)
T5-2-22
Control Valve 1 Section A
2 1
E 3
T195-03-03-002
7 6
T195-03-03-015
4 5
View
Section B Section C
23 11
8, 24
22 10
T195-03-03-003 23 11
T195-03-03-004
T5-2-23
1 2 3 4 5 6 7
25 26 27
10
24
23 11
12
22
28 13
21
14
20
19 18 17 16 15
T192-03-03-003
(EX75URLC-3:
(EX75URLC-3:
T5-2-24
Section D Section E
13 21
17
15
12 18, 20
14
16
13 21
T195-03-03-005 T195-03-03-006
Section F
5 4
19
T195-03-03-007
T195-03-03-008
T5-2-25
1 2 3 4 5 6 7
25 26 27
10
24
23 11
12
22
28 13
21
14
20
19 18 17 16 15
T192-03-03-003
(EX75URLC-3:
(EX75URLC-3:
T5-2-26
Control Valve 2
25
T192-03-03-005
28
26, 27
T192-03-03-006
T5-2-27
(Blank)
T5-2-28
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Use troubleshooting A procedure when fault codes are

shown on Dr.EX.
• How to Read the Troubleshoting Flow Charts
YES(OK)
(2) After checking or measuring item (1), select either YES (OK) or NO
(NOT OK) and proceed to item (2) or (3), as appropriate.
・ (1)
(3)
NO(NOT OK)
・ Special instructions or reference item are indicated in the spaces under the box. Incorrect
measuring or checking methods will render troubleshooting impossible, and may damage
・ Key switch: ON components as well.
・ Explanation of how to use lamp harness kit required. Refer to “Electrical System
Inspection” Group (Group 7) in this section.
・
Use Dr. EX function.
・ Causes are stated in a thick-line box. Scanning through thick-line boxes, possible causes
can be seen without going through the flow chart.
NOTE: For all connector drawings illustrated in this

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

Open End
Side
Harness End Connector
T158-05-03-001
T5-3-1
FAULT CODE 01 (ABNORMAL EC SEN-
SOR)
Check if the harness NO

Faulty in MC.
between terminal
YES No.15 on MC ・ Refer to page T4-6-1.
connector D and
Disconnect EC sensor terminal No.2 on EC
connector, check if sensor is broken or MC と EC
Faulty センサ間
harness
Disconnect EC sensor
short-circuited.
connector, check if YES voltage between のハーネス不良
between MC and
resistance between terminal No.1 and No.3 YES EC sensor.
terminal No.1 and No.3 on the harness
on the sensor connector connector is within the
is within the range of 2.0 range of 5 ± 0.5 V. Faulty harness
± 0.4 kΩ. In addition, ・ Key switch: ON between MC and
attach test harness NO EC sensor.
(ST7129) to EC sensor.
Check if voltage changes
in accordance with Faulty EC sensor
specifications when NO
engine conrol dial /
engine speed control
lever is operated.
・ Standard values: Refer to
page T4-2-12.
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector D EC Sensor Connector
1 2 5 6 7 8 9 10 11
1 2 3
12 13 14 15 16 17 18 19 20 21 22
T5-3-2
(Blank)
T5-3-3
FAULT CODE 07
(ABNORMAL ENGINE CONTROL DIAL
ANGLE)
• Check for loose harness connections beforehand.

NOTE: EX60-5: Engine Control Dial
EX75UR-3, EX75URLC-3: Engine Control
Sensor Check harness bet- Faulty harness
YES
ween MC connector D between MC and
harness end terminal engine control dial.
YES No.21 and engine
control dial terminal S
for breakage or short Faulty MC.
Disconnect switch circuit.
EX60-5 NO
panel. Check if volta- ・ Refer to T4-6-1.
YES ge between harness
Disconnect engine control end connector termin- Broken harness
dial connector. als plus and minus is YES between MC and
Check if voltage bet-
Check if resistance bet- 5±0.5 V. engine control dial
ween harness end
ween plus and in minus terminal minus.
・ Key switch: ON connector terminal
terminals is 5±0.5 kΩ. plus and vehicle
Reconnect engine control NO Broken harness
frame matches spe-
dial connector. Insert tes- between MC and
cification.
ter probe into connector NO engine control dial
from the reverse side. ・ Key switch: ON terminal plus.
Check if voltage varies as ・ Specification: 5±0.5 V
specified when engine
control dial is turned. Faulty engine control
・ Specification: Refer to NO dial.
table below.
Engine Control Dial Specification

Minimum Speed 0.3 to 1.0 V
Maximum Speed 4.0 to 4.7 V
T5-3-4
Faulty harness
YES between MC and
engine control
sensor.
Check if harness
between terminal
YES No.21 on MC
connector D and
terminal No.2 on
engine control sensor
Disconnect engine is broken or short-
control sensors circuited.
YES connector, check if Faulty in MC.
voltage between NO
terminal No.1 and No.3 ・ Refer to page T4-6-1
on the harness Broken harness
Disconnect engine connector is within the YES
between MC and
control sensor connector, range of 5 ± 0.5 V. engine control
check if resistance Check if voltage dial terminal #3.
・ Key switch: ON
between terminal No.1 between harness end
and No.3 on the sensor connector terminal
connector is within the NO Broken harness
No.1 and vehicle
range of 2.0 ± 0.6 kΩ. between MC and
frame matches.
NO engine control
specfication
dial terminal #1.
Faulty engine
NO control sensor.
Connector (Harness End Connector Viewed from the Open End Side.)
MC Connector D Engine Control Dial Engine Control Sensor Connector
1 2 5 6 7 8 9 10 11
+ S - 1 2 3
12 13 14 15 16 17 18 19 20 21 22
T5-3-5
(Blank)
T5-3-6
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault

codes are displayed on Dr.EX even though the ma-
chine’s operation is abnormal. At the front section of
this group, are tables indicating the relationship be-
tween machine trouble symptoms and related parts
which may cause such trouble if failed. Start the trou-
bleshooting with more probable causes selected by
referring to these tables.
YES(OK)
(2)
• After checking or measuring item (1), select either YES (OK) or
・ (1) NO (NOT OK) and proceed to item (2) or (3), as appropriate.
(3)
NO(NOT OK)
・ • Special instructions or reference item are indicated in the spaces under the box.
Incorrect measuring or checking methods will render troubleshooting impossible,
· Key switch: ON and may damage components as well.
• Explanation of how to use test harness kit required. Refer to “Electrical System
・
Inspection” Group (Group 7) in this section.
・ • Use the Dr. EX troubleshooting/monitor function for the description in a double-line

box.
・ • Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes can be seen without going through the flow chart.
T5-4-1
RELATIONSHIP BETWEEN MACHINE
TROUBLE SYMPTOMS AND SUSPECTED
PARTS
This table indicates machine symptoms and proce-

dures to diagnose the failed part.
Part Name
EC Motor EC Sensor Engine Control Sensor
To operate governor lever. To detect governor lever position To detect engine speed control
for idle speed (2.5 V) lever and accelerator pedal posi-
tion.
Part Function
Governor lever does not move. Whenever key switch is ON, gov- Even if engine speed control lever
ernor lever position is learned as in or accelerator pedal is operated,
Symptoms in Control the slow idle speed position based engine speed is unchanged. If en-
on which engine speed is regu- gine control sensor circuit is bro-
System when lated afterward. Accordingly, if any ken or short-circuited, target speed
Trouble Occurs. discrepancy is learned, engine 1600 min-1 is used as the backup
speed is always controlled with the value.
same amount of discrepancy.
Even if fuel lever or accelerator If a discrepancy has occurred on the Engine speed is held constant at
pedal is operated, engine speed slower side: 1600 min-1. (Auto-idle function op-
does not increase from slow speed Although engine speed changes when erates, and engine stops by turn-
range. Starter rotates but engine engine speed control lever or accelera- ing key switch.)
fails to start, occasionally. tor pedal is operated, engine speed is
Engine stalls if broken EC motor slower than normal in all operation
occurs while engine is running ranges.
faster than a specified speed. (Note: If a discrepancy has occurred on
Engine becomes uncontrollable if the faster side, the EC motor intends to
broken EC motor occurs while en- operate outside the control range with
Machine Trouble engine speed control lever or accelera-
gine is running slower than the
Symptoms specified speed. tor pedal fully stroked. However, gover-
nor lever stays stationary at the full
Engine does not stop with Key
stroke position as EC motor is a worm
switch turned OFF.
gear type. If engine speed control lever
or accelerator pedal is moved to the
slowest position, governor lever returns
to the slow idle position.)
When starting engine, engine speed
fluctuates.
Engine start may become difficult.
By Dr. EX Self- Fault code 01 is displayed. Fault code 07 is displayed.
Diagnosing −
Function
By Dr. EX Monitor Item : EC angle Monitor Item: Lever angle
Monitoring −
Judgme Function
nt By Lamp Install lamp harness (ST7125).
Harness Then, check EC output signal and − −
check if harness is normal
Others − − −
Engine is stopped by EC motor. If EC sensor has failed, engine

No engine stop motor provided. learning operation becomes im-
Note However, fuel cut off cable is in- possible. −
stalled.
Descriptions of Op- T2-1 T2-1 T2-1

erational Principles
(Operational Princi-
ples Section in
Technical Manual)
T5-4-2
Pressure Switch Pressure Switch (Swing)

Pressure Switch (Travel) Learning Plug
(Front Attachment/Swing) (EX75UR-3 and EX75URLC-3)
To detect travel spool operation. To detect that front attachment To detect that swing spool is To start engine control learning.
(For auto-idle operation and and/or swing spool is operated. shifted (for auto-idle and pump
pump control) (For auto-idle operation and control). ON: 0V → Learning
pump control) OFF: 5V → Normal Control
No signal is sent to MC. No signal is sent to MC. No signal is sent to MC. Engine learning does not func-
tion.
Engine speed does not increase Engine speed does not increase Engine speed does not in- If trouble is caused by broken
even if machine is traveled with even if either front attachment or crease. circuit or faulty harness only,
auto-idle switch ON. swing control lever is operated Even if the precise swing mode machine operates normally.
Travel is slow. with auto-idle switch ON. switch is turned ON, and the (Only engine learning function
Front attachment and swing op- machine travels with the auto- fails.)
eration are slow. idle switch ON. If the trouble is caused by a
short circuit, the learning mode
operates when key switch is
turned ON. Therefore, engine
may stall 5 seconds after start-
ing.
− − − −
Monitor Item: Pressure switch Monitor Item: Pressure switch Monitor Items: Engine learning
Monitor ON-OFF while travel- Monitor ON-OFF while operating front at- − switch
ing. tachment and/or swing function.
− − − −
− − − −
It is possible to check if the It is possible to check if the

pressure switch has failed or if a pressure switch has failed or if a
port is clogged by switching the port is clogged by switching the − −
pressure switch with an adja- pressure switch with an adja-
cent one (for front attachment
and swing). cent one (for travel).
T2-1 T2-1 T2-1
T5-4-3
Part Name Flow Combiner Valve E Mode Switch

MC (Main Controller)
To regulate engine and pump op- To supply hydraulic oil to both right To select E mode
erations. and left travel spools from pump 1
(rear) when the combined opera- ON: 0V → E Mode
tion of travel and front attach- OFF: 5V → Normal Control
Part Function ment/swing is performed.
Symptoms may differ depending Hydraulic oil is not supplied or a −

on the trouble. sufficient amount of oil is not sup-
(Machine symptoms shown below plied to the left travel spool when
Symptoms in Control signify that the logic circuit in MC the combined operation of travel
System when has failed.) and front attachment/ swing is per-
Trouble Occurs. formed.
Engine cannot start even if key Machine mistracks when swing Broken Wire: Even if work mode
switch is turned ON since EC mo- lever is operated while traveling switch is depressed, engine runs
tor does not rotate to the start posi- straight. at full speed.
tion. Even if engine starts, engine Short Circuit: Engine speed does
speed is slow. not increase up to full speed.
Machine Symptoms
By Dr. EX Self- − − −
Diagnosing
Function
Monitor Items: E mode switch Monitor Items: E mode switch Monitor Items: E mode switch
By Dr. EX
Monitoring
Judg Function
ment
By Lamp − − −
Harness
− − −
Others
Be sure to check fuses in the con- − −

trol system before suspecting a
Note failure in MC.
Descriptions of Op- T2-3, T3-3 T2-1

erational Principles
(Operational Princi- −
ples Section in
Technical Manual)
T5-4-4
Precise Swing Mode Switch Pump Control Solenoid Solenoid Valve (Swing Switch Valve) 7-Spool Solenoid Valve
(EX75UR-3 and EX75URLC-3) Valve (EX75UR-3 and EX75URLC-3) (EX75UR-3)
To change swing speed. Supplies pressure oil to regulate When precise swing mode To control pilot pressure to con-
pump displacement. switch is turned ON, supply trol front function
swing pilot pressure to control (Automatic Work Range Restric-
valve 2. tion, Cab collision Prevention,
Normal swing :0 V Auto-MARCCINO control).
Precise swing :5 V
Control system malfunction may If solenoid valve is not operated, Control system malfunction may Front stops, moves slow, or
differ depending on trouble pump displacement angle is differ depending or trouble situa- keep moving.
situation. fixed. tions.
Wire breakage: Swing speed is Travel speed does not change. When solenoid valve is left Deceleration solenoid valve
not decreased even if the pre- (Fixed to fast or slow speed) closed: Even if the precise spool stuck open causing the
cise swing mode switch is Front/Swing speed is fast or swing mode switch is turned front function not to stop or de-
turned ON. slow. ON, the swing speed is not re- celerate.
Relay short-circuit: Swing speed duced. Deceleration solenoid valve
is reduced even if the precise When the solenoid valve is left spool stuck shut making the
swing mode switch is turned open: Even if the precise swing front function immovable.
OFF. mode switch is not turned ON, Acceleration solenoid valve
MC short-circuit: Normal opera- the swing speed is reduced. spool stuck open causing the
tion. front function not to stop.
Acceleration solenoid valve
spool stuck shut making the
front function immovable.
Fault code 40,

− − − 41,42,43,44,45,47 is displayed
(Auto MARCCINO system)
Monitor Items: Boom
raise/boom lower/arm roll-
in/current through left offset de-
− − celeration solenoid valve.
− Right offset/left offset/current
through arm roll-out accelera-
tion solenoid valve.
− − − −
− − − −
− − − −
T2-1 T3-3 T2-1 T2-2
T5-4-5
CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
Engine System Troubleshooting

E-1 E-2 E-3 E-4
Starter doesn’t rotate Although starter ro- Engine runs slower than Even if engine control
Trouble tates, engine doesn’t normal at all operation dial is rotated, engine
Symptom start. speeds. speed remains un-
Slow idle speed is either changed. (EX60-5)
slower or faster than nor- Even if either the ac-
mal. celerator pedal or en-
gine speed control
lever is operated, en-
gine speed is un-
Parts changed. (EX75UR-3
and EX75URLC-3)
MC(Main Controller)
QHS Controller
EC Motor
EC Sensor
Pressure Switch (Travel)
Pressure Switch
(Front Att./Swing)
Pressure Switch (Swing)
(EX75UR-3 and EX75URLC-3)
Key Switch
Engine Control Dial
Auto-Idle Switch
E Mode Switch
Engine Learning Switch
Engine Electrical Equipment
Engine Unit
Governor
Remarks
T5-4-6
NOTE: The trouble symptoms in this table are de-

scribed provided that each trouble occurs
independently.
In case more than one trouble occurs at the
same time, find out all faulty components
while checking all suspected components
in each trouble symptom.
E-5 E-6 E-7 E-8 E-9

Even if key switch is Auto-idle system is inop- Even if E mode switch is Engine stalls within Engine is difficult to start
turned OFF, engine erable. depressed engine speed several seconds after at low temperature.
doesn’t stop. remains unchanged. engine has started.
: Related, required to check

: Related. However, in case this component fails, other trouble
symptom will be more noticeable so that this component will not
be the direct cause of the trouble concerned.
T5-4-7
All Actuator System Troubleshooting

A-1 A-2
All actuator speeds are Actuator doesn’t stop
Trouble slow. even if control lever is
Symptom returned to neutral.
Parts
Auto MARCCINO Control

Unit (EX75UR-3 )
Emergency Stop Solenoid
Valve (EX75UR-3 )
Spool
Main Relief Valve
Main Pump
Pilot Valve
Pump Control Solenoid
Valve
7-Spool Solenoid Valve
Unit (EX75UR-3 )
Engine Unit
Governor
Remarks

NOTE: The trouble symptoms in this table are de- : Related. However, in case this component fails, other trouble
scribed provided that each trouble occurs symptom will be more noticeable so that this component will not
independently. In case more than one trou- be the direct cause of the trouble concerned.
ble occurs at the same time, find out all
faulty components while checking all sus-
pected components in each trouble symp-
tom.
T5-4-8
Front Attachment System Troubleshooting

F-1 F-2 F-3 F-4 F-5
All front attachment Some cylinder are Front attachment When boom raise Abnormal front
Trouble actuator power is inoperable or drifts remarkably. or arm roll-out is attachment control
Symptom weak. speeds are slow. operated, boom or (EX75UR-3)
arm starts to move
after slightly mov-
ing downward.
Parts
Auto-MARCCINO Control
Unit (EX75UR-3 )
Spool
Main Relief Valve
Overload Relief Valve
Load Check Valve
Relief Valve
Change Valve
7-Spool Solenoid Valve
Unit (EX75UR-3 )
Shockless Valve
Pilot Valve
Cylinder
Main Pump
Pilot Pump
Pilot Relief Valve
Remarks

NOTE: The trouble symptoms in this table are de- : Related. However, in case this component fails, other trouble
scribed provided that each trouble occurs symptom will be more noticeable so that this component will not
independently. In case more than one trou- be the direct cause of the trouble concerned.
ble occurs at the same time, find out all
faulty components while checking all sus-
pected components in each trouble symp-
tom.
T5-4-9
Swing/Travel/Blade System Troubleshooting

S-1 S-2 T-1 T-2
Swing is slow or unmov- Precise swing mode is One side track does Machine mistracks dur-
Trouble ing. not selected. not move or moves ing travel and front at-
Symptom slowly. The machine tachment combined op-
cannot travel straight eration.
(mistracks)
Parts
MC (Main Controller)
Main Pump
Travel Mode Switch
Precise Swing Mode Switch
(EX75UR-3and EX75URLC-3)
Swing Relay
(EX75UR-3 and EX75URLC-3)
Solenoid Valve (Precise
Swing Mode) (EX75UR-3 and
EX75URLC-3)
Spool
Load Check Valve
Flow Combiner Valve
Pump Control Solenoid Valve
Shockless Valve
Swing Device
Travel Device
Center Joint
Pilot Valve
Cylinder
Main Relief Valve
Overload Relief Valve
Remarks
T5-4-10
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at the
scribed provided that each trouble occurs same time, find out all faulty components
independently. while checking all suspected components
in each trouble symptom.
T-3 B-1 B-2

Travel mode is not se- Blade does not move, Blade drifts remarkably.
lected. weak or its speed is (EX75UR-3)
slow. (EX75UR-3)

: Related. However, in case this component fails, other trouble
symptom will be more noticeable so that this component will not
be the direct cause of the trouble concerned.
T5-4-11
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter does not rotate.
Related Fault Code: None
• Measure each voltage by referring to the table

below.
• Electronic system such as MC has nothing to do
with the trouble obstructing the rotation of starter.
YES
Regardless of key switch

position ON or START,
voltage at terminal B on starter
With key switch positioned as and starter relay is 0 volts.
shown in table below, check if
YES
each terminal voltage on
starter and starter relay is · Key switch: ON⇔OFF
normal.
Starter Unit（ V）
Key Switch
ON START With key switch positioned at
Terminal
START, voltage at terminal C
B 24 24 on starter and starter relay
S 0 24 NO does not increase to 24 volts.
Starter Relay Unit

（V） · Key switch: START
Key Switch
ON START
Terminal
Check if battery voltage and B 24 24
electrolyte density are nor- C 0 24
mal. S 0 24 With key switch positioned at
· Voltage: 24 volts or more START, voltage at terminal S
Density: 1.25 to 1.28 Starter Relay Terminal Position on starter and starter relay
does not increase to 24 volts.
Starter Relay Connector
Terminal B
Terminal S
Terminal C
T192-05-04-003
NO (When key switch is turned to the START position, if voltage at

terminal B is lower than 18 volts, battery may be faulty.)
S
Starter Terminal Position

T554-07-02-001
T5-4-12
Faulty starter.
YES Faulty harness between

When key switch is turned battery relay and starter.
from the ON position to the
OFF position, check if battery
relay sounds. Faulty battery.
NO
· Key switch: ON⇔OFF
YES Broken harness between

Voltage at terminal fusible link and key switch.
No.1: 0 V Check if fusible link (60A)
is normal.
Faulty fusible link.
Measure each voltage at · Visual check
terminals No.1 and No.5 on NO
key switch. Voltage at terminal No.1: 24 V
· Key switch: START Voltage at terminal No.5: 0 V Faulty key switch.
Voltage at terminal No.: 24 V

Voltage at terminal No5: 24 V Faulty harness between key
switch terminal No.5 and
starter relay terminal C.
Faulty starter relay.
Faulty battery.
• Key Switch Voltage Check

5(C)
NOTE: Remove the key switch from the console.
6(Acc)
1(B)
V
3(R1)
2(Br)
4(R2)
T505-07-03-001
T5-4-13
E-2 Although starter rotates, engine does not
start.
• Check the governor lever position and the fuel cut

lever position while the engine is cranking. If they
are in normal position, the engine and the fuel
system may be faulty.
YES Faulty engine.
With key switch ON, check if · Refer to engine shop manual.

governor lever moves from
position B shown in the right
figure.
· Key switch: ON Check EC motor activating
NO circuit.
· Refer to T5-7-16.
T152-05-04-001
1- Fuel Cut-Off Cable

2- EC Motor Cable
3- Governor Lever
4- Fuel Cut Lever
T5-4-14
• Governor Lever Position
A - Key Switch OFF(Engine Stop Position)

B - Key Switch OFF(Engine standby-to-start position)
A B
FULL
STOP
T152-05-04-001
• Fuel Cut Lever Position
A - Fuel Cut Handle Pulled Position

B - Fuel Cut Handle Returned Position
A
STOP
T152-05-04-001
T5-4-15
E-3 Engine runs slower than normal at all
operation speeds.
Slow idle speed is faster or slower than
normal.
Related Fault Code: 01
• Before the engine learning operation is carried out,

or when the engine learning operation is made in
a wrong procedure, the engine may run slower at
all operation speeds.
• If the EC sensor is faulty, the governor lever
position which is located when the key switch is
turned ON, is learned as the idle position. Then,
the engine is controlled based on this engine
learning operation. Accordingly, the engine runs
with discrepancy from the standard control speed.
Further more, this trouble may not reemerge as
the extent of discrepancy in the governor lever
position differs each time when the key switch is
turned ON.
• Refer to the Control System Group titled “Engine
Learning Control” in the SYSTEM Section in the
Operational Principle book (Technical Manual).
• Even if the EC motor control becomes abnormal,
the governor lever position is constantly kept at
the full stroke end since the EC motor is a worm
gear type. Accordingly, the engine does not stall.
YES Return fuel cut

燃料カットレバーを
lever to the original
元の位置に戻す
position.
Check if fuel cut YES Faulty EC sensor.

EC センサ不良
lever is fully
operated.
· Refer to T4-6-1.
Check if fault code

NO 01 is displayed.
YES End. 終了
Check if the trouble is
reconditioned after
エンジン学習実施
engine learning
NO 後、正常になるか
operation is
conducted. Monitor the engine
· Refer to T5-4-36. NO learning operation.
· Monitor item:
Engine learning
operation
T5-4-16
YES Faulty engine or fuel

Check if governor lever
comes in contact with system.
OK the stopper when
conducting engine Faulty control cable.
learning operation. Faulty engine governor
NO lever adjustment.
· Adjust engine speed.
· Refer to T4-6-1.
Faulty MC. Faulty learn-

ing plug connector or
harness between learn-
NOT OK ing plug connector and
MC.
· Refer to T4-6-1.
T5-4-17
E-4 Even if engine control dial is turned, engine
speed is unchanged. (EX60-5)
Even if either accelerator pedal or engine
speed control lever is operated, engine
speed is unchanged. (EX75UR-3, EX75URLC-
3)
Related Fault Code: 07
• Refer to the Control System group titled “Engine

Learning Control” in the SYSTEM Section in the
• If the EC motor collectly moves, the engine
governor is faulty.
Faulty engine control dial
YES (sensor) or faulty harness
between engine control dial
(sensor) and MC.
Check if fault code 07 is YES

displayed. Faulty EC motor.
Connect Lamp Harness (ST · Refer to T4-6-1.

7125) to EC motor. Check if
NO the lamp comes ON when
engine control dial is turned.
Faulty MC or broken harness
· Refer to T5-7-16. between MC and EC motor.
NO
· Refer to T4-6-1.
T5-4-18
E-5 Engine does not stop even if key switch is
turned OFF.
(When the engine does not stop, be sure to
stop the engine by pulling the fuel cut
handle located under the seat stand before
checking.)
Related Fault Codes: 01 and 07
• Trouble symptoms such as “Engine runs slower

than normal at all operation speed.”or “Even if
engine control dial is turned, engine speed is
unchanged (EX60-5)” or “Even if either accelerator
pedal or engine speed control lever is operated,
engine speed is unchanged. (EX75UR-3,
EX75URLC-3)” are sure to exist at the same time.
Perform the troubleshooting of all symptoms.
E-6 Auto-Idle function does not function.
• When trouble corresponding to E-1 to E-5 exist,

perform the troubleshooting of them beforehand.
• Refer to the Control System group titled “Auto-Idle
Control” in the SYSTEM Section in the
Faulty pressure switch (travel ,

front/swing).
NO Faulty harness between MC
and pressure switches.
Filter in the pilot signal circuit
is clogged.
Monitor pressure switches for
travel and front/swing. NOTE: Pressure switches
YES Check if indication of “Tr” or (travel and front/swing)
“Fr” is displayed or deleted are installed on control
when each control lever is op- valve.
erated.
Monitor auto-idle switch.
Check if indication of “AI” is · Monitor item: Pressure switches
displayed or deleted when Faulty MC.
· In the case of monitoring swing
auto-idle switch is turned ON YES
pressure switch, check on pre-
or OFF. cise swing mode check if indica- · Refer to T4-6-1.
tion of “Tr” is displayed.
· Monitor Item: Auto-idle switch (EX75UR-3, EX75URLC-3)
Faulty auto-idle switch, or
broken harness between
NO auto-idle switch and MC.
T5-4-19
E-7 Engine speed does not change, even if E
mode switch is depressed.
• If trouble corresponding to E-1 to E-6 exist, per-

form the troubleshooting of them before hand.
• Refer to the Control System group titled “E Mode
Control” in the SYSTEM Section in the
Monitor E mode switch. NO Faulty E mode switch, or

Check if indication of “E”or broken harness between E
“P” is displayed alternately mode switch and MC.
on Dr.EX screen by
operating the E mode
switch on the right console
ON or OFF. Faulty MC.
YES
· Monitor item: E mode · Refer to T4-6-1.
switch
E-8 Engine stalls several seconds after engine

starts.
• Refer to the Control System group titled “Engine

Learning Control” in the SYSTEM Section on the
• Engine comes to a stop 5 seconds after engine is
started if engine learning plug connector is
connected.
YES Disconnect learning plug con- End.

nector.
Check if learning plug connec-

tor is connected.
Short circuit of harness be-
tween learning plug harness
and MC. Or, check if fuel sys-
NO
tem is clogged.
T5-4-20
(Blank)
T5-4-21
E-9 Engine is hard to start at low ambient
temperature.
NOTE: Air heater always operates for longer than 1

second regardless of coolant temperature.
• Refer to the Electrical System group titled

“Preheat Circuit” in the SYSTEM Section on the
operational principle book (Technical Manual).
0V Faulty harness.
Disconnect QHS
controller. Measure Faulty harness be-
voltage at harness 0V tween key switch and
end connector QHS controller.
terminal No.7.
· Key switch: ON Measure voltage at Faulty QHS controller
terminal No.1 on QHS or faulty harness be-
controller harness 0V
24 V tween heater relay
end connector. and QHS controller.
Re-connect QHS con-
· Key switch: ON troller. Disconnect
heater relay. Measure
24 V voltage at harness end
connector. Re-connect heater
relay. Disconnect air
· Key switch: ON heater terminal.
24 V
Measure voltage at
harness end terminal.
· Key switch: ON
T5-4-22
Connector（Harness End Connector Viewed from the Open

End Side）
QHS Controller
4 3 2 1
7 5
0V Faulty heater relay.
Faulty air heater.

24 V
T5-4-23
ALL ACTUATOR CONTROL SYSTEM
TROUBLESHOOTING
A-1 All actuator speeds are slow or all actuators
do not move.
• In cases when speed is normal, but power is weak,

main relief valve may be faulty (F-1). If speed is
extremly slow, main pump failure may be a
possible cause.
• Travel spools are mechanically operated so that
the trouble cause will not exist in the pilot system.
YES Faulty main pump.
If only front or swing function is slow, refer to F-1.
YES Check if main relief pressure · Continue into A. (EX75UR-3)

is normal.
· Refer to the Operational Faulty main relief valve.
Check if engine speed is cor- Performance Test section. NO
rect.
· Refer to the Operational
Performance Test section. Faulty engine.
NO
• EX75UR-3
Related Fault Codes: 11, 12, and 13 (Auto-
MARCCINO Control Unit
Faulty emergency
System) Check if trouble symp- YES
stop solenoid
tom is corrected by valve, or clogged
NO disconnecting inlet pipe pilot filter.
from pilot filter and
Check if trouble symp- connecting inlet pipe
tom is corrected by directly to outlet pipe.
NO disconnecting emer-
Faulty pilot pump.
gency stop solenoid NO
valve.
YES (Continuity) Faulty emergency
Disconnect emergency stop solenoid valve
stop relay. Check if relay.
Check if fault codes circuit between relay
are displayed.
YES terminals No.3 and
No.5 has continuity. Faulty auto-
MARCCINO con-
NO (No Continuity) trol unit.
Check suspected
parts referring to
the displayed fault
YES code.
Connector (Harness End Connector Viewed seen from the Open End Side.)
Emergency Stop Solenoid Valve Emergency Stop Solenoid Valve Relay
1 2
1 2 3 5
4
T5-4-24
A-2 Actuator does not stop even after control
lever is returned to neutral. (Except for travel
lever)
YES Bound spool in pilot valve.
· When control lever is in neu-

Check if actuator stops when tral, pilot pressure is guided
pilot control shut-off lever is to control valve spool ends.
raised.
Bound spool in control valve.

NO
· Pilot pressure is not guided to
control valve spool end.
However, control valve is
kept open as spool is bound.
T5-4-25
FRONT ATTACHMENT CONTROL SYSTEM
TROUBLESHOOTING
F-1 All front cylinder forces are weak.
Checking Instruction
• If cylinder force is weak but speed is normal, the
main relief valve may be faulty.
In case speed is too slow, pump control may be
faulty. Pilot system may also be faulty.
2
NOTE: 1kgf/cm = 0.09807 MPa
YES Faulty main pump.
2
265 kgf/cm
Check if travel
mode is selected.
Faulty pump
control solenoid
NO Valve.
YES Measure main

relief pressre.
・ Specification: YES END (Binding of
Refer to the main relief
Operational pressure change
Performance Test Disasseble and valve.)
Section clean main relief
Check if primary 2
265 kgf/cm or less pressure change
pilot pressure is
valve.
correct. Faulty main relief
Check if trouble
symptom valve.
・ Specification: NO
Refer to the disappears.
Operational
Performance Test ・ Go to NO (EX60-5)
Section
Faulty pilot pump.
NO
T5-4-26
F-2 Some Cylinders Do Not Move or Speeds are
Slow.
Checking Instructions
• Diagnose whether the cause of the trouble is in
the pilot system or in the main circuit system.
• In case other functions (swing) are normal, pilot
pump may be normal.
YES End (Binding
Disassemble and spool in control
YES clean control valve valve).
corresponding to the
Check if overload cylinder.
YES relief pressure Faulty cylinder
Check if trouble is
corresponding to the (Seal kits are
corrected. NO
cylinder is correct. faulty).
Faulty overload
relief valve.
NO
Faulty shockless
Check if the pilot
Check if valve.
secondary pressure
secondary pilot at the inlet port of the
pressure NO shockless valve is Faulty corres-
corresponding to ponding to the
correct.
the cylinder is pilot valve.
・ Only when operating
correct.
boom raise and arm
Faulty auto-
roll-out, otherwise YES
・ Specification: Disconnect the MARCCINO
go to NO.
Refer to the corresponding control unit.
Operational NO
solenoid valve
Performance Test connector. Check if
Section Check if the pilot Faulty solenoid
trouble symptom is valve unit
secondary pressure at corrected.
the inlet port of the 7- corresponding to
NO
NO spool solenoid valve the cylinder.
unit is correct.
Check if the pilot YES Faulty shockless
・ Only when operating secondary pressure valve.
boom raise and at the inlet port of the
lower, arm roll-in, or YES
shockless valve is
left offset. Otherwise correct. Faulty pilot valve
go to YES. corresponding to
・ Only when NO
the cylinder.
7-Spool Solenoid Valve Unit operating boom
raise and arm
roll-out, otherwise
1 go to NO.
2
3
4
5
6
1 - From the boom raise 4 - From the arm roll-out

pilot valve pilot valve
2 - From the boom lower 5 - From the right offset pilot
pilot valve valve
3 - From the arm roll-in pilot 6 - From the left offset pilot
valve valve
T191-05-04-003
T5-4-27
F-3 Front attachment cylinder drift is large.
YES
Normal.
NO Faulty cylinder
seals.
Check if each front
attachment
cylinder drift is Check if cylinder
NO internal leakage is
within the specified
value. present.
Scored control
valve spool,
Check if cylinder broken spring, or
drift is reduced YES loose spool end.
NO when pilot shut-off
valve is closed.
Faulty pilot valve.

YES
• Boom Cylinder Internal Leakage Check

1. With the bucket cylinder fully retracted and the
arm cylinder slightly extended from the fully re-
tracted position, lower the bucket teeth onto the
ground.
2. Disconnect boom cylinder rod side hoses. Then,

drain oil from hoses and cylinders. (Plug the dis-
connected hose ports.) T105-07-04-009
3. Retract the arm cylinder to lift the bucket above

the ground.
At this time, if oil flows out of the pipes from which

the hoses were disconnected and the boom cylin-
ders are retracted, boom cylinder internal oil leak-
age exists. If no oil flows out of the pipes but the
boom cylinders are retracted, control valve inter-
nal oil leakage exists.
T5-4-28
F-4 When operating the control lever to raise
boom or roll-out arm, boom or arm starts to
move after lowering slightly.
YES Cylinder Internal

leak.
Check if load
check valve in
control valve
operates correctly.
・ Disassembly
Visual Inspection.
Faulty load check
NO valve.
NOTE: 1. During the initial stage of operation, oil

pressure and flow rate from the pump is
low. Therefore, if the load check valve is (B)
malfunctioning, the oil in the boom cyl-
inder bottom side flows back into the
When the load check
circuit through the load check valve, valve is malfunctioning:
causing the boom cylinder to temporar- (A)
ily retract.
2. If the clearance between the piston and

the cylinder barrel is incorrect, oil
pressure in cylinder bottom side (A)
leaks to rod side (B). As oil pressure
and flow rate from the pump is low, the
pump cannot feed sufficient pressure oil
T105-07-04-012
to make up for oil leaks during the initial
stage of operation, causing the boom
cylinders to temporarily retract.
Accordingly, cylinder force is reduced
and the cylinder drift is increased in this
case.
T5-4-29
F-5 Front control (automatic work range restric-
tion, cab collision prevention, auto-
MARCCINO) is abnormal. (EX75UR-3 only)
Related Fault Code:
Checking Instruction
• When a fault code is displayed, refer to T5-6
(Trouble shooting D).
• When adjusting front speed, refer to the following
procedure.
YES End. (Binding 7-
spool solenoid
Disassemble and
valve.)
clean 7-spool
solenoid valve.
Reassemble.
Check if trouble is YES
Check solenoid Replace harness.
corrected.
valve harness
NO breakage or short
circuit. Faulty Auto
MARCCINO
NO control unit.
Adjusting method of front acceleration speed

and deceleration speed
Adjust solenoid valve set pressure to change front Lock Nut

acceleration or deceleration.
Repeat adjusting pressure and operating front.
Adjusting Screw
IMPORTANT: Do not adjust arm acceleration sole-
noid valve (for arm keep off control).
1. Select the following switch positions:

Engine Speed E Mode Auto-
Control Lever Switch MARCCINO
Mode Switch
T107-06-05-001
Fast Idle OFF ON
Lock Nut Adjusting Screw
2. Paint matching marks on adjusting screw and lock
nut before working. (Note do not paint on threads
of adjusting screw)
3. Loosen lock nut and adjust by adjusting screw.

Clockwise :acceleration
Counterclockwise :deceleration Pressure Pressure
: 18 mm Increase Decrease
: 8.8 N⋅m (0.9 kgf⋅m, 0.08 lbf⋅in) W107-02-05-129
: 4 mm
Reference: Standard Pressure Change

Screw Turns 1/4 1/2 3/4 1
kPa 66 132 198 265
2
kgf/cm 0.7 1.3 2.2 2.7
psi 10 18 31 38
4. Tighten lock nut.
T5-4-30
(Blank)
T5-4-31
SWING SYSTEM TROUBLESHOOTING
S-1 Swing speed is slow or swing function does
not operate.
Checking Instructions
• Check whether the pilot system or the main hy-
draulic system is malfunctioning.
• Check with the precise swing mode switch turned
OFF. (EX75UR-3, EX75URLC-3)
• If front attachment function operates normally, the
pilot pump is considered to be normal. If the pilot
system is malfunctioning, the cause of the trouble
may exist in the pilot system after the pilot valve.
Check for loose harness connections beforehand. YES Check if swing
motor oil drain
amount is normal.
・ Refer to the
Operational
Check if swing Performance Test
YES relief pressure is Section
normal.
・ Refer to the
Disassemble Operational Faulty swing relief
spool in control Performance Test valve.
YES valve and clean. Section. NO
Check if trouble
symptom
disappears.
Check if pilot End. (Binding

secondary pressure spool in control
is correct. NO valve).
Refer to the
Operational
Performance Test
NO
Section. Faulty pilot valve.
Check if the pilot

secondary
pressure at the
NO inlet port of the
shockless valve is
normal.
Faulty shockless
YES valve.
Refer to the
Operational
Performance Test
Section.
T5-4-32
Faulty swing
YES motor parking
brake release
valve.
Check if swing
motor parking
YES brake release NO Faulty swing
valve is galling or When measuring reduction gear.
sticking. the swing speed,
check if it is equal Disconnect YES
solenoid valve A
NO to that in the from swing
Connector pricise swing
mode. change valve.
Swing Relay Solenoid Valve Check if voltage Sticking of
・ Refer to the YES at harness
1 2
solenoid valve or
1 2 Operational connector spool in swing
3 5 Performance Test terminal No. 1 is NO charge valve.
4 section. 12V.
YES ・ Go to NO (EX60-5) Faulty precise
swing mode
A switch.
Disconnect Short circuit of
precise swing YES
harness between
mode switch Disconnect swing swing relay and
connector. Check relay. Check for precise swing
if trouble symptom continuity between mode switch.
is corrected. NO harness connector
terminal No.2 and
vehicle frame. Faulty swing
NO relay.
・ Precise swing
mode switch: OFF
Faulty swing
NO motor.
T5-4-33
S-2 Precise swing mode cannot be selected.
(EX75UR-3, EX75URLC-3)
Sticking swing
YES solenoid valve, or
faulty main pump
2.
Disconnect swing
solenoid valve. Faulty precise
Check if voltage swing mode
at harness YES switch, or broken
connector harness between
terminal No.1 is swing mode switch
12V. Check if failure is
corrected by and swing relay.
connecting swing
NO relay terminal YES Faulty swing relay.
No.2 to the Check if failure is
machine. corrected by
exchanging the
・ With the connector NO swing relay and Broken harness
connected, make horn relay. between swing
connection to the relay and swing
machine with a clip. ・ Before exchanging NO
solenoid valve.
check if the horn
sounded.
T5-4-34
(Blank)
T5-4-35
TRAVEL SYSTEM TROUBLESHOOTING
T-1 One side track does not move or moves
slowly, or machine cannot travel straight
(mistrack)
• If one side system only does not operate, control

valve, travel motor, or center joint might be faulty.
YES Check if travel motor

oil drain quantity is
normal.
Check if travel ・ Refer to the

relief pressure in Operational
NO
slow speed side Performance Test
system is normal. section.
Check if symptom is
reversed when right ・ Refer to the
and left travel line Operational Switch rear and front
hoses connected to Performance Test or right and left travel
top of center joint are section. relief valves each
NO other. Check if
switched each other.
symptom is reversed.
Bound spool in
YES control valve.
Relation between Faulty Seal Position and Mistrack Direction

Seal No Symptom
1 Mistracks to the left when traveling reverse.
2 Reverse travel side motor becomes slow
when making a pivot turn.
3 Mistracks to the left when traveling forward.
Mistracks to the right when traveling reverse.
4 Forward travel side motor becomes slow
１
when making a pivot turn.
Left Travel 2
5 Mistracks to the right when traveling forward. （Reverse） Right Travel
（Reverse）
Left Travel 3
（Forward） 4
Right Travel
（Forward）
5
T191-05-04-002
T5-4-36
NO Faulty travel motor.
YES Faulty counterbalance

Disassemble and
clean travel motor valve.
counterbalance valve.
YES
Recheck if same
Faulty travel reduction
symptom arises.
NO gear.
NO Faulty center joint.
Faulty travel relief

YES valve.
Layout of Hydraulic Lines on Center Joint

Front
Left Travel (Forward) Right Travel (Forward)
Right Travel (Reverse)

Left Travel (Reverse)
Rear
T191-05-04-008
T5-4-37
T-2 During a combined operation of travel and
front function, the machine mistracks.

Trace the cause of the
YES trouble by checking
other symptoms.
YES Check if load check
valve is normal.
Faulty load check
NO valve.
Check if flow com-
biner valve is normal.
Faulty flow combiner

NO
valve.
T-3 Travel mode is not selected. (EX60-5)
• The travel mode is selected by controlling the

pump flow rate. Accordingly, failure in the pump
flow rate control system is mostly suspected.
However, if the main pump or the pump control so-
lenoid valve is failed, the front attachment and
swing speed should be affected. (Refer to F-1.)
YES Faulty travel motor.

Check if pump
control solenoid
valve output signal Check continuity
Fast Speed
is OFF by between terminal No.25 YES Faulty travel mode
monitoring with Dr. on monitor 16P switch or MC.
EX. connector and terminal
・ Travel Mode Switch: No.16 on MC connector
NO D.
Fast (Rabbit) Broken harness
between travel mode
Check what travel NO switch and MC.
mode is not
selected.
YES Faulty travel motor.

Check if pump
control solenoid
valve output signal
Slow Speed
is ON by monitoring
with Dr. EX. Faulty travel mode
NO switch or MC.
・ Travel mode switch:
Slow (turtle).
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector D Monitor (16P)
1 2 5 6 7 8 9 10 11 20 19 18 17 16 15 14 13
12 13 14 15 16 17 18 19 20 21 22 28 27 26 25 24 23 22 21
T5-4-38
BLADE SYSTEM TROUBLESHOOTING
(EX75UR-3)
B-1 Blade does not move, weak or its speed is
slow.
• If swing is also malfunctioning, faulty main relief

valve of control valve 2, or faulty pump is sus-
pected.
YES Faulty cylinder or
Check if main relief center joint seal.
pressure and
YES overload relief
Disassemble and pressure in blade
Faulty main relief
YES clean blade spool in circuit is normal.
control valve 2. valve or overload
Check if same relief valve.
Check if secondary symptom occurs.
pilot pressure is End (Bound blade
collected. spool in control
NO valve 2).
Faulty pilot valve.

NO
B-2 Blade drifts remarkably.
End (Bound blade

YES spool in control
valve 2).
Disassemble and
clean blade spool in
control valve 2. Remove blade
Check if same cylinder and fully YES Faulty cylinder.
symptom occurs. retract it. Then, (Replace seal kit.)
connect hydraulic
line to cylinder rod
side only and
perform blade raise YES Faulty center joint
NO Connect center joint
operation. Check if upper hose and lower seal.
oil flows out of hose directly.
cylinder bottom side
NO Check if symptom
oil port. disappears. Faulty overload
relief valve in control
NO valve 2.
T5-4-39
(Blank)
T5-4-40
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C PROCEDURE
(Troubleshooting for Monitor)
Use troubleshooting C when any monitors, such as

gauges or indicators malfunction.
YES (OK)
(2) After checking or measuring in step (1), select either YES(OK) or
NO(NOT OK) depending on the result obtained in step (1) and
・ (1) proceed to step (2) or (3).
(3)
NO
(NOT OK)
・ Special instructions or reference items may be indicated under the box. Incorrect
measuring or checking methods will not only render troubleshooting impossible but may
· Key switch: ON damage components.
・ Causes are described in a thick-line box. Scanning the descriptions in the thick-line boxes
wiil indicate suspected sections and possible causes.

Wire Harness Side
Open End Side

Harness End Connector
T158-05-03-001
T5-5-1
MALFUNCTION OF COOLANT
TEMPERATURE GAUGE
• Check for loose harness connection beforehand.

YES
Remove coolant temperature

Gauge pointer does not move sensor terminal, ground
at all. (It does not rise from harness side terminal to
zero.) vehicle. Does pointer swing to With sensor terminal discon-
the (H) side? nected, remove 12P connec-
tor from monitor, and check
· Key switch : ON NO continuity between terminal
below and sensor terminal.
· EX60-5: terminal No.11

· EX75UR-3, EX75URLC-3:
No.3
When removing coolant

Gauge pointer swings over temperature sensor, does
scale. pointer swing back to zero?
With sensor terminal discon-
· Key switch : ON nected, remove 12P connec-
tor from monitor, and check
NO continuity between vehicle
frame and sensor terminal.
YES
Remove coolant temperature
sensor terminal, and ground
Gauge pointer swings harness side terminal to vehi-
unstably. cle. Does the pointer swing to
(H) side, and stably?
· Key switch : ON NO
T5-5-2
Coolant Temperature Gauge

EX60-5
105 °C
(221 °F)
95 °C
Faulty coolant temperature (203 °F)
sensor.
70 °C
(158 °F)
YES Faulty monitor (coolant
temperature gauge).
Broken harness between

monitor (coolant temperature
NO gauge)and sensor.
T157-07-05-001
EX75UR-3, EX75URLC-3
103 °Ｃ 135 °Ｃ
(217 °F) (275 °F)
Faulty coolant temperature
sensor.
Short circuit of harness 50 °Ｃ

YES between monitor (coolant (122 °F)
temperature gauge) and
sensor.
Faulty monitor (coolant

NO temperature gauge).
M554-01-013
Coolant Temperature Sensor
Faulty coolant temperature
sensor. Coolant
Resistance
Temperature
50±0.2 °C
112.4±10 Ω
Faulty monitor (coolant (122±0.4 °F)
temperature gauge). 60±0.2 °C
79.3±5 Ω
(140±0.4 °F)
80±0.2 °C
41.8±2.5 Ω
(176±0.4 °F)
100±0.3 °C
23.6±0.9 Ω
(212±0.5 °F)
105±0.3 °C
20.7±0.6 Ω
(221±0.5 °F)
120±0.3 °C
14.2±0.3 Ω
(248±0.5 °F)
Connector (Harness End Connector Viewed from the
Open End Side)
EX60-5 Monitor (12P)
6 5 4 3 2 1
12 11 10 9 8 7
EX75UR-3, 75URLC-3
5 4 3 2 1
12 11 10 9 8 7 6
T5-5-3
MALFUNCTION OF FUEL GAUGE

YES
Remove connector of fuel

Gauge pointer does not swing. sensor, connect harness end
(It does not rise from zero.) connector terminal below by
using a clip. Does pointer With fuel sensor connector
swing to the right (FULL) side? disconnected, remove 12P
connector from monitor, and
check for continuity between
· Key switch : ON NO monitor terminal below and
· Fuel sensor terminal: fuel sensor terminal below.
EX60-5: No.1 and No.2
EX75UR-3, EX75URLC-3: · Fuel sensor terminal:
No.2 and No.3 EX60-5: No.1
EX75UR-3, EX75URLC-3: No.2
· Monotor terminal:
EX60-5: No.12
YES EX75UR-3, EX75URLC-3: No.4
Gauge pointer swing over When fuel sensor connector is

removed, does pointer swing With the fuel sensor connector
scale.
back to zero? disconnected, remove 12P
connector from monitor, and
· Key switch : ON check for continuity between
NO machine and fuel sensor
terminal below.
· Fuel sensor terminal:

EX60-5: No.1
EX75UR-3, EX75URLC-3: No.2
· Monotor terminal:
EX60-5: No.12
Remove connector of fuel
YES EX75UR-3, EX75URLC-3: No.4
sensor, connect harness
connector terminal below by
Gauge pointer swings using jumper wire. Does
unstably. pointer swung to the right
(FULL) side, and stabilized?
· Key switch : ON NO
· Fuel sensor terminal:
EX60-5: No.1 and No.2
No.2 and No.3
T5-5-4
Fuel Sensor
1 mm=0.03937 in
Float
Faulty fuel sensor.
FULL
YES Faulty monitor (fuel gauge).

EX60-5: 257 mm
EX75UR-3, EX75URLC-3: EX60-5: R370
230 mm EX75UR-3,
EX75URLC-3: R300
monitor (fuel gauge) and fuel
NO sensor.
EX60-5: 110°
EX75UR-3,
EX60-5: 338 mm EX75URLC-3: 104°
EX75UR-3,
Faulty fuel sensor. EX75URLC-3: 242 mm
EMPTY
Short circuit harness between
YES
monitor (fuel gauge) and fuel
sensor. T190-04-04-001
Resistance (Ω)
Faulty monitor (fuel gauge).
NO Float EX75UR-3,
EX60-5
75URLC-3
+1.0 +0
FULL 10 － 0.5 10 －4
3/4 (19.5) -
Faulty fuel sensor. 1/2 32±3 38±5
1/4 (49.5) -
+10
EMPTY 80±2 90 －0
Faulty monitor.
Open End Side)
EX60-5
Monitor (12P)
Fuel Sensor
6 5 4 3 2 1
12 11 10 9 8 7 １２
Fuel Sensor
Monitor (12P)
5 4 3 2 1 1 2 3
12 11 10 9 8 7 6
T5-5-5
MALFUNCTION OF INDICATOR LIGHT
CHECK SYSTEM
EX60-5 YES Faulty fuse or monitor.

Remove connector C
(20P)from
12P frommonitor.
monitor.
YES Check for continuity
between harness end
terminal No.8
#1 and
and
fuse
fuse
terminal No.6.
#5. Broken harness between
Indicator doesn’t light NO fuse and monitor.
when indicator light Check if all indicators
check operation is don’t light.
performed.
Troubleshoot unlit indicator

NO individually.
EX75UR-3, EX75URLC-3 YES Faulty fuse or monitor.

Remove connector B
(20P) from MC. Check
YES for continuity between
harness end terminal
No.7 and fuse terminal
No.15. Broken harness between
Indicator doesn’t light NO fuse and MC.
when indicator light Check if all indicators
check operation is don’t light.
performed.
Troubleshoot unlit indicator

NO individually.
Connector (Harness End Connector Viewed from

the Open End Side)
EX60-5
Monitor (12P)
6 5 4 3 2 1
12 11 10 9 8 7
MC (Connector B)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
T5-5-6
(Blank)
T5-5-7
MALFUNCTION OF ALTERNATOR
INDICATOR
EX60-5
13V or higher
Measure voltage at
13 V or higher monitor 12P
connector terminal
No.5.
Alternator indicator Measure voltage at · Engine : Running Less than 13 V
does not go off after alternator terminal
engine is started. L.
· Engine : Running
Less than 13 V
Less than 10 V
YES Check voltage at

regulator terminal
L.
Although alternator Check if indicator
comes on when · Key switch : ON
output is low, · Engine : Stopped 10 V or more
alternator indicator key switch is
does not come on. turned to ON
position.
· Key switch : ON
NO
T5-5-8

Faulty monitor.
Open End Side)
Monitor (12P) Alternator
6 5 4 3 2 1 R
12 11 10 9 8 7 L
regulator terminal L and
monitor terminal No.5.
Faulty regulator or alternator.
Faulty monitor.
Faulty regulator.
Blown indicator bulb.
T5-5-9
NOTE: Regulator terminal L is a water-resistance

type connector so that voltage measure-
ment at terminal L is difficult. Try to meas-
ure voltage at starter relay terminal R. Be-
fore measuring, check continuity between
the starter relay terminal R and the regula-
tor terminal L.
No continuity
Check continuity
Less than 10 V between terminal
No.5 on MC connec-
tor A and monitor
terminal No.5.
Reconnect the wiring.

Check voltage at
Although alternator
output is low, alterna-
Check voltage at Continuity terminal No.1 on MC
regulator terminal connector B.
tor indicator does not L.
come on.
· Engine: Running
· Refer to T5-7-8.
10 V or More
13 to 14.5 V
Check voltage at
13 V or More
terminal No.1 on MC
connector B.
· Engine: Stopped
Alternator indicator Check voltage at Less than 13 V

does not go off after regulator terminal
engine is started. L.
· Engine: Running · Engine: Running
· Refer to T5-7-8.
Less than 13 V
T5-5-10
Connector (Harness End Connector Viewed from
the Open End Side)
Monitor (12P) MC (Connector A) MC (Connector B)
5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8
12 11 10 9 8 7 6 14 15 16 17 18 19 20 21 22 23 24 25 26 9 10 11 12 13 14 15 16

MC and monitor.
YES
With connector A Faulty in MC.
disconnected, ground
13 V or more terminal No.5 to
vehicle. Check if
alternator indicator
lights.
Burned out indicator
· Key switch: ON NO light.

alternator terminal L and
MC connector B terminal
No.1.
Less than 13 V
Faulty regulator or alter-

nator.
YES Short-circuit harness

Disconnect connector between MC and moni-
A from MC and con- tor.
nector from monitor.
Check continuity be-
tween MC terminal
No.5 and vehicle.
Faulty MC.
NO

regulator terminal L and
MC connector B terminal
No.1.
Faulty regulator or alter-

nator.
T5-5-11
MALFUNCTION OF ENGINE OIL
PRESSURE INDICATOR

YES
NOTE: During one to two minutes after the engine

is stopped, engine oil pressure may exist.
This phenomenon is normal. With engine oil
pressure switch
EX60-5 disconnected,
check if indicator
YES comes ON when
harness side PLUS Reconnect engine
terminal oil pressure switch.
(lightgreen/red line) Check if indicator
is grounded to comes ON when
vehicle. NO monitor 16P
Check if indicator
Although engine oil comes ON when ・Key switch : ON connector terminal
pressure is low, key switch is No.23 is grounded
indicator does not turned to ON to vehicle.
come ON. position. · Key switch: ON
· Key switch : ON · Without disconnecting,
ground connector to
vehicle using a clip from
the wire side of the
connector.
NO
YES
Check if indicator
Indicator stays ON goes OFF when
after engine is engine oil pressure
started. switch is Reconnect engine YES
disconnected. oil pressure switch
· Check if oil filter is
and remove
clogged or not. · Key switch : ON connector B from
· Engine : Stopped MC.
NO Check continuity
between harness Check if indicator
end connector goes OFF when
terminal No.2 and connector A is
vehicle frame. NO
removed from MC.
・Key switch : ON
T5-5-12
Faulty engine oil

pressure switch.
Engine Oil Pressure Switch
Faulty MC, or
Remove connector broken harness Pressure Indicator
YES
A from MC. Check if between MC and
indicator comes ON engine oil pressure Approx.39 kPa
YES when harness end switch. 2
connector terminal (0.4 kgf/cm ) or ON
No.18 is grounded Broken harness less
to vehicle. between monitor
NO
and MC. Approx.39 kPa
・Key switch : ON 2
(0.4 kgf/cm ) or OFF
higher
Faulty monitor. Connector (Harness End Connector Viewed from the

NO
Open End Side)
Monitor(16P)
Burned out 20 19 18 17 16 15 14 13
indicator light. 28 27 26 25 24 23 22 21
MC(Connector A)
Faulty engine oil 1 2 3 4 5 6 7 8 9 10 11 12 13

pressure switch, or 14 15 16 17 18 19 20 21 22 23 24 25 26
faulty engine oil
lubrication system,
or clogged oil filter. MC(Connector B)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
Short circuit of
harness between
MC and engine oil
pressure switch.
YES Faulty MC.
Faulty monitor, or
short circuit of
NO harness between
monitor and MC.
T5-5-13
NOTE: One or two minutes after the engine is

stopped, engine oil pressure may still be
remaining. This is normal.
EX75UR-3, 75URLC-3 YES
With the engine oil

pressure switch’s
At insufficient engine plug disconnected,
oil pressure, indicator ground harness end
does not light. plug to vehicle. Reconnect the har-
Check if indicator Continuity ness.
lights. Check continuity
· Key switch: ON between terminal
Reconnect the har- No.2 on MC connec-
ness. tor B and engine oil
Check continuity pressure switch.
between terminal
NO
No.18 on MC con-
nector A and monitor
terminal No.6.
No continuity
YES
Check if indicator
After engine starts, goes OFF when
indicator does not go engine oil pressure
OFF. switch is discon- NO
nected. Reconnect the har-
· Check if the oil filter
is clogged. · Key switch: ON ness.
· Engine: Stopped Check if indicator
goes OFF when
NO connector A is re- Reconnect the har-
moved from MC.
ness.
· Key switch: ON Disconnect MC con-
nector B.
YES Check continuity
between terminal
No.2 on connector B
and vehicle.
T5-5-14
Engine Oil Pressure Switch
Faulty engine oil pres- Pressure Indicator

sure switch.
Reconnect the har- Approx. 39 kPa
ness. YES 2
(0.4 kgf/cm or less) ON
Faulty MC.
Disconnect connec-
tor A from MC Con- Approx. 39 kPa
Continuity 2 OFF
nect terminal No.18 (0.4 kgf/cm or more)
on connector A to
vehicle.
Check if indicator Burned out indicator
lights. NO light.
· Key switch: ON Connector (Harness End Connector

Viewed from the Open End Side)
MC and engine oil pres-
No continuity sure switch. Monitor (12P)
5 4 3 2 1
Broken harness between 12 11 10 9 8 7 6
MC and monitor.
MC (Connector A)
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
MC (Connector B)
Faulty engine oil pres-
sure switch, or faulty
engine lubrication sys- 1 2 3 4 5 6 7 8
tem, or clogged oil filter. 9 10 11 12 13 14 15 16
Short circuit of harness

between monitor and
MC.
Continuity Short circuit of harness

between monitor and
engine oil pressure
switch.
Faulty MC.
No continuity
T5-5-15
MALFUNCTION OF OVERHEAT
INDICATOR
EX60-5
YES
With overheat switch

disconnected, check
YES Reconnect
if indicator comes
ON when harness is overheat switch.
grounded to vehicle. Check if indicator
comes ON when
· Key switch : ON monitor 16P
connector terminal
NO No.22 is grounded
Check if indicator
Indicator does not to vehicle.
comes ON when
come ON even if key switch is
engine overheats. · Key switch : ON
turned to ON · Without disconnecting,
position. ground connector to
· Key switch : ON vehicle using a clip from
the reverse side of the
connector.
NO
YES
Check if indicator
Indicator comes ON goes OFF when
even if coolant overheat switch is YES
temperature is low. disconnected. Disconnect overheat
switch and remove
· Key switch : ON connector B from MC.
Check continuity
NO between MC harness
end connector
terminal No.10 and
vehicle frame.
NO
T5-5-16
Overheat Switch
Faulty overheat Coolant Indicator

switch.
Temperature
Lower than 105 °C
YES Broken harness OFF
between monitor (221 °F)
and MC. 105 °C (221 °F) or
ON
more
Remove connector A YES Faulty MC.
from MC. Check if
indicator comes ON
NO when harness end
connector terminal Faulty monitor or
No.4 is grounded to broken harness
vehicle. NO between MC and
overheat switch.
· Key switch : ON Connector (Harness End Connector Viewed from
Burned out the Open End Side)
indicator light. Monitor (16P)
20 19 18 17 16 15 14 13
28 27 26 25 24 23 22 21
MC(Connector A)
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Faulty overheat
switch.
MC(Connector B)
1 2 3 4 5 6 7 8
Short circuit of 9 10 11 12 13 14 15 16
harness between
MC and overheat
switch.
YES Faulty MC.

Check if indicator
goes OFF when
connector A is Faulty monitor or
removed from MC. broken harness
· Key switch : ON NO between monitor
and MC.
T5-5-17
EX75UR-3, 75URLC-3
YES
With overheat switch

disconnected, ground
YES harness side terminal
to vehicle. Check if
indicator lights.
· Key switch: ON
· Reconnect the harness
after checking. NO
Indicator does not light Check if indicator
even if engine over- lights with key
heats. switch ON.
· Key switch: ON
NO
YES
Check if indicator
Indicator lights even if goes OFF by
coolant temperature is disconnecting
low. overheat switch. YES
· Key switch: ON Disconnect overheat switch

and remove connector B from
MC.
NO Check continuity between
connector terminal No.10 and
vehicle.
Check if indicator
· Reconnect the harness goes OFF by re-
after checking. NO moving connector
A from MC.
· Key switch: ON
T5-5-18
Overheat Switch
Coolant
Temperature Indicator
Faulty overheat switch. Lower than 105 °C OFF

105 °C or more ON
YES Broken harness between

MC and overheat switch. Connector (Harness End Connector
Check continuity between Viewed from the Open End Side)
terminal No.10 on MC
connector B and overheat
MC (Connector A)
switch.
Faulty MC.
NO 1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
MC (Connector B)
YES Faulty MC.
Disconnect connector A
from MC and connect 1 2 3 4 5 6 7 8
harness side connector
9 10 11 12 13 14 15 16
terminal No.4 to vehicle. Burned out indicator
Check if indicator lights. light, or broken harness
NO between MC and indica-
· Key switch : ON tor.
Faulty overheat switch.
Short circuit of harness

between MC and over-
heat switch.
YES Faulty MC.

MC and monitor.
NO
T5-5-19
MALFUNCTION OF FUEL LEVEL INDICA-
TOR (EX75UR-3, EX75URL-3)
NOTE: Fuel level indicator lights when fuel be-

comes about 9L (about 75 mm from fuel
tank bottom).
YES
Disconnect fuel senser

and connect harness
YES end connector terminal
No.1 to No.3.
Check if indicator
lights.
· Key switch: ON
NO
Although fuel gauge
pointer indicates E, Check if indicator
indicator does not lights with key
light. switch ON.
NO
YES
Check if indicator
Indicator lights even if goes OFF by
fuel is remaining in disconnecting
fuel sensor. YES
tank.
· Key switch: ON
Disconnect fuel sensor and

NO connector A from MC.
Check if indicator goes OFF.
NO
T5-5-20
Faulty fuel sensor. Connector (Harness End Connector Viewed from the
Open End Side)
Fuel Sensor
1 2 3

indicator and fuel sensor. MC (Connector A)
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
Burned out indicator or

MC and indicator.
Faulty fuel sensor.
Faulty MC.
Short circuit of fuel sen-

sor or harness between
MC and indicator.
T5-5-21
MALFUNCTION OF AIR FILTER
RESTRICTION INDICATOR
EX60-5
YES
Disconnect restriction
switch. Check if
YES indicator comes ON
when harness end
Reconnect restriction
PLUS terminal is
switch.Remove 16P
grounded to vehicle.
connector from
· Key switch : ON monitor. Check
continuity between
NO
Check if indicator harness end
When air filter is comes ON when connector terminal
clogged, indicator key switch is No.13 and vehicle
does not come ON turned to ON frame.
position
· Key switch : ON
NO
YES
Although air filter is When air filter

not clogged, restriction switch
indicator lights. is disconnected, YES
does the indicator Disconnect air filter
· Disassembled goes OFF? restriction switch and
and visual check. remove 16P
· Key switch : ON connector from
· Make sure that air
filter is not moist. monitor. Check
NO continuity between
monitor harness end
connector terminal
No.13 and vehicle NO
frame.
T5-5-22
Air Restriction Switch

Faulty air filter
restriction switch. Pressure Indicator
5.1 kPa (520 mmH2O) OFF
6.2 kPa (630 mmH2O) ON
YES Faulty monitor.

Broken harness Open End Side)
between monitor
NO and air filter
restriction switch. Monitor (16P)
20 19 18 17 16 15 14 13
28 27 26 25 24 23 22 21
Burned out
indicator light.
Faulty air filter

restriction switch.
Short circuit of
harness between
monitor and air
filter restriction
switch.
Faulty monitor.
T5-5-23
YES
Disconnect air filter restriction

YES switch’s plug and ground har-
ness side plug to vehicle.
Check if indicator lights.
· Key switch: ON
NO
Indicator does not light Check if indicator
even if air filter is lights with key
clogged. switch ON.
· Key switch: ON
NO
YES
Disconnect air
Indicator lights even if filter restriction
air filter is not clogged. switch. YES
Check if indicator
· Disassemble and goes OFF.
check by visual in- · Key switch: ON
spection. Disconnect air filter restriction
· Make sure that air switch and remove connector
filter is not moist. NO A from MC. Check if indicator
goes OFF.
· Key switch: ON
NO
T5-5-24
Air Filter Restriction Switch
Pressure Indicator
Faulty air filter restriction 5.1 kPa
switch. (520 mm H2O) OFF
6.2 kPa
(630 mm H2O) ON

Indicator and air filter
restriction switch.
Burned out indicator or

MC and indicator.
Faulty air filter restriction

switch.
Faulty MC.
Short circuit of air filter

restriction switch or har-
ness between MC and
indicator.
T5-5-25
MALFUNCTION OF ELECTROLYTE LEVEL
INDICATOR (EX75UR-3, EX75URLC-3)
YES Faulty electrolyte level switch.

Check if indicator comes ON
Even if electrolyte level falls, when electrolyte level switch
indicator does not come ON. connector is removed. Remove connector B from
· Check that electrolyte level MC.
switch is not in contact with · Key switch: ON NO Check if indicator comes ON.
electrolyte. · Reconnect the connector
after checking. · Key switch: ON
· Engine: Stopped · Reconnect the connector
after checking.
YES Faulty electrolyte level switch.

Remove electrolyte level
switch connector.
Indicator comes ON even if Connect harness end terminal
electrolyte level is normal. to the vehicle check if indicator Remove connector B from
· Check that electrolyte level goes OFF MC.
switch is not in contact with · Key switch: ON Connect terminal No.3 on
NO
electrolyte. · Reconnect the connector harness end connector to the
after checking. vehicle.
Check if icdicator goes OFF.
· Key switch: ON
· Reconnect the connector
after checking.
· Without disconnecting,
ground connector to vehicle
using a clip.
T5-5-26
Electrolyte level switch

YES tween electrolyte level switch
and MC.
YES Faulty MC.

59±1
Remove connector A from mm
MC.
Connect terminal No.15 on
NO harness end connector to the
vehicle. Burned out indicator light or
Check if indicator comes ON. broken harness between MC
NO and indicator. 3 mm T192-05-05-001
· Key switch: ON
Connector (Harness End Connector

Viewed from the Open End Side)
MC (Connector A)
1 2 3 4 5 6 7 8 9 10 11 12 13
Harness brakage between 14 15 16 17 18 19 20 21 22 23 24 25 26
YES
electrolyte level switch and
MC. MC (Connector B)
1 2 3 4 5 6 7 8
YES 9 10 11 12 13 14 15 16
Faulty MC.
Remove connector A from

MC.
NO Check if indicator goes OFF.
Short circuit between MC and
NO indicator.
T5-5-27
MALFUNTION OF BUZZER

type connector so that it is not practical to
measure voltage at these terminals. Meas-
ure voltage at starter relay terminal R in-
stead. Check for continuity between starter
relay terminal R and regulator terminal L
beforehand.
EX60-5
YES
Faulty MC.
Buzzer keeps sounding Check if buzzer stops
when key switch is sounding when con-
turned ON before nector A is removed
starting engine. from MC. Faulty buzzer or
short circuit of
· Key Switch : ON NO harness between
(Engine is stopped.) buzzer and MC.
ジ始ず
YES
Faulty engine oil
pressure system.
Buzzer keeps Check if engine oil

sounding when pressure indicator YES Overheat of
engine is started. is ON. engine.
Check if overheat
NO indicator is ON.
Check if buzzer
stops when buzzer
NO stop switch is
depressed.
YES Normal.
Buzzer does not

sound even if Check if engine is
engine oil pressure running at 1000
indicator or min 1 (rpm) or
－
overheat indicator faster. YES Normal.

comes ON.
Check if alternator
NO indicator is ON.
Check voltage at
NO alternator terminal
L.
· Engine speed:
1000 min 1 (rpm)
－
or faster.
T5-5-28

Open End Side)
Buzzer Alternator
R
2 1 L
YES Faulty MC.
YES Faulty MC.

Check if buzzer stops
sounding when connector
NO A is removed from MC.
Faulty buzzer.
NO
Less than 13 V Faulty alternator.
Broken harness
Less than 13 V between alternator
terminal L and
Measure voltage at
buzzer terminal
buzzer connector
No.2.
13 V or more terminal No.2.
· Engine speed:
1000 min 1 (rpm)
－ Faulty buzzer.
or faster. 13 V or more
T5-5-29

beforehand.
Short circuit of
YES
harness between
Buzzer continues Check if buzzer stops MC and buzzer.
sounding when key sounding by removing
switch is turned ON. connector A from MC.
Faulty buzzer or
· Key Switch : ON short circuit of
(Engine is stopped.)
NO harness between
buzzer and MC.
YES Faulty engine

lubrication system.
Buzzer keeps Check if engine oil

sounding when pressure indicator YES Overheat of
engine is started. is ON. engine.
Check if overheat
NO indicator is ON.
Faulty MC.
NO
YES Normal.
Buzzer does not

sound even if Check if engine is
engine oil pressure running at 1000
indicator or min 1 (rpm) or
－
overheat indicator faster. YES Normal.

comes ON.
Check if alternator
NO indicator is ON.
Check voltage at
NO alternator terminal
L.
· Engine speed:
1000 min 1 (rpm)
－
or faster.
T5-5-30

Open End Side)
MC (Connector B) Alternator
R
1 2 3 4 5 6 7 8
L
9 10 11 12 13 14 15 16
Less than 13 V Faulty alternator or alter-

nator.

Less than 13 V alternator terminal L and
terminal No.1 on MC
Check voltage at connector B.
terminal No.1 on
13 V or more MC connector B.
· Engine speed: Faulty MC.
-1
1000 min (rpm) 13 V or more
or faster
T5-5-31
MALFUNCTION OF HOUR METER

beforehand.
Broken harness
EX60-5 between monitor
0V
12P connector
Check voltage at terminal No.10 and
NO monitor 12P fuse terminal No.6.
connector terminal
No.10.
Faulty monitor.
24 V
Hour meter does
not count operating
hours when engine Check if alternator
is running. indicator is ON.
Less than 13 V Faulty alternator.
· Engine : Running
Check voltage at
alternator terminal
YES L. 13 to 14.5 V or more Faulty monitor.
· Engine speed: Check voltage at
-1
1 000 min (rpm) monitor 12P
or faster connector terminal
13 V No.5. Broken harness
or more between alternator
Less than terminal L and
13V. monitor 12P
connector terminal
No.5.
Open End Side)
Monitor (12P) Alternator
6 5 4 3 2 1 R
12 11 10 9 8 7
L
T5-5-32

beforehand.
EX75UR-3, EX75URLC-3 Disconnect connec-

tor A from MC. Con- Faulty MC.
nect terminal No.16
NO on harness end
connector to the
vehicle. Check if Broken harness
hour meter counts between hour
Hour meter does operating hours.
not count operating meter and MC.
hours while engine Check if alterna-
tor indicator is Less than 13 V
is running.
ON. Faulty alternator.
· Engine: Running · Engine: Running

Check voltage at
regulator terminal 13 to 14.5 V or Faulty hour meter
YES L. more MC.
· Engine speed:
-1
1000 min (rpm) Check voltage at
or faster terminal No.1 on
13 V or more MC connector B.
Broken harness
between regulator
terminal L and
Less than terminal No.1 on
13 V MC connector B.

Open End Side)
MC (Connector B) Alternator
R
1 2 3 4 5 6 7 8
L
9 10 11 12 13 14 15 16
T5-5-33
(Blank)
T5-5-34
TROUBLESHOOTING / Troubleshooting D
TROUBLESHOOTING D PROCEDURE
(EX75UR-3)
Troubleshooting D procedures are to be applied to the front
attachment control system.
Use troubleshooting D procedure when fault codes are
shown on Dr. EX after monitoring the main controller
(MC) with Dr. EX or on the system monitor.
• How to Read the Troubleshooting Flow Charts
YES (OK)
(2)
• After checking or measuring item (1), according to the results
・ (1) select either YES (OK) or NO (NOT OK) and proceed to next
item (2) or (3), as appropriate.
(3)
NO (NOT OK)
・ • Special instructions or reference items are indicated in the space under the box. In-
correct checking or measuring methods will render the troubleshooting impossible,
· Key switch: ON and may damage components as well.
・ • Use Dr. EX when the item is shown in a double line frame.
・ • Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes and locations can be found.

Wire Harness Side
Open End
Side Harness End Connector
T158-05-03-001
T5-6-1
AUTO-MARCCINO CONTROL UNIT SYS-
TEM FAULT CODE LIST
Fault Code
System
System Buzzer Sound Problem
Dr. EX Indicator
Monitor
Continuously Abnormal RAM in CPU
03 E03 ON
sounds
Continuously Abnormal calibration value
07 E07 ON
sounds
Continuously Abnormal code selection
08 E08 ON
sounds
11 E11 Abnormal arm roll-out function
Continuously
12 E12 ON Abnormal right offset function
sounds
13 E13 Abnormal left offset function
14 − − Abnormal arm roll-out pilot pressure sensor
15 − − Abnormal right offset pilot pressure sensor
ON
16 − − Abnormal left offset pilot pressure sensor
20 − − Abnormal boom raise pilot pressure sensor
40 E40 Abnormal 7 spool-solenoid valve unit (boom raise deceleration)
Long beep
41 E41 Abnormal 7 spool-solenoid valve unit (arm roll-in deceleration)
sounds ON
42 E42 Abnormal 7 spool-solenoid valve unit (left offset deceleration)
intermittently
44 E44 Abnormal 7 spool-solenoid valve unit (boom lower decelera-
43 − − Abnormal 7 spool-solenoid valve unit (right offset acceleration)
45 − − ON Abnormal 7 spool-solenoid valve unit (arm roll-out accelera-
47 − − tion)
50 E50 Abnormal boom angle sensor
Continuously
51 E51 ON Abnormal arm angle sensor
sounds
52 E52 Abnormal offset angle sensor
60 E60 Faulty boom angle sensor initial setting

Continuously
61 E61 ON Faulty arm angle sensor initial setting
sounds
62 E62 Faulty offset angle sensor initial setting
80 E80 Boom angle sensor deviation
Continuously
81 E81 ON Arm angle sensor deviation
sounds
82 E82 Offset angle sensor deviation
Faulty hydraulic oil temperature sensor

90 − − ON
NOTE: Unless the solenoid valve has failed boom

raise operation is correctly controlled in the
range lower than boom foot pin height.
T5-6-2
Trouble on the Machine Corrective Action Group
G1
operate correctly.
G1
operate correctly.
* Movement to the cab stops. 1) Input the front and bucket codes again.
G1
All movement stops.(No pilot pressure) 1) Check harness.
2) Replace the pilot pressure sensor. G0
3) Replace the solenoid valve.
Cab collision prevention control stops. 1) Check harness.
Offset movement by offset switch stops. 2) Replace pilot pressure sensor.
G4
Offset movement by offset switch stops.
Cab collision prevention control stops.
Boom raise movement stops. 1) Check harness.
Arm roll-out movement stops. 2) Replace solenoid valve.
G3
Left offset movement stops.
Boom lower movement stops.
Movement by the right offset switch stops. 1) Check harness.
Cab collision prevention control stops. 2) Replace the solenoid valve. G4
Movement by the left offset switch stops.
4.5 V).
* Movement to the cab stops. 1) Perform initial setting again.
2) Replace angle sensor. G1

4.5 V).
as if oil temperature is lowest (input value from 2) Replace the hydraulic oil temperature sensor. G4
sensor: 4.5V).
NOTE: If two or more trouble occurs at the same

time, the system monitor displays the fault
code for the lower group number only.
T5-6-3
FAULT CODE 03 (ABNORMAL RAM IN
CPU)
YES
Normal.
Check if any fault codes are

deleted when retrial is per-
formed.
YES Normal.
In case all machine operations
are normal, retry several
NO times. Check if any fault codes
are deleted.
Replace auto-MARCCINO
NO control unit with new one.
T5-6-4
FAULT CODE 07 (ABNORMAL CALIBRA-
TION VALUE)
• Calibration values are input into the auto-

MARCCINO control unit beforehand. Accordingly,
this fault code is rarely displayed during machine
operation.
YES
Normal.
Check if any fault codes on

system monitor are deleted
when sensor is initialized.
· Refer to T4-6-5.
After initializing, restart
the engine. Replace auto-MARCCINO
FAULT CODE 08 (ABNORMAL CODE SET-

TING)
• When no front attachment or bucket codes are

registered, this fault code is displayed. Register
the front attachment or bucket code.
(front attachment and bucket codes: refer to
“General section”.)
YES
Normal.
Register front attachment or

bucket code using the Dr. EX.
Check if fault codes displayed
on system monitor are de-
leted.
· After initializing, restart
the engine. Replace auto-MARCCINO
T5-6-5
FAULT CODE 11
(ABNORMAL ARM ROLL-OUT OPERA-
TION)
FAULT CODE 12
(ABNORMAL RIGHT OFFSET OPERA-
TION)
FAULT CODE 13
(ABNORMAL LEFT OFFSET OPERATION)
• Fault code 11 is displayed when the arm roll-out

pilot-pressure sensor sends a signal correspond-
2
ing to a pressure of 10 kgf/cm or more to the
auto-MARCCINO control unit while the auto-
MARCCINO control unit sends no signal to the 7-
spool solenoid valve unit (arm roll-out accelera-
tion).
• Fault codes 12 and 13 are displayed when right or
left offset pilot pressure sensor sends a signal
2
corresponding to a pressure of 10 kgf/cm or more
to the auto-MARCCINO control unit while the off-
set switch is not depressed.
• Sticking solenoid valve or delayed response in the
hydraulic system at very low temperature may be
the cause of these troubles.
With pilot control shut-off lever

held in the LOCK position, moni-
YES tor pilot pressure sensor corre-
With pilot control shut-off lever sponding to the fault code using
held in the UNLOCK position, 2
Dr. EX. Check if 0 kgf/cm pres-
monitor pilot pressure sensor sure is displayed.
NO corresponding to the fault
code using Dr. EX. Check if 10
2
kgf/cm or more pressure is · Engine: Running
displayed. · System deactivation switch:
ON
· Engine: Running
· System deactivation switch:
Check if any fault codes are ON
deleted when engine is re- Faulty auto-MARCCINO con-
started. NO trol unit.
· Refer to corrective measure 2.
Normal.
YES
· Check operation of the arm
keep-off control and the offset
switch.
T5-6-6
YES
Faulty solenoid valve.
Faulty pilot pressure sensor.

NO
The Corrective Measures 1 and 2 described below Front

should be applied when the machine must be oper-
ated.
Port P
• Corrective Measure 1
Disconnect the hose from port P on the 7-spool
solenoid valve unit. Plug port P and the hose end.
Then, the arm keep-off control and offset switch
function are deactivated.
• Corrective Measure 2 Rear

Remove the emergency stop solenoid valve con- T191-05-04-003
nector provided on the pilot filter.
T5-6-7
FAULT CODE 14
(ABNORMAL ARM ROLL-OUT PILOT
PRESSURE SENSOR)
FAULT CODE 15
(ABNORMAL RIGHT OFFSET PILOT
PRESSURE SENSOR)
FAULT CODE 16
ABNORMAL LEFT OFFSET PILOT PRES-
SURE SENSOR)
FAULT CODE 20
(ABNORMAL BOOM RAISE PILOT PRES-
SURE SENSOR)
• These fault codes are displayed when signal volt-

age from the pilot pressure sensor to the auto-
MARCCINO control unit is in the range of 0.25 V Disconnect pilot pressure sen-
sor and auto-MARCCINO con-
or less, or 4.75 V or more. trol unit. Check continuity be-
NO
• Check for loose harness connections beforehand. tween sensor harness end con-
nector terminal No.2 and auto-
Disconnect pilot pressure MARCCINO control unit har-
sensor and connect harness ness end terminal.
end connector terminal No.1
YES to terminal No.3. With connec- · Terminals:
tor 1 removed from auto- Boom (Connector 2: Terminal No.7)
MARCCINO control unit, Arm (Connector 3: Terminal No.9)
check continuity between har- Right Offset
ness end connector terminal (Connector 2: Terminal No.14)
Disconnect pilot pressure No.4 or No.17 and vehicle.
sensor and connect harness Left Offset
end connector terminal No.1 (Connector 3: Terminal No. 8)
to terminal No.3. With connec-
tor 1 removed from auto-
MARCCINO control unit, Short circuit of harness be-
check continuity between har- tween pilot pressure sensor
ness end connector terminal and auto-MARCCINO control
YES
No.4 and No.17. unit.
Broken harness between pilot

pressure sensor and auto-
NO MARCCINO control unit.
Connectors (Harness End Connector Viewed from the Open

Side.)
Pilot Pressure Sensor Auto-MARCCINO Control Unit (Connector 1)
13 12 11 9 8 7 5 4 3 2 1
1 3 26 25 23 22 20 18 17 16 15 14
T5-6-8

tween pilot pressure sensor
YES and auto-MARCCINO control
Disconnect pilot pressure unit.
sensor and auto-MARCCINO
YES control unit. Check continuity
between sensor harness end
connector terminal No.2 and
vehicle. NO Faulty in auto-MARCCINO
Switch pilot pressure sensor control unit.
· Connectors: with arm roll-in pilot pressure
Boom (Connector 2) NO sensor, and retry. Check if the
Arm (Connector 3) fault code is deleted.
Right offset (Connector 2) Faulty pilot pressure sensor.
YES
Left offset (Connector 3)
Broken harness between pilot

pressure sensor and auto-
Auto-MARCCINO Control Unit (Connector 2) Auto-MARCCINO Control Unit (Connector 3)

8 7 5 3 2 1 6 5 4
16 14 12 11 10 9 12 11 9 8
T5-6-9
FAULT CODE 40
(ABNORMAL 7-SPOOL SOLENOID VALVE
UNIT [BOOM RAISE DECELERATION])
FAULT CODE 41
UNIT [ARM ROLL-IN DECELERATION])
FAULT CODE 42
UNIT [LEFT OFFSET DECELERATION])
FAULT CODE 44
UNIT [BOOM LOWER DECELERATION])

NO Faulty auto-MARCCINO
Disconnect solenoid control unit.
valve. Connect harness
end connector terminal
YES No.1 to No.2. Remove
connector 4 from auto-
MARCCINO control unit.
Disconnect solenoid valve. tween harness end con- Short circuit of harness
Connect harness end connector terminal and vehi- between solenoid valve
nector terminal No.1 to
YES No.2. cle. YES and auto-MARCCINO
control unit.
Remove connector 4 from · Boom raise (No. 8 and 19)
auto-MARCCINO control · Arm roll-In (No. 7 and 18)
unit. Check continuity be- · Left offset (No.4 and 15)
tween harness end connec- · Boom lower (No.6 and 17)
Disconnect solenoid tor terminals. Broken harness between
valve. Check if solenoid solenoid valve and auto-
· Boom raise (No. 8 and 19)
valve electrical resis- NO MARCCINO control unit.
· Arm roll-In (No. 7 and 18)
tance is approx. 2.24
· Left offset (No.4 and 15)
kΩ.
· Boom lower (No.6 and 17)

NO

Side.)
Solenoid Valve Auto-MARCCINO Control Unit (Connector 4)
1 2 11 10 9 8 7 6 4 3 2 1
22 21 20 19 18 17 15 14 13 12
T5-6-10
FAULT CODE 43
UNIT [RIGHT OFFSET ACCELERATION])
FAULT CODE 45
UNIT [ARM ROLL-OUT ACCELERATION])
FAULT CODE 47
UNIT [LEFT OFFSET ACCELERATION])
NO Faulty auto-MARCCINO
Disconnect solenoid control unit.
valve. Connect harness
side connector terminal
YES No.1
NO. 1totoNo.2.
No. 2.Remove
Remove
connector 4 from auto-
Disconnect solenoid valve. tween harness side con- Short circuit of harness
Connect harness end connector terminal
and vehicle.
and vehi- between solenoid valve
nector terminal No.1 to
YES No.2. Remove connector 4 cle. YES and auto-MARCCINO
control unit.
from auto-MARCCINO con- · Right offset (No. 3 and 14)
trol unit. Check continuity Arm roll-out (No.2 and 13)
between harness end con- Left offset (No.9 and 20)
nector terminals.
With solenoid valve Broken harness between
disconnected, check if solenoid valve and auto-
solenoid valve electrical · Right offset (No. 3 and 14) NO MARCCINO control unit.
resistance is approx. Arm roll-out (No.2 and 13)
2.24 kΩ. Left offset (No.9 and 20)

NO

Side.)
Auto-MARCCINO Control Unit (Connector 4)
Solenoid Valve
11 10 9 8 7 6 4 3 2 1
1 2 22 21 20 19 18 17 15 14 13 12
T5-6-11
FAULT CODE 50
(ABNORMAL BOOM ANGLE SENSOR)
FAULT CODE 51
(ABNORMAL ARM ANGLE SENSOR)
FAULT CODE 52
(ABNORMAL OFFSET ANGLE SENSOR)
• Fault code 50 is displayed when signal voltage

sent from the boom angle sensor to the auto-
MARCCINO control unit is in the range of 0.1 V or
less, or 4.9 V or more.
• Fault codes 51 and 52 are displayed when signal
voltage sent from the arm or offset angle sensor
to the auto-MARCCINO control unit is in the range
of 0.2 V or less, or 4.8 V or more.
Disconnect angle sensor.

Connect harness end connec-
tor terminal No. 1 and No. 3.
YES Remove connector 1 from
Disconnect angle sensor. auto-MARCCINO control unit.
Connect harness end connec- Check continuity between
tor terminal No.1 to No.3. Re- harness end connector termi-
move connector 1 from auto- nal No.3 or No. 16 and vehi-
YES cle.
Check continuity between
harness end connector termi-
nal No.3 and No.16.
Broken harness between an-
gle sensor and auto-
With angle sensor discon-
nected, check if angle sensor
electrical resistance is 5.0±1.0
kΩ.
Faulty angle sensor.

NO
Connectors (Harness End Connector Viewed from the Open Side.)
Boom Angle Sensor Arm Angle Sensor, Offset Angle Sensor Auto-MARCCINO Control Unit (Connector 1)
13 12 11 9 8 7 5 4 3 2 1
1 2 1 2 3
26 25 23 22 20 18 17 16 15 14
3
T5-6-12

YES tween angle sensor and auto-
Disconnect angle sensor and MARCCINO control unit.
auto-MARCCINO control unit.
YES Check continuity between
sensor harness side connec-
Disconnect angle sensor and tor terminal No.2 and vehicle.
auto-MARCCINO control unit. Faulty auto-MARCCINO con-
NO Check continuity between · Connectors: NO trol unit.
sensor harness connector Boom (Connector 2)
terminal No.2 and auto- Arm (Connector 3)
MARCCINO control unit har- Offset (Connector 2)
ness end terminal. Broken harness between an-
· Terminals: gle sensor and auto-
Boom (Connector 2: Terminal No.8)
Arm (Connector 3: Terminal No.4)
Offset (Connector 2: Terminal No.16)

tween angle sensor and auto-
YES MARCCINO control unit.
Auto-MARCCINO Control Unit (Connector 2) Auto-MARCCINO Control Unit (Connector 3)
8 7 5 3 2 1 6 5 4
16 14 12 11 10 9 12 11 9 8
T5-6-13
FAULT CODE 60
(FAULTY INITIAL SETTING OF BOOM AN-
GLE SENSOR)
FAULT CODE 61
(FAULTY INITIAL SETTING OF ARM AN-
GLE SENSOR)
FAULT CODE 62
(FAULTY INITIAL SETTING OF OFFSET
ANGLE SENSOR)
• These fault codes are displayed when signal volt-

age sent from the angle sensor to the auto-
MARCCINO control unit is out of specifications
more than ±0.3 V.
• Check for loose harness connections beforehand. Faulty sensor initialization or
YES auto-MARCCINO control unit.
YES Check if initialization

connector harness is
normal.
Monitor signal voltage sent out Faulty harness.

of angle sensor with front at- NO
tachment maintained in angle
sensor initialization position.
Check if signal voltage is
within ±0.3 V of the specifica-
tion.
· Specifications:
Boom : 0.722 V
Arm : 3.417 V Faulty sensor harness or sen-
Offset : 2.167 V sor link-related parts.
NO
T5-6-14
FAULT CODE 80
(BOOM ANGLE SENSOR DEVIATION)
FAULT CODE 81
(ARM ANGLE SENSOR DEVIATION)
FAULT CODE 82
(OFFSET ANGLE SENSOR DEVIATION)

sent out of the boom angle sensor to the auto-
MARCCINO control unit is in the range of either
0.1 to 0.222 V or 4.778 to 4.9 V.
sent out of the arm angle sensor to the auto-
0.2 to 1.079 V or 3.921 to 4.8 V.
sent out of the offset angle sensor to the auto-
0.2 to 0.817 V or 4.183 to 4.8 V.
YES Faulty sensor link and related

parts.
Disconnect angle sensor.

Check if angle sensor electri-
cal resistance is 5.0±1.0 kΩ.
Faulty angle sensor.

NO
Boom Angle Sensor Arm Angle Sensor, Offset Angle Sensor
1 2 1 2 3
T5-6-15
FAULT CODE 90
(ABNORMAL OIL TEMPERATURE SEN-
SOR)

corresponding to -30° C or lower, or +100° C or
more is sent out of the oil temperature sensor to
the auto-MARCCINO control unit.
Oil Temperature Sensor

Oil Temperature Electrical Resis-
(°C) tance (kΩ)
-20 16.2±1.6
0 (5.88)
20 2.45±0.24
40 (1.14)
60 (0.534)
Disconnect oil tempera-
80 0.322 Short circuit of harness
ture sensor, and connect
YES between oil temperature
harness end connector
terminal No.1 and No.2. sensor and auto-
Remove connectors 1 MARCCINO control unit.
YES and 3 from auto-
Disconnect oil tempera-
ture sensor, and connect Faulty auto-MARCCINO
tween harness side con-
harness end connector
nector No.11 or No.16 NO control unit.
YES terminal No.1 and No.2. and vehicle.
Disconnect auto-
MARCCINO control unit
connector, check conti-
nuity between harness
Disconnect oil Broken harness between
end terminals.
temperature sen- oil temperature sensor
sor. Check if oil and auto-MARCCINO
NO
temperature sen- control unit.
sor electrical resis- · Terminals:
tance is within Connector 1: Terminal No.16
specification. Connector 3: Terminal No.11
Faulty oil temperature

NO sensor.
Oil Temperature Sensor Auto-MARCCINO Control Unit (Connector 1) Auto-MARCCINO Control Unit (Connector 3)
13 12 11 9 8 7 5 4 3 2 1 6 5 4
1 2
26 25 23 22 20 18 17 16 15 14 12 11 9 8
T5-6-16
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source.

Be sure to remove the negative terminals from the
batteries first when removing wire harnesses and
connectors for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses, and fusible links and, in some
cases, cause fire due to short circuit.
Codes Color Codes Color
2. Color coding of wire harnesses.
The color codes of the wire harness in the R Red W White
electrical system are shown in the table on the L Blue G Green
right.
Or Orange Lg Light Green
In cases on the design sheet where two colors are
indicated for one wire, the left initial stands for the Y Yellow B Black
base color, while the right initial stands for the Br Brown P Pink
marking color.
Gr Gray V Violet
NOTE: 1) Code BW indicates a black base wire

with white fine-line marking.
Right Wrong
2) Initials “O” and “Or” both stand for the
color orange..
3) Wires with longitudinal stripes printed on
them are not color coded. Be sure not to
confuse them with color coded wires.
3. Precautions for connecting and disconnecting T107-07-06-001
terminal connectors.
1) When disconnecting harnesses, grasp them
by their connectors. Do not pull on the wire
itself. Be sure to release the lock first before Right
attempting to separate connectors, if a lock is
Rust
provided. (Refer to “Instructions for
Wrong
Disconnecting Connector” on page T5-7-3.)
(Deformation)
2) Water-resistant connectors keep water out so
that if water enters them, water will not easily Wrong
drain from them. When checking water- (Separation)
resistant connectors, take extra care not to T107-07-06-002
allow water to enter the connectors. In case

water should enter the connectors, reconnect
only after the connectors are thoroughly dried.
3) Before connecting terminal connectors, check
that no terminals are bent or coming off. In
addition, as most connectors are made of
brass, check that no terminals are rusting.
4) When connecting terminal connectors
provided with a lock, be sure to insert them
together until the lock clicks.
T5-7-1
4. Precautions for Using a Circuit Tester
1) Before using a circuit tester, set the circuit
tester to meet the object to be measured,
voltage range and current polarity by referring Wind a piece of wire. Tester Probe
to the instructions in the circuit tester manual.
2) Before starting the connector test, always
check the connector terminal numbers,
referring to the circuit diagram and the
Sharpen the wire tip.
connector drawing. When the connector size is T107-07-06-003
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.
3) When performing the connector test with the
circuit tester, be sure to insert the tester probe
from the connector harness side in order not to
damage the terminais in the connector.
T5-7-2
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
1. Push the lock to disconnect.
NOTE: 1) Connectors may not be separated if the

lock is pushed while the connectors are
pulled. Push the lock first before pulling
the connectors.
2) The lock is provided on the female con-
nector (harness side).
T107-04-05-002
Locations of This Type Connector
Fuel Sensor Washer (Optional) Alternator Heater

Coolant Temperature Sensor 2 EC Motor Engine Control Dial Starter Relay
Horn EC Sensor Engine Control Sensor Wiper
Cab Harness Diode Radio Monitor
Pressure Switch (Travel) Buzzer Air-Conditioner Generalized Relay
Pump Control Solenoid Valve Key Switch Heater Relay
2. Pull up the lock to disconnect.
Pressure Switch (Front Attachment/Swing)

Pilot Pressure Sensor (EX75UR-3)
T107-04-05-003
3. Pull to disconnect.
Dr. EX
7-Spool Solenoid Valve Unit (EX75UR-3)
Oil Temperature Sensor (EX75UR-3)
T107-04-05-004
T5-7-3
FUSE CONTINUITY TEST
Fuse failure is often caused by a fine crack in the fuse, EX60-5:

and such fine cracks are very hard to detect by visual
inspection. Checking fuse continuity with a tester is far
superior to visual inspection. Fuse continuity test with a
tester is introduced in the following.
Fuse Box
1. Turn the key switch ON.
With the key switch ON, the battery relay is acti-
vated by the current from key switch terminal BR.
Then, electric power is supplied to all circuits ex-
cept the glow plug relay circuit. (Refer to the cir-
cuit diagram.)
2. Remove the fuse box cover and set the correct
voltage measurement range of the tester.
(Measurement Range: 0 to 30 V) M152-01-008
3. Ground the negative probe to the vehicle and
touch the fuse box outward terminal of each fuse EX75UR-3,EX75URLC-3 Fuse Box
with the positive probe of the tester. When normal
continuity of a fuse is intact, the tester will indicate
20 to 25 volts.
NOTE: All the inward terminals of the fuses in the

fuse box are connected to the power
source, while the outward terminals are
connected to the accessories. Test all fuses
using the same method, except the fuse for
the glow plug relay circuit.
T191-01-02-008
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
M191-07-066
T5-7-4
EX60-5
Fuse Fuse
Capacity Connected to Capacity Connected to
No. No.
1 5A Monitor, Radio 11 20A Work Light Relay
2 5A MC(Main Power) 12 5A Wiper Motor, Wiper Relay
3 5A MC(EC Motor Power) 13 20A Heater Unit
4 5A Pump Control Solenoid Valve 14 - Empty
5 5A MC(Power ON Signal) 15 10A Horn Relay
6 5A Monitor, QHS Controller 16 5A Radio
7 - Empty 17 - Empty
8 - Empty 18 5A Room Light
9 - Empty 19 10A Auxiliary
10 - Empty 20 10A Air Conditioner
EX75UR-3
Fuse Fuse
No. No.
1 5A Optional 11 20A Work Light Relay
2 10A MC (Power) 12 5A Washer Relay, Wiper Relay, Wiper Motor
3 10A MC (EC Motor Power) 13 20A Heater
4 5A Radio (Backup) 14 10A Emergency Evacuation Switch
5 10A Optional 15 5A MC (Power ON Signal)
6 5A Optional 16 10A Horn Relay
7 5A MC (Solenoid Valve Power) 17 5A Radio (Power)
8 5A System Monitor, Buzzer, Switch Panel, Monitor 18 10A Auxiliary
Panel, QHS Controller, Hour Meter
9 5A Auto-MARCCINO Control Unit (Power) 19 5A Room Light
10 10A Auto-MARCCINO Control Unit (Solenoid Valve 20 5A Empty
Power Source), Emergency Stop Solenoid Valve
Relay
EX75URLC-3
Fuse Fuse
No. No.
1 5A Optional 11 20A Work Light Relay
2 10A MC (Power) 12 5A Washer Relay, Wiper Relay, Wiper Motor
3 10A MC (EC Motor) 13 20A Heater
4 5A Radio (Backup) 14 10A Empty
5 10A Optional 15 5A MC (Power ON Signal)
6 5A Optional 16 10A Horn Relay
7 5A MC (Solenoid Valve Power) 17 5A Radio (Power)
8 5A Monitor, Buzzer, Switch Panel, QHS Controller, 18 10A Auxiliary
Hour Meter
9 5A Empty 19 5A Room Light
10 10A Empty 20 5A Empty
T5-7-5
FUSIBLE LINK INSPECTION
Inspection Battery Relay
1. Remove the negative cable from the battery.
2. Loosen bolt M8 connecting the cable in front of
the fusible link box. Turn the cable to the horizon-
tal position as illustrated.
3. Open the front cover of the fusible link box and
visually inspect the fusible link inside. Fusible Link Box
Cable
Bolt M8
T107-04-02-006
Cover
T107-04-05-007
Replacement Battery Relay

1. Make sure that the negative cable is removed
Bolt M8
from the battery.
2. Remove bolt M8 and take the fusible link box off
the battery relay.
3. Open the top and bottom covers of the fusible link
box and remove screws M6 (2 used).
4. Take out the fusible link and replace it.
5. Retighten screws M6 (2 used).
6. Connect the fusible link box cable to the battery
relay.
7. Connect the negative cable to the battery.
Screw M6
Cable
T107-04-05-008
T5-7-6
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between

the battery positive terminal and the vehicle
ground.
Specification: 24 V
NOTE: If voltage is out of the specification, re-

charge or replace the battery.
2. Start the engine. Check voltage between the bat-

tery positive terminal and the vehicle ground.
Specification: 26 V to 28 V
NOTE: If voltage is out of the specification, check

the charging system.
T157-07-06-007
T5-7-7
HOW TO TROUBLESHOOT ALTERNATOR
MALFUNCTIONS
In general, the alternator indicator remains off when

the alternator is generating power.
If the alternator indicator comes on while the engine is
running, the alternator might be defective.
How to check the circuit
1. Stop the engine. Turn the key switch to the ON 3. Next, start the engine and measure the voltage
position. Confirm that the alternator indicator generated while as the alternator rotates.
comes on. As described above, measure the voltage
between terminals B and E on the side of the
2. Measure the voltage between the B and E alternator. If the voltage is around 28 V, the
terminals of the alternator. If the measured alternator is operating normally.
voltage is around 24 V, the alternator circuit can If the measured voltage is around 24 V
be considered normal. If the measured voltage (equivalent to battery voltage) there is some trou-
is low, a shortage in battery capacity or looseness ble with the alternator or regulator.
of the wire connectors of the alternator circuit
might be the cause of the malfunction. When the
voltage is 0 V, the wiring between the fuse box
and alternator might be loose or disconnected.
Also, the alternator cannot generate electricity if
the ground line is disconnected.
T102-04-04-008
T5-7-8
CONTINUITY CHECK Harness
A a
Single-Line Continuity Check
Disconnect both end connectors of the wire and
check continuity between both ends:
When the ohm-meter reading is:
0 Ω = Continuity Ω
∞ Ω = Discontinuity
NOTE: When the one end connector is far apart Connected to the
vehicle frame. A a
from the other, connect one end connector
(A) to the vehicle using a clip. Then, check
continuity of the wire through the vehicle as
illustrated.
Connected to the
vehicle frame. Ω
0 Ω = Continuity
∞ Ω = Discontinuity
A a
Single-Line Short Circuit Check Short-circuit

Disconnect both end connectors of the wire and between the
check continuity between one end connector of the harness and
the vehicle.
wire and the vehicle. Ω
0 Ω = Short circuit is present.
∞ Ω = No short circuit is present.
T107-07-05-003
Multi-Line Continuity Check First short-circuit

Disconnect both end connectors of the harness, and
short-circuit two terminals (A and B) at one end con-
nector as illustrated. Then, check continuity between A a
terminals (a and b) at the other connector. B b
C c
When 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 Second short-circuit
check on both lines individually, or after changing the
short-circuited terminals from (A) - (B) to (A) - (C),
check once more between terminals (a) and (c). Ω
NOTE: Repeat checking twice to find out which line

is discontinued. With terminals (A) and (C)
short-circuited, check continuity between T107-07-05-004
terminals (a) and (c).

Short-circuit between harnesses.
0 Ω = Line (B) - (b) has discontinuity.
∞ Ω = Line (A) - (a) has discontinuity. A a
B
× b
Multi-Line Short Circuit Check C c
Disconnect both end connectors of the harness, and
check continuity between terminals (A) and (B) or (C).
0 Ω = Short circuit exists between the lines.
∞ Ω = No short circuit exists between the lines. Ω
T107-07-05-005
T5-7-9
VOLTAGE AND CURRENT CHECK 24 Voltage Circuit
Turn switch ON so that the specified voltage (current) Start checking in order up to the point where voltage is
is applied to the point to be measured. Then start measured from either power source or actuator side.
measuring either voltage or current. Judge if the Thereby, the faulty location in the circuit will be found.
specified voltage is applied. Black Probe (Minus) of Tester : To ground (vehicle
frame).
Red Probe (Plus) of Tester : To location to be
measured.
EX60-5
Engine Key Check Point Standard
Switch
Power Sourse Circuit
Stopped OFF Between (2) and (1): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (1): Two Batteries 20 to 25 V
Stopped OFF Between (4) and Ground: Power Source 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link 20 to 25 V
Stopped OFF Between (1) and Ground: Backup Current* 6 mA
Preheat Circuit
Stopped HEAT Between (6) and Ground: Heater Relay 20 to 25 V
Stopped HEAT Between (7) and Ground: QHS Controller 20 to 25 V
Starting Circuit
Started START Between (8) and Ground: Key Switch 20 to 25 V
Started START Between (9) and Ground: Battery Relay (Coil) 20 to 25 V
Started START Between (10) and Ground: Batter Relay (Switch) 20 to 25 V
Started START Between (12) and Ground: Starter (S) 20 to 25 V
Started START Between (13) and Ground: Starter Relay (S) 20 to 25 V
Charging Circuit
Fast Speed ON Between (14) and Ground: Alternator Generating Voltage (N) 26 to 30 V
Fast Speed ON Between (10) and Ground: Alternator Generating Voltage 26 to 30 V
Fast Speed ON Between (16) and Ground: Alternator Generating Voltage (L) 13 to 30 V
Fast Speed ON Between (17) and Ground: MC 13 to 30 V
Surge Voltage
Prevention Circuit
Slow Idling ON Between (14) and Ground: Alternator (N) 26 to 30 V
Slow Idling ON Between (16) and Ground: Alternator (L) 13 to 30 V
Slow Idling ON Between (18) and Ground: Load Dump Relay 26 to 30 V
Slow Idling ON Between (10) and Ground: Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (19) and Ground: Room Light 20 to 25 V
Stopped ON Between (20) and Ground: Auxiliary 20 to 25 V
Stopped ON Between (21) and Ground: Radio 20 to 25 V
Stopped ON Between (22) and Ground: Horn 20 to 25 V
* After disconnection the minus cable to the battery,

start, easiromg.
T5-7-10
Key Switch
Load
Dump
Relay
1 2 3 4 5 9
18
Battery
Battery
Relay
Fuse Box 8
Starter
10
11
12 15 22 21 19 20
Starter
Relay Fuse Box
13
16
Alternator
QHS Controller 17
7
Heater Relay
6
MC
T152-05-06-001
T5-7-11
Key
Engine Check Point Specification
Switch
Power Source Circuit
Stopped OFF Between (3) and (2): One Batteries 10 to 12.5 V
Stopped OFF Between (3) and (1): Two Batteries 20 to 25 V
Stopped OFF Between (4) and Ground: Power Source 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link 20 to 25 V
Stopped OFF Between (1) and Ground: Backup Current* 6 mA
Preheat Circuit
Stopped HEAT Between (6) and Ground: Heater Relay 20 to 25 V
Stopped HEAT Between (7) and Ground: QHS Controller 20 to 25 V
Starting Circuit
Started START Between (8) and Ground: Key Switch 20 to 25 V
Started START Between (9) and Ground: Battery Relay (Coil) 20 to 25 V
Started START Between (10) and Ground: Battery Relay (Switch) 20 to 25 V
Started START Between (11) and Ground: Starter (B) 20 to 25 V
Started START Between (12) and Ground: Starter (S) 20 to 25 V
Started START Between (13) and Ground: Starter Relay (C) 20 to 25 V
Charging Circuit
Fast Speed ON Between (14) and Ground: Alternator Generating Voltage (N) 26 to 30 V
Fast Speed ON Between (16) and Ground: Alternator Generating Voltage (L) 13 to 30 V
Fast Speed ON Between (17) and Ground: MC 13 to 30 V
Surge Voltage
Prevention Circuit
Slow Idling ON Between (14) and Ground: Alternator (N) 26 to 30 V
Slow Idling ON Between (16) and Ground: Alternator (L) 13 to 30 V
Slow Idling ON Between (18) and Ground: Load Dump Relay 26 to 30 V
Slow Idling ON Between (10) and Ground: Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (19) and Ground: Room Light 20 to 25 V
Stopped ON Between (20) and Ground: Auxiliary 20 to 25 V
Stopped ON Between (21) and Ground: Radio 20 to 25 V
Stopped ON Between (21) and Ground: Work Light 20 to 25 V
* After disconnecting the negative cable from the bat-

tery, start measuring.
T5-7-12
Key Switch
1 2 3
5 4 9
Battery
Battery Relay
Load
Starter Dump Fuse Box
B 10 Relay
11
S
Starter Relay 12
S 18 15 22 21 20 19
B 16
Fuse Box
ACC
C
N
13
Alternator
N
BAT 14
R
L
QHS Controller
Heater Relay 6
17
1 7 B1
2
M C
7
3 4
T192-05-07-001
T5-7-13
5 Voltage Circuit
Power Source Signal or
Ground
• Voltage between terminal No.1 and the vehicle 1 2
ground Two Polarities
With the key switch OFF, disconnect the sensor
connector. Measure the voltage between terminal
No.1 on the machine harness side connector and
the vehicle under the following conditions.
V
• Key Switch: ON
• Tester Black Probe (Negative):
Connected to the vehicle
• Tester Red Probe (Positive):
Connected to terminal No. 1. T107-07-05-006
Evaluation: Power Source Signal Ground

When the measured voltage is within 5±0.5 volts,
1 2 3
the circuit up to terminal No.1 is normal. Three Polarities
T107-07-05-007
• Voltage between terminal No.1 and the ground

terminal
With the key switch OFF, disconnect the sensor 1 2
Two Polarities
connector. Measure the voltage between terminal
No.1 on the machine harness side connector and
the ground terminal (terminal No.2 for the two po-
larities, or terminal No.3 for the three polarities) V
under the following conditions.
• Key Switch: ON
• Tester Black Probe (Negative):
Connected to the ground terminal
(terminal No.2 or No.3) T107-07-05-008
• Tester Red Probe (Positive):
Connected to terminal No. 1.
Evaluation: 1 2 3
Three Polarities
When the measured voltage is within 5±0.5 volts,
the circuit up to terminal No.1 or the ground termi-
nal (terminal No.2 or No.3) is normal.
V
T107-07-05-009
T5-7-14
CHECK BY FALSE SIGNAL
With the key switch OFF, disconnect the sensor or

switch connector. Short-circuit terminal No.1 (power 1 2
source) on the machine harness side connector to
terminal No. 2 (signal) with a wire and supply the Two Polarity
power source voltage as a false signal to the connector.
Check this condition using Dr. EX monitor function. (Pressure Switch)
When checking sensor, if the maximum value is dis-
played, the system up to the MC and the machine har-
ness side connector is normal. Connect
When checking pressure switch, if the status ON is
displayed, the system up to the MC and the machine
harness side connector is normal.
T107-07-05-010
IMPORTANT: On three-polarity connectors, do not

short-circuit terminal No.1 or No.2 to
terminal No.3 or to the vehicle . 1 2 3
Three Polarity
(EC Sensor)
Connect
T107-07-05-011
T5-7-15
TEST HARNESS
With a test harness installed between connectors, the
circuit condition is checked depending on whether the
test harness lamp lights or extinguishes during opera-
tion.
Parts Number 4283594 (ST 7126)

Use to check a single-line (discontinuity and/or volt-
age).
During Operation: Lamp is ON.
To Location to be Measured.
To Ground
T107-07-05-012

Use to check the EC motor circuit.
5
(Refer to T5-4-14.)
6
50
• EC Motor Circuit
1 2 2 1
When the engine control dial is rotated: 150 50
50
Both lamps ON: Normal 4 3 4 3
Only one lamp ON: Check for continuity of the cir- 7 50
cuit connected to the lamp OFF. 8
Both lamps OFF: Check the harness together with
the relay.
Parts Number 4274589 (ST 7125) T107-07-06-024
Parts Number 4284347 (ST 7129) (Red)

Use to measure the EC sensor circuit signal line volt-
age (between terminals #2 and #3).
(Refer to T5-3-2.)
(Black)
Parts Number 4284347 (ST 7129) T107-07-03-009
T5-7-16

Troubleshooting: Section 5

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What are the main components discussed in the document?

What are the main components discussed in the document?

What troubleshooting procedures are covered?

What troubleshooting procedures are covered?

SECTION 5

• General • Electrical System Inspection

Example: Fault Code 01: EC Sensor Failure

• Troubleshooting B (starting with symptoms)

Example: Engine speed does not change even

• Troubleshooting C (gauges and indicators)

Example: The fuel gauge does not operate.

These six basic steps are essential for efficient

1. Study the System

2. Ask the Operator

• Operating Conditions: Check what kinds of work

Also, check the electrical system, including the

CAUTION: Never attempt to disconnect har-

Connect Dr.EX to the MC to obtain malfunction

are displayed again, start checking following

* Note that fault codes do not always indicate ma-

Before performing troubleshooting based on the

check whether the fault codes are displayed again

6. Recheck Possible Causes

Dr.Ex is a diagnosing tool to be used for checking the

When Dr.EX is connected to the MC, malfunction

Input signals from the sensors or switches that are

Controller Record Monitor Data

Applicable Dr.EX Version: Dr.EX Ver 1.03

Fault Code Trouble Cause of Trouble

50 E50 Abnormal boom angle sensor

52 E52 Abnormal offset angle sensor

60 E60 Faulty boom angle sensor initial setting

80 E80 Boom angle sensor deviation

82 E82 Offset angle sensor deviation

Faulty hydraulic oil temperature sensor

NOTE: * Unless the solenoid valve has failed,

Trouble on the Machine Corrective Action Group

Interference prevention control system functions 1) Check harness.

NOTE: If two or more trouble occurs at the same

Dr.EX has a function to monitor the command signals

Monitor Item Descriptions Unit

NOTE: * White letters (or figures) are shown on the

Dr.EX has a function to monitor the command signals

Selected Function Key Data Unit

When the optional front attachment or bucket is used,

NOTE: After completing the data input in the serv-

• Self-diagnosing by Dr.EX doesn’t operate.

Machine Model Menu

Select the displayed No. for the ”Medium Size UR.”

Program Version Confirmation

Execute (F1) after confirming.

Machinery Co., Ltd. 1996

F1: Self-Diagnostic Result Screen

1 To T5-1-12 2 To T5-1-13 3 To T5-1-13

Trouble exists. No trouble exists.

Following fault codes are detected by No trouble exists or trouble beyond

F1: Details F2: Retrial F5: Exit F5: Exit

Fault Code: 41 Retrial successful.

F3: Next F5: Exit F1:Self Diagnostic Operation