16089714-New Holland E200sr Excavator Service Repair Manual

Copyright New Holland
INTRODUCTION
E200SR
WORKSHOP MANUAL
ENGLISH
Print No. 604.13.431
Edition: 03/2005
English - Printed in Italy
Printed by Studio ti - 20105
0-1

INTRODUCTION
TO THE READER
This manual has been written for a skilled technician,
in order to give him the information necessary to
repair this machine.
- For any question or comment, or in case you

notice a mistake in this manual content, please
contact:
- Read this manual carefully for correct

information about repair procedures.
NEW HOLLAND KOBELCO CONSTRUCTION

MACHINERY S.p.A.
Strada di Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax. ++39 011 0077357
ADDITIONAL REFERENCE MANUALS

In addition to this Workshop Manual, refer also to
the following:
- Operation and maintenance instruction
manual
- Spare parts catalog
DESCRIPTION OF THE COMPLETE

WORKSHOP MANUAL
The complete repair manual consists of two volumes:
equipment, information on maintenance standards,

remove and install procedures, disassembly and
assembly procedures.
- E200SR Workshop Manual "Excavator"
The complete Workshop Manual for the excavator

model E200SR consists of the following volumes
identified by print number as shown herebelow:
"Excavator" and "Engine" Workshop Manuals

contain the technical information necessary for
machine/engine service and repair, service
VOLUME
Workshop Manual - "Excavator"
MACHINE TYPE
E200SR
0-3
PRINT No.
604.13.431

INTRODUCTION
AVOID ACCIDENTS
Most accidents, whether they occur in industry, on the farm, at home or on
the highway, are caused by the failure of some individuals to follow simple and
fundamental safety rules or precautions. For this reason MOST ACCIDENTS
CAN BE PREVENTED by recognising the real cause and doing something
about it before the accident occurs.
Regardless of the care used in the design and construction of any type of
equipment there are conditions that cannot be completely safeguarded
against without interfering with reasonable accessibility and efficient operation.
Carefully read indications, cautions and safety warning quoted in the
SAFETY RULES section.
A careful operator is the best insurance against an accident.
The complete observance of one simple rule would prevent many thousand
serious injuries each year.
That rule is:
Never attempt to clean, oil or adjust a machine while it is in motion.
ATTENTION
On machines having hydraulically, mechanically and/or cable controlled

equipment (such as showels, loaders, dozers, scrapers etc.) be certain
the equipment is lowered to the ground before servicing, adjusting and/
or repairing.
If it is necessary to have the equipment partially or fully raised to gain
access to certain items, be sure the equipment is suitably supported by
means other than the hydraulic lift cylinders, cable and/or mechanical
device used for controlling the equipment.
COPYRIGHT BY NEW HOLLAND KOBELCO CONSTRUCTION
MACHINERY S.p.A.
Product Support - Documentation Centre
Strada di Settimo, 323 - 10099 - S. Mauro T.SE (TO) ITALY
All rights reserved. Reproduction of text and illustrations in whole or in part, is

strictly prohibited.
0-4

INDEX
INDEX
SPECIFICATIONS
Section 1 - Outline
Section 2 - Specification
Section 3 - Attachment dimension
MAINTENANCE
Section 11 - Tools
Section 12 - Standard maintenance time schedule
Section 13 - Maintenance standard and test procedure
SYSTEM
Section 21 - Mechatro control system
Section 22 - Hydraulic system
Section 23 - Electric system
Section 24 - Components system
Section 25 - Air-conditioner system
DISASSEMBLING
Section 31 - Disassembling and assembling
Section 32 - Attachment
Section 33 - Upper structure
Section 34 - Travel system
TROUBLESHOOTING
Section 41 - Troubleshooting (mechatro control)
Section 42 - Troubleshooting (Hydraulic)
Section 43 - Troubleshooting (Electric)
Section 44 - Troubleshooting (Engine)
ENGINE
Section 51 - Engine
OPT
Section 63 - Mounting the breaker and nibbler & breaker
0-5

SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
YY
WARNING
5.
YY
The proper and safe lubrication and maintenance for

this machine, recommended by Distributor, are
outlined in the OPERATORS MANUAL for the
machine.
Improper performance of lubrication or maintenance
procedures are dangerous and could result in injury
or death. Read and understand the MANUAL before
performing any lubrication or maintenance.
The serviceman or mechanic may be unfamiliar with
many of the systems on this machine. This makes it
important to use caution when performing service
work. A knowledge of the system and or components
is important before the removal or disassembly of any
component.
Because of the size of some of the machine
components, the serviceman or mechanic should
check the weights noted in this manual. Use proper
lifting procedures when removing any components.
Weight of components table is shown in the section;
SPECIFICATIONS.
YY
Read and understand all Warning plates and

decal on the machine before Operating,
Maintaining or Repairing this machine.
2.
Always wear protective glasses and protective

shoes when working around machines. In
particular, wear protective glasses when using
hammers, punches or drifts on any part of the
machine or attachments. Use welders gloves,
hood/goggles, apron and the protective clothing
appropriate to the welding job being performed.
Do not wear loose fitting or torn clothing. Remove
all rings from fingers, loose jewelry, confine long
hair and loose clothing before working on this
machinery.
3.
Disconnect the battery and hang a Do Not

Operate tag in the Operators Compartment.
Remove ignition keys.
4.
If possible, make all repairs with the machine

parked on a level, hard surface. Block the machine
so it does not roll while working on or under the
machine. Hang a Do Not Operate tag in the
Operators Compartment.
0-6
WARNING
YY
Do not operate this machine unless you have read

and understand the instructions in the OPERATORS
MANUAL. Improper machine operation is dangerous
and could result in injury or death.
6.
Relieve all pressure in air, oil or water systems

before any lines, fittings or related items are
disconnected or removed. Always make sure all
raised components are blocked correctly and be
alert for possible pressure when disconnecting
any device from a system that utilizes pressure.
7.
Lower the bucket, dozer, or other attachments to

the ground before performing any work on the
machine. If this cannot be done, make sure the
bucket, dozer, ripper or other attachment is
blocked correctly to prevent it from dropping
unexpectedly.
8.
Use steps and grab handles when mounting or

dismounting a machine. Clean any mud or debris
from steps, walkways or work platforms before
using. Always face to the machine when using
steps, ladders and walkways. When it is not
possible to use the designed access system,
provide ladders, scaffolds, or work platforms to
perform safe repair operations.
9.
To avoid back injury, use a hoist when lifting

components which weigh 20 kg (45 lbs) or more.
Make sure all chains, hooks, slings, etc., are in
good condition and are the correct capacity. Be
sure hooks are positioned correctly. Lifting eyes
are not to be side loaded during a lifting operation.
The following is a list of basic precautions that must

always be observed.
1.
Do not work on any machine that is supported

only by lift, jacks or a hoist. Always use blocks or
jack stands, capable of supporting the machine,
before performing any disassembly.
10. To avoid burns, be alert for hot parts on machines

which have just been stopped and hot fluids in
lines, tubes and compartments.
11. Be careful when removing cover plates. Gradually
back off the last two capscrews or nuts located at
opposite ends of the cover or device and carefully
pry cover loose to relieve any spring or other
pressure, before removing the last two capscrews
or nuts completely.
12. Be careful when removing filler caps, breathers
and plugs on the machine. Hold a rag over the cap
or plug to prevent being sprayed or splashed by
liquids under pressure. The danger is even

SAFETY PRECAUTIONS
Shields that protect against oil spray onto hot
exhaust components in event of a line, tube or seal
failure must be installed correctly.
greater if the machine has just been stopped

because fluids can be hot.
13. Always use the proper tools that are in good
condition and that are suited for the job at hand.
Be sure you understand how to use them before
performing any service work.
14. Reinstall all fasteners with the same part number.
Do not use a lesser quality fastener if replacements
are necessary.
15. Repairs which require welding should be
performed only with the benefit of the appropriate
reference information and by personnel
adequately trained and knowledgeable in welding
procedures. Determine type of metal being
welded and select correct welding procedure and
electrodes, rods or wire to provide a weld metal
strength equivalent at least to that of the parent
metal. Make sure to disconnect battery before
any welding procedures are attempted.
21. Do not operate a machine if any rotating part is

damaged or contacts any other part during
operation. Any high speed rotating component
that has been damaged or altered should be
checked for balance before reusing.
22. Be careful when servicing or separating the
tracks (crawlers). Chips can fly when removing or
installing a track (crawlers) pin. Wear safety
glasses and long sleeve protective clothing. Tracks
(crawlers) can unroll very quickly when separated.
Keep away from front and rear of machine. The
machine can move unexpectedly when both tracks
(crawlers) are disengaged from the sprockets.
Block the machine to prevent it from moving.
16. Do not damage wiring during removal operations.

Reinstall the wiring so it is not damaged nor will be
damaged in operation of the machine by contacting
sharp corners, or by rubbing against some object
or hot surface. Do not connect wiring to a line
containing fluid.
17. Be sure all protective devices including guards
and shields are properly installed and functioning
correctly before starting a repair. If a guard or
shield must be removed to perform the repair
work, use extra caution and replace the guard or
shield after repair is completed.
18. The maintenance and repair work while holding
the bucket raised is dangerous due to the possibility
of a falling attachment. Dont fail to lower the
attachment and place the bucket to the ground
before starting the work.
19. Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not
bend or strike high pressure lines or install ones
which have been bent or damaged. Inspect lines,
tubes and hoses carefully. Do not check for leaks
with your hands. Very small (pinhole) leaks can
result in a high velocity oil stream that will be
invisible close to the hose. This oil can penetrate
the skin and cause personal injury. Use cardboard or paper to locate pinhole leaks.
20. Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are
installed correctly to avoid excessive heat, vibration
or rubbing against other parts during operation.
0-7

SAFETY PRECAUTIONS
NOTE
0-8
E200SR
SECTION 1
OUTLINE
TABLE OF CONTENTS
1. GENERAL PRECAUTIONS FOR MAKING REPAIRS ................................................ 1
2. INTERNATIONAL UNIT CONVERSION SYSTEM...................................................... 4
1. GENERAL PRECAUTIONS FOR MAKING REPAIRS

4) Confirm the position of first-aid box and fire
extinguisher, and also where to make contact
for emergency measure and ambulance to
prepare for accidents and fire.
5) Choose a hard, flat and safe place, and put
attachment on the ground without fail.
6) Use crane, etc. to remove parts of heavy
weight (20kg [44 lbs] or more).
7) Use proper tools, and change or repair
defective tools.
8) Machine and attachment required to work in
the lifting condition should be supported with
supports or blocks securely.
1.1
(1)
(2)
(3)
(4)
1)
2)
3)
4)
5)
6)
(5)
1)
2)
3)
PREPARATION BEFORE
DISASSEMBLING
Knowledge of operating procedure
Read Operators Manual carefully to
understand the operating procedure.
Cleaning machines
Clean machines of soil, mud, and dust before
carrying into the repair shop.
Carrying a soiled machine into the repair
shop, causes making less efficient work and
damage of parts, and interferes with rust
prevention and dust protection while
reassembling.
Inspecting machines
Confirm the disassembling section before
starting work, determine the disassembly
procedure taking the conditions in repair
shop into account, and request to procure
necessary parts in advance.
Recording
Record the following items to keep contact
and prevent malfunction from recurring.
Inspecting date, place
Model name, Applicable machine No.,
Records on hour meter
Trouble condition, place, cause
Visible oil leakage, water leakage and
damage
Clogging of filters, etc., oil level, oil quality,
oil contamination and looseness which can be
inspected.
Examine the problems on the basis of
operation rate with the last inspection date
and records on hour meter.
Arrangement and cleaning in repair shop
Tools required for repair work.
Specify places to put the disassembled parts
on in advance.
Prepare oil pans for leaking oil, etc.
1.2
1.3
(1)
1)
2)
3)
4)
(2)
1)
2)
3)
4)
SAFETY WHEN
DISASSEMBLING AND
ASSEMBLING
(1) Safety
1) Wear appropriate clothing, safety shoes,
safety helmet, goggles, and clothes with long
sleeves.
2) Suspend warning tag Dont operate from
lever, and begin preliminaries before getting
down to work.
3) Before starting inspection and maintenance
which contain the danger of being caught in
machine, stop the engine.
5)
6)
DISASSEMBLING AND
ASSEMBLING HYDRAULIC
EQUIPMENT
Removing hydraulic equipment assy
Before removing pipes, release the pressure
of hydraulic oil tank, or open the cover on the
return side to tank, and take out the filter.
Put the oil in the removed pipes in reservoir
taking care it is not spilled on the ground.
Pipes with plugs or caps to prevent oil
leaking, entry of dust, etc.
Clean the outside surface of equipment, etc.
before disassembling, and drain hydraulic oil
and gear oil before putting them on working
bench.
Disassembling hydraulic equipment
Since performance and function of hydraulic
equipment after disassembly and assembly
results in immunity from responsibility on
the
manufactures
side,
disassembly,
assembly and conversion without permission
are strictly prohibited.
If it is unavoidably necessary to disassemble
and convert, it should be carried out by
experts or personnel authorized through
service training.
Make match mark on parts for reassembling.
Before disassembling, read Disassembling
Instruction supplied with equipment in
advance, and determine if the disassembly
and assembly are permitted or not.
For parts which are required to use jig and
tools, dont fail to use the specified jig and
tools.
For parts which can not be removed in the
specified produre, never force removal. First
check for the cause.
7) The removed parts should be put in order and

tagged so as to install on proper places
without confusion.
8) For common parts, pay attention to the
quantity and places.
(3) Inspecting parts
1) Check that the disassembled parts are free
from
adherence,
interference
and
non-uniform working face.
2) Measure the wear of parts and clearance, and
record the measured values.
3) If an abnormality is detected, repair or
replace the parts.
3) For air bleed of hydraulic pump and swing

motor, loosen drain plug on the upper part,
start engine, and run in low idling, then
bleed air until hydraulic oil is oozed out.
After completion of air bleed, tighten plug
securely.
4) For air bleed of travel motor and hydraulic
cylinder, starts engine and operate it for 10
minutes or more at no-load and low speed.
For cylinder, dont move it to the stroke
end at beginning.
5) Air in pilot circuit can be bled out by only
operating digging, swing and traveling
motions thoroughly.
6) Check hydraulic oil level.
Move attachments to hydraulic oil check
position, and check hydraulic oil level of tank.
Refill oil if the oil level is lower than the
minimum level.
(4) Reassembling hydraulic equipment

1) Before cleaning, turn the fun on or open doors
to ventilate air.
2) Before assembly, clean parts roughly first,
and then completely.
3) Remove with oil by compressed air, and apply
hydraulic oil or gear oil, and then assemble
them.
4) Replace the removed O ring, back-up rings
and oil seal with new ones, and apply grease
oil on them before assembling.
5) Removes stain and water on the surface on
which liquid sealant are applied, decrease
them, and apply liquid sealant on them.
6) Before assembling, remove rust preventives
on new parts.
7) Use special tools to fit bearings, bushing and
oil seal.
8) Assemble parts matching to the marks.
9) After completion, check that there is no
omission of parts.
Important Information
LEVEL GAUGE
Oil level of hydraulic oil tank.
If the indicator is within level
marks, the oil quantity is
allowable.
How to check oil level of hydraulic oil tank
1.4 ELECTRICAL EQUIPMENT

(1) The disassembly of electrical equipment is
not allowed.
(2) Handle equipment with care so as not to drop
it or bump it.
(3) Connector should be removed by unlocking
while holding the connector.
Never stress in tension to the caulked section
by pulling wire.
(4) Check that connector is connected and locked
completely.
(5) Switch starter key off before removing and
connecting connector
(6) Switch starter key off before touching
terminals of starter and alternator.
(7) Remove battery grounding terminal before
beginning work close to battery and battery
relay with tools.
(8) Wash machine with care so as not to splash
water on electrical equipment and connector.
(5) Installing hydraulic equipment

1) Confirm hydraulic oil and lubrication oil.
2) Air release is required in the following cases ;
a. Change of hydraulic oil
b. Replacement of parts on suction pipe
side
c. Removing and attaching hydraulic pump
d. Removing and attaching swing motor
e. Removing and attaching travel motor
f. Removing and attaching hydraulic cylinder
If hydraulic oil and lubricating oil are
not filled and also air bleed is not
performed, the hydraulic equipment
may be damaged.
2
(9) When water has entered in the waterproofed

connector, the removing of water is not easy.
So check the removed waterproofed connector
with care to protect it from entry of water. If
moisture adheres on it, dry it completely
before connecting.
Tighten it to the specified torque,

and check that it is free from
distortion, over tension, interference,
and oil leakage.
1.6 WELD REPAIR

(1) The weld repair should be carried out by
authorized personnel in the specified
procedure after disconnecting the grounding
cable of battery. If the grounding cable is not
disconnected, the electrical equipment may
be damaged.
(2) Remove parts which may cause flame due to
the entry of spark beforehand.
(3) Repair attachments which are damaged,
giving particular attention to the plated
section of piston rod to protect it from sparks,
and don't fail to cover the section with fire
clothes.
Battery electrolyte is dangerous.

The battery electrolyte is dilute
sulfuric acid, and causes scald and loss
of eyesight by adhering on eyes, skin
and clothes. When the electrolyte has
adhered on them, take an emergency
measure immediately and see a doctor
for medical advice.
When it has adhered on skin ;
Wash with soap and water.
When it has got in eyes ;
Wash in water for 10 minutes or
more immediately.
When it has spilled out in large
quantity ;
Use
sodium
bicarbonate
to
neutralize, or wash away with
water.
When it was swallowed ;
Drink milk or water.
When it has adhered on clothes ;
Wash it immediately.
1.7 ENVIRONMENTAL ISSUES

(1) Engine should be started and operated in the
place where air can be sufficiently ventilated.
(2) Industrial waste disposal
The following parts follows the regulation.
Waste oil, waste container
Battery
(3) Precautions for handling hydraulic oil
Hydraulic oil may cause inflammation of
eyes.
Wear goggles to protect eyes on handling it.
When it has got in eyes ;
Wash eyes with water until the
stimulus is gone.
When it was swallowed ;
Immediately see a doctor for
medical advice.
When it has adhered on skin ;
Wash with soap and water.
(4) Others
For spare parts, grease and oil, use
Distributor genuine ones.
1.5 HYDRAULIC PARTS

1) O ring
Check that O ring is free from flaw
and has elasticity before fitting.
Even if the size of O ring is equal,
the usage differs, for example in
dynamic and static sections, the
rubber
hardness
also
differs
according to the pressure force, and
also the quality differs depending on
the materials to be seated. So, choose
proper O ring.
Fit O ring so as to be free from
distortion and bend.
Floating seal should be put in pairs.
2) Flexible hose (F hose)
Even if the connector and length of
hose are the same, the parts differ
according to the withstanding
pressure. Use proper parts.
2. INTERNATIONAL UNIT CONVERSION SYSTEM

(4) Derived Units bearing Peculiar Designations
Introduction
Although this manual uses the JIS unit system.
If you need SI unit, refer to following
international system of units.
Given hereinunder are an excerpt of the units
that are related to this manual :
1. Etymology of SI Units
French : Le Systme International d Units
English : International System of Units
2. Construction of SI Unit System
Table 2-4
QUANTITIES
Frequency
Force
Pressure,
Stress
Energy
Work,
Quantity of
heat
Power
Motive power,
Electric power
Charge,
Quantity of
electricity
Potential
Voltage,
Electromotive
force
Quantity of
static
electricity
Capacitance
Electric
resistance
Celcius
temperature
Illuminance
Basic units
Table 2-1
SI unit
system
SI units
Supplementary units
Table 2-2
Derived units of
basic units
Table 2-3
Derived
units
Derived units
bearing peculiar
designations
Table 2-4
Prefixes of SI
(n-th power of 10, where n is an integral)
Table 2- 5
(1) Basic Units

Table 2-1
QUANTITIES
DESIGNATION
Length
Meter
Mass
Kilogram
Time
Second
Current
Ampere
Thermodynamic
Kelvin
temperature
Gram molecule
Mol
Luminous intensity Candela
(2) Supplementary Units
Table 2-2
QUANTITIES
DESIGNATION
Plane angle
Radian
Solid angle
Steradian
Hertz
Newton
Pascal
m
kg
s
A
K
mol
cd
SIGN
rad
sr
SIGN
DERIVED UNIT
Hz 1Hz=1s-1
N 1N=1kgfym/s2
Pa 1Pa=1N/m2
Joule
1J=1Nym
Watt
1W=1J/s
Coulomb
1C=1As
Volt
1V=1J/C
(1W/A)
Farad
1F=1C/V
Ohm
1=1V/A
Celcius degree
or degree
lux
(5) Prefixes of SI
Table 2-5
PREFIX
DESIGNATION SIGN
GigaG
MegaM
Kilok
Hectoh
Decada
Decid
Centic
Millim
Micro
Nanon
Picop
SIGN
(3) Derived Units of Basic Units

Table 2-3
QUANTITIES
DESIGNATION
Area
Square meter
Volume
Cubic meter
Velocity
Meter per second
Acceleration
Meter per second / second
Density
Kilogram per cubic meter
DESIGNATION
X 1 X=1 m/m2
POWER
109
106
103
102
10
101
102
103
106
109
1012
(6) Unit Conversion Table

Table 2-6
QUANTITIES
Mass
Force
Torque
Pressure
Motive power
Revolution
SIGN
m2
m3
m/s
m/s2
kg/m3
JIS
kg
kgf
kgfym
kgf/cm2
PS
rpm
SI
kg
N
Nym
MPa
kW
min1
REMARKS
1kgf=9.807N
kgfym=9.807Nym
1kgf/cm2=0.098MPa
1PS=0.7355kW
r/min 1
Units that are allowed to use
E200SR
SECTION 2
SPECIFICATIONS
TABLE OF CONTENTS
1. NAME OF COMPONENTS ....................................................................................... 1
2. GENERAL DIMENSION ............................................................................................ 2
3. WEIGHT OF COMPONENTS ................................................................................... 3
4. TRANSPORTATION DIMENSION AND WEIGHT ..................................................... 4
5. SPECIFICATIONS AND PERFORMANCE ................................................................ 6
6. TYPE OF CRAWLER ............................................................................................... 7
7. TYPE OF BUCKET ................................................................................................... 8
8. COMBINATIONS OF ATTACHMENT ........................................................................ 9
9. ENGINE SPECIFICATION ...................................................................................... 10
1. NAME OF COMPONENTS
2. GENERAL DIMENSION
NOTE :
Dimensions marked
the shoe lug.
2.1 5.05m (167) Boom+2.60m (86) Arm+0.75m3 (0.98cu yd) Bucket
do not include the height of
Unit : mm (ft-in)
E200SR
E200SRLC
Unit : mm (ft-in)
3. WEIGHT OF COMPONENTS
Model
Item
Machine complete
1.
E200SR
Shoe
600mm Shoe
E200SR (
(600mm
2.6m Arm )
2.6m Arm )
19,900 (43,870)
Upper frame
2,110 (4,650)
1.2
Counterweight
4,620 (10,900)
1.3
Counterweight (ADD-on)
1.4
Cab
1.5
Engine
1.6
Hydraulic oil tank
1.7
Fuel tank
1.8
Slewing motor (including reduction unit)
220 (485)
1.9
Control valve
130 (290)
1.10
Boom cylinder
1.11
Pin (for mounting boom)
40 (90)
1.12
Pump
90 (200)
1.13
Radiator & oil color
99 (220)
370 (815)
*
*
*
125 (280)
125 (280)
170 (370)
Lower frame assy (including the following :)
7,130 (15,720)
7,630 (16,820)
2,450 (5,400)
2,650 (5,840)
Lower frame
2.2
Slewing bearing
245 (540)
2.3
Travel motor (including reduction unit)
250 (550)X2
2.4
Upper roller
2.5
Lower roller
2.6
Front idler
106 (230)X2
2.7
Idler adjuster
150 (330)X2
2.8
Sprocket
2.9
Swivel joint
2.10
Track link with 600mm (24in) shoe assy
1,260 (2,780)X2
Track link with 700mm (28in) shoe assy
1,360 (3,000)X2
3.
22 (48)X4
35 (77)X14
30 (66)
510 (1,120)X2
Track link assy

Attachment (including the following)
2,890 (6,370)
Bucket assy (Japanese standard bucket)
640 (1,410)
3.2
Arm assy (including the following :)
890 (1,960)
3.2.1
Arm
3.2.2
Bucket cylinder
3.2.3
Idler link
20 (44)X2
3.2.4
Bucket link
80 (180)
3.2.5
Pin
70 (150)
3.3.2
Arm cylinder
4.
125 (280)
1,390 (3,060)
Boom assy
Boom
3.3.3
550 (1,210)
(2pcs. for mounting bucket cylinder/2pcs. for mounting bucket)
3.3.1
1,100 (2,430)
Pin (Mounting armMounting arm cylinde

Lubricant and water (including the following :)
4.1
Hydraulic oil
4.2
Engine oil
4.3
Fuel
4.4
Water
NOTE : Numerical values marked
35 (77)X16
54 (120)X2
3.1
3.3
20,400 (44,970)
200 (440)
2.1
2.11
LC
9,880 (21,780)
Upper frame assy (including the following :)
1.1
2.
Unit : kg (lb)
195 (430)
40 (88)
440 (970)
185 (410)
11 (24)
225 (500)
19 (40)
indicate the dry weight.
1,420 (3,130)X2
540 (1,190)X2
4. TRANSPORTATION DIMENSION AND WEIGHT

4.1
OVERALL DIMENSIONS OF A COMPLETE MACHINE ON A TRAILER

[ 5.05m (16ft-7in) Boom+2.60m (8ft-6in) Arm+0.75m3 (0.9cuyd) Bucket ]
NOTE :
This illistration is for demonstration purposes only.
Always, make sure to check actual dimensions
after machine is loaded on trailer.

#

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! "!
OVERALL DIMENSIONS OF BOOM

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'((

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OVERALL DIMENSIONS OF ARM AND BUCKET

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OVERALL DIMENSIONS OF ARM

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OVERALL DIMENSIONS OF BUCKET

*
+ (

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Hoe bucket
H

L
5
5. SPECIFICATIONS AND PERFORMANCE
SPEED AND CLIMBING CAPABILITY

DESCRIPTION
SPECIFICATIONS
Swing speed
Travel speed (1-speed/2-speed)
Gradeability
11 rpm
km/h
(mile/h)
3.5 / 5.0 (2.2 / 3.1)

70 (35)
%(degree)
ENGINE
Enging model
ISUZU AA-4BG1 TC
Water-cooled, 4-cycle direct injection type engine
with turbo charger & inter cooler
Type
Number of cylinders - Bore X Stroke
4 - 105mm X 125mm (4.13in X 4.92in)
Total displacement
4,329cc (264cuin)
Rated output / Rotation speed
91.9kW (125PS) / 2,200rpm
Maximum torque / Rotation speed
42.5kgfm (308lbfft) / 1,800rpm
Starter
24V/ 4.5kW
Alternator
24V / 40A
HYDRAULIC COMPONENTS
Hydraulic pump
Variable displacement axial piston + gear pump
Hydraulic motor (swing)
Axial piston motor
Hydraulic motor (travel)
2-speed axial piston motor
Control valve
6-spool control valve
Cylinder
(Boom, Arm, Bucket)
Double action cylinder
Oil cooler
Air -cooled type

Unit : kg (lb)
WEIGHT
Fully equipped weight
E200SR
Shoe
600mm Shoe
E200SR (
(600mm
2.6m Arm )
2.6m Arm )
19,900 (43,870)
Upper structure
9,880 (21,780)
Lower machinery
7,130 (15,720)
Attachment
(Boom + Arm + Bucket)
2,890 (6,370)
LC
20,400 (44,970)
E200SRLC
Shoe
(800mm
3.0m Arm )
22,000 (48,500)
10,500 (23,150)
7,630 (16,820)
8,200 (18,100)
3,300 (7,280)
6. TYPE OF CRAWLER

!"" #
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NOTE :
Use grouser shoes on rough ground (areas covered with rocks and gravel). If you drive or excavate with
other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly (link, roller, etc.)
damage.
7. TYPE OF BUCKET
,

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+ * ,
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8. COMBINATIONS OF ATTACHMENT
% 3# '

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NOTE :
Standard combination
General operation : Excavation or loading of sand, gravel, and clay
Light operation : Mainly loading or loose gravel (e.g., cultivation or loading of sand or gravel)
Prohibited combination : There are problems from the view points of strength and stability.
Use the attachments recommended by the Manufacturer. Reinforcement of arm allows to use it as
nibbler and breaker.
The trouble due to the use in the condition Use not allowed described in the above table is not included in our responsibility
When bucket marked by has been attached or nibbler has been attached on long arm, the specified
stability may not be obtained. So attach add-on type counterweight (1,000kg : 2,200lb) in as required.
If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage to
the arm and bucket may occur.
9. ENGINE SPECIFICATION
9.1 SPECIFICATIONS
E200SR(LC)
Model
Engine model
ISUZU AA-4BG1 TC
Diesel, 4-cycle water-cooled, in-line,
direct injection, turbo charged & inter cooled
Type
Number of cylinder X
Bore X Stroke
Total displacement
mm (in)
4 X 105 X 125 (4.13 X 4.92)
cc (cuin)
4,329 (264)
Compression ratio
18.0
Rated out put

Maximum
torque
PS (kW) at rpm
125 (91.9) at 2,200
kgfm (lbfft) at rpm
42.5 (308) at 1,800
High idling
rpm
2,420 30
Low idling
rpm
1,000 25
kgf/cm2 (psi)
185 (2,630)
Injection valve
opening pressure
Thermostat action
Start/Full open
82 / 95 (180 / 203)
C (F)
Firing order
Compression
pressure
Lubrication
oil pressure
1-3-4-2
kgf/cm2 (psi)
31 (440)
kgf/cm2 (psi) at rpm

9 before top dead point
Fuel injection timing
Valve clearance
Intake valve
Exhaust valve
Starter capacity
Valve clearance
Open
Close
0.4mm (0.016")
in cold condition
0.4mm (0.016")
in cold condition
19 before
top dead point
47 after
bottom dead point
57 before
bottom dead point
15 after
top dead point
V X kW
24 X 4.5
VXA
24 X 40
Engine oil quantity
l (gal)
550 (21.7") suction type 8 fans, V-belt drive,

pulley ratio Crank / Fan= 1.01
Full level 13 (3.4)
Low level sensor actuation 11 (2.9)
Dry weight
kg (lb)
370 (820)
Fuel consumption ratio
g/PSh
174 10
Thermostat action
Start/Full open
Cooling fan drive method
Allowable inclination
Dimension (L X W X H)
Rotating direction
Front / Rear and Right / Left : 35

mm (in)
894 X 746 X 861 (35.2 X 29.4 X 33.9)

Counterclockwise seeing from flywheel side
10
9.2 ENGINE CHARACTERISTIC CURVE (ISUZU AA-4GB1 TC)

Condition to be measured : With fan, generator and
without air cleaner and muffler
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11 1
E200SR
SECTION 3
ATTACHMENT DIMENSIONS
TABLE OF CONTENTS
1. BOOM
1.1 Boom dimensional drawing ................................................................................................... 1
1.2 Boom maintenance standard ................................................................................................ 2
2. ARM
2.1 Arm dimensional drawing ...................................................................................................... 4
2.2 Arm maintenance standard .................................................................................................... 5
3. BUCKET
3.1 Bucket dimensional drawing .................................................................................................
3.2 Bucket dimensional table ......................................................................................................
3.3 Detail dimensional drawing of lug section .............................................................................
3.4 Detail dimensional drawing of boss section ...........................................................................
7
7
8
9
1. BOOM
1.1 BOOM DIMENSIONAL DRAWING
SECTION B-B
Fig. 1-1 Boom dimensional drawing
Table 1-1
5.05M (16ft-7in) BOOM

Code
NAME
A Boom length
B Boom foot width
C Boom end inner width
D Boom end outer width
E Height of boom cylinder rod pin
F Height of arm cylinder (head side) pin
G Distance between pins of boss
H Distance between pins of bracket
I
Arm cylinder (head side) inner width
J Outer width of bracket on the boom cylinder
d1 Boom foot pin dia.
d2 Boom cylinder (rod side) pin dia.
d3 Pin dia. of boom end.
d4 Arm cylinder (head side) pin dia.
1
Unit : mm (ft-in)
DIMENSION
5,050 (167 )
612 (24.1 )
287 (11.3 )
421 (16.6 )
1,023 (34 )
1,132 (39 )
R 2,344.5 (78 )
R 2,435 (712 )
122 (4.8 )
426 (16.8 )
90 (3.54 )
85 (3.35 )
80 (3.15 )
80 (3.15 )
1.2 BOOM MAINTENANCE STANDARD

(1) Clearance of pin and bushing
Fig. 1-2 Clearance of pin and bushing
Table 1-2
Code
Item
Boom foot
B
C
D
Boom cylinder
(Head side)
Boom cylinder
(Rod side)
Arm cylinder
(Head side)
Standard value
Unit : mm (in)
Clearance
Standard Repairable Service Remedy

limit
value
level
+0.224
(+0.0088)
+0.053
(+0.0021)
Pin dia. Bushing ID

Pin dia. tolerance tolerance
+0.204
fl90
(+0.0080)
(3.5433) +0.020 +0.073
(+0.0008) (+0.0029)
-0.020
(-0.0008) +0.210
(+0.0083)
fl85
+0.057
(3.34645)
(+0.0022)
+0.230 More than

2.5
(+0.0091) 2.0
+0.037
(0.1)
(0.08)
(+0.0015)
-0.050 +0.180
fl80 (-0.0020) (+0.0071)
(3.1496) -0.110 +0.100
(-0.0043) (+0.0039)
+0.290
(+0.0114)
+0.150
(+0.0059)
Replace
bushing
or pin
(2) Clearance in thrust direction
SECTION C-C
SECTION A-A
SECTION D-D
SECTION B-B
Fig. 1-3 Clearance in thrust direction
Table 1-3
Shim adjusting clearance
Basic size
(Total of both sides)
SecItem
tion
Sym- Size Standard Repairable Service
value
level
limit
bol
Boom
612 (24.1) 0.5 (0.02)
A-A Boom foot
L1
Upper frame
614 (24.2) or less
2.0
2.5
(0.08)
(0.10)
Boom
cylinder
105
(4.13)
0.6~1.0
B-B Boom cylinder
L2
(0.02~0.04)
(Head side)
Upper frame
107 (4.21)
Boom cylinder
C-C Boom cylinder
(Rod side)
Boom
Arm cylinder
D-D (Head side)
Arm cylinder
Arm
L3
Unit : mm (in)
Length under
pin neck
Remedy
No. Length
1
768
(30.2)
217
(8.54)
105 (4.13) 0.6~2.0

3.0
L3 426 (16.8) (0.02~0.08) (0.12)
4.0
(0.16)
690
(27.2)
120 (4.72) 0.6~1.0

2.0
(0.08)
(0.02~0.04)
122 (4.8)
2.5
(0.10)
249
(9.8)
L4
Shim
adjustment
2. ARM
2.1-1 ARM DIMENSIONAL DRAWING
E
F
G
D
R
C
D1
D2
d5
d3
N
d1
d2
VEIW I
SECTION A-A
D4
d4
M
SECTION B-B
Fig. 2-1 Arm dimensional drawing

Table 2-1

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6 ! 3/75
87! /65
83! / !5
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0 6 64
2 1/!5
1 /15
1! 2/5
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2 /15
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12 5
122 /15
! / 35
832 /!5
862 /615
832 /!5
832 /!5
832 /!5
2.2 ARM MAINTENANCE STANDARD

(1) Clearance of pin and bushing

Table 2-3
Standard value
Code
Item
Unit : mm (ft-in)
Clearance
Standard Repairable Service Remedy
limit
value
level
+0.286
(+0.0113)
+0.173
(+0.0068)
Pin dia. Bushing ID

Pin dia. tolerance tolerance
+0.226
(+0.0089)
Arm point
-0.020 +0.153
80 (-0.0008) (+0.0060)
(3.1496) -0.060 +0.231
(-0.0024)
Bucket link
(+0.0091)
+0.161
(Bucket connection)
(+0.0063)
+0.291
(+0.0115)
+0.181
(+0.0071)
+0.240
(+0.0094)
+0.174
(+0.0069)
+0.300
(+0.0118)
+0.174
(+0.0069)
Idler link
70
(Arm connection) (2.7559)
Bucket link
(Idler link connection)
Bucket cylinder
(Rod side)
+0.000
+0.287
(+0.0000)
(+0.0113)
-0.060
+0.155
(-0.0024) +0.227 (+0.0061)
(+0.0089)
+0.155 +0.287
(+0.0061) (+0.0113)
+0.155
(+0.0061)
+0.020
+0.250
(+0.0008)
(+0.0098)
-0.020 +0.230 +0.130
(-0.0008) (+0.0091)
(+0.0051)
+0.150
+0.030
+0.260
80 (+0.0012) (+0.0059) (+0.0102)
+0.120
(3.1496) -0.030
(-0.0012)
(+0.0047)
Bucket cylinder
(Head side)
Arm cylinder
(Rod side)
-0.050
(-0.0020)
-0.110
(-0.0043)
+0.180
(+0.0071)
+0.100
(+0.0039)
+0.290
(+0.0114)
+0.150
(+0.0059)
Arm foot
+0.020
(+0.0008)
-0.020
(-0.0008)
+0.244
(+0.0096)
+0.174
(+0.0069)
+0.264
(+0.0104)
+0.154
(+0.0061)
2.0
(0.08)
2.5
(0.1)
Replace
bushing
or pin
(2) Clearance in thrust direction
SECTION F-F
SECTION A-A
SECTION C-C
SECTION E-E
SECTION B-B
SECTION D-D,D-D
SECTION G-G

Table 2-4

6 $
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78
7
7
3. BUCKET
3.1 BUCKET DIMENSIONAL DRAWING
(1) Hoe bucket
Fig. 3-1 Hoe bucket dimensional drawing

Table 3-1
No.
A
B
C
D
E
F
No.
NAME
Distance between pin and bracket
Distance between bucket pin and tooth end
Inner width of bucket top end
Inner width of lug
Inner width of bracket
Outer width of side cutter
G
H
I
I0
d1
d2
3.2 BUCKET DIMENSIONAL TABLE

Table 3-2
Unit : mm (ft-in)
Hoe bucket
Type
[STD]
Capacity
A
B
C
D
E
F
G
H
I
I0
d1
d2
0.75m3 (0.98cuyd)
445 (17.5 )
R1,440 (49 )
964 (38 )
399 (15.7 )
327 (12.9 )
1,122 (38 )
826 (32.5 )
1,020 (34 )
214 (8.43 )
213.5 (8.41 )
95 (3.74 )
80 (3.15 )
0.63m3 (0.82cuyd)
830 (32.7 )
989 (389 )
693 (27.3 )
887 (34.9 )
180.5 (7.11 )
180.5 (7.11 )
NAME
Outer width of bucket bottom
Bucket outer width of front side
Pitch between teeth
Pitch between teeth
Outer dia. of bushing
Pin dia.
3.3 DETAIL DIMENSIONAL DRAWING OF LUG SECTION
VIEW II
Boss X
Boss Y
DETAIL I
Fig. 3-2 Dimension of lug section

Table 3-3
Bushing length
Hole dia.
Spring pin dia.
Boss outer dia.
Screw dia.
Boss width.
Boss outer dia.
Boss width.
Screw hole P.C.D
Capacity
of bucket
m3 (cuyd)
Lug plate thickness
Type of
bucket
Pin hole dia.
Unit : mm (ft-in)
[STD]
67 95 13 180
25 170 36 140
0.75
(0.98) 80 25
Hoe bucket
M16
(3.15) (0.984) (2.64) (3.74) (0.512) (7.09)
(0.984) (6.69) (1.42) (5.51)
0.63 (0.82)
3.4 DETAIL DIMENSIONAL DRAWING OF BOSS SECTION
5 (0.2 )
15 (0.59 )
DETAIL K
E
F
Fig. 3-3 Dimension of boss section
Table 3-4
Type of
bucket
Capacity
of bucket A
m3 (cuyd)
Unit : mm (ft-in)
E
[STD] 114.3 84 105.5 111.5 27

42
17
13
3.0
0.75 (0.98) (4.50) (3.31) (4.15) (4.39) (1.06) (1.65) (0.669) (0.512) (0.118)
Hoe bucket
0.63 (0.82)
23
38
(0.91) (1.50)
10
E200SR
SECTION 11
TOOLS
TABLE OF CONTENTS
1.TIGHTENING TORQUES FOR CAPSCREWS AND NUTS ......................................... 1
2. SCREW SIZE ............................................................................................................ 2
3. TIGHTENING TORQUES FOR NUTS AND SLEEVES .............................................. 3
4. PLUG ......................................................................................................................... 4
5. SPECIAL SPANNER FOR TUBE ............................................................................... 7
6. SPECIAL TOOLS ...................................................................................................... 8
7. APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND ..... 10
8. SUCTION STOPPER ................................................................................................ 11
9. COUNTER WEIGHT LIFTING JIG ........................................................................... 12
10. UPPER FRAME LIFTING JIG ............................................................................... 13
11. ENGINE MOUNTING PEDESTAL .......................................................................... 14
12. TRACK SPRING SET JIG ..................................................................................... 14
1. TIGHTENING TORQUES FOR CAPSCREWS AND NUTS

Tables 1-1 and 1-2 indicate tightening torques
applicable to cases where no special note is given.
Overtightening of bolts may result in a twist-off
and a fracture under load.
Table 1-1
Tightening torque for coarse thread metric screws (not plated)
Strength
4.8T
grade
Use No lubrication Oil lubrication
Size
M6
P=1
M8
P=1.25
M10
P=1.5
M12
P=1.75
M14
P=2
M16
P=2
M18
P=2.5
M20
P=2.5
M22
P=2.5
M24
P=3
M27
P=3
M30
P=3.5
M33
P=3.5
M36
P=4
Table 1-2
Size
M8
Insufficient tightening may lead to a loosening or

loss of bolts. Always tighten bolts to proper
torques.
0.450.05
(3.30.4 )
1.090.11
(7.90.8)
2.20.2
(161)
3.70.4
(273)
5.90.6
(434)
9.00.9
(657)
12.41.2
(909)
17.51.7
(13012)
232
(17014)
303
(22022)
444
(32029)
606
(43043)
818
(59058)
10510
(76072)
0.380.04
(2.70.3)
0.920.09
(6.70.7)
1.830.18
(131)
3.20.3
(232)
5.00.5
(364)
7.60.7
(555)
10.51.0
(767)
14.71.4
(11010)
19.62.0
(14014)
243
(17022)
364
(26029)
505
(36036)
687
(49051)
889
(64065)
7T
10.9T
No lubrication Oil lubrication No lubrication Oil lubrication
0.980.1
(7.10.7)
2.40.2
(171)
4.70.5
(344)
8.10.8
(596)
12.81.3
(939)
19.52.0
(14014)
273
(20022)
384
(27029)
515
(37036)
657
(47051)
9610
(69072)
13113
(95094)
17618
(1300130)
22723
(1600170)
0.830.08
(6.00.6)
2.00.2
(141)
4.00.4
(293)
6.80.7
(495)
10.81.1
(788)
16.41.6
(12012)
232
(17014)
323
(23022)
434
(31029)
535
(38036)
788
(56058)
11011
(80080)
14815
(1100110)
19019
(1400140)
Tightening torques for fine threads metric screws (not plated)
Strength
4.8T
grade
Use No lubrication Oil lubrication
P=1
M10
P=1.25
M12
P=1.25
M16
P=1.5
M20
P=1.5
M24
P=2
M30
P=2
M33
P=2
M36
P=3
1.150.11
(8.30.8)
2.30.2
(171)
4.00.4
(293)
9.40.9
(687)
191.9
(14014)
323
(23022)
656
(47043)
879
(63065)
10911
(79080)
0.970.1
(7.00.7)
1.910.19
(141)
3.40.3
(252)
7.90.8
(576)
15.81.6
(11012)
273
(20022)
545
(39036)
727
(52051)
919
(66065)
unit : kgfym (lbfyft)
7T
1.770.18
(131)
4.30.4
(323)
8.50.9
(617)
14.61.5
(11011)
232
(17014)
354
(25029)
495
(35036)
687
(49051)
929
(67065)
11812
(85087)
17317
(1300120)
23524
(1700170)
31732
(2300230)
40941
(3000300)
1.50.15
(111)
3.60.4
(263)
7.20.7
(525)
12.31.2
(899)
19.51.9
(14014)
293
(21022)
414
(30029)
576
(41043)
778
(56058)
9610
(69072)
14014
(1000100)
19820
(1400140)
26627
(1900200)
34334
(2500250)
unit : kgfym (lbfyft)

10.9T
No lubrication Oil lubrication No lubrication Oil lubrication
2.50.2
(181)
4.90.5
(354)
8.70.9
(637)
202
(14014)
414
(30029)
707
(51051)
14214
(1000100)
19019
(1400140)
23823
(1700170)
1
2.10.2
(151)
4.20.4
(303)
7.30.7
(535)
17.21.7
(12012)
343
(25022)
586
(42043)
11812
(85087)
15816
(1100120)
19820
(1400140)
4.50.4
(333)
8.90.9
(647)
15.71.6
(11012)
374
(27029)
747
(54051)
12612
(91087)
25526
(1800190)
34134
(2500250)
42843
(3100310)
3.80.4
(273)
7.50.7
(545)
13.21.3
(959)
313
(22022)
626
(45043)
10510
(76072)
21221
(1500150)
28428
(2100200)
35736
(2600260)
2. SCREW SIZE
(1) Capscrew
(2) Socket bolt

d
B
B
Table 2-1
Table 2-2
Nominal
screw size
B mm
(d)
Tool
size
M6
10
Table 2-3
B mm
Nominal
screw size
B mm
Tool
size
(d)
Tool
size
1/4-20UNC
11
M6
Nominal
screw size
Unified
(screw threads)
M8
13
5/16-18UNC
13
M8
M10
17
3/8-16UNC
14
M10
M12
19
7/16-14UNC
16
M12
10
(M14)
(22)
1/2-13UNC
19
M14
12
M16
24
5/8-11UNC
24
M16
14
(M18)
(27)
3/4-10UNC
29
(M18)
14
M20
30
7/8-9UNC
33
M20
17
19
(M22)
32
1-8UNC
38
M24
M24
36
1 1/8-7UN
43
M30
22
(M27)
(41)
1 1/4-7UN
48
M36
27
M30
46
1 1/2-6UN
57
M42
32
M36
55
M48
36
M42
65
M52
36
M45
70
M48
75
M56
85
(M60)
90
M64
95
(M68)
100
M72
105
(3) Set screw
Table 2-4
Nominal
screw size
B mm
(d)
Tool
size
M2.5
1.27
1.5
M76
110
M3
M80
115
M4
M5
2.5
M6
M8
M10
M12
M16
M20
10
3.
TIGHTENING TORQUES FOR NUTS AND SLEEVES
Table 3 indicates standard tightening torques

applicable to cases where no particular note is
given.
Overtightening or undertightening of nuts and
Manufacturers name
Nippon A.M.C.
Table 3-1
Tube size
Working pressure
OD thickness
kgf / cm (psi)
mm (in)
10 1.5
(0.394 0.059)
15 2.0
(0.591 0.079)
18 2.5
300
(4270)
(0.709 0.098)
2
300
(4270)
Ihara Koatu
sleeves in flareless joint may develop oil leaks

through pipe connections.
Always tighten nuts and sleeves to proper
torques.
Opposing
flats (HEX)
Tightening torque
kgfm (lbfft)
5
(36
12
(87
19
27
1
7)
1.2
9)
32
15 1.5
(108 11)
22 3.0
(0.866 0.118)
36
22 2.2
(159 16)
28
(1.10
35
(1.38
41
28 2.8
(200 20)
55
45 4.5
(330 33)
4.0
0.157)
5.0
0.197)
Table 3-2
NUT
SLEEVE
Tube size
Parts No.
Ihara Koatu
Nippon A.M.C.
Opposing
Tube size
flats (HEX)
d
B
14
17
10
10
19
12
12
22
15
15
27
18
18
32
22
22
36
28
28
41
32
32
50
35
35
55
38
38
60
Parts No.
Ihara Koatu
Nippon A.M.C.
4.
PLUG
(1) Plug for hydraulic pipe joint

1) Cap nut (Plug for joint)
Table 4-1
Applicable
pipe
O. D : A
H1
T screw
Opposing flat
Cap nut parts No.
T screw
H1
M12 1.5
14
14
M14 1.5
17
17
10
M16 1.5
17
19
12
M18 1.5
19
22
15
M22 1.5
24
27
18
M26 1.5
27
32
22
M30 1.5
32
36
28
M36 1.5
38
41
Table 4-2
2) Plug (Plug for tube)
Applicable
pipe
O. D : A
Plug parts No.
6
8
10
12
15
18
Flareless
joint body
22
Nut
28
3) Nut
Table 4-3
HEX
Applicable
pipe
O. D : A
D screw
D screw
Opposing
flat
M12 1.5
14
M14 1.5
17
10
M16 1.5
19
12
M18 1.5
22
15
M22 1.5
27
18
M26 1.5
32
22
M30 1.5
36
28
M36 1.5
41
32
M42 1.5
50
35
M45 1.5
55
38
M48 1.5
60
Nut parts No.
(2) Plug for hydraulic equipment

1) PF(G) screw
B
Table 4-4
PF (G)
screw Plug parts No. B mm
PF 1/4
19
O ring
PF screw
O ring parts
No.
PF 3/8
22
1B
P14
PF 1/2
27
1B
P18
PF 3/4
36
1B
P24
PF 1
41
1B
P29
2) PT(R) screw
Table 4-5
PT(R)
screw
PT 1/8
B
PT(R) screw
Plug parts No. B mm

5
PT 1/4
PT 3/8
PT 1/2
10
PT 3/4
14
PT 1
17
PT 1 1/4
22
PT 1 1/2
22
(3) Plug for (F) flare hose

Table 4-6
PF(G) screw
PF(G)
screw
PF 1/4
Plug parts No. B mm

14
PF 3/8
17
PF 1/2
Opposing
PF 3/4
flat B
PF 1
22
27
36
Table 4-7
PF (G) Plug parts No. E mm F mm
screw
PF 1/4
14
19
PF(G)
screw
Opposing
flat F
Opposing
flat E
Norminal
O ring
1B P11
PF 3/8
17
22
PF 1/2
23
27
PF 3/4
27
36
PF 1
36
41
PF 1 1/4
40
50
(4) Plug for ORS joints

Male
O RING
Table 4-8
Screw size A
A
Applicable
hose
O.D
Plug parts No.
Opposing
flats(HEX)
O ring parts Norminal

No.
O ring
1-14UNS
21.7
27
1B
A16
1 3/16-12UN
27.2
36
1B
A18
1 7/16-12UN
34.0
41
1B
A21
HEX
Table 4-9
Female
Screw size A
Applicable
tube
O.D
Plug parts No.
Opposing
flats(HEX)
A 1-14UNS
1 3/16-12UN
21.7
32
27.2
36
1 7/16-12UN
34.0
41
HEX
5.
SPECIAL SPANNER FOR TUBE

Table 5-1
Applicable tube diameter

mm (in)
Part No.
HEX
mm
Shape mm (in)
70 (2.76)
8(0.315)
15
(0.591)
16
(0.630)
27
HEX27
PART-No.
22(0.866)
40(1.57)
12.7
0.3
0.1
( 0.500
0.012
0.004
70 (2.76)
42(1.65)
18
(0.709)
19
(0.748)
32
22(0.866)
PART-No.
22(0.866)
HEX32
12.7
( 0.500
0.3
0.1
0.012
0.004
70 (2.76)
40(1.57)
22
(0.866)
19
(0.748)
30
22(0.866)
PART-No.
22(0.866)
HEX30
48 (1.89)
22
(0.866)
23
(0.906)
36
HEX36
60 (2.36)
28
(1.10)
29
(1.14)
41
HEX41
80 (3.15)
28
(1.10)
31
(1.22)
46
HEX46
80 (3.15)
32
(1.26)
33
(1.30)
50
HEX50
12.7
( 0.500
0.3
0.1
0.012
0.004
70 (2.76)
11.5 (0.453)
PART-No.
12.7
22(0.866)
0.3
0.1
( 0.500
0.012
0.004
109 (4.29)
14.5 (0.571)
PART-No.
12.7
0.3
0.1
22(0.866)
( 0.500
0.012
0.004
109 (4.29)
PART-No.
19.05
35(1.38)
0.5
0.1
( 0.750
0.020
0.004
109 (4.29)
PART-No.
19.05
35(1.38)
0.5
0.1
( 0.750
0.020
0.004
6.
SPECIAL TOOLS
Table 6-1
No.
Tools name
Allen wrench
Nominal B : 10
Tools No.
Shape
Use
Pump
suction
Commercial tool length (L1)
cut length = Required
length
40(1.57 )
10(0.39 ) = 30(1.18 )
Allen wrench
Nominal B : 14
Pump
install
Commercial tool length (L1)
cut length = Required
length
56(2.20 )
11(0.43 ) = 45(1.77 )
Cut
Swing
motor
A,B port
Spanner
Nominal S : 32
Commercial tool outer width (D)
cut length = Required length
73(2.87 )
13(0.51 )
= 65(2.56 )
Additional M10 22
threading
for M10 eye bolt
Plug
PF3/4
For
slinging
the swing
motor
O ring
PF3/4
Eye bolt
M10 18
5
M10
For
slinging
the swing
motor
&
Flare hose
Table 6-2
No.
Tools name
Tools No.
Shape
Use
M8 Eye bolt
Plug
(Nominal
tube dia. 22 )
6
Nut
(Reference)
Eye bolt
Nut
Flare hose
M8 18
Additional
threading for
M8 Eye bolt
M8 Eye bolt
Plug
7
M8 18
Additional
threading
Nominal
Flare hose
1-14UNS
Eye bolt
Plug
8
M8 Eye bolt
M8 18
Additional
threading
Nominal
Flare hose
1 3/16-12UN
Eye bolt
For slinging the

9
swing motor
Eye bolt
M8 15
&
Flare hose
M8
M8 20
Additional
threading for
M8 Eye bolt
Plug
10
PF1/2
PF1/2
O RING
For slinging the

swivel joint
7.
(1) For general use
APPLICATION OF SCREW LOCKING

COMPOUND AND SEALING COMPOUND
Table 7-1
Manufacturer
Use
Features
Locktite
Three-Bond
#242
1360K
#262
1374
Middle strength
#271
1305
High strength
#515
1215
Sealing
Application of
screw locking
compound
Sealing
compound
Low strength
(2) For specific location

Table 7-2
Use
Manufacturer
Name
Equivalent
Location
(Manufacture ; Locktite)
Three-Bond
#1901
Anti-seizure
Cylinder
#1215 gray
#5699
Swing motor
#1211 white
#5301J
Swing motor
#1303B
#211
Main pump
(Manufacturer ; Three-Bond)
Sealing
compound
&
#222
#1344N
Main pump
#277
#1307N
Pilot valve
Locktite
adhesive
(Manufacture ; Three-Bond)
Locktite
Sumitomo
Chemical
Co., Ltd.
Parmatex 98D
#1121
Hydraulic oil tank : Hose
Cyano Bond P01
Locktite #515
Three-Bond #1215
For swing bearing : Seal
Showa-Shell
petroleum
Shell Alvania EP2
New Molyknock Grease 2
Swing bearing grease

bath
10
8.
SUCTION STOPPER
8.1 COMPONENTS
No.
NAME
PARTS No.
Q TY
SUCTION STOPPER ASSY

1
ROD
NUT
COVER
O RING
1 Rod
2 Nut
3 Cover
4 O ring
8.2 DIMENSION
50
(1.97 )
Fig. 8-1
Components of suction stopper
113 (4.45 )
2
M8 NUT
9(0.354 )
M8
100 +0.5
0
(3.94 +0.0197
)
0
ROD
108
(4.25 )
COVER
fig. 8-2
Dimension of suction stopper
11
9. COUNTER WEIGHT LIFTING JIG

(1) Use these jigs for the standard counter
weight lifting tools.
QTY : R.H. and L.H. as pairs

Fig.
Counter weight lifting jig
(2) Use two commercial eye bolts M24 for the

lifting tools for the additional weight
(knapsack type).
M24
12
10.
UPPER FRAME LIFTING JIG
SECTION
AA
Q'ty : 2set
Fig. 10-1
Upper frame lifting jig

13
11. ENGINE MOUNTING PEDESTAL

Note) Hold the oil pan
section of engine.
Material : Plywood or wooden plate

Fig. 11-1
Engine stand
12. TRACK SPRING SET JIG

M30
Retainer nut
Retainer plate
Stand
Hydraulic jack
Base
Fig. 12-1
Track spring set jig

14
E200SR
SECTION 12
STANDARD MAINTENANCE TIME SCHEDULE
TABLE OF CONTENTS
1. STANDARD MAINTENANCE TIME SCHEDULE FOR EXCAVATOR ....................... 1-1
01. Attachment .........................................................................................................................
02. Cab & Guard ......................................................................................................................
03. Swing frame .......................................................................................................................
04. Travel system ....................................................................................................................
06. Electric equipment .............................................................................................................
1-1
1-2
1-3
1-6
1-7
2. STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF ENGINE ...... 2-1
1. STANDARD MAINTENANCE TIME SCHEDULE FOR EXCAVATOR

(1) Standard maintenance time schedule
1) Units of working time : 6 minutes=0.1 hour
2) Calculating method of standard maintenance
time :
Maintenance time=Working time
the number of workers
(Working time=Maintenance time
the number of workers)
3) When more than one operation is going on :
Add each standard service time.
A pure time (readily started) is given except
covers easily removed by hand. Assy works
include the following works marked with
black dot .
4)O/H : Basically the installing and removing
operations are not included.
5) Abbreviations in the table.
A/C ; Air conditioner
F hose ; Flexible hose
ASSY ; Assembly
O/H ; Over haul
ATT ; Attachment
SOL ; Solenoid
BRG ; Bearing
SW ; Switch
C/V ; Control valve
V ; Valve
Cyl ; Cylinder
E/G ; Engine
Group
Location
(2) Classification of working code

No.
01
02
03
04
06
Group
Attachment
Cab & Guard
Swing frame
Travel system
Electric
equipments
09 E/G relation
Indicates installing,
removing, replacement
and overhaul.
Indicates the installing,
removing and
replacement of single
items.
Indicates overhaul of the
single engine.
(Materials prepared by
manufacturer )
(3) Conditions for standard service time of the

engine
1) Tools designated by E/G maker are used
2) Genuine parts are changed
3) Correct working procedures are observed.
The time required for works specified
in this Chapter shows the total time
for maintenance.
Work to be
Unit
done
00 Bucket relation
Remark
Unit : Hour
E200SR
E200SRLC
2. Reference for bucket
01 Bucket ASSY
02 Bucket attaching and detaching position
Detach/attach
Preparation
1 pc.
1 pc.
03 Bucket attaching pin

04 Bucket drive pin
Detach/attach
Detach/attach
1
1
Preparation
1 pc.
O/H
1 pc.
07 Tooth
08 Side cutter
Replace
Replace
1 pc.
1 pc.
0.6
1.2
09 Bushing
Replace
1 pc.
0.6
11 Arm ASSY
Bucket cylinder attaching and detaching
12
position and piping
13 Bucket cylinder rod pin
Detach/attach
1 pc.
Preparation
Detach/attach
1 pc.
1 pc.
14 Bucket cylinder head pin

15 Bucket cylinder assy
Detach/attach
Detach/attach
1 pc.
1 pc.
Include lock pin.
0.1
0.1
16 Arm cylinder rod pin

17 Boom top pin
Detach/attach
Detach/attach
1 pc.
1 pc.
Include lock pin.

Include detent of pin.
0.1
0.1
18 Arm sling and movement
Detach/attach
1 pc.
Detach/attach
1 pc.
1.4
Preparation
Preparation
1 pc.
2 pcs.
0.1
0.2
05 Bucket sling and movement

06 Bucket (single)
01 Attachment
Remarks
10 Arm relation
32 Boom attaching and detaching position

33 Boom cylinder temporary slinging
34 Boom cylinder rod pin
0.6
0.1
Include lock pin.
0.1
0.1
0.2
Not include attaching and detaching.
2.4
3. Reference for arm
30 Boom relation
31 Boom ASSY
Include adjustment.
1.2
Include lock pin.
0.4
0.1
0.2
4. Reference for boom
Detach/attach 2 pcs. Include lock two pins.
11
0.2
Unit : Hour
Group
Location
Unit
E200SR
E200SRLC
Boom cylinder piping
Detach/attach
2 pc.
0.2
36
Arm & bucket piping
Detach/attach
1 pc.
0.2
37
Boom assy temporary slinging
Detach/attach
1 pc.
38
Boom foot pin
Detach/attach
39
Boom assy slinging
Detach/attach
1 pc.
0.2
Detach/attach
1 pc.
0.4
0.1
Include lock pin.
0.2
41
Arm cylinder piping
Detach/attach
1 pc.
42
Arm cylinder head pin
Detach/attach
43
Arm cylinder slinging
Detach/attach
1 pc.
0.1
Detach/attach
2 pcs.
0.7
50 Boom cylinder attaching and detaching

51
Boom cylinder piping
Detach/attach
52
Boom cylinder head pin
Detach/attach
2 pcs.
53
Boom cylinder slinging
Detach/attach
O/H
Replace
O/H
Replace
1 set
O/H
Replace
1 set
60 Bucket cylinder
61
Pin bushing
70 Arm cylinder
71
Pin bushing
80 Boom cylinder
81
Pin bushing
10 Cab relation
11 Cab ASSY
0.2
Include lock pin.
0.1
0.3
Include lock two pins.
0.2
0.2
3.6
Include seal.
1.2
3.6
Include seal.
1.2
7.0
Include seal.
1.2
1. Reference for cab

Detach/attach
1.2
Detach/attach
1 pc.
1 pc.
each
5 places
Seat rear cover
Detach/attach
1 pc.
0.2
15
Air-con duct
Detach/attach
0.2
16
Coupler for gauge cluster (electric)
Detach/attach
0.1
17
Cab slinging
Detach/attach
3 places
0.4
12
Front lower glass, floor mat
Detach/attach
13
Rear cover mounting bolts
14
20 Guard relation
02 Cab & Guard
Remark
35
40 Arm cylinder attaching and detaching
01 Attachment
Work to be
done
0.1
0.2
4. Reference for guard
21 Box (1-1)
Detach/attach
1 pc.
0.2
22 Box (1-2)
Detach/attach
1 pc.
0.2
23 Panel assy (2)
Detach/attach
1 pc.
0.2
24 Panel assy (3)
Detach/attach
1 pc.
0.2
25 Cover (4)
Detach/attach
1 pc.
0.1
26 Cover assy (5)
Detach/attach
1 pc.
0.1
27 Cover assy (6)
Detach/attach
1 pc.
0.2
28 Cover (7)
Detach/attach
1 pc.
0.2
29 Cover assy (8)
Detach/attach
1 pc.
0.1
30 Bonnet (9)
Detach/attach
1 pc.
0.2
31 Bonnet assy (10)
Detach/attach
1 pc.
0.3
32 Cover assy (11)
Detach/attach
1 pc.
0.3
33 Cover assy (12)
Detach/attach
1 pc.
0.1
34 Cover assy (14)
Detach/attach
1 pc.
0.1
35 Cover assy (15)
Detach/attach
1 pc.
0.2
36 Bracket (16)
Detach/attach
1 pc.
0.2
37 Bracket assy (17)
Detach/attach
1 pc
0.3
38 Cover assy (18)
Detach/attach
1 pc
0.2
39 Bracket (19)
Detach/attach
1 pc.
0.2
40 Cover assy (20)
Detach/attach
1 pc.
0.3
Detach/attach
1 pc.
0.1
42 Cover (25)
Detach/attach
1 pc.
0.1
Detach/attach
1 pc.
0.2
1-2
Unit : Hour
Work to be
done
Unit
44 Guard assy (47)
Detach/attach
1 pc.
0.2
45 Stay (49)
Detach/attach
1 pc.
0.2
46 Cover (52)
Detach/attach
1 pc.
0.1
47 Cover (53)
Detach/attach
1 pc
0.1
48 Cover (54)
Detach/attach
1 pc
0.1
49 Cover (68)
Detach/attach
1 pc
0.1
50 Cover assy (83)
Detach/attach
1 pc.
0.1
51 Cover assy (91)
Detach/attach
1 pc.
0.1
53 Cover (1)
Detach/attach
1 pc.
0.1
54 Cover (2)
Detach/attach
1 pc.
0.1
55 Cover (3)
Detach/attach
1 pc.
0.1
56 Cover (4)
Detach/attach
1 pc.
0.1
57 Cover (5)
Detach/attach
1 pc.
0.1
58 Cover (6)
Detach/attach
1 pc.
0.1
Detach/attach
1 pc.
0.6
Detach/attach
1 set
0.1
Preparation
1 pc.
0.2
02 Cab & Guard
Group
Location
52 Cover relation
E200SR
E200SRLC
5. Reference for under cover
60 Counter weight relation

61 Counter weight ASSY
Remark
11. Reference for counter weight
62
Counter weight lifting jig
63
Counter weight temporary slinging
64
Counter weight mounting bolt
Detach/attach
1 pc.
0.2
65
Counter weight slinging
Detach/attach
1 pc.
0.1
Detach/attach
1 pc.
Replace
1 pc.
00 Control relation
01 E/G control ASSY
03 Swing frame
02
Emergency stop knob (control) cable
10 Intake relation
Include adjustment.
0.2
0.2
9. Reference for Air cleaner
11 Air cleaner ASSY
Detach/attach
1 pc.
0.4
12
Hose (3)
Detach/attach
0.1
13
Hose (4)
Detach/attach
0.1
14
Element
Replace
0.1
21 Muffler ASSY
Detach/attach
1 pc.
0.4
22
U bolt
Detach/attach
1 pc.
0.1
23
Clamp ASSY
Detach/attach
1 pc.
0.1
24
Gasket
Replace
1 pc.
0.1
Detach/attach
1 pc.
5.0
Replace
1 pc.
0.2
Measuring
1 pc.
0.2
20 Exhaust relation
10. Reference for muffler
30 Radiator relation (Indlude inter cooler)

31 Radiator ASSY
12. Reference for Radiator
32
Coolant (LLC)
33
Concentration of coolant
34
A/C condenser
Detach/attach
1 pc.
0.2
35
Stay
Detach/attach
1 pc.
0.1
36
Bracket
Detach/attach
0.3
37
Sub tank
Detach/attach
1 pc.
0.1
38
Fan guard
Detach/attach
1 pc.
0.2
39
Water hose (radiator E/G)
Detach/attach
0.2
40
Radiator mounting bolts removing
Detach/attach
1 pc.
0.2
41
Under cover
Detach/attach
1 pc.
0.1
42
Hydraulic oil tank suction stopper
Attach/detach
1 pc.
0.2
Note : The numbers in the parentheses like cover(1) match the

guard numbers YB33 Upper Structure.
1-3
Unit : Hour
Group
Location
Work to be
Unit
done
E200SR
E200SRLC
43
Hydraulic oil piping coupling
Detach/attach
1 pc.
1.0
44
Hydraulic oil piping
Detach/attach
1 pc.
0.2
45
Water hose (E/G radiator)
Detach/attach
0.2
46
Radiator lifting or hoisting
Detach/attach
1 pc.
0.2
47
Radiator core
Cleaning
1 pc
1.0
48
Inter cooler air leak
Check
1 pc.
0.5
Detach/attach
1 pc
1.8
Replace
1 pc.
0.3
53 Hose (water separator side)
Detach/attach
0.1
54 Water separator
Detach/attach
1 pc.
0.1
55 Tube (tank side)
Detach/attach
0.1
57 Fuel tank installing bolts
Detach/attach
1 pc.
0.3
58 Tank slinging
Detach/attach
1 pc.
Detach/attach
1 pc.
50 Fuel relation
51 Fuel tank ASSY
52 Fuel
Other necessary works
6. Reference for fuel tank
60 Hydraulic oil tank relation

61 Hydraulic oil tank ASSY
03 Swing frame
Remark
0.3
Removing and installing guard
0.4
Removing and installing battery
0.2
7. Reference for hydraulic oil tank

Detach/attach
1 pc.
3.0
Detach/attach
1 pc.
0.2
Replace
1 pc.
0.5
65
Cover
66
Hydraulic oil
68
Pilot drain hose
Detach/attach
1 pc.
0.2
69
Pump suction hose
Detach/attach
0.5
70
Mounting bolt
Detach/attach
1 pc.
0.2
71
Hydraulic oil tank slinging
Detach/attach
1 pc.
0.3
72
Return filter
Replace
0.2
73
Suction filter
Cleaning
0.2
80 Pump relation
81 Pump ASSY
After removing counter weight

Detach/attach
1 pc.
2.3
82
Hydraulic oil tank cover
Detach/attach
1 pc.
0.3
83
Strainer & stopper
Detach/attach
1 pc.
0.3
84
Piping
Detach/attach
1 set
0.8
85
Guard
Detach/attach
2 pcs
0.4
86
Pump slinging
Detach/attach
1 pc.
0.4
87
Cleaning
Cleaning
1 pc.
0.1
88
Vent air
Adjust
1 pc.
0.1
O/H
1 pc.
Detach/attach
1 set
Detach/attach
1 pc.
2.7
89 Pump ASSY
90 Swing motor unit relation
91 Swing motor ASSY
3.0
Counter weight
0.6
19. Reference for swing motor unit
92
Piping
Detach/attach
1 set
1.0
93
Drain hose clamp
Detach/attach
0.3
94
Mounting bolt
Detach/attach
1 pc.
0.7
95
Unit slinging
Detach/attach
1 pc.
0.5
96
Cleaning and sealant
Cleaning
1 set
0.2
97
Swing motor
O/H
1 pc.
3.6
98
Swing reduction gear
O/H
1 pc.
4.2
1 4
Unit : Hour
Group
Location
Work to be
Unit
done
100 Swivel joint relation

101 Swivel joint ASSY
E200SR
E200SRLC
20. Reference for swivel joint

Detach/attach
2.6
102
Piping (Top part only)
Detach/attach
1 set
0.5
103
Whirl stop bolt
Detach/attach
0.2
104
Cover
Detach/attach
0.4
105
Joint & elbow
Detach/attach
1 set
0.4
106
Mounting bolt
Detach/attach
1 set
0.4
107
Swivel joint slinging
Detach/attach
0.4
108
Cleaning
Cleaning
1 set
O/H
1 set
3.6
Detach/attach
1 set
Lower piping
0.6
Detach/attach
1 pc.
1.5
Preparation
1 pc.
0.5
109 Swivel joint

120 Main control valve
121 Main control valve ASSY
03 Swing frame
Remark
0.3
16. Reference for control valve
122
Attach tag to port name of pipe
123
Piping
Detach/attach
1 set
0.8
124
Bracket mounting bolt
Detach/attach
1 pc.
0.1
125
Valve slinging
Detach/attach
1 pc.
0.1
O/H
1 set
Detach/attach
1 set
126 Main control valve ASSY

5.0
Guard
0.7
130 Valve relation

131 Solenoid valve ASSY
Detach/attach
1.0
Preparation
1 set
0.2
Piping
Detach/attach
1 set
0.5
Mounting bolt
Detach/attach
1 set
0.3
Detach/attach
1 pc.
132
Attach tag to port name of pipe
133
134
140 Engine (E/G) mounting relation

141 Engine ASSY
13. Reference for engine

After removing pump & radiator
1.6
142
Harness connector & grounding & cable connection
Detach/attach
1 pc.
0.2
143
Fuel hose
Detach/attach
1 pc.
0.1
144
Others
Detach/attach
1 set
0.4
145
Mounting bolt
Detach/attach
1 pc.
0.4
146
Engine slinging
Detach/attach
1 set
0.2
147
Cleaning
Cleaning
1 pc.
O/H
1 set
Reference for engine
Detach/attach
1 set
0.7
Detach/attach
1 set
Removing and installing counter weight
0.6
Detach/attach
1 set
Removing and installing pump
2.3
Detach/attach
1 set
Removing and installing air cleaner
0.4
Detach/attach
1 set
Removing and installing muffler
0.4
Detach/attach
1 set
Removing and installing radiator
5.0
148 Engine
1 5
0.2
Unit : Hour
Group
Work to be
Unit
done
Location
150 Upper frame

Detach/attach
1 pc.
After removing swivel joint
1.3
152
Mounting bolt
Detach/attach
1 set
0.4
153
Upper frame slinging
Detach/attach
1 pc.
0.4
154
Cleaning
Cleaning
1 pc.
0.3
155
Sealant
Apply
1 pc.
0.2
Detach/attach
1 set
Cab
1.2
Detach/attach
1 set
Guard
0.7
Detach/attach
1 set
Counter weight
0.6
Detach/attach
1 set
Boom
1.4
Detach/attach
03
Swing frame
E200SR
E200SRLC
21. Reference for upper frame
151 Upper frame ASSY
00 Travel relation
2. Reference for crawler
02
Track link attaching and detaching position
03
Master pin
Detach/attach
04
Track link extending and winding
Detach/attach
One
side
One
side
One
side
One
side
Replace
1 pc.
01 Track link ASSY
Preparation
05 Shoe plate
10 Upper roller relation
11 Upper roller ASSY
Detach/attach
O/H
20 Lower roller relation

21 Lower roller ASSY
Include adjustment of tension.
1.5
0.1
0.5
0.5
0.4
3. Reference for upper roller
12 Upper roller
After removing track link
0.2
1.0
4. Reference for lower roller

Detach/attach
0.2
O/H
1.5
31 Front idler ASSY
Detach/attach
32 Front idler ASSY slinging
Detach/attach
O/H
One
side
One
side
One
side
One
side
One
side
One
side
Replace
One
side
51 Travel motor ASSY
Detach/attach
52
Motor cover
Detach/attach
53
Hydraulic piping
Detach/attach
54
Motor mounting bolt
Detach/attach
55
Motor slinging
Detach/attach
22 Lower roller
30 Front idler relation
33 Front idler ASSY
5. Reference for front idler
Detaching
34 Idler ASSY
O/H
35 Idler adjuster ASSY
O/H
36
Grease cylinder
0.6
0.3
0.3
1.0
Replace spring
2.4
0.6
04
Travel system
Remark
40 Sprocket
6. Reference for sprocket
41 Sprocket
50 Travel motor relation
0.6
7. Reference for travel motor
57 Travel motor
O/H
58 Travel reduction gear
O/H
One
side
One
side
One
side
One
side
One
side
One
side
One
side
One
side
Detach/attach
1 pc.
Include bonnet assy removing and

installing.
0.6
O/H
1 pc.
Refer to Upper structure on page 1-5
3.6
56 Motor cleaning
Cleaning
1.7
0.1
0.9
0.5
0.1
0.1
3.6
3.6
60 Swivel joint relation

61 Pipe on swivel joint travel side
62 Swivel joint
16
Unit : Hour
04 Travel system
Group
Location
Work to be
Unit
done
70 Swing bearing
Remark
E200SR
E200SRLC
8. Refer for Swing bearing
71 Swing bearing ASSY
Detach/attach
1pc.
72 Swing bearing mounting bolt
Detach/attach
1pc.
0.5
73 Swing bearing slinging
Detach/attach
1pc.
0.3
C-1 Controller (KPSS)
Replace
0.2
C-2 Gauge cluster

C-4 Air conditioner Amplifier
Replace
0.2
Replace
0.2
C-5 Air conditioner switch (panel)
Replace
0.2
C-6 Power window controller (OPT)
Replace
0.2
D-1 Diode
Replace
0.2
D-2 Diode
Replace
0.2
D-3 Diode
Replace
0.2
D-4 Diode
Replace
0.2
D-5 Diode
Replace
0.2
D-6 Diode
Replace
0.2
E-1 Fuse box
Replace
E-2 Alternator
Replace
1.0
E-3 Hour meter
Replace
0.2
E-4 Horn (low)
Replace
0.2
E-5 Horn (high)
Replace
0.2
E-6 Cigar lighter
Replace
0.2
E-7 Tuner AM & FM(OPT)
Replace
0.2
E-7 Tuner AM(OPT)
Replace
0.2
E-8 Speaker left (OPT)
Replace
0.2
E-9 Speaker right
Replace
E-10 Receiver dryer
Replace
Include gas sealing.
0.3
E-11 Air compressor
Replace
Include counter weight removing and

installing.
0.5
L-1 Boom work light left
Replace
Bulb
0.2
L-2 Work light right
Replace
0.2
L-3 Room light
Replace
0.2
L-4 CAB work light
Replace
0.2
L-5 CAB work light (OPT)
Replace
0.2
M-1 Starter motor
Replace
M-2 Governor motor
Replace
M-3 Wiper motor (Non rise up)
Replace
0.2
M-4 Washer motor
Replace
0.2
M-5 Cable assy (P/W motor OPT)
Replace
0.5
M-6 Power window lock motor (OPT)

M-7 Power window lock motor (OPT)
Replace
0.2
Replace
0.2
M-8 Skylight wiper motor (OPT)
Replace
0.2
After removing upper frame
0.7
Controller
Diode
06
Electric equipments
Electric equipments
Include C1 controller removing and
installing.
0.3
0.2
Light
Motor
17

installing.
installing.
1.0
0.5
Unit : Hour
Group
Location
Work to be
Unit
done
Remark
E200SR
E200SRLC
Proportional valve
Include proportional valve removing and
installing.
installing.
installing.
installing.
PSV-A Arm re-circulation confulx proportional valve

PSV-B P2 by-pass cut proportional valve
Replace
Replace
2.0
PSV-C Travel straight proportional valve
Replace
PSV-D P1 bypass cut proportional valve
Replace
R-1 Battery relay
Replace
R-3 Glow relay
Replace
R-4 Safety relay
Replace
R-5 Wiper motor relay

R-6 Washer motor relay
Replace
Replace
0.3
R-7 Horn relay
Replace
0.3
R-8 Work light relay
Replace
0.3
SE-1 Pressure sensor (low pressure ; bucket digging)
Replace
SE-2 Pressure sensor (low pressure ; bucket dump)
Replace
0.2
SE-3 Pressure sensor (low pressure ; boom up)
Replace
0.2
SE-4 Pressure sensor (low pressure ; boom down)
Replace
0.2
SE-5 Pressure sensor (low pressure ; swing)
Replace
0.2
SE-7 Pressure sensor (low pressure ; arm in)
Replace
SE-8 Pressure sensor (low pressure ; arm out)
Replace
SE-9 Pressure sensor (low pressure ; travel right)
Replace
SE-10 Pressure sensor (low pressure ; travel left)
Replace
Include removing and installing guard on

cab lower side.
cab lower side.
cab lower side.
SE-13 Engine speed sensor
Replace
Include guard removing and installing.
SE-14 Engine water temperature sensor
Replace
SE-15 Fuel sensor
Replace
SE-16 Accel potentio
Replace
0.2
SE-22 P1 pump pressure sensor
Replace
0.2
SE-23 P2 pump pressure sensor
Replace
0.2
SV-1 Swing parking SOL
Replace
SV-2 ATT boost pressure SOL
Replace
SV-3 2-speed travel SOL
Replace
SV-4 Lever lock SOL
Replace
SW-1 Key switch
Replace
0.2
SW-2 Switch
Replace
0.2
SW-3 2-speed travel switch

SW-4 Swing parking release switch
Replace
Replace
1
1
0.2
0.2
SW-5 KPSS release switch
Replace
0.2
SW-6 Engine water temperature switch
Replace
0.2
SW-7 Engine oil pressure switch

SW-8 Clogged air filter switch
Replace
Replace
1
1
0.2
0.1
SW-10 Horn switch

SW-11 Lever lock switch
Replace
Replace
1
1
0.2
0.3
SW-12 Heater switch (OPT)
Replace
0.2
SW-13 Air conditioner switch
Replace
0.2
2.0
2.0
2.0
Relay
0.2
0.2
Include guard removing and installing
Include C1 controller removing and
installing
0.4
0.3
06
Electric equipments
Sensor
cab lower side.
0.4
0.2
0.4
0.4
0.4
0.5
0.2
Include guard removing and installing.
0.3
Solenoid
installing.
installing.
installing.
installing.
2.0
2.0
2.0
2.0
Switch
18
2.
STANDARD WORKING TIME TABLE

FOR THE MAINTENANCE OF ENGINE
Introduction
This standard working time table provides time
required for maintenance (if the work is carefully
carried out) under the following condition :
Tools designated by us are used.
Genuine parts are prepared.
Correct working procedures are observed.
The engine is mounted correctly to the
machine.
1. The working hours given in this table can not
be applied because of special machine
construction.
2.
If such operations are performed, fill out reasons

in the Claim Application Sheet in detail and
submit it to us.
(Note 1) Unit of maintenance time
The maintenance time is given in
6 minutes=0.1 hour in the decimal system.
(Note 2) Applicable models :
A-4BG1T ........... SK115SRDZ, SK135SR(LC)
AA-4BG1TC ...... SK200SR(LC)
A-4BG1 ............. SK115SR
Location of work
Work
to be
done
Special equipments not listed in this table

may be used for operation.
Maintenance
time
Engine body
Location of work
0.9
Rocker arm & shaft assy
Engine cushion rubber (both sides)
Replace
0.4
Tappet
Drain plug
Replace
0.1
Detach &
attach
21.6
Including replacing of ring gear, etc.
Engine assy
Incl. overhaul of engine and cylinder body
0.2
Cylinder block drain cock assy
Replace
0.1
Detach &
attach
11.8
Incl. replacing parts (4 cycle)
Crank shaft pulley
Tappet chamber cover

Valve rocker stand
Timing gear casing cover
Replace
Crank shaft rear oil seal
Replace
Detach &
attach
Cam shaft
0.2
Air intake hose
0.8
Manifold fastening bolts

Inlet manifold
Oil pan
0.3
Exhaust manifold
Oil pan
Detach &
attach
0.9
Throttle valve assy
Incl. overhaul of oil pump
Oil pan level gauge guide tube
Cylinder head cover
Detach &
attach
2.5
Intake shutter spring

Intake shutter
Replace
0.1
0.4
Replace
0.4
Detach &
attach
1.2
Detach &
attach
11.6
Replace
0.3
Retighten
0.3
Detach &
attach
Detach &
attach
Detach &
attach
1.1
0.7
0.8
Adjust
0.5
Detach &
attach
0.5
9.6
Overhaul of cylinder head, replacement of valve guide,
etc.
21
0.1
0.5
Detach &
attach
1.8
Incl. overhaul of turbo charger
Inlet pipe assy
Detach &
attach
Detach &
attach
Detach &
attach
Exhaust pipe adapt assy
Detach &
attach
Turbo charger oil pipe (1 pc.)

Turbo charger oil pipe (2 pcs.)
Detach &
attach
Replace
Detach &
attach
Incl. overhaul of intake shutter

Turbo charger assy (If equipped)
Incl. retightening cylinder head

Cylinder head assy
5.4
Incl. overhaul of throttle valve
Cylinder head
Valve clearance
Replace
Detach &
attach
Incl. replacement of bearing and tappet
Intake, exhaust system
Retighten
Incl. overhaul of oil pump and replacement

of other parts
0.6
Incl. replacement of gear
11.4
Incl. replacement of front oil seal
Crank casing & oil pan
Detach &
attach
Incl. overhauling locker arm
Sealing plug
Piston & conn rod (2 cycle)
Maintenance
time
Valve timing mechanism

Detach &
attach
Flywheel assy
Work
to be
done
0.1
0.2
0.2
0.2
Location of work
Work
to be
done
Maintenance
time
Fuel filter assy
Lubricating system
Oil filter element cover
Detach &
attach
0.5
Oil filter assy
Replace
Detach &
attach
Replace
0.4
0.2
Fuel pipe (Filter injection)
Replace
0.4
0.6
Fuel return pipe
Replace
0.4
Fuel hose
Replace
0.2
Incl. overhaul of oil filter

Oil filter oil pipe
Oil cooler assy (incl. replacement of one hose)
Oil cooler assy (2 hoses)
Detach &
attach
Detach &
attach
Detach &
attach
Fuel filter overflow valve
0.3
Cooling system
0.7
Fan belt
Adjust
0.1
0.9
Fan belt
Replace
Detach &
attach
Detach &
attach
0.1
Oil cooler water hose
Replace
0.1
Cooling fan
Oil relief valve
Replace
0.2
Water pump assy
Injection pump assy
Adjust
Detach &
attach
0.3
3.8
Injection pump diaphragm

Fuel feed pump assy
Replace
Detach &
attach
0.3
Electrical equipments of engine
1.2
Starter assy
Generator pulley
Detach &
attach
Detach &
attach
Detach &
attach
1.0
Detach &
attach
0.6
Detach &
attach
0.8
Incl. performance test
0.3
Replace
Detach &
attach
0.6
Generator drive belt
Replace
0.1
0.1
Voltage regulator
Adjust
0.5
0.3
Incl. cleaning strainer

Injection pipe (2 pcs.)
1.2
Incl. replacement of pipe and packings
Replace
Incl. overhaul of pump and replacement of

check valve
Feed pump strainer
Water pipe and hose
Thermostat
Incl. replacement of governor, feed pump, etc.

Injection pump overflow valve
0.3
Incl. overthaul of pump
Fuel system
Injection time
Work Mainteto be
nance
done
time
Detach &
0.6
attach
Detach &
0.4
attach
Fuel pump (feed pump filter)
Incl. replacement of relief valve

Oil filter element (cartridge)
Location of work
Generator assy
1.3
0.2
Voltage regulator
Replace
0.1
Injection pipe clip
Replace
0.1
Glow plug (2 pcs.)
Replace
0.3
Nozzle leakoff pipe
Replace
0.3
Glow plug (4 pcs.)
Replace
0.4
Primimg pump
Replace
0.4
Glow plug relay
Replace
0.1
Injection pump
Vent air
0.1
Switch, unit, relay
Fuel cut solenoid
Replace
Detach &
attach
Detach &
attach
Detach &
attach
0.1
Ignition & starter switch
Replace
0.2
0.7
Oil pressure unit
Replace
0.1
1.2
Oil pressure switch
Replace
0.1
1.7
Thermo unit
Replace
0.2
Replace
Detach &
attach
0.1
Control resistor
0.2
0.2
Auto stop motor assy
Replace
Detach &
attach
Injection pipe (4 pcs.)
Nozzle holder assy (1 pc.)

Incl. replacement of nozzel (2 pcs.)
Incl. replacement of nozzel (4 pcs.)
Fuel filter (cartridge)
Fuel filter element
22
0.2
E200SR
SECTION 13
MAINTENANCE STANDARD
AND TEST PROCEDURE
TABLE OF CONTENTS
1. HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE
EXERCISED .............................................................................................................. 1
2. PERFORMANCE INSPECTION STANDARD TABLE ................................................. 2
3. MEASUREMENT OF ENGINE SPEED ...................................................................... 4
4. MEASUREMENT OF HYDRAULIC PRESSURE ........................................................ 5
5. MEASURING TRAVEL PERFORMANCES ................................................................ 9
6. MEASURING SWING PERFORMANCES ............................................................... 11
7. MEASURING ATTACHMENT OPERATING PERFORMANCES ............................... 13
8. MEASURING PERFORMANCES OF SWING BEARING ........................................ 14
9. MECHATRO CONTROLLERAADJUSTMENT ........................................................ 15
1. HOW TO USE THE MAINTENANCE STANDARD

AND CAUTIONS TO BE EXERCISED
(1) Application
1) When the machine is new ;
Confirm that the performances are in
accordance with standard specifications as
compared to the performance standards.
(3) Cautions to be Exercised at Judgment

1) Evaluation of measured data ;
Disagreement of measuring conditions,
variations of data peculiar to a new machine,
and measuring errors are to be evaluated.
Determine generally at what levels measured
values are located, instead of determining
whether or not values fall within or run out
of the reference values.
2) At specific self inspection ; (Rule by country)

Use the data for the criterion, for the purpose
of correction, adjustment and replacement.
3) When performances are deteriorated ;
Determine whether it is caused by a fault or
end of service life after long hours of
operation, to be used for safety and
economical considerations.
2) Determining correction, adjustment or

replacement ;
Machine performances deteriorate with time
as parts wear and some deteriorated
performances may be restored to new levels.
Therefore, determine correction, adjustment
or replacement, depending upon the
operating hours, kind of work and
circumstances in which the machine is
placed,
and
condition
the
machine
performances to its most desirable levels.
4) When main components are replaced ;

For
example,
use
data
to
restore
performances of pumps and others.
(2) Terminology
1) Standard values ;
Values to be used to condition or assemble a
new machine. Where special notes are not
given, these values represent standard
specifications
(machine
with
standard
attachments and standard shoes).
(4) Other Cautions to be Exercised

1) Parts liable to degrade ;
Rubber products, such as, hydraulic hoses,
O rings, and oil seals deteriorate with time ;
replace them at regular intervals or at
overhauls.
2) Repairable level;
Values at which readjustment is required. In
order to ensure performance and safety it is
strictly prohibited to use the machine over
the specified values.
2) Parts requiring regular replacement ;

Out of critical hoses that are necessary to
secure safety, we designate Very Important
Parts (V.I.P) and recommend that they
should be replaced regularly.
3) Service limit ;
This is the limit value at which
reconditioning
is
impossible
without
replacement of parts. If the value is expected
to exceed the service limit before next
inspection and correction are performed,
replace the parts immediately. The operation
over the specified values causes increase of
damage and requires the down time of
machine, and also causes safety problems.
3) Inspection and replacement of oils and greases ;

In performing maintenance, it is necessary
for the user to familiarize himself with how to
handle the machine safely, cautions to be
exercised
and
inspection/lubrication
procedures. Refer to the operators manuals
as well.
2.
PERFORMANCE INSPECTION STANDARD TABLE

Table 1 (1/2)
Note ; The mode is already S mode when power is thrown.
Unless otherwise specified, measure it on H mode.
Measuring Position
Standard
value
Position
Size
Port
Cleanliness of hydraulic oil
Hydraulic oil in tank
Hydraulic oil temperature
Tank surface
Coolant temperature
Radiator surface
Engine speed
Standard
Measuring condition
Inspection Item
Lo idle
Hi idle
Selector switch on
the gauge cluster
screen
(Injection pipe)
S mode
FC mode
Decel
Bucket
Travel
Over load relief valve pressure
High pressure circuit
Boom
RH
LH
Swing
Arm
Proportional Valve block
Main
pump
a2
a1
a2
H
R
Forward
Reverse
Forward
Reverse
LH
PF1/4 a1
a2
a2
RH
H
a2
Travel
straight valve
P1 cut valve
Arm variable
recirculation
P2 cut valve
Travel
straight valve
P1 cut valve
Arm variable
recirculation
21
22
20
23
1
5
(23)
15
(5)
1000
+25
25
LOW throttle
FULL throttle
(HI idle)
(
F)
2420
+30
30
2300
+30
30
1800
+30
30
1050
51
(725)
+50
+3
(40)
50
3
(40)
350
(4980)
+5
(70)
MR1
385
+10
(5470) (140)
5
(70)
MR1
55
(780)
35
(500)
55
(780)
35
(500)
0
0
0
0
Adjustment
Sampling
Ambient temp.
5010
(122
F14
F)
rpm not required Perform all
+15
0
(210)
+15
0
(210)
+55
+10
(780) (140)
+55
+10 kgf/cm2
(780) (140) (psi)
35
0
(500)
55
0
(780)
measurement with
the air-conditioner
OFF
.
PR1
HI
idle
RH and LH
Simultaneous
Operation or
Boom up
ATT boost
pressure SW. ON
Boom up
OR3
Boom up
OR4
Boom down
OR1
Bucket digging
OR2
OT1
OT2
OT3
OT4
OR5
Bucket dump
OR6
Swing RH
OR7
Arm in
OR8
Arm out
Simultaneous
Operation of
travel
RH and LH
Swing LH
6.9
(100)
25
(300)
25
(300)
28.6
(410)
25
(300)
425
(60360)
Class
Measuring
condition
+5
(41)
+15
(59)
20
23
Adjusting
Point
+1
21
22
Unit
50
(122)
75
(167)
405
(5760)
385
(5470)
405
(5760)
385
(5470)
350
(4980)
350
(4980)
285
(4050)
285
(4050)
385
(5470)
405
(5760)
a1
Lo
NAS 8
a1
P2 cut valve
Secondary pilot
Pressure circuit
P2
P1
P2
a1
Service diagnosis screen No.
Boost
pressure
a4
P1
Main pump
ATT
Travel
Gauge cluster
C2 Multi display
Main relief
Valve pressure
Pilot primary pressure circuit G pump
Hi
+1.5 0.5
(20)
(7)
Indicated
current value
(mA)
3505
642
642
+2 1.5
(30)
(20)
700
642
303642
Performs proportional
calculation from actual
current reading on
display No. Values
which are calculated
by converting pressure
values in the left figure
to current
values are shown.
E/G Hi, Lever on neutral
position
E/G Hi
The max. value is
displayed as the
full lever strokes
differ with types of
operations.
Table 1 (2/2)
P2 pump
proportional valve
Service diagnosis screen No.
&
Position
Gauge cluster
Multi display
P1 pump
proportional valve
Standard
Hi
Screen code value
Measuring Posision
C2
Secondary pilot pressure circuit
Inspection Item
No.24
&
No.25
Operating speed
Operating time of
cylinder
(At no load)
Swing speed
Travel speed
Amount of travel
deviation
Performance
Parking brake drift

Performance of
Swing brake
Performance of
Swing parking brake
Adjusting
Measuring
Point
condition
Indicated
6
(90)
+0.5 0.5
(7) (7)
Current value
(mA)
MIN 350
E/G Hi
Lever on
neutral
position
(psi)
No.24
30
+1.5 1.5
&
(430) (20) (20)
No.25
1-speed
2-speed
S mode
2-speed
FC mode 2-speed
Raise
Boom
Lower
In
Arm
Out
Digging
Bucket
Dumping
Variable speed
STD speed
Rubber
1-speed
Iron
Rubber
2-speed
Iron
H mode
2-speed
15Gradient
Newtral position after

180full speed swing
15Gradient
Tip of the bucket tooth
ATT amount of
drift
Unit
kgf/cm2
Inspection item
Sprocket revolution
(RH,LH)
Lo
Boom cylinder
Arm cylinder
Dozer cylinder
Amount of horizontal play at the bucket tooth
Standard value
26.629.4
39.043.2
37.841.8
29.432.6
2.73.3
3.03.6
3.13.7
2.32.9
2.93.5
1.72.3
5.05.6
20.622.8
14.115.7
0240
0
5575
0
96
3
6
5070
(1.972.76)
MAX 750
E/G Hi
Lever on
full
Unit
rpm
sec
sec/1 rev
sec/20m
mm / 20m
mm / 5min
degree
mm (in)
mm/5min
(At no load)
mm (in)
The port relief valves No.OR1OR8 on the control section are adjusted to the following
operation numbers in advance.
Bucket digging Bucket dumping Boom raise

Boom lower
Swing left
Swing right
Arm in
Arm out
LH
RH
CONTROL LEVER
3
3. MEASUREMENT OF ENGINE SPEED

3.1 MEASUREMENT OF ENGINE SPEED
(1) Warming up of engine
Start engine to raise the coolant temperature of engine
to 40to 80_. (104to 176F)
Engine coolant
The E/G coolant tem-perature gauge
temperature gauge
is used to measure. The range in white
color shows the temperature of
approx. 40to 100_ (104to 212F), so
confirm that the measured value indicates the temperature within the
range of white color.
(2) Actual measurement of engine revolution by the
screen select switch
After the engine starts, the following
items are displayed in that order each
time the screen change switch is
pressed.
z Engine
s p e e d
(At this time, each mode is
chosen and engine speed is
measured.)
z Hours after the engine oil was
replaced
(3) Engine speed measured value through service
diagnosis
1) Turn "ON" the starter switch with the buzzer stop
switch pressed.
2) A program No. and an actual engine revolution are
displayed as the No.2 Item.
3) At the "H" mode, if work mode select switch is
pressed after pressing buzzer stop switch and
returning a display screen, the engine speed in "H"
mode is displayed.
4) Press a work mode select switch in "S" and "FC" mode,
select each mode, and the engine speed in each mode is
displayed.
5) The screen advances like No.2, No.3....each time the
screen select switch is pushed.
6) The screen returns like No.40, No.39....each time the
buzzer stop switch is pressed.
7) The display does not disappear unless the starter
switch is turned to "OFF".
(4) Measuring with diesel engine speed meter
1) Install diesel engine speed meter pickup on and of
injection pipes on which the pickup can be easily
installed. (See Fig. 3.)
2) Check E/G speed shown in Table 1 in idling speed.
MONITOR
SYSTEM OK
2250RPM
256 Hr AFT
E/G OIL CH
Example of screen change
BUZZER STOP
SWITCH
(RETURNS)
SCREEN
SELECT SW
(ADVANCES)
WORK MODE
SELECT SW
Fig. 1 Gauge cluster

No.2
E/G SET
2205
MEAS
2201
No load set rpm

Actual rpm
E/G PRS.
LIVE
LIVE/DEAD indication
KPSS SW
H/S/FC indication
Fig. 2 Engine speed measuring service diagnosis
PICK UP
SPEED METER
Fig. 3 Measurement of E/G speed
4.
MEASUREMENT OF HYDRAULIC PRESSURE
4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE

(1) Hydraulic equipment
70kgf/cm2 (1000psi) pressure gauge ..... 1 unit
400500kgf/cm2 (57007100psi)
pressure gauge .............................................. 3 unit
Pressure measuring equipment and
instrument for analysis ............................... 1 set
A3
(2) Measuring cleanliness of hydraulic oil

After releasing air in the hydraulic oil
tank, open the cover and sample oil in
the hydraulic tank, and measure with
the instrument for analysis. If the
measured value is higher than the
reference value, replace the return
filter or change the hydraulic oil.
a2(a1)
Fig. 3
Gauge port on main pump
a3
4.2 PLACE TO INSTALL PRESSURE GAUGE

(1) Main circuit
Replace plugs PF1/4 of main pump gauge
ports a1,a2 with plugs for pressure
measurement, and attach pressure gauge
500kgf/cm2 (7100psi).
A3
PUMP
(2) Pilot circuit

Replace pilot gauge plug a3 with plug PF1/4
for pressure measurement, and attach
pressure gauge 70kgf/cm2 (1000psi).
a2
a1
Fig. 4
Location of plugs for pressure

mesurement
4.3 PRESSURE ADJUSTMENT POSITION

(1) Main control valve
MAIN RELIEF
VALVE
MR1
BUCKET
DUMPING
OR2
ARM IN
OR7
BOOM
UP
OR3
OPTION
OR12
View from the top of the machine
OPTION
OR11
ARM OUT
OR8
BOOM DOWN
OR4
BUCKET
DIGGING
OR1
View from the bottom of the machine

Fig.5
Relief valve position on main control valve
A3
(2) Pilot relief valve

The pilot relief valve PR1 is located on the
gear pump that is attached to the main
pump.
a3
Dr4
B3
PR1 ADJUST SCREW
FOR PILOT RELIEF
Fig.6
Pilot relif valve position
SWING LEFT
OVER LOAD RELIEF
(3) Swing over load relief

The swing motor is equipped with plugs
PA,PB for pressure measurement, but the
measurement is carried out using gauge ports
a1 and a2 . (See Fig. 4)
SWING RIGHT
OVER LOAD RELIEF
OR5
OR6
PB
PA
Fig. 7
Swing over load relief position
4.4 PROCEDURE FOR ADJUSTING RELIEF

VALVE
(1) Pilot relief valve
Adjust it with adjust screw (311).
: 24mm Tightening torque :
3.0kgfym (22 lbfyft)
: 6mm
Table 2
No. of turns of adjust screw
Pressure change
kgf/cm2(psi)
1 turn
Approx. 21 (300)
LOCK NUT HEX24
311
Fig. 8
7
Pilot relief valve
(2) 2-stage main relief valve

(Commom for travel and ATT sections)
Start from the boosting side, first. Loosen nut
(1), adjust the pressure with adjusting screw
(2) and tighten nut (1) after completion of the
adjustment on the boosting side.
Then, loosen nut (3), adjust the pressure on
the normal side with adjusting screw (4) and
tighten nut (3) after completion of the
adjustment.
2.8~3.2kgfym (20~23 lbfyft)
: 19mm Adjust screw
: 6mm
Table 3
Pressure change
kgf/cm2 (psi)
Boosting side 1 turn
Approx. 180 (2560)
Normal side 1 turn
Approx. 180 (2560)
HEX32 HEX19
1 2
4 3
HEX22
Fig. 9 Main relief valve
(Travel section, ATT common section)
(3) Over load relief valve

(Boom, bucket, arm sections)
Loosen lock nut (1) and adjust it with adjust
screw (2).
: 6mm
Table 4
Pressure change
kgf/cm2(psi)
1 turn
2
Fig. 10 Over load relief valve
(Boom, bucket, arm sections)
Approx. 180 (2560)
(4) Over load relief valve (Swing)

When the adjustment of pressure is required,
loosen lock nut (1) and adjust the pressure
with cap (2).
: 30,38mm
Tightening torque :
12kgfym (87 lbfyft)
: 12mm
Table 5
Pressure change
kgf/cm2 (psi)
1 turn
Approx. 102 (1450)
5)
1
HEX22
HEX38
1
HEX30
2
Travel over load relief valve

The adjustment is done by manufacturer
before shipment. When adjustment is
required, loosen nut (1) and adjust the
pressure with adjusting screw (2).
: 19mm
: 6mm
Fig. 11
Swing over load relief valve
Fig. 12
Travel over load relief valve
2
1
5.
MEASURING TRAVEL PERFORMANCES
5.1 TRAVEL SPEED

(1) Purposes
Measure the travel sprocket revolution and
confirm the performances between the
hydraulic pump and the travel motor of the
travel drive system.
(2) Conditions
F)
Operating oil temperature ; 4555(113131
4555
Crawler on the right and left sides are
Fig. 13 One side lifted position
tensioned evenly.
(3) Preparation
REFLECTION
Install the reflection panel with a magnet to
PANEL
the travel motor cover.
Swing the swing frame through 90as shown
in Fig.13 and make the crawler on one side
take off the ground, using the attachment.
(4) Measurement
YN-B74
Engine speed
; Hi idle
Fig. 14 Adhering position of reflection panel
2-speed travel switch ; 1-speed and 2-speed
Sprocket revolution
Table 6
Unit : rpm
Measuring points
; Right and left
Measurement
Standard
Method, example 1
;
Repairable level Service limit
item
value
Measure revolution with a stroboscope.
H1 26.629.4 20.722.9
18.8
Method, example 2
;
RH
H2
39.043.2
30.433.7
27.5
&
Measure the revolutions per minute
37.841.8 29.532.6
26.7
LH S2
visually.
FC2 29.432.6 22.925.4
20.8
5.2 DEVIATION OF TRAVEL
(1) Purpose
Measure the amount of deviation at 20m
(22yard) travel and confirm the horizontal
balance between the hydraulic pump and the
travel motor of the travel drive system.
(Approx. 1ft)
(2) Condition
3040cm
Hydraulic oil temperature ; 4555(113131
4555C
F)
RH and LH crawler are tensioned evenly.
Fig. 15 Travel position
Plain, level and solid ground
Engine speed
; Hi idle
(3) Preparation
1) Straight course more than 30m (33yard)
A
2) Travel position in which the bottom of the
20m
(22yard)
bucket is lifted by about 30cm (1ft).
(4) Measurement
1) Measure the max. deviation distance of the
Fig. 16 Measuring method
circular arc in the 20m (22yard) length,
Travel deviation
Table 7
Unit : mm/20m
excluding the preliminary run of 35m (3.3
Measuring
5.5yard).
position Standard value Repairable level Service limit
2) Operate the both travel levers at the same
A
240 (9.5 ) or less 480 (17 )
720 (24 )
time.
9
5.3 PERFORMANCES OF PARKING BRAKE

(1) Purpose
Confirm that the parking brake holds a
stopped condition of the machine in a no-load
travel position and on a 15deg. slope.
(1ft)
30cm
(2) Condition
A slope with 15deg. gradient and a stopped
condition in a no-load travel position
15deg.
Fig. 17 Parking brake operating position
(3) Preparation
Place an angle meter on the shoe plate and
confirm that it makes an angle more than
15deg..
Hang a perpendicular in parallel with the
guide frame rib on the track frame and put a
mark (matching mark) on the shoe plate.
Parking brake
Measuring
position
Table 8 Unit : mm/5 min.

Service
limit
Standard value Repairable level
1 (0.04in)
22 PIPE
(0.866 )
FORWARD
2 (0.08in)
10
90
(3.54 ) (0.394 )
40
(1.57 )
RIBA
(2) Conditions
Hydraulic oil temperature ; 45~55 C(113~131F )
Engine speed
; Hi idle
(3) Preparation
1) Place a stopper under the RH and LH travel
sprockets.
2) Stop the engine and vent pressure from the
hydraulic circuit.
3) Connect a hose with the drain port of the
travel motor and take drain in a container.
ANGLE METER
Fig. 18 Method of measurement
(4) Measurement
Five minutes after the engine stops, measure
the movement distance of the matching
mark.
5.4 DRAIN RATE OF TRAVEL MOTOR
(1) Purpose
To measure the drain rate of the travel motor
and to confirm the performances of the travel
motor.
GUIDE FRAME
130
(5.11 )
STOPPER
B
70
ROTARY DIRECTION
(2.76 )
Fig. 19 Location of stopper applied to travel sprocket
(4) Measurement ; at Travel Lock

Unless you observe the rotary force direction
at travel lock (See Fig. 19), rib A may be
broken by stopperBin some cases.
Fig. 20 Method of measuring

the drain rate of travel motor
Drain rate of
Table 9
Unit : /30sec
travel motor
1) Start the engine and relieve pressure at the

full stroke of the travel lever.
2) Measure the drain rate for 30 seconds of
relieving.
Measuring
position
Drain rate
10
Standard value Repairable level Service limit
7 (1.85 gal)
14 (3.7 gal) 21 (5.55 gal)
6. MEASURING SWING PERFORMANCES

6.1 SWING SPEED
(1) Purpose
Measure the swing time and confirm the
performances between the hydraulic pump
and the swing motor of the swing drive
system.
(2) Conditions
Hydraulic oil temperature ;4
4555(113131
F)
Plain, level, and solid ground
Engine speed
;Hi idle (H mode)
(3) Preparation
Bucket empty, arm cylinder fully retracted
(Max. reach), or arm cylinder fully extended
(Min. reach)
(4) Measurement
Swing the machine by bringing the swing
lever to its full stroke. Measure the time
required to make two turns after one turn of
preliminary run and calculate the time
required for one turn.
Fig. 21
Fig. 22
Swing speed measuring position

(at the max. reach)
Swing speed measuring position

(at the min. reach)
6.2 PERFORMANCE OF SWING BRAKE

Swing speed
Table 10
Unit : sec / rev
(1) Purpose
Measuring
Confirm the braking torque performances by
position
max.
the swing relief valve.
5.05.6
6.47.2
8.0
Swing reach
(2) Conditions
speed min.
5.05.6
6.47.2
8.0
reach
4555(113131
F)
Hydraulic oil temperature ;4555C
Engine speed
;Hi idle (H mode)
(3) Preparation
1) A height of 1.5m (5ft) at which the bottom of
the bucket matches the tip of the tooth on
condition that the bucket is empty, the arm
cylinder is most retracted and the bucket is
1.5m (5ft)
used for digging.
2) Put a matching mark on the outer circumference Fig. 23 Swing brake performance measuring position
of the swing bearing of the upper frame side
Measuring the length of the arc over the
and of the track frame side. Erect two poles
outer circumference of outer race
(flags ) at the front and back of the extended
line of the matching mark.
Matching marks
on outer race
(4) Measurement
B
1) When operating in regular swing speed, by
shifting lever to neutral position at pole
position the swing operation stops.
2) Calculate the swing drift angle by the
following equation, after the upper swing
body stops, using the amount of deflection
Matching marks on inner race
(m) of the matching marks on the swing race
and the length (m) of the circumference of the Fig. 24 Measuring position of swing brake performances
swing race :
Swing brake
Table 11
Unit : degree
Amount of deflection of
performance
Swing drift matching marks [m (ft-in)]
Measuring
angle (
)=
360
position Standard value Repairable level Service limit
Circumferential length of
85
90
Swing 180 Less than 75
swing race [m (ft-in)]
11
6.3 PERFORMANCE OF SWING PARKING BRAKE

(1) Purpose
To confirm the mechanical performances of
the swing parking brake that is fitted to the
inside of the swing motor.
(2) Conditions
On a slope with 15deg. gradient.
Stop the machine at right angles with the
slope at the height of 1.5m (5ft) at which the
bottom of the bucket matches the tip of the
tooth on condition that the bucket is empty,
the arm cylinder is most retracted and the
bucket is operated for digging.
(3) Preparation
Put the angle meter on the shoe plate and
make sure that the angle is more than
15deg..
Put a matching mark on the outer race side
and on the inner race side.
(4) Measurement
When five minutes has passed after the
engine stops, measure the length of the
movement of the matching marks.
15
Fig. 25
Swing parking brake

performance measuring position
Measuring the length of the arc over the

outer circumference of outer race
Matching marks
on outer race
C
Matching marks on inner race

Fig. 26
Measuring position
of swing brake performances
6.4 DRAIN RATE OF SWING MOTOR

Performance of swing
(1) Purpose
Table 12 Unit : mm/5 min
parking brake
Measure the drain rate of the swing motor
Measuring
position
and confirm the performances of the swing
C
0
1 (0.04in)
2 (0.08in)
motor.
(2) Conditions
4555(113131
F)
Hydraulic oil temperature;4555
C
Engine speed
;Hi idle
(3) Preparation
1) Stop the engine.
2) Release pressure from inside the hydraulic
circuit.
3) Disconnect the swing motor drain hose from
its end returning to the hydraulic oil tank
and take oil in a container.
4) Put a plug to the tank side.
(4) Measurement ; at Swing Lock
1) Start the engine and put the side faces of
bucket against the inside of the right or left
shoe plates.
2) Relieve the swing motor at full stroke of the
swing motion.
3) Receive in a container the amount of drain
Fig. 27
Drain rate of
accumulated in 30 seconds of relieving.
Table 13
Unit : /30sec
swing motor
Measuring
item
Drain rate 2.0 (0.53gal)
12
5.0 (1.3gal) 6.0 (1.6gal)
7.
MEASURING ATTACHMENT OPERATING
7.1 OPERATING TIME OF CYLINDERS

(1) Purpose
Measure the operating time of the boom, arm
and bucket and confirm the performances
between the hydraulic pump and the cylinder
of the attachment drive system.
(2) Condition
4555(113131
F)
Engine speed
;Hi idle
Operating time excluding the cushion stroke
(3) Preparation
Plain, level and solid ground and bucket is
empty
(4) Measurement 1 ; Boom up and down
With the boom operating lever at full stroke,
measure the required operating time of the
bucket between the ground surface and its
highest position.
When lowering the boom, allow the
bucket onto a soft ground or cushioning
such as rubber tires ; never hit the
bucket against concrete or other solid
material.
(1ft)
30cm
Fig. 28
Measuring position for bucket digging

and dump
Fig. 29
Measuring position for boom up

and down motions
(1ft)
30cm
Fig. 30
Measurement 2 ; Arm in and out, bucket

digging and dump
In a position in which the tooth of the bucket
rises to a level of about 30cm (1ft) above
ground, measure the full stroke operating
time required with the arm and bucket
operating levers at full stroke.
Measuring position for arm in

and out motions
Cylinder Operating time

Measuring
position
Standard
Table 14
Unit :
Repairable level Service limit
value
2.93.5
1.72.3
2.73.3
3.03.6
3.13.7
2.32.9
B
3.74.5
2.42.9
3.44.2
3.84.6
4.04.7
3.03.7
4.8
3.0
4.5
5.0
5.1
3.9
7.2 OIL TIGHTNESS OF CYLINDERS

(1) Purpose
Confirm that the cylinder oil tight by
checking the moving length of the cylinder
C
rods.
(2) Condition
A
4555(113131
F)
Falling distance D
from 1.5m(5ft)
Immediately after cylinders are replaced,
height
bleed off air from the cylinders, before
Fig. 31
checking for oil tightness.
(3) Preparation
Oil tightness of
Keep the tip of the bucket at 1.5m (5ft)
Table 15
Unit : mm/5min
cylinder
height, with the bucket empty and the arm
Measuring
position
cylinder is most retracted. (but not in stroke
A
3 (0.12in) 4.5 (0.18in) 6 (0.24in)
end.)
B
6 (0.24in)
9 (0.35in) 12 (0.47in)
(4) Measurement
C
Measure the items five minutes after the

D
96
(3.8in)
150
(5.9in)
200
(7.9in)
engine is turned off.
13
8.
MEASURING PERFORMANCES OF SWING BEARING

LOCATION OF BEARING
ATTACHING CAPSCREWS
(1) Purpose
Measure the gap between the lower frame
and the bottom face of the swing bearing and
estimate the degree of wear of the swing
bearing.
SWING BEARING
A
DIAL INDICATOR
(2) Condition
The swing bearing mounting bolts are not
loosened.
The swing bearing is lubricated well, not
making abnormal sound during turning.
LOWER FRAME
Fig. 32
(3) Preparation
1) Install a dial indicator to the magnetic base
and fix it to the lower frame.
2) Direct the upper swing body and the lower
frame toward the travel direction, bring the
probe of the dial indicator in contact with the
bottom surface of the outer race on the swing
body side and set the reading at zero.
90110
(1ft)
30cm
Fig. 33
(4) Measurement 1 (Measuring position and

)
1) Measure the travel of the outer race in the
axial direction in position[The arm at 90
110 and the crawler front lifted about
30cm (1ft)] and in position , using a dial
indicator.
2) Take measurement three times on the right
and the left respectively, and make the mean
value a measured value.
Measuring position
1.5m (5ft)
Fig. 34
Measuring position
Axial play of
swing bearing
Measuring
position
(5) Measurement 2 (Measuring position )

1) With the arm cylinder most retracted and the
bucket dump, lift the tip of the tooth of the
bucket about 10mm (0.4in) and swing the tip
of the bucket to the right and the left by man
power.
But in this case, the gap of the attachment is
included.
How to measure the axial play

of swing bearing
Table 16
Unit : mm (in)
0.81.8
2.33.3
(0.030.07) (0.090.13)
3.6
(0.14)
10mm
(0.4in)
Fig. 35 Measuring position

Right and left
movement of
Table 17
Unit : mm (in)
the tip of bucket
Measuring
position
Bucket
tiptoe
14
Standard
value
Repairable level
Service limit
60 (2.36)
120 (4.72)
180 (7.09)
9. MECHATRO CONTROLLERAADJUSTMENT
9.1 ENGINE CONTROL INPUT/OUTPUT
C-1 MECHATRO CONTROLLER
ENGINE
GOVERNOR
MOTOR
GAUGE CLUSTER
PUMP
ACCEL DIAL
STARTER SWITCH
Fig. 36
9.2 ENGINE CONTROL INSTALLATION
E/G EMERGENCY
STOP KNOB
(1.77_)
DETAIL OF
E/G STOP KNOB
Fig. 37(1/2)
15
E/G SPEED SENSOR
Tightening torque1.1kgfym (8.0 lbfyft)

Apply Locktite #262 or equivalent.
Tightening torque
ADJUST BOLT
Fasten it with the mounting plate
for the engine lifting hook
Tightening torque
Apply Locktite
#242 or equivalent.
Tightening torque
1.1kgfym (8.0 lbfyft)
GOVERNOR
MOTOR
Tightening torque
Tightening torque
Apply Locktite
#262 or equivalent.
E/G EMERGENCY
STOP CABLE
NORMAL USE
Center of crank shaft
VIEW
Fig. 37 (2/2)
16
9.3 E/G CONTROL EQUIPMENT

(1) Governor motor and C1 controller
1) By operating accel dial, the input voltage
change is sensed by CN1132 pins of C1
controller.
2) The C 1 controller computes the input
voltage, and outputs command current to
governor motor (M2), and incline governor
lever of engine to the swing angle
corresponding to accel dial set value.
3) The limit switch in governor motor is set to a
angle from motor rotation OFF to ON
position (Starting point).
REDUCTION GEAR SECTION

OIL SEAL
MOTOR SECTION
OUTPUT SHAFT
CAM
LIMIT
SWITCH
Fig. 38
(2) Speed sensor
1) Installing place
Engine flywheel housing
M161.5
Opposing flat 19
Opposing flat 17
2) Sensor attaching procedure

Apply Locktite #262 on pick-up thread
section.
Tighten thread until it contacts flywheel ring
gear, and turn it back one and half times.
After turning it back one and half, check that
the tightening torque of nut is 2.53.5kgym
(1825 lbfyft).
After installation, check that the Engine
speed meter measured value corresponds to
the engine speed in service diagnostics while
operating engine.
Output voltage at 2,420rpm 20V(AC) or more
at 1,000rpm 40V(AC) or less
Fig. 39
(3) Work mode select switch

Press work mode select switch, and the
operation signal is sent to C1 controller,
and when ever switch is pressed, work mode
changes in turn.
SIGNAL(Yellow)
GND(Black)
WORK MODE
SELECT SW
BUZZER STOP
SWITCH
(4) Buzzer stop switch

When the error is detected by self-diagnosis,
the C1 controller sends alarm by sounding
buzzer. And press buzzer stop switch to stop
buzzer sounding. Also, when engine coolant
temperature has risen or the engine oil
pressure has lowered, buzzer sounds. But in
this case the buzzer sounding does not stop.
Fig. 40
17
9.4 A
AADJUTMENT OF MECHATRO CONTROL
(1) When adjustment of mechatro control is
required;
Case
GROMMET
Aadjustment
Replace mechatronic controller.

Replace governor motor.
To be adjusted
CPU ROM DATA FAILURE
on display.
CPU ROM DATA FAILURE and
CPU MECHATRO SET ERROR
are shown by turns.
C1 MECHATRO CONTROLLER
Fig. 41
Preparation
Warm up engine.
Turn A/C switch OFF.
Turn starter switch OFF to stop engine.
Pull up the safety lock lever and pull up the
left control box upwards.
5) Pull operator seat forward fully and incline
MULTI DISPLAY
seat back forward.
6) Remove resin cover on the rear side, then
mechatro controller appears. (Remove
5
SCREEN
CHANGE SWITCH
atta-ching bolts from resin cover with driver
,).
Note : Check to be sure that the engine
emergency stop lever knob is fully
pressed down. If mechatro controller is
adjusted in the condition where the knob
is pulled out, the engine speed can not be
Fig. 42
set properly.
Table 18 (1/2)
(3) Adjustment
Procedure
Multi display
Movement of governor motor
(2)
1)
2)
3)
4)
Remove grommet on upper surface of
STOP
mechatro controller, and switch internal

adjustment JP switch from
RUN
FULL
to
TEST .
LEVER
RUN
In normal
position
TEST
During
adjustment
LEVER
GOVERNOR
MOTOR
Turn starter switch ON .
Turn the accel dial to a certain position.

MONITOR
SYSTEM OK
Stop at the position set by accel dial.
18
Table 18 (2/2)
Procedure
Keep the buzzer stop switch pressed and
when it is let free after 5 to 10 seconds,
STEP 1 is displayed on the multi display.
Then let your hand free and wait till the
display changes to STEP 2.
Multi display
Movement of governor motor

A
Self-traveled to the engine stop

position (S).
After confirming the STEP 2 display,
move to the engine room and adjust the

rod assy to its standard length
250mm(9.84in) so the clearance between
the governor lever and the engine stop set
bolt becomes0.1mm(0.004in).
Stop at the position

Tools
Spanner
13mm2pcs
Spanner
6mm
Thickness gauge
Then if the governor motor is replaced,

insert the rod assy after the STEP 2
indication.
Press the buzzer stop switch once, and wait

until the STEP 3 indication is provided.
Automatically run to the engine

available position(A).
When STEP 3 comes up, start the engine.
On that occasion, the accel dial may be in
any position.
Stop at the A position

If the buzzer stop switch is pressed once
time, STEP 4 comes up. The controller
reads revolution from the A position of
governor motor to LOW IDLE and then to
HI IDLE. (The required time is approx 3
minutes.)
Lo
A Hi
Move from A position to Lo

idling position, and self-travels
from Lo position to high idling
(Hi) position.
Wait till the indication on the multi display
changes to "FINISH" after reading is
completed.
When the indication on the display changes,
the engine revolution returns automatically
to an initial position of the accel dial.
After a while, it switches "SYSTEM OK".
Note: If "FINISH" is not indicated, it means
that the adjustment has failed. Then turn
OFF the starter switch and readjust it.
Hi
MONITOR
SYSTEM OK
19
(Approx.
5 seconds)
A Hi

.
(4) After completion of adjustment

1) Turn starter switch OFF to stop engine.
2) Return the inner adjust switch to RUN from TEST, attach the grommet, push the screen change
switch on the gauge cluster one time, and get an engine rpm indication.
3) Auto accel release switch is switched and turn the mode to HIGH IDLE after the engine starts.
4) Make sure that the engine speed is changed on multi-display by switching the mode select switch of
gauge cluster.
5) Return accel dial to low position and stop the engine. Press the auto-accel switch to actuate
auto-accel function, and start the engine.
6) Set accel dial to high idling, and check engine speed when running in auto accel position.
7) Get "MONITOR SYSTEM OK" by pushing the screen change switch on the gauge cluster two times.
8) Attach resin cover as it was, and slide operator seat backward to move the seatback backward.
Then, check connector of speaker for disconnection.
9) Turn the left control box forward, bring down the safety lock lever, and start the engine again. Then
make sure that the actual engine revolution under the service diagnosis No.2 matches the measured
value on the diesel revolution meter. This completes the operation.
(5) Releasing auto accel (For checking the High Idling)

1) Auto accel release switch position
AUTO ACCEL RELEASE SWITCH (SW-16)
GAUGE CLUSTER
Fig. 43
20
E200SR
SECTION 21
MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS
1. SUMMARY OF MECHATRO CONTROL SYSTEM
1.1 Mechatro Control System in General ..................................................................................... 1
1.2 Boom Raise Conflux ............................................................................................................. 2
1.3 Swing Cut Valve Control ....................................................................................................... 2
1.4 Arm in Recirculation & Sequence Conflux ............................................................................. 3
1.5 Arm in Anti-cavitation Control ................................................................................................ 4
1.6 Arm Out Conflux .................................................................................................................... 4
1.7 Travel Straight ...................................................................................................................... 5
1.8 Swing Priority Control ........................................................................................................... 6
1.9 Pressure Draining (Releasing) Control ................................................................................. 7
1.10 Pump Control ...................................................................................................................... 8
1.11 Standby flow Constant Control ............................................................................................ 9
1.12 FC Mode Control ............................................................................................................... 10
2. MECHATRO CONTROLLER
2.1 Summary of Mechatro Controller.......................................................................................... 11
2.2 Self Diagnosis Display Function .......................................................................................... 11
2.3 Service Diagnosis ................................................................................................................ 13
2.4 Trouble History Diagnosis .................................................................................................... 14
2.5 How to Correct the E/G Oil Supply Cumulative Time ........................................................... 14
2.6 Engine starting frequency dispay function ............................................................................ 15
2.7 Mechatro Control Equipment ............................................................................................... 17
1.
SUMMARY OF MECHATRO CONTROL SYSTEM
1.1 MECHATRO CONTROL SYSTEM IN GENERAL
System summary
: GOVERNOR MOTOR
: ENGINE SPEED SENSOR
: HIGH PRESSURE SENSOR
: LOW PRESSURE SENSOR

: ACCEL DIAL POTENTIOMETER
Furtures
Purpose
P1, P2 pump is
1
controlled by
proportional valve.
2
P1 pump is controlled by
proportional valve.
A) The power curve shall be an

ideal curve.
P2 pump is controlled by
proportional valve.
B) Supply an optimum flow for

each operation.
Part of the control

valve is
controlled by the
proportional
valve.
The travel straight valve is

controlled by proportional valve.
z Make the changeover soft.
The bypass cut valve is controlled

by proportional valve.
z Make the changeover soft.
The arm variable recirculation

valve is controlled by proportional
valve.
The swing action is controlled by
P2 bypass cut
valve(=proportional valve.)
The open and close actions of the
swing P/B are controlled by
solenoid valve.
z Control the arm speed as
The main spool is

controlled
hydraulically.
you desire.
z Make the controllability soft.
1.3 SWING CUT VALVE CONTROL
(1) Boom raise conflux

1) Start boom raise operation, and the boom raise operation pilot pressure switches boom spool and boom
conflux spool, and inputs into low pressure sensor.
2) The voltage output by low pressure sensor is input into mechatro controller, and the controller processes
the pilot signal and outputs the command corresponding to input voltage to P1,P2 pump and P2 bypass
cut valve.
3) Each proportional valve puts out the secondary pressure for the pilot proportional valve according to
command values from the mechatro controller, changes the delivery rates of the P1, P2 pump and
switches the P2 bypass cut valve.
4) A pure hydraulic command switches the boom main spool and the boom conflux valve. A mechatro
command switches the P1, P2 pumps and the P2 bypass cut valve. This causes the oil delivered by the
P1 pump to combine with that by the P2 pump at boom raise operation.
(1) Swing cut valve control

1) Start swing operation, and the swing pilot secondary pressure switches swing spool, and is input into
low pressure sensor.
2) The output voltage of the low pressure sensor is put into the mechatro controller which processes the
pilot signal. A command value is then put out to the P2 bypass cut proportional valve.
3) The P2 pump and the P2 bypass cut proportional valve put out secondary pilot pressure according to a
command value of the mechatro controller.
This changes the delivery rate of the P2 pump and switches the P2 bypass cut valve.
4) The pure hydraulic command switches the swing main spool. Then a mechatro command switches the
P2 pump and the P2 bypass cut valve.
If the amount of change is controlled, the swing motion is controlled softly.
1.2 BOOM RAISE CONFLUX
1.4 ARM IN RECIRCULATION & SEQUENCE CONFLUX
(1) Recirculation cut control

2
1) If load increases and the load pressure of the pump rises above 200kgf/cm (2840psi) during arm in
operation, the output voltage of the high pressure sensor (SE-23) is put into the mechatro controller.
The mechatro controller processes pilot signals and puts out a command current that cuts off the
variable recirculation, to the variable recirculation proportional valve.
2) The variable recirculation proportional valve puts out secondary pilot pressure according a command
current of the mechatro controller, brings back the variable recirculation valve to the recirculation cut
position and blocks the recirculation passage.
(2) Sequence conflux control
2
1) If load increases and the load pressure rises above 220kgf/cm (3130psi) during arm in operation, the
mechatro controller processes a pilot signal and puts out a command current to the travel straight
proportional valve and the P1 bypass cut proportional valve according to the secondary operating pilot
pressure.
2) The travel straight proportional valve and the P1 bypass cut proportional valve put out the secondary
pilot pressure according to a command current of the mechatro controller and switches the travel straight
valve and the P1 bypass cut valve.
3) When the travel straight valve is changed over, the parallel passage on the P1 side connects with the
parallel passage on the P2 side.
When the P1 bypass cut valve and the P2 bypass cut valve are changed over, the oil delivered by the P1
pump is combined with that by the P2 pump by arm operation.
Note: If sequence conflux control operates during slope finishing work, the oil is combined in the parallel
passage. The operability is deteriorated as the oil for the bucket operation is combined together. If a
signal is put into the low pressure sensor on the bucket dump side, the sequence conflux control does
not operate.
(3) Recirculation control
1) Start arm in operation simultaneously, and arm operation pilot secondary pressure switches arm spool,
and is input into low pressure sensor.
2) The output voltage of the low pressure sensor is put into the mechatro controller. The mechatro
controller processes the pilot signal and puts out a command current according to the input voltage to
the P2 pump proportional valve, the P2 bypass cut proportional valve and the variable recirculation
proportional valve.
3) Each proportional valve puts out secondary pilot pressure according to a command current from the
mechatro controller and switches the delivery rate of the P2 pump. At the same time it switches the P2
bypass cut valve and the variable recirculation valve of the control valve.
4) The pure hydraulic command switches the arm main spool. Then a command from the mechatro
controller switches the P2 pump, the P2 bypass cut valve and the variable recirculation valve. This
causes the returned oil of the arm cylinder rod side to be recirculated to the oil delivered by the P2 pump.
1.6 ARM OUT CONFLUX
(1) Arm in anti- cavitation control

1) If the arm in is performed, the secondary pilot pressure for arm operation switches the arm spool and is
put into the low pressure sensor.
2) An engine speed command put out from the acceleration potentiometer is put into he mechatro
controller.
3) The output voltage from the low pressure sensor is put into the mechatro controller, and processes the
pilot signal and puts out a command current according to the input voltage to the P2 pump proportional
valve and the P2 bypass cut proportional valve.
4) Also, the mechatro controller puts out a command current to the variable recirculation proportional valve
according to the input voltage from the accel potentiometer.
5) Each proportional valve puts out a secondary pilot pressure according to a command current from the
mechatro controller. This controls the variable recirculation valve to provide a spool stroke according to
the engine speed and changes the recirculation ratio. This holds down cavitation when the engine speed
is low and the delivery rate of the pumps is low.
(1) Arm out conflux

1) Start arm out operation simultaneously, and arm operation pilot pressure switches arm spool, arm conflux
spool and is input into low pressure sensor.
2) The output voltage of the low pressure sensor is put into the mechatro controller. The mechatro controller
processes pilot signals and puts out command current according to the input voltage to the P1, P2 pump
proportional valves and the P1 cut proportional valve.
mechatro controller, changes the delivery rate of the P1 and P2 pumps and switches the P1 bypass cut
valve of the control valve.
4) A pure hydraulic command switches the arm main spool. A mechatro command switches the P1, P2
pumps and the P1 bypass cut valve. This causes the oil delivered by the P1 pump to combine with the oil
delivered by the P2 pump during arm operation.
1.5 ARM IN ANTI- CAVITATION CONTROL
TRAVEL STRAIGHT
1.7
TRAVEL STRAIGHT
1) Start ATTs work operations (boom, arm, bucket, swing) in travel operation (right and left), and the pilot
pressure switches respective spools, and is input into respective low pressure sensors.
Note: Boom raise operation is explained here.
2) If mechatro controller receives the input satisfying the following combination shown in Table, the
controller determines it as travel straight, and the travel straight signal turns on.
3) After the travel straight signal has turned on, the signal is input to respective proportional valve
corresponding to the following commands.
Travel straight proportional valve command
Outputs switching command corresponding to boom raise pilot pressure
(Selection of the higher ATT pilot pressure in operation)
P1 bypass cut valve command
The P1 bypass cut valve does not operate if the boom raise operation is performed. During the arm and
swing operation, the higher of the remote control pressures is selected to put out a select pressure.
P2 bypass cut valve command
Outputs switching command corresponding to boom raise pilot pressure (Selection of the higher ATT pilot
pressures from C/V on P1 side during operation) and the pressure selected by travel right pilot pressure
as high priority.
(Reference) Operating condition where travel straight signal turns on

ATT operation
Boom
Bucket
Arm
Swing
In travel right operation(P1)
In travel left operation(P2)
(1) Swing priority control at Arm in (The forced recirculation position)

1) If swing operation is performed during arm in (or arm in is performed during swing), the secondary pilot
pressure for arm operation switches arm spool and swing spool. Respective pressure is simultaneously
put into each low-pressure sensor (SE-7, SE-5).
2) The output voltage of the low pressure sensor is put into the mechatro controller.
The mechatro controller processes pilot signals. The command currents according to the input voltage
are put out to the ,P1 pump proportional valve(PSV-P1), P2 pump proportional valve (PSV-P2), travel
straight proportional valve (PSV-C), P1 bypass cut proportional valve (PSV-D), P2 bypass cut
proportional valve (PSV-B) and the arm variable recirculation valve (PSV-A).
mechatro controller and switches the delivery rate of the P1&P2 pumps. At the same time, the pressure
moves the P1&P2 bypass cut spool to full stroke position, and switches the arm variable recirculation
valve to the forced recirculation position.
4) If arm in and swing operations are performed simultaneously, the secondary pilot pressure moves
sub-spool of arm spool and consequently passage in arm cylinder head is restricted. The arm variable
recirculation spool is shifted to forced recirculation position, the return oil from rod side is recirculated at
head side while restricton. The operation pressure of arm cylinder is risen by restriction of arm cylinder
circuit.
5) Delivery oil of P2 pump flows into swing and arm sections of P2 side, but it flows preferentially into swing
side because the operation pressure of arm cylinder is higher than swing side pressure.
6) On the other hand, as travel straight spool is shifted to travel straight position and P1 bypass cut spool is
switched, delivery oil of P1 pump flows into parallel circuit of P2 side and confluxes with swing circuit, and
swing priority is available.
7) By this operation the operating pressure of arm cylinder is risen, delivery oil of P2 pump preferentially
flows into swing side which pressure is lower than arm.
Arm working speed keeps minimum loss because recirculation oil is used to arm cylinder, and as P1
pump delivery oil confluxes with swing circuit, swing priority control is more available.
8) If arm in and swing operation are performed, energized signal from mechatro controller to swing parking
brake solenoid valve (SV-1) is cut, and swing parking brake is released.
1.8 SWING PRIORITY CONTROL
(1) Pressure draining (releasing) control

1) Simultaneously the screen select switch and the buzzer stop switch of gauge cluster are kept pressed for
more than five seconds, the mechatro controller judges it as Pressure Releasing Control.
2) If the mechatro controller judges it pressure releasing control, the mechatro controller performs the
following regardless of input signals (From operation pilot valve, accel potentiometer, etc.):
a. Puts out a minimum tilting angle command to the pump proportional valve.
b. Puts out a command current for pressure releasing control revolution to the governor motor.
c. Puts out a command current for the pressure position switch to the travel straight proportional valve.
d. Puts out a standby command current to the P1 bypass cut valve and the P2 bypass cut proportional
valve.
3) A command current from the mechatro controller causes the following to occur:
a. The pump proportional valve puts out a secondary pilot pressure to the pump to minimize the tilting
angle of the pump.
b. The governor motor controls the engine revolution to a pressure releasing control revolution.
c. The travel straight proportional valve puts out a secondary pilot pressure to switch the travel straight
valve to the pressure releasing position.
d. The P1 bypass cut valve and the P2 bypass cut proportional valve put out a secondary pilot pressure
to hold the P1 bypass cut valve and the P2 bypass cut valve in their standby position.
4) The mechatro controller senses the output voltage of the high pressure sensor of the main pump, judges
it as pump pressure and displays DRAINING HYD. PRESS or FAIL DRAIN HYD. PRESS on the
gauge cluster.
5) Since the travel straight valve is in the pressure releasing position, the oil delivered by each pump is
unloaded to the tank passage.
If the operating levers are operated and the spools switched, the pressure remaining in the actuators may
be discharged.
1.9 PRESSURE DRAINING (RELEASING) CONTROL
(1) Positive control

1) If any operation performed, the secondary pilot pressure switches the spools and is put into the low
pressure sensors.
2) The output voltage of the low pressure sensor is put into the mechatro controller which processes pilot
signals and puts out command current to the proportional valve of each pump according to the input
voltage.
3) The proportional valve of each pump puts out a secondary pilot pressure according to a command current
from the mechatro controller, switches the tilting angle of the pump and controls the delivery rate of the
pump.
4) This causes the delivery rate according to a lever stroke to be supplied to the actuator, thus an operating
speed according to a lever stroke is achieved.
(2) P-Q control
1) The output voltage of the high pressure sensor attached to each pump piping is put into the mechatro
controller, which processes pilot signals and computes command current according to input voltage (load
pressure).
2) The lower of the command current computed by positive control and the command value (1) computed by
P-Q control is selected and put out to the proportional valve of each pump as a command current.
3) The proportional valve of each pump puts out a secondary pilot pressure according to a command current
of the mechatro controller, switches the tilting angle of the pump and controls the delivery rate of the
hydraulic pressure.
4) This increases the load of the actuator, enabling the engine to keep running even if the pump is highly
loaded.
1.10 PUMP CONTROL (POSITIVE CONTROL & P_Q CONTROL)
1.11 STANDBY FLOW CONSTANT CONTROL
(1) Standby flow constant control

1) An engine rotation command put out of the accel potentiometer is put into the mechatro controller.
2) The mechatro controller processes pilot signals and puts out a command current to the proportional valve of
each pump so as to make the delivery rate of the pump constant when the engine speed is below an
intermediate rpm between the FC mode and the Decel revolutions.
3) The proportional valve of each pump puts out a secondary pilot pressure according to a command current of
the mechatro controller, changes the tilting angle of the pump till the engine speed arrives at an intermediate
rpm between the FC mode and the Decel revolutions.
4) If the engine speed increases an intermediate rpm between the FC mode and the Decel revolutions, command
current from the mechatro controller become constant, with the result that the delivery rate of each pump rises
linearly as the engine speed increases.
5) The result is that the motion of the lever at the start of each operation becomes the same as that when a
standby flow is available. Also, if the engine revolution is increased, the operating feeling according to each
revolution is available.
10
(1) FC mode control

1) If the FC mode is selected by the work mode selector switch on the gauge cluster, FC mode signal is put
into the mechatro controller.
2) Upon receipt of the FC mode signal, the mechatro controller;
a. Judges it as FC mode.
b. Puts out a FC mode rpm command to the governor motor.
3) The governor motor controls the engine speed to a level that matches a command current from the
mechatro controller. During operation it puts out, to each proportional valve, a command current in the FC
mode according to the input voltage from the low pressure sensor.
(2) Peculiar control of proportional valve at FC mode
1) If arm in action is performed at FC mode, the secondary pilot pressure for arm in operation switches the
arm spool and is put into the lower pressure sensor.
2) The output voltage of the low pressure sensor is put into the mechatro controller. The mechatro controller
processes pilot signals and puts out command current according to the input voltage to the P2 pump
proportional valve and the P2 bypass cut proportional valve.
3) In that case, a peculiar control command current at the FC mode is put out to the variable recirculation
proportional valve. (the recirculation ratio higher than normal recirculation operation)
4) This combines the speed drop of the ATTs as the engine speed decreases with the fine arm operation at
the FC mode, in order to improve the delicate controllability of the entire working.
1.12 FC MODE CONTROL
2. MECHATRO CONTROLLER
2.1 SUMMARY OF MECHATRO CONTROLLER
Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster. However, the
mechatro display and the cumulative engine oil lubrication time may be changed over if the screen change
switch is pressed.
RIGHT HAND
OPERATOR
CONTROL LEVER
CIGARETTE LIGHTER
PLUG
(Opt.switch)
The functions displayed on the multidisplay are classified roughly into the following 7 types.
* 1. CPU error display............................................. Display the error of the mechatro controller, etc.
* 2. Self-diagnosis display ...................................... Displays the failure of the I/O system of the mechatro controller such
as the low and high pressure sensors, governor motor, proportional
valve, solenoid valve, etc. (31 items)
3. Service diagnosis display................................. Displays the information output by the mechatro controller such as the
pressure sensor detection, proportional valve, solenoid valve, etc.
(23 items)
4. Trouble history display ................................... Stores and displays the contents of the troubles detected through the
mechatro self diagnosis.
5. Mechatro A adjustment display........................ Displays it by procedure during the mechatro A adjustment.
6. E/G oil supply cumulative (integrated) time ... Displays the E/G oil supply cumulative time and E/G speed (rpm) list.
7. Warning displays ........................................... When the machine is normal after self-diagnosis ( ) but the actual
operation fails, the occurence of any of the following items is indicated
every time.
NO.1
MAIN CONT. P/N
STARTER CHG
PROGRAM VER
VER 3.00
AUTO IDLE STOP

SELECT SWITCH
When the number of starting up of

starter reaches set value, and each
time the starter key is truned on, this
No.1 display is always flashed for 10
seconds.
Note 1. The buzzer sounds on display
No. 2,3,5,6,7,32 and 33.
Note 2. The buzzer does not stop by
the buzzer stop switch,
exept No.7.
ACCEL DIAL
STARTER SWITCH
FUSE BOX
SWING PARKING BRAKE RELEASE SWITCH

KPSS WORK MODE RELEASE SWITCH
The work mode selector switch contains the following functions.

- Display item roll forwarded in trouble history operation
- Time display roll forwarded when correcting E/G oil
supply cumulative time
- Number of engine starting up is increased.
SCREEN SELECT
SWITCH
MULTI DISPLAY LCD
Buzzer stop switch contains the following functions.

- Stops the warning sounding
- Display item rollbacked in service diagnosis operation
- Display item rollbacked in trouble history operation
- Time display rollbacked when correcting E/G oil supply
cumulative time
- Number of engine starting up is decreased.
2.2 SELF DIAGNOSIS DISPLAY FUNCTION

(1) Summary
It performs self diagnosis of control inputs and outputs of pressure sensors and proportional valves
while the machine is in operation. Errors coming out of the self diagnosis are displayed on the multi
display of the gauge cluster. Regarding the connector numbers and the pin numbers, refer to the C-1
Mechatro Controller which described later. Wire numbers and colors may be confirmed on the
electric circuit diagram or on the harnesses.
(2) I/O configuration
INPUT
SERIAL COMMUNICATION
Pressure sensor
Proportional valve
Selector valve (SOL)
Governor motor
Gauge cluster
Control
GAUGE CLUSTER
MECHATRO
CONTROLLER
(Buzzer alarm)
Battery relay
11
No.
Indication item
No.
Contents
Mechatro controller
fail
ROM data
Mechatro set error
Boom raising
pressure sensor fail
Boom lowering
Connector
No.
-Pin No.
CN1425
Wire No.
600
Wire color
When the E/G

speed is not in
the range from
300rpm~3000rpm
CN113
CN112
CN111
CN114
CN115
CN116
CN119
CN118
CN117
CN1110
CN1111
CN1112
CN1115
CN1114
CN1113
CN1116
CN1117
CN1118
CN1121
CN1120
CN1119
CN1127
CN1126
CN1125
CN1128
CN1129
CN1130
CN123
CN122
CN121
CN124
CN125
CN126
902
502
952
903
503
953
904
504
954
905
505
955
900
500
950
901
501
951
906
506
956
908
508
958
909
509
959
941
514
964
915
515
965
WV
LgY
BR
OB
LO
BrW
OL
PW
BrY
OW
PL
Gr
RB
LgR
BrR
RL
LgW
BL
YB
V
GrL
YL
VY
BY
YR
Sb
BG
YL
VY
BrB
YR
Sb
BrL
P1 bypass cut
16 propo-valve fail
CN154
CN155
755
756
BP
PW
P2 bypass cut
17 propo-valve fail
CN156
CN157
751
752
BO
GrR
18 Travel priority
propo-valve fail
CN158
CN159
753
754
BG
GrB
Arm in
Arm out
Bucket digging
Bucket dump
10 Swing
12
Display of monitor
12
Travel right
13
Travel left
14
Pump P1
15
Pump P2
Contents
Display of monitor
Connector
No.
-Pin No.
Wire No.
Wire color
Arm variable recirculation

propo-valve fail
CN1510
CN1511
757
758
BrG
YV
Pump P1
20 Proportional valve fail
CN1517
CN1518
760
759
VR
BrG
Pump P2
Proportional valve fail
CN1519
CN1520
764
763
VW
GY
Travel two-speed
22 solenoid valve fail
CN1521
702
LgB
Swing parking
solenoid valve fail
CN1522
700
VR
ATT boost pressure

24 solenoid valve fail
CN1523
703
Governor motor
25 current fail
CN151
CN152
CN1515
CN1516
851
852
853
854
G
B
R
W
CN1134
560
CN1133
CN1132
CN1131
930
530
970
WR
P
BW
28 controller communication
CN1426
CN1427
601
602
W
B
29 Battery relay fail
CN1524
805
WG
19
21
23
Governor motor
26 starting point indexing
fail
27 Accel potentio meter
fail
Gauge clusterMechatro
failure
Draining
30 hyd. pressure
Fail drain
hyd. pressure
31
(3) Self diagnosis
No.
11
12
GAUGE CLUSTER
No.1
MAIN CONTROLLER
PROGRAM VERSION
VER
Screen select switch

Advances the screen
5.60
(As an example)
Buzzer stop switch

Returns the screen
3) By pressing the screen select switch, goes to No.2,No.3 in order.

4) By pressing the buzzer stop switch, returns from No.13, No.12 in order.
5) Turn the starter switch off, and the display also goes off.
No.
DISPLAY
REMARKS
No.
No.1
PROGRAM VER
No.2
E/G SET
MEAS
E/G PRS.
KPSS SW
No.3
H1
ACCEL
VOLT.
POS.
MOTOR STEP
POS.
P/No. indication
Version indication
2420
2420
LIVE
H
4.2V
100%
440
100%
No.4
GOVERNOR MOTOR
G1 COIL A
1.0A
G1 COIL B
1.0A
G2 LIMIT
OFF
No.5
SOL. VALVE
F2 SWING-BRAKE
COMP.
OFF
MEAS.
OFF
RELEASE SW
OFF
No load set rpm

Actual rpm
LIVE/DEAD indication
H / S / FC indication
Potentio voltage
Voltage position
No of motor steps
Step position
A phase current
B phase current
ON/OFF indication
ON/OFF indication
ON/OFF indication
ON/OFF indication
14
REMARKS
No.6
SOL. VALVE
F3 1/2-TRAVEL
COMP.
OFF
MEAS.
OFF
SWITCH OFF
No.7
SOLENOID VALVE
F1 POWER UP
COMP.
OFF
MEAS.
OFF
KEY SWITCH OFF
No.8
RELAY
I2 BAT. RELAY
COMP.
OFF
MEAS.
OFF
KEY SWITCH OFF
ON/OFF indication
ON/OFF indication
ON/OFF indication
No.9
PRESS. SENSOR
B1 BOOM RAISE
3.5V
35k
B2 BOOM LOWER
3.5V
35k
Sensor voltage /
Pressure converted value
Sensor voltage /
No.10
PRESS. SENSOR
B3 ARM OUT
3.5V 36k
B4 ARM IN
3.5V 36k
Sensor voltage /
Sensor voltage /
Service
diagnosis
MAIN
CONT. display
1 VER 5.60
DISPLAY
10
13
15
ON/OFF indication
ON/OFF indication
ON/OFF indication
20
ON/OFF indication
ON/OFF indication
ON/OFF indication
21
DISPLAY
No.11
PRESS. SENSOR
B5 BUCKET DIG
3.5V 37k
B6 BUCKET DUNP
3.5V 37k
No.12
PRESS. SENSOR
B7 SWING (R)
3.5V
38k
B8 SWING (L)
0.5V
0k
No.13
PRESS. SENSOR
B9 TRAVEL (R)
3.5V
39k
B10 TRAVEL (L)
3.5V
39k
No.14
PRESS. SENSOR
C1 PUMP P1
3.5V
350k
C2 PUMP P2
3.5V
350k
No.15
PRESS. SENSOR
B16 P1 OPT.
3.5V
36k
B17 P2 OPT.
3.5V
36k
No.20
PROPO-VALVE
D1 P1 BYPASS
COMP. 600mA 45k
MEAS. 600mA 45k
No.21
PROPO-VALVE
D2 P2 BYPASS
COMP. 600mA 45k
MEAS. 600mA 45k
REMARKS
Sensor voltage /
Sensor voltage /
Sensor voltage /
Sensor voltage /
Sensor voltage /
Sensor voltage /
Sensor voltage /
Sensor voltage /
Sensor voltage /
Sensor voltage /
Command current /
Feedback current /
No.
22
23
24
25
39
40
DISPLAY
No.22
PROPO-VALVE
D3 S-TRAVEL
COMP. 600mA
MEAS. 600mA
2.3 SERVICE DIAGNOSIS

The result of the service diagnosis at the present time is displayed in 23 categories depending on the
data output by the mechatro controller.
How to display
1) Turn the starter key switch on, keeping the buzzer stop switch depressed, and place the attachment
to the travel position while operating in the low idling condition after the engine starts.
2) The mechatro controller P/NO and the program version in the 1st item are displayed.
REMARKS
45k
45k
No.23
PROPO-VALVE
D6 A-RECIRCULAT
COMP. 600mA 45k
MEAS. 600mA 45k
Command current /
Feedback current /
Command current /
Feedback current /
No.24
PROPO-VALVE
E1 P1 PUMP
COMP.
600mA 45k
MEAS.
600mA 45k
POWER SHIFT 100mA
Command current /
Feedback current /
No.25
PROPO-VALVE
E2 P2 PUMP
COMP.
600mA 45k
MEAS.
600mA 45k
POWER SHIFT 100mA
Command current /
Feedback current /
No.39
MECHATRO ADJT.
CONT. SW
TEST
CONT. VOL
100%
PROG. SW
OFF
RUN/TEST indication
Inner trimmer
ON/OFF indication
No.40
RELEASE SW
KPSS
SWING BRAKE
ON/OFF indication
ON/OFF indication
OFF
OFF
Command current /
Feedback current /
Note:
Service diagnosis and trouble history can be displyed with the screen select switch and the buzzer stop
switch. Note that the displays do not come out in some cases if the switches are pressed too quickly.
(This is not a fault.) Give one second or more before pressing next switch.
13
(1) How to display

1) Turn the starter switch on.
2) Press the buzzer stop switch 5 times in
sequence for 10 seconds.
(Example)
CONTENTS
4) To scroll the page, use the work mode selector

switch and the buzzer stop switch.
z Press the work mode selector switch, page up.
z Press the buzzer stop switch, page down.
Note :
All the error items are stored by hour meter, when
the hour meter is differed, press the work mode
selector switch and the buzzer stop switch, and
displays all items and make sure that they are
right.
DISPLAY
No errors
2.5 HOW TO CORRECT THE E/G OIL SUPPLY CUMULATIVE TIME

(1) LCD display
LCD display
O
Normal
B-1 BOOM RAISE
past
D-1 P1 BYPASS CUT

F-3 TRAVEL 1.2-SPEED
3) Transmits the error data (one or many) and

hour meter to the gauge cluster.
z Hour meter and 3 error data are displayed
on the screen.
z If three error data or more exist, display the
data three by three in order for every 5
seconds.
(2) How to cancel the contents of the trouble

history
1) Display the trouble history mode.
2) Press the work mode selector switch and the
buzzer stop switch for 10 seconds or more
concurrently.
3) When the deletion is completed, the NO
ERROR is displayed.
4) Turn the starter switch off.
screen may be changed over.
(2) How to correct
(3) Contents of the trouble history

Display
Controller relation
A 1
A 2
MECHATRO SET ERROR
Low pressure
sensor
B
B
B
B
B
B
B
B
B
BOOM RAISING
BOOM LOWERING
ARM OUT
ARM IN
BUCKET DIGGING
BUCKET DUMP
SWING RIGHT
TRAVEL RIGHT
TRAVEL LEFT
High pressure
sensor
(Hydraulic pump)
1
2
3
4
5
6
7
9
10
C 1
C 2
Symbol
ROM DATA FAILURE
PUMP P1
PUMP P1
G
H
I
14
Display
D 1 P1 BYPASS CUT
Proportional valve D 2 P2 BYPASS CUT
D 3 TRAVEL PRIORITY
(Control valve)
D 6 ARM VARIABLE
RECIRCULATION
Portional valve
E 1
(Hydraulic pump) E 2
F 1
Solenoid valve
F 2
F 3
G 1
E/G Accessory
G 2
Potentio relation
G 3
H 1
Operating procedure
Display on multidisplay
(Normal)
B
Symbol
None
If the screen change switch is pressed, the above three
Proce-d
ure
Note :
All the stored items are erased.
It is impossible to erase data partially.
1515 RPM
Supplementary explanation :
00025H
Error detected in the
Buzzer sound
256Hr. have passed

after E/G oil was
display
5) Turn the starter switch off, and the display is

disappeared.
NO ERROR
Operating procedure
Turn the starter switch ON.

Press the gauge cluster screen change switch
once, and the E/G speed (rpm) is displayed.
is displayed.
E/G speed is displayed
MONITOR
SYSTEM OK
Press once more, and the engine oil supply E/G speed is displayed
2250RPM
cumulative time screen is displayed.
Press once
Press once more
2250RPM
100Hr AFT
E/G OIL CH
Press the screen change switch for 3 to 10

D
seconds and release the hand, it returns to

the correction mode.
PUMP P1 PORPO- VALV

PUMP P2 PORPO- VALV
POWER UP
SWING PARKING
TRAVEL 1,2-SPEED
STEP MOTOR
CURRENT-NG
STEP MOTOR S/PT.
ERROR
Press the work mode selector switch, and the

cumulative time increases. (once 1Hr)
Press the buzzer stop switch, the cumulative
time decreases. (once 1Hr)
E/G REV. SENSOR
Press the gauge cluster screen change switch
ACCELERATR
POTENTIO
once the correcting time is stored, and exits
I 1
RECEIVE ERROR
I 2
BAT. RELAY
MONITOR SYSTEM OK
MONITOR
SYSTEM OK
from the correction mode and OK symbol is
100Hr AFT
E/G OIL CH
MONITOR
SYSTEM OK
100Hr AFT
E/G OIL CH
100Hr AFT
E/G OIL CH
Cumulative time
increases
101Hr AFT
E/G OIL CH
100Hr AFT
E/G OIL CH
The cumulative
time decreases
99Hr AFT
E/G OIL CH
99Hr AFT
E/G OIL CH
Complete the
correction
(Normal)
MONITOR
SYSTEM OK
displayed to complete the correction.

Note :
Press the screen change switch once after the procedure D, and the condition is stored and the correction is
completed.
2.4 TROUBLE HISTORY DIAGNOSIS

The error item detected by the self-diagnosis is
stored in the mechatro controller as a history and
is displayed on the multidisplay.
2.6 ENGINE STARTING FREQUENCY DISPLAY FUNCTION

Since it is supposed that the engine starting frequency increases because of adoption of auto idling stop
function, the engine starting frequency can be indicated on multidisplay as a guide for maintenance of
starter motor.
(1) How to display engine-starting frequency
1) Switch auto idling stop selector switch on.
2) While keeping buzzer stop switch pressed, switch starter switch on.
(Display service diagnosis.)
3) Press screen change switch in the condition the initial main controller parts number is displayed,
and the following screen is displayed.
(Ex.)
No.1
MAIN CONT. P/N
START
12345
PROGRAM VER
VER
3.00
Starting frequency 12345 times

Replacing reminder frequency 30,000 times
(Differ with machine model)
(2) How to correct the value of engine starting frequency

Set starting frequency to zero when starter was replaced, and reset starter frequency to the value
set before replacing controller.
In the engine condition shown in Item (1)-3).
4) Press screen change switch for 5 seconds or more and release it, and "Reset" mode is displayed.
5) Press work mode selector switch, and starting frequency increases. (By 100 times. By 1000 times
while keeping it pressed)
6) Press buzzer stop switch, and starting frequency decreases. (By 100 times. By 1000 times while
keeping it pressed)
7) Press screen change switch after setting starting frequency to the desired value, and the desired
value is memorized (stored).
(3) Warning contents when starting frequency was reached to the replacing reminder frequency.
Each time starter switch is switched on; the following screen is displayed and flickers on cluster
gauge for 10 seconds.
In this case, overhaul or replace the starter.
(Ex.)
No.1
MAIN CONT. P/N
STARTER
CHG
PROGRAM VER
VER
3.00
Replacing reminder frequency 30,000 times

(Differ with machine model)
15
This page is left blank for editing convenience
16
2 1
10
16
2 1 4 2 18
Connector No.
2 1
CN11
+5V
+5V
A2
A3
+5V
10
+5V
11
A4
12
13
Boom raise pressure sensor
Engine oil pressure low LS

Without/With
IN
GND / OPEN
D8
34
B10
Air filter clogged LS

Clogged/Normal
IN
GND / OPEN
D8
B11
Double single select SW. opt
IN
GND / OPEN
D9
B12 ATT boost pressure SW.
IN
GND / OPEN
D9
B13
B14 Travel alarm SW.
IN
GND / OPEN
B15
IN
670/1140
B16 Wiper motor rise up(stop)
IN
GND / OPEN
10
B17
IN
24V / OPEN
11
B18 Connector for flat control
12
C1
Wiper motor (rise up)
OUT
C2
Wiper motor (not rise

up)
OUT
13
Boom lower pressure

sensor
Arm in pressure senor
22 18 16 12 28
CN12 CN13
CN14
2 18
2 1 11
22
2 1
14
IN
IN
Signal level
0.5~4.5V
0.5~4.5V
0.5~4.5V
CN12
16 9
CN16
Pin Port
No. name
22
CN17
12
ADJUSTMENT SWITCH
In/out
put
Specification
A12 P1 pump pressure sensor
+5V
+5V
A13 P2 pump pressure sensor
A14 Opt. 2 pressure sensor
+5V
10
+5V
11
A15 Extra press.
12
IN
IN
0.5~4.5V
G
IN
0~36V
IN
GND / OPEN
Key switch(ON) ON/OFF
IN
+24V / OPEN
16
B3
Key switch(GLOW) ON/OFF
IN
+24V / OPEN
17
B4
Travel 1.2 speed switch ON/OFF
IN
GND / OPEN
18
B5
Swing parking
Release/Normal
19
B6
KPSS rerease switch

Release/Normal
20
E1
21
E1
A5
15
+5V
16
+5V
17
A6
18
19
20
A7
21
+5V
22
+5V
23
A8
24
25
26
A9
27
+5V
28
+5V
29
A10
30
31
Bucket digging pressure

sensor
Bucket extend pressure
sensor
IN
0.5~4.5V
0.5~4.5V
22
Swing pressure sensor
Travel right pressure sensor
IN
IN
0.5~4.5V
0.5~4.5V
CN13
Travel left pressure sensor
32
A11 Accel potentio
33
+5V
B1
IN
Governor motor starting point

indexing LS starting Point/Reguler
IN
IN
IN
0.5~4.5V
0~5.0V
GND / OPEN
release
select
switch
Engine revolution sensor
IN
IN
IN
A18 Opt. 1 Pressure sensor
+5V
+5V
A19
G
A20 Angle sensor (Boom)
+5V
10
+5V
11
A21 Angle sensor (Arm)

G
13
14
A22
15
+5V
16
B7
IN
0.5~4.5V
CN15
12
+24V / OPEN
15
C4
Washer motor relay Out/Stop
OUT
GND / OPEN
16
C5
Front working light relay ON/OFF
OUT
GND / OPEN
C6
18
+5V
19
B19
20
C7
21
C8
22
C9
23
C10
IN
IN
0.5~4.5V
0.5~4.5V
IN
GND / OPEN
IN
GND / OPEN
G
IN/OUT
26 RXD1 Gauge cluster
IN/OUT
CN17
G
F1
F1
Governor motor A phase
D1
D1
D2
D2
D3
D3
10
D4
11
D4
12
+24V
13
+24V
14
+24V Battery back up
15
F2
16
F2
17
D5
D11
10
D11
11
D12
12
D12
Signal level
13
H1
14
H1
15
B26
16
C22
C15 Rotating N&B relay right
OUT
GND / OPEN
C16 Rotating N&B relay left
OUT
GND / OPEN
C17
(Swing flasher & working light unit)
OUT
GND / OPEN
C18
(Swing flasher & working light unit)
OUT
GND / OPEN
C19
C20 Travel alarm relay
OUT
GND / OPEN
C21 Power window controller OUT
GND / OPEN
B20 Auto decel releasing switch
IN
GND / OPEN
B21 Rotating N&B switch right
OUT
GND / OPEN
10
B22
11
B23 Lever lock switch
12
B24 Rotating N&B switch left
13
B25 Power window controller
17
SHG
OUT
0~800mA
18
+5V
0~800mA
19
P2 bypass cut
proportional valve B
OUT
OUT
A23
0~800mA
20
A24
0~800mA
21
OUT
A25
0~800mA
22
OUT
0~800mA
DL
OUT
0~800mA
TXD3
Arm variable recirculation OUT

proportional valve A
OUT
RXD3
0~800mA
(Swing flasher select switch)
IN
GND / OPEN
IN
GND / OPEN
OUT
GND / OPEN
IN
GND / OPEN
CN18
IN/OUT
Handy checker
IN/OUT
IN/OUT
Power supply + 24V
Governor motor B phase
P1 pump proportional
D5 valve
OUT
0 800mA
18
OUT
0 800mA
19
D6
OUT
0 800mA
20
D6
OUT
0 800mA
OUT
+24V / OPEN
OUT
+24V / OPEN
OUT
+24V / OPEN
OUT
+24V / OPEN
C11
D10
16
OUT
P1 bypass cut
proportional valve D
Travel straight
proportional valve C
D10
In/out
put
15 RXD2
OUT
SHG Shield ground
Specification
14 TXD2
SHG Shield ground
21
Over load SW ON/OFF
Extra dis-press. SW. OPT.
25 TXD1
SHG Shield ground
+24V / OPEN
OUT
17
CN16
IN
Wiper motor (rise up)
28
~12V / 12V~
3.0~20Vp-p
Wiper motor rise up(reverse)
C3
27
17/ OPEN
Fuel level thermistor

Low/Normal
14
24
B2
0.5~4.5V
CN14
0.5~4.5V
15
IN
13
0.5~4.5V
14
Arm out pressure sensor
13
IN
Signal level
A16 Alternator voltage

Auto idle stop
A17 switch
14
34
IN
D7
B9
2) List of connectors
A1
D7
26
Connector No.
Pin Port
No. name
GND / OPEN
CN15
Connector No.
IN
27
CN11
In/out
put
Signal level
Engine coolant high temp. LS

High/Normal
26
Specification
In/out
put
B8
ROM REWRITE COUPLER
Pin Port
No. name
Specification
GROMMET
FOR
ADJUST
Connector No.
Pin Port
No. name
2.7 MECHATRO CONTROL EQUIPMENT

(1) C1 Mechatro controller
1) Outside view
P2 pump proportional
valve
Travel 1,2-speed selector valve
2 speed/1 speed
22
C12
23
C13
Swing parking selector valve

,P /Release
ATT boost pressure solenoid
valve
24
C14
Battery relay Operation/Stop
25
26
Power supply (GND)
17
(2) Gauge cluster (symbol C-2)

1) General view
(3) Governor motor(Symbol M 2)

NAME PLATE
Gauge and
Display lamp
Multi display LCD
MATED SIDE
AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2
(Liquid crystal display)
Screen select
switch etc.
No.
VIEW
Item name
No.
Item name
Fuel sensor
GND
Engine water temp. sensor
Sourse (+24V)
RXD (Serial communication)
GND
TXD (Serial communication)
(None)
CONNECTION DIAGRAM
RED
BROWN
(A)
MOTOR CONNECTOR
LIMIT SWITCH CONNETOR
(B)
LIMIT SWITCH MOTION RANGE
YELLOW
ORANGE
(A)
(B)
MOTOR CONNECTOR WIRE TABLE
LIMIT SWITCH CONNECTOR WIRE TABLE
No. Lead color Connection
3) Function
It processes signals by communication between the gauge cluster and the mechatro controller, displays
them in lamps, displays them in LCDs and actuates the buzzer.
It puts out coolant temperature signals, fuel level signals and panel switch signals to the mechatro
controller through the communication port.
Screen Select SW: Scroll forward (See Page 11.), and displays of the E/G revolution and the cumulative
hours after changing engine oil (See Page 14.).
Other functions
MODE SW. : The display changes S, H, FC, S, in that order each time the switch is pressed.
After the key is turned OFF, the display begins with S.
Adjusting the engine :
Perform mechatronic adjustment in a conventional way, using the Buzzer
Stop SW.
(See the Maintenance)
Service diagnosis :
This is displayed if the key is turned ON with the Buzzer Stop SW pressed.
This is the same as before.
Trouble history :
Turn ON the key and press the Buzzer Stop SW five times
continuously in ten seconds. (See Page 14.)
Pressure release control : Press both the Screen Select SW and the Buzzer Stop SW. at the same
time and hold it for more than five seconds.
18
No. Lead color Connection

1
Brown
White
COM
Orange
Red
NO
Yellow
NC
Red
Yellow
E200SR
SECTION 22
HYDRAULIC SYSTEM
TABLE OF CONTENTS
1. SUMMARY ................................................................................................................ 1
2. HYDRAULIC CIRCUITS AND COMPONENT ............................................................. 2
2.1 STD Model ........................................................................................................................... 3
2.2 Boom & Arm Safety ............................................................................................................... 4
2.3 EXTRA .................................................................................................................................. 5
3. OPERTATION EXPLANATION OF HYDRAULIC CIRCUITS ...................................... 6

3.1 Color Coding Standard for Hydraulic Circuits ......................................................................... 6
3.2 Neutral Circuit ........................................................................................................................ 6
3.3 Travel Circuit ......................................................................................................................... 8
3.4 Bucket Circuit ..................................................................................................................... 10
3.5 Boom Circuit ....................................................................................................................... 12
3.6 Swing Circuit ....................................................................................................................... 16
3.7 Arm Circuit .......................................................................................................................... 18
3.8 Combined Circuit ................................................................................................................ 24
3.9 Pressure Draining (Releasing) Circuit ................................................................................. 28
4. PILOT PIPING ......................................................................................................... 30

5. MAIN PIPING .......................................................................................................... 40
1. SUMMARY
The hydraulic circuits are built up with the following functions and features in order to achieve easy operability,
safety, mass volume handling and low fuel consumption.
Table. 1
Swing
Attachment
Pump
Micro
Attachment
computer
Low fuel
consumption
Mass handling capability
Others
Easy operability and safety
Travel
Perfor- Device
mance
Function
Features
Travel straight
Travel 2 speed change & Auto 1st (low)
speed return
Auto parking brake
Motor overrun protection
Travel straight at combined operation

2 speed changeover of travel speed.
Boom raise conflux circuit

Arm conflux circuit
Speed up of boom raise operation

Speed up of arm operation
Auto accel
Reduce fuel consumption and noise by

lowering engine speed when control
lever is in neutral position.
Automatic braking when parking

Prevents overrunning of travel motor on
the slope.
Prevents hunting by the built in travel
Travel pilot operation
shockless mechanism
Reverse rotation protective function
Easy positioning to protect it from
(Swing shockless function)
swinging back when stops swinging.
Modification of swings on stop of swing action Prevention of swings on stop of swing
action by means of by-pass valve.
Easy operation of stable swing speed,
Swing priority circuit
arm slanted leveling, swing press
(simultaneous operation of arm
digging and swing motions)
digging
Automatic swing parking brake
Protect it from swing drift on the slope.
Hydraulic pilot control system
Delicate operability
Pilot safety lock system
Cut out of pilot circuit by safety lock lever .
Lock valve (boom / arm)
Protect boom and arm from unexpected
drop.
To prevent hydraulic oil from being
Pressurized hydraulic oil tank
contaminated and to promote self
suction ability of pump
Suction strainer
Remove dust on suction side.
Line filter ; pilot circuit
To prevent pilot operating circuit from
malfunctioning
To prevent hydraulic oil from fouling
Return circuit
To prevent hydraulic oil from being
Cooling hydraulic oil by oil cooler
deteriorated.
To release the main circuit pressure
Pressure drain (release) circuit
for piping repair work
Variable displacement pump of electric
Pump delivery rate control by a
flow control type
current command to the solenoid
proportional valve of the variable
displacement pump
2. HYDRAULIC CIRCUITS AND COMPONENTS
NAME
No.
(Note)
Maker's code
HYD. PUMP ASSY (WITH GP)
K5V80DTP100R
CONTROL VALVE (MAIN)
KMX13YC/B33046
SWING MOTOR UNIT
M2X120B-CHB-10A
TRAVEL MOTOR UNIT
M4V 150/100-RG3.5B
BOOM CYL. (RH)
115-80-1200
BOOM CYL. (LH)
115-80-1200
ARM CYL.
125-90-1290
BUCKET CYL.
105-75-1055
SWIVEL JOINT
10
PILOT VALVE (ATT)
PV48K2005
11
PILOT VALVE (TRAVEL)
07291-00000
12
INLINE FILTER
YTD9257
13
SUCTION STRAINER
SB281JOA0004A
14
SOLENOID VALVE
8KWE5G-30/G24WR-814
17
RETURN FILTER
18
AIR BREATHER
AB0210GA001A
19
BOOST CHECK VALVE
E2005A001A
20
BY-PASS CHECK VALVE
VA1000SA001A
21
SLOW RETURN CHECK VALVE
07579-00000
22
07580-00000
23
16092-00000
24
SHUTTLE VALVE
25
HYD. VALVE ASSY
26
HYD. VALVE ASSY
27
CONTROL VALVE ASSY
KADV22Y / S10102
The Part numbers and serial numbers of machine may be changed due to modifacation, so use only the
numbers for reference.
2.1 KCME STD Model
PH1
PSV1
A1 a1
MB
SE-23
P
SE-22
P
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
VA
VA
VB
SWING
PB
DB
12
M
B1
a5
PUMP ASSY
725psi
18
Pcr
P
5200~
5400psi
TRAVEL RIGHT
A3
MA
Pcr
5200~
5400psi
TRAVEL LEFT
P
MA
B DE E F F A C
Pi1
PG
PA
26
Dr3
B3
BUCKET DIS.
BUCKET DIG.
17
2
13
71psi
36psi
20
P2
MAIN CONTROL VALVE
P1
ARM OUT
19
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
PL1
PTb
4980psi
CMR2
TRAVEL
LEFT
TRAVEL
PRIORITY
CT2
PBr REV.
PAr FOR.
LCs
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
SE-3
P
14
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
TRAVEL
1/2SPEED
3 CHANGEOVER
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
PT
SWING
1 P/B
25
PB3
PA3
PA4 PB4
PB1
PA1
PA2 PB2
10
10
23
5470psi
PBb LOW.
Drc
PAb RAI.
SE-7
PLc2 P
CCb
5760psi
LCb
Drd
OUT PBa
Pisc
LCa ARM
BOOM
P
BOOM
& BUCKET
21
5760psi
5470psi
CAr
5470psi
Ab RAI.
X1
ARM
CONFLUENCE
P1
BY-PASS
P
ARM
& SWING
11
CRa
TRAVEL
PILOT VALVE P
IN PAa
IN Aa
CRb
PCb
PB1
5760psi
SOL/V BLOCK
ATT.
PILOT VALVE
Bc DIG.
Bb LOW.
PLc1
P
SE-4
SE-8
P
22
SE-5
P
RIGHT BS
BUCKET
Ac DIS.
21
LEFT AS
BOOM
CONFLUENCE
LCc
RELAY
BLOCK
FOR. PAI
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
TRAVEL
RIGHT
24
REV. PBI
SE-1
P
BOOM RAI.
BOOM LOW.
REV. AI
FOR. BI
CP2
Drb
P1
BY-PASS
CUT
4060psi
Pi2
OUT Ba
5
P
SE-9
P
SE-10
Pis
P2
BY-PASS CUT
CCa
PA1
ARM VARIABLE
RECIRCULATION
PCa
(P4)
PBo2
27
LCo2
5480psi
PAo2
5480psi
Bo2
Ao2
Po
6
5
8
3
2.2 Boom & Arm safety KCME
Boom & Arm Safety Spec.

NO.
NAME
50 HOLDING VALVE
51 HOLDING VALVE
52 HOLDING VALVE
Note:This hydraulic circuit is used to add following circuit

for completion.
REMARKS
E200SR(LC)-1S KCME
PUMP
MAIN CONTROL VALVE
P2
P1
HYD. TANK
BOOM(LH)
A B1
DR
51
5760psi
PL
C B
SW
SE-7
PLc2 P
PBb DOWN
Drc
PAb UP
Bb DOWN
PLc1
P
SE-4
Drd
OUT PBa
Pisc
LCa ARM
PL
ARM IN
IN PAa
BOOM
5760psi
IN Aa
CAr
DR
CRa
5470psi
A B1
ARM
OUT Ba
BOOM(RH)
Ab UP
A B1
DR
5760psi
PL
C B
C B
52
50
2.3 EXTRA KCME
Extra Spec.
NO.
50
51
52
53
54
50
B4
NAME
HYD.PUMP ASSY
PILOT VALVE
CONTROL VALVE
HYD. VALVE ASSY
SOLENOID VALVE
Note:This hydraulic circuit is used to add following circuit

for completion.
A4
PUMP
REMARKS
E200SR(LC)-1S KCME
MAIN CONTROL VALVE
P2
P1
HYD. TANK
EXTRA 52
TO EXTRA HYD.
VALVE
A1 B1
3300psi
(R.H)
PA1
PB1
3000psi
51
GAUGE PORT
53
T
P
54
C1
C2
P SE11
SOL/V BLOCK
LEVER
4 LOCK
3.1 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS

Blue ................................ Feed, drain, tank circuit
less than 2.5kgf/cm2 (36psi)
Green ............................. Return, make up circuit,
Negative control circuit
2.5~6kgf/cm2 (36~85psi)
Purple ............................. Secondary pilot pressure,
6~50kgf/cm2 (85~710psi)
Red ................................ Primary pilot pressure,
35~50kgf/cm2 (500~710psi)
Orange ........................... Main pump drive pressure,
50~350kgf/cm2 (710~4980psi)
When power boosting
385kgf/cm2 (5470psi)
Blue tone ........................ At valve operation
Red valve ....................... At solenoid proportional valve
(reducing) is operating.
Red solenoid .................. In active and exciting
Displaying the flow circuit and standby circuit
when operating.
Regrarding the electrical symbols in this manual,
refer to the electric circuit diagram.
3.2 NEUTRAL CIRCUIT

This section describes the following.
1) Safety lock lever and pilot circuit
2) Pump control
(1) SAFETY LOCK LEVER AND PILOT CIRCUIT
Purpose:
To protect attachment from unexpected operation
for safety.
Principle:
Cut pressure source of pilot valve for operation.
Operation:
After engine starts, push down the safety lock lever (red), and the limit switch (SW-11) is turned
on, the pilot operation circuit is changed to standby
condition.
(2) PUMP CONTROL
Type:
Variable displacement pump of electric flow control type.
Principle:
Controls the tilting angle of the pump (delivery rate)
by changing the command current I to the solenoid proportional reducing valve.
Operation:
1) Flow increase function (for example; P1 pump):
This is a positive control type that increases the
command current I of the mechatro controller. If
each attachment, the swing and travel is operated, the secondary pilot operating pressure is put
in each low pressure sensor. The output voltage
of the low pressure sensor is put into the mechatro
controller. The mechatro controller processes pilot signals and put out a current command according to the input voltage. If the secondary pressure of the solenoid proportional valve increases,
the spool (652) is pushed to the right via the pilot
piston (643) and stops where it balances the action of the pilot spring (646).
The larger diameter of the servo piston (532)
opens to the tank port, moves to the left by the
discharge pressure P1 of the smaller diameter of
it and increases the tilting angle ().
The servo piston and the sleeve are linked together by the feedback lever (611). A pin is provided at point A of the feedback lever. Since the
feedback lever turns on the fulcrum, the servo piston and the sleeve (651) move in the opposite di-
rections and stop where the spool-sleeve opening is closed.

2) Flow reducing action
If the command current I of the mechatro controller decreases, the secondary pressure of the solenoid proportional valve decreases. This causes
the pilot spring (646) to move the spool (652) to
the left. If the spool is shifted, the discharge pressure P1 is flowed to the larger diameter chamber
of the servo piston by way of the spool.
The discharge pressure P1 is there at the smaller
diameter of the servo piston at all times, but because of the difference in the area causes the
servo piston to move to the right and to decrease
the tilting angle. If the servo piston moves to the
right the same way as above, the sleeve moves
to the left by the feedback lever, till the opening of
the spool-sleeve is closed.
Regarding the detail of the pump functions, refer
to the Component system I-1.
3. OPERATON EXPLANATION OF HYDRAULIC CIRCUITS
A1 a1
MB
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
SWING
VA
PB
DB
VB
VA
12
M
a5
PUMP ASSY
725psi
18
Pcr
P
5200~
5400psi
TRAVEL RIGHT
A3
B1
Pcr
5200~
5400psi
TRAVEL LEFT
P
MA
MA
B DE E F F A C
4060psi
Pi2
Pi1
PA
PG
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
17
71psi
2
13
36psi
20
P2
MAIN CONTROL VALVE
P1
ARM OUT
19
PL1
PTb
4980psi
CMR2
CT2
LCs
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
25
PB3
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
SE-7
PLc2 P
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
PA3
PA4 PB4
PB1
PA1
PA2 PB2
10
P
BOOM
& BUCKET
21
P
ARM
& SWING
TRAVEL
PILOT VALVE P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
2
OUT Ba
X1
ARM(O125/O90/1290)
PCb
14
10
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
ATT.
PILOT VALVE
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
SE-5
P
RIGHT BS
BUCKET
Ac DIS.
21
LEFT AS
BOOM
CONFLUENCE
LCc
SE-8
P
RELAY
BLOCK
FOR. PAI
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
TRAVEL
RIGHT
SE-1
P
REV. AI
FOR. BI
CP2
Drb
PAr FOR.
24
REV. PBI
TRAVEL
LEFT
TRAVEL
PRIORITY
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
PH1
PSV1
SE-23
P
SE-22
P
5
P
SE-9
P
SE-10
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
ARM VARIABLE
RECIRCULATION
PCa
(P3)
TRAVEL
1/2SPEED
3 CHANGEOVER
6
5
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
SWING
1 P/B
PT
NEUTRAL CIRCUIT:SAFETY LOCK LEVER ON
(1) TRAVEL FORWARD PILOT SIMULTANEOUS

OPERATION CIRCUIT
Purpose:
Light operating force and shockless operation
Operation:
1) If the travel lever with damping mechanism is operated for travel right, left and forward motions,
the secondary pilot proportional pressure comes
out of the 2, 4 ports of P/V (11). The higher of the
pressures is selected, comes out of the 5, 6 ports
and acts upon the low pressure sensors (SE9),
(SE10).
2) Pilot secondary pressure flows into PAr, PAl ports
of control valve (2), acts on travel spool, and
switches main circuit.
3) The output voltage of the low pressure sensor is
put into the mechatro controller. The mechatro
controller processes signals and puts out a flow
increase current to the P1 pump proportional valve
(PSV-1) and the P2 pump proportional valve (PSV2).
(2) 2 SPEED TRAVEL SOLENOID COMMAND
CIRCUIT AND AUTO 1st SPEED RETURN
FUNCTION
Purpose:
Change travel motor speed with switch.
Principle:
If the switch is turned, an electric signal is issued.
It excites the 2-speed travel solenoid which in turn
converts the primary pilot pressure and the self
pressure to a tilting angle of the variable displacement motor.
Operation:
Press switches with rabbit and turtle marks on
travel lever grips, and the solenoid (SV-3) of proportional valve block (15) is excited and is
switched, and solenoid command is output by port
3 and sends to P port of travel motor (4), opens
oil passage to 2 speed piton, and switches it to 2
speed tiling rotation with self pressure.

Provided if the main circuit pressure exceeds
280kgf/cm2 (3980psi), the self pressure pushes
back the 2 speed select piston to select 1st speed.
(3) TRAVEL MAIN CIRCUIT
Operation:
If the travel spool is changed by the travel pilot
action, the oil discharged from port A2, A1 of the
main pump enters ports Ar, Al of the travel motor
(4) by way of the VB, VA port of C/V and the D,C
ports of the swivel joint (9) and performs the following functions in the travel motor.
(Refer to the travel motor functions.)
(4) TRAVEL MOTOR FUNCTION
Function:
1) Prevents overrunning of travel motor on down
hill slope.
2) Hydraulic motor cavitation protective check
valve.
3) Shockless relief valve and anticavitation valve
when stopping it with the force of inertia.
4) High/Low 2 step change mechanism and auto
1st speed return at high load.
5) Travel parking brake.
3.3 TRAVEL CIRCUIT

1) Travel forward pilot simultaneous operation circuit
2) 2 speed travel solenoid command circuit and
auto 1st.-speed return function
3) Travel main circuit
4) Travel motor function
A1 a1
MB
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
SWING
VA
PB
DB
VB
VA
12
M
a5
PUMP ASSY
725psi
18
Pcr
P
5200~
5400psi
TRAVEL RIGHT
A3
B1
Pcr
5200~
5400psi
TRAVEL LEFT
MA
MA
B DE E F F A C
4060psi
Pi2
Pi1
PA
PG
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
17
71psi
2
13
36psi
20
P2
MAIN CONTROL VALVE
P1
ARM OUT
19
PL1
PTb
4980psi
CMR2
CT2
LCs
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
25
PB3
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
SE-7
PLc2 P
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
PA3
PA4 PB4
PB1
PA1
PA2 PB2
10
P
BOOM
& BUCKET
21
P
ARM
& SWING
TRAVEL
PILOT VALVE P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
2
OUT Ba
X1
ARM(O125/O90/1290)
PCb
14
10
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
ATT.
PILOT VALVE
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
SE-5
P
RIGHT BS
BUCKET
Ac DIS.
21
LEFT AS
BOOM
CONFLUENCE
LCc
RELAY
BLOCK
FOR. PAI
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
TRAVEL
RIGHT
SE-8
P
SE-1
P
REV. AI
FOR. BI
CP2
Drb
PAr FOR.
24
REV. PBI
TRAVEL
LEFT
TRAVEL
PRIORITY
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
PH1
PSV1
SE-23
P
SE-22
P
5
P
SE-9
P
SE-10
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
ARM VARIABLE
RECIRCULATION
PCa
(P3)
TRAVEL
1/2SPEED
3 CHANGEOVER
6
5
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
SWING
1 P/B
PT
TRAVEL CIRCUIT:TRAVEL 2nd SPEED OPERATION
(1) BUCKET DIGGING PILOT CIRCUIT

Operation:
1) If bucket digging action is performed, the secondary pilot pressure comes out of port 1 of the right
pilot valve (10), enters port PBc of C/V (2) and
acts upon the low pressure sensor (SE-1). At the
same time, the pressure changes the bucket
spool.
put into the mechatro controller. The controller processes signals and puts out a command current
for pump flow increase to the solenoid proportional
valve (PSV-1) on the P1 pump. The relation between the low pressure sensor and the pump flow
increase is the same as above; the explanation
of it is deleted hereafter.
(2) AUTO ACCEL OPERATION
Principle:
Start operating with signal output by low pressure
sensor.
Operation: <Lever in neutral position>
When the signal is not input to low pressure sensor for 4 seconds or more after turning accel dial
to Max. position, become engine speed to
1050rpm automatically.
<Lever in operation position>
If a pressure signal of 5.7kgf/cm2 (81psi) or over
enters the low pressure sensor of the machine
with standard specifications (travel, bucket, boom,
swing and arm), a proportional voltage signal from
the low pressure sensor enters the mechatro controller and brings the engine revolution back to
the accel dial setting according to the lever strokes.
(3) CONSTANT FLOW CONTROL FOR STANDBY
Principle:
At pressures below the intermediate revolution
between the decel and the FC mode, a command
current is put out so as to make the delivery rate
of the pump constant.
Operation:
10
Even if the engine revolution of the accel potentiometer is set in Lo rpm, the pump delivers a discharge rate equal to the intermediate revolution
between the above decel and the FC mode. For
this reason, the actuator operates faster than the
moving of the operating lever when load is light.
(4) BUCKET DIGGING MAIN CIRCUIT
Operation:
With pilot operation, the pressure oil switches
bucket spool, and is fed into bucket cylinder H
side through C/V (2) BC port. And the return oil
from cylinder R side flows into tank circuit while
being restricted by bucket spool through C/V (2)
AC port.
3.4 BUCKET CIRCUIT

1) Bucket digging pilot circuit
2) Auto accel operation
3) Constant flow control for standby
4) Bucket digging main circuit
A1 a1
MB
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
SWING
VA
PB
DB
VB
VA
12
M
a5
PUMP ASSY
725psi
18
Pcr
P
5200~
5400psi
TRAVEL RIGHT
A3
B1
Pcr
5200~
5400psi
TRAVEL LEFT
MA
MA
B DE E F F A C
4060psi
Pi2
Pi1
PA
PG
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
17
71psi
2
13
36psi
20
P2
MAIN CONTROL VALVE
P1
ARM OUT
19
PL1
PTb
4980psi
CMR2
CT2
LCs
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
25
PB3
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
SE-7
PLc2 P
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
PA3
PA4 PB4
PB1
PA1
PA2 PB2
10
P
BOOM
& BUCKET
21
P
ARM
& SWING
TRAVEL
PILOT VALVE P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
2
OUT Ba
X1
ARM(O125/O90/1290)
PCb
14
10
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
ATT.
PILOT VALVE
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
SE-5
P
RIGHT BS
BUCKET
Ac DIS.
21
LEFT AS
BOOM
CONFLUENCE
LCc
RELAY
BLOCK
FOR. PAI
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
TRAVEL
RIGHT
SE-8
P
SE-1
P
REV. AI
FOR. BI
CP2
Drb
PAr FOR.
24
REV. PBI
TRAVEL
LEFT
TRAVEL
PRIORITY
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
PH1
PSV1
SE-23
P
SE-22
P
5
P
SE-9
P
SE-10
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
ARM VARIABLE
RECIRCULATION
PCa
(P3)
TRAVEL
1/2SPEED
3 CHANGEOVER
6
5
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
SWING
1 P/B
PT
BUCKET CIRCUIT:BUCKET DIGGING OPERATION
11
(1) BOOM RAISE PILOT CIRCUIT

Operation:
1) If the boom raise action is performed, the secondary pilot pressure from the right pilot valve (10)
comes out of port 3 and acts upon the low pressure sensor (SE3). At the same time, the pressure acts upon the PAb port and the PB1 port of
C/V (2).
2) The voltage output by low pressure sensor is processed by mechatro controller and outputs command current to P2 bypass cut valve (PSV-B) and
solenoid valve outputs proportional secondary
pressure and the pressure acts on C/V (2) PCa
port.
3) Then, the secondary pressure fed into C/V (2) PAb
port switches boom conflux spool. And the solenoid proportional secondary pressure fed into PCa
port switches P2 bypass cut valve.
(2) BOOM RAISE 2 PUMPS CONFLUX MAIN CIRCUIT IN C/V
Purpose: Boom raise speed up
Principle: Confluxing oil from 2 pumps
Operation:
1) The oil delivered through A1 port of P1 pump flows
into C/V (2) P1 port, and branches into bypass
circuit and parallel circuit. However since the boom
spool is moved and bypass circuit is closed, the
oil opens load check valve through parallel circuit
and flows into boom spool.
2) Then the oil passes through boom spool, opens
lock valve of boom lock valve, and is led into H
side of boom cylinder through C/V (2) Ab port.
12
3) Meanwhile, the oil delivered from the A2 port of

the P2 pump enters the P2 port of C/V (2) and is
branched to the bypass circuit and the parallel circuit. If the P2 bypass cut valve is changed over,
the center bypass circuit is closed. The oil then
passes through the parallel circuit and via the
restrictor on the circumference of the boom
conflux spool, pushes the load check valve open
from the boom conflux circuit, and combines the
oil delivered by the P1 pump internally.
4) The return oil from boom cylinder R side flows
into tank circuit through boom spool from C/V (2)
Bb port.
3.5 BOOM CIRCUIT

This section describes the boom raise conflux operation.
1) Boom raise pilot circuit
2) Boom raise 2 pumps conflux main circuit in C/V
A1 a1
MB
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
SWING
VA
PB
DB
VB
VA
12
M
a5
PUMP ASSY
725psi
18
Pcr
P
5200~
5400psi
TRAVEL RIGHT
A3
B1
Pcr
5200~
5400psi
TRAVEL LEFT
MA
MA
B DE E F F A C
4060psi
Pi2
Pi1
PA
PG
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
17
71psi
2
13
36psi
20
P2
MAIN CONTROL VALVE
P1
ARM OUT
19
PL1
PTb
4980psi
CMR2
CT2
LCs
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
25
PB3
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
SE-7
PLc2 P
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
PA3
PA4 PB4
PB1
PA1
PA2 PB2
10
P
BOOM
& BUCKET
21
P
ARM
& SWING
TRAVEL
PILOT VALVE P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
2
OUT Ba
X1
ARM(O125/O90/1290)
PCb
14
10
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
ATT.
PILOT VALVE
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
SE-5
P
RIGHT BS
BUCKET
Ac DIS.
21
LEFT AS
BOOM
CONFLUENCE
LCc
RELAY
BLOCK
FOR. PAI
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
TRAVEL
RIGHT
SE-8
P
SE-1
P
REV. AI
FOR. BI
CP2
Drb
PAr FOR.
24
REV. PBI
TRAVEL
LEFT
TRAVEL
PRIORITY
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
PH1
PSV1
SE-23
P
SE-22
P
5
P
SE-9
P
SE-10
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
ARM VARIABLE
RECIRCULATION
PCa
6
5
(P3)
TRAVEL
1/2SPEED
3 CHANGEOVER
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
SWING
1 P/B
PT
BOOM CIRCUIT:BOOM UP OPERATION,CONFLUX FUNCTION
13
(3) BOOM LOWER PILOT CIRCUIT

Operation:
1) Start boom lower operation, and the pilot secondary pressure is output through port 4 of pilot valve
(10), and acts on low pressure sensor (SE4), at
the same time branches into two circuits, then acts
C/V (2) PBb and PLC1 ports.
2) The voltage output by low pressure sensor (SE4)
is input into mechatro controller.
3) Then, the secondary pressure fed into C/V (2) PBb
port switches boom spool. And the secondary
pressure flowed into C/V (2) PLC1 port releases
boom lock valve.
(4) PREVENTION OF NATURAL FALL BY LOCK
VALVE AND ACTUATION AT LOWERING
Purpose:
Prevention of natural fall when the lever is neutral
Principle:
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
Operation:
During the boom lowering, the boom spool shifts
to change the selector valve of the lock valve located at the end of the spool. Then the poppet
spring chamber of the lock valve connects with
the drain line (Drc), with the result that the lock
valve poppet is moved to an open state. When
the boom spool is neutral, the drain line on the
lock valve poppet spring chamber side is closed.
Since the poppet is closed, the oil returning to
the boom spool from the boom cylinder head (H)
is held. This prevents oil leaks from the boom
spool, thereby preventing the boom cylinder from
making a natural fall.
14
(5) FIXED RECIRCULATION FUNCTION OF BOOM

LOWER MAIN CIRCUIT
Purpose:
Prevention of cavitation during boom
lowering motion.
Principle:
The oil returning from the boom cylinder head (H)
is recirculated to the rod (R).
Operation:
When the oil is supplied to the boom cylinder rod
(R) side during boom lower operation, the boom
moves faster than it should do in some cases by
the self weight of the attachment. On that occasion, the circuit pressure on the rod (R) side is on
the negative side. The oil supplied to the boom
cylinder rod (R) flows into the A1 port of the P1
pump and the P1 port of C/V. The oil then passes
through the boom spool and goes out of the Bb
port. On that occasion, the oil returning from the
head (H) goes through the recirculation path in
the boom spool, pushes the check valve in the
spool open, is recirculated to the Bb port and is
supplied to the rod (R). When the (R) pressure is
larger than the (H) pressure, the check valve
closes. Thereupon, the recirculation is stopped.
This section describes boom lower operation.

1) Boom lower pilot circuit
2) Prevention of natural fall by lock valve and actuation at lowering
3) Fixed recirculation function of boom lower main
circuit
A1 a1
MB
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
SWING
VA
PB
DB
VB
VA
12
M
a5
PUMP ASSY
725psi
18
Pcr
P
5200~
5400psi
TRAVEL RIGHT
A3
B1
Pcr
5200~
5400psi
TRAVEL LEFT
MA
MA
B DE E F F A C
4060psi
Pi2
Pi1
PA
PG
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
17
71psi
2
13
36psi
20
P2
MAIN CONTROL VALVE
P1
ARM OUT
19
PL1
PTb
4980psi
CMR2
CT2
LCs
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
25
PB3
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
SE-7
PLc2 P
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
PA3
PA4 PB4
PB1
PA1
PA2 PB2
10
P
BOOM
& BUCKET
21
P
ARM
& SWING
TRAVEL
PILOT VALVE P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
2
OUT Ba
X1
ARM(O125/O90/1290)
PCb
14
10
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
ATT.
PILOT VALVE
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
SE-5
P
RIGHT BS
BUCKET
Ac DIS.
21
LEFT AS
BOOM
CONFLUENCE
LCc
RELAY
BLOCK
FOR. PAI
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
TRAVEL
RIGHT
SE-8
P
SE-1
P
REV. AI
FOR. BI
CP2
Drb
PAr FOR.
24
REV. PBI
TRAVEL
LEFT
TRAVEL
PRIORITY
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
PH1
PSV1
SE-23
P
SE-22
P
5
P
SE-9
P
SE-10
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
ARM VARIABLE
RECIRCULATION
PCa
6
5
(P3)
TRAVEL
1/2SPEED
3 CHANGEOVER
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
SWING
1 P/B
PT
BOOM CIRCUIT:BOOM LOWER(DOWN) OPERATION
15
(1) SWING LEFT PILOT CIRCUIT

Operation:
1) If the swing left action is performed, the secondary pilot pressure goes out of port 5 of left pilot
valve (10) and acts upon the PAS port of C/V (2).
At the same time, high-pressure selection is carried out, and the pressure acts upon the low pressure sensor (SE5).
2) The low pressure sensor output voltage enters in
the mechatro controller, and after signal processing the mechatro controller outputs the command
current to P2 bypass cut solenoid proportional
valve (PSV-B), and the proportionl valve secondary pressure is discharged from this the solenoid
valve and acts on PCa port of the C/V (2).
3) Then, the secondary pressure entered into PAS
port of the C/V (2) switches the slewing spool.
And the solenoid proportionl valve secondary pressure entered in PCa port switches the P2 bypass
cut valve together with the slewing conflux valve.
(2) SWING AUTO PARKING BRAKE
Purpose:
Swing lock and parking in neutral position
Principle:
Release mechanical brake only when required to
operate
Operation:
1) The swing parking function operates usually when
the key switch is ON condition and the mechanical brake is actuated.
2) The mechanical brake is released if the swing
parking solenoid is de-excited only when the secondary operating pressure in the swing and arm
digging actions acts upon any of the low pressure
sensors (SE-5,7).
3) The swing parking solenoid (SV-1) is excited five
seconds after the pressure of the swing low pressure sensors (SE-5) is reduced to zero.
16
In the case of arm digging operation, the swing

parking solenoid (SV-1) is excited the moment the
pressure of the arm digging low pressure sensor
(SE7) is reduced to zero. This causes the mechanical brake to operate.
(3) PREVENTION OF SWINGS ON STOP OF SWING
ACTION BY MEANS OF BY-PASS VALVE
Purpose:
Prevention of swings on stop of swing action
Principle:
Reducing pressure surges of main circuit on stop
of swing action
Operation:
1) At the start of swing action and during continuous
operation, the swing pilot pressure comes out of
the PSS port of C/V (2) and acts upon both the
Pi1 and pi2 ports of the swing motor. Therefore,
the ports A and B are shut off by spring action.
2) If the swing lever is brought back to neutral, the
pressure drop on the slow return valve (25) side
is delayed. As the result, the pressure pushes the
valve leftward against the spring action of the bypass valve and causes ports A and B to be connected together.
(4) SWING MAIN CIRCUIT
Operation:
The delivery oil through A2 port of P2 pump flows
into P2 port of the C/V (2) and is branched into
the bypass circuit and parallel circuit, but the bypass circuit is closed with the movement of the
slewing spool, the pressure opens load check
valve through the parallel circuit, flows into B port
of the slewing motor through AS port of the C/V
(2) and rotates the slewing motor counterclockwise. However, when starting slewing operation,
the confluxed oil flows out in the tank circuit
through P2 bypass cut valve from the bleed off
passage of the slewing spool. The P2 bypass cut
valve closes in late and consequently the slewing
hunting due to the control of the slewing flow rate
is prevented.
(5) SWING MOTOR FUNCTION
1) Anticavitation circuit when reducing swing speed.
2) Shockless relief to protect it from reverse rotation.
3.6 SWING CIRCUIT

This section describes the following operations.
1) Swing left pilot circuit
2) Swing auto parking brake
3) Prevention of swings on stop of swing action by
means of by-pass valve.
4) Swing main circuit
5) Swing motor function
A1 a1
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
SWING
VA
PB
DB
VB
VA
12
M
A3
B1
725psi
18
MA
MA
a5
PUMP ASSY
4060psi
Pi2
B DE E F F A C
TRAVEL RIGHT
Pi1
PA
PG
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
17
71psi
2
13
36psi
20
P2
MAIN CONTROL VALVE
P1
ARM OUT
19
PL1
PTb
4980psi
CMR2
FOR. PAI
CT2
LCs
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
PAr FOR.
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
25
PB3
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
PA4 PB4
PB1
PA1
PA2 PB2
10
21
P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
2
OUT Ba
X1
ARM(O125/O90/1290)
PCb
14
PA3
SE-7
PLc2 P
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
10
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
RIGHT BS
BUCKET
Ac DIS.
21
SE-5
P
LEFT AS
BOOM
CONFLUENCE
LCc
REV. AI
FOR. BI
CP2
Drb
SE-8
P
SE-1
P
24
REV. PBI
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
PH1
PSV1
MB
SE-23
P
SE-22
P
5
P
SE-9
P
SE-10
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
PCa
(P3)
6
5
3
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
1
PT
SWING CIRCUIT:SWING OPERATION
17
(1) ARM DIGGING, LIGHTDUTY OPERATING PILOT CIRCUIT

Purpose:
Speed-up and Anticavitation when the arm is at
light duty.
Principle:
The oil returning from the arm cylinder rod (R)
side is recirculated to the head of C/V.
Operation:
1) If the arm digging operation is performed, the secondary pilot pressure gets out of port 7 of the left
pilot valve (10) and acts upon the low pressure
sensor (SE-7).
At the same time, the pressure is branched off to
two flows, acts upon the PAa port and the PLC2
port, changes over the arm spool and the arm
lock valve selector.
put into the mechatro controller and processes
pilot signals. It is then put out to the P2 pump proportional valve (PSV-2) of the arm variable recirculation proportional valve (PSV-A).
3) The P2 pump proportional valve (PSV-2) acts on
the P2 pump in proportion to the secondary pilot
pressure. However, in the case of the arm variable displacement proportional valve, the secondary pressure of the solenoid proportional valve
operates in reverse proportion to the secondary
pilot pressure. This causes the secondary pressure of the solenoid proportional valve to be reduced by the secondary pilot pressure in light duty
arm in operation. This change over the machine
mode from the forced recirculation to the normal
recirculation mode.
18
(2) ARM DIGGING,LIGHTDUTY VARIABLE NORMAL RECIRCULATION MAIN CIRCUIT

Operation:
1) The oil returning from the arm cylinder (R) side
opens the arm lock valve and flows into the arm
variable recirculation spool through the arm spool.
2) Since the passage to the tank is blocked by the
arm variable recirculation spool, the oil returning
from the arm cylinder (R) side flows into the load
check valve.
3) Since the R side pressure of the cylinder is higher
than the H side pressure of it when working load
is light, the pressure pushes the load check valve
open and is recirculated to the (H) side so as to
speed up the light-duty digging operation.
4) If the FC mode is selected, the command current
to the arm variable recirculation solenoid proportional valve decreases. This reduces the secondary pressure of the solenoid proportional valve.
The result is that the arm variable recirculation
valve is turned to the normal recirculation, thereby
causing the arm variable recirculation function to
prevent cavitation.
3.7 ARM CIRCUIT

1) Arm digging, light-duty operating pilot circuit
2) Arm digging, light-duty variable normal recirculation main circuit
A1 a1
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
SWING
VA
PB
DB
VB
VA
12
M
A3
B1
725psi
18
MA
MA
a5
PUMP ASSY
B DE E F F A C
TRAVEL RIGHT
4060psi
Pi2
TRAVEL LEFT
Pi1
PA
PG
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
17
71psi
2
13
36psi
20
P2
MAIN CONTROL VALVE
P1
ARM OUT
19
4980psi
PL1
PTb
CMR2
FOR. PAI
CT2
LCs
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
PAr FOR.
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
25
PB3
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
PA4 PB4
PB1
PA1
PA2 PB2
10
21
P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
2
OUT Ba
X1
ARM(O125/O90/1290)
PCb
14
PA3
SE-7
PLc2 P
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
10
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
RIGHT BS
BUCKET
Ac DIS.
21
SE-5
P
LEFT AS
BOOM
CONFLUENCE
LCc
REV. AI
FOR. BI
CP2
Drb
SE-8
P
SE-1
P
24
REV. PBI
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
PH1
PSV1
MB
SE-23
P
SE-22
P
5
P
SE-9
P
SE-10
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
(P3)
PCa
6
5
3
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
8
BUCKET(O105/O75/1055)
1
PT
ARM CIRCUIT:ARM IN (DIGGING)LIGHT LOAD OPERATION,RECIRCULATION FUNCTION
19
(3) ARM DIGGING, HEAVY DUTY OPERATING PILOT CIRCUIT

Operation :
1) If the arm is at heavy duty [(more than 160 kgf/
cm2 (2280psi)] of the pump pressure during arm
digging operation, the current of the arm variable
recirculation solenoid proportional valve is reduced
to a minimum, and the arm variable recirculation
function is cut off.
2) The moment the arm variable recirculation cut is
performed, the travel straight proportional valve
and the P1 bypass cut valve change to sequence
conflux circuit.
(4) SEQUENCE CONFLUX CIRCUIT AT HEAVYDUTY ARM DIGGING
Purpose: Arm in speed up.
Principle: Confluxing oil from 2 pumps in C/V (2).
Operation:
1) The oil delivered by the P2 pump flows into the
travel left section from the P2 port of C/V (2). The
oil is then branched to the bypass circuit and the
parallel circuit. The pressure then pushes the load
check valve via the parallel circuit and flows into
the arm spool.
2) Meanwhile, the oil delivered by the P1 pump enters the P1 port of C/V (2) and then the travel
straight section, confluxed with the oil from the
load check valve of the P2 parallel line, and enters the arm spool.
3) Then, the confluxed oil is fed into arm cylinder H
side through C/V (2) Aa port from arm spool.
4) In addition, the return oil from arm cylinder (R)
side flows into arm lock valve through Ba port,
but since the arm lock valve is open, it flows into
arm spool.
5) Then, the oil passes though orifices on arm spool
and returns into tank while restricting.
20

3) Arm digging, heavy duty operating pilot circuit (recirculation cut)
4) Arm digging, heavy-duty sequence confluxed main
circuit
A1 a1
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
SWING
VA
PB
DB
VB
VA
12
M
A3
B1
725psi
18
MA
a5
PUMP ASSY
MA
B DE E F F A C
TRAVEL RIGHT
4060psi
Pi2
TRAVEL LEFT
Pi1
PA
PG
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
17
71psi
2
13
36psi
20
P2
MAIN CONTROL VALVE
P1
ARM OUT
19
PL1
PTb
4980psi
CMR2
FOR. PAI
CT2
LCs
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
PAr FOR.
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
25
PB3
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
PA4 PB4
PB1
PA1
PA2 PB2
10
21
P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
2
OUT Ba
P
SE-9
X1
PCb
14
PA3
SE-7
PLc2 P
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
10
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
RIGHT BS
BUCKET
Ac DIS.
21
SE-5
P
LEFT AS
BOOM
CONFLUENCE
LCc
REV. AI
FOR. BI
CP2
Drb
SE-8
P
SE-1
P
24
REV. PBI
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
PH1
PSV1
MB
SE-23
P
SE-22
P
P
SE-10
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
(P3)
PCa
6
5
3
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
1
PT
ARM CIRCUIT:ARM IN (DIGGING)OPERATION,CONFLUX FUNCTION
21
(5) ARM OUT PILOT CIRCUIT

Operation :
1) If arm out operation is performed, the secondary
pilot pressure comes out of port j of the left pilot
valve (10) and acts upon the low pressure sensor
(SE8). At the same time, the pressure is branched
to two circuits and acts upon the PA1, PBa ports
of C/V (2).
2) The output voltage of the low pressure sensor
(SE8) puts in the mechatro controller which processes signals. The controller puts out a current
command to the P1 bypass cut solenoid proportional valve (PSV-D). The secondary pressure
comes out of the solenoid valve, acts upon the
PCb port of C/V (2) and switches the spool of P1
bypass cut valve.
3) Then, the pilot secondary pressure fed into C/V
(2) PBa port switches arm spool.
(6) ARM OUT 2 PUMPS CONFLUX MAIN CIRCUIT
Purpose : Arm out operation speed up.
Principle :
The oil delivered by the P1 pump is combined with
that delivered by the P2 pump in C/V (2).
Operation :
1) The action is the same as the arm digging till the
oil delivered by the P2 pump enters the arm spool.
In the arm out action, the oil runs freely through
the arm lock valve from the arm spool and is supplied to the arm R side from the Ba port of the
control valve (2).
2) The oil delivered by the P1 pump passes through
the arm conflux valve and is combined with the oil
of the arm cylinder (R) side.
3) And, the return oil from arm cylinder (H) side flows
into Aa port, passes through arm spool, and returns into tank circuit.
22
(7) NATURAL DROP PROTECTION WITH ARM

LOCK VALVE
Purpose :
To prevent the arm from falling naturally by the
weight of the arm & bucket.
Principle :
Complete seat of the return circuit against the arm
spool of the arm cylinder (R) side circuit.
Operation :
1) If the secondary pressure for arm operation disappears and the arm cylinder stops, the pressure
on the rod (R) side passes through the selector of
the lock valve from the Ba port of C/V (2), acts the
back pressure on the lock valve and seats the
lock valve.
2) Since the oil flow from the lock valve to the arm
spool is blocked completely, the arm is prevented
from falling naturally due to oil leaks through the
arm spool.

5) Arm out pilot circuit
6) Arm out 2 pumps conflux main circuit
7) Natural fall protection with arm lock valve
A1 a1
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
SWING
VA
PB
DB
VB
VA
12
M
A3
B1
725psi
18
MA
MA
a5
PUMP ASSY
B DE E F F A C
TRAVEL RIGHT
4060psi
Pi2
TRAVEL LEFT
Pi1
PA
PG
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
17
71psi
2
13
36psi
20
P2
MAIN CONTROL VALVE
P1
ARM OUT
19
PL1
PTb
4980psi
CMR2
FOR. PAI
CT2
LCs
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
PAr FOR.
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
25
PB3
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
PA4 PB4
PB1
PA1
PA2 PB2
10
21
P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
2
OUT Ba
X1
ARM(O125/O90/1290)
PCb
14
PA3
SE-7
PLc2 P
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
10
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
RIGHT BS
BUCKET
Ac DIS.
21
SE-5
P
LEFT AS
BOOM
CONFLUENCE
LCc
REV. AI
FOR. BI
CP2
Drb
SE-8
P
SE-1
P
24
REV. PBI
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
PH1
PSV1
MB
SE-23
P
SE-22
P
5
P
SE-9
P
SE-10
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
PCa
6
5
(P3)
3
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
1
PT
ARM CIRCUIT:ARM OUT(EXTEND)OPERATION,CONFLUX FUNCTION
23
(1) BOOM RAISE/TRAVEL, PILOT CIRCUIT

Operation :
<Points which are differed from the independent operation>
1) With signal processing of mechatro controller, the
controller outputs command current to travel
straight valve (PSV-C) and P2 bypass cut valve
(PSV-B) and this solenoid valve outputs secondary pressure, then acts on C/V (2) PTb and PCa
ports.
2) Next, the PTb port pressure changes the travel
straight valve by one step. The solenoid proportional secondary pressure which flows into the PCa
port of C/V (2) changes over the P2 bypass cut
valve.
(2) BOOM RAISE/TRAVEL, MAIN CIRCUIT
Purpose:
Trevel straight operation is available even if the
attachment is operated during travel operation.
Principle:
The travel motion and attachment operations are
performed by respective pump.
Operation:
1) The P1 pump and P2 pump delivery oil flows into
travel straight section through P1 and P2 ports of
the C/V (2). But the P2 pump delivery oil is
branched into P1 and P2 bypass circuits because
of travel straight spool is shifted.On the other hand,
the P1 pump delivery oil is branched into P1 and
P2 parallel circuits.
2) And, both travel operations are performed bypass
circuit, then is performed by the oil delivered by
P2 pump.
Since boom spool and other spool are operated
through paralel circuit, so oil delivered by P1 pump
is available.
24
3) However, a part of flow is connected at the notched

orifice of the travel straight spool. When the attachment is operated during running, a part of the
pressure oil on the attachment side flows in and
changes the travel speed reducing the travelling
shock.
3.8 COMBINED CIRCUIT

This section describes only the difference in combined
operation.
1) Boom raise/travel, pilot circuit
2) Boom raise/travel, main circuit
A1 a1
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
VA
VA
VB
SWING
PB
DB
12
M
A3
B1
725psi
18
MA
a5
PUMP ASSY
MA
B DE E F F A C
TRAVEL RIGHT
4060psi
Pi2
TRAVEL LEFT
Pi1
PA
PG
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
17
71psi
2
13
36psi
20
P2
MAIN CONTROL VALVE
P1
ARM OUT
19
4980psi
PL1
PTb
CMR2
FOR. PAI
CT2
LCs
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
PAr FOR.
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
25
PB3
CCb
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
PA4 PB4
PB1
PA1
PA2 PB2
10
LCb
PBb LOW.
Drc
PAb RAI.
Drd
OUT PBa
Pisc
LCa ARM
BOOM
21
P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
2
OUT Ba
X1
ARM(O125/O90/1290)
ARM
CONFLUENCE
14
PA3
SE-7
PLc2 P
5760psi
PCb
23
5760psi
SOL/V BLOCK
10
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
RIGHT BS
BUCKET
Ac DIS.
21
SE-5
P
LEFT AS
BOOM
CONFLUENCE
LCc
SE-8
P
REV. AI
FOR. BI
CP2
Drb
SE-1
P
24
REV. PBI
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
PH1
PSV1
MB
SE-23
P
SE-22
P
5
P
SE-9
P
SE-10
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
(P3)
PCa
6
5
3
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
8
BUCKET(O105/O75/1055)
1
PT
COMBIEND OPERATION:BOOM RAISE/TRAVEL LHRH FORWARD 1st-SPEED TRAVEL
25
(3) SWING/ARM IN, PILOT CIRCUIT

Operation :
1) When swing and arm in operations are concurrently carried out, with signal processing of
mechstro controller, the controller outputs commands current to travel straight valve(PSV-C) &
P1 bypass cut valve(PSV-D) & P2 bypass cut valve
(PSV-B) and this solenoid valve outputs secondary pressure, then acts on C/V (2) PTb & PCb &
Pca ports.
(These operations are the same as that of the
combined respective independent operation.)
2) The arm variable recirculation valve operates the
same as usual, but the spool moves toward the
forcible recirculation side according to the pilot
pressure for the swing action.
26
(4) SWING/ARM IN, SWING PRIORITY MAIN CIRCUIT

Purpose :
Stabilization in the swing speed
Principle :
The supplied oil to swing motor is used to have
the P1 pump flow rate confluxed to P2 pump flow
rate.
Operation ;
Swing main circuit is actuated by P2 pump flow,
but when the operation of swing and arm in are
operated simultaneously, the secondary pressure
of travel straight valve switches its spool and the
secondary pressure of P1 cut proportional valve
closes P1 cut valve and oil of P1 pump confluxes
consequently with P2 pump circuit. The oil flows
into swing and arm circuits in the same time because both circuits are paralleled.
Return oil pressure rises and also arm cylinder
head (H) pressure rises because of following two
reason.
Arm variable recirculation spool returns to forced
recirculation side according to swing pilot pressure. Return oil from arm cylinder rod (R) side is
restricted in arm variable recirculation valve.
And swing pilot pressure is led from Pisc port to
sub-spool in arm spool, the pressure of arm cylinder head (H) rises higher by restricting opening of
arm spool circuit according to swing pilot pressure, as a result the oil P2 pump flows preferentially into swing circuit.
This is so-called. swing priority control.
This section describes difference in combined operation from single operation.

3) Swing/Arm in, pilot circuit
4) Swing/Arm in, swing priority main circuit
A1 a1
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
SWING
VA
PB
DB
VB
VA
12
M
A3
B1
725psi
18
MA
MA
a5
PUMP ASSY
B DE E F F A C
TRAVEL RIGHT
4060psi
Pi2
TRAVEL LEFT
Pi1
PA
PG
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
17
71psi
2
13
36psi
20
P2
MAIN CONTROL VALVE
P1
ARM OUT
19
PL1
PTb
4980psi
CMR2
FOR. PAI
CT2
LCs
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
PAr FOR.
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
25
PB3
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
PA4 PB4
PB1
PA1
PA2 PB2
10
21
P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
2
OUT Ba
X1
ARM(O125/O90/1290)
PCb
14
PA3
SE-7
PLc2 P
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
10
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
RIGHT BS
BUCKET
Ac DIS.
21
SE-5
P
LEFT AS
BOOM
CONFLUENCE
LCc
REV. AI
FOR. BI
CP2
Drb
SE-8
P
SE-1
P
24
REV. PBI
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
PH1
PSV1
MB
SE-23
P
SE-22
P
5
P
SE-9
P
SE-10
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
PCa
6
5
(P3)
3
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
1
PT
COMBINED OPERATION:SWING/ARM(DIGGING),SWING PRIORITY
27
(1) PRESSURE RELEASE PILOT CIRCUIT

Purpose:
To release the main circuit pressure for piping repair work.
Principle:
If the SCREEN SELECT switch & BUZZER STOP
switch are kept pressed for more than five seconds simultaneously, the mechatro controller
judges it a pressure release control and puts out
the following commands.
1) Puts out the minimum tilting command value to
the pump proportional valve (PSV-1, PSV-2).
2) Puts out a pressure release control revolution
command value to the governor motor. (electric
system).
3) Travel straight solenoid proportional valve (PSVC) outputs the command value to change the pressure release position to the travel straight valve.
4) Puts out a standby command value to the P1, P2
bypass cut proportional valves. (a command that
does not put out the secondary pressure of the
P1, P2 bypass proportional valves).
Operation:
1) The pump proportional valve minimizes the delivery rates of the P1, P2 pumps.
2) The secondary pilot pressure for the travel straight
valve pressure release position selection comes
out of the travel straight proportional valve (PSVC), flows into the PTb port of C/V (2) and switches
the travel straight valve to its pressure release position.
(2) PRESSURE RELEASE MAIN CIRCUIT
Operation:
If the operating lever is shifted to neutral during
engine running and the SCREEN SELECT switch
& BUZZER STOP switch are kept pressed for
more than five seconds simultaneously, DRAINING HYD. PRESS is displayed on the gauge
cluster and the intermittent buzzer sounds for five
seconds and is stopped. If the operating levers
of the right and left are operated back and forth
28
and right and left four to five times to their full

stroke, pressure may be relieved. If the pump
pressure is determined to be more than 5 kgf/cm2
(70psi) by the output value of the high pressure
sensor or the high pressure sensors (SE22, 23)
are broken, the buzzer sounds continuously. In
that case, the buzzer is not stopped unless the
engine key is turned to OFF.Repeat the pressure
releasing procedure once again.
Operation:
If the travel straight valve is turned to the pressure release position, the oil delivered by each
pump is unloaded to the tank passage. If the
spools are switched by pilot operation, the remaining pressure from the actuators may be relieved
to the tank circuit, i.e. the main circuit pressure
may be released.
3.9 PRESSURE DRAINING (RELEASING) CIRCUIT

1) Pressure drain (releasing) pilot circuit
2) Pressure drain (releasing) main circuit
A1 a1
MB
MB
Dr1 a2 A2 PH2
PSV2
a4
a3
VB
SWING
VA
PB
DB
VB
VA
12
M
A3
B1
725psi
18
a5
PUMP ASSY
MA
MA
B DE E F F A C
TRAVEL RIGHT
4060psi
Pi2
TRAVEL LEFT
Pi1
PA
PG
26
Dr3
B3
A
BUCKET DIS.
BUCKET DIG.
17
71psi
2
13
36psi
20
P2
MAIN CONTROL VALVE
P1
ARM OUT
19
PL1
PTb
4980psi
CMR2
FOR. PAI
CT2
LCs
RIGHT PBS
PBS2
Pss
LEFT PAS
SWING
CT1
PAr FOR.
Br FOR.
CP1
Ar REV.
Dra
PBc DIG.
PAc DIS.
SE-2 P
25
PB3
CCb
5760psi
LCb
PBb LOW.
Drc
PAb RAI.
Drd
OUT PBa
Pisc
LCa ARM
BOOM
LEVER
4 LOCK
TRAVEL
STRAIGHT
P2
BY-PASS
CUT
PA4 PB4
PB1
PA1
PA2 PB2
10
21
P
IN PAa
IN Aa
CRb
5760psi
5470psi
CAr
CRa
7
5470psi
Ab RAI.
11
2
OUT Ba
X1
ARM(O125/O90/1290)
PCb
14
PA3
SE-7
PLc2 P
ARM
CONFLUENCE
23
5760psi
SOL/V BLOCK
10
Bc DIG.
Bb LOW.
PLc1
P
SE-4
PB1
5470psi
SE-3
P
22
RIGHT BS
BUCKET
Ac DIS.
21
SE-5
P
LEFT AS
BOOM
CONFLUENCE
LCc
REV. AI
FOR. BI
CP2
Drb
SE-8
P
SE-1
P
24
REV. PBI
PBr REV.
BOOM RAI.
BOOM LOW.
ARM IN
SWING R
SWING L
CMR1
HYD. TANK
P1
BY-PASS
CUT
PH1
PSV1
SE-23
P
SE-22
P
5
P
SE-9
P
SE-10
Pis
P1
BY-PASS
P2
BY-PASS CUT
CCa
PA1
(P4)
PCa
(P3)
6
5
3
BOOM(O115/O80/1200)
ATT
2 BOOSTING
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
1
PT
PRESSURE DRAIN (RELEASE) CIRCUIT
29
No.
(1)
NAME
QTY
REMARKS
Pump delivery
No.
NAME
QTY
REMARKS
No.
NAME
QTY
REMARKS
No.
NAME
QTY
REMARKS
No.
NAME
QTY
REMARKS
36
CONNECTOR
PF3/8-PF1/4
10
CONNECTOR
PF3/8 With olifice L=23
27
TUBE
L=650
37
TEE
PF1/4
11
ELBOW
PF1/4
28
TEE
PF3/8
38
CONNECTOR
PF1/4
12
ELBOW
PF1/4-PF3/8
29
TEE
PF3/8
13
ELBOW
PF3/8
31
HOSE GUARD
L=500
14
ELBOW
PF3/8
32
HOSE GUARD
L=600
INLINE FILTER
CONNECTOR
PF3/8
40
HYD. VALVE ASSY
TEE
PF1/4
41
TEE
ELBOW
PF3/8
42
SHUTTLE VALVE
ELBOW
PF3/4
43
CAPSCREW
ELBOW
PF1/4
44
WASHER
45
CONNECTOR
PF1/4
M8x50
PF1/4-PF3/8
Block Control valve. Multiless
HOSEPF3/8 L=3700
Bucket dump secondary, Boom up secondary,

Arm in secondary
15
TEE
PF1/4
33
HOSE GUARD
L=550
HOSEPF3/8 L=2650
Boom down secondary, Swing right secondary
16
TEE
10
PF3/8
34
ELBOW
PF3/8
BRACKET
17
TEE
PF1/4
35
HOSE GUARD
L=650
BRACKET
18
TEE
2-PF1/4-PF3/8
36
CONNECTOR
PF1/4 L=38
19
PRESSURE SENSORPF1/4
37
HOSE GUARD
L=450
20
HOSEPF1/4 L=300
Arm conflux select command
38
TEE
PF1/4
21
HOSEPF1/4 L=760
Boom conflux select command
39
ELBOW
PF1/4
(4)
CONNECTOR
PF1/4L=23
46
HOSE ; PF3/8 L=2300
PRESSURE SENSOR ; PF1/4
ELBOW
PF1/4 With mesh filter
47
HOSE ; PF3/8 L=1700
RUBBER
TEE
PF3/8
48
HOSE ; PF1/4 L=400
GROMMET
10
HOSEPF1/4 L=400
P2 S/V primary
49
HOSE ; PF1/4 L=1600
RUBBER
L=370
22
HOSEPF1/4 L=300
Drain
40
CONNECTOR
PF1/4 With filter L=23
11
HOSEPF3/8 L=500
Pilot pump delivery
50
HOSE ; PF3/8 L=900
PLUG
15
PF1/4
23
HOSEPF1/4 L=600
Drain
41
CHECK VALVE
12
HOSEPF1/4 L=540
P1 S/V primary
51
HOSE GUARD
10
ELBOW
PF3/8
24
HOSEPF1/4 L=700
Arm lock valve release command
42
CONNECTOR
PF3/8-PF1/4
13
HOSEPF3/4 L=400
Pilot pump suction
52
CLIP
11
BLOCK
25
HOSEPF1/4 L=660
Boom lock valve release command
43
HOSEPF1/4 L=550
14
CONNECTOR
PF1/4-PF3/8 L=23
53
ELBOW
PF1/4
12
ELBOW
PF3/8
26
ELBOW
PF1/4
44
VALVE ASSY
PF3/8
15
CAPSCREW
M10x20
54
TUBE
L=500
13
CAPSCREW
M8x20
27
TUBE
L=650
45
CONNECTOR
PF3/8
16
WASHER
WASHER
29
PLUG
PF3/8
46
CONEECTOR
PF1/4 L=60
17
CONNECTOR
PF1/4 With mesh filter L=23
CAPSCREW
30
HOSE GUARD
L=500
18
PLUG
PF1/4
HOSEPF1/4 L=1450
Pilot primary
16
HOSEPF3/8 L=2700
31
HOSE GUARD
L=600
(7)
Remote Control lines for Travel
19
CONNECTOR
PF1/4-PF3/8
HOSEPF1/4 L=1750
Pilot primary
17
HOSEPF3/8 L=2900
Bucket digging secondary
32
HOSE GUARD
L=550
PILOT VALVE
20
ELBOW
PF3/8
HOSEPF3/8 L=1400
Drain
18
HOSEPF3/8 L=3500
Swing left secondary
33
ELBOW
PF3/8
21
HOSEPF3/8 L=2000
Drain
HOSEPF3/8 L=1750
Drain
19
CUSHION RUBBER
L=325
34
TEE
PF3/8
CONNECTOR
22
HOSE GUARD
L=250
HOSEPF3/8 L=2600
Drain
20
CHECK VALVE
PF3/8 With orifice
35
HOSE GUARD
L=650
WASHER
23
HOSE GUARD
L=400
HOSEPF3/8 L=1850 RED
24
HOSE GUARD
L=1900
HOSEPF3/8 L=1850 BLUE
Bucket dump secondary
28
PLUG
PF1/4 L=23
HOSEPF3/8 L=1850 GREEN
Boom up secondary
29
TEE
PF3/4-PF1/4
HOSEPF3/8 L=1900 GRAY
30
CONNECTOR
PF1/4 With olifice
10
HOSEPF3/8 L=1600 RED
31
CONNECTOR
PF1/4
11
(2)
Proportional valve block lines
(3)
L=600
Remote control (ATT)
L=370
M8x55
PF3/8
36
CONNECTOR
PF1/4 L=38
CONNECTOR
PF1/4 With filter
Multi control piping
37
HOSE GUARD
L=450
ELBOW
PF3/8
PRESSURE SENSOR ; PF1/4
38
TEE
PF1/4
HOSEPF1/4 L=300
Pilot primary
Boom down secondary
BRACKET
40
CONNECTOR
PF1/4 With filter L=23
HOSEPF3/8 L=380
Drain
Swing right secondary
BRACKET
41
CHECK VALVE
HOSEPF3/8 L=3000
1.Travel RH R. 3.Travel LH R.
HOSEPF3/8 L=1600 BLUE
Arm in secondary
BRACKET
42
CONNECTOR
PF3/8-PF1/4
10
CAPSCREW
M10x30
12
HOSEPF3/8 L=1600 GREEN
Arm out secondary
RUBBER
L=370
43
HOSEPF1/4 L=550
11
HOSEPF3/8 L=3800
1.Travel RH F. 3.Travel LH F.
13
HOSEPF3/8 L=1800 GRAY
ELBOW
PF1/4
44
VALVE ASSY
PF3/8
14
HOSE
CUSHION RUBBER
L=325
45
CONNECTOR
PF3/8
(8)
Boom ,Arm safety control
15
PILOT VALVE
RUBBER
12
L=300
46
CONEECTOR
PF1/4 L=60
HOSEPF3/8 L=2600
Arm in command
10
CAPSCREW
12
M8x20
47
ELBOW
PF1/4
HOSEPF3/8 L=2600
Arm H/V drain
HOSEPF3/8 L=1900
Boom RH H/V drain
HOSEPF3/8 L=2100
Boom RH down command
(4a)
SOLENOID VALVE ASSY 1
CONNECTOR
PF1/4
16
WASHER
CONNECTOR
PF3/8
17
CONNECTOR
11
PF3/8
11
WASHER
ELBOW
PF1/4
18
CONNECTOR
12
GROMMET
ELBOW
19
BOOT
13
PLUG
GUIDE
20
CLIP
14
CONTROL VALVE
CLIP
21
CAPSCREW
15
CONNECTOR
CAPSCREW
M10x20
22
GROMMET
16
CONNECTOR
M10x75
(6)
PF1/4
Control Valve piping

(with boom,arm safety)
CONNECTOR
PF1/4
HOSEPF3/8 L=2100
Boom LH H/V drain
CONNECTOR
PF1/4-PF3/8
HOSEPF3/8 L=2300
Boom LH down command
PF1/4 L=38
CONNECTOR
PF3/8
CONNECTOR
PF3/8
10
PF1/4 L=17
CONNECTOR
PF1/4 L=23
HOSE GUARD
CLIP
16
CAPSCREW
17
ELBOW
PF3/8-PF1/4
CONNECTOR
PF1/4-PF3/8 L=23
10
WASHER
18
ELBOW
PF3/8-PF1/4
CONNECTOR
PF3/8 L=46
11
WASHER
19
HOSEPF3/8 L=2650
CHECK VALVE
PF3/8 With olifice
12
HOSEPF1/4 L=600
Travel straight
20
HOSEPF3/8 L=3700
Boom down secondary,

Swing right secondary
Boom up secondary, Bucket dump secondary
Arm in secondary
HOSE
PF3/8 L=760
BLOCK
13
HOSEPF1/4 L=700
P2 bypass cut secondary
21
HOSEPF3/8 L=3100
CONNECTOR
CONNECTOR
PF1/4 L=23
14
HOSEPF1/4 L=850
ATT power boost command primary
22
HOSEPF3/8 L=3500
10
CONNECTOR
CONNECTOR
PF3/8 L=23
15
HOSEPF1/4 L=1250
Travel 1,2 speed primary
23
HOSEPF3/8 L=2700
Arm out secondary
11
ELBOW
PF1/4
ELBOW
PF1/4
16
HOSEPF1/4 L=1350
P1 bypass cut secondary, Swing P/B primary
26
TEE
PF1/4
12
ELBOW
PF1/4-PF3/8
ELBOW
PF3/8
17
HOSEPF1/4 L=1400
Arm variable recirculation secondary
29
CHECK VALVE
13
ELBOW
PF3/8
ELBOW
PF1/4
18
HOSEPF3/8 L=2000
P/V block pressure supply
30
CONNECTOR
14
ELBOW
PF3/8
ELBOW
PF3/8
19
HOSEPF3/8 L=2700
Lever lock primary
15
TEE
PF1/4
PLUG
PF1/4
20
HOSEPF3/8 L=300
Drain
16
TEE
13
PF3/8
CAPSCREW
M8 x 40
21
HOSE GUARD
L=1900
17
TEE
PF1/4
10
WASHER
22
BRACKET
CONNECTOR
PF1/4
18
TEE
2-PF1/4-PF3/8
14
PLUG
23
CAPSCREW
M10x25
CONNECTOR
PF1/4-PF3/8
19
24
ELBOW
PF3/8
CONNECTOR
PF3/8
20
HOSEPF1/4 L=300
Arm conflux select command
25
GROMMET
CONNECTOR
PF1/4 L=23
21
HOSEPF1/4 L=760
Boom conflux select command
26
CLIP
10
CONNECTOR
PF1/4-PF3/8 L=23
22
HOSEPF1/4 L=300
Drain
31
HOSE GUARD
L=450
CONNECTOR
PF3/8 L=46
23
HOSEPF1/4 L=600
Drain
32
ELBOW
PF1/4-PF3/8
CHECK VALVE
PF3/8 With olifice
24
HOSEPF1/4 L=700
Arm lock valve release command
33
CONNECTOR
PF1/4 L=38
HOSE
PF3/8 L=760
25
HOSEPF1/4 L=660
Boom lock valve release command
34
HOSE ; PF3/8 L=1500
S/M bypass V command 1
CONNECTOR
26
ELBOW
PF1/4
30
(5)
PF1/4-PF3/8
Control Valve piping
(9)
Block control lines
PF3/8
4. PILOT PIPING
(1) Pump delivery;
31
32
(2) Proportional valve block lines;
(3) Remote control (ATT);
33
34
Control valve;
(4) Block
(5) Control valve piping;
35
36
(6) Control valve piping; (With boom, arm safety)
(7) Remote control lines for travel;
37
38
(8) Boom,arm safety control;
(9) Block control lines
39
No.
40
NAME
QTY
(1)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Pump delivery
TUBE
TUBE
HOSE
(2)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Control valve piping

TUBE 27.2
TUBE 27.2
TUBE 34
TUBE 27.2
TUBE 27.2
TUBE 27.2
(3)
1
2
3
4
5
Swivel joint hyd. Piping

CONNECTOR
CONNECTOR
TUBE
TUBE
O RING
1
4
2
2
8
(4)
1
2
3
4
5
6
7
Return piping
TUBE
TUBE
TUBE
TUBE
HOSE ; PF1/2 L=940
HOSE ; PF1/2 L=2100
HOSE ; PF1/2 L=2700
1
1
1
1
1
1
1
1
1
2
HOSE ; L=1110 1-3/16-12UN 1
HOSE ; L=1040 1-3/16-12UN 1
O RING
1
O RING
2
HALF CLAMP
4
CAPSCREW
8
CAPSCREW
4
U-BOLT
2
WASHER
4
LOCK WASHER
8
LOCK WASHER
4
NUT
8
CLIP
8
PRESSURE SENSOR : PF3/8 2
ELBOW
1
GROMMET
2
CLIP
2
HOSE ; 1 3/16-12UN L=1250
CAPSCREW
HOSE ; 1 3/16-12UN L=1400
HOSE ; 1 3/16-12UN L=1500
CAPSCREW
HOSE ; 1 3/16-12UN L=1600
PLATE
O RING
O RING
O RING
CONNECTOR
CONNECTOR
CONNECTOR
CONNECTOR
CONNECTOR
HOSE ; 1 3/16-12UN L=1450
ELBOW
CONNECTOR
NUT
CLAMP
CLAMP
WASHER
CAPSCREW
SUPPORT
SUPPORT
GROMMET
HOSE ; 1 3/16-12UN L=1300
GROMMET
CLIP
CAPSCREW
CONNECTOR
CAPSCREW
TUBE
TUBE
1
1
1
1
1
1
1
2
1
2
2
1
1
2
22
2
3
5
1
2
1
1
4
1
3
1
4
12
2
1
1
1
2
2
4
2
2
1
1
1
REMARKS
Suction
Suction
Suction
P1 Pump delivery
P2 Pump delivery
1A G75
1B P26
3/4
M10x35
M12x30
PF1/2
Boom (H)
Boom (R)
Arm (H)
Arm (R)
Bucket (H)
Bucket (R)
Travel right
M12 x 70
Travel right
Swing motor
M12 x 55
Travel left
1-14UNS
1"3/16-12UN
1"7/16-12UN
1"3/16-12UN - PF3/4
1"3/16-12UN - PF3/4
1"3/16-12UN - PF3/4
1"3/16-12UN - PF3/4
1"7/16-12UN - PF3/4
Travel left
1-3/16-12UN - PF3/4
PF3/4 L=60
M12 x 25
No.
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
62
63
64
65
NAME
HOSE ; PF1 L=1900
COUPLING
COUPLING
COUPLING
CHECK VALVE
CHECK VALVE
SUPPORT
SUPPORT
SUPPORT
SUPPORT
CLAMP
CLAMP
CLAMP
CLAMP
O-RING
CONNECTOR
CONNECTOR
CONNECTOR
ELBOW
ELBOW
TEE
TEE
SPACER
CLIP
CLIP
TUBE
BUSHING
HOSE GUARD
CAPSCREW
CAPSCREW
CAPSCREW
CAPSCREW
CAPSCREW
CAPSCREW
CAPSCREW
CAPSCREW
WASHER
WASHER
NUT
NUT
CLIP
TUBE
PLUG
TUBE
CLIP
GROMMET
CLIP
SUPPORT
U BOLT
NUT
WASHER
QTY
1
3
2
1
1
1
3
1
2
1
3
2
3
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
3
4
3
12
2
4
12
25
2
4
1
1
1
1
1
1
1
1
1
4
2
REMARKS
L=1600
42.7
48.6
50.8
245 KPa
500 KPa
42.7 P85
42.7 P85
42.7
50.8
1A G45
PF3/4 - PF1
PF3/4
PF3/4
PF1/2
PF3/4 - PF1
PF1/2-PF1/2-PF3/8
PF1/2-PF1/2-PF3/4
L=22.5
L=1000
L=1000
M10 x 25
M10 x 30
M10 x 55
M10 x 90
M12 x 25
M12 x 30
M12 x 35
M12 x 65
L=1100
PF1
L=750
No.
NAME
QTY
REMARKS
(5)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Travel system hyd. piping

TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
HOSE
HOSE
CLIP
CLAMP
CLAMP
SPACER
CAPSCREW
WASHER
LOCK WASHER
1
1
1
1
1
1
2
4
10
2
2
4
4
4
4
(5a)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Travel system hyd. piping

TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
HOSE
HOSE
CLIP
CONNECTOR
CONNECTOR
CLAMP
CLAMP
SPACER
CAPSCREW
WASHER
LOCK WASHER
1
1
1
1
1
1
1
1
1
1
1
1
2
4
10
4
2
2
2
4
4
4
4
(6)
1
2
3
4
5
Travel motor hyd. piping

CONNECTOR
CONNECTOR
CONNECTOR
O RING
O RING
4
2
2
4
2
PF1- 28
PF1/2- 18
PF1/4
1B P29
1B P18
(7)
1
2
3
4
5
Swivel hyd. piping

CONNECTOR
CONNECTOR
CONNECTOR
O RING
O RING
4
2
2
4
2
PF1- 28
PF1/4
PF1/2- 18
1B P29
1B P18
(8)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Boom hyd. piping

TUBE
TUBE
TUBE
TUBE
HOSE
HOSE
O RING
CLAMP
CLAMP
CLAMP
CAPSCREW
LOCK WASHER
CLIP
O RING
HOSE ; L=1430
CAPSCREW
GUARD
GUARD
1
1
1
1
1
2
7
2
2
4
6
6
4
1
1
2
1
1
1
2
(10)
L=300
PF1/2
1"3/16-12UN - PF1
1"3/16-12UN - PF1
1"3/16-12UN - PF1
1"3/16-12UN - PF1
PF1/2
PF3/4
PF1
Travel 2-speed command
L=300
h=17.5
M8 X 40
44
Arm (R)
Bucket (H&R)
M12 x 55
Arm (H)
M12 x 60
QTY
HOSE ; L=1200
HOSE ; L=1200
REMARKS
Arm (H&R)
Arm (H&R)
1
1
1
1
2
2
2
2
16
1
2
2
2
4
2
1
Left boom cyl. (H)

Right boom cyl. (H)
Left boom cyl. (R)
Right boom cyl. (R)
Boom cyl. (H)
Boom cyl. (R)
Boom cyl. Piping
4
5
6
7
8
9
10
11
12
13
14
15
16
TUBE
TUBE
TUBE
TUBE
HOSE
HOSE
CLAMP
CAPSCREW
CAPSCREW
CONNECTOR
GREASE NIPPLE
O RING
O RING
O RING
LOCK WASHER
PLUG
(11)
1
2
3
4
5
6
7
8
9
10
11
12
13
Arm cyl. hyd. piping

TUBE
HOSE ; L=860
HOSE ; L=860
CLAMP
CONNECTOR
HALF CLAMP
GREASE NIPPLE
CAPSCREW
CAPSCREW
O RING
O RING
LOCK WASHER
LOCK WASHER
1
1
1
1
1
2
1
8
1
2
1
4
1
(12)
1
2
3
4
5
6
7
8
9
10
11
Bucket cyl. hyd. piping

TUBE
TUBE
CLAMP
CAPSCREW
CAPSCREW
CAPSCREW
O RING
O RING
GREASE NIPPLE
GREASE NIPPLE
LOCK WASHER
1
1
1
1
4
4
2
2
1
1
1
(13)
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
Boom cyl. Piping for boom safety
2
3
h=17.5
M8 X 40
NAME
Arm hyd. piping
marked parts have different

parts number between KCME,
KCMA and OCE.
Travel 2-speed command
Boom (R)
M12 x 30
PF3/4 L=75
M12 x 75
L = 22.0
L = 26.0
No.
(9)
TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
TUBE
TAPPED BLOCK
HOSE ; L=860
HOSE ; L=860
HOSE ; L=1300
CONNECTOR
HOLDING VALVE
HOLDING VALVE
CLAMP
CLAMP
ELBOW
ELBOW
CONNECTOR
CONNECTOR
CONNECTOR
CONNECTOR
O RING
O RING
1
1
1
1
1
1
1
1
2
2
2
1
4
1
1
2
2
2
2
1
2
2
2
4
4
M12 x 50
M10 x 30
PF1/4
Arm (R)
Arm (H)
PT1/8
M10 x 35
M12 x 55
1B P26
27.2 x t3.2
27.2 x t3.2
M10 x 55
M10 x 55
M10 x 35
1B P26
PT1/8
PT1/8
21.7
21.7
27.2
27.2
15
15
15
15
Arm (R)
Arm (H)
Equalizer
28- 22
15- 15
1B P26
No.
NAME
QTY
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
O RING
4
O RING
4
CAPSCREW
2
CAPSCREW
2
CAPSCREW
8
CAPSCREW
8
WASHER
2
LOCK WASHER
2
LOCK WASHER
2
LOCK WASHER
16
GREASE NIPPLE
2
CLIP
4
BLOCK
2
CAPSCREW
8
PLUG
2
TEE
1
CONNECTOR
1
OIL PRESSURE SWITCH 1
CLAMP
1
CLAMP
1
PLATE
1
BRACKET
1
ELBOW
1
CONNECTOR
1
CAPSCREW
2
CAPSCREW
2
CAPSCREW
2
WASHER
2
WASHER
2
LOCK WASHER
2
O RING
1
(14)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Arm cyl. piping for arm safety
HOLDING VALVE
TUBE
HOSE ; L=860
HOSE ; L=860
HOSE ; L=4000
HOSE ; L=3900
HALF CLAMP
CLAMP
ELBOW
ELBOW
CONNECTOR
CONNECTOR
GREASE NIPPLE
O RING
O RING
CLIP
PLUG
CAPSCREW
CAPSCREW
CAPSCREW
LOCK WASHER
LOCK WASHER
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
15
1
1
4
4
1
8
REMARKS
1B P14
M10 x 65
M8 x 35
M10 x 65
M10 x 30
PT1/8
48 L=188
M10 x 45
M5 x 40
M8 x 25
M12 x 65
27.2
Arm (R)
Arm (H)
18- 18
15- 15
PF3/4 1"3/16-12UNS
PT1/4-PF1/4
PT1/8
1B P26
1B P18
M12 x 55
M10 x 65
M10 x 35
5. MAIN PIPING
(1) Pump delivery;
41
42
(2) Control valve piping (1/2);
Control valve piping (2/2);
43
44
(4) Return piping (1/2);
(3) Swivel joint hyd. piping;
Return piping (2/2);
45
(5) Travel system hyd. piping;
(6-2) Connector installing

procedure (RH MOTOR)
(6-1) Connector installing procedure (LH MOTOR);
(7) Connector installing procedure (S/J);
46
(5a) Travel system hyd. piping;
47
(8) Boom hyd. piping;
(12) Bucket cyl. piping;
(9) Arm hyd. piping;

(10) Boom cyl. piping;
(11)Arm cyl. piping;
48
(13) Boom cyl. piping for boom safety;
49
50
(14) Arm cyl. piping for arm safety;
E200SR
SECTION 23
ELECTRIC SYSTEM
TABLE OF CONTENTS
1. ELECTRIC CIRCUIT DIAGRAM ................................................................................ 1
2. ELECTRICAL EQUIPMENT LIST .............................................................................. 5
2.1 Specification ......................................................................................................................... 5
3. HARNESS
3.1 Harness list ........................................................................................................................... 6
3.2 Harness Connection Drawing ............................................................................................... 7
3.3 Controller Assy ...................................................................................................................... 8
3.4 Instrument Panel Assy ......................................................................................................... 12
3.5 Upper Electric Assy ............................................................................................................. 13
3.6 Upper Harness Assy ........................................................................................................... 14
3.7 Engine Harness Assy .......................................................................................................... 20
3.8 Upper Harness Assy (Floor Plate) ....................................................................................... 22
3.9 Cab Harness Assy .............................................................................................................. 24
3.10 Cab Assy ........................................................................................................................... 27
3.11 Boom Harness Assy .......................................................................................................... 29
3.12 Installing Light ................................................................................................................... 31
3.13 Fuel Pump Assy Install ...................................................................................................... 34
3.14 Name plate install (electric component for auto idle stop) ................................................. 35
FUEL PUMP
R
CAB WORKING LIGHT 11 1.25
10A
TRAVEL ALARM, 12 RG
SWING FLASHER
10A
W
GAUGE CLUSTER 13
RB 20A
WIPER,WASHER 14
1.25
WB 10A
SOLENOID 15
RW 20A
WORK LIGHT 16 1.25
WL 10A
RESISTOR 17
WG 20A
AIR CON.
HEATER 18 1.25
RL 10A
AIR CON. 19
WR 20A
RESERVE 20
1.25
20A
SE-2:BUCKET DUMP
C-1
3
SE-3:BOOM RAISING
SE-4:BOOM LOWERING
SE-7:ARM IN
G
B
R
W
60A
60A
60B
BATTERY
BATTERY
60B
60B
SE-8:ARM OUT
SHIELD
SE-5:SWING
R-28:
AUTO IDLE STOP RELAY 1
60 GrL
D-1
D-3
R-1:
BATTERY RELAY
70 YW
B
71 YL
SE-9:TRAVEL RIGHT
GLOW
SE-10:TRAVEL LEFT
D-7
D-4
M-1:STARTER MOTOR
B
910 RL (5V)
510 GO
960 BL (GND)
OPTION
SE-11:OPT.1
S
R-4:
SAFETY RELAY
65 5L
651 WR
SE-20:OPT.2
E-2:ALTERNATOR
5B
E
B
65 L
R
L
C-2:GAUGE CLUSTER
13
SE-15:FUEL SENSOR
13 W
21-6
537 YR
21-2
SE-23:PUMP P2
12-18
ENG. WATER TEMP

INDICATOR
C-1:MECHA
5 TRO CONT21-1
536 BrB ROLLER
730 YR
FUEL METER
KEY ON
60 GrL
12-15
61 BrY
12-16
FC
SW-34:POWER BOOST SW.
559 PL
12-17
567 GR
14-5
534 B
12-20
M-2:GOVERNER MOTOR
N L E
TIO A AS
SI RM LE
PO NO RE
SW-4:SWING PARKING RELEASE SW.

3
2
1
701 PB
15-22
15-21
702 LgB
15-23
703 P
15-6
15-7
15-8
15-9
15-5
15-10
15-11
12-19
15-18
15-17
12-13
SW-3:TWO-SPEED SELECT SW.

B
15-24
561 Lg
751 BO
752 GrR
15-20
15-19
SV-3:TWO-SPEED SELECT SOL.

SV-2:POWER BOOST SOL.
PSV-D:P1 BY-PASS CUT

PROPORTIONAL SOL.
757 BrG
758 YV
PSV-A:ARM VALUABLE RECIRCULATION

PROPORTIONAL SOL.
650 Sb
17 WL
763 GY
764 VW
SV-1:SWING PARKING BRAKE SOL.
PSV-C:TRAVEL PRIORITY
PROPORTIONAL SOL.
755 BP
756 PW
759 GrG
760 VR
PSV-B:P2 BY-PASS CUT

PROPORTIONAL SOL.
753 GB
754 GrB
17
651 WR
BACK LIGHT
E-14:RESISTOR
CHARGE
GLOW
700 VR
RY
805 WG
GREEN
BLACK
RED
WHITE
SHIELD
560 V
R-29:
1
553 BrB
B
11-34
851
852
853
854
650 Sb
TERMINAL
914 YL (5V)
12-3
514 VY
12-2
964 BrB(GND) 12-1
915 YR (5V)
12-4
515 Sb
12-5
BrL(GND)
965
12-6
PRESS.SENSOR(HIGH)
SE-22:PUMP P1
E-3:HOUR METER
B
HM
13-3
13-2
13-1
912 RB (5V)
12-9
512 LgR
12-8
962 BO (GND) 12-7
D-5
SE-14:
COOLANT THERMO
SENSOR
15-1
15-2
15-15
15-16
15-3
15-4
D-2
61 BrY
62 GrB
63 WY
66 5W
B
53 5Y
R-3:GLOW RELAY
64 GW
60B
10 1.25WV
ION ATING
POSIT
PREHE
TERMINAL
SW-1:
STARTER KEY SW.
906 YB (5V)
11-21
506 V
11-20
956 GrL(GND) 11-19
908 YL (5V)
11-27
508 VY
11-26
958 BY (GND)
11-25
909 YR (5V)
11-28
509 Sb
11-29
959 BG (GND) 11-30
C-1:MECHATRO CONTROLLER
TERMINAL
WV 10
KEY SW.
1.25
SE-1:BUCKET DIGGING
20A
10A
20A
10A
10A
10A
RL
YG
MECHATRO
CONTROLLER
7 BACK UP
FUEL SUPPLY
WR
8 PUMP
DC-DC
YB
9 CONVERTER
CIGARETTE
3 LIGHTER
OL
4 TUNER DC-DC
CONVERTER.
WG
5 HORN
WIPER/WASHER
2 RELAY
WY
10A
10A
MECHATRO
1B CONTROLLER
1A
RY
RY
20A
PRESS. SENSOR(LOW)
E-1:FUSE BOX
52 5R
53 5Y
51A
EA
51B
EB
10
930 WR (5V)
11-33
530 P
11-32
970 BW (GND) 11-31
900 RB (5V)
11-15
500 LgR
11-14
BrR(GND)
950
11-13
901 RL (5V)
11-16
LgW
501
11-17
951 BL (GND) 11-18
902 WV (5V)
11-3
502 LgY
11-2
952 BR (GND) 11-1
903 OB (5V)
11-4
503 LO
11-5
953 BrW(GND)
11-6
904 OL (5V)
11-9
504 PW
11-8
954 BrY(GND) 11-7
905 OW (5V) 11-10
505 PL
11-11
955 Gr (GND) 11-12
SE-16:ACCEL POTENTIO
50 1.25L
C-1:MECHA
TRO CONTROLLER
4
51 2W
1. ELECTRIC CIRCUIT DIAGRAM
N
IO AL SE
SIT RM EA
PO NO REL
SW-5:K.P.S.S MODE RELEASE SW.
1
2
3
4
5
6
7
8
9
10
11
12
B
761 G
762 L
B
PSV-P1:PUMP P1
PROPORTIONAL SOL.
765 GB
766 LB
PSV-P2:PUMP P2
PROPORTIONAL SOL.
21-7
SE-13:ENG.SPEED SENSOR
LCD
535 W
SHIELD
12-21
12-22
21-3
600 0.5R
14-25
21-4
601 0.5W
14-26
21-5
602 0.5B
SHIELD
1A
1B
DISPLAY
BUZZER MODE WASHER
SELECT SW. STOP
LED
WORKING WIPER
LIGHT
3
4
Fig.1 (1/3)
14-27
14-28
1A RY
15-12
1B RY
15-13
EA B
15-25
EA W
15-26
YG
TO 2/3
15-14
FROM 1/3
550 O
SW-7:ENG.OIL PRESS.SW.
B
SW-8:AIR FILTER RESTRICTION SW.

SW-6:ENG. WATER TEMP. SW.
E-1:FUSE BOX
SE-15:FUEL SENSOR
RY
551 BrL
14-3
552 GB
14-1
R-5:
WIPER MOTOR RELAY 80 LY
14
2
330
FUEL WARNING
B
SW-16:AUTO ACCEL RELEASE SW.
14 RB
14-2
558 YV
FLOW CONTROLLER CONECTOR
17-8
M-3:
WIPER MOTOR
E-10:
RECEIVER DRIER
R-8:
WORK LIGHT 10
RELAY
553 BrB 14-8

555 LB
81 BrB
14 1.25RB
WY
2
85 WB
C-4
14-13
800 GB
180 OL
18
19
14-11
14
2
OPTION
563 PL
SW-22:DOUBLE SINGLE SELECT SW.
14-4
14-15
14 RB
2 WY
82 GO
18 1.25WG
19 RL
AIR
CONDITIONER
AMP.
COOLING
UNIT
801 GrL
16
16 1.25RW
85 1.25WB
16
16
14-16
SW-39:OVERLOAD SW.
971 VR
583 VW
85
L-1:BOOM WORKING LIGHT LEFT
85
L-9:BOOM WORKING LIGHT RIGHT

B
85
802 BrY
WORKING
LIGHT ON
85
L-2:WORKING LIGHT RIGHT
10
C-4:AIR CONDITIONER AMP.
13-16
SW-32:OVERLOAD INDICATE SW.

FKOPT
SWING FLASHER UNIT

B
SW-52:AUTO IDLE STOP SELECT SW.
KCMESTD
590 PB
CONTACT AT RELEASE
12-14
R-19:FLASHER RELAY
L-11:SWING FLASHER RIGHT
12
RG
25W
209 LY
17-3
865 GL
17-4
866 GrR
L-12:SWING FLASHER LEFT

25W
210 Lg
17-10
557 Gr
SW-17:SWING FLASHER SELECT SW.

OPT
R-20:TIMER RELAY
15
15 WB
87 WL
86 OW
SV-4:
OPERATING
LEVER LOCK SOL.
B
R-17:EXTRA DIS-PRESS RELAY

15
SW-11:LEVER LOCK SW.
2
TIMER
14-17
12-10
12-11
12-12
WB
WY
200 OB
SV-5:
EXTRA DIS-PRESS SOL
B
17-11
24V
TXD
RXD
M-4:WINDOW WASHER MOTOR
R-8:WORK LIGHT RELAY
E-11:
AIR COMMPRESSOR CLUTCH
93 LW
SW-23:WIPER INTERLOCK SW.

800 GB
R-6:WINDOW WASHER MOTOR RELAY
92 BP
566 VR
918 RG (5V)
518 WY
968 BG (GND)
SE-24:EXTRA PRESS
OPT.
EXTRA DIS-PRESS
Fig.1 (2/3)
1.25B
181 R
608 G
609 W
184 B
24V
TXD
GND
SW-13:
AIR CONDITIONER SW.
C-1:MECHATRO CONTOLLER
L-3:ROOM LIGHT
9
E-16:DC-DC CONVERTER
4
9
OL
IGN
YB
24V
12V
207 PB
MEM
208 PW
ANT.
YB
RL
E-7:TUNER AM&FM
2(+)
6(-)
FM/AM
E-17:SOCKET
1(+)
5(-)
B
207 PB
208 PW
7
6
88 LR
89 OB
90 LW
91 Br
B
E-9:SPEAKER RIGHT
3
E-6:
CIGARETTE LIGHTER
E-8:SPEAKER LEFT
11 R
11
M
M-9:FUEL PUMP
OPTION
11
11 1.25R
R-10:CAB WORK LIGHT RELAY 1

11
179 1.25L
L-4:CAB WORKING LIGHT(FRONT 1)
185 LY
11
B
SW-21:
WORK LIGHT SW.
20
20 1.25WR
M-11:FUEL SUPPLY PUMP

178 WY

B
10A
WR
L-10:CAB WORKING LIGHT(BACK)
R-11:CAB WORK LIGHT RELAY 2

B
176 LO
L-15:ROTARY LIGHT
SW-30:ROTARY LIGHT SW.
EXAMPLE OF WIRE COLOR

W
L
Stripe color (Blue)
Ground color (White)
L-8:
ENG.ROOM LIGHT
B
SW-42:
ENG.ROOM LIGHT SW.
YB
WIRE COLOR CODING TABLE

Sign
Color
Sign
Color
Sign
Color
Sign
Color
Black
White
Br
Brown
Violet
Lg Light Green
R-7:HORN RELAY
5
WG
5
5
83 WL
84 WB
SW-10:HORN SW.(LEFT)
84 WB
E-5:HORN HIGH
Green
Yellow
E-4:HORN LOW
Blue
Pink
Gr
Gray
Red
Orange
Sb
Sky Blue
SW-20:HORN SW.(RIGHT)
OPTION
Fig.1 (3/3)
2. ELECTRICAL EQUIPMENT LIST

2.1 SPECIFICATION
LIGHT
Note :
C4
Air conditioner amplifier
C6
IT controller (ORBCOMM) (OPT.)
D1
D2
D3
D4
D5
D6
Diode
Diode
Diode
Diode
Diode
Diode
E1
E2
E3
E4
E5
E6
E7
E8
E9
E10
E11
Fuse box
Alternator
Hour meter
Horn (Low)
Horn (High)
Cigarette lighter
Tuner AM&FM
Speaker LH
Speaker RH
Receiver dryer
A/C compressor
E14
Resistor
E16
E17
Converter (DC24V12V)
Socket
E23
E24
Antenna (OPT.)
GPS Antenna (OPT.)
L1
L2
L3
L4
L5
L6
L7
L8
L9
L10
Boom work light LH

Deck light RH
Room light
Cab work light (Front 1)
Engine room light
Boom work light RH
Cab work light (Rear)
L15
Rotary light
Starter motor
Governor motor
Wiper motor
Washer motor
NAME
Fuel pump (OPT.)
M11
Fuel supply pump
PSVA
PSVB
PSVC
PSVD
Arm variable recirculation proportional valve

P2 bypass cut proportional valve
Travel straight proportional valve
PSVP1
PSVP2
P1 pump proportional valve

R1
R3
R4
R5
R6
R7
R10
R11
R19
R20
R28
R29
Battery relay
Glow relay
Safety relay
Wiper motor relay
Washer motor relay
Horn relay
Cab work light relay 1
Flusher relay (OPT.)
Timer relay
Auto idle stop relay 1
SE1
SE2
SE3
SE4
SE5
SE6
SE7
SE8
SE9
SE10
SE11
Press. Sensor (LOW) : bucket digging

Press. Sensor (LOW) : bucket dump
Press. Sensor (LOW) : boom raising
Press. Sensor (LOW) : boom lowering
Press. Sensor (LOW) : swing
SE13
SE14
SE15
SE16
Engine speed sensor

Engine water thermo sensor
Fuel sensor
Accel potentiometer
SE20
Press. Sensor (LOW) : opt. 2
SE22
SE23
Press. Sensor (HIGH) : P1 pump

Press. Sensor (HIGH) : P2 pump
Press. Sensor (LOW) : arm in

Press. Sensor (LOW) : arm out
Press. Sensor (LOW) : travel right
Press. Sensor (LOW) : travel left
Press. Sensor (LOW) : opt. 1
Group
Code
SV1
SV2
SV3
SV4
NAME
Swing parking SOL
ATT boost pressure SOL
Travel 1-2 speed SOL
Safety lock lever SOL
SW1
Key switch
SW3
SW4
SW5
SW6
SW7
SW8
Travel 1-2 speed switch

Swing parking release switch
KPSS release switch
Engine water temperature switch
Engine oil pressure switch
Air filter clogging switch
SOLENOID
Mechatro controller
Gauge cluster
Code
M1
M2
M3
M4
M5
M8
M9
SW10 Horn switch (LH)

SW11 Safety lock lever switch
SW13 Air conditioner switch
SWITCH
C1
C2
Group
MOTOR
NAME
PROPORTIONAL
VALVE
Battery
RELAY
Code
B1
SENSOR
ELECTRIC EQUIPMENTS
DIODE
CONTROLLER
POWER
Group
SW16 Auto accel release switch

SW17 Swing flusher select switch (OPT.)
SW20
SW21
SW22
SW23
Horn switch (RH) (OPT.)

Work light switch
Single/Conflux select switch (OPT.)
Wiper inter lock switch
SW30 Rotary light switch

SW32 Overload indicate switch
SW34 Power boost switch
SW39 Overload switch

SW42 Engine room light switch
SW52 Auto idle stop select switch
z The
part numbers and serial numbers of machine may be changed due to

modification, so use only the numbers for references.
3. HARNESS
3.1 HARNESS LIST
Table 1
INDEX No.
DEVICE
ITEM
EQUIPMENT
NAME
3.3
Controller assy
3.4
Instrument panel assy
3.5
Upper electric assy
ITEM
NAME
25
254
Cab harness
Instrument panel harness
Starter cable
Battery relay cable
Battery cable
Battery ground cable
Main harness
Frame ground cable
E/G room light harness
Over load switch harness
3.6
Upper harness assy
1
2
3
4
5B
6
15
16
3.7
Engine harness
Engine sub harness
3.8
Upper harness assy

(Floor plate)
2
7
Ground cable
Harness
3.9
Cab harness assy
3
2B
1B
Cab right front harness (STD)

RH instrument panel harness
LH instrument panel harness
Cab assy
Cab install
237
61
64
65
189
Wiper harness
Curl code harness
Cab wiper motor harness
Antenna
Room lamp harness
Harness
Harness
UPPER
FRAME
HARNESS
3.10
3.11 Boom harness assy

1. Boom
UPPER 3.12
Light instal 2. Deck
FRAME
3. Cab
& BOOM 3.14 Fuel pump assy install
3.15 Name plate install
(Electric component for AIS)
(Note : AIS=Auto idle stop)
Note :
z The
part numbers and serial numbers of machine may be changed due to

modification, so use only the numbers for references.
SOL. BLOCK
3.5.1 BATTERY
3.6.2 BATTERY RELAY CABLE
3.2 HARNESS CONNECTION DRAWING
CONTROL VALVE
GROUNDING POSITION
MECHATRO CONTROLLER
FUEL SENSOR
FUEL PUMP (AUTO AIR BLEED )
AIR FILTER CLOGGING SWITCH
WASHER MOTOR
GLOW RELAY
BATTERY RELAY (POWER SUPPLY)
HORN (HIGH)
HORN (LOW)
DECK LIGHT
GOVERNOR MOTOR
ATT POWER BOOST SOL.
OVER LOAD DETECT SWITCH
2-SPEED TRAVEL SOL.
LEVER LOCK SOL.

SWING PARKING SOL.
FUEL SUPPLY PUMP
TRAVEL ALARM
SWING FLSHER RH
SWING FLSHER LH
HYDRAULIC PUMP
P-1
B
L
DECK LIGHT
3.6.3 BATTERY CABLE
B2
3.6.4
BATTERY GROUND CABLE
CN-150F
CN-152M
GLOW RELAY
BATTERY GROUND
KCME
STARTER MOTOR
P2 CN-158F
E/G GROUND
3.11.1 BOOM HARNESS

3.11.1-A
CN-165F
HORN (H)
CN-110M CN-157F
CB-104
CN-166F
OVER LOAD SWITCH
CB-104
3.6.16
OVER LOAD DETECT SWITCH
2PAM-HW
GROUNDING POSITION
GAUGE CLUSTER
2-SPEED TRAVEL SWITCH

BOOM WORKING LIGHT
3.6.6
FRAME GROUND CABLE
1PAM
CN234F
HOUR METER
1PAF
3.9.2
3.9.2B INSTRUMENT PANEL
3.9.2A RH HARNESS
CN-4M
CN-351M
GOVERNOR MOTOR
F-32
SAFETY RELAY
STARTER
ACCESSORY
3.7.1
E/G SUB HARNESS
CN-350F
3.3.28-3 INSTRUMENT PANEL HARNESS

3.3.6-3
TO WASHER MOTOR
FUEL SENSOR
RECEIVER DRIER
FUEL SUPPLY PUMP
CN-252F
P-36
P-37
B
ALTERNATOR
GROUND
P-31
P1
CN-30F
(GROUND CONNECTOR)
CN-251F
E
P-35
CN-251M
CN-3M
CN-10F
INPANE LEFT
3.9.1
3.9.1B INSTRUMENT PANEL LH HARNESS
3.9.1A
M-32
3.6.5A
3.6.5B MAIN HARNESS
3.6.5C
3.3.25-4
3.8.1
3.8.7 UNDER FLOOR HARNESS
3.8.8
B
C
CONTROLLER
3.9.10
3.9.3 CAB FRONT HARNESS
3.9.3A
P1
CN-318F
CN-76M
CN-34F
CN-352M
CN-4F
GROUNDING POSITION
WARM UP SWITCH
HEAVY LIFT SWITCH
ENGINE ROOM LIGHT
AUTO ACCEL RELEASE SWITCH
HAND CONTROL
HYD. OIL TEMP SWITCH
CIGARETIE LIGHTER
AUTO IDLE STOP SELECT SWITCH
CN-318M
CN-76F
CN-77F
CN-352F
HORN (L)
INPANE RIGHT
3.8.2 UNDER FLOOR GROUND CABLE
ROOM LAMP
WIPER MOTOR RELAY
AIR CONDITIONER SWITCH
CAB WORK LIGHT
DC-DC CONVERTER
TIMER RELAY
ROTARY LIGHT
MAIN HARNESS
TUNER
GAUGE CLUSTER
HORN SWITCH
POWER RESERVE
MAINTENANCE CONNECTOR
KPPS. MODE RELEASE SWITCH
DIODE (GLOW RELAY)
HOUR METER
ATT POWER BOOST SWITCH
CAB WORK LIGHT SWITCH
SINGLE/CONFLUX SELECT SWITCH
12V SOCKET
FLASHER RELAY
SWING FLASHER SELECT SWITCH
TO E/G ROOM LIGHT
3.6.1 STARTER CABLE
CN-10M
ALTERNATOR
TO AIR CONDITIONER
CN-11F
CN-3F
CN-70M
Fig.2 Harness connection drawing

7
3.3 CONTROLLER ASSY
Fig.3 Controller harness assy

CONTROLLER ASSY
ITEM
REMARKS
SWITCH ASSY
RELAY
CAB HARNESS ASSY
For swing parking release
6-3
HARNESS
Not shown
Inst-panel harness
13
SWITCH ASSY
16
RESISTOR
23
TIMER
25
CAB HARNESS ASSY
Not shown
HARNESS
Inst-panel harness
26
FUSE ASSY
27
CONTROLLER
28
CAB HARNESS ASSY
25-4
KPSS release SW.
29
FUSE ASSY
30
RELAY ASSY
Not shown
Inst-panel harness
32
RELAY
37
CONTROLLER
38
FUSE ASSY
39
RELAY
40
CONTROLLER
28-3
PART NAME
HARNESS
3.3.25-4 INSTRUMENT PANEL HARNESS
Fig. 4 (1/2) Instrument panel harness
Fig. 4 (2/2) Instrument panel harness

10

11
3.4 INSTRUMENT PANEL ASSY

INSTRUMENT PANEL ASSY
ITEM
1
1-2
1-3
2
11
17
21
21A
21B
22
24
26
38
40
40A
41
43
46
PART NAME
PANEL ASSY
POTENTIO METER
KEY SWITCH
GAUGE CLUSTER
SPEAKER
GAUGE CLUSTER
SWITCH
TUNER
TUNER AM/FM
GAUGE CLUSTER
SWITCH
CONVERTER
SOCKET
ANTENNA
SWITCH
SWITCH
SWITCH
HOUR METER
QTY
1
1
1
1
2

1

1
1

1
1

1
REMARKS
RH
Auto accel release
Auto accel release

DC-DC
12V power source
Over load indication
Rotary light
Fig.5 Instrument panel assy

12
3.5 UPPER ELECTRIC ASSY

BATTERY RELAY
UPPER ELECTRIC ASSY

ITEM
PART NAME
QTY
1
REMARKS
BATTERY RELAY
HORN
High
HORN
Low
LIGHT ASSY
For E/G room
Tighten from the forward

TIGHTENING TORQUE :
1.09kgfym {7.9 lbfyft}
TORQUE :
DETAIL OF HORN
5Y(YELLOW)
5W(WHITE)
1PAF
(R-3)
GLOW RELAY
WL
2PAF
Fix the
connector with clip.
To right work light
VIEW I
VIEW
II
Connect as shown so
as to avoid short
circuit power source
id
(R-1)
BATTERY RELAY
DETAIL OF E/G ROOM LIGHT
8
SECTION A
STARTER
CABLE
TORQUE :
TORQUE :
1.09kgfym
{7.9 lbfyft}
Fix the rubber

with this hole.
Case of fix rubber

(R-3)
GLOW RELAY
UPPER
HARNESS
BATTERY
RELAY CABLE
Cover the rubber as shown in drawing,

and fix the battery relay with sems bolt.
Then fit the cable (harness).
DETAIL OF BATTERY RELAY
DETAIL OF FIXING THE RUBBER
Fig. 6 Upper electric assy
13
3.6 UPPER HARNESS ASSY

UPPER HARNESS ASSY
ITEM
1
2
3
4
5A
5B
5C
6
15
16
PART NAME
CABLE
CABLE
CABLE
CABLE
HARNESS
HARNESS
HARNESS
CABLE
HARNESS
HARNESS
QTY
1
1
1
1
1
REMARKS
Starter
Battery relay
Battery
Ground
Main harness
Main harness
Main Harness
Frame ground
E/G room light
Over load SW.
NOTE :
1. Torque for battery terminal is 0.34kgfym {2.46 lbfyft}.
2. Unspecified torque for grounding is 2.4kgfym {17.3 lbfyft}.
Fig. 7 (1/3)
14
Upper harness assy
(PSV-P1)
PROPO. VALVE : P1 PUMP
(SE2)
PRESS. SENSOR :
BUCKET DUMP
CLIP
(PSV-P2)
PROPO. VALVE : P2 PUMP
(SE5)
PRESS. SENSOR :
SWING LEFT
Fix the harness at

white taping portion.
Connect with governor

motor harness.
(M2)
GOVERNOR MOTOR
CLIP
CLIP
CLIP
CLIP
(L-11)
SWING FLASHER RIGHT
(SE7)
PRESS. SENSOR :
ARM IN
(SE4)
PRESS. SENSOR :
BOOM DOWN
(SE13)
E/G SPEED SENSOR
(SE3)
PRESS. SENSOR :
BOOM UP
(SE22)
PRESS. SENSOR :
P1 PUMP
(SE23)
PRESS. SENSOR :
P2 PUMP
VIEW III CONNECTION WITH ENGINE HARNESS
DETAIL OF CONTROL VALVE
YAZAKI
1 PAM-58Y
VIEW I DETAIL OF PUMP
(PSV-A)
ARM VARIABLE
RECIRCULATION
PROPO. VALVE
(PSV-B)
P2 BYPASS CUT
PROPO. VALVE
(PSV-C)
TRAVEL
STRAIGHT
PROPO. VALVE
(PSV-D)
P1 BYPASS CUT
PROPO. VALVE
TORQUE :
Fix the
connector with clip.
Fix the harness at

E/G SUB HARNESS
To right work light
CLIP
(R-1)
BATTERY RELAY
STARTER
CABLE
MAIN
HARNESS
SUMITOMO
8 PAF-HW
1
VIEW IV CONNECTION WITH ENGINE HARNESS
(SV1)
SWING PARKING SOL
(R-3)
GLOW RELAY
MAIN
HARNESS
(SW-37)
HYD. FLUID TEMP. SW
(SV3)
TRAVEL
1,2 SPEED SOL
DETAIL OF PROPORTIONAL VALVE BLOCK
(R-3)
GLOW RELAY
5W(WHITE)
1PAF
5
(SV2)
ATT BOOST SOL
5Y(YELLOW)
2PAF
(SV4)
LEVER LOCK SOL
BATTERY
RELAY CABLE 2
VIEW V DETAIL OF GLOW RELAY

VIEW II DETAIL OF BATTERY RELAY
Fig. 7 (2/3) Upper harness assy

15
Fig.7 (3/3)
16
Upper harness assy
3.6.4 BATTERY GROUND CABLE

4000 (131)
100
(3.94)
WHITE TAPING
CAP
YAZAKI 7034-1283
450
(17.7)
INSTALL
CORRUGATE TUBE
60sq
3.6.6 FRAME GROUND CABLE
300 (11.8)
(0.787)
[20]
TERMINAL
60-8
INSTALL
CORRUGATE
TUBE
TAPING
100
(3.94)
TERMINAL
BA710
LA308 5B
AVX5sq
Bundle two connectors back to

back with vinyl tape and put a cap.
CAP
YAZAKI 7034-1283
TERMINAL
BC816
TERMINAL
LA310
AV60B
DOUBLEWOUND TAPING
TERMINAL
60-8
Fig. 11
E/G ROOM LIGHT HARNESS
SW-42 :
E/G ROOM LIGHT SW
CONNECTORS SELECTION TABLE
1PAF-58Y
YAZAKI
5B
1PAM
YAZAKI 7122-3010
3.6.15
DETAIL OF A PORTION
MANUFUC.
100 (3.94)
Fig. 12
150
(5.91)
50
(1.97)
1PAF-58Y
[20]
(0.787)
CONNECTOR
NAME
(PIN NUM.)
3.6.1 STARTER CABLE
CB104
PART. NUMBER
HOUSING
TERMINAL HARNESS SEAL
7123-4210-40
7116-3250
7157-3580-60
Fig. 8
LA105
2PAM-MK
L-8 :
E/G ROOM LIGHT
TO UPPER HARNESS
3.6.2 BATTERY RELAY CAB

800 (31.5)
CAP
YAZAKI 7034-1283
TERMINAL
60-8
AV60B
TERMINAL
BC818
CAP
BTC-135-R(RED)
Fig. 9
Fig. 13
3.6.3 BATTERY C
3.6.16
OVER LOAD SWITCH HARNESS
250 (9.84)
AV60B
CAP LEFT
CAP RIGHT
TERMINAL LEFT
TERMINAL RIGHT
INSTALL CORRUGATE TUBE
Fig. 10
Fig. 14
17
3.6.5 MAIN HARNESS
18
Fig. 14
Main harness

19
CONNECTOR FOR
E/G SPEED SENSOR
E/G HARNESS ASSY

ITEM
NAME
HARNESS
3.7 E/G HARNESS ASSY
BRACKET
QTY REMARKS
1
Fit this clip directing

as shown.
E/G SUB
CLIP
Fix harness using

this hole as shown.
This harness not to be

contacted with the pulley.
VIEW II
UPPER
FRAME HARNESS
DETAIL B
GND (E/G ACCESSORY)

Clamp with grounding bolt.
STARTER MOTOR(M-1)
Fix the harness at

YAZAKI
1PAM-58Y
GOVERNOR MOTOR(M-2)
CLIP
Clamp this clip
with level gauge.
Fix connector
of harness.
GLOW
MAIN
HARNESS
Fix the harness free from

contacting with engine.
AIR-CON
COMPRESSOR
B
ALTERNATOR(E-2)
Tighten ground terminal to

A/C compressor bracket.
SUMITOMO
8PAF-HW
DETAIL OF
STARTER MOTOR
DETAIL OF GOVERNOR
MOTOR BRACKET
C
Tighten to fuel filter using

existing capscrew.
TORQUE : 6.6kgfym {47.7 lbfyft}
CLIP
NUT
E/G
LOCK
ACCESSORY
WASHER
Tighten to lifting lug using

exsisting capscrew.
TORQUE : 6.6kgfym {47.7 lbfyft}
HARNESS
WASHER
BRACKET
CLIP
CLIP
Insert this portion into

clip of connector.
DETAIL C
DETAIL OF ALTERNATOR
DETAIL A
VIEW I
20
CLIP
E/G OIL
PRESS.SW
(SW-7)
E/G COOLANT
TEMP.SENSOR
(SE-14)
E/G SUB HARNESS
SAFETY RELAY
(R-4)
GLOW
E/G COOLANT
TEMP. SW
E/G SUB HARNESS
E/G SPEED SENSOR

CONNECTOR INSTALLATION
Fig. 15 E/G harness
3.7.1 ENGINE SUB HARNESS

SW-7 :
E/G OIL SW
LA104
P-32
GND
LA310
P-31
CONNECTORS SELECTION TABLE

2FY-SWP
CN-350F
1MY-58Y
CN-351M
M-1 :
STARTER MOTOR
GLOW
CAP : YAZAKI 7034-1279
LA304
P-38
PLUG
CB104
F-32
CA104
M-32
LA305
P-35
CB104
F-31
E-11 :
AIR-CON COMPRESSOR
LA306
P-37
CAP :
YAZAKI 7034-1279
LA306
P-36
R-4 : SAFETY RELAY

8FS-HW090
CN-318F
E-2 :
ALTERNATOR
CONNECTOR
NAME
(PIN NUM.)
MANUFUC.
2FY-SWP
PART. NUMBER
HOUSING
TERMINAL
YAZAKI
7123-1424-40
7116-1471
1MY-58Y
YAZAKI
7222-4210-40
7114-3250
STRAIGHT
TERMINAL
YAZAKI
7120-3011
7116-2270
8FS-HW090
SUMITOMO
6189-0134
1500-0106
CA104
YAZAKI
7120-8012
7113-1020-02
CB104
YAZAKI
7120-1010
7115-1050-02
WITH TAPING
1MY-58Y
CN-352M
TO MAIN HARNESS
STRAIGHT
FEMALE
F-33
SE-14 :
E/G COOLANT TEMP. SENSOR
LA104 SW-6 :
P-34 E/G COOLANT TEMP.SW
Fig. 16 Engine sub harness
21
3.8 UPPER HARNESS ASSY (FLOOR PLATE)

UPPER HARNESS ASSY
(FLOOR PLATE)
ITEM
PART NAME
QTY
REMARKS
CABLE
GROUND
HARNESS
UNDER FLOOR
Fig. 17
22
Upper harness assy (Floor plate)
3.8.7 UNDER FLOOR HARNESS
Fig. 18
Under floor harness
23
3.9 CAB HARNESS ASSY

CAB HARNESS ASSY
PART NAME
3 HARNESS
1B HARNESS
2B HARNESS
ITEM
QTY
1
1
1
REMARKS
Cab front
Inst LH
Inst RH
Fig. 19 Cab harness assy

24
3.9.9 INSTRUMENT PANEL LH HARNESS
Fig. 20
Instrument panel LH harness

25
INSTRUMENT PANEL RH HARNESS
Fig. 21 Instrument panel RH harness

26
3.9.2A
3.10 CAB ASSY

CAB ASSY
PART NAME
QTY
FRONT WINDOW ASSY
2-8
WIPER ASSY
ITEM
REMARKS
M/W
2-37 HARNESS
25
SWITCH
Door
61
HARNESS
Curl code
64
HARNESS
M/W
65
ANTENNA
68
ROOM LIGHT
189
HARNESS
M/W, Room lamp
195
STOPPER ASSY
Wiper control
195-3 INTER ROCK SWITCH
CAB INSTALL
ITEM
PART NAME
QTY
WATER TANK ASSY
4-1 ELEC MOTOR ASSY
REMARKS
Fig. 22 Cab install
Fig. 23 Cab assy

27
WIPER HARNESS
3.10.61
CURL CODE HARNESS
Fig. 24
3.10.64
3.10.2-37
CAB WIPER MOTOR HARNESS
Fig. 25
Fig. 26
3.10.65
ANTENNA
3.10.189
ROOM LAMP HARNESS
3.10.4
WINDOW WASHER TANK & MOTOR
Fig. 27 Antenna
Fig. 29 Wind washer pump
Fig.28 Room lamp harness

28
3.11 BOOM HARNESS ASSY

BOOM HARNESS ASSY
ITEM
PART NAME
HARNESS
QTY
1
REMARKS
Boom harness
Fig. 30 Boom harness assy
29
3.11.1
BOOM HARNESS
Fig. 31 Boom harness
30
3.12.2
INSTALLING BOOM LIGHT

ITEM
PART NAME
LIGHT
QTY
2
3.12 INSTALLING LIGHT

3.12.1 INSTALLING BOOM LIGHT
INSTALLING DECK LIGHT

INSTALLING DECK LIGHT
REMARKS
ITEM
Install two lights

symmetrically
PART NAME QTY REMARKS

LIGHT
1
1
To bucket bottom center

Direct the light beam to the bottom
of bucket, when arm is completely
extended (Arm out) and bucket is
fully closed.
NUT(LIGHT ACCESSORY)
TORQUE ;
BRACKET
TORQUE ;
INSTALLING PROCEDURE OF RIGHTSIDE DECK LIGHT
SECTION A-A
Fig. 32 Boom light installing
Fig. 33 Deck light installing

31
3.12.3
CAB LIGHT INSTALL

CAB LIGHT INSTALL
ITEM
PART NAME
18 HARNESS
QTY REMARKS
1
Fig. 34 Cab light install

32
CAB LIGHT HARNESS
3.12.4
3.12.3.18
SWING FLASHER LAMP INSTALL
SWING FLASHER LAMP INSTALL

ITEM
Fig. 35
Cab light harness
PART NAME
QTY REMARKS
LAMP
SWITCH
Fig. 36
Swing flasher lamp

33
FUEL PUMP ASSY INSTALL

ITEM
PART NAME
FUEL PUMP ASSY
QTY REMARKS
1
Fig. 37 Fuel pump assy
34
3.13 FUEL PUMP ASSY INSTALL
3.14 NAME PLATE INSTALL (ELECTRIC COMPONENT FOR AUTO IDLE STOP)
NAME PLATE INSTALL
ITEM
PART NAME
SWITCH
QTY
REMARKS
Fig. 38 Switch install
35
36
E200SR
SECTION 24
COMPONENTS SYSTEM
TABLE OF CONTENTS
I. HYDRAULIC COMPONENTS
1. Hydraulic Pump_Regulator ...............................................................................................
2. Pilot Valve (ATT) ...............................................................................................................
3. Pilot Valve (Travel) ............................................................................................................
4. Control Valve ....................................................................................................................
5. Swing Motor Unit ..............................................................................................................
6. Travel Motor .....................................................................................................................
7. Swivel Joint .......................................................................................................................
8. Hydraulic Cylinder.............................................................................................................
H1-1
H2-1
H3-1
H4-1
H5-1
H6-1
H7-1
H8-1
II. ELECTRIC EQUIPMENT

1. List of Electric Equipments .................................................................................. E1-1
2. Specification of Electric Equipments .................................................................... E1-3
1. HYDRAULIC PUMP REGULATOR

1.1 SUMMARY
(1) Outside view and hydraulic port
a3 PSV1 5 a5,Dr3
A3
No.
3
B3
Dr1
NAME
MAIN PUMP ASSY
REGULATOR ASSY
GEAR PUMP ASSY(FOR PILOT)
PTO GEAR CASE ASSY

SOLENOID PROPORTIONAL
REDUCING VALVE
PSV2 a4
6
a3
6
a4 2
PSV1
A3
a5
Dr3
1
B3
Dr1
A1
A2
B1
PH2
Table 1-1
Code
a2
A2
Hydraulic ports
Ports name
Size
A1,2
Delivery port
3/4
B1
Suction port
2 1/2
Dr1
Drain port
PF1/2
PSV1,2 Servo assist port
PF1/4
PH1,2 Pressure sensor port
PF3/8
a15 Gauge port
PF1/4
A3
Delivery port of gear pump(for pilot)
PF3/8
B3
Suction port of gear pump(for pilot)
PF3/4
Dr3
Drain port of gear pump(for pilot)
PF3/8
Fig. 1-1
Hydraulic pump y regulator

H11
(2) Hydraulic circuit diagram
Solenoid
proportional
reducing valve
Solenoid
proportional
reducing valve
Regulator
Regulator
Engine
Main pump
PTO Gear case
Gear pump for pilot
(3) Specification
Table 1-2
Item
Main pump
Gear pump for pilot
cm3 /rev
802
10
Rated revolution
rpm
2,200(clockwise as seen from shaft end)
Working pressure
kgf/cm2(psi)
Max.displacement
capacity
Max. flow
Max. input horsepower
/min(gal/min)
51(725)
176(46)2
22(5.8)
PS
Max. input torque kgfym (lbfyft)

Model
Regulator
350(4,980)
125 (Gear pump only : 4.3)

40.7(290) [Gear pump only :1.5 (11)]
KR380E02
Control function
Positive electric flow control
Others
With solenoid proportional reducing

valve(KDRDE5K)
Relief set pressure kgf/cm2(psi)
350(4980)
H12
51(725)
1.2 HYDRAULIC PUMP

1.2.1 CONSTRUCTION
(1) Main pump
535
789
732 212 156 532 214 531,548 534 702 792 724 954 124 901 116 711 312 719 151
152
113
252
953
808
251
886
406
717
261
406
111
123
824
774
127
710
262
401
490
271
211 153
467,728 157
Fig. 1-2
313 466,725 885
886 314
141
468,728
Construction of main pump
Table 1-3
No.
QTY
No.
NAME
SHAFT(F)
SHAFT(R)
1st GEAR
ROLLER BEARING
1
1
1
2
SEAL COVER(R)
PUMP CASING
VALVE BLOCK
124 NEEDLE BEARING
262
271
312
313
314
4
2
18
18
2
2
18
2
2
2
SWASH PLATE SUPPORT(F)
1
1
SWASH PLATE SUPPORT(R)
SEAL COVER(F)
1
401
406
466
467
468
490
531
532
534
535
548
702
710
SOCKET BOLT : M16175 8 728 O RING : 1B P18

SOCKET BOLT : M616
8 732 O RING : 1B P16
VP PLUG : PF1/4
2 774 OIL SEAL
VP PLUG : PF1/2
3 789 BACKUP RING
VP PLUG : PF1/2
1 792 BACKUP RING
PLUG : NPTF1/16
15 808 HEX. NUT : M16
TILTING PIN
2 824 SNAP RING
SERVO PISTON
2 885 VALVE PLATE PIN
STOPPER : L
2 886 SPRING PIN
STOPPER : S
2 901 EYE BOLT : M10
FEED BACK PIN
2 953 SET SCREW : M16
O RING : 1B G30
2 954 SET SCREW : M16
O RING : 1B G85
2
111
113
116
123
127
141
151
152
153
156
157
211
212
214
251
252
261
NAME
BEARING SPACER
CYLINDER BLOCK
PISTON
SHOE
RETAINER PLATE
SPHERICAL BUSHING
CYLINDER SPRING
SHOE PLATE
SWASH PLATE
TILTING BUSHING
VALVE PLATE (For clockwise)

VALVE PLATE
(For counter clockwise)
H13
QTY
No.
1
2
1
1
1
711
717
719
724
NAME
O RING : 1B
O RING : 1B
O RING : 1B
O RING : 1B
725 O RING : 1B
QTY
G95
G120
G115
P8
1
2
2
18
P11
2
4
2
1
2
2
4
2
2
4
2
2
2
(2) Gear pump(for pilot)
700
354
433
351
434
728
435
312
311
732
710
361
850
307
353
310
308
309
434
466 355
725
Fig.1-3 Construction of gear pump(for pilot)
Table 1-4
No.
NAME
307
308
309
310
311
POPPET
SEAT
SPRING SEAT
SPRING
ADJUST SCREW
1
1
1
1
1
433
434
435
466
467
312 LOCK NUT : M14
700 RING
351
353
354
355
1
1
1
1
710
725
728
732
850 SNAP RING
GEAR CASE
DRIVE GEAR
DRIVEN GEAR
FILTER
361 FRONT CASE
QTY No.
H14
NAME
FLANGE SOCKET : M840
VP PLUG : PF1/4
ADAPTER : PF1/2-PF3/8
O RING : 1B
O RING : 1B
O RING : 1B
O RING : 1B
QTY
2
2
2
1
1
1
G80
P11
P18
P16
1
1
1
1
1
467
(3) PTO gear case
326
118
125
825
GEAR PUMP
(for pilot)
728 468
117
126
128
435
886
827
115
826
FRONT SIDE
REAR SIDE
Fig.1-4
Construction of PTO gear
Table 1-5
No.
NAME
QTY
No.
NAME
QTY
115 IDLE SHAFT
435 FLANGE SOCKET : M1020
117 2nd GEAR
468 VP PLUG : PF3/4
118 3rd GEAR
728 O RING : 1B
125 BALL BEARING
825 SNAP RING
126 ROLLER BEARING
826 SNAP RING
128 BEARING SPACER
827 SNAP RING
326 GEAR CASE
886 PIN
H15
P24
1.2.2 OPERATION
The pump assy is equipped with two pumps
arranged on the same axis that are connected
with gear(116) and distribute the rotating power
to the gear trains on a different axis. Thus the
engine rotation is transmitted to front shaft(111)
that drives the two pumps and, at the same time,
drives the pilot gear pump arranged on a different
axis.
The pump assy consists largely of the rotary
group, the main part of the pump that makes
rotary on; the swash plate group that changes the
delivery rate; the valve block group that selects
between oil suction and delivery ; and the PTO
group that transmits the drive power to the gear
pump.
REGULATOR
116
111
(1) Rotary group

The rotary group consists of shaft(111),
cylinder block(141), piston(151), shoe(152),
plate(153), spherical bushing(156), and
cylinder spring(157).
The shaft is supported by bearings(123) and
(124) at its both ends. The shoe, which is
caulked to the piston, forms a spherical joint
and relieves it of thrust force that is
generated by load pressure.
Further, the piston is provided with a pocket
so it moves lightly on shoe plate(211), taking
hydraulic balance.
The sub group of the piston-shoe is pressed
against the shoe plate by the cylinder spring,
via the retainer plate and the spherical
bushing, so that it moves smoothly over the
shoe plate. The cylinder block(141) is also
pressed against valve plate(314)
by the
action of cylinder spring(157).
PTO
GEAR
GEAR PUMP CASE
(FOR PILOT)
Fig. 1-5
Construction of hydraulic pump
124
313
312
111
141
211
156
151
153
152
314124
116
157
Fig. 1-6
Rotary group
H16
(2) Swash plate group

The swash plate group consists of swash
plate(212), shoe plate(211),swash plate
support(251), tilting bushing(214), tilting
pin(531),and servo piston(532). The swash
plate is the cylindrical part that is formed on
the opposite side of the shoe sliding surface
and is supported by the
swash plate
support.
The hydraulic force controlled by the
regulator flows into the hydraulic chamber
that is provided on both sides of the servo
piston. This moves the servo piston to the
right and left. The result is that the swash
plate swings on the swash plate support via
the spherical part of the tilting pin and
changes the tilting angle().
(3) Valve block group
The valve block group consists of valve
block(312), valve plates(313),(314), and valve
plate pin(885). The valve plates having two
crescent-shaped ports are installed to valve
block(312) to feed oil and recycle it from
cylinder block(141). The oil switched over by
the valve plate is connected
with the
external pipe by way of the valve block.
(4) PTO group
The PTO group is composed of 1st gear(116),
2nd gear(117) and 3rd gear(118). The 2nd
and the 3rd gear are supported by
bearings(125) and (126) respectively and
installed to the valve block.
Now, if the shaft is driven by the engine, the
cylinder block rotates together by the spline
linkage. If the swash plate is inclined, the
pistons arranged in the cylinder block make
reciprocating motion with respect to the
cylinder while rotating with the cylinder
block. If we keep an eye on a single piston,
it makes a motion away from the valve
plate(oil suction process)in the first 180
and
a motion toward the valve plate(oil delivery
process) in the remaining 180. If the swash
plate is not inclined(zero tilting angle), the
piston does not stroke i.e. delivers no oil.
At the same time, the shaft rotation is taken
up by the 1st gear(116) and transmitted to
the 2nd gear(117) and the 3rd gear(118), in
that order, to drive the gear pump that is
linked to the 3rd gear.
H17
532
531
214
211
212
251
Fig. 1-7
Swash plate group

313
312
116
111
141 314
885
Fig. 1-8
Valve block group
117
126
118
125
125
Fig. 1-9
PTO group
Table1-7
1.3 REGULATOR
1.3.1 CONSTRUCTION
No.
418
415
601
897
496
755
543
614
545
541
708
756
611
SECTION
325
496
AA
079
079
325
402
407
415
418
466
496
541
543
545
601
611
614
624
627
631
643
646
651
652
656
658
708
724
731
733
755
756
801
887
897
924
NAME
REDUCING VALVE
VALVE CASING
SOCKET BOLT : M616
SOCKET BOLT : M630
SOCKET BOLT : M845
SOCKET BOLT : M512
VP PLUG : PF1/4
PLUG
SEAT
STOPPER
BALL
CASING
FEED BACK LEVER
FULCRUM PLUG : PF1/4
SPRING SEAT
PLUNGER
SLEEVE
PISTON
SPRING
SLEEVE
SPOOL
COVER
PLUG : NPTF1/16
O RING : 1B G75
O RING : 1B P8
O RING : 1B P25
O RING : 1B P18
O RING : 1B P11
O RING : 1B P12.5
HEX NUT : M8
PIN
PIN
SET SCREW
624 646 627 733 656 402

643
466
755
924
407
A
724
887
631
731
801
651
733
652
Fig. 1-10
658
H18
Construction of regulator
Q'TY
1
1
4
4
6
2
1
9
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
5
1
2
2
2
1
1
1
1
1.3.2 OPERATION
DELIVERY RATE Q
(1) Summary
Regulator KR38-0E02 for the inline axial
piston pump K5V series is of electric flow
control type that regulates the tilting angle
(delivery rate) of the pump as the command
current I to the solenoid proportional
reducing valve is varied.
This regulator is of positive flow control type
that increases the delivery flow Q as the
command current I increases.
If an electric current is put in by this control
according to the flow needed for the
operation, the pump delivers at a flow rate
that is only required by the pump,
consequently holding down unwanted power
consumption.
(2) Positive control.
As shown in the figure on the right, the
regulator regulates the delivery rate of the
pump by command current I.
1) Flow increasing action
As the command current I rises, the
secondary pressure of solenoid proportional
reducing valve (079) increases. This causes
spool (652) to move via pilot piston (643) and
stops where the hydraulic pressure pushing
the spool rightwards balances with the action
of pilot spring (646).
If the spool (652) moves, port C opens to the
tank port. This causes the pressure of the
large diameter part of servo piston (532) to go
away. This causes the servo piston (532) to
the left by delivery pressure P1 of the small
diameter part, resulting in an increase in the
tilting angle .
643 652
611
651
COMMAND CURRENT I
Fig.1-11 Positive flow control
624
627
646 801
924
532
808
808
954
953
TILTING MIN.
TILTING MAX.
Fig. 1-12 Functions of regulator

H19
Feedback lever(611) is linked with the servo

piston and sleeve(651). As the servo piston
moves to the left, the feedback lever rotates
on point A which causes the sleeve to the
right. As the servo piston moves to the right,
the feedback lever rotates on point A to move
the sleeve to the right. The result is that the
opening of the spool sleeve begins to close
gradually and the servo piston settles down
when the opening of the spool sleeve closes
completely.
(2) Flow decrease function
As the command current decreases, the
secondary
pressure
of
the
solenoid
proportional valve decreases. This causes the
spool to move to the left.
When the spool(652) has moved, delivery
pressure P1 reaches port C via spool and is
admitted to the large diameter chamber of
the servo piston. Delivery pressure P1 is
admitted to the small diameter part of the
servo piston at all times. The servo piston
moves rightward by areal difference to
decrease tilting angle ( ). As the servo
piston moves to the right, the feedback lever
rotates on point A to move the sleeve to the
left. The sleeve keeps moving till the opening
of the spool sleeve closes and settles down
when the spool sleeve closes completely.
REDUCING VALVE
REGULATOR
646
652
MAIN
PUMP
643
651
H110
PORT 532
Fig. 1-13
POINT 611
A
Regulator hydraulic circuit
1.3.3 ADJUSTING REGULATOR

The maximum flow, minimum flow and flow
control characteristics of the regulator may be
controlled by the adjust screw of the
regulator.(Amounts of adjustment are shown in
table 1-8.)
However, the adjustment may change
the flow characteristics. Therefore, do
not tamper with the adjust screws
unless there is special reason.
Table1-8 Amounts of change by the adjustment of regulator
KR380E02
Solenoid proportional valve model
2200rpm-1
Pump revolution
Max. flow
Adjust screw(954)1/4turn
Flow rate Q=3.5 /min (0.87gal/min)
Min. flow
(1) Adjusting the maximum flow

For adjustment, loosen the hex nut (808) and
tighten (or loosen) the set screw (954) on the
large diameter part of the servo piston.
Tightening it decreases the flow and
loosening it increases the flow.
Only the maximum flow changes with other
control characteristics unchanged.
DELIVERY RATE Q
Current I=24.5mA
Flow control characteristics
COMMAND CURRENT I
DELIVERY RATE Q
Fig. 1-14 Adjusting the max. delivery rate

(2) Adjusting the minimum flow
For adjustment, loosen hex nut (808) and
tighten (or loosen) the set screw (953) on the
small diameter part of the servo piston.
Tightening it increases the flow and
loosening it decreases the flow.
Other characteristics do not change the same
way as the adjustment of the maximum flow.
Note that if the set screw is tightened too
much, the power requirement at the
maximum delivery pressure (at relieving)
increases in some cases.
COMMAND CURRENT
Fig. 1-15 Adjusting the min. delivery rate

H111
DELIVERY RATE Q
(3) Adjusting the flow control characteristics

For adjustment, loosen hex nut (801) and tighten
(loosen) the set screw (924). If the set screw is
tightened, the control curve moves rightwards, as
shown in Fig.1-16.
COMMAND CURRENT
Fig. 1-16
1.3.4 CAUSES OF FAULT RESULTING FROM
REGULATOR
(1) Engine is overloaded
Load each of the pumps and check which of the
pumps, front or rear is faulty. In case both are faulty,
check the following
and : If only one of the
pumps is faulty, start with
.
Check that the command current
of the solenoid
proportional reducing valve is normal.
The secondary pressure
Check amplifier
of solenoid proportional
dither.
reducing valve is high.
Replace solenoid
proportional
reducing valve.
Spool (652) and
Sleeve (651) are
stuck.
Disassemble and
clean.
Pilot piston (643)

is stuck
Disassemble and
clean.
(2) Max. delivery rate can not be attained

Confirm that the secondary pressure of the solenoid
proportional reducing valve is normal.
Pilot piston (643)
is stuck.
Spool (652) and
sleeve (651) are
stuck.
Disassemble and clean.
Disassemble and clean.
H1
12
Flow control characteristics
1.4 CONTROL CURVE OF PUMP E200SR

(1) At H mode
1
Input rotation_2200min_ {rpm}
Delivery flow rate_Q
/min (gal/min)
200
(52.8)
(Travel_ATT)
Independent loading (P2=5.1kgf/cm (72.5psi),Qmin)

83.6kw (113PS)
150
(39.6)
100
(26.4)
Simultaneous loading
83.6kw (113PS)
50
(13.2)
Min. flow rate
0
0
50
711
100
1422
150
2133
200
2844
250
3555
300
4266
kgf/cm
(psi)
350
4977
Delivery pressure Pd
(2) At S mode
1
200
(52.8)
(Travel) Independent loading

2
(P2=5.1kgf/cm (72.5psi),Qmin) 79.8kw (108PS)
/min (gal/min)
(Travel_ATT)
(ATT) Independent loading

2
(P2=5.1kgf/cm (72.5psi),Qmin)
78kw (106PS)
150
(39.6)
100
(26.4)
(Travel)
79.8kw (108PS)
(ATT) Simultaneous loading

78kw (106PS)
50
(13.2)
Min. flow rate
0
0
0
50
711
100
1422
150
2133
200
2844
250
3555
H1-13
300
4266
350
4977
kgf/cm
(psi)
(3) At FC mode
1
/min (gal/min)
200
(52.8)
150
(39.6)
Independent loading
2
(P2=5.1kgf/cm (72.5psi),Qmin)
53.1kw (72.2PS)
(Travel_ATT)
100
(26.4)
53.1kw (72.2PS)
50
(13.2)
Min. flow rate
0
0
0
50
711
100
1422
150
2133
200
2844
H1-14
250
3555
300
4266
350
4977
kgf/cm
(psi)
2. PILOT VALVE (ATT)

2.1 OUTLINE
(1) Outside view
(2)
SINGLE
OPERATION
ANGLE
(PORT 2,4)
The adjust nut

(opposing flats : 22) :
Fix adjust nut
(opposing flats : 22)
when the lever is installed by
means of spanner or the like.
Then tighten the mating lock
nut to 4.20.3kgfym
(302.2 lbfyft).
SINGLE
OPERATION
ANGLE
(PORT 1,3)
Specification
Table 2-1
Item
Specification
Model
PV48K2005
Operating torque
Refer to the curve below
Max. primary pressure 70kgf/cm2 (995psi)

Primary pressure
51kgf/cm2 (725psi)
Rated flow
20 /min (5.3gal/min)
Weight
Approx. 1.9kg (4.2 lbs)
(3) Performance characteristics
5-PF3/8
T=50.5(363.6)
PF1/4
T=30.2(221.4)
T=Tightening torque : kgfym (lbfyft)
Hydraulic simbol
Fig. 2-1
H21
2.2 CONSTRUCTION,FUNCTION AND OPERATION

(1) Cross section view
312
302
501
Apply grease
on rotating and
sliding sections.
301 Be careful the
assembling
direction
212
213
Apply grease on
top section
151
246
211
218-2
214
218-1
216-2
216-1
241-2
241-1
201-2
201-1
217
Secondary
101
pressure
adjusting shim
Designed value
t=0.4 (0.016 ),
1 pc.
221
PORT 2,4
PORT 1,3
Fig. 2-2 Pilot valve (ATT)

Apply Loctite #277 to areas marked
Tightening torque
kgfym (lbfyft)
No.
NAME
QTY
Tightening torque
kgfym (lbfyft)
No.
101
151
201-1
201-2
211
CASING
PLATE
SPOOL
SPOOL
PLUG
1
1
2
2
4
218-1
218-2
221
241-1
241-2
212
213
214
216-1
216-2
PUSH ROD
SEAL
O RING : 1B P20
SPRING SEAT 1
SPRING SEAT 1
4
4
4
2
2
246
301
302
312
501
WASHER 2 (SHIM)
217
Note) The parts marked
4.8 (35)
7 (51)
may not be equipped depending on value type.

H22
NAME
QTY
SEAT
SEAT
SPRING
SPRING
SPRING
2
2
4
2
2
SPRING
JOINT : M14
CIRCULAR PLATE
ADJUST NUT : M14
BOOTS
4
1
1
1
1
(2) Construction
The pilot valve is constructed as shown in the
cross-sectional view (Fig.2-2). The casing has
a vertical shaft hole in which a reducing
valve is assembled.
The reducing valve consists of spool (201),
spring (241) (for secondary pressure setting),
spring (221) (for return), spring seat (216),
and washer (217). The spring (241) (for
secondary pressure setting) is so set as to
achieve the secondary pressure conversion
5~10kgf/cm2 (71~140psi) (varies with the
model.). The spool (201) is pressed against
push rod (212) by spring (221) (for return).
If push rod (212) is pushed down by tilting
the control part of the handle, the spring seat
(216) falls at the same time and changes a set
pressure of spring (241) (for secondary
pressure setting).
The casing (101) and the port plate (111) are
provided with an oil inlet (primary pressure)
port P and an outlet (tank) port T. They are
further provided with ports 1, 2, 3, 4 from
which secondary pressure is discharged.
(3) Function
1) Basic functions
The pilot valve controls the stroke and the
direction of the control valve spool. This is
achieved by applying the output pressure of
the pilot valve to the end of the control valve
spool.
In order to satisfy the functions, the pilot
valve is constructed with the following
elements :
Inlet port (P) to which the oil of the
hydraulic pump is supplied.
Multiple output ports (1, 2, 3, 4) that
exert the supply pressure from the input
port upon the end of the spool of the
control valve.
Tank port (T) to control the above
mentioned output pressure.
Spool that connects the output port with
the inlet port or the tank port.
The mechanical means including springs
that act upon the above- mentioned
spool, in order to control the output
pressure.
2) Main functions
The function of spool (201) is to receive the
supply pressure of the hydraulic pump by
port P and admit the hydraulic pressure at
port P to output ports (1, 2, 3, 4) or admit the
hydraulic pressure at the output ports to port
T. Spring (241) (for secondary pressure
setting) acts upon spool (201) and determines
the output pressure.
Push rod (212) that changes the deflection of
spring (241) (for secondary pressure setting)
is inserted in plug (211) so as to enable
smooth movement.
Spring (011) (for return) acts upon casing
(101) and spring seat (216) and brings push
rod
(212)
toward
zero
displacement
regardless of output pressure, in order to
positively bring spool (201) back to neutral.
The spring also acts as a reactive force that
gives the operator a proper operating feeling.
H23
(4) Function
Now, let us explain the function of the pilot
valve, using the hydraulic diagram (the
figure on the right) and the functional
explanation drawing (Fig.2-3 to 2-5).
c
1
3
P T
d
cPilot valve dPilot pump
Lever in neutral
1) Handle in neutral (See Fig.2-3.)

The action of spring (241) (for secondary
pressure setting) that determines the output
pressure of the pilot valve does not act upon
spool (201). Therefore, spool (201) (for return)
is pushed up by spring (221) [spring seat 1
(216)]. The output ports (2,4) connect with
the T port. The result is that the output
pressure is equal to the tank pressure.
216
241
221
201
PORT(2,4)
Fig. 2-3 Handle in neutral
H24
2) When the pilot lever is tilted (See Fig. 2-4 )

When the lever is tilted and the push rod
(212) strokes, the spool (201) spring seat
(216) moves down-ward to make the port P to
connect with the port 2, 4, with the result
that the oil of the pilot pump flows to the port
2 ,4 to produce a pressure.
212
216
201
PORT(2,4)
3) Handle held (See Fig.2-5.)

When the pressure at ports (2,4) rises to a
level equivalent to the action of spring (241)
that is set by tilting the handle, the hydraulic
pressure balances the spring action. When
the pressure of ports (2,4) rises above a set
value, ports (2,4) and the P port close while
ports (2,4) and the T port open. When the
pressure at ports (2,4) falls below a set value,
ports (2,4) and the P port open while ports
(2,4) and the T port close. Thus the secondary
pressure is kept constant.
Fig. 2-4 When the lever is tilted
241
T PORT
P PORT
PORT (2,4)
Fig. 2-5 When the handle is held

(When the secondary pressure is higher than a set value)
4) Operation in the area where the tilting angle
of the handle is large. (varies with the model)
If the handle is inclined beyond a certain
angle on certain models, the top end of the
spool contacts the bottom of the bore of the
push rod. This keeps the output pressure
connected with the P port pressure.
Furthermore, on a model in which a spring
seat and a spring are built in the push rod,
H25
the bottom of the bore of the push rod

contacts the spring if the handle is turned
beyond a certain angle. This causes the
secondary pressure gradient to change by the
spring action. Thereafter, the bottom of the
bore of the push rod contacts the top end of
the spring seat, keeping the output pressure
connected with the P port.
H26
3. PILOT VALVE (TRAVEL)

3.1 OUTLINE
(1) Outside view
VIEW FROM MACHINE REAR SIDE
Port
size
Tightening
Port
torque
kgfym (ftylbs) name
7.50.5
(543.6)
PF3/8
3.70.2
(271.4)
PF1/4
(2) Specification
4-11
Function
Through
1
2
3
4
T
RH travel reverse port

RH travel forward port
LH travel reverse port
LH travel forward port
Tank port
5
6
P
Travel pressure sensor

port
Travel pressure sensor
port
Pilot primary pressure port
Item
MACHINE FRONT
Specification
Type
07291-00000
Primary pressure
51kgf/cm2 (725psi)
Secondary pressure
5.524kgf/cm2 (78340psi)
Rated flow
10
Weight
Approx. 11kg (24 lbs)
Fig. 3-1
Out side view of travel pilot valve
(3) Performance characteristics
/min (2.6gal/min)
RIGHT
LEFT
Hydraulic simbol
Control diagram
H31
3.2 CONSTRUCTION AND OPERATION

Z
13
12
28
36
33 2
19
37
1,3
20
34
22
20
39
32
44,16
6
18
24
41
14
42
26
30
25
15
21
20
17
40
7
8
25,42
27
10,11
9 31
29
36 33
RORT5
PORT
5
25
42
PORT
PORT66
33 36
33
SECTION AA
35
4-M10
T=4.30.4(3129)
24,41
Tightening
torque
No.
kgfym (lbfyft)
1
2
1.5(11)
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
38
SECTION BB
VIEW
Fig. 3-2
NAME
ORIFICE(SHIM)
SEAT
ORIFICE(SHIM)
SPOOL
BODY
STOPPER
SPRING
SPRING
NAME PLATE
SHIM t=0.2
SHIM t=0.1
CAM
BOOTS
PIN
COVER
PISTON
GUIDE
SLEEVE
HOLDER
RING
ORIFICE(SHIM)
Construction of travel pilot valve

Apply Locktite #262 to areas marked .
Tightening
torque
QTY
No.
NAME
QTY
kgfym (lbfyft)
4
22 SPRING
4
2
1.0(7.2)
24 PLUG : PF1/8
3
4
2.5(18)
25 PLUG : PF1/4
3
4
6.0(43)
26 SOCKET BOLT : M1060
2
1
0.5(3.6)
27 FLANGE BOLT
4
4
1.5(11)
28 SETSCREW : M8
4
4
29 WASHER
4
4
30 WASHER
2
1
31 RIVET
2
4
32 PIN : 5
4
4
33 BALL
6
2
34 BALL
4
2
35 BALL
4
2
36 BALL
6
2
37 U PACKING
4
4
38 O RING : 1A P5
4
4
39 O RING : 1A P24
4
4
40 O RING : 1A P26
4
4
41 O RING : 1B P8
3
12
42 O RING : 1B P11
3
4
44 PISTON ASSY
4
H32
3.3 OPERATION
(1) Construction
The valve consists of the following parts in
terms of hydraulic function:
A : Damper section
B : Reducing valve section
C : Shuttle section
(2) Operation
1) Damper section
z If the primary pressure is supplied by P, it is
flowed to the damper chamber by way of
circuits D and E.
The pressure is then filled up in the damper
chamber via the orifice and the check valve.
In that case, the air present in the damper
chamber is pushed out to the T port from
circuits F and G, in order to prevent the
damper characteristics from fluctuating by
air mixture.
z If the cam operates during travel operation,

the oil in the damper chamber is kept from
flowing back by the check valve. Thus the oil
flows to part E oly from the orifice. Damper
action operates by the resistance that is built
up as the oil passes through the orifice.
Let us explain the profile of the piston (See
Fig. 3-4.)
The upper part of the piston has a diameter
of 12mm(0.472in), while the lower part of it
has a diameter of 11mm(0.433in). This
results in an areal difference, with the result
that the piston is constantly subject to a
vertical force.
For this reason, the orifice rises by the pressure
caused by the areal difference between the
operating part of the cam and the piston on the
opposite side i.e. the piston follows the cam.
That is to say, constant damper action
operates wherever the cam is located.
Since the larger diameter of the piston, the
cover, the 11mm diameter part of the piston
and the guide are manufactured with
minimal clearance, only a little leakage
occurs.
Consequently,
the
damper
performance is not affected at all.
CAM
F
G
PISTON
COVER
CHECK
VALVE
GUIDE
ORIFICE
SPRING FOR
SECONDARY
PRESSURE
DAMPER
CHAMBER
D
T
I
SPOOL
H
BODY
SECONDARY PRESSURE PORT
Fig. 3-3
H3
2) Reducing valve section

z At neutral
The primary pressure supplied by P is shut off
by the seal between the circumference of the
spool and the body hole.
The secondary pressure port is connected
with the T port through the vertical hole H
and the horizontal hole I in the center of the
spool. This causes the pressure to be reduced
to zero.
z At operation
If the cam tilts toward the operating
direction, the piston goes down. The spool sub
assy moves down.
If the notch J on the circumference of the
spool connects with the secondary pressure
port, the primary pressure supplied by P
enters the secondary pressure port.
In that case, the horizontal hole I enters the
hole of the body and seals it. As the result,
the circuit from the secondary pressure port
to the T port is shut off.
If the pressure at the secondary pressure port

rises above the action of the secondary
pressure spring, the spool is pushed up by the
pressure. The result is that the notch J
enters the hole of the body, shuts off the
circuit from the primary pressure port to the
secondary pressure port, and causes the
horizontal hole I to connect with the T port to
let the pressure of the secondary pressure
port out to the T port.
If the above-mentioned action is repeated, the
pressure at the secondary pressure port
becomes a level that balances the
compressive load of the secondary pressure
spring proportional to the cam stroke.
The return spring provides proper repulsive
force and positively brings the spool of the
reducing valve back to its neutral position.
12
(0.472 )
11
(0.433 )
RETURN
SPRING
J
P
J
H
SECONDARY
PRESSURE PORT
Fig. 3-4
H3
3) Shuttle section
z If pressure is built up at port 1 or 3, the ball
is pressed against the seat by the pressure.
The pressure goes through from port 1 to port
5(or from port 3 to port 6).
Only a little leakage occurs from port 2 or 4
as the ball is sealed metallically by the seat.
If pressure occurs at port 2 or 4, the ball is
pressed against the body by the pressure. The
result is that the pressure connects with port
5 from port 2(with port 6 from port 4).
Only a little leakage occurs at port 1 or 3 as
the ball is sealed metallically against the
body.
PORT 5
PORT 1
PORT 2
BALL
SEAT
BODY
PORT 3
PORT 4
PORT 6
Fig. 3-5
Shuttle section
H35
H36
Table 4-1(1/2)
4-M10 SCREW DEPTH 13
Port
size
4.1 SPECIFICATION
(This shows the valve with OPT2.)
Tightening
torque
kgfym (lbfyft)
Port
name
15~18
(110~130)
P1
P2
Ab
Bb
Ac
Bc
Ar
Br
AL
BL
Aa
Ba
As
Bs
Ao2
Bo2
(1) General view and hydraulic ports

PF3/4
3-M10-20/27 (FOR LIFTING)
TRAVEL
STRAIGHT
PTb
TRAVEL
RIGHT
PBr
PAr
TRAVEL LEFT
PAb
PA1
P1 CUT
ARM
CONFLUX
PCb
Port
size
Port
name
PF1/2
10~12
(72~87)
(P3)
(P4)
7~8
(51~58)
PAa
PBa
PAb
PBb
PAc
PBc
PAr
PBr
PAL
PBL
PAs
PBs1
PBs2
Pis
PA1
PB1
PTb
PCa
PCb
PAo2
PBo2
Arm in pilot port

Arm out pilot port
Boom up pilot port
Boom down pilot port
Bucket dump pilot port
Bucket digging pilot port
Travel right pilot port (forward)
Travel right pilot port (reverse)
Travel left pilot port (forward)
Travel left pilot port (reverse)
Swing right pilot port
Swing left pilot port 1
Swing left pilot port 2
Arm recirculation port
Arm conflux pilot port
Boom conflux pilot port
Travel straight pilot port
P2 bypass pilot port
P1 bypass pilot port
Option 2 pilot port (A)
Option 2 pilot port (B)
PF1/4
3.5~3.9
(25~28)
PL1
Dra
Drb
Drc
Drd
Pss
Pisc
PLc1
PLc2
Att power boost port

Drain port
Drain port
Drain port
Drain port
Swing pilot press. sensor port
Swing priority pilot port
Boom lock valve release pilot port
Arm lock valve release pilot port
M10
5~6.6
(36~48)
Description
Pump P1 port
Pump P2 port
Boom up port
Boom down port
Bucket dump port
Bucket digging port
Travel right port (forward)
Travel right port (reverse)
Travel left port (forward)
Travel left port (reverse)
Arm in port
Arm out port
Swing port (right)
Swing port (left)
Option 2 port (A)
Option 2 port (B)
BOOM
CONFLUX
BUCKET
ARM
BOOM
Pss
PF3/8
(P4)
PBL
PBs1
PAs
BOOM
CONFLUX
PB1
PLc2
ARM
PAa
ARM
Pis
RECIRCULATION
P1 CUT
TRAVEL
LEFT
SWING
SWING
TRAVEL
RIGHT
BOOM
PBb
PAL
Dra,Drb
PAc
PBc
Table 4-1(2/2)
Tightening
torque
kgfym (lbfyft)
TRAVEL
STRAIGHT
BUCKET
B
P1
4. CONTROL VALVE
Drd
ARM
RECIRCU-LAT
ION
PCa
PA02
Description
Option port
Option port
Tank port
PB02
(P3)
(2) Machine specification

Table 4-2
ARM
CONFLUX
(CUT)
Item
CUT
STD VALVE
Model
BOOM
KMX13YC/B33046
174 /min
Max flow
(46gal/min)2
350(4980) at 120 /min
Main relief valve set pressure
(32gal/min)
386(5490) at 110 /min
Power boost pressure
(29gal/min)
OPT VALVE
ARM
BUCKET
BOOM CONFLUX
TRAVEL
RIGHT
SWING
TRAVEL
STRAIGHT
Boom H, Bucket H, Arm R

Boom R, Bucket R, Arm H
OPT1, OPT2 H&R
P2
Fig. 4-1-1 Control valve outside view and hydraulic
Over load relief valve set pressure
TRAVEL LEFT
VIEW B
405(5760) at 30 /min
(7.9gal/min)
386(5490) at 30 /min
(7.9gal/min)
386(5490) at 30 /min
(7.9gal/min)
VIEW A
H41
164
155
4.2 CONSTRUCTION
101
273
PBL
H
C
PAL
H
TRAVEL
STRAIGHT
TRAVEL
LEFT
PAs
PBs1
PBs2
Pss
TRAVEL
RIGHT
SWING
BOOM
CONFLUX
BUCKET
E
BOOM
PB1
ARM
PAa
PBa
Pis
PCa
F
ARM
RECIRCULATION
CUT
(ARM
CONFLUX)
OPTION 2
PAo2
PBo2
(CUT)
162 164 155

SECTION
162
A
166 156
(974)
162
562
562
552
552
P2
973
102
974 973
P1
PTb
CT1
CT2
973
522
522
512
512
162
PAr
PBr
168
158
973
(973)
SECTION
PAc
PBc
JJ
973 PBb
SECTION
PAb
HH
PCb
PA1
973
162 164
H42
Fig. 4-2 (1/3)
Construction of control valve
155
SECTION
162
B
973
166
156
201
201
333
PAL
337
326
325
327
332
325
262
332
601
513
522
552
562
562
552
522
CP2
CMR1
BL
CMR2
512
522
206
552
562
562
162
162
304
333
PAs
338
332
337
327
324
332
262
163
512
Drb
329
332
Ar
262
512
As
522
LCs
552
562
163
Bs
Dra
265
206
552
SECTION
SECTION
206
201
333
PLc1 Drc
(PLc2) (Drd)
262
337
324
329
602
332
SECTION
211
262
562
162
162
512
522
512
303
PAb
PAa
(HEAD
SIDE)
CRb
Aa
522
552
LCb
LCa
Bb
CRa
562
562
556
(ROD SIDE)
Pisc
162
301
265
602
PBs1
(SWING)
PB1
(BOOM CONFLUX)
552
206
PBr
(TRAVEL RIGHT)
PBc
(BUCKET)
305
265
332
556
524
514
562
265
306
(HEAD
SIDE)
332
562
Br
Bc
552
562
329
522
CP1
LCc
324
325
206
Fig. 4-2 (2/3)
Construction of control
262
512
522
552
562
332
337
202
Pss
CCB
Ac
201
333
201
PAr
332
206
PBs2
332
325
265
603
333
326
522
552
PBL
(TRAVEL
LEFT)
SECTION
328
512
206
PTb
(TRAVEL
STRAIGHT)
337
(ROD SIDE)
265
265
332
337
329
332
262
162
163
306
513
162
307
PAc
602
262
162
AL
201
333
332
332
338
166
333
333
332
156
201
PBb
(BOOM)
PBa
(ARM)
SECTION
524
514
302
211
265
206
H43
(CUT)
PCb
204
333
332
(ARM RECIRCULATION)
Pis
337
326
325
332
262
512
562
552
PAL
Ab
CAa
(HEAD SIDE)
308
512
522
552
562
262
332
325
326
Tightening torque
kgfym (lbfyft)
No.
11~13 (80~94)
7~8 (51~58)
1.3~1.7 (9.4~12)
101
102
155
156
158
CASING A
CASING B
PLUG ; PF1/2
PLUG ; PF3/8
PLUG ; PF1/8
162
163
164
166
168
O RING ; 1B
O RING ; 1B
O RING ; 1B
O RING ; 1B
O RING ; 1B
201
522
310
162
CCa
(ROD SIDE)
Ba
337
332
333
204
PA1
(ARM CONFLUX)
PCa
(CUT)
SECTION GG
309
262
332
325
326
603
337
332
333
204
PAo2
272
271
Apply Loctite #262 to areas marked .
Table 4-3
10~12 (72~87)
10~12 (72~87)
2.6~3.5 (19~25)
NAME
Q'TY
Tightening torque
kgfym (lbfyft)
1
1
3
3
1
No.
NAME
Q'TY
308
309
310
324
ARM CONFLUX SPOOL

BYPASS CUT SPOOL
ARM RECIRCULATION SPOOL ASSY
SPRING(BOOM, ARM,SWING INNER)
1
2
1
3
17
3
3
3
1
325
SPRING (TRAVEL,CUT,ARM CONFLUX,
326
SPRING (CUT,ARM CONFLUX,
327
SPRING(TRAVEL INNER)
SPRING COVER
328
SPRING(BUCKET INNER)
202
204
206
211
SPRING COVER
SPRING COVER
SPOOL COVER
1
4
8
2
329
332
333
337
SPRING(ARM,BOOM, BUCKET,SWING OUTER)
SPRING SEAT
SPACER BOLT ; M8
STOPPER(OTHER THAN TRAVEL)
4
24
12
10
213
214
262
265
271
CONTROL VALVE FOR OPTION
O RING
O RING ; 1B G35
SOCKET BOLT M1225
1
2
12
8
4
338
512
513
514
522
STOPPER(TRAVEL)
POPPET
POPPET
POPPET(LOCK VALVE)
SPRING
2
11
2
2
13
272
273
301
302
303
SOCKET BOLT M1290

SOCKET BOLT M825
BOOM SPOOL ASSY
ARM SPOOL ASSY
SWING SPOOL
4
40
1
1
1
7~8 (51~58)
524
552
556
562
601
SPRING(LOCK VALVE POPPET)

PLUG M22
PLUG M22
O RING ; 1B P20
RELIEF VALVE(MAIN)
2
14
2
16
1
304
BUCKET SPOOL
7~8 (51~58)
602
RELIEF VALVE(OVER LOAD)
305
306
307
BOOM CONFLUX SPOOL

TRAVEL SPOOL
TRAVEL STRAIGHT SPOOL
1
2
1
7~8 (51~58)
14~18 (100~130)
14~18 (100~130)
603
973
974
RELIEF VALVE(PORT)
SOCKET BOLT M14110
SOCKET BOLT M1475
3
7
1
G30
P15
P18
P14
P8
LOCK VALVE SELECTOR SUB ASSY
PLATE
BOOM CONFLUX,TRAVEL)
BOOM CONFLUX, TRAVEL)
1.6~1.8 (12~13)
13~15 (94~110)
13~15 (94~110)
Note : *marked parts differ according to specifications.

Ao2
214
Bo2
271
PBo2
SECTION HH
Fig. 4-2 (3/3) Construction of control valve
H44
272
213
204
333
332
337
326
325
332
262
603
309
(3) Over load relief valve (602) ,(603)

103 614 661 613
123 124 125 561 562 611 104
512 541 521 121 122 621 663

163 664
Fig. 4-3
Tightening
torque
No.
kgfym (lbfyft)
78 (5158)
(2) Main relief valve (601)
NAME
103 PLUG
Q'TY
M27
301
673 652 671
Tightening
torque
kgfym (lbfyft)
No.
564 563
511
NAME
Q'TY
562 BACKUP RING
104 ADJUST SCREW
611 POPPET
121 C RING
613 STOPPER
122 SPACER
614 PISTON
123 C RING
621 SPRING
124 FILTER STOPPER
652 ADJUST SCREW
125 FILTER
661 O RING
163 O RING
663 O RING
512 PLUNGER
664 O RING
521 SPRING
2.83.2 (2023)
671 LOCK NUT ; M14
541 SEAT
2.83.2 (2023)
673 LOCK NUT ; M24
561 O RING
521
522 161
Tightening
torque
No.
kgfym (lbfyft)
124 561
123 125 562
541
NAME
611
621
661 612
102
651
101
162
Fig. 4-5
Tightening
torque
kgfym (lbfyft)
Q'TY
671
No.
NAME
Q'TY
78 (5158)
101 BODY
M27
(HEX 32)
541 SEAT
78 (5158)
102 PLUG
M27
(HEX 30)
561 O RING ; 1A,
123 SNAP RING
562 BACKUP RING
124 FILTER STOPPER
563 O RING ; 1A,
125 FILTER
564 BACKUP RING
P16
P10
161 O RING ; 1B,
P24
611 POPPET
162 O RING ; 1B,
P22.4
612 SPRING SEAT
301 PISTON
621 SPRING
511 PLUNGER
651 ADJUST SCREW
521 SPRING
661 O RING ; 1B,
P8
522 SPRING
671 LOCK NUT
M14 (HEX
2.83.2 (2023)
22)
(5) Boom spool (301)

315
353
316
340
317
301
352
(4) Arm spool (302)
320
330
Fig. 4-6
359
Tightening
torque
No.
kgfym (lbfyft)
302
Fig. 4-4
Tightening
torque
No.
kgfym (lbfyft)
56 (3643)
NAME
Q'TY
302 SPOOL
359 PLUG
NAME
Q'TY
Tightening
torque
kgfym (lbfyft)
No.
NAME
Q'TY
301 SPOOL
330 SPRING B2
315 PLUNGER 1
340 SPRING B3
316 PLUNGER 2
56 (3643)
352 PLUG 1
M16
317 PLUNGER 3
56 (3643)
353 PLUG 2
M16
320 SPRING B1
1
H45
(6) Control valve for option (213)
(7) Lock valve selector sub assy (211)
S202
S334
S337
S333
S323
S324
S271
S337
PAo
L101
L162
L163
S261
TA
S162
L541
S603
S512
S522
S561
S551
Ao
S101
S301
L171
Po
L511
B
Bo
L512
L161
TB
L201
S262
SECTION AA
S204
S603
PBo
Fig. 4-8
(Po)
Tightening
torque
kgfym (lbfyft)
L101
L161
L162
L163
1~1.4 (7.2~10) L171
Po
SECTION BB
Fig. 4-7
Tightening
torque
kgfym (lbfyft)
2.5~3.5 (18~25)
H46
No.
NAME
Q'TY
S101
S162
S202
S204
S261
CASING
O RING
SPRING COVER
SPOOL COVER
O RING
1
3
1
1
1
S262
S271
S301
S323
S324
O RING
SOCKET BOLT ; M825
SPOOL
SPRING (INNER)
SPRING (OUTER)
1
4
1
1
1
Tightening
torque
kgfym (lbfyft)
1.6~1.8 (12~13)
12~14 (87~100)
7~8 (51~58)
No.
No.
NAME
Q'TY
S333
S334
S337
S512
S522
STOPPER
BOLT M8
SPRING SEAT
POPPET
SPRING
1
1
2
1
1
S551
S561
S603
S991
S992
PLUG (M24 ; HEX 12)

O RING
RELIEF VALVE Over
load
NAME PLATE
RIVET
1
1
2
1
2
NAME
CASING
O RING
O RING
O RING
CAPSCREW ; M645
Q'TY
1
1
3
2
4
Tightening
torque
kgfym (lbfyft)
7~8 (51~58)
No.
NAME
Q'TY
L201
L511
L512
L541
PLUG (M27 ; HEX 22)

SPOOL
SPRING
BUSHING
1
1
1
1
4.3 HYDRAULIC CIRCUIT
Table 4-4
No.
601
513
307
54
TRAVEL
STRAIGHT
306
512
306
TRAVEL LEFT
303
51
512
56
TRAVEL
RIGHT
SWING
53
304
52
512
512
305
55
BUCKET
BOOM CONFLUX
302
301
602
512
602
ARM
BOOM
602
(CUT)
ARM RECIRCULATION
CUT
(ARM CONFLUX)
514
211
309
514
308
211
309
NAME
51
Main passage (P1 side)
52
Bypass circuit (P1 side)
53
Parallel circuit (P1 side)
54
Main passage (P2 side)
55
Bypass circuit (P2 side)
56
Parallel circuit (P2 side)
211
Lock valve selector A sub
301
Boom spool
302
Arm spool
303
Swing spool
304
Bucket spool
305
Boom conflux spool
306
Travel spool
307
Travel straight spool
308
Arm conflux spool
309
P1,P2 bypass cut valve
310
Arm recirculation spool
512
Poppet D=20
513
Poppet
514
Lock valve poppet
601
Main relief valve
602
Over load relief valve
310
S301 Spool for option valve
OPTION 2
S603 Over load relief valve for option valve
S603
512
S603
S301
Fig. 4-9 Hydraulic circuit diagram

H47
This page is left blank for editing convenience.
H48
4.4 OPERATION
(1) Control valve in neutral
The oil delivered by hydraulic pump P1
enters port P1 of the control valve and passes
through the travel straight spool (307) and
the main passage (51). It then passes through
the bypass circuit (52) that passes the right
travel bucket and boom circuits and then the
P1 bypass cut spool (309) and is brought back
to the hydraulic tank via the tank port (T).
The oil delivered by hydraulic pump P2 also

goes past the main passage (54), passes
through the bypass circuit (55) that goes
through the left travel, swing, boom conflux
and arm circuits and then the P2 bypass cut
spool (309) and is brought back to the
hydraulic tank via the tank port (T).
309
P1
P2
T
307
(54)
(55)
SECTION
309
(51)
(52)
SECTION
AA
Flow of hydraulic oil from hydraulic pump P1
Flow of hydraulic oil from hydraulic pump P2
Fig. 4-10
BB
Functions at neutral
H49
(2) Functions for travel action

1) At independent travel
If travel operation (forward) is performed, the
secondary pilot pressure from ports (2) and
(4) of the travel pilot valve acts upon ports
PBr and PBL of the control valve and moves
the right and left travel spools (306).
The pressurized oil delivered by pump (P1)
flows to the main passage (51) past the travel
straight spool (307), passes between the outer
circumference of the right travel spool (306)
and the casing and is supplied to the right
travel motor B by way of port Br.
In the meantime, the pressurized oil
delivered by pump (P2) passes between the
outer circumference of the left travel straight
spool (306) and the casing, runs to port BL
and is supplied to the left travel motor A side,
the same way as the pressure oil by pump
(P1).
Meanwhile, the oil which has returned from

the right travel A side and the left travel A
side passes between the outer circumference
of the left travel spool (306) and the casing
and returns to the hydraulic tank via the
tank port (T) of the low pressure circuit (D).
At backward travel action (when the
secondary pilot pressure acts upon ports PAr
and PAL of the control valve), the pressurized
oil works the same way as in the forward
travel action.
RIGHT TRAVEL MOTOR
Br
306
Ar
PILOT PORT
PBr
PAr
51
52
SECTION
Fig. 4-11
51
DD (Travel right)
At right travel forward (when PBr is pressurized)

H410
2) At travel straight motion

If an actuator except the one for travel action
is actuated with the travel system
i
n
position [ ], the secondary pressure of the
electromagnetic proportional valve [C] acts
upon port PTb of the control valve and moves
the travel straight spool (307) right in order
to take position [].
The result is that the pressurized oil
delivered by pump P1 flows from A to B in
most amount of oil and becomes the pressure
for the actuators except one for travel action.
P1
The pressure oil delivered by pump P2 flows,

in most amount of oil, in the CD direction
and the main passage (54), becomes the oil
pressure for the right travel and the left
travel motions and realizes simultaneous
operation of the actuator and travel action.
(travel straight function)
The secondary pressure of the solenoid
proportional valve [C] is applied additionally
and shifts the travel straight spool (307) to
the right to take the position . All of A to D
ports connect with the T-port in order to
unload the pressure of the circuits as a
whole.(unload function)
CMR2 CMR1
P2
307
PTb
CA
DB
T
Position []
CA
DB
At travel straight action
Position []
CA
DB
At unload action
SECTION
CC
Fig. 4-12
Position []
Functions at travel straight action

H411
(3) Bucket
1) When the bucket is digging
When the bucket is digging, secondary pilot
pressure coming from port (1) of the pilot
valve enters port PBc of the control valve and
moves the bucket spool (304) to the right.
The pressure oil delivered by pump (P1) flows
to the bypass circuit (52) past the main
passage (51), but since it is blocked by the
bucket spool (304) that has shifted, it pushes
the check valve open, enters the parallel
circuit (53), pushes the load check valve (512)
open, goes between the outer circumference of
the bucket spool (304) and the casing by way

of the U-shaped passage and is supplied to
the bucket cylinder head (H) via port (Bc).
In the meantime, the oil which has returned
from the bucket cylinder rod side goes
between the outer circumference of the
bucket spool (304) and the casing through the
port (Ac) and returns to the hydraulic oil
tank by way of the low pressure circuit (D)
and the tank port (T).
(52)
304
PAC
PBC
BC
AC
(53)
U-SHAPED PASSAGE
512
R
BUCKET CYLINDER
SECTION
Fig. 4-13
EE (Bucket)
When bucket is digging
H412
PILOT PORT
2) When the bucket is dumped

When the bucket is dumped, secondary pilot
pressure from port (2) of the pilot valve
enters port PAC of the control valve and
moves the bucket spool (304) to the right.
The pressure oil delivered by the pump P1
flows to the bypass circuit (52) through the
main passage (51), but since it is blocked by
the bucket spool (304), it pushes the check
valve open, enters the parallel circuit (53) the
load check valve (512) open, goes between the
outer circumference of the bucket spool (304)

and the casing via the U-shaped passage and
supplied to the bucket cylinder rod (R) via
port (AC).
from the bucket cylinder head goes between the
outer circumference of the bucket spool (304)
and the casing through the port (Bc) and is
supplied to the hydraulic oil tank by way of the
low pressure circuit (D) and the tank port (T).
(52)
(53)
PAC
304
PBC
AC
BC
U-SHAPED PASSAGE
512
R
BUCKET CYLINDER
SECTION
Fig. 4-14
EE
When bucket is dumped
H413
(4) Boom
1) When the boom is up
When the boom is up, secondary pilot
pressure from port (3) of the pilot valve
enters port PAb of the control valve and
moves the boom spool (301) to the right. It
also acts upon port PB1 (Refer to next page)
and change over the boom conflux spool (305).
At the same time the secondary pressure of
the electromagnetic valve [B] acts upon port
PCa of the control valve and change over
the P2 bypass cut spool (309).
The pressurized oil delivered by the pump P1
flows into the bypass circuit (52) through the
the boom spool (301), it pushes the check
valve open, enters the parallel circuit (53)
and pushes the load check valve (512) open.
INSIDE CONFLUX PASSAGE
The pressure oil then passes through the

U-shaped passage, Pushes the boost check
valve open via chamber E of the boom spool
(301), enters chamber BH.
Or the pressure oil enters chamber BH,
passing between the outer circumference of
the boom spool (301) and the casing, pushes
the lock valve poppet (514) open, flows into
the port (Ab) and is supplied to the boom
cylinder head (H).
Meanwhile, the oil port (Bb) which returns
from the boom cylinder rod (R) goes between
the outer circumference of the boom spool
(301) and the casing, flows into the tank port
(T) via the low pressure circuit (D) and
returns to the hydraulic tank.
(53)
301
PAb
PBb
(CRb)
Ab
CHAMBER BH
514
R
Bb
512
SECTION
BOOM CYLINDER
Fig. 4-15
When boom is up (Boom spool)
H414
U-SHAPED PASSAGE
2) Conflux for boom up

The oil delivered by the pump P2 flows into
the main passage (54), but since the bypass
circuit (55) and the parallel circuit (56) are
closed by the P2 bypass cut spool (309) which
has shifted as explained in 1) above (Refer to
Fig. 4-16), the oil enters the parallel circuit
(56) from travel spool. (Refer to Fig. 4-17)
The oil then pushes the load check valve

(512) open, passes between the outer
circumference of the boom conflux spool (305)
and the casing via the A side of the U-shaped
passage, enters port Ab through the conflux
passage in the casing and combines with the
pressure on the pump P1 side.
PCa
P2 BYPASS CUT SPOOL (309)
SECTION
Fig. 4-16
GG
P2 cut valve
CONFLUX CHECK VALVE (512)
(56)
U-SHAPED PASSAGE
BOOM CONFLUX
PB1
305
TO PORT Ab THROUGH THE CONFLUX PASSAGE IN CASING
SECTION
Fig. 4-17
EE (Boom conflux)
When boom is up (Boom conflux spool)

H415
3) When the boom is down (in H or S mode)

When the work mode selector switch on the
instrument panel is set to the H (heavy
digging) mode or S (save energy) mode,
operation is as follows.
If the boom down action is performed, the
secondary pilot pressure from port (4) of the
pilot valve acts upon port PBb of the control
valve and lock valve selector port PBb and
shifts the boom spool (301) to the left, it also
change over the lock valve.
The pressure oil delivered by the pump (P1)
the boom spool (301), it pushes the check
valve open, enters the parallel circuit (53),
pushes the load check valve (512) open,
enters the U-shaped passage, goes between
the outer circumference of the boom spool
(301) and the casing and is supplied to the
boom cylinder rod side via port (Bb).
In the meantime, the oil which returns from
the boom cylinder head enters the control
valve by way of port (Ab). Lock valve poppet
(514) is located in front of boom spool (301),
but the lock valve is pushed open as the
lock valve selector spool is changed over in
conjunction of the boom spool whereupon the

back pressure of lock valve poppet (514)
connects with DrC.
The returned oil then enters chamber BH and
runs into the boom spool (301) through the
circular notch of the boom spool (301). Since
the returned oil has sufficient pressure by the
weight of the boom, arm, etc. , it pushes the
poppet on the right of the illustration through
in the spool, passes through its outer
circumference and is supplied to the boom
cylinder rod side as the hydraulic oil for boom
down motion. (Boom fixed recirculation
function).
Some of the return oil from the head end of the
boom cylinders forces open the boost check
valve, and flows through the low pressure
circuit D to the tank port T, and back to the
hydraulic oil tank. The purpose is to allow
excess return oil to escape to the tank. This
excess oil is caused by the fact that the area of
the piston at the head end is larger than the
area of the piston at the rod end.
The boost check valve acts on oil flowing to
the tank to secure an adequate amount of
recirculating oil.
CONFLUX
PASSAGE IN CASING
301 (52) (53)
BOOST CHECK
LOCK VALVE
SELECTOR SPOOL
PBb
PAb
PLC1
Drc
LOCK VALVE
SELECTOR
CHAMBER BH
514
(CRb) Ab
Bb
512
R
SECTION
U-SHAPED PASSAGE
BOOM CYLINDER
Fig. 4-18
When boom is down (in H or S mode)

H416
FF
(5) Arm
1) Arm out operation
If arm out operation is performed, the
secondary pilot pressure from port (8) of the
pilot valve acts upon ports PBa and PA1 of
the control valve. (refer to next page)
The pressure oil which enters port PBa shifts
the arm spool (302) leftwards. The pressure
oil which enters port PA1 changes over the
arm conflux valve.
The secondary pressure of the electromagnetic
proportional valve [D] acts upon port PCb of
the control valve and changes over the P1
bypass cut valve (309).
The pressure oil delivered by pump P2 flows
into the bypass circuit (55) by way of the main
passage (54), but since it is blocked by the arm
spool (302), it pushes the check valve open,

flows into the parallel circuit (56), pushes the
outer circumference of the arm spool and the
casing by way of the U-shaped passage, runs
into chamber AR, pushes the lock valve
poppet (514) open and is supplied to the arm
cylinder rod side via port (Ba).
In the meantime, the oil which returns from
the arm cylinder bottom side passes between
the outer circumference of the arm spool
(302) and the casing by way of the port (Aa),
flows into the tank port (T) from the low
pressure circuit (D) and returns to the
hydraulic oil tank.
ARM CYLINDER
512
302
514
(Ba)
Aa
CHAMBER AR
PBa
PAa
(55)
(56)
U-SHAPED PASSAGE
SECTION
Fig. 4-19
At arm out operation (Arm spool)
H417
FF
2) Arm out conflux

In operation 1), the oil delivered by pump P1
main passage (51), but since the bypass
circuit (52) and the low pressure circuit (D)
are blocked by the bypass cut spool (309), it
does not run into the low pressure circuit (D).
Meanwhile, since the arm conflux spool (308)
has now been changed over, the pressure oil
of the bypass circuit (52) goes between the
outer circumference of the arm conflux spool
(308) and the casing.
Part of the delivered oil passes through the

parallel circuit (53) and the restrictor,
combines with the pressure oil of the bypass
circuit (52), pushes the conflux check poppet
(512) open, enters port Ba by way of the
conflux circuit in the casing and finally
combines with the pressure oil on the pump
P2 side.
To port Ba through the conflux

passage in the casing
P1 BYPASS CUT SPOOL
309
(52)
308
PA1
PCb
(53)
SECTION
Fig. 4-20
512
GG (Arm conflux)
At arm out operation (Bypass cut spool and arm conflux spool)
H418
ORIFICE
SECTION
3) When the arm is digging (under light load)

If the arm digging operation is performed, the
secondary pilot pressure coming out of port(7)
of the pilot valve acts upon the PAa port of
the control valve and the PLc2 port of the
lock valve selector. This causes the arm
spool(302) to move to the right and changes
the lock valve. The secondary pressure of the
solenoid proportional valve [A] acts on the Pis
port of the control valve and changes the arm
recirculation spool(310) to position [].
The pressure oil delivered by the pump P2
flows into the bypass circuit (55) past the
main passage (54), but since the bypass
circuit (55) is blocked by the arm spool (302),
the oil pressure pushes the check valve open,
flows into the parallel circuit (56), pushes the
outer circumference of the arm spool
(302) and the casing through the U-shaped
passage and is supplied to the arm cylinder
head (H) side via port (Aa).
Meanwhile, the oil which has returned from

the arm cylinder rod (R) enters the control
valve through the port (Ba).
Lock valve poppet (514) is located before arm
spool (302). Since the lock valve selector spool
is changed over, the lock valve poppet (514) is
pushed open and the oil enters the AR
chamber. Since the return oil has sufficient
pressure by the weight of the arm, it flows
into the arm spool, passes through the inside
of the arm spool, the notch of the arm spool
and the recirculation passage (60), and flows
into arm recirculation spool (310).
Since the arm recirculation spool is at
position [], the pressurized oil thus flowed
enters passage (61) through the inside of arm
recirculation spool (310), pushes arm
recirculation check valve poppet (512) open,
and is supplied again to the arm cylinder
head (H) as the hydraulic oil for arm digging.
(arm recirculation function)
ARM CYLINDER
D (60)
LOCK VALVE
SELECTOR SPOOL
CHAMBER AR
302
514
(61)
LOCK VALVE
SELECTOR
Aa
Position []
PAa
522
310
(61) (60)
SECTION
(56) (55)
Ba
Pis
D
Fig. 4-21
SECTION
GG
When arm is digging (under light load)

H419
FF
PLc2
Drd
4) When the arm is digging (under heavy load)

The arm oil recirculation function is effective
when operating the arm cylinder quickly
under a light load, but under a heavy load
(when heavy duty is required), this function
wastes power.
The control valve switches automatically
between oil recirculation under light load
conditions and no recirculation under heavy
load conditions by detecting pump pressure.
This is called the variable recirculation
function. When the arm is under a heavy
load, that is, when no recirculation occurs,
the oil supply passage to the arm cylinder is
the same as during recirculation described
above, but the return oil passage is different.
The system detects the pump pressure at
heavy load condition [more than 200kgf/cm2
(2840psi) of pump pressure]. This causes the
secondary pressure of solenoid proportional
valve [A] to operate and changes the arm
recirculation spool (310) to position [I].
Then, the hydraulic oil flowed into arm

recirculation spool (310) does not flow to the
arm cylinder head [H] that is heavily loaded,
but flows to tank port (T) from low pressure
circuit(D) and returns to the hydraulic oil
tank. (recirculation cut)
Sequenced conflux :
If the arm cylinder head (H) is loaded
heavily, the solenoid proportional valves [C],
[D]
operate
in
addition
to
the
above-mentioned recirculation cut action. As
the result, each secondary pressure acts upon
the PTb and PCb ports of the control valve,
changes the travel straight spool (307) to
position [ ] [Refer to the above 4.4.(2).2).]
and changes the P1 bypass cut spool (309).
As the result, the oil flow from the pumps P1
and P2 are confluxed in the parallel circuit
(56) of the control valve and are supplied to
the arm cylinder head (H).
ARM CYLINDER
D (60)
LOCK VALVE
SELECTOR SPOOL
302
CHAMBER AR
514
(61)
LOCK VALVE PLc2

SELECTOR
Aa
Position []
PAa
310
(61) (60)
522
(56) (55)
SECTION
Ba
Pis
D
Fig. 4-22
SECTION
GG
When arm is digging (under heavy duty)

H420
FF
Drd
5) Simultaneous operation of swing and arm

digging
If the swing and arm digging actions are
performed at the same time, the hydraulic oil
from pump P2 which is confluxed with P1
pump by switching travel straight valve and
closing P1 cut valve passes through the
parallel circuit (56) and flows into the swing
motor and the arm cylinder at the same time.
However, since the swing system is more
heavily loaded than the arm system at the
start of swing action and during arm digging
(at light load), most of the hydraulic oil flow
to the arm cylinder that is lighter loaded.
This causes the simultaneous operation to
deteriorate.
In order to improve such a condition, the load
on the arm digging side is increased
intentionally so the simultaneous operation
of swing and arm digging motions is
performed easily.(swing priority)
In the above condition, the system detects the

pilot pressure that actuates the swing spool.
The secondary pressure of the solenoid
proportional valve (A) acts upon the Pis port
of the control valve and changes the arm
recirculation spool (310) to position [].
The result is that the hydraulic oil flowed
into arm recirculation spool (310) is higher on
the arm cylinder rod (R) because the passage
to the arm cylinder head (H) are restricted.
The result is that the pressure on the arm
cylinder head side (H) rises which in turn
increases the operating pressure for the arm
digging operation.
And swing pilot pressure is led from Pisc
port to sub-spool in arm spool, the pressure of
arm cylinder head (H) rises higher by
restricting opening of arm spool circuit
according to swing pilot pressure, as result
the oil P2 pump flows preferentially into
swing circuit.
ARM CYLINDER
LOCK VALVE
SELECTOR SPOOL
D (60)
H
302
CHAMBER AR
514
(61)
Aa
LOCK VALVE PLc2

SELECTOR
Pisc
Position []
PAa
310
522
(61) (60)
SECTION
(56) (55)
FF
Ba
Pis
D
Fig. 4-23
SECTION GG
Simultaneous operation of swing and arm digging
H421
Drd
(6) Swing action

If swing action is performed, the secondary
pilot pressure from port (5) or (6) of the pilot
valve acts upon port PAS or PBS1 of the
control valve and shifts the swing spool (303)
rightward or leftward.
The pressurized oil delivered by the pump
P2 enters the bypass circuit (55) through the
the swing spool (303), it pushes the check
valve (512) open and enters the parallel
circuit (56).
Then the pressure oil pushes open the load
check valve (512) for swing action, flow into
U-shaped passage of the swing spool (303).
Then the pressurized oil which has entered

the U-shaped passage of the swing spool
(303) passes between the outer circumference
of the swing spool (303) and the casing and is
supplied to the A or B side of the swing motor
through port AS or BS.
from the B or A side of the swing motor
passes between the outer circumference of
the swing spool (303) and the casing through
the port (BS) or (AS), flows from the low
pressure circuit (D) to the tank port (T) and
returns to the hydraulic oil tank.
PARALLEL CIRCUIT (56) P2 SIDE
SWING MOTOR
U-SHAPED PASSAGE
FOR SWING MOTION
512
AS
303
Pss
BS
PAs
PBs2
PBS1
(55)
SECTION
Fig. 4-24
DD
Swing left action (When PBS1 is
H422
(7) Action of option valve (for P2 pump) :

If such an attachment as the dozer that uses
an option valve, the secondary pilot pressure
from port (P) of the pilot valve acts upon the
PAo2 or PBo2 port of the control valve and
shifts the option spool to the right or the left.
At the same time, the secondary pressure of
solenoid proportional valve [B] acts upon the
PCa port of the control valve and changes the
P2 pilot bypass cut spool (309).
The hydraulic oil delivered by pump P2 runs
into bypass circuit (55) through the main
passage (54), but since it is cut off by P2
bypass cut spool (309) that has shifted, the oil
pushes the check valve open, flows into

parallel circuit (56), pushes the load check
valve open, passes through the clearance
between the outer circumference of the option
spool and the casing and is supplied to each
attachment from port (Ao2) or (Bo2).
In the meantime, the oil returned from the
attachment enters the control valve from port
(Bo2) or (Ao2), passes through the clearance
between the outer circumference of the option
spool and the casing and returns to the
hydraulic oil tank from the low pressure
circuit (D) and the tank port (T).
Ao2
LOAD CHECK VALVE (LCo2)
Bo2
PAo2
PBo2
(56)
Sectional view of option valve
PCa
(55)
SECTION
Fig. 4-25
GG
Action of option valve

H423
309
(8) Functions of lock valve

Lock valve(514) is located between arm
cylinder rod side(R) and arm spool(302) of the
control valve to decrease the leakage due to
the holding pressure from the cylinder.
Similarly, lock valve(514) is located between
arm cylinder head side(H) and boom
spool(301) of the control valve to decrease the
leakage due to the holding pressure from the
cylinder.
In this position, the holding pressure from

boom cylinder head(H) side passes through
passage Sa, passage(a) of bushing(L541) and
around spool(L511), and connects to (b), then
flows through passage Sb, consequently
poppet(514) of the lock valve is pressed down
maintaining the seated condition, and the
leakage results in minimal quantity.
1) When the Main spool is Neutral ;

The boom spool (301) will be explained
hereinunder. The arm spool (302) will be
explained also.
When boom spool (301) is in neutral position,
it is held in the position shown in Fig. 4-26.
That is to say, lock valve selector sub spool
(L511) is pressed against bushing (L541) by
the action of spring (L512).
BOOM CYLINDER
HEAD (H) SIDE
L512
L511
CHAMBER RH
PLc1
514
Drc
Sb
Sa
(a)
(301)
Fig. 4-26
Functions of lock valve (when the main spool is neutral)
H424
(b)
L541
2) At boom lower action :

The secondary pilot pressure from port (4) of
the pilot valve acts upon the PBb port of the
control valve and the PLc1 port of the lock
valve selector and shifts the boom spool (301)
to the right. At the same time, the pressure
shifts the spool (L511) of the lock valve
selector to the right.
As the spool (L511) is shifted, the orifice (a)
in the bushing (L541) closes. This shuts off
the continuity from passage Sa to passage Sb
in the lock valve selector B sub (212) and the
hold pressure received from the boom
cylinder head (H) side ceases to act upon the
spring chamber (RH) of the lock valve poppet
(514).
As the spool (L511) moves, continuity is
established from the orifice (b) of the bushing
(L541) to the drain port (Drc) through the
inside of the bushing (L541).
This causes the orifice (b) of the bushing

(L541) to connect with the passage Sb, the
spring chamber of the lock valve poppet (514)
and the low pressure circuit. The lock valve
poppet (514) is received by the ring-shaped
pressure bearing area that consists of the
guide diameter and the seat diameter of the
lock valve poppet (514), so that the lock valve
poppet is pushed open upwards to release the
lock function.
Note : The action in the above takes place
before the opening (meter-out opening) that
brings the oil returning from the boom
cylinder head (H) of the boom spool (301)
during boom lower action, back to the
hydraulic oil tank; the action operates before
the boom spool strokes from its neutral
position. Therefore, the action does not affect
the controlability of the boom lower motion.
BOOM CYLINDER
HEAD (H) SIDE
L511
CHAMBER RH
PLc1
514
L512
Drc
Sb
Sa
(a)
Pressurized
part of poppet
(514)
PBb
PAa
301
Fig. 4-27
Functions of lock valve (at boom lower)

H425
(b) L541
(9) Operation of main relief valve

The main relief valve is built in casing and
operates as follows :
1) The pressure oil is filled up in chamber A
through the orifice (B) of the plunger (512)
and seats the plunger (512) securely against
the body (541).
A
R
541
PL
512
Fig. 4-28
2) When the hydraulic pressure of (P) reaches a
set pressure of the spring (621), it pushes
open the poppet (611) through the orifice (B)
and flows through the hole (D) to (R).
D
R
611 PL 621
Fig. 4-29
3) When the poppet (611) opens, the pressure in
chamber A falls, which causes the plunger
(512) to open and the pressure oil of port (P)
to flow directly to (R).
A
R
P
512
611
PL
Fig. 4-30
4) Press the boost

Press the boost button, and the pilot pressure
enters in PL port. The pilot pressure pushes
piston (614) leftward, the spring (621) force is
raised, and finally the relief pressure is
raised.
R
P
z The numbers of the parts of the

main relief valve in this section
correspond to those in Fig.4-3.
621
PL
614
Fig. 4-31
H426
(10) Operation of over load relief valve

The over load relief valve is located between
the cylinder port and the low pressure
passage, functions as both a relief valve and
an anti cavitation check valve, as mentioned
below :
301
1) Operation as a relief valve

1. The pressurized oil enters the hole A through
the clearance between piston (301) and
plunger (511) and fills up chamber B. Thus
plunger (511) is seated tightly against seat
(541).
P
R
511
541
2. When the hydraulic pressure of the port (P)

arrives at a set pressure of the spring (621), it
pushes the poppet (611) open, flows on the
circumference of the poppet (611) and passes
through the hole (C) to (R).
Fig. 4-32
C
P
R
3. When the poppet (611) opens, the hydraulic
pressure in chamber B falls which causes the
plunger (511) to open and allows the
hydraulic pressure of port (P) to flow directly
to (R).
Fig. 4-33
611
511
P
2) Operation of anti cavitation check valve
The check valve supplies oil from port (R)
when a negative pressure is built up at port
(P). When the pressure at (R) gets higher
than that of port (P), the push-up force of
circuit (R) gets stronger than the pressing
force of chamber B.
This causes seat (541) to move to the right.
Then the oil passes through the clearance of
seat (541) and enters port (P) in sufficient
quantity to fill up the vacancy.
R
611
Fig. 4-34
z The numbers of the parts of the over

load relief valve in this section
correspond to those in Fig.4-5.
541
Fig. 4-35
H427
621
H428
5. SWING MOTOR UNIT

5.1 SPECIFICATIONS
(1) General view
Port
Tightening
Port
torque
size kgfym (lbfyft)
Port name
A,B Main port
PF3/4
17 (120)
DB
Drain port
PF3/8
7.5 (54)
Make-up port
PF3/4
17 (120)
PA,PB Pressure measuring port
PF1/4
3.7 (27)
PF1/4
3.7 (27)
PF1/4
3.7 (27)
PG
Parking brake release port
Pi1,Pi2 Pilot ports

L
Gear oil level Gauge
PT1/2
6.6 (48)
IP
Gear oil filling port
PT3/4
10 (72)
PB
THREAD FOR EYE

BOLT 2-M12
DEPTH 24
RELIEF VALVE
(B PORT SIDE)
IP
PG
RELIEF VALVE
(A PORT SIDE)
DB
PA
PB
Pi2
SWING SHOCKLESS
PA VALVE BLOCK
Pi1 M
DB
A,(B)
IP
FILLING PORT
PT3/4
PG
DB
M
PB
PA
Pi2
REDUCTION UNIT
DRAIN OIL HOSE
Pi1
Hydraulic diagram
Fig. 5 -1 General view of swing motor unit
H5-1
(2) Specification
Swing motor unit
Hydraulic motor
Type
M2X120BCHB10A58/285
Displacement
cm3 (in3)
121.6 (7.54)
Working pressure
kgf/cm2 (psi)
285 (4050)
Max. flow
/min (gal/min)
Braking torque
kgfym (lbfyft)
63.5 (460)
Release pressure
(Stroke end)
kgf/cm2 (psi)
29 (410)
Relief set pressure
kgf/cm2 (psi)
285 (4050)
Weight
kg (lbs)
54 (119)
Speed reduction type
Planetary 2-stage
Reduction ratio
15.38
Reduction unit
Lublicate oil
Lublicate oil volume
Gear oil SAE90 (API class GL4 grade)

(gal)
7.5 (1.98)
Grease
Extreme pressure multi-purpose grease
Grease volume
Weight
Total weight
179 (47)
A small amount
kg (lbs)
154 (339)
kg (lbs)
208 (458)
H52
5.2 CONSTRUCTION
(1) Swing motor
488
992
469
355
401
ANTI CAVITATION
PLUNGER
051 RELIEF VALVE
351
051-1
391 390
VALVE CASING SECTION
SWING SHOCKLESS
VALVE BLOCK
052
171
161,
152 162
163
V162
053
303
(400-1)
981 111 984 131 451
(400-2)
444
052
981
485
438
464
472
706
712
743
V981
742
V162 V163
121
V164
113 V154
707
980
400
SECTION AA
V252
V262
122
702
123
114
118
V301
116
V154
V101
117
301
(053)
V164
443 491 305
101
437 124
994
V261V251 V981
SECTION BB
Fig. 5-2 Swing motor

H53
V324
TIGHTENING
TORQUE
kgfym (lbfyft)
18 (130)
No.
PARTS
051 RELIEF VALVE ; M33-P1.5

051-1 O RING ; 1B
052
053
100
3.7 (27)
7 (51)
G30
SWING SHOCKLESS VALVE

SUB ASSY
BYPASS VALVE BLOCK SUB
ASSY
CASING FOR SHOCKLESS
VALVE
No.
PARTS
QTY
443 ROLLER BEARING
444 ROLLER BEARING
451 PIN
3.7(27)
464 VP PLUG ; PF1/4
34 (250)
469 ROMH PLUG ; M30-P1.5
2
1
101 DRIVE SHAFT
472 O RING
111 CYLINDER
485 O RING ; 1B
P11
113 SPHERICAL BUSHING
488 O RING ; 1B
P28
114 CYLINDER SPRING
491 OIL SEAL
116 PUSH ROD
12
702 BRAKE SPRING
117 SPACER F
706 O RING
118 SPACER
707 O RING
121 PISTON
712 BRAKE SPRING
24
122 SHOE
742 FRICTION PLATE
123 SET PLATE
743 SEPARATOR PLATE
124 SHOE PLATE
0.09 (0.65) 980 PLUG ; PF1/4
131 VALVE PLATE
0.45 (3.3)
981 PLUG ; PF3/4
152 PLUG
0.17 (1.2)
984 PLUG ; PF3/8
161 O RING ; 1B
P11
6.6 (48)
992 PLUG ; PT1/2
162 O RING ; 1B
P12
10 (72)
994 PLUG ; PT3/4
163 O RING ; 1B
P6
V154 PLUG
303 VALVE CASING
V162 O RING
305 SEAL COVER
V163 O RING
351 PLUNGER
V164 O RING
355 SPRING
3.0 (22)
V171 SOCKET BOLT ; M890
390 NAME PLATE
17 (120)
V251 PLUG 1
391 RIVET
11 (80)
V252 PLUG 2
V261 O RING
V262 O RING
V301 SPOOL
401 SOCKET BOLT ; M2045
V304 SPRING
437 SNAP RING
438 SNAP RING
400
SWING SHOCKLESS VALVE ;

M22-P1.5
P20
400-2 BACKUP RING
3.7 (27)
V101 CASING FOR BYPASS VALVE
301 CASING
400-1 O RING ; 1B
44 (320)
TIGHTENING
TORQUE
QTY
kgfym (lbfyft)
0.09 (0.65) V981 PLUG
H54
(2) Swing reduction unit

33
19
29 28 27
26
25
18
22
17
23
16
24
22
14
20
15
21
13
10
12
11
37
34
35
36
9
8
6
2
Fig. 5-3
Tightening
torque
kgfym (lbfyft)
3.4 (25)
18.5 (130)
No.
Cross-sectional view of swing reduction unit

PARTS
QTY No.
PARTS
QTY
1 PINION SHAFT
19 #.1 SUN GEAR
2 SLEEVE
20 SPRING PIN
4 PLUG (Not shown)
21 SHAFT
5 O RING
22 THRUST WASHER
6 OIL SEAL
23 #.2 PINION
7 RETAINER
24 NEEDLE BEARING
12
25 THRUST WASHER
9 BEARING
26 #.1 PINION
10 HOUSING
27 ROLLER
11 SPACER
28 THRUST WASHER
12 BEARING
29 SNAP RING
13 SNAP RING
33 SNAP RING
14 #.2 SPIDER
34 SET SCREW ; M2020
15 #.2 SUN GEAR
35 CONNECTOR
16 RING GEAR
36 HOSE
17 #.1 SPIDER ASSY
37 PLUG
10
z Apply Three-Bond #1360K
H55
3
102
5.3 OPERATION
5.3.1 OPERATION OF HYDRAULIC MOTOR
If the high pressure oil flows into the cilynder
through the inlet port (a) of valve plate (131), as
shown on the right figure, the hydraulic pressure
acts upon piston (121) and generates force F in
the axial direction.
The force F may be divided into force F1 vertical
to shoe plate (124) via shoe (122) and force F2 at
right angles with the shaft.
The force F2 is transmitted to cylinder block (111)
via pistons (121) and causes drive shaft to turn so
as to produce a rotating moment.
The cylinder block (111) has nine pistons equally
arranged. Rotating torque is transmitted to drive
shaft by turns by pistons connected to inlet port of
high pressure oil.
If the oil supply and discharge directions are
reversed, the drive shaft rotates in the opposite
direction.
CYLINDER BLOCK(111)
F2
F1
F
DRIVE SHAFT(101)
SHOE
PLATE
(124)
PISTON
(121)
(LOW PRESSURE OIL)
Theoretical output torque T can be given by the

following equation.
T=
SHOE
(122)
VALVE
PLATE
(131)
OUTLET
(HIGH PRESSURE OIL)
INLET
(a)
pq
2
p : Effective differential pressure kgf/cm2
q : Displacement per revolution c.c. /rev
Fig. 5-4
Operation of hydraulic motor
351
5.3.2 VALVE CASING SECTION

(1) Operation of anti-cavitation check plunger
Since the system using this type of motor is
not equipped with a valve having a
counterbalance function, the motor is rotated
beyond the oil feed rate in some cases.
The system has check plunger(351) and sucks
in dificient oil, in order to prevent cavitation
from occurring due to oil deficiency.
Fig. 5-5 Operation of anti-cavitation check plunger

H56
(2) Operation of relief valve

1) Consider where the P port is pressurized
from the tank pressure.
The pressure at the P, R ports is equal to the
tank pressure at the beginning, as shown in
Fig.5-6-(1).
The relief valve begins to operates when the
hydraulic pressure that is determined by
the product of the pressure-receiving area A1
of plunger(301) and the pressure P balances
the hydraulic pressure that is determined by
the product of the pressure-receiving area A2
of the plunger(301) and the pressure Pg of
chamber g.
Thereafter, the pressure of chamber g rises
and the piston 1 (302) begins to stroke. The
load to spring (321) increases by this
movement of the piston.
As the result, the relief pressure P is raised
and controlled in the pressure boost time t1
from P1 till Ps.
This process is explained in the following in
the relationships between the movements of
the components shown in (2) to (4) of Fig.
5-6 and the relief pressure :
1.
Condition shown in Fig. 5-6. (2)
If the P port of the relief valve is pressurized,
pressure is built up in chamber g via the
restrictor m of plunger (301).
The hydraulic pressure acting on plunger
(301) increases and when it balances the load
Fsp of spring (321), the relief valve performs
relieving action by the pressure P1.
This relationship is expressed as :
P1A1FSP1Pg1A2
where Fsp1:
primary set load value of spring (321)
2. Condition shown in Fig.5-6. (3)
The pressure of chamber g acts upon the
pressure-receiving area A3-A4 of piston 1
(302). When the hydraulic pressure rises
above the load of spring (321), the piston 1
begins to move to the left.
On that occasion, since the machine turns to
the left while discharging the oil of chamber
h arranged between piston 1 and adjust plug
(401) into chamber g via restrictor n provided
in piston 1 (302), chamber h serves as a
dumping chamber.
The load of the spring increases slowly till
piston 1 reaches the end of the adjust plug.
The relief pressure P rises smoothly.
3. Condition shown in Fig.5-6. (4)
The machine does not travel to the left
further when piston 1 (302) arrives at the end
of adjust plug (401). Therefore, the relief
valve keeps its normal relieving action
whereby the relief pressure is held at P2.
In the processes 1 to 3 above, the relief
pressure changes as shown in Fig.5-7.
2) Function when the relief valve pressure is
reduced
Let us consider the pressure of the P port is
reduced.
When the pressure at port P is reduced to
zero, the pressure of chamber g falls to the
tank pressure level. The result is that the
plunger (301) which is now open moves to the
left and is seated on seat (341). At the same
time, the piston 1 (302) moves to the right by
the action of spring (321) and returns to the
condition of Fig.5-6 (1).
CHAMBER h
PISTON 1(302)
SPRING(321)
ORIFICE m
P
R
PRESSURERECEIVING
AREA A1
PLUNGER (301)
CHAMBER g
A3 A2 ORIFICE n A4
Fig. 5-6-(1)
ORIFICE m
CHAMBER h
SPRING(321)
PIN(303)
PISTON 1(302)
P
R
PLUNGER (301)
ORIFICE n
CHAMBER g
Fig. 5-6-(2)
SPRING(321)
ORIFICE m
H57
PIN(303)
CHAMBER h
PISTON 1(302)
P
R
PLUNGER (301)
ORIFICE n
CHAMBER g
Fig. 5-6-(3)
ORIFICE m SPRING(321)
PIN(303)
PISTON 1(302)
P
R
PLUNGER (301)
Fig. 5-6
ORIFICE n
CHAMBER g
Fig. 5-6-(4)
Functional explanation of relief valve
Fig. 5-7
Pressure boost characteristics
(3) Operation of swing shockless valve
1) Neutral condition :
Fig.5-8 illustrates the relationship between
the neutral condition of the swing shockless
valve and the hydraulic circuits. Now, let us
consider a braking condition in which brake
pressure generates on the AM port side.
2) When brake pressure occurs :
If pressure (P) generates at the AM port, it
passes through the passage l, the hole on the
shaft of seat (313) and the passage m of
plunger (311) and is admitted to the n
chamber.
When the pressure P rises above a value (Ps)
set by spring (321), plunger (311) compresses
spring (321) and shifts it to the left.
Seat (313) compresses weak spring (322) as
pushed by plunger (311) and moves to the
left.
3)
At swing shockless action
When inertia load stops moving (point Y,
Fig.5-10), brake pressure (P) tries to fall.
When P<PS, plunger (311) moves toward the
right return side by the action of spring (321).
Seat (313) tries to move to the right by the
action of spring (322), but since chamber p
provides damping action by orifice g, the
return of the seat makes a time delay with
regard to the return of the plunger.
Consequently, seat t opens. This makes a
passage connecting the AM port and BM
ports or both ports of the hydraulic motor by
way of t r k. The result is that the
pressures at the AM and BM ports become
equal (PB), falling into the condition at point
Z in Fig.5-10. This prevents the hydraulic
motor from swing shock by the closing
pressure of the AM port.
Fig. 5-8 Hydraulic circuit diagram for

swing shockless valve.
k
313
322
321
311
Fig. 5-9(1) Neutral condition

m
n
P=PS
322
313
321
311
Fig. 5-9(2) When brake pressure occurs

p
t
P<PS
k
r
322 313 g
321
311
Fig. 5-9(3) At swing shockless action
H58
Fig. 5-9
Operation of swing shockless valve
Fig. 5-10
Pressure change diagram of swing

shockless operation
(4) Operation of bypass valve

1) Neutral condition :
In the case where pilot pressure Pi1 is not
inputted, the spool is pushed rightward with
the spring (324). A and B port are not
connected in this state.
2) Operation state :
If pilot pressure Pi1 is inputted and the
hydraulic pressure is became higher than the
set load of spring, the spool moves leftward
and A and B port are connected.
If pilot pressure is lowered, the spool will
return according to spring power again, and a
connecting circuit will be blocked.
5.3.3 OPERATION OF BRAKE SECTION

The cylinder (111) is jointed by drive shaft (101)
and a spline. Separator plate (743) is fixed in its
circumferential direction by circular grooves
provided in casing (301).
Now, if the friction plate (742) splined to the outer
circumference of the cylinder is pressed against
casing (301) via separator plate (743) and brake
piston (702) by the action of brake spring (712),
frictional force is generated between friction plate
(742) and casing (301) and between separator
plate (743) and brake piston (702). The frictional
force bounds the drive shaft to brake the motor.
In the meantime, when brake release pressure
applied to the oil chamber formed between brake
piston (702) and casing (301) overcomes the
spring force, the brake is released as brake piston
(702) moves till friction plate (742) is detached
from casing (301).
SPOOL
CASING
Pi1
Pi2
PLUG (1)
SPRING (324)
PLUG (2)
Fig. 5-11
Operation of bypass valve
111
712
702
712
743
742
702
H59
743
301
742 301
Fig. 5-12
101
Operation of swing brake
5.3.4 SWING REDUCTION UNIT

The swing reduction unit is used to reduce the
rotating speed which is transmitted by the
hydraulic motor and to convert it to the strong
turning effort (torque).
This swing speed reduction unit is equipped with
planetary speed reducing mechanism.
The planetary mechanism is made up of sun gear,
planetary pinion, planetary shaft, spider and ring
gear, as shown in Fig. 5-12.
For the operation of the 1st stage planetary, the
hydraulic motor rotates #1 sun gear (19). Sun
gear (19) is engaged with planetary pinion (26)
and rotates, but since ring gear (16) is fixed,
planetary pinion (26) revolves about sun gear (19)
with the planetary shaft and spider (17).
RING GEAR (FIXED)
PLANETARY SHAFT
SPIDER
SUN
GEAR
The role of spider is to hold the planetary pinion

and planetary shaft and transmits the power from
the planetary pinion to the spider through the
planetary shaft.
The #1 spider (17) is linked with #2 sun gear(15)
by the involute spline, and transmits the power to
the 2nd stage planetary mechanism.
For the operation of the 2nd stage planetary, the
power is transmitted to sun gear (15)planetary
pinion (23)spider(14) similarly to the 1st stage.
PLANETARY PINION
Fig. 5-12
Planetary mechanism
SWING MOTOR
The #2 spider (14) is linked with pinion shaft (1)

by the involute spline, and pinion shaft(1) is
engaged with the swing gear fixed on the
undercarriage (lower frame) and rotates.
26
19
16
17
15
14
10
23
12
Fig. 5-13
H510
Function of reduction unit
(2) Specifications
TRAVEL MOTOR
Travel motor unit

Motor
6.1 SPECIFICATIONS
(1) General view
M4V150/100-RG3.5B
Type
M4V150/100Z
Reduction
SPROCKET CENTER
Reduction unit
22-M18
OVERLOAD RELIEF VALVE
P
T=5.5 (40)
8-M12
T=10 (72)
Travel motor
Y
MA
VA,VB
PT3/4
17-M20
FILLING PORT
OIL LEVEL CHECK PORT
41.46
Number of reduction stages

Lube oil capacity
2
(gal)
Lube oil capacity specification
T=5.5 (40)
MB
Reduction ratio
M27
T=11 (80)
6.
Unit
5.5 (1.5)
Gear oil SAE#90 (GL-4)
Max. displacement
cc/rev (cuyin/rev)
154.4 (41)
Min. displacement
cc/rev (cuyin/rev)
103.7 (27)
Relief valve set pressure

2 speed changeover
pilot pressure
kgf/cm2 (psi)
350 (4,980)
kgf/cm2 (psi)
51 (725)
Parking brake torque

Parking brake release
pressure
kgfym (lbfyft)
More than 4570 (330510)
kgf/cm2 (psi)
Less than 16 (230)
Allowable drain pressure
kgf/cm2 (psi)
Weight (With oil)
kg (lbs)
Working
2.0 (28)
Surge
10.0 (140)
Motor 82 (181)Reduction 156 (344)=238 (525)
Dr
8-M16
T=23.5 (170)
T=10 (72)
GEAR OIL LEVEL

FILL
LEVEL
15-M10
T=8 (58)
LOCKTITE#242
DRAIN
PT3/4
DRAIN PORT
VIEW
T=10 (72)
Fig. 6-1
Travel motor
Rotation direction
Rotation direction
Oil inlet Oil outlet
port
port
(Viewed from valve side)
VA
VB
Right (Clockwise)
VB
VA
Left (Counterclockwise)
Port name Port size
Tightening
torque
kgfym(lbfyft)
Function
PF1/4
5.5 (40)
Pilot (2 speed changeover) port
Dr
PF1/2
11.0 (80)
Drain port
VA,VB
PF1
26.0 (190)
Motor drive port
MA,MB
PF1/4
3.0 (22)
Pressure measurement
H61
35
12 13 3 7 5
37
40 24
28
36
20
33
21
23
29
QTY No.
NAME
QTY No.
NAME
QTY
CASING
21
BALL
41
O RING1B
P11
REAR COVER
22
PIVOT
42
O RING1B
P14
CYLINDER BLOCK
23
PISTON SEAL
43
O RING190.172.62
SHOE RETAINER
24
M6 RESTRICTOR (0.6)
44
OVERLOAD RELIFE VALVE
FRICTION PLATE
25
OIL SEAL
45
SPOOL
32
17
BRAKE PISTON
26
SPRING
46
PLUGPF3/8
18
26
38
SEPARATOR PLATE
27
SPRING (CYLINDER)
47
SPRING RETAINER
VALVE PLATE
28
SPRING (BRAKE)
12
48
PIN
40
SHAFT
29
BEARING
49
SPRING
10
COUPLING
30
BEARING
50
CONNECTOR
11
SHOE PLATE
31
SOCKET BOLTM1645
51
SPOOL ASSY
12
BALL JOINT
32
SHIM
COVER
13
SPRING RETAINER
33
PARALLEL PIN612
14
PISTON ASSY
15
D RING (SMALL)
35
PLUGNPT1/16
16
D RING (LARGE)
36
17
CHECK VALVE
18
SNAP RING
19
20
39
41
10
2
19
30
8
25
22
44
11
50
4 27
15 16
42 45 48 47
49
43
42
14
46
58
54
60
53
52
57
41
51
31
VIEW
H62
NAME
59
55 56
Z (Sectional view is shown partially)

Fig. 6-2
Travel motor
12 52
1
53
SPRING
54
SPRING RETAINER
55
RESTRICTOR VALVE
PLUGNPT1/16(Meck : TB) 10
56
SPRING
37
PLUG
57
PLUG
38
PLUGPF1/8
58
O RING42.522.62
SNAP RING
39
PLUGPF1/4
59
O RING1B
TILTING PISTON
40
O RING1B
60
SOCKET BOLTM1235
P8
P9
No.
6.2 CONSTRUCTION
6.2.1 TRAVEL MOTOR
6.2.2 REDUCTION UNIT
24
15
16
14 13
12
18
25
4
7
3
5
20
10
Clearance :
0.08 to + 0.02mm
(0.0031 to + 0.0008in)
Adjust it with one shim.
6
9
Store it so the shaft center is

level with regard to the ground.
8
1
2
11
26
17
21
22
23
19
Fig6-3 Reduction unit
No.
NAME
QTY No.
NAME
QTY No.
NAME
QTY
COVER
10 SUN GEAR 2
19 BEARING
CARRIER 1
11 CARRIER 2
20 SHIM
CARRIER PIN 1
12 CARRIER PIN 2
21 LOCK WASHER
NEEDLE BEARING
13 NEEDLE BEARING
22 SUPPORT RING
THRUST WASHER 1
14 PLANETARY GEAR 2
23 FLOATING SEAL
PLANETARY GEAR 1
15 SPRING PIN; 840
24 SOCKET BOLT M1025
15
SPRING PIN; 532
16 THRUST WASHER 2
25 SOCKET BOLT M1680
19
THRUST PLATE
17 RING GEAR
26 SOCKET PLUG PT3/4
SUN GEAR 1
18 HOUSING
H63
6.3 MAKEUP OF TRAVEL MOTOR

The travel motor consists mainly of the rotary
group that generates rotating power, the negative
brake that prevents the machine from moving by
itself while it is parked, the variable displacement
mechanism that switches over the motor capacity
to the large or small mode, the overload relief
valve that is built in the rear cover, and the brake
valve (counterbalance valve) that controls the
hydraulic circuits.
(1) Rotary group
Cylinder block (3) is inserted in the gear
tooth grooves of the spline of shaft (9) that is
supported by bearings (29, 30) at it both ends.
The cylinder block (3) is pressed against rear
cover (2) with valve plate (8) by the action of
spring (27).
9 piston assy (14) slide over shoe plate (11),
while stroking in cylinder block (3).
A bearing retainer is arranged at the end face
of piston assy (14) to reduce the sliding
resistance. The action of spring (27) is
transmitted to spring retainer (13), ball joint
(12), and shoe retainer (4) and presses the
end face of piston assy (14) against shoe plate
(11) so the piston assy moves close to the
surface of shoe plate (27).
(3) Variable displacement mechanism

The variable displacement mechanism
consists of pivot (22) supporting shoe plate
(11) that is put in two semispherical concaves
provided in shoe plate tilting piston (20) that
tilts shoe plate on pivot (22) tilting stopper
(1-1) supporting the piston at a certain
position; the pilot valve that admits the
pressurized oil to the tilting piston (20) by an
external command; and three check valves
(17) that take out the highest of the external
command activated pilot pressure, the motor
inlet pressure and the motor outlet pressure
and that sends it to the pilot valve.
(4) Overload relief valve
The overload relief valve consists of socket
(44-1) that has valve seat (44-3) metallically
seating rear cover (2) of the motor and
screwed up in rear cover (2) valve (44-2)
engaged with socket (44-1) that is tangential
in contact with valve seat (44-3) by the action
of adjust spring (44-9) connecting piston
(44-4) that is inserted in valve (44-2) and
serves also as an oil path to pilot body (44-6)
piston (44-7) that is put in pilot body (44-6)
and pressed against plug (44-5) and shim
(44-8).
(2) Negative brake

44-3
Four separator plates (7) and three friction
plates (5) are inserted by turns in the spline
grooves in the outer surface of cylinder block
(3) and are pressed against casing (1) by the
action of 2 springs (28) via brake piston (6).
44-2
44-9 44-12 44-9 44-12 44-11

44-7
44-13 44-8 44-10 44-6
44-1
44-5
Fig. 6-4
No.
Construction of overload relief valve
NAME
No.
NAME
44-1 SOCKET
44-8 SHIM
44-2 VALVE
44-9 SPRING
44-3 VALVE SEAT
44-10 O RING1B
P7
44-4 CONNECTING PISTON 44-11 BACKUP RING

44-5 PLUG
44-12 O RING1B
44-6 PILOT BODY
44-13 BACKUP RING
44-7 PISTON
H64
G25
(5) Brake valve

1) Spool
If the spool (51) is shifted, the oil discharged
from the hydraulic motor is shut off and
throttled automatically. The hydraulic motor
performs holding, acceleration, stop and
counterbalance actions.
2) Check valve (built in the spool)

It is the oil feeding passage to the hydraulic
motor and locks the exhaust oil. Therefore,
the check valve serves as the suction valve
and the holding valve for the hydraulic
motor.
Spool select pressure

Check valve cracking pressure
53
57
54
0.1kgf/cm2 (1.4psi)
60
58
41
6.110.2kgf/cm2 (87150psi)
56
55
59
51
Fig. 6-5
Brake valve
H65
52
6.4 FUNCTIONS OF TRAVEL MOTOR

(1) Functions of motor
The high pressure hydraulic oil delivered by
the hydraulic pump enters from the inlets
(VA, VB), passes through the brake valve,
rear cover (2) and valve plate (8), and is
admitted into cylinder block (3).
The high pressure oil acts upon each of the
pistons arranged in 180bordering on the
line Y-Y that connects the upper dead point
with the lower dead point of the piston, as
shown in Fig.6-6 (a).
And the high pressure oil generates ;
Force F1=P A (P; Pressure, A; Sectional
area of piston).
This force F1 becomes thrust component F2
and radial components F31-F34 (or F35) by
shoe plate (11) having a tilting angle .
[See Fig.6-6 (b).] These radial components act
upon the Y-Y axis as rotating force, and
T=r1yF31+r2yF32+r3yF33+r4yF34
(If high pressure acts upon five pistons, add
r5yF35.) is produced.
This torque is transmitted to the spline via
cylinder block (3) and then to shaft (9).
(2) Functions of negative brake
The negative brake is released when
preferentially selected high pressure from the
counterbalance built in rear cover (2) acts
upon brake piston (6) and is generating
braking torque when there is no pressure.
The braking torque is produced by frictional
force that is generated by separator plate (7)
linked to casing (1) with the spline and
friction plate (5) linked to cylinder block with
the spline.
When pressure is not acting upon the brake
piston, brake piston (6) is pushed by the
action of spring (28). Friction plate (5) and
separator plate (7) are sandwiched between
brake piston (6) and casing (1).
This sandwiching force generates frictional
force between friction plate (5) and separator
plate (7) and acts as braking torque that
binds cylinder block (3) or shaft (9).
Fig. 6-6
(a)
5 28
9
1
Fig. 6-7
H66
Fig. 6-6
Negative brake
(b)
(3) Functions
of
variable
displacement
mechanism
Fig.6-8
shows
a
modeled
variable
displacement mechanism.
When pressure overcoming spring (49) enters
the high speed travel command line PA,
spring (49) is compressed. Then spool (45)
moves to the right which connects port P with
port C. The highest of motor pressures A, B
and the high speed travel command line
pressure is selected in check valve (17) and
presses tilting piston (20). For that reason,
shoe plate (11) tilts along the broken line
with the line L connecting two pivots (22) as
the axis center, stops tilting when it hits
tilting stopper (H), and keeps that condition.
This decreases the stroke of piston (14) and
makes the motor displacement smaller. The
motor is capable of rotating at high speed
without increasing the oil flow from the main
pump. The speed is approx. 1.5 times on this
machine.
Inversely, if the high speed travel command
line pressure PA disappears, spool (45) is
brought back to the left by the action of
spring (49). The result is that the hydraulic
pressure pressing tilting piston (20) is
released to the tank and makes the pressing
force zero.
The motor has nine pistons that are arranged
evenly over shoe plate (11) and presses shoe
plate (11).
The point on which the sum of the forces act

is nearly the center of shoe plate (11) as
shown in Fig. 6-8. Since pivot (22) is located
away from the center by distance S, the
rotating force resulting from S multiplied by
the pressing force of the piston is generated.
The pistons return to their original position
and the motor changes to the low speed.
In case the engine power lacks in climbing up
a steep slope at high speed or during
steering, the motor speed is changed to low
speed automatically to prevent engine stop.
The mechanism is as below :
The hydraulic pump pressure is admitted to
the PB port as in Fig.6-8.
This pressure acts upon pin (48). When the
pressure exceeds a specified level, spool (45)
is brought back to the left by the reaction of
pin (48). Then the pressure which has been
pressing tilting piston (20) is released to the
tank. Shoe plate (11) tilts which makes a
larger displacement motor to take up low
speed.
When the pressure falls below a specified
level, spool (45) moves to the right and the
motor changes to high speed.
TO CONTROL VALVE
HIGH SPEED TRAVEL COMMAND LINE
21
20 H
17
14
17
17
22
22
11
45
Fig. 6-8
PB P C
Function of variable displacement mechanism
H67
48
49
(4) Function of overload relief valve

Two overload relief valves are arranged in
the crossover and operate as below :
1) To stop the hydraulic motor, the system
keeps the braking pressure generating on the
motor discharge side at a certain level to stop
inertia load.
2) At start, the hydraulic motor is driven at a
specified set pressure to make sharp
acceleration. At stop, generated pressure is
held low for a short time to dampen shocks by
braking the motor.
Further, the circuit pressure is held at a set
pressure so the reduction and travel crawler
sprockets are engaged smoothly.
In short, boost pressure cushioning action is
performed.
If the A port pressure of the overload relief

valve rises at the start of the hydraulic
motor,
it
acts
upon
the
effective
circumference on which valve seat (44-3) of
valve (44-2) is seated and upon connecting
piston (44-4) in the valve (44-2) through the
small holes of it. The valve (44-2) causes the
pressure to rise to a set pressure by standing
against adjust spring (44-9) by the areal
difference
between
the
effective
circumference of the valve seat and the
circumference of the connecting piston.
When the hydraulic motor is braked, piston
(44-7) at the back of the valve is on its left by
the drive pressure. As the A port pressure
rises, it acts upon piston (44-7) through the
small hole in the valve. The piston moves to
the right till the piston hits plug (44-5).
During this period, valve (44-2) holds the A
port pressure relatively low, counteracting
adjust spring (44-9) and discharges the oil to
the B port side.
After piston (44-7) strikes plug (44-5), the
valve operates the same way as at the start of
the motor.
PLUG
CONNECTING PISTON
B port
(44-4)
(44-5)
VALVE SEAT
(44-3)
A port
Small hole
VALVE
ADJUST SPRING
(44-2)
Fig. 6-9
(44-9)
Function of overload relief valve
H68
PISTON
(44-7)
(5) Function of brake valve

1) Hold condition (See Fig. 6-10)
When the selector valve is at neutral, the VA
and VB ports are connected with the tank.
Spool (51) is held in its center position by the
action of springs located at its both ends.
Since the VAMA passage and the VBMB
passage are closed, the MA and MB ports
that are connected with both sides of the
hydraulic motor are closed.
Furthermore, since the parking brake
passage is connected with the tank, the feed
pressure for the brake cylinder of the
negative brake mechanism is equal to the
tank pressure. This makes the brake in
operating condition and prevents the
hydraulic motor from turning mechanically.
Fig. 6-10
If an external force acts upon the hydraulic

motor, the motor is kept normally from
turning by the negative brake. Suppose the
negative brake is released, pressure is built
up at the MA or MB port. Since the hydraulic
motor turns a little as the high pressure of
the closed circuit escapes due to internal
leaks of the hydraulic motor, cavitation is
about to be built up on the low pressure side
of the closed circuit. The check valve built in
the spool operates to prevent cavitation it
allows the VAMA or VBMB passage to be
formed and makes up an amount of oil equal
to the leakage to the closed circuit from the
tank.
Hold condition
H69
2) At acceleration (See Fig. 6-11)

If the selector valve is shifted, the VA port is
connected with the main pump and the VB
port with the tank, the hydraulic oil from the
hydraulic pump pushes up the check valve in
the spool via the VA port. Then hydraulic oil
is fed to the hydraulic motor from the MA
port to turn it.
The result is that the oil delivered by the
pump rises and releases the brake in the
negative brake mechanism. Meanwhile, since
the pressure in the pilot chamber rises, the
spool overcomes the spring action in the pilot
chamber of the VB port side and moves to the
left. Then the return passage MB VB is
formed which makes the hydraulic motor to
rotate.
Fig. 6-11
If the inertia load of the hydraulic motor is

large, the pressure required for acceleration
reaches a set pressure of the relief valve.
Then the hydraulic motor increases
revolution, while relieving the pressurized
oil. As the hydraulic motor increases speed,
the amount of relieving oil falls and the
motor arrives at a constant speed.
At acceleration
H610
3) At stop operation (See Fig. 6-12)

If the selector valve is brought back to
neutral while the hydraulic motor is rotating
to cut off the oil supply and the VA and VB
ports are connected with the tank, the
pressures of the pilot chamber at both ends of
the spool are equalized. Then the spool
returns to neutral position by the spring
action. This closes the MB VB passage.
However, since the hydraulic motor tries to
rotate by inertia load, the hydraulic motor
makes pumping action to discharge the
hydraulic oil to the MB port. Since the
passage is shut off, the pressure rises, the
relief valve operates and the hydraulic motor
is decelerated gradually to a complete stop.
Fig. 6-12
The release pressure for the negative brake

falls slowly by the restrictor. The brake falls
into an operating condition which causes the
hydraulic motor to stop mechanically.
At stop operation
H611
4) Counterbalance function (See Fig. 6-13)

If the hydraulic motor is decelerated which is
rotating by inertia force, counterbalance
action is required. Now if the hydraulic oil
supplied to the VB port of the hydraulic
pump decreases gradually, the hydraulic
motor tries to rotate by inertia beyond the oil
feed rate.
Then the pressure in the pilot chamber of the
VB side falls. The spool is pushed to the left
by spring action and moves toward neutral
position. Then the area of the MA VA
passage decreases and the passage resistance
increases. The pressure on the MA side rises.
The hydraulic motor is braked and
decelerated below a revolution equal to the oil
feed rate.
Fig. 6-13
Then the pressure in the pilot chamber on the

VB port side rises. The result is that the
spool moves to the right which makes the MA
VA passage area larger and decreases the
braking action. The revolution of the
hydraulic motor is at last controlled to a level
equal to the oil feed rate.
A restrictor that gives damping effect to the
spool is built in the pilot chambers at its both
ends to make the counterbalance action
stable.
The negative brake is released while the
spool is regulating the pressure.
At counterbalance action
H612
6.5 FUNCTIONAL PRINCIPLE OF REDUCTION

GEAR
The reduction gear reduces the revolution
transmitted from the hydraulic motor and
converts it to powerful rotating power.
The reduction gear employs a planetary
2-stage reduction method.
The planetary mechanism consists of a sun
gear, a planetary gear, a (planetary) carrier,
and a ring gear.
If the sun gear (s) on the input side is rotated,
the planetary gear (b) revolves meshed with
the fixed ring gear (a) while rotating by itself.
This revolution is transmitted to the carrier
(k) to convey torque.
This is the planetary gear mechanism.
FIXED RING GEAR
CARRIER (k)
PLANETARY
PINION
(b)
INPUT
OUTPUT
SUN GEAR (s)
RING GEAR (a)

CARRIER (k)
SUN GEAR (s)
PLANETARY PINION
(b)
Fig. 6-14
In Fig.6-15, if the sun gear S1 on the input
side rotates, planetary motion occurs between
gear S1, a and b. The revolution of gear b
conveys the input of carrier K1 to the No.2
sun gear S2 to cause planetary motion to
occur between gear S2, a and d.
On that occasion, since carrier K2 is fixed to
the frame body, gear d transmits the power to
the ring gear and makes ring gear a rotate.
a
b
S1
K1
Fig. 6-15
H613
Planetary gear mechanism
d
S2
K2
2-stage reduction mechanism
H614
7. SWIVEL JOINT
7.1 OUTSIDE VIEW
Y
VIEW Y
VIEW Z
Z
Fig. 7-1 Outside view of swivel joint
7.2 SPECIFICATIONS
Table 7-1
Item
Spec.
Working pressure
High pressure ports
Max. impact pressure
A,B,C,D
Rated flow
Low pressure ports Working pressure
E
Rated flow
Low pressure ports Working pressure
F
Rated flow
Revolution
A,B,C,D
Ports size
E
F
Length (height)
Weight
H71
350kgf/cm2(4980psi)
525kgf/cm2(7470psi)
255 /min(67gal/min)
5kgf/cm2(71psi)
50 /min(13gal/min)
50kgf/cm2(710psi)
30 /min(8gal/min)
15rpm
PF1
PF1/2
PF1/4
355mm(14)
27.4kg(60.4 lbs)
7.3 CONSTRUCTION
Y
E
X
2
6
X
E
D
B
D
C
VIEW Y
VIEW Y
12
A
5
7
3
13
9
Tightening torque
8
Tightening torque
SECTION XX
Fig. 7-2 Construction

Table 7-2
No.
1
2
3
5
6
NAME
BODY
STEM
THRUST PLATE
COVER
SEAL ASSY
QTY No.
1
7
1
8
1
9
5
12
2
13
7.4 OPERATION
The swivel joint consists mainly of body (1) and
stem(2) that rotate mutually, thrust plate (3)
preventing both components from falling off,
cover(13) closing one side of body (1), seal (5) that
partitions off the circuits and O rings(6) and (7)
that prevent external leaks.
Four ports for the travel main circuits are
provided on body (1) and stem (2). Further, four
oil passing grooves are arranged in the inner
surface of body (1), with seal (5) fixed above and
below the circumferential groove.
NAME
O RING
SOCKET BOLT; M820
SOCKET BOLT; M830
PLUG
COVER
QTY
1
2
4
1
1
The body (1) and the stem (2) rotate mutually.

The oil flowing in from body (1) or stem (2) keeps
on flowing to stem (2) or body (1) past the
circumferential groove between body (1) and stem
(2); the oil flow is never shut off because of
rotation. Further, an oil groove for lubrication
that connects with the drain port is provided, in
order to prevent the body (1) from seizure with
the stem (2).
This construction keeps on connecting the circuits
between the swing bodies by means of a swivel joint.
H72
8. CYLINDER
8.1 SPECIFICATIONS
(1) General view
Part No. and Manufacturing No.

Stamp position
Fig. 8-1 General view of cylinder
(2) Specifications
Table 8-1
Use
Unit : mm (ft-in)
Cylinder bore /
Stroke
Rod Dia.
Center distance
Dry
of pins
weight
Cushion
Full extend B /
kg (lbs)
Full retract A
2,970 / 1,770 With cushion
160 (353)
(974 / 58 )
on rod side
Boom
115 / 80
(4.53 / 3.15 )
1,200
(41)
Arm
125 / 90
(4.92 / 3.54 )
1,290
(411)
3,060 / 1,770
(10 / 58)
With cushion
on both sides 190 (419)
Bucket
105 / 75
(4.13/ 2.95)
1,055
(346)
2,630 / 1,575
(862 / 516 )
With cushion
120 (264)
on rod side
H81
0
0
(4.13-0.0197
)
105-0.5
660 (26.0)
M121.75 (Through)
24 25
0
0
105 -0.5
(4.13-0.0197
)
T=Tightening torque ; kgfym (lbfyft)
8.2 CONSTRUCTION
(1) Boom cylinder
25 24
27
SLIT
26
BLACK
GREEN
28,2
T=3.2(23)
With hole
(1 place)
DETAIL B
VIEW Z
DETAIL C
T=27.2(200)
9
7 6
T=421(3000) T=5.8(42)
12 10,11
2 1
13 14 15 16 17 18 19 20 21 22,23
C
SLIT
Fig. 8-2 Construction of boom cylinder
(The figure shows the right-hand cylinder.)
No.
NAME
QTY No.
1
2
3
4
5
CYLINDER TUBE
PISTON ROD
CYLINDER HEAD
BUSHING
SNAP RING
1
1
1
1
1
11
12
13
14
15
BUFFER RING
7
8
9
10
U RING
BACK-UP RING
WIPER RING
O RING
1
1
1
1
NAME
BACK-UP RING
SOCKET BOLT
CUSHION BEARING
CUSHION SEAL
PISTON
QTY No.
NAME
1
10
1
1
1
21
22
23
24
25
16 SEAL RING
26 BAND
17
18
19
20
2
2
2
1
27 BAND
28 BOLT
29 WASHER
1
2
2
BACK-UP RING
SLIDE RING
SLIDE RING
SHIM
H82
NUT
SET SCREW
STEEL BALL
PIN BUSHING
WIPER RING
QTY
1
1
1
2
4
(2) Arm cylinder
0
0
120 -0.5
(4.72 -0.0197
)
200 (7.87)
28 27
0
120 -0.5
0
(4.72 -0.0197 )
27 28
T=3.2(23)
31,32
30
29
SLIT
BLACK
GREEN
With hole
(1 place)
DETAIL B
VIEW Z
DETAIL C
T=27.2(200)
7,8
T=836.5(6100)
5 3 12 10,11
2 1
T=5.8(42)
13 14 20 15 17 16 18 19 21,22 26 24 23 25
Fig. 8-3 Construction of arm cylinder

No.
1
2
3
4
5
NAME
QTY No.
NAME
SLIT
QTY No.
SLIT
NAME
QTY
CYLINDER TUBE
PISTON ROD
CYLINDER HEAD
BUSHING
SNAP RING
1
1
1
1
1
12
13
14
15
16
SOCKET BOLT
CUSHION BEARING
CUSHION SEAL
PISTON
SEAL RING
12
1
1
1
1
23
24
25
26
27
CUSHION BEARING
CUSHION SEAL
STOPPER
SNAP RING
PIN BUSHING
1
1
2
1
2
BUFFER RING
U RING
BACK-UP RING
WIPER RING
O RING
1
1
1
1
1
17
18
19
20
21
BACK-UP RING
SLIDE RING
SLIDE RING
SHIM
SET SCREW
2
2
2
1
1
28
29
30
31
32
WIPER RING
BAND
BAND
BOLT
WASHER
4
1
1
2
2
11 BACK-UP RING
22 STEEL BALL
6
7
8
9
10
H83
0
0
100 -0.5
(3.94 -0.0197
)
0
0
(3.94 -0.0197
)
100 -0.5
(3) Bucket cylinder

B
210 (8.27)
24 25
25 24
T=3.2(23)
28,29
27
SLIT
BLACK
GREEN
With hole
(1 place)
DETAIL B
26
VIEW Z
DETAIL C
T=17.4(130)
8
7 6
3 4
5 12 10,11
T=491(3600) T=5.8(42)
2 1
13 14 15 16 17 18 19 20 21 22,23
C
SLIT
Fig. 8-4 Construction of bucket cylinder
No.
1
2
3
4
5
6
7
8
9
10
NAME
QTY No.
NAME
QTY No.
NAME
QTY
CYLINDER TUBE
PISTON ROD
CYLINDER HEAD
BUSHING
SNAP RING
1
1
1
1
1
11
12
13
14
15
BACK-UP RING
SOCKET BOLT
CUSHION BEARING
CUSHION SEAL
PISTON
1
12
1
1
1
21
22
23
24
25
NUT
SET SCREW
STEEL BALL
PIN BUSHING
WIPER RING
1
1
1
2
4
BUFFER RING
U RING
BACK-UP RING
WIPER RING
O RING
1
1
1
1
1
16
17
18
19
20
SEAL RING
BACK-UP RING
SLIDE RING
SLIDE RING
SHIM
1
2
2
2
1
26
27
28
29
BAND
BAND
BOLT
WASHER
1
1
2
2
H84
Hydraulic cylinder construction

(See Fig. 8-2, 8-3, 8-4)
By construction the hydraulic cylinder consists
mainly of cylinder tube assy (1), piston rod assy
(2) that takes out the motion of pistons
reciprocating in the cylinder tube assy, and
cylinder head (3) that serves as both a lid and a
guide. Cylinder tube assy (1) is equipped with a
pin mount (clevis) that connects piston rod assy
(2) with other parts.
In addition to these main components, seal ring
(16) and back-up ring (17) are located between,
cylinder tube assy (1) and piston rod assy (2) ;
buffer ring (6), U ring (7) back-up ring (8) and
wiper ring (9) are located between piston rod assy
(2) and cylinder head (3) ; and an O ring (10) and
a back-up ring (11) are placed between cylinder
tube assy (1) and cylinder head (3).
CUSHION RING(13)
CHAMBER A
TANK
PATH B
PISTON(15)
8.2.2 OPERATION
If pressurized oil is fed alternatively to the oil
inlet and outlet provided in the cylinder, force
acts on the piston which in turn causes the piston
rod (2) to extend and retract.
ROD(2)
ROD SIDE
HEAD
SIDE
CYLINDER HEAD(3)
(1) Operation of cylinder with cushion

(Cushion on rod side)
The cushion mechanism is provided to
prevent the generation of shock when the
moving speed of piston (15) is not reduced
and strikes cylinder head (3).
An oil in chamber "A" returns to the tank by
passing through paths "B" at a fixed flow rate
in a intermediate stroke state (Fig. 8-5) of
pressing bottom side. Next, in a state of just
before stroke end (Fig. 8-6), cushion ring (13)
plunges into path "B".
At this time, an oil in chamber "A" passes
clearance "D" and mouth gap "C", an oil flow
volume returning to tank suddenly drops and
the piston part movement slows down.
CUSHION STROKE
Fig. 8-5
Cushion mechanism on the rod side
CLEARANCE D
TANK
MOUTH GAP C
H85
Fig. 8-6
Cushioning action on the rod side
(Cushion on head side)

This construction is similar to the one of
cushion on rod side. In a state of intermediate
stroke pressing rod side, an oil in chamber
"A" returns to tank by passing through paths
"B" at a fixed flow rate.
Next, in a state of just before stroke end,
cushion bearing (24) plunges into path "B".
At this time, an oil in chamber "A" path
clearance "D" and cushion seal (25) are
mouth gap "C", an oil flow volume returning
to tank suddenly drops and the piston part
movement slows down
PATH B
CUSHION SEAL (25)

TANK
CUSHION BEARING (24)
CHAMBER A
CLEARANCE D
GAP "C"
CUSHION SEAL (25)
Fig. 8-7 Cushion mechanism on the head side
H86
II. ELECTRICAL EQUIPMENT

1. LIST OF ELECTRICAL EQUIPMENTS
ELECTRIC EQUIPMENTS
(E)
LIGHT
(L)
C-4
C-6
IT controller (ORBCOMM) (OPT.)
(R)
D-1
D-2
D-3
D-4
D-5
D-6
Diode
Diode
Diode
Diode
Diode
Diode
E-1
E-2
E-3
E-4
E-5
E-6
E-7
E-8
E-9
E-10
E-11
Fuse box
Alternator
Hour meter
Horn (Low)
Horn (High)
Cigarette lighter
Tuner AM & FM
Speaker LH
Speaker RH
Receiver dryer
A/C compressor
E-14
Resister
E-16
E-17
Converter (DC24V12V)
Socket
E-23
E-24
Antenna (OPT.)
GPS Antenna (OPT.)
L-1
L-2
L-3
L-4
L-5
L-6
L-7
L-8
L-9
L-10
Boom work light LH

Deck light RH
Room light
Engine room light
Boom work light RH
Cab work light (Rear)
L-15
Rotatry light
M-1
M-2
M-3
M-4
M-5
M-8
M-9
Starter motor
Governor motor
Wiper motor
Washer motor
M-11
Fuel supply pump
Fuel pump (OPT.)
(SE)
SOLENOID
MOTOR
NAME
Key switch
Travel1-2 speed switch
Swing parking release switch
KPSS release switch
Engine water temperature switch
Engine oil pressure switch
Air filter clogging switch
Horn switch (LH)
Safety lock lever switch
Air conditioner switch
Auto accel pressure switch
Swing flusher select switch (OPT.)
R-10
R-11

R-19
R-20
Flusher relay (OPT.)

Timer relay
R-28
R-29

SE-1
SE-2
SE-3
SE-4
SE-5
SE-6
SE-7
SE-8
SE-9
SE-10
SE-11
Press. sensor (LOW) : Bucket digging

Press. sensor (LOW) : Bucket dump
Press. sensor (LOW) : Boom raising
Press. sensor (LOW) : Boom lowering
Press. sensor (LOW) : Swing
SW-34 Power boost switch
Press. sensor (LOW) : Arm in

Press. sensor (LOW) : Arm out
Press. sensor (LOW) : Travel right
Press. sensor (LOW) : Travel left
Press. sensor (LOW) : OPT. 1
SW-52 Auto idle stop select switch
SE-13
SE-14
SE-15
SE-16
Engine speed sensor

Engine water thermo sensor
Fuel sensor
Accel potentiometer
SE-20
Press. sensor (LOW) : OPT. 2
SE-22
SE-23
Press. sensor (HIGH) : P1 pump

Press. sensor (HIGH) : P2 pump
SV-1
SV-2
SV-3
SV-4
Swing parking SOL

SW-20
SW-21
SW-22
SW-23
Horn switch (RH) (OPT.)

Work light switch
Single / Conflux select switch (OPT.)
SW-30 Rotary light switcfh
(SV)
(M)
SWITCH
Mechatro controller
Gauge cluster
RELAY
DIODE
(D)
C-1
C-2
Group Code
NAME
Arm variable recirculation proportional valve (SW) SW-1
SW-3
SW-4
SW-5
PSV-P1 P1 Pump proportional valve
SW-6
PSV-P2 P2 Pump proportional valve
SW-7
SW-8
Battery relay
R-1
SW-10
Glow relay
R-3
SW-11
Safety relay
R-4
Wiper motor relay
R-5
SW-13
Washer motor relay
R-6
Horn relay
R-7
SW-16
Work light relay
R-8
SW-17
Group Code
(P) PSV-A
PSV-B
PSV-C
PSV-D
ELECTRIC SENSOR
CONTROLLER
(C)
NAME
PROPORTIONAL
VALVE
1.1 SPECIFICATION
Group Code
Battery
(B) B-1
SW-32
Overload indicate switch
SW-39 Overload switch

SW-42 Engine room light switch
(Note)
The Part numbers and serial numbers of machine may be changed

due to modifacation, so use only the numbers for reference.
E1 1
E1 2
2.2. SPECIFICATION OF ELECTRIC EQIUPMENTS
File No.
Name of part
Specification
Description
Use
B-1
Type
130E41R
115E41R
12V
12V
Voltage
Battery
92Ah
88Ah
30kg (66 lbs)
28kg (62 lbs)
Capacity 5HR
Weight
1 3 0E4 1 R
130E41R
115E41R
5E4 1 R
OR 11
Power
Terminal
C-1
Controller
Maker
Rated voltage
Terminal
SHINKO ELECTRIC
DC 24V
Window for adjust
Mechatro controller
C-2
Maker
Rated voltage
Controller
Insulation resistance
KANSEI
DC24V
More than 3M at
500Vmegger
LCD
Gauge cluster
E13
4-7 Attaching hole
File No.
Name of part
Specification
Description
Use
C-4
Maker's part No.

Rated voltage
TKS-C215AO
DC 20~30V
Controller
Air-con controller
D-1,2,3,5,6
Diode
Maker's part No.

Peak reverse voltage
Mean output current
Surge current
7321-9822-30
400V
3A
200A
Key switch relay

Battery relay
Gauge cluster
D-4
Part No.
Rated current
7321-9332-60
2.5A
Diode
Glow relay
E14
CONTROLLER
File No.
Name of part
Specification
Description
Use
E-1
Fuse box
Fuse capacity and circuit name

1
2
Fuse
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
E-2
Capacity
20A
10A
10A
10A
10A
10A
20A
10A
20A
20A
20A
10A
20A
10A
20A
10A
20A
10A
20A
Name of circuit
Mechatro controller
Wiper / washer relay
Cigarette lighter
DC-DC Converter, Tuner
Horn
Blank
Mechatro controller back-up
Fuel supply pump
Tuner back-up, room lamp
Key switch
Fuel pump, cab work light
Travel alarm,swing flasher
Gauge cluster
Wiper, Washer
Solenoid valve
Work light
Resistor
Air conditioner, Heater
Air conditioner
Spare (24V)
Rated output
24X40A
R
Alternator
18PAF-HD
SUMITOMO
HOUSING : 6098-0257
TERMINAL : 8240-4422
18PAF-HD
II
7PAM-HD
7PAM-HD
SUMITOMO
HOUSING : 6950-1030
TERMINAL : 8230-4050
: 8232-4238
M5 X 0.8
TERMINAL E
12.5
VIEW A
Generator
M6 X 1.0
TERMINAL B
M5 X 0.8
E-3
Movement
Quartz
GM TERMINAL P No. : 2962447

GM CONNECTOR P No. : 2962448
Hour meter
Service meter
E15
File No.
Name of part
Specification
Description
Use
E-4,5
Horn
LOWER
Type
STAMP
DC24V
Rated voltage
Operating voltage range DC 20~30V

1135 dB
42020Hz high sound
Basic frequency
35020Hz low sound
More than 3M /
DC500V
Sound level
Warning sound
8.5
E-6
Cigar lighter
409112-0000
Model
DC 24V
Rated voltage
Max. current
5A
Return time
Less than 18sec

More than 3M /
500V megger
180C~250C
(356F~482F)
Cigar lighter
Fusing temp.
E-7
Rated voltage
Tuner
1
2
3
4
5
6
7
8
9
Radio (AM & FM)
E-8,9
Speaker
Model
DC24V
L SPEAKER(+)
R SPEAKER(+)
ACC(+B)
OPEN
L SPEAKER(-)
R SPEAKER(-)
GND(-)
BACK UP (+)
OPEN
SX-M1024K
Rated input
8W
Impedance
Freguency
33.3Hz
Radio
E16
PLUG COMPLETE
KNOB
JIS CA104
CASE
SOCKET COMPLETE
File No.
Name of part
Specification
Description
Use
E-10
Maker's part No.
56640-A0450
Receiver dryer
CAULK
Air conditioner
2-M6 X 1.0
E-11
Air compressor
1
Maker's part No.
DC 24V
Max. revolution
4000rpm
V belt
Refrigerant
Air conditioner
7351-6000
Rated voltage
Oil
Type B
R-134a
SP-20 : 135cc
Cover (clutch)
CP3.96MA
YAZAKI 7120-8019
AVX1.25 (BLACK)
AVX1.25 (GREEN)
E-14
Resistor
Rated power consumption

Resistance value
CONNECTOR YAZAKI 2PAM

HOUSING 7122-2128
TERMINAL 7114-2020
40W
16
DC500V /
More than 20M
P1,P2 pump
proportional valve
SILICONE GLASS
Braided wire
(NISSEI DENKI)
NS-GE 1.25sq
FURUKAWA DENKO
Viewmex ER400 or equivalent
heat resistant tube
5X20mm (0.197" X0.787")
Hot soldering treatment
[melting point 240C (464F)]
Sumi-tube K
-55C+175C
(-67F~+347F)
20mm (0.787")
-4.70.3
(0.185"0.012")
E17
File No.
Name of part
Specification
Description
Use
E-15
Rated voltage
DC 12V36V
Rated current
0.2A at 24V
Input voltage
DC 24V
Output voltage
DC 12V
Output current
2.5A Max
Ground
Negative
Alarm
Travel
E-16
Converter
YV
WG
Power socket
YB
OL
B
Fix the wire with tape

HOUSING YAZAKI 7122-2262
TERMINAL YAZAKI 7114-2020
VIEW A
A
E-17
Power supply
For 12V
Socket
Power socket
L-1,9
Light (halogen)
Type
BL84-130
Bulb
24V,70W
Boom work light (left)

Boom work light (right)
CA104
M14X1.5
E18
File No.
Name of part
Specification
Description
Use
L-2
Light (halogen)
Type
BL84-200
Bulb
DC 24V,70W
Effective area of lens
71cm2
Deck work light(right)
CA104 R
CB104 W
L-3
Bulb
24V,5W
BODY
Note) Equivalent to 2456Z322F1

LENS
Light
Room light
BULE
BULB
OFF
ON
View Z
L-8
Light
Maker's part No.
3509-KB
Bulb
12V,10W
E/G room light
SECTION A-A
E19
File No.
Name of part
Specification
Description
Use
M-1
Rated output
DC 24V,4.5kW
ISUZU
897029-8634
M10 TERMINAL (B)
Motor
Starter motor
TERMINAL (R)
TERMINAL (S)
SAFETY RELAY
REDUCTION GEAR SECTION
M-2
Motor
Drive voltage
DC 24V
Rated voltage
DC 8.5V
Rated current
1.5A / phase
2 phase
Excitation method
2 Excitation
MOTOR SECTION
Number of phases
Step angle
Governor motor
OUTPUT OIL SEAL

SHAFT
(INVOLUTE)
1.8
More than 100M
(500V megger)
CAM
LIMIT
SWITCH
Excitation sequence
Step
Brown(A)
Red(B)
Lead
A
B
Yellow(B)
A
B
Orange(A)
Limit switch connector
No. Lead
color
6
5
7
+
+
+
+
+
+
-
+
+
-
Motor connector
Connection
1 White COM
NO
2 Red
3 Yellow NC
Lead
2 No. color
HOUSING : 6181-0072 (SUMITOMO DENSO)

TERMINAL : 1500-0134 (SUMITOMO DENSO)
RETAINER : 6918-0327 (SUMITOMO DENSO)
WATER
RESISTANCE : 7165-0118 (SUMITOMO DENSO)
1 Blown
2 Orange
3 Red
4 Yellow
MOTOR
LIMIT SWITCH
CONNECTOR CONNECTOR
Connection
A
A
B
B
HOUSING : 6181-0073 (SUMITOMO DENSO)

TERMINAL : 1500-0105 (SUMITOMO DENSO)
RETAINER : 6918-0329 (SUMITOMO DENSO)
WATER
RESISTANCE : 7165-0118 (SUMITOMO DENSO)
E1 10
VIEW Z
LIMIT
SWITCH
MOTION
RANGE
File No.
Name of part
Specification
Description
Use
M-3
Motor
DENSO Part No.
5-159200-377
Rated voltage
24V
Wipe-out angle
106
Insulation resistance 1MMIN/500V megger

Wiper
M-4
Rated voltage
Injection pressure
Motor(tank)
Tank capacity
Time rated
Injection nozzle
DC 24V
(+)
(-)
More than 780cc / min

1.5L (0.4gal)
Max. continuous 20sec
1 X 2 pcs.
Window washer
PUMP
M-9
Motor (pump)
Fuel pump (OPT.)
Maker's part No.

Rated voltage
Current
Operating fluid
Discharge rate
(open circuit)
375-01016
DC24V
Less than 1.5A
HEX24
Light oil
More than 200cc/min
IN
OUT
Z
M6X1
GROMMET
BLACK / RED
VINYL TUBE (WHITE)
L=100 (3.94 )
BLACK
VIEW Z
E1 11
WATERPROOF
CONNECTOR (MALE)
YAZAKI 7322-9021
File No.
Name of part
Specification
Description
Use
M-11
Pump
Flow rate
More than 30L/min
Voltage
24V
Current
Less than 14A
Fuse
15A
Fuel supply pump
R-1
Relay
Battery relay
Rated voltage /
current
Exciting current
At start 24V2000A (0.1sec.)

At charge 28V120A (continuous)
Less than 0.4A / 24V
More than
Contact force
3.5kgf (7.7 lbs)
Less than 16V
Closed circuit voltage
Open circuit voltage
TERMINAL A
TERMINAL
B
FLW2.0
FLW2.0
F HOUSING :
SUMITOMO
7123-4220-30
F TERMINAL :
SUMITOMO
7116-3251
REAR HOLDER :
SUMITOMO
7157-6801-30
WATER
RESISTANCE :
SUMITOMO
7157-3580-60
Less than 7V
More than 3M /
500V megger
MODEL
NUMBER STAMPING
POSITION IN A
PRODUCTION PROCESS
AVS1.25B
EARTH
TERMINAL
FLOWING DIRECTION OF
MAIN CURRENT
TERMINAL A
Z
AVS1.25G
AVS1.25L
TERMINAL B
TERMINAL A1
LOCK SECTION
TERMINAL B1
BLACK
EARTH
VIEW I
CIRCUIT DIAGRAM
E1 12
L TERMINAL
B
TERMINAL
HOUSING SUMITOMO
6181-0072
RETAINER SUMITOMO
6918-0327
TERMINAL SUMITOMO
1500-0105
WIRE SEAL SUMITOMO
7165-0119
EARTH TERMINAL
VIEW Z
File No.
Name of part
.
Use
R-3
Specification
ISUZU part No.

Rated voltage
Relay
Glow relay
Rated load
Description
894258-0140
DC24V
In-rush current 130A
Breaking current 30A
Operating voltage
Less than DC16V
Release voltage
More than DC2V
Exciting current
Less than 1A
Z
1
INTERNAL CONNECTION DIAGRAM
CONNECTOR ON
MATED SIDE.
YAZAKI 7323-3010
CONNECTOR ON
MATED SIDE.
YAZAKI 7323-2228
VIEW Z
R-4
ISUZU part No.

Rated voltage
897129-9360
DC 24V
Relay
M10 TERMINAL (B)
Safety relay
TERMINAL (R)
TERMINAL (S)
SAFETY RELAY
TO ALTERNATOR
TO STARTER SWITCH (C)
SAFETY RELAY STARTER
E1 13
File No.
Name of part
Specification
Description
Use
R-5,6,7,8,10,11,18
Relay
Rated voltage
DC 24V
Coil resistance
360 10%
Insulation resistance 20M (500V megger)
Wiper motor,
Washer motor,
Horn relay,
Work light relay,
Travel alarm relay,
Applicable connector
VCF41003 (P&B)
CONNECTION DIAGRAM
R-19
Relay
Flasher relay (OPT.)
R-20
Relay
Rated voltage
DC 24V
Delay time
1 sec.
Operation
ON : 10 sec, OFF : 5 sec
Timer relay
R-28,29
Maker
MITSUBA
Rated voltage
Relay
DC 24V
More than 1M (500V megger)
Auto idle stop relay 1,2
with bracket
without bracket
CIRCUIT
E1 14
File No.
Name of part
Specification
Description
Use
SE-1~5,7~11,20
Pressure range
Pressure sensor
(low pressure)
Rated voltage
0~30kgf/cm2(0~430psi)
5 0.5V DC
More than 100M /
DC50V megger
Vcc
Vout
GND
AMP HQS-TYPE
3-poles (TYPE-B)
Bucket digging, dump,

Boom up, down,
Swing
Arm in, out
Travel R, L
Option 1, 2
(HEX) 19
PF1/4
TIGHTENING TORQUE 3.7kgfm (26.8 lbfft)
SE-13
Revolution sensor
E/G speed sensor
Rated
Output voltage
More than 2.5V
Clearance
1.0mm (0.04in)
M16 X 1.5
TORQUE2.5~3.5kgfm
(18~25 lbfft)
CONNECTOR
YAZAKI 7322-1424
HEX 19
HEX 17
SIGNAL (YELLOW)
GND (BLACK)
SE-14
Water temperature
sensor
E/G Water
temperature
Maker part No.
71400-KW0300
Resistance characteristics
50C(122F)
80
60C(140F)
56.3
80C(176F)
29.5
100C(212F)
16.5
106C(222.8F)
14.3
120C(248F)
10
E1 15
M16 X 1.5
TORQUE
2.5 kgfm
(18ftlbs)
VIEW Z
File No.
Name of part
Specification
Description
Use
SE-15
Fuel sensor
Fuel sending
Float operating standard

Float
Resistance value
FULL
+0.1
10-0.5
3/4
(19)
1/2
32 3
1/4
(49.5)
EMPTY
80+12
+2
FULL
FLOAT
3/4
110
1/2
1/4
FUEL LEVEL
WARNING LAMP POSITION
FUEL METER
EMPTY
24V3W
SENSOR SWITCH
FLU
S
DC
24V
FLOAT
SUMITOMO CONNECTOR
PART 6187-3231
VIEW A
SE-16
Potentio meter
Total resistance value
2K
Effective electric angle
120
Number of notches
10
Source voltage
5V
NOTCH PART
Accel dial
3MA-JM II + AMP
HOUSING : 174359-2
TERMINAL : 171661-1
RETAINER : 1-174360-1
HARNESS SEAL : 172888-2
DIAL
POTENTIO
BRACKET
SE-22,23
Pressure sensor
(High pressure)
Pressure range
0~500kgf/cm2(0~7110psi)
Max. allowable press 750kgf/cm2(10700psi)

Operating source voltage
5 0.5V DC
More than 100M
AMP HQS-TYPE 3-poles (TYPE-B)

HOUSING : 2-967642-1
TERMINAL (GOLD PLATING) : 965906-5
HARNESS SEAL : 967067-1
TERMINAL No. CONNECTION
P1 pump, P2 pump
1 COMMON
2 OUTPUT (+)
3 POWER SUPPLY (+)
22 x 25.4 HEX
PF3/8
E1 16
File No.
Name of part
Specification
Description
Use
SV-1,2,3,4
Rated press.
51kgf/cm2 (710psi)
Directional valve
Rated voltage DC24V
Solenoid valve assy

(8-SPOOLS)
Refer to HYD. SYMBOL
Dither 100Hz, 300mA P-P
Proportional valve
Coil resistance 17.51 (at 20)

Equivalent to AMP econoseal J series
connectors MARK II (+W)
CAP HOUSING
Specifications of connector
CAP HOUSING
174354-2 or Equivalent
TERMINAL
173706-1 or Equivalent
PORT P,T,4
PORT A,B,C,D,1,2,3
PF3/8
PF1/4
PSV-A,B,C,D
Solenoid valve assy
(8-SPOOLS)
Refer to HYD. SYMBOL
SECTION A-01-02-A
E1 17
File No.
Name of part
Specification
Description
Use
PSV-P1,P2
Solenoid
Type
KDRDE-5K
Rated feed press
50kgf/cm2 (710psi)
Allowable back press
10kgf/cm2 (140psi)
Control pressure range 0~30kgf/cm2 (0~430psi)

DC24V
Rated voltage
Proportional valve for
pumps P1,P2
AMP MARK II 2P
HOUSING 174354-2 or equivalent
TERMINAL 173706-1 or equivalent
O RING
1B P20
E1 18
HEX 10
Tightening torque
0.5kgfm (3.6 lbfft)
File No.
Name of part
Specification
Description
Use
SW-1
Switch
AUTO RETURN
T
P
G1
G2 ACC
ST
AUTO RETURN
OFF
Starter switch
VIEW A
ACC
ON
K250 STAMPED
START
A
TERMINAL
ARRANGEMENT
SW-3
Type
Buried in right travel lever
MARKS ON SWITCH PORTION
Switch
(Right travel grip)
Travel 1,2-speed
CA103
E1 19
File No.
Name of part
Specification
Description
Use
SW-4
Switch
Type
Single-pole double-throw
(alternate)
Rated
DC 30V,10A
INSULATION TAPE
R B W
VINYL TUBE
Swing parking release
SW-5
Contact
construction
T No
Position
ON 1
Normal
ON 2
Type
Switch
(2)
RED (2)
1 2
WHITE (3)
YAZAKI
7122-2237
7114-2020
BLUE (1)
M12P1
ST-425N
(2)
(3)
(5)
KEY WAY
(6)
KPSS release
~
(4)
(8)
(7)
(9)
(11)
(10)
12PAM-HD
SUMITOMO 6098-0252
TERMINAL 8230-4282
(12)
SW-6
Switch
Rated voltage
Operating
temperature
WDC24V, DC12V,
Contact type
A
More than 100M
(500V megger)
E/G water
temperature switch
[105C (221F)]
M4 X 0.7
ON 105
2 C
HEX 21
VIEW Z
PT 3/8
SW-7
Engine oil
pressure switch
ISUZU Part No.

Rated voltage
Operating pressure
Contact type
182410-0082
DC24V
More than 0.3kgf/cm2
(4psi)
Normally closed
Engine oil pressure

PT 1/8
E1 20
M4 X 0.7
File No.
Name of part
Specification
Description
Use
SW-8
Rated output
24X40A
CA104
CB104
CLOGGING SWITCH
Switch
Air filter
clogging switch
SW-10,20,34
Switch
Buried in left grip
Type
Grip assy (with switch) YT03M01102F2
YN03M01367F1
Use
Power boost (Horn)
Horn
Rated switch
Horn
power boost
Buried in right grip
125V X 3A
More than 100M /
DC500Vmegger
SUMITOMO DENSO HOUSING ITEM No. : 6090-1031 (2P MALE)

SUMITOMO DENSO TERMINAL ITEM No. : 8230-4282
SW-11
Roller plunger type

D4MC-5020
Type
Switch
HEX 17
CONNECTION TABLE
Safety lock lever
NO
2PAM
2
COM
NC
YAZAKI HOUSING 7122-2228
TERMINAL 7114-2020
E1 21
1
2
File No.
Name of part
Specification
Description
Use
SW-13
Maker's part No.
TAP-151N40
Operating voltage range
DC 20V~30V
Switch
Air conditioner
operation panel
SW-16
Maker's part No.
Switch
Type
RS-31700
Single-pole single-throw
(Alternate)
DC 24V
Rated voltage
More than 1M /
500V megger
Auto accel release SW.
~
CONNECTOR (WITH LOCK)

EQUIVALENT YAZAKI 7122-2228
(R)
RED
TERMINAL CONNECTOR
Terminal
Position
RW
RED / WHITE
(RW)
OFF
ON
SW-17
Switch
(Alternate)
Type
Rated voltage
DC 24V
More than 1M /
500V megger
Swing flasher select SW.

(R)
RED
TERMINAL CONNECTOR
(OPT.)
Terminal
Position
RW
RED / WHITE
(RW)
OFF
ON
SW-21
Switch
(Alternate)
Type
Rated voltage
DC 24V
More than 1M /
500V megger
Work light
~

(R)
RED
TERMINAL CONNECTOR
Terminal
Position
RW
RED / WHITE
(RW)
OFF
ON
E1 22
File No.
Name of part
Specification
Description
Use
SW-22
Rated voltage
Switch
Type
DC 24V
(Alternate)
More than 1M /
500V megger
Conflux/single select
(OPT.)
(R)
RED

TERMINAL CONNECTOR
Terminal
Position
RW
RED / WHITE
(RW)
OFF
ON
SW-23
Switch
DS-431
Contact components
ON- (OFF) momently
Maker's part No.
More than 100M /

500V megger
Wiper interlock switch
SW-30
Switch
BLACK
CB104
RED
CA104
(Alternate)
Type
Rated voltage
DC 24V
More than 1M /
500V megger
Rotary light
8.7
14

(R)
RED
TERMINAL CONNECTOR
Terminal
Position
RW
RED / WHITE
(RW)
OFF
ON
SW-32
Switch
(Alternate)
Type
Rated voltage
DC 24V
More than 1M /
500V megger
Overload indicator

(R)
RED
TERMINAL CONNECTOR
Terminal
Position
RW
RED / WHITE
(RW)
OFF
ON
E1 23
File No.
Name of part
Specification
Description
Use
SW-42
Switch
Engine room
light switch
CA-104
TERMINAL YAZAKI : 7113-1020-02
CAP YAZAKI
: 7120-8012
CB-104
TERMINAL YAZAKI : 7115-1050-02
CAP YAZAKI
: 7120-1010
E1 24
(R)
RED
LA103 M3
BLACK
(B)
E200SR
SECTION 25
AIR-CONDITIONER SYSTEM
TABLE OF CONTENTS
1. CONSTRUCTION AND PIPING
1.1 Construction ......................................................................................................................... 1
1.2 Piping ................................................................................................................................... 2
2. CONSTRUCTION OF MAIN COMPONENTS

2.1 Intake Unit ............................................................................................................................. 4
2.2 Air-Conditioner Unit ............................................................................................................... 5
2.3 Receiver Dryer ...................................................................................................................... 6
3. FUNCTION
3.1 Mechanism of Cooling Circuit ............................................................................................... 7
3.2 Cooling Circuit ...................................................................................................................... 8
3.3 Component Parts .................................................................................................................. 9
4. DISASSEMBLY AND ASSEMBLY

4.1 Precautions to be Exercised in Operation ........................................................................... 13
4.2 Removal and Installation of Unit .......................................................................................... 14
5. CHARGING REFRIGERANT
5.1 Precautions to be Exercised in Operation ........................................................................... 18
5.2 Operating Procedure .......................................................................................................... 19
5.3 Charging Procedure ............................................................................................................ 20
6. ELECTRIC CIRCUIT
6.1 Wiring Diagram and Connectors ......................................................................................... 24
6.2 Inspecting Functional Parts ................................................................................................. 25
7. TROUBLESHOOTING ............................................................................................. 27
1. CONSTRUCTION AND PIPING

1.1 CONSTRUCTION
1-1
1-3
F
A
1-5
1-4
6
2-7
D
TO CONDENSER
2-3
2-8
TO
COMPRESSOR
2-6
TO CONDENSER
2-4
2-1
F
2-2
2-5
TO COMPRESSOR
TO AIR CONDITIONER
A
TO AIR CONDITIONER
Fig. 1 Air-conditioner group
No.
NAME
QTY No.
NAME
QTY No.
NAME
1 AIR-CONDITIONER ASSY 1
2 AIR DRYER ASSY
1
3 COMPRESSOR ASSY
1-1 AIR-CONDITIONER UNIT 1
2-1 RECEIVER DRYER 1
4 PANEL ASSY
1-3 SENSOR
1
2-2 BRACKET
1
5 FILTER ASSY
1-4 PLATE
1
2-3 L HOSE ASSY
1
6 CONDENSER
1-5 MACHINE SCREW
1
2-4 D HOSE ASSY
1
2-5 S HOSE ASSY
1
2-6 L HOSE ASSY
1
2-7 D TUBE ASSY
1
2-8 S TUBE ASSY
1
QTY
1
1
1
1
1.2 PIPING
T : Tightening torque kgfym (lbfyft)
28
19
T=6.6 (48)
T=6.6 (48) 18
21
28
27
24
15
1
T=1.1 (8.0)
T=4.6 (33)
Nut for tension pully
26
AC
OUT
IN
HEATER
10
4
10
4
10
11
6
11
T=2.3 (17)
11
T=4.0 (29)
T=1.0 (7.2)
14
21
12
3
T=1.0
(7.2)
16
23
25
28
25
12
28
20
7
8
20
11
17
T=1.0 (7.2)
T=4.0 (29)
20
23
9
16
T=0.45 (3.3)
Fig. 2(1/2) Installing air conditioner and heater
2
HEATER CIRCUIT
AIR CONDITIONER UNIT

ENGINE
OUT
IN OUT
IN
AIR CONDITIONER CIRCUIT

AIR CONDITIONER UNIT
L HOSE
S HOSE
D HOSE
COMPRESSOR
CONDENSER
L TUBE (HOSE)
Fig. 2(2/2)
RECEIVER DRYER
Installing air conditioner and heater

Note) Apply Locktite #262 to mark.
Tightening
torque
kgfym (ftylbs)
4.0 (29)
1.1 (8.0)
No.
1
2
3
4
5
6
7
8
9
10
11
12
14
15
NAME
BRACKET
SUPPORT
SUPPORT
HOSEL=4150
SPACER
TUBEL=3800
TUBEL=2800
TUBEL=1900
TUBEL=3200
CLIP
CLIP
CLIP
CAPSCREWM816
CAPSCREWM8100
Tightening
torque
QTY
kgfym (ftylbs)
0.45 (3.3)
1
1
1
2
2
2
1
1
1
4
4
2
2
4
6.6 (48)
6.6 (48)
No.
16
17
18
19
20
21
23
24
25
26
27
28
NAME
CAPSCREWM650
CAPSCREWM620
CAPSCREWM1050
CAPSCREWM1060
WASHER
WASHER
LOCK WASHER
LOCK WASHER
NUT
GROMMET
V BELTB42
WASHER
QTY
6
2
2
2
8
6
6
4
2
1
1
6
2. CONSTRUCTION OF MAIN COMPONENTS

2.1 INTAKE UNIT
51
64
62
61
64
50
61
62
52
62
61
48
61
53
62
62
43
49
62
62
62
57
61
62
45
61
44
45
47
42
61
55
46
63
63
63
Fig. 3 Intake unit
4
60
2.2 AIR-CONDITIONER UNIT
39
36
40
61
37
9
36
14
60
62
1
62
62
31
61 20
64
21
64
26 22
65
62
62
60
19
30
62
18
29 32
10
17 62
24
23
34
25 67
35
24
67
62
33
24 23
67
27
11
62
16
62
12
67
8
23
56
59
58
28
6
13
62 64
20
1 62
5
64
6
56
54
Fig. 4
Air-conditioner unit
5
62
41
15
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
NAME
QTY No.
ACTUATOR
VALVE
THERMISTOR
CLAMP
ROD HOLDER
SENSOR HOLDER
CLAMP
EVAPORATOR
CASING
CASING
CASING
THERMAL INSULATION
THERMAL INSULATION
PACKING
PACKING
PACKING
BRACKET
CLAMP
PLATE
LEVER
LEVER
LEVER
LEVER
NAME
QTY No.
NAME
QTY
3
1
1
2
2
24
25
26
27
28
LEVER
CAM
ROD
ROD
ROD
3
1
1
1
1
47
48
49
50
51
BLOWER MOTOR
CASING
CASING
FILTER
LEVER
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
3
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
DAMPER
DAMPER
DAMPER
DAMPER
DAMPER
DAMPER
HEATER CORE
CONTROLLER
RELAY
CLAMP
BAND
DUCT HOSE
HARNESS
RESISTOR
CASING
CASING
BRACKET
HOSE
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
LEVER
DAMPER
FLANGE PLATE
SENSOR
SEMS BOLT
GASKET
O RING
O RING
TAPPING SCREW
TAPPING SCREW
SCREW
SEMS BOLT
TAPPING SCREW
SCREW
CAPSCREW
TAPPING SCREW
1
1
1
1
1
1
1
1
6
13
30
3
9
1
2
4
2.3 RECEIVER DRYER

REFRIGERANT
INLET
2
REFRIGERANT
OUTLET
No.
1
2
3
4
5
6
2-M6
1
3
4
Fig. 5 Receiver dryer

6
NAME
PRESSURE SWITCH
SIGHT GLASS
DESICCANT
SUCTION PIPE
FILTER
RECEIVER TANK
QTY
1
1
1
1
1
1
3. FUNCTION
3.1 MECHANISM OF COOLING CIRCUIT
(1) Mechanism of Cooling
In the cooling process, the refrigerant that
Table 1
flows through the cooling circuit changes its
Item
HFC-134a (R134a)
phases from liquid to gas and vice versa
Chemical formula
CH2FCF3
during which process heat is transferred from
the low temperature part (compartment) to
Molecular weight
102.03
the high temperature part (outside of the
Boiling point
F)
26.19 (15.14
vehicle).
Critical temperature 101.14 (214.05
F)
1) Kind of Refrigerant
Many kinds of refrigerants that change in
Critical pressure
4.065MPa (41.45kgf/cm2 1)
that way are available, but the following
Critical density
511kg/m3 (31.9 lb/ft3)
requirements are needed for use in such
Density of saturated 1206kg/m3 (75.3 lb/ft3)
applications:
liquid [25 (77.0
F)]
z Latent heat of vaporization (heat of
vaporization) is large.
Specific volume of
0.0310m3/kg (0.496ft3/lb)
z It is easy to liquefy (condense). (It dose not
saturated vapor
require very high pressure for condensation.)
[25 (77
F)]
z It is easy to gasify (evaporate). (It evaporates
Latent heat of
197.5KJ/kg {47.19kcal/kg}
sufficiently at not too low pressure, i.e. cools
vaporization
down an object.)
[0 (32
F )]
z It has small specific heat. (Since the
Flammability
Nonflammable
refrigerant itself is cooled by the expansion
Ozone destruction
0
valve, the loss resulting from it must be held
coefficient
down to a minimum.)
z It has a high critical temperature and a low
1 : 1MPa (mega pascal) equals 10.1972kgf/cm2
solidification point.
(145psi)
z It is stable chemically and does not corrode
and permeate into the circuit parts.
z It is free from toxicity, objectionable odor,
flammability and explosiveness and excels in
thermal conductivity and electric insulation.
z It has small specific volume.
z It is easy to find out leakage.
Out
of
refrigerants
meeting
the
above-mentioned requirements, ones having
characteristics that suit the intended cooling
unit are chosen and used. If a refrigerant
other that those designated is used, sufficient
refrigeration will not be performed or the
equipment in which the refrigerant is used
may be broken. Therefore, always use a PRESSURE
designated refrigerant for the cooling unit.
MPa(kgf/cm2)
Table 1 shows the principal characteristics of
R134a
the R134a refrigerant that is used in this 4 (40.8)
machine.
3 (30.6)
(2) Characteristics of Refrigerant (See Fig.6.)

In general, the fluid (general term of gas and
liquid) has the following qualities:
2 (20.4)
1) As a gas under certain pressure is cooled
down, it begins to condensate at a certain
1 (10.2)
temperature to take a liquid state. The
(5.2)
temperature at which condensation begins is
unique to each substance (fluid) at a given
0
pressure. The temperature determined by a
given
pressure
is
called
saturation
Fig. 6
temperature.
7
LIQUID
GAS
TEMPERATURE
0
(32)
35
50
15 18
(59)(64) (95) (122)
F)]
100 [ (
(212.0)
Pressure-temperature characteristics of R134a
2) Inversely to 1) above, the pressure at which a

gas condenses for a temperature is
determined.
This
pressure
is
called
saturation pressure.
Fig.6 illustrates the relationships between
the saturation temperature and the
saturation pressure in the case of refrigerant
R134a used in the air-conditioner. At the
temperature and the pressure on the lower
righthand side of the curve in Fig.6, the
refrigerant take a gaseous state, while at the
temperature and the pressure on the upper
lefthand side of the curve, the refrigerant
takes a liquid state.
Let us think of a case where an
air-conditioner is operated in the midst of
summer. As the refrigerant evaporates, it
absorbs evaporation heat from the air of the
compartment. In order to cool the inside of
the compartment down to 25 (77
F), the
refrigerant must transform (evaporate) from
a liquid to a gaseous state at a lower
temperature. It can be seen from Fig.6 that
R134a under a pressure above the
atmospheric pressure is capable of cooling the
inside of the compartment sufficiently. (If a
refrigerant that requires a pressure below the
atmospheric pressure to cool it to a required
temperature is used, air is mixed into the
circuits,
thereby
deteriorating
the
performance of the cooling unit.) In the
process in which gaseous refrigerant is
brought back to a liquid state, the refrigerant
is cooled and condensed by the outer air
exceeding 35 (95
F).
Accordingly the refrigerant is capable of
condensing
at
a
pressure
exceeding
10.2kgf/cm2 (145psi), as seen from Fig.6.
3.2 COOLING CIRCUIT
Fig.7 illustrates the cooling circuit of the car
air-conditioner.
In this circuit diagram, the portion that cools
the air of the compartment is the evaporator.
The object air is cooled off by utilizing the
fact that the refrigerant takes heat off the
surrounding area as evaporation heat as it
evaporates in the cooling circuit. Since the
part at which vaporization of the refrigerant
takes place is the evaporator, cooled air is
constantly delivered to the circumference of
the evaporator by the blower fan. In the
meantime, liquid refrigerant (slightly wet
vaporized refrigerant) is fed into the
evaporator, when cooling effect is attained.
For instance, in order to cool the air to 15
(59
F), the refrigerant can not absorb
evaporation heat from the air unless it
evaporates at a temperature lower that 15
(59
F). For that purpose, it can be seen from
Fig.6 that the pressure of the refrigerant in
the evaporator must be less than 5.2kgf/cm2
(74psi).
Furthermore, the cooling effect deteriorates
unless the feed rate of the refrigerant is
controlled so that all of the refrigerant
supplied to the evaporator vaporizes and
turns into dry vapor.
INSIDE OF COMPARTMENT (CAB)
EVAPORATOR EXPANSION
VALVE
BLOWER
INSIDE OF ENGINE
S
D ROOM
COMPRESSOR COOLING FAN
RECEIVER
DRYER
CONDENSER
Fig. 7
8
Construction of cooling circuit
Consequently, the cooling circuit is so

constructed that the evaporator can cool
down an object (air in this case) sufficiently
(i.e. so as to decrease the pressure in the
evaporator) and that an adequate amount of
refrigerant can be fed to the evaporator.
The feed rate of the refrigerant is controlled
by the expansion valve, but the pressure in
the evaporator is held low by the throttling
action of the expansion valve and the suction
action of the compressor. The compressor acts
as a pump that allows the refrigerant to
circulate. The compressive action of the
compressor and the heat exchange (heat
radiation) action of the condenser transform
the refrigerant in a dry vapor state back to a
liquid state.
3.3 COMPONENT PARTS
(1) Evaporator (See Fig.8.)
The evaporator is an important heat
exchanger that absorbs the heat of the
compartment air (object) by the utilization of
the latent vaporization heat of the
low-temperature, low-pressure liquid-state
refrigerant. Therefore, it is necessary that
satisfactory heat transfer between the object
and the refrigerant take place in the
evaporator.
To that end, the evaporator is equipped with
fins on the air side in order to increase the
heat transfer area of the air side and thereby
perform excellent thermal transfer between
the refrigerant and the air.
The humidity in the air condenses as the air
cools down and adheres to the outside of the
evaporator as water drops. The cooling effect
deteriorates if the water drops freeze.
Therefore, how to discharge water is an
important point.
The amount of refrigerant supplied to the
evaporator is controlled by the expansion
valve which is described in the following. In
order to attain proper control, it is necessary
to reduce the pressure drop of the refrigerant
of the evaporator. Accordingly, reducing the
pressure drop is one element that makes the
evaporator attain its full performances.
(2) Expansion Valve
In order for the evaporator to fulfill its
performances,
a
proper
amount
of
low-pressure
low-temperature
liquid
refrigerant must be fed to the evaporator.
If the feed rate is too low, the refrigerant
completes
vaporization
early
in
the
evaporator which results in deterioration of
the cooling effect. If the feed rate is too high,
unvaporized liquid refrigerant returns to the
compressor (liquid back). This not only
deteriorates the cooling effect, but also
damages the compressor valves.
EVAPORATOR
O RING
EXPANSION
VALVE
SOCKET
BOLT
M540
(2 PCS.)
EVAPORATION
SENSOR
Fig. 8
Evaporator
The expansion valve feeds the flowing

high-pressure
high-temperature
liquid
refrigerant to the evaporator as low-pressure
low-temperature liquid refrigerant (damp
vapor of low dryness). The expansion valve
controls the feed rate of the refrigerant at the
same time.
Fig.9 shows how the block type expansion
valve is constructed. The temperature
sensing part is provided in the shaft of the
expansion valve to directly detect the
refrigerant temperature at the outlet of the
evaporator.
The diaphragm contains R134 a in saturated
state. The pressure in the diaphragm changes
according to the temperature detected by the
sensor. The change in the pressure causes the
force acting upon the diaphragm to vary
accordingly.
The high-pressure high-temperature liquid
refrigerant that is fed from the receiver side
reduces the pressure abruptly as it passes
through the valve (throttling action). On that
occasion, part of the refrigerant evaporates
by the very heat of the refrigerant and cooled
off. The result is that low-pressure
low-temperature damp refrigerant vapor is
fed to the evaporator.
The opening of the valve is determined by the
equilibrium between the pressure (low) of the
evaporator side, the action of the adjust
spring and the pressing force of the
diaphragm
(the
temperature
of
the
refrigerant at the outlet of the evaporator to
be sensed by the thermowell). The feed rate is
controlled automatically so that under the
pressure in the evaporator, the refrigerant is
properly overheated (3 ~ 8 degrees) and goes
out of the evaporator. This action is carried
out by sensing the refrigerant temperature at
the outlet of the evaporator as against the
inlet pressure of the evaporator and
consequently controlling the feed rate of the
refrigerant.
This means that if the refrigerant pressure
drop in the evaporator is excessive, it is
difficult to control the overheating or the feed
rate of the refrigerant. For this reason, the
smaller the pressure drop of the evaporator,
the better.
The expansion valve senses the pressure and
the temperature at the outlet of the
evaporator and controls the overheating of
the refrigerant and the refrigerant supply to
the
evaporator
more
securely.
The
air-conditioner of this machine adopts a block
type expansion valve.
DIAPHRAGM
EVAPORATOR
SIDE
BALL
VALVE
REFRIGERANT
OUTLET
SHAFT
REFRIGERANT
INLET
SPRING
Fig. 9 Block type expansion valve
Fig. 10 Expansion valve outside view

10
(3) Compressor (See Fig.11)

The compressor performs the following three
functions in the cooling circuit:
1) Suction action
2) Pumping action
3) Compressive action
1) The suction action, as combined with the
throttling action, works to decrease the
refrigerant pressure in the evaporator. This
permits the refrigerant to vaporize at low
temperature in order to perform cooling
effect.
2) The pumping action serves to cause all the
refrigerant to circulate in the cooling circuit.
This enables enables continuous cooling.
3) The compressive action, as combined with the
action of the condenser which is mentioned
hereunder, transforms vaporized refrigerant
back to a liquid state again.
The saturation temperature gets higher as
the pressure increases. For instance, it
becomes possible to cool down the refrigerant
by the use of an outer air of 35 (95
F) and
liquefy it. The compressive action of the
compressor works to turn low pressure
vaporized refrigerant to high pressure vapor
refrigerant. The condenser then serves to cool
down the refrigerant. However, since the
compressive action takes place only for a
short
period,
the
refrigerant
hardly
exchanges heat with outer air. That is to say,
it takes a near form of thermally insulated
compression, so that the refrigerant
discharged by the compressor turns into
high-temperature high-pressure vapor and is
delivered to the condenser.
D HOSE
S HOSE
(4) Condenser (See Fig. 12)

This is a heat exchanger that cools the
vaporized refrigerant at high temperature
and high pressure by the use of outer air and
condenses the refrigerant. The direction in
which heat moves is from the refrigerant to
air, the opposite to the case of the evaporator.
Fins are equipped on the outer air side to
improve thermal transfer. If the refrigerant
is not cooled well by the condenser, the air in
the compartment can not be cooled
sufficiently by the evaporator. For that
purpose, it is necessary to secure ventilation
required for the cooling of the refrigerant.
11
Fig. 11
Compressor
Fig. 12
Condenser
(5) Receiver Dryer (See Fig.13)

1) Receiver Tank
On the air-conditioner, the revolution of the
compressor varies greatly which causes the
proper flow of refrigerant in the cooling
circuit to vary. It is the receiver tank that
receives the variations. When the cooling
circuit does not need much refrigerant, the
receiver tank stores extra refrigerant
temporarily and supplies it when the cooling
circuit needs much refrigerant. The receiver
tank also stores an extra amount of
refrigerant to be used for filling balance and
supplement small amounts of leakage of the
refrigerant through penetration into rubber
hoses.
2) Dryer
If water is mixed in the cooling circuit, it
deteriorates the compressor valves and oil,
corrodes the metallic parts of the circuit or
clogs the circuit as the water freezes in the
expansion valve. It is desirable that the
amount of water mixed in the refrigerant
should be held below a concentration of
30ppm. The air-conditioner uses a molecular
sieve as desiccant suited for the circuit, in
order to absorb water content that intrudes
into the circuit when the dryer is installed or
when refrigerant is charged.
3) Sight Glass
This is a inspection window with which the
refrigerant level in the circuit is determined,
the only means of confirming the inside of the
circuit visually.
4) Filter
5) Pressure Switch
This machine employs pressure switches of
high/low pressure type.
The pressure switch protects the circuit by
cutting off the power supply to the
compressor when high pressure increases
abnormally high [more than 32kgf/cm2
(460psi) ].
The pressure switch also detects the leakage
of refrigerant by cutting the power supply to
the compressor when the pressure of the
circuit falls below 2kgf/cm2 (28psi).
REFRIGERANT
INLET
SIGHT GLASS
REFRIGERANT
OUTLET
PRESSURE SWITCH
DESICCANT
SUCTION PIPE
FILTER
RECEIVER TANK
Fig. 13
12
Receiver dryer
4. DISASSEMBLY AND ASSEMBLY

4.1 PRECAUTIONS TO BE EXERCISED IN
OPERATION
(1) Special Refrigerator Oil
This air-conditioner uses special refrigerator
oil SP20 for use with new refrigerant R134a.
Oils other than SP20 may not be used. Since
SP20 tends to absorb moisture and may
corrode paint and resin, the following points
must be noted:
1) Keep open all pipe connections on a new
compressor and the component parts of the
installed refrigeration circuit
(Remove valves and caps at the pipe openings
of the compressor, just before connecting
pipes. If you have removed a pipe joint for
repair, put a cap to both ports immediately.)
2) Use care so SP20 does not adhere to the
painted surface and resin parts. In case SP20
has adhered to such surfaces, wipe it off
immediately.
(2) The receiver dryer is filled with desiccant to
absorb moisture in the circuit. Therefore,
remove the valve at the pipe port
immediately before connecting pipes.
(3) Tightening Torque
1) Pipe Joints (See Table 2.)
When connecting pipe joints, coat the O ring
with special oil (SP20) and fasten to the
tightening torque indicated in the table,
using a double spanner.
2) Screws and Bolts (See Table 3.)
(4) Amount of Oil for Compressor (See Table 4.)
The compressor SD7H (HD type) is filled with
135cc (8 cuyin) of oil. If the oil volume is
small, seizure at high revolution and
shortening of service life will occur. If the oil
volume is large, the cooling ability will be
deteriorated.
Once the air-conditioner is operated, part of
the oil is dispersed in the refrigeration
circuit. Therefore, when replacing the parts
in Table 4, adjust the oil level to that of table.
(5) Before performing operation, stop the engine
and turn off all power supplies to the
equipment related to the air-conditioner.
(6) After the operation is over, confirm that all
faults have been repaired completely, by
operating the air-conditioner.
Unit : kgfycm (lbfyft)
Table 2
Pipe Fastening Part
Tightening Torque
D hose and compressor

(M8 bolt)
D hose and condenser
L hose and condenser
L hose and receiver dryer
(M6 bolt)
L hose and air-conditioner unit
S hose and air-conditioner unit
Inlet of expansion valve
Outlet of expansion valve
Pressure sensing part of
expansion valve
200 ~ 250 (14 ~ 18)

200 ~ 250 (14 ~ 18)
120 ~ 150 (8.7~11)
80~120 (5.8~8.7)
120~150 (8.7~11)
300~350 (22~25)
120~150 (8.7~11)
200~250 (14~18)
70~90 (5.1~6.5)
Unit : kgfycm (lbfyft)
Table 3
Screw Size
Tightening Torque
N4, T4 machine screw, M4

N5, T5 machine screw, M5
M6 (mounting part of
L hose joint)
M6 (except mounting part of
L hose joint)
M8 (mounting parts of S, D
hose joints)
M8 (mounting part of A/C unit)
M8 (other than those
mentioned above)
M10
8~12 (0.58~0.87)
20~25 (1.4~1.8)
80~120 (5.8~8.7)
100~120 (7.2~8.7)
200~250 (14~18)
100~120 (7.2~8.7)
120~160 (8.7~12)
400~550 (29~40)
Table 4
Replaced parts
Evaporator
Condenser
Compressor
13
Amount to be filled in
40cc (2.4cuyin)
40cc (2.4cuyin)
Drain out the volume of oil
left in the compressor to be
replaced, from the new
compressor.
4.2 REMOVAL AND INSTALLATION OF THE UNIT

(1) Removing the blower unit
1) Remove the connectors connected to the
inner/outer air select motor actuator, the
blower motor and the blower controller. Also
remove the harness from the blower casing.
INNER / OUTER
AIR MOTOR
ACTUATOR
CONNECTOR
HARNESS
EVAPORATOR
SENSOR
BLOWER
CONNECTOR CONTROLLER BLOWER MOTOR
CONNECTOR CONNECTOR
Fig. 14
2) Draw out the inner air filter from the intake
casing. Remove four cross-recessed screws
T514 (T1) from the top of the intake casing,
using a screwdriver. Then remove the intake
casing.
INNER AIR FILTER
INTAKE
CASING
3) Remove three cross-recessed screws T514

(T1) fastening the blower casing with the unit
casing. Then separate the blower unit from
the air-conditioner unit.
INTAKE
CASING
MOUNTING
SCREWS
(4 PCS.)
BLOWER
CASING
MOUNTING
SCREWS
(3 PCS.)
UNIT
(2) Replacing the blower motor

1) Disconnect the cooling hose that is connected
between the blower motor and the blower
casing.
BLOWER
CASING
Fig. 15
2) Remove three cross-recessed screws N516

(W) fixed from the bottom of the blower unit
casing. Then draw out the blower motor.
BLOWER CASING
z Do not separate the fan from the

blower motor.
BLOWER
MOTOR
3) Assembly is the reverse order of disassembly.
BLOWER
CONTROLLER
(3) Replacing the blower controller

1) Remove two cross-recessed screws T4 14
(T1) fixed from the bottom of the blower unit
casing and draw out the blower controller.
COOLING
HOSE
BLOWER
CONTROLLER
MOUNTING
SCREWS (2 PCS.)
2) Install a new blower controller in the reverse

order of removal.
Fig. 16
z Do not disassemble the blower
controller in any circumstances.
14
BLOWER MOTOR
MOUNTING
SCREWS (3 PCS.)
(4) Removing the heater core

1) After discharging the cooling water,
disconnect the heater hose from heater core.
HEATER CORE
2) Remove one cross-recessed screw N516 (T2)

each for the AHC bracket fixing the heater
core to the unit and for the pipe clamp. Then
remove the AHC bracket and the pipe clamp
and draw out the heater core from the unit
casing.
PIPE CLAMP
PIPE CLAMP
MOUNTING
SCREW
(1 PC.)
AHC BRACKET AHC MOUNTING
SCREW (1 PC.)
3) Assembly is the reverse order of disassembly.
Fig. 17
(5) Removing the upper and lower parts of the

air-conditioner unit casing
1) Draw out the connectors for the mode motor
actuator and the evaporation sensor.
2) Separate the rod 120 from the rod holder that
is fixed to the lever MAL1 on the mode motor
actuator.
3) Remove three cross-recessed screws N422
(T2) fastening the mode motor actuator that
install the bottom of the unit casing to the
back of the unit casing. Then separate the
mode motor actuator.
ROD 120
REAR OF
UNIT CASING
ROD HOLDER
MOUNTING SCREW
LEVER MAL1
BOTTOM OF
UNIT CASING
MOUNTING
SCREW
MOUNTING
SCREW
4) Remove eleven cross-recessed screws N516

(T2) that install the bottom of the unit casing
to the top of the unit casing.
Draw out the top of the unit casing upwards,
using care so the evaporator sensor cord is TOP OF UNIT
CASING
not arrested by the casing.
MODE MOTOR
ACTUATOR
Fig. 18
z On that occasion, do the work with

the heater core off the unit casing.
EVAPORATOR ASSY
EXPANSION
VALVE
EVAPORATION
SENSOR
BOTTOM OF
UNIT CASING
TOP / BOTTOM
UNIT CASING
MOUNTING
SCREWS (11 PCS.)
Fig. 19
15
(6) Replacing the evaporator and the expansion

valve
1) Remove the evaporator assy from the bottom
of the casing, together with the casing
insulator and the expansion valve.
EVAPORATOR
2) Remove the upper and lower casing

insulators from the evaporator assy and draw
out the evaporator sensor with the sensor
holder.
O RING
EXPANSION
VALVE
SOCKET HEAD
CAPSCREW
M5 x 40 (2 pcs.)
3) Remove the socket head cap screws M5 x 40

(2 pcs.) from the evaporator. Then separate
the expansion valve from the evaporator.
: 4mm
EVAPORATION SENSOR
Fig. 20
4) Attach O rings (NFO ring 5/8 and 1/2, one
piece each) to a new evaporator. Then install
the expansion valve to it.
: 4mm,
Tightening torque 0.7kgfym (5.1 lbfyft)
z When attaching O rings, use care so
the O rings are not caught.
3rd row
(7) Installing the evaporator sensor

Install the evaporation sensor as shown in
Fig.21.
5th and 6th rows
13th and 14th rows
z When installing the casing, exercise

care so the sensor cord is not caught
by the casing.
EVAPORATION SENSOR
(8) Replacing the motor actuator

1) Replacing the mode motor actuator
Remove the connector fixed to the motor
actuator.
Remove the rod 120 linking the motor
actuator with the mode cam, from the rod
holder.
Remove three cross-recessed screws T4 x 14
(T1) fixing the motor actuator. Separate the
motor actuator from the unit, together with
the rod holder and the lever MAL1. Remove
the rod holder and the lever MAL1 from the
motor actuator and install them to a new
motor actuator. Assembly is the reverse order
of disassembly.
Fig. 21 Installing the evaporator sensor
ROD 120
REAR OF
UNIT CASING
ROD HOLDER
MOUNTING
SCREW
LEVER MAL1
BOTTOM OF
UNIT CASING
MOUNTING
SCREW
MOUNTING
SCREW
Fig. 22
16
MODE MOTOR
ACTUATOR
2) Replacing the air mix motor actuator

Disconnect the connector connected with the
motor actuator.
Separate the rod 67 linking the motor
actuator with the lever AM, from the rod
holder.
Remove three cross-recessed screws T414
(T1) fastening the motor actuator. Then
remove the motor actuator with the rod
holder and the lever MAL1, from the unit.
Remove the rod holder and the lever MAL1
from the motor actuator and install them to a
new motor actuator. Assembly is the reverse
order of disassembly.
LEVER AM
ROD 67
ROD HOLDER
LEVER MAL1
AIR MIX MOTOR
ACTUATOR
Fig. 23
3) Replacing the inner/outer air select motor
actuator
Disconnect the connector connected with the
motor actuator.
Separate the motor actuator with lever MAL2
from the unit.
Remove the lever MAL2 from the motor
actuator and install it to a new motor
actuator, in the reverse order of disassembly.
LEVER MAL2
INNER / OUTER AIR

MOTOR ACTUATOR
Fig. 24
17
5.
CHARGING REFRIGERANT
(3) Charging
1) When warming the can in which refrigerant
is charged, do not fail to open the service can
valve and the low pressure valve of the gauge
manifold and warm the can in warm water of
40 (104
F) or below (to an extent that you
do not feel hot when you put your hand in the
water.) If the can is put in hot water or
heated by a direct fire, the pressure of the
can may rise sharply, thereby blowing off the
can.
2) When charging refrigerant while running the
engine, do not open the high pressure valve
(HI) of the gauge manifold in any case.
(4) Others
Re-use of service cans is prohibited by law;
never use them again. Do not allow foreign
matter to enter the air-conditioner circuit.
Air, water and dust are detrimental to the
refrigeration cycle. Install the components of
the air-conditioner correctly and speedily.
Pay full attention to the entry of water and
dust.
5.1 PRECAUTIONS TO BE EXERCISED IN

OPERATION
(1) Always assign a person in charge of handling
refrigerant.
Refrigerant
charge
operation
involves
dangers as it handles high pressure gas.
Always assign a person familiar with how
work is done for handling refrigerant.
z Always wear protective goggles. (You
may lose your sight if the refrigerant
gets in your eyes.)
z The refrigerant in liquid state is at
very low temperature [approx. 26
(15
F)]. Therefore, handle it with
care. (You may get a frostbite if the
refrigerant is sprayed over your
skin.)
(2) Storage and Transportation
1) Keep the service can (hereinafter called can)
less than 40 (104
F). Since high pressure
gas of R134a is filled in the can in a
saturated liguefied state, the pressure in the
can increases sharply as temperature rises.
The can may blast as the result.
It is for this reason why the can temperature
must be kept below 40 (104
F).
2) For storage, choose a cold dark place not
exposed to direct sunlight.
3) If the can is placed near a fire source, it is
subject to radiation heat and gets hot. This
causes the inside pressure to rise and may
cause the can to blow out. Therefore, never
bring the can close to a fire.
4) The inside of the closed compartment gets
very hot as the radiation heat of the sunlight
enters the compartment. The areas of the
compartment which are exposed to direct
sunlight
may rise
to
a dangerous
temperature level. Therefore, do not bring the
can into the compartment. Also, the inside of
the trunk room may rise to a dangerous
temperature level even in the summer time.
Use sufficient care, therefore, taking the
above into account.
5) Note that if the can has scratches, marks and
distortion, the strength of the can will
deteriorate.
1. Do not drop or knock on the can.
2. When transporting, loading or unloading
cans and packages containing cans, do
not throw or drop them.
6) Store cans beyond the reach of children.
z Be careful about overcharge of gas.

z Fasten pipes to a specified torque.
18
5.2 OPERATING PROCEDURE

(1) Refrigerant charge into the air-conditioner
consists
mainly
of vacuum
making
operation, and gas charging operation.
1) The vacuum making operation consists of
removing water in the air-conditioner circuit.
If only a little water remains in the circuit,
the small holes of the expansion valve are
frozen during operation. This causes the
circuit to clog up or rust, resulting in a
variety of malfunctions. Therefore, before
filling refrigerant in the circuit, make
vacuum and allow the water in the circuit to
boil and vaporize. Water in the circuit is thus
eliminated.
2) The gas charging operation consists of

filling refrigerant in the circuit after forming
vacuum. Filling gas not only depends upon
the
cooling
performances
of
the
air-conditioner, but also affects the service
life of the component parts of the circuit.
Extreme overcharge will make the circuit
pressure extremely high and causes the
cooling performance to deteriorate. On the
contrary, undercharge causes poor circulation
of the lubricating oil of the compressor and
causes seizure of the moving parts of the
compressor.
The gas charging operation involves handling
of high pressure gas; filling gas according to
incorrect operation procedure is dangerous.
Fill refrigerant correctly following the
operation procedures and cautions stated in
this manual.
Gas charging operation
(2) Operation Chart

Vacuum making operation
More than
30 min.
Begin vacuum
making
Leave it as it is,
for five minutes.
Stop vacuum
making
Fill in
refrigerant
Check
air-tightness
Check for
gas leak
Fill in
refrigerant
Lower than
750mmHg
Gauge
indicates
b
li
Check and correct joints
Charge refrigerant gas to a gauge

pressure of 1kgf/cm2 (14 psi)
(3) Tools
Table
No. Name of Part Q
TY
1 Gauge
Sketch
Service
unit : mm
No. Name of Part Q

TY
hose
3 Quick joint
1
27.5
Red : high
pressure
side
Blue : low
pressure
side
Yellow :
vacuum
pump
side
High
pressure
side
5 T joint
6 Service can
For service
can
For
vacuum
pump
valve
7 Vacuum
pump adapter
19
Service
Low
pressure
side
For service
can valve
4 Quick joint
manifold
2 Charging
Sketch
23.5
5.3 CHARGING PROCEDURE

5.3.1 VACUUM MAKING OPERATION
(1) Connecting Gauge Manifold (See Fig.25.)
1) Close the high pressure valve (HI) and the
low pressure valve (LO) of the gauge
manifold.
2) Connect the charging hoses (red and blue)
with the service valves of the compressor.
Red hose : High pressure side (HI) of the
gauge manifold high pressure
side (DIS) of compressor
Blue hose : Low pressure side (LO) of gauge
manifold low pressure side
(SUC) of compressor
Note) DIS : Discharge

SUC : Suction
HIGH
PRESSURE GAUGE
GAUGE MANIFOLD
LOW PRESSURE
GAUGE
(CLOSED) LOW
PRESSURE VALVE
HIGH PRESSURE
VALVE (CLOSED)
BLUE
RED
HIGH
PRESSURE
SIDE
DIS
YELLOW
LOW
PRESSURE
SIDE
SUC
z Do not mistake the high pressure

hose for the low pressure hose in any
circumstances
when
connecting
them. Put the hose in firmly till a
clicking sound is heard.
z Connect the end bent like L of the
charging hose with the service valve
of the compressor. If the charging
hose is connected the opposite way,
the mini core valve of the compressor
does not open. (See Fig.26.)
COMPRESSOR
Fig. 25
VACUUM PUMP
(STOP)
Connecting gauge manifold
BLUE
RED
CHARGING
HOSE
3) Connect the center valve of the gauge

manifold with the charging hose of the
vacuum pump.
(MINI CORE VALVE)
Fig. 26
Some kinds of gauge manifolds are not

equipped with an open/close valve in
the center.
Connecting piping with compressor
LOW PRESSURE VALVE (OPEN)

HIGH PRESSURE VALVE (OPEN)
(CLOSE)
(CLOSE)
More than 30 min
(2) Vacuum Making (See Fig.27.)

1) Open the high pressure valve (HI) and the
low pressure valve (LO) of the gauge
manifold.
2) Turn on the switch of the vacuum pump and
make vacuum for more than 30 minutes.
3) When vacuum making for a specified
duration is over (degree of vacuum : less than
750mmHg), close the high pressure valve
and the low pressure valve of the gauge
manifold.
4) Then turn off the vacuum pump.
GAUGE MANIFOLD
DIS
SUC
Fig. 27
20
Vacuum making operation
(3) Air-tightness Check

Close the high pressure valve and the low
pressure valve of the gauge manifold, leave it
as it is for more than five minutes and make
sure that the gauge indication does not
return toward O.
If the gauge indication swings toward
O, there is somewhere that is leaking.
Retighten pipe joints, make vacuum
again and make sure of no leakage.
5.3.2 GAS CHARGING OPERATION
(1) Charging from High Pressure Side
(See Fig.28.)
1) After making vacuum repeatedly, change the
charging hose (yellow) of the gauge manifold
from the vacuum pump to the service can.
2) Air purge
Open the service can valve. (However, close
the high and low pressure valves of the gauge
manifold.) Then push the mini core valve of
the side service port on the low pressure side
of the gauge manifold, using a screwdriver, in
order to let out the air in the charging hose
by the pressure of the refrigerant. (See
Fig.28.) (The operation ends when a hissing
sound is heard.)
3) Open the high pressure valve of the gauge
manifold and charge in refrigerant. [Charge
in gaseous refrigerant to a gauge pressure of
1kgf/cm2 (14psi).]
After charging, close the high pressure valve
of the gauge manifold and the service and
valve. (See Fig.29.)
AIR PURGE
CLOSE
RED
OPEN SERVICE CAN VALVE
SCREWDRIVER
YELLOW
BLUE
Fig. 28
LOW PRESSURE
VALVE (CLOSE)
BLUE
Do not run the compressor in any case,

(Otherwise the refrigerant flow in
reverse direction which causes the
service can and the hoses to rupture.
This is very dangerous.)
HIGH PRESSURE VALVE

(CLOSE)
(OPEN)
RED
FILL IN 11.5 CANS
OF REFRIGERANT
YELLOW
DIS
SERVICE CAN
VALVE
(OPEN)
(CLOSE)
CHARGE
SUC
(2) Checking for Gas Leakage

Check for gas leakage in the cycle, using a
gas leak detector (electric type). Retighten
and correct leaking points.
Fig. 29
Always use the leak tester for R134a.

(Do not use one for flon gas service as it
provides poor sensitivity.)
21

(High pressure side)
(3) Charging from Low Pressure Side

(See Fig.30.)
1) Make sure that the high-pressure and
low-pressure valves of the gauge manifold
and the service can valve are closed.
2) Start the engine and run the revolution to
1500100rpm and fully open the cab door
and the windows.
3) Turn on the air-conditioner switch, set the
fan switch to Max and the temperature
control switch to cool Max.
4) When charging gas, set the discharge
pressure of the compressor to 1416kgf/cm2
(200230psi).
5) Open the low pressure valve of the gauge
manifold and the service can valve and fill in
refrigerant till air bubbles of the sight glass
of the receiver go away. (See Fig.30.)
[Total amount of gas to be charged :
1000g100g (2.20.22 lbs )]
6) When refrigerant charge is over, close the low
pressure valve of the gauge manifold and the
service can valve.
HIGH PRESSURE
VALVE (CLOSE)
(MUST BE CLOSED
POSITIVELY)
LOW PRESSURE
VALVE
CLOSE
OPEN
RED
WHEN AIR
BUBBLES IN THE
SIGHT GLASS
DISAPPEAR
BLUE
DIS
YELLOW
SERVICE CAN
VALVE (OPEN)
SUC
COMPRESSOR
OPERATION
SERVICE CAN
(DO NOT TURN IT OVER)
Fig. 30

(Low pressure side)
SIGHT GLASS
z Do not open the high pressure valve

of the gauge manifold in any
circumstances.
z Never place the service can upside
down. (The compressor valve may be
scored because the refrigerant is
sucked in a liquid state.)
Fig. 31
22
Receiver dryer
(4) Criterion for Checking

Refrigerant Filled in
the
Amount
of
Judgment of refrigerant level through the sight glass of receiver dryer

Proper level
After A/C is turned on,

only a little bubbles are
seen and thereafter light
milky white is seen.
Overcharge

no air bubbles are seen.
Undercharge

continuous air bubbles
are seen.
z If the air-conditioner is run with

poor refrigerant R134a, it has
adverse effect on the compressor.
z If the refrigerant is charged too
much (overcharged), the cooling
performance
is
deteriorated.
Moreover, the circuit pressure gets
abnormally high : Always keep a
proper level.
(5) Removing Gauge Manifold
When the refrigerant level has been checked,
disconnect the charging hoses from the
compressor in the following manner :
1) Press the L shape metal fitting of the
charging hose (blue) on the low pressure side
against the service valve of the compressor so
the refrigerant does not leak out and loosen
the nut. As soon as the nut has been
removed, disconnect the charging hose from
the service valve.
2) Leave the high pressure side as it is till the
high pressure gauge reading falls. [below
10kg/cm2 (140psi)].
3) Disconnect the charge hose (red) on the high
pressure side the same way as on the low
pressure side.
23
6.
ELECTRIC CIRCUIT
6.1 WIRING DIAGRAM AND CONNECTORS
Fig. 32
Electric diagram
24
6.2
(1)
1)
2)
3)
INSPECTING FUNCTIONAL PARTS

Relay (244PE)
Coil resistance : 320 (across 1 and 2)
Operating voltage : DC2030V
The coil of the relay has polarity : Care is
needed.
4) Turn on and off the power to the blower
motor by controlling the controller.
5) Check: Check conductance across 3 and 4 in
the following condition :
Apply 2030V across terminals 1 and 2 :
continue
No voltage applied across terminals 1 and 2 :
not continue
2
As viewed from A
Fig. 33
Relay
(2) Inner air sensor (C44)

Resistance across terminals :
at 0 (32
F) : 7.2K
at 25 (77
F) : 2.2K
The inner air temperature sensor is installed
to the sensor bracket under the operator's
seat. The temperature in the cab is sensed by
the thermistor. Changes in the resistance
according to temperature variations are
transmitted to the controller.
Fig. 34
Inner air temperature sensor
(3) Blower controller

The blower controller changes output
voltages for the motor according to signals
emitted by the controller.
Fig. 35
Blower controller
(4) Motor actuator

1) Operating voltage : DC2030V
2) Operating temperature range :
F) to +75 (167
F)
30(22
The motor is controlled by signals (pulses)
put out by the controller.
CONNECTOR
PIN NUMBER
Fig. 36
25
Motor actuator
(4)
Pressure Switch (Attached to Receiver

Dryer)
1) Contents of checking (specification)
Low pressure side OFF pressure :
2.00.2kgf/cm2 (283psi)
Low pressure side return pressure :
OFF pressure +0.3kgf/cm2 (4.3psi) or below
High pressure side OFF pressure :
322kgf/cm2 (45528psi)
High pressure side return pressure :
OFF pressure62kgf/cm2 (8528psi)
PRESSURE SWITCH
Fig. 37
LOW PRESSURE RETURN

(26)
1.8
(30) (31)
2.1 2.2
(36)
2.5
Pressure switch
HIGH PRESSURE RETURN

(310)
22
(430)
30
LOW PRESSURE OFF
(480)
34
HIGH PRESSURE OFF
2) Performance
Low pressure side : To prevent actuation of
the compressor clutch
where refrigerant is
deficient
High pressure side : To prevent actuation of
the compressor clutch
where pressure rises
abnormally because of
the clogging of the
refrigeration circuit, etc.
(5) Thermistor (C19)
1) Contents of checking (specification)
Resistance across terminals
at 0 (32
F) : 7.2k
at 25 (77
F) : 2.2k
Note :
Normally check that there is no shortcircuit
or disconnection.
2) Performance
In order to prevent freezing of the evaporator,
the blowoff air temperature of the evaporator
is controlled by turning the compressor clutch
ON and OFF. The thermistor operates as the
sensor of the control.
Fig. 38
26
Thermistor
kgf/cm2 (psi)
7. TROUBLESHOOTING
Temperature does not fall.
Note) M/A : Motor actuator
If A/C switch is pushed, HL.E is indicated on the set temp. display of the panel.
YES
NO
HL. is shown on the set temp. display of the panel.
YES
NO
on display.
Connector for air mix M/A is

disconnected or in poor contact.
M/A is broken.
Main harness shows poor conductance.
is any of the
numbers 0 9.
A snow mark ( ) on panel is flashing.
A snow mark on the

panel is flashing.
NO
Note)
YES
NO
Inspect and correct or replace parts.
YES
Inner air sensor or harness

is disconnected or shorted.
Inner air sensor connector is
Both inner air sensor

and
evaporation sensor are
disconnected or shorted.

A
B
Blowout temp. falls if temp. is set

at 18.0 (64.4
F) (COOLMAX) and the
blowout mode is changed to vent mode.
YES
NO
1
Evaporation sensor connector

is disconnected or in poor contact.
Evaporation sensor is
disconnected or shorted.
Air mix damper is

in COOLMAX.
NO
Chilly air flowing

into inner air sensor
NO
YES
If M/A is at stop
halfway, eliminate
cause, correct and
measure operating
force.(less than
1.5kgf : OK)
NO
Turn compressor clutch

on and off. Inspect and
correct electric circuits.
Controller is faulty
or inner air sensor
is faulty.
Refer to Troubleshooting
for refrigeration cycle.
Inspect duct or
eliminate cause for
chilly air intrusion.
Inspect and replace.

1
: COOL-MAX
action condition
YES
Inspect, correct or replace

M/A lever link.
After cleaning lever link,
apply grease.
YES
M/A failed or controller

is out of order.
Replace.
27
Temperature does not rise.

HL.E is shown on the set temp. display of panel.
YES
NO
HL. is shown on the set temp display the panel.

NO
Note)
is any of the numbers 09
YES
Blowout temp. rises at blowout

mode if temp. is set at
HOTMAX 32.0 (89.6
F).
z Inner air sensor or harness

is disconnected or shorted.
z Inner air sensor connector
is off or in poor contact.
NO
2
Inspect and correct

or replace parts.
YES
Air mix damper is

at HOT MAX.
NO
If M/A action is at
stop, eliminate cause,
correct and measure
operating force.
(less than 1.5kgf : OK)
Warm air is flowing into

inner sensor.
YES
NO
Inspect warm water piping.
YES
Controller or
inner air sensor
is out of order.
Inspect duct or
eliminate causes
for warm air entry.
Inspect and replace.
NO
YES
z Inspect, correct or
replace M/A lever link.
z Clean lever link and apply grease.
M/A failed or controller

is out of order.
Replace.
28
: HOT-MAX
operating condition.
Blower motor does not run.

At air flow HI, battery voltage acts across
both terminals (+) and () of blower motor.
YES
NO
Blower motor fails.
Battery voltage acts across red

(+) and body of blower motor.
Note 1) Always turn off
air-conditioner,
starter key switch
and light switch
NO
Replace.
YES
Approx. 10V acts across

blue / black (0.85) and
ground of blower amplifier.
Inspect blower motor relay.

Note 1 Blower motor rotates if white /
green (2.0) and red of blower
motor relay are direct connected.
NO
Note) Measure with

connector set.
NO
YES
YES
Controller is out of order.
Wire harness is
faulty. Inspect
and correct or replace.
Battery voltage acts across

white / green (0.85) and
body of blower motor relay.
NO
YES
NO
Inspect and repair
harness or replace.
Remove blower amplifier and check for

continuity across blue / black (0.85)
and black wires ; you get continuity.
Blower turns if
brown / red of
blower motor
relay is connected
with ground.
NO
YES
Eliminate cause
and replace
blower amplifier.
Inspect and
repair
harness.
YES
Replace relay.
Inspect and correct harness

or replace controller.
Blower motor speed does not change.

HL. is shown on the set temp. display of panel.
NO
Note) is any of the

numbers 09.
YES
Air flow rate is constant regardless of readings.
z Inner air sensor and harness

are disconnected or shorted.
z Inner sensor connector is
Replace blower
amplifier or controller.

29
Magnet clutch does not engage.

Snow mark ( ) lights if A/C switch is
NO
YES
Snow mark flickers and E is

shown on panel display.
Voltage acts upon clutch.

NO
To B
On page 27.
YES
Clutch faulty.
Terminal voltage present across

pressure switch harness.
Voltage acts across red and

blue terminals of connector
connected to excavator.
NO
Replace compressor.
YES
NO
Pressure switch is faulty or gas

is under charged or overcharged.
YES
Inspect air-conditioner
and machine connector.
Also clutch fuses.
Inspect air-conditioner
harness. No fault.
NO
Replace harness.
YES
Replace controller.
Inner air and outer air do not change over.

Inner / outer air mode display on
operation panel is flickering.
NO
YES
M/A lever includes

foreign matter
or is broken.
NO
M/A failed
Connector of inner/outer air M/A is

Or M/A failed or main harness failed.
YES
Inspect or replace.
Remove foreign matter
and replace parts.
Replace
30
Modes do not change.

Mode display (Mark of person)
on operating panel is flickering.
NO
YES
M/A rod does not disengage.
NO
Repair.
Mode M/A connector is disconnected or

in poor contact or M/A failed or main
harness is faulty.
YES
Inspect or replace.
Each damper lever does not disengage.
NO
YES
When rod is removed and cam is operated
by hand, it is heavy. (more than 2kgf.)
Repair.
NO
YES
M/A or controller is out of order.
z Cam or damper shaft includes

foreign matter or is broken
z Erroneous motion occurs due to
dirty grease.
Replace.
z Remove foreign matter or replace parts.

z Clean cam and apply new grease.
31
Trouble with refrigeration cycle.

Both high and low pressures are lower.
Low pressure is higher.
Air bubbles are seen in sight glass.

NO
YES
Cooling does not work

if run at high speed.
NO
High pressure
is lower.
Air bubbles are

seen in sight glass.
Oil oozes out from

piping and parts.
NO
YES
Compressor
cylinder does
not get hot.
Hot air
comes out of
heater unit.
Compressor
cylinder gets
very hot.
YES
Expansion
valve is
clogged
or maladjusted.
Expansion
valve is
frozen or
intruded
by water.
Natural
leak from
hose.
Gas leaks
from pipe
joints and
parts.
Expansion
valve is maladjusted.
(too much
open)
Water cock
is maladjusted
or faulty.
Compressor
does not
discharge
well.
Adjust or
replace
expansion
valve.
After making
vacuum, refill
refrigerant
and replace
receiver.
Charge gas.
Retighten
or replace
parts.
Replace
expansion
valve.
Adjust or
replace
water cock.
Replace
compressor
If system is run continuously in HI idle,

it does not cool down or air flow decreases.
High pressure is lower.
Frost deposits.
Air bubbles are seen in sight glass.
NO
YES
High pressure gets

lower slowly.
Thermistor does
not cool off.
Condenser is
fouled or clogged.
NO
YES
YES
High pressure
circuit before
receiver is
clogged up.
Remove
clogging
or replace
parts.
NO
Thermostat is
not turned off.
Air bubbles are hard to

go out even if water
is poured on condenser.
Clean
condenser
Air is mixed.
Make vacuum
and refill
refrigerant.
NO
Functions and
performances
are normal.
Familiarize
the user with
how to use it.
32
YES
Thermistor
is faulty or
cord is
disconnected.
Thermistor position
is normal.
NO
Thermistor
position is
faulty.
Correct
position.
YES
Air
leaks
out of
casing.
E200SR
SECTION 31
DISASSEMBLING AND ASSEMBLING
TABLE OF CONTENTS
1. EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY ....................... 1
1. EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY

1.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY
This chapter is consist of 3-Section as follows.
(1) ATTACHMENTS .......................................................................................................... Code No.:32
Part I; Removing and Installing
Part II; Disassembling and Assembling
1) Cylinder
(2) UPPER SLEWING STRUCTURE ............................................................................... Code No.:33
1) Hydraulic pump
2) Control Valve
3) Pilot Valve (ATT)
4) Pilot Valve (Travel)
5) Slewing Motor
6) Swivel Joint
(3) TRAVEL SYSTEM ....................................................................................................... Code No.:34
1) Travel Motor
1.2 INDICATION OF TIGHTENING TORQUE
Tightening torque is indicated as follows, for example;
T=10kgfym (72 lbfyft)
Tolerance is 10% unless specified.
z Refer Code No. 11 TOOLS for standard tightening torque.
E200SR
SECTION 32
ATTACHMENT
TABLE OF CONTENTS
[Part I. Removing and Installing Assy]
1. ATTACHMENT ASSY AND NAME ............................................................................
2. BUCKET ..................................................................................................................
3. ARM ........................................................................................................................
4. BOOM .....................................................................................................................
I-1
I-1
I-4
I-7
[Part II. Disassembling and assembling equipment]

1. CYLINDER ............................................................................................................. II-1
1. ATTACHMENT ASSY AND NAME

(D) ARM CYLINDER HEAD PIN
(C) BOOM CYLINDER ROD PIN
ARM CYLINDER
(A) BOOM FOOT PIN
4. BOOM
(F) BOOM TOP PIN
(E) ARM CYLINDER

ROD PIN
(G) BUCKET CYLINDER

HEAD PIN
BUCKET CYLINDER
3. ARM
(I) IDLER LINK PIN
(J) BUCKET DRIVE PIN

(B) BOOM CYLINDER
BUCKET LINK
IDLER LINK
(H) BUCKET CYLINDER ROD
HEAD PIN
(K) BUCKET ATTACHING PIN
Fig. 1-1 Front attachment name and position
2. BUCKET
2.1 REMOVING BUCKET
(1) Put the machine in position to remove
bucket.
Fig. 2-1 Position to remove bucket

BOSS
DRIVER
(2) Removing lock pin (2)

Expand slit of ring (1) with driver, and
remove it. Push out the pin (2) with driver
().
BOSS SECTION
Fig. 2-2 Removing pin (2)
I1
(3) Removing bucket attaching pin (K).

Lift up bucket, position it so that bucket
attaching pin (K) is not loaded, adjust bucket
link, and pull out bucket attaching pin (K).
(4) Removing bucket drive pin (J)

Put bucket on the ground, position it so that
the bucket drive pin (J) is not loaded, adjust
bucket link, and pull out pin (J).
Fig. 2-3
Removing bucket attaching pin
Fig. 2-4
2.2 ATTACHING BUCKET
(1) Attaching bucket drive pin (J)
Attach bucket drive pin (J) first, then
continue in the reverse procedure of the
pulling out.
Removing bucket drive pin
CROWBAR
z When aligning the pin holes, do not

put your finger in the pin holes in
any circumstances, but align them
visually.
z Check that the seals are not scored
and replace a faulty one if necessary.
zWhen inserting the pin, coat the shaft
with grease.
Fig. 2-5
Attaching bucket
2.3 PROCEDURE FOR ADJUSTING CLEARANCE

Adjustment of clearance between bucket and
arm
(1) Shift O ring (3) toward the bucket boss, using
a spatula. (ab)
(2) When adjusting clearance (B), bring the
non-adjusting side of the bucket in contact
with the arm.
BUCKET
12
3
10
(b)
(a)
(3) Measure clearance (B) and check that it is

within 1.2mm (0.05in).
ARM
(4) Adjust clearance (B) where it is more than

1.2mm (0.05in).
(5) An average of 5 shims (12) of 1mm (0.04in)
thickness are set in the plate (13) fixed by the
three capscrews M1650 (10). The clearance
can be adjusted by 1mm (0.04in) if one shim
is removed in the fixed plate.
BUCKET ATTACHING PIN (K)
13
: 24mm
(6) After adjustment, tighten the capscrews
evenly.
z The gap exceeding the specified
dimension causes a premature wear.
(7) Operate the bucket and confirm that the total
sum of both clearance is within 1.2mm
(0.05in)
(8) Refit O ring (3) to its original position.
z When shifting O ring (3) by means of
a spatula, use care so as not to score
O ring (3).
z Remove shims (12), push out
bushing (8) rightwards by means of
three capscrews (10) and adjust
clearance (B) so it falls within the
standard value evenly all round.
z Check the clearance at 120 hours
intervals in normal operation.
Shorten these intervals in heavy
digging. Adjust the intervals as
necessary.
Fig. 2-6
Adjusting clearance between

bucket and arm
3.
ARM
3.1 REMOVING ARM

(1) Put the machine in position to remove arm.
Extend the arm cylinder, retract the bucket
cylinder to a maximum and bring the arm
down on the ground.
Fig. 3-1
Position to remove arm
(2) Disconnecting piping of bucket cylinder

Release pressure of hydraulic tank, place oil
pan to prepare for oil leaking, and separate
pipes.
Plug both section of separated pipes.
ORS plug : 4-(4)
When the removal of bucket cylinder is not
required, skip to procedure (6).
Fig. 3-2
Disconnecting piping of bucket cylinder
(3) Removing bucket cylinder rod pin (H)

1) Loosen nut (9), remove capscrew M16140
(8), and push out pin (H).
: 24mm
After adjustment of shim,

the total gap should be
within 0.61.0mm (0.02
0.04in).
2) Retract cylinder rod.
SECTION
Fig. 3-3
9
Detail of bucket cylinder rod pin (H)
(4) Removing cylinder head pin (G)

Loosen nut (3), remove capscrew M16140
(2), and push out pin (G).
After adjustment of shim,

the total gap should be
within 0.61.0mm (0.02
0.04in).
: 24mm
SECTION
Fig. 3-4
4
Detail of bucket cylinder head pin (G)
(5) Removing bucket cylinder

Sling tube of bucket cylinder with nylon
sling, and remove it.
Bucket cylinder weight : 125kg (276 lbs)
Fig. 3-5
(6) Removing arm cylinder rod pin (E)
Put a wooden block between the arm cylinder
and the boom.
(4), and push out arm cylinder rod pin (E).
Slinging bucket cylinder

4
: 24mm
Retract arm cylinder rod, and return pin (E)
to the original position (hole).
6
SHIM
After adjustment of shim, the
total gap should be within
0.62.0mm (0.020.08in).
E
BLOCK
SECTION
Fig. 3-6
Detail of arm cylinder rod pin (E)
After adjustment of shim, the total

gap should be within 0.5mm (0.02in).
(7) Removing boom top pin (F)

Loosen capscrew M1225 (5), remove plate
(3) and pull out boom top pin (F).
: 19mm
Insert pin (F) into the original hole.

5
3
SECTION
Fig. 3-7
5
Detail of boom top pin (F)
(8) Slinging arm assy

Sling arm with nylon sling and remove it.
Arm weight
Standard spec ; 550kg (1170 lbs)
Fig. 3-8 Slinging arm assy

3.2 ATTACHING ARM
Install the arm in the reverse order of
removing, paying attention to the following :
1) When aligning the pin holes, do not put your
finger in the pin holes in any circumstances,
but align them visually.
2) Check that the dust seals is not scored and
replace a faulty one if necessary.
3) When inserting the pin, coat the shaft with
grease.
4) Apply Locktite #242 to the pin-securing
capscrews and nuts and fasten them.
Pin lock nut handling procedure
5) When installing the arm and the cylinder,

inspect the clearance in the thrust direction
of the mounts and decide the thickness of
shims by referring to the Maintenance
Standard.
6) Tightening torque
Tightening torque
Classification
Size
kgfym
lbfyft
M12
11.7
85
M-threads
M16
28.5
210
PF,PT
1.7
1/8
12
threads
I6
4.
BOOM
4.1 PREPARATION FOR REMOVING AND

ATTACHING BOOM
When removing and attaching boom in the
position shown in Fig.4-1, to remove and
attach boom foot pin (A), removing and
attaching of cab and guard are required.
4.2 REMOVING BOOM
(1) Put the machine in position to remove boom.
Place top end of boom down on block, etc.
giving attention for arm cylinder rod not to be
extended.
BLOCK
Fig. 4-1
Position to remove boom
(2) Lifting up boom cylinder temporarily

Remove the right and left boom cylinders one
side by one side according to the following
procedure:
Lift up boom cylinder temporarily to prevent
it from dropping.
A
C
STAND
Fig. 4-2
Lifting up boom cylinder temporarily
(3) Removing boom cylinder rod pin (C)

(3), boss (4) and push out pin (C).
After adjustment of shim, the total gap
should be within 0.62.0mm (0.020.08in).
: 24mm
SHIM
3
C
(4) Preparing for disconnecting cylinder pipes

Retract boom cylinder rod, and place one side
of cylinder on block. (See Fig.4-2.)
Fig. 4-3
7
SECTION AA
Detail of boom cylinder rod pin (C)
(5) Disconnecting piping of arm cylinder and bucket

cylinder
Release pressure in hydraulic tank, and disconnect
pipe at section AA.
: 36mm 18kgfym (130 lbfyft)
41mm 21kgfym (150 lbfyft)
After disconnection of pipe, plug every pipe.
ORS plug : 4-(4)
TO CLAMP
After connecting the

hoses to the body,
clamp them at a point
450mm (17.7in) from
the ARM (R) hose.
Fig. 4-4_Boom piping disconnection

SECTION_AA
VIEW__
(6) Lifting up boom assy temporarily

Lift up boom cylinder with nylon sling so that boom
foot pin (A) is not loaded.
Weight of single boom

Standard spec. : 1000kg (2200 lbs)
Fig. 4-5_Boom assy temporary lift up procedure

(7) Removing boom foot pin (A)
1) Remove pin (3) and pull out lock pin (2).
2) Draw out pin (A).
After adjustment of shim, the total gap

should be within 0.5mm (0.02in).
SHIM
DUST SEAL
2
A
Apply molybdenum added grease

in the inner surface of the bushing.
SECTION_AA
Fig. 4-6_Details of boom foot pin (A) section
I-8
(8) Slinging boom assy

Sling and remove boom assy.
Weight of single boom
Standard spec. : 1000kg (2200 lbs)
Fig. 4-7 Boom assy slinging procedure

(9) Completion of removal of front attachments
When the removing and attaching of cylinder
are not required, the work is finished.
(10) Removing arm cylinder

1) Disconnect hose at A section, and plug both
ends.

total gap should be within 0.6
1.0mm (0.02 0.04in).
ORS plug 4-(4)
SHIM
: 36mm,
Tightening torque ; 18kgfym (130 lbfyft)
2) Removing arm cylinder head pin (D)

Loosen nut (3), remove capscrew M16140 (2)
and pull out pin (D).
3
: 24mm
3) Remove arm cylinder.
Fig. 4-8 Removing arm cylinder

(11) Removing boom cylinder
1) Disconnect hose at B section. and plug both
ends.
ORS plug 4-(4)
: 32mm,
Tightening torque ; 14kgfym (100
lbfyft)
: 36mm,
Tightening torque ; 18kgfym (130
lbfyft)
Fig. 4-9 Removing boom cylinder

I9

total gap should be within
0.6~1.0mm (0.02~0.04in).
2) Removing boom cylinder foot pin (B)

(See Fig. 4-10)
Loosen capscrew M16 30 (6) and plate (7)
and pull out pin (B).
SHIM
: 24mm
B
3) Remove boom cylinder (02).
4) Remove other boom cylinder in the same way.
6,7
SECTION BB
Fig. 4-10 Removing boom cylinder head pin (B)
4.3 ATTACHING BOOM

(1) Attaching boom foot pin (A)
First of all, insert boom foot pin (A) and
install the boom assembly.
Attach it in the reverse procedure of
removing, paying attention to the following
points.
B
z When aligning the pin holes, do not

put your finger in the pin holes in
any circumstances, but align them
visually.
z Check that the dust seals is not
scored and replace a faulty one if
necessary.
z When inserting the pin, coat the
shaft with grease.
z M16 Tightening torque : 28.5kgfym
(210 lbfyft)
z Pin lock nut handling procedure
B
B
Fig. 4-11 Boom foot pin (A),
boom cylinder head pin (B)
I10
1. CYLINDER
1.1 PREPARATION BEFORE DISASSEMBLY
Before assembly, secure a dustfree workshop and
necessary equipment and facilities.
1.1.1 WORK AREA
The following working area is required for
disassembly:
(1) Ample space
For the disassembly of the hydraulic cylinder,
the cylinder tube and the piston rod must be
drawn out. For this reason, the first condition
is that the working area is long enough for
the work. In terms of width, it is also
necessary to keep sufficient space so
disassembly,
cleaning
and
measuring
equipment are placed and the work can be
performed.
(2) Suitable working environment
The
hydraulic
cylinder
is
a
precision-machined product that uses seals
and packings made of rubber and plastic
materials. For this reason full care should be
exercised so the hydraulic cylinder is free
from dust, dirt, and in particular, such hard
particles as sand, metal chips, and weld slag
(spatter). If the hydraulic cylinder is
assembled with hard particles adhered on
such components as the cylinder tube and the
piston rod, the tube inner surface and the rod
surface are scratched as the cylinder
operates, consequently disabling it in worst
cases. Damage to the piston seals and the rod
seals will result in oil leaks. For this reason,
grinding and welding operation should not be
performed in the neighborhood of the working
area to keep it clean
(2) Work bench

The work bench must have strength and
rigi-dity capable of accommodating the total
length of the cylinder in its most retracted
condition and of withstanding the repulsive
force of the tightening torques of the cylinder
head and the piston nut. Since a vise is
attached to the bench, the width of the work
bench must be sufficiently large.
(3) Support stand
If the clevis part of the piston rod is fully
extended in a free condition, the bushing and
the seals may be damaged as the rod bushing
and the piston are twisted due to the weight
of the rod. A stand is required to support the
rod to prevent such.
(4) Hydraulic source
A Hydraulic source is required for
disassembly and assembly of the cylinder
head and piston nut and for oil leak tests
after completion of assembly.
(5) Jet air source
It is used for drying after oil draining and
cleaning of the cylinder.
(6) Cleaning bath, cleaning oil and detergent
(7) Oil pan and oil reservoir
An oil pan is necessary to contain oil drained
from the cylinder and oil spilt during work.
An oil reservoir is required to collect oil spilt
on the floor and waste oil.
(8) Others
Oil extracting hoses, wooden skids, rag and
sawdust in which oil soaked are also
necessary.
1.1.2 APPARATUS
The following equipment are required for
disassembly:
(1) Hoist or crane
The hoist or crane must be capable of
carrying the cylinder in an assembled
condition. It must also be capable of marking
level and liner movement under load for
retracting and extending the piston rod and
the tube.
11
1.1.3 NECESSARY TOOLS

Tools and jigs vary with types of cylinder, but it is
necessary to prepare the tools in Table 1-1 as a
guideline.
Table 1-1
Tool / Jig
Hammer
List of Tools and Jigs

Tool / Jig
Remarks
1. Steel hammer
Remarks
Spatula
Metallic one with smooth

corners.
Jig
1. For fitting piston seals C
2. Wooden or plastic mallet

Screwdriver
A few types of large and small sizes
Chisel
Flat chisel
2. For hodling in slipper seals D
Vise
One having an operation wide

enough to hold cylinder head O.D.
and tube mounting pins (clevis)
3. For inserting piston rod bushing

A
Wrench
1. Hook wrench
5. For pressing piston seal G
2. Allen wrench
Rust remover
3. Extension pipe for wrenches

Gimlet
4. For pressing in dust seal E
A sharp-point tool may be used in

place of a gimlet.
Measuring
instruments
1. Slide calipers
2. Micrometer
3. Cylinder gauge (Fig. 1-1)
4. V-block
z For the details of special tools and

jigs, refer to the end pages of this
article.
1.1.4 EXTERNAL CLEANING
The cylinder taken off the excavator has dust and
foreign matter, and grease is usually adhered to
the clevis part. For this reason, remove external
soil and contamination from the cylinder with
water and steam before bringing it into the
workshop.
z The
following
describes
the
construction of boom cylinder (with
cushions on both sides). When
disassembling and servicing the
cylinder, confirm the construction of
cylinder referring to Parts Manual.
Fig. 1-1
Cylinder gauge
WOODEN
BLOCK
PORT B
V BLOCK
1.1.5 DISCHARGING OIL

Place a wooden-block on the work bench and
mount the cylinder on it to prevent it from
rotating. Charge air into ports A and B
alternately to actuate the piston rod till the
hydraulic oil in the cylinder is drained out. At this
time, connect a suitable hose to each port so that
the hydraulic oil may not gush out.
12
AIR
PORT A
OIL PAN
Fig. 1-2
Discharging oil
660 (26.0)
M12 x1.75 (Through)
24 25
0
0
105 -0.5
(4.13-0.0197
)
0
0
105-0.5
(4.13 -0.0197
)
1.2 CONSTRUCTION OF CYLINDER (AN EXAMPLE OF BOOM CYLINDER)

25 24
27
SLIT
26
BLACK
GREEN
28,2
T=3.2(23)
With hole
(1 place)
DETAIL B
VIEW Z
DETAIL C
T=27.2(200)
9
7 6
T=421(3000) T=5.8(42)
12 10,11
13 14 15 16 17 18 19 20 21 22,23
2 1
C
SLIT
Fig. 1-3
No.
NAME
Construction of boom cylinder

(The figure shows the right-hand cylinder.)
QTY
No.
NAME
QTY
No.
NAME
QTY
1
2
3
4
5
CYLINDER TUBE
PISTON ROD
CYLINDER HEAD
BUSHING
SNAP RING
1
1
1
1
1
11
12
13
14
15
BACK-UP RING
SOCKET BOLT
CUSHION BEARING
CUSHION SEAL
PISTON
1
10
1
1
1
21
22
23
24
25
NUT
SET SCREW
STEEL BALL
PIN BUSHING
WIPER RING
1
1
1
2
4
6
7
8
9
10
BUFFER RING
U RING
BACK-UP RING
WIPER RING
O RING
1
1
1
1
1
16
17
18
19
20
SEAL RING
BACK-UP RING
SLIDE RING
SLIDE RING
SHIM
1
2
2
2
1
26
27
28
29
BAND
BAND
BOLT
WASHER
1
1
2
2
II13
1.3 DISASSEMBLY
z When disassembling and servicing
the cylinder, check the construction
and the availability of service parts
as well as necessary tools and jigs on
separate Parts Manual.
z The figures in parentheses after part
names correspond to those in
Fig.1-3.
z The explanations and quantities
below are for a boom cylinder. Apply
the same to other cylinder as well.
1.3.1 REMOVING CYLINDER HEAD AND PISTON
ROD
1) Hold the clevis section of the tube in a vise.
Use mouth pieces so as not to damage
the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.
2) Pull out piston rod (2) about 200mm (8in).
Because the piston rod (2) is heavy, finish
extending it with air pressure after the
above-mentioned oil draining operation.
3) Loosen and remove socket bolts (12) of the

cylinder head in sequence.
Fig. 1-4
ALLEN WRENCH 12
: 14mm
Cover the extended piston rod (2) with rag
to prevent it from being accidentally
damaged during operation.
Turn counterclockwise
4) Strike the corner of the cylinder head flange

by means of a plastic mallet till cylinder head
(3) comes off.
3
2
Cover here with rag.
Fig. 1-5
14
z At this time, the weight of piston rod

(2) is loaded on cylinder head (3).
Therefore, lift the top end of the
piston rod with a crane or something
to the extent that only the rod
weight may be held.
KNOCK THIS EDGE

WITH A PLASTIC
MALLET.
LIFT HERE.
5) Draw out the piston rod assy (2) from

cylinder tube (1).
Since the piston rod assy is heavy in
this case, lift the tip of the piston rod
(2) with a crane or some means and
draw it out. However, when piston rod
(2) has been drawing out to
approximately two thirds of its length,
lift it in its center to draw it
completely. However, since the plated
surface of piston rod (2) is lifted, do not
use a wire rope or something which
may score the surface, but use a strong
cloth, a belt or a rope.
3
2
Fig. 1-6 Drawing out piston rod assy (2).
1
LIFT HERE.
PULL
STRAIGHT
SIDEWAYS
HORIZONTALLY
OIL PAN
Fig. 1-7 Method of drawing out the piston rod

assy
6) Place the removed piston rod assy on a

wooden V-block that is set level.
PISTON ROD ASSY
z Cover a V-block with rag.

WOODEN V-BLOCK
(PLACE RAG.)
Fig. 1-8 Method of placing the piston rod

7) Remove slide ring (18),(19) and back-up ring
(17) from piston (15).
15
TAKE IT OFF BY WIDENING
THE SLIT TOWARD
THE ARROW
17
18,19
Fig. 1-9 Remove slide ring (18),(19) and

back-up ring (17)
II15
1.3.2 REMOVING PISTON ASSY

1) Fix piston rod (2) by holding its clevis section
in a vise. Fix the piston rod (2) rigidly as
piston nut (21) is tightened to a high torque.
WOODEN
PIECE
15
21
z Note that the tightening torque

differs with the type, the working
pressure and the mounting method
of the piston (15), though the rod
diameter remains the same.
z It is also necessary to place a
suitable supporting block near the
piston (15). In case a V-block is used,
put rag or something over the rod to
prevent it from being scored
WOODEN V-BLOCK
(PLACE RAG.)
Fig. 1-10
2) Scrape off the caulked part of setscrew (22) of
piston nut (21) by means of a hand drill and
loosen and remove setscrew (22).
How to loosen piston nut (21)

22
DRILL
: 6mm
21
23
Fig. 1-11
Removing setscrew (22), ball (23)
3) Loosen and remove piston nut (21).

Since piston nut (21) is strongly
tightened, use a ring spanner most
suitable with the outside diameter of
piston nut (21) and also use a power
wrench equipped with hydraulic jack
and hydraulic cylinder.
TURN
COUNTER
CLOCKWISE.
15
HOOK
WRENCH
Fig. 1-12
21
How to loosen piston nut (21)
4) Strike it lightly with plastic hammer and

remove it while supporting piston (15).
Fig. 1-13
16
15
Removing piston (15)
5) After removing cushion bearing (13), remove

cushion seal (14) and remove cylinder head
(3) from piston rod (2). If it is difficult to slide
it, strike the flange section of cylinder head
(3) with plastic hammer and slide it. And
then hang cylinder head (3) with crane and
pull it out horizontally.
LIFT WITH A CRANE.

STRIKE WITH
A PLASTIC MALLET.
PULL STRAIGHT.
NOTE:
DO NOT
DAMAGE
PISTON ROD
SURFACE.
Take care so bushing (4) and the lip of

pistons (6), (7), (8), (9) may not be
damaged by screw the piston rod (2).
8,7 9
Fig. 1-14 Removing cylinder head (3)

1.3.3 DISASSEMBLING PISTON ASSY
1) Remove seal ring (16) and buck-up ring (17).
HAMMER
Cut the seal ring (16) by tapping it

with a screwdriver or a chisel. Take
care not to strike it too hard, otherwise
the groove may be damaged.
SCREWDRIVER (OR CHISEL)
BACK-UP RING
17
SEAL RING
16
15
USE CARE NOT

TO DAMAGE
THE GROOVE.
O RING
Fig. 1-15 Removing seal ring (16) and back-up

ring (17)
II17
1.3.4 DISASSEMBLING CYLINDER HEAD ASSY

1) Remove O ring (10) and back-up ring (11)
extending them with a spatula like an
earpick.
SPATULA
10
11
3
Fig. 1-16
2) Remove buffer ring (6), U ring (7) and
back-up ring (8). Each seal is fixed in the
groove on the bore and removing in flawless
is impossible.
Stab each seal with a gimlet and pull it out of
the groove.
Removing the outer circumferential

seal of cylinder head (3)
GIMLET
8
7
Take care in this operation not to

damage the grooves.
Fig. 1-17
3) Remove wiper ring (9). When taking out

wiper ring (9), fix cylinder head (3) in a vise.
Removing the inner circumferential

seal of cylinder head (3)
3
HAMMER
SCREWDRIVER
WOOD PIECE
WOOD PIECE
VISE
Fig. 1-18
4) Remove snap ring (5) and bushing (4). After
taking out snap ring (5) in the same way as
mentioned above, remove rod bushing (4).
Bushing (4) is impossible to remove as it is
press fitted in cylinder head (3). Machine the
bushing thin on a lathe, insert a steel
spatula hard into the gap at the chamfered
edge of the remaining bushing and pry it up.
Removing wiper ring (9)

5
4
3
WOOD PIECE
WOOD PIECE
VISE
Center the work on a lathe sufficiently

so the bushing may be shave on a lathe
as thin as possible.
Fig. 1-19
18
Removing rod bushing (4)
1.3.5 REMOVING PIN BUSHING
PUSH WITH A PRESS.
Cylinder tube (1) is pressed hard in the pin

bushing
(24)
of
piston
rod
(2).
When
METAL PIECE
(JIG A)
disassembling them, use the jig A and push the

rod with a press.
2
24
Fig. 1-20
BASE
Drawing out pin bushing (24)
1.4 CLEANING
1) When the cylinder has been disassembled,
wash all parts with a suitable commercial
detergent.
Do not use volatile agents (gasoline
and thinner) as they deteriorate
rubber.
2) Do not reuse the once-removed oil seals, O
rings and back-up rings even though they
have found reusable on inspection.
3) After cleaning, dry all parts with jet air and
place them on a clean work bench so that
they may not be damaged.
1.5 ASSEMBLY
Start assembly with the subassemblies listed
below:
Cylinder tube assy
Piston assy
Cylinder head assy
1.5.1 INSTALLING PIN BUSHING
Press fit pin bushing (24) into cylinder tube (1)
and piston rod (2), using a press.
PUSH WITH A PRESS
24
OIL HOLE LOCATION
Fig. 1-21
19
Pressing fit pin bushing (24)
1.5.2 ASSEMBLING PISTON ASSY

1) A special jig shown in Fig. 1-22 is required to
fit seal ring (16). Push seal ring (16) in by
means of a press and using the pressing jig
that is shown in the figure.
(Fit O ring of seal ring (16) and back up ring
(17) on one side in advance.)
PRESS HERE
METAL
HOLDING
JIGD
The slipper seal softens if heated, but

do not heat it above 100 (212.0
F) in
any circumstance.
JIGC
2) Fit back-up ring (17) on other side. After

fitting, press it for 2 or 3 minutes with
pressure jig G as shown in Fig. 1-23.
15
16
17
z After fitting the seal ring (16), wind

vinyl tape a few turns around the
slipper seal and do not take it off
immediately before piston (15) is set
in cylinder tube (1).
z Attach slide ring (18), (19) when
inserting piston (15) into cylinder
tube (1).
Fig. 1-22
Installing seal ring (16)

HOLDING JIG G
for piston seal.
HANDLE
Fig. 1-23
1.5.3 ASSEMBLING CYLINDER HEAD ASSY
1) Press bushing (4) into cylinder head (3) using
a metal ring. There after fix snap ring (5) into
the groove. Before pressing in the bushing,
coat the inner face of cylinder head (3) with
hydraulic oil.
PRESS HERE. (STRAIGHT DOWN)

METAL
(MAKE O.D.SMALLER
THAN ROD
BUSHING O. D.)
GROOVE FOR
FIXING SNAP RING (5)
Snap ring (5) can be pushed in by

hand, but it can not be set in place
unless bushing (4) is press fitted full to
the stop surface.
PRESS BUSHING TILL

BUSHING COMES IN
CONTACT WITH
THIS FACE.
2) Apply grease to wiper ring (9) or the hole of

cylinder head (3), and fit wiper ring (9) to the
bottom of the hole. At this moment, press the
metal ring of wiper ring (9) with a jig E.
Installing seal ring (16)
Fig. 1-24
Pressing in bushing (4)
PRESS HERE. (STRAIGHT DOWN)

PRESSING
JIGE
PRESS METAL
RING.
METAL RING
Fig. 1-24
110
RUBBER
LIP
Pressing in wiper ring
3) Fit buffer ring (6), back-up ring (8) and U

ring (7) in their grooves in that order. Before
setting packings, coat them with hydraulic oil
(or vaseline if not available). If you forget the
coating, the packings may be scored. When
attaching seals, deform them in a heart
shape as illustrated.
PUT IN GROOVE FROM THIS SIDE.
Fig. 1-26
Inserting a seal into the inner

circumference of cylinder head.
PUSH BAR
(WOOD OR PLASTIC)
z U ring (7) is harder than other

packing and it would be difficult to
deform them in a heart shape. In
such a case, put a rod packing in the
groove obliquely by hand as deep as
possible and push in the last part
with a push bar till it is set with a
click.
z Buffer ring (6) have directions in
which they should be fixed.
Therefore
check
their
fitting
directions.
z If U ring (7) is set upside down, the
lip may be damaged. Check that it is
positioned correctly Fig. 1-27.
z Attach backup ring (11) on the open
air side of O ring (10).
10
11
3
Open air side
Fig. 1-27
1.5.4 INSERTING CYLINDER HEAD ASSY TO
PISTON ROD
Inserting the cylinder head (3) to the piston rod
assy as follows:
1) Fix the piston rod assy into the work bench.
111
How to fit U ring (7)
7
8
9
2) Apply hydraulic oil or grease to the O. D. of

3 LIFT WITH A CRANE
piston rod (2), the bore of packings (6,7,8,9)
CYLINDER HEAD
and bushing (4). Hold the cylinder head
PRESS IN.
carefully and slide it over piston rod (2),
taking care not to damage the lip of dust
wiper ring (9). It may be difficult in some
cases to slide the cylinder head over the
TURN
piston rod (2) because of the resistance of U CLOCKWISE.
ring (7), buckup ring (8) and buffer ring (6).
In such a case, force it in, using a suitable
plate and piston nut (21), (See Fig. 1-28.) In
this operation, hold the cylinder head
horizontally with a crane.
4
6 7,8 9
21 AUXILIARY PLATE
2
FOR PUSHING
3) After lifting cylinder head (3) to the level
Fig. 1-28 Inserting cylinder head
where it is pressed by piston nut (21), remove
piston nut (21) and the plate. Press in the
cylinder head about 300mm (12in) further. In
some cases, the cylinder head must be
pressed into piston rod (2) by striking the
flanged part of cylinder head (3) with a
wooden or plastic mallet.
During the above operation, use care so
not to allow the cylinder head to turn
with respect to piston rod (2).
1.5.5 ASSEMBLING PISTON ASSY TO PISTON

ROD
1) Fit cushion seal (14), insert cushion bearing
(13), and install the piston assy on piston rod
(2).
14
13 2
2) Apply hydraulic oil or grease to the inside of

the piston assy and to the piston mounting
part of piston rod (2). Then install the piston
assy as shown in Fig. 1-29.
TURN
CLOCKWISE.
V-BLOCK
PISTON ASSY
Fig. 1-29
112
HOLD THE POINT AS

CLOSE TO THE PISTON
AS POSSIBLE.
Tightening piston assy
3) Place shim (20) in, screw piston nut (21) in,

and tighten it. Always tighten the piston nut
(21) to a specified torque (Refer to-1-16.)
21
HOOK WRENCH
Always correct the threads of the

tapped hole in piston nut (21) before
fixing piston nut, using a tap.
TURN CLOCKWISE.
Fig. 1-30
4) Place steel ball (23) in and screw set screw

(22) in.
: 6mm
23
Tightening piston nut (21)
22 ANTI-LOOSENING CAULKING
20
5) After tightening the setscrew to a specified

torque of 5.8 1.1kgfym (42 7.9 lbfyft),
caulk the two places of the thread of the
piston nut side to secure the setscrew.
6) Fit slide rings (18), (19). Remove vinyl tape
around piston (15), apply quality grease (or
vaseline) on slide rings (18), (19) and wind
and fit it around the groove.
Shift it 90 degree in order that the slits are
not on the same axis.
V-BLOCK
13
Fig. 1-31
22
21
18
Attaching setscrew (22)

19
V-BLOCK
Fig. 1-32 Attaching slide ring (18)

1.5.6 OVERALL ASSEMBLY
1) Place a V-block on a rigid work bench (A
wooden V-block is preferable.). Place the
cylinder tube assy (1) on it and fix the assy by
passing a bar through the clevis pin hole to
1
lock the assy.
2) Insert the piston rod assy into the cylinder
LIFT
tube assy, while lifting and moving the piston
rod assy with a crane. In this operation,
apply hydraulic oil (or vaseline) to the inner
surface of the tube mouth and the
circumference of the piston. Align the center STRAIGHT
FIX IT WITH A BAR
of the piston rod assy with the center of the
(A WOODEN ONE
PREFERABLE)
cylinder tube assy and put it in straight
OR IN A VISE.
forward.
Fig. 1-33 Inserting piston rod assy
When inserting, make sure that slide ring
(18), (19) on the perimeter of the piston is
not out on the groove.
113
3) Turn up socket bolt (12). Match the bolt holes

of the cylinder head flange to the tapped
holes in the cylinder assy, and screw in
socket bolts (12) one by one. Tighten the bolts
to a specified torque, taking care so the bolts
may not be tightened unevenly.
12
PLACE RAG.
:14mm,
Tightening torque :
Take care so as not to damage the rod
surface by accidentally slip a wrench.
Covering the rod surface with rag is
recommended to prevent damage to it.
For the tightening torques, refer to
(-1-16).
TORQUE WRENCH
TURN
CLOCKWISE.
Fig. 1-34
1.6 INSPECTION AFTER ASSEMBLY
(1) No-load functional test
Place the cylinder level at no load, operate
the piston rod 5 to 6 strokes by the
directional valve and make certain that it
operates without fault.
Tightening socket bolts (12)
DIRECTIONAL VALVE
PUMP
z Do not raise the hydraulic pressure

above the maximum pressure of
385kg/cm2 (5470psi) for the cylinder
of the machine.
z Grease coated on the O rings and the
seals of the cylinder head may ooze
out. Wipe it off and retest the
cylinder head in such a case.
HYDRAULIC CYLINDER
Fig. 1-35
(2) Leak test (See Fig. 1-36)

1) Apply a test pressure to the retracting and
extending sides of the cylinder for three
minutes independently, and check that the
rod section and the welds have external leaks
and permanent deformation. For an internal
leak test, connect the cylinder with a test
unit .
External leak test
MEASURE THE
INTERNAL LEAK.
FROM DIRECTIONAL VALVE
Fig. 1-36
2) After completing the test, apply a plug to
each port and store it (Fig. 1-37).
Internal leak test
CYLINDER ASSY
For storage, place the cylinder on

wooden V-blocks and bring the cylinder
to the most retracted condition.
PLUG
PLUG
Fig. 1-37
114
How to store the cylinder
1.7 MAINTENANCE STANDARDS

1.7.1 INSPECTION AFTER DISASSEMBLY
Visually inspect all parts after cleaning to see
that excessive wear, crack and other faults that
are detrimental to use are not present.
(1) Inspection Item
Table 1-2
Part Name
Piston rod
Cylinder
tube
Cylinder
head
Inspecting Section
Inspection Item
Remedy
1. Neck of rod pin
Presence of crack
Replace.
2. Weld on rod hub
Presence of crack
Replace.
3. Stepped part to which

piston is attached
Presence of crack
Replace.
4. Threads
Presence of seizure
Recondition or replace
5. Bend
Measure degree of bend

(See Fig. 1-38.)
Refer to Table 1-3.
6. Plated surface
Check that:
1) Plating is not worn off
to base metal
2) Rust is not present on
plating.
3) Scratches are not
present.
1) Replace or replate
2) Replace or replate
3) Recondition, replate or
replace.
7. Rod
Wear of O. D.
Recondition, replate or replace.
8. Bushing at mounting
part
Wear of I. D.
Replace.
1. Weld on bottom
Presence of crack
Replace.
2. Weld on head
Presence of crack
Replace.
3. Weld on hub
Presence of crack
Replace.
4. Tube interior
Presence of faults
Replace if oil leak is seen.
5. Bushing at mounting
part
Wear on inner surface
Replace.
1. Bushing
1) Wear on inner surface

2) Flaw on inner surface
1) See para. 1.7.2.

2) Replace if flaw is deeper than
coating.
(2) Repair method

Check all seals and parts to see that they do
not show excessive damage and wear. For
co-rrection of faults on the piston rod, observe
the following procedure:
1) Correct very fine longitudinal scratches with
an oilstone. Replace the piston rod if the
scratch is so deep as may be caught by your
nail.
2) In case of a smooth indention, recondition by
removing the sharp area around the
inden-tion with an oilstone. If the flaw or the
in-dention is excessive, replace or replate the
faulty part.
115
z Always regrind after replating. The

thickness of the plating must be
maximum 0.1mm (0.004in).
z In case plating is removed to the
base metal during reconditioning
with an oilstone, do not fail to
replate the surface.
1.7.2 LIMIT OF SERVICEABILITY

Serviceability limits represent the limits of wear
on the sliding surfaces of the cylinder tube and
the rod that have no such faults as may degrade
the sealing effect.
(1) Clearance between piston rod and rod
bushing
Replace the bushing if the clearance between
the piston rod and the rod bushing exceeds
0.25mm (0.01in).
(2) Bend of piston rod
The allowable bend of the rod is maximum
1mm / 1m (0.04/33). For measurement,
support both ends of the parallel section of
the piston rod with V-blocks, set a dial
indicator in the middle between the two
V-block turn the piston rod, and read the
difference between the maximum and
minimum oscillations on the dial indicator.
Fig. 1-39
Table 1-4
Unit : kgfym (lbfyft)
Cylinder
A
Piston nut
B
Socket bolt
Boom
421
(3050)
27.2
(200)
Arm
837
(6050)
27.2
(200)
Bucket
491
(3550)
17.4
(130)
Measuring Method
Cylinder
Table 1-3 shows an example of measurement.
Table 1-3 Example of Measurement
Remedy
m (in)
Oscillation of the dial

indicator in the middle
of the rod.
mm (in)
1 (33)
1 (0.04)
Replace
Distance
between
V-blocks
1.7.4 VOLUME OF OIL LEAKAGE

The oil leak rates as mentioned in 1.6 (2) of
Ins-pection after Assembly are as shown in Table
1-5.
Table 1-5
Middle of rod
Fig. 1-38
1.7.3 TIGHTENING TORQUE
Even if the bend is within the above

limit, the cylinder may not operate
smoothly because of localized bend.
Beware of it during function test after
assembly. Replace the rod if the
cylinder makes a squeaking noise or
dose not operate smoothly.
116
Volume of Internal Oil Leakage
Boom
1 cc (0.06 cuyin) or below / 3min
Arm
Bucket
Table 1-6
1.8 TROUBLESHOOTING
Trouble
Faulty Part
Cause
Remedy
1. Oil leakage through

1. Rod packing 1. Foreign
matter
is
sliding surface of piston
included in the bore of
rod oil ring is formed on
rod packing
piston rod, and the ring
2. Lips on outer and inner
grows up to oil drops,
diameter surfaces of rod
and they drip.
packing are scored.
3. Other rod packing are
faulty.
2. Buffer seal 1. Foreign matter is caught
in the bore of buffer seal.
2. Flaw is present on the
bore of buffer seal.
3. Other buffer seals are
OIL LEAKS FROM HERE.
faulty.
3. Dust seal
1. Foreign matter is include
in the bore of dust seal.
2. Lip on the bore of dust
seal is scored.
3. Other dust seals are
faulty
4. Piston rod
sliding surface of piston
rod.
2. Oil leaks from the

perimeter of cylinder
head
1. Remove foreign matter.

2. Replace rod packing.
3. Replace rod packing.
2. Replace buffer seal.
3. Replace buffer seal.
2. Replace dust seal.
3. Replace dust seal.
1. Smooth out the sliding

surface with an oilstone.
If leakage occurs even if
the sliding surface is
finished below 1.6S, rod
packings may be scored.
Disassemble and inspect
it
and
replace
rod
packings as required.
If leakage will not stop by
that treatment, replace
piston rod.
2. Hard chromium plating 2. Replate.
has peeled off
1. O ring
1. O ring is damaged.
1. Replace O ring.
2. Back-up ring 1. Backup ring is damaged. 1. Replace backup ring.
OIL LEAKS FROM HERE.
3. Oil leaks from welds.
1. Cylinder
tube
1. Welds of
fractured.
cylinder
are 1. Replace cylinder tube.
WELDS
4. Cylinder falls by it-self. 1. Piston seal

[When the rod is loaded
with a static load equal
to the maximum
working pressure
multiplied by the area
of the cylinder bore, the
maximum movement of
the piston is more
2. Wear ring
than 0.5mm (0.02) in
ten minutes.]
3. O ring
1. Foreign matter is caught

on the sliding surface of
slipper seal
sliding surface of slipper
seal.
3. Other back rings are
faulty.
1. Sliding surface of wear
rings is scored.
1. O ring is scored.
117

2. Replace slipper seal.
3. Replace back ring.
1. Replace wear ring.
2. Replace O ring.
1.9 TOOLS AND JIGS LIST

The tool and jig list provides the materials and
the dimensions of tools and jigs so that they may
be utilized in manufacturing in a service shop.
Follow the directions given below in selecting,
manufacturing and using the tools and jigs.
1) For the cylinder head, piston nut and others
that require large tightening torques, use eye
wrenches (symbol FS) as much as possible.
The tools and the jigs are so designed
dimensionally that they can withstand the
maximum tightening torques even if material
SS400 (JIS) is used. However, the hook of the
tool (symbol PS) may be distorted if struck
with a hammer. If such occurs, apply
reinforcement weld and finish it by grinding.
1.9.1 ALLEN WRENCH (AW)
(For cylinder head socket bolt)
(For nut setscrew)
B
A
C
MATERIAL : SNCM 6 OR SCM 3

SURFACE TREATMENT : PARKERIZING
Fig. 1-40
Table 1-7
Unit : mm (inch)
Cylinder Used
Boom, Arm
A
140 (5.51)
B
56 (2.20)
C
14 (0.55)
Socket Bolt
M16
Bucket
125 (4.92)
45 (1.77)
10 (0.39)
M12
Boom, Arm, Bucket
90 (3.54)
32 (1.26)
6 (0.24)
M12 (setscrew)
1.9.2 DUST SEAL PRESSING JIG [SYMBOL E]

(For cylinder head)
15
D
MATERIAL : SS41
SURFACE TREATMENT : PARKERIZING
A
B
C
Fig. 1-41
Table 1-8
Cylinder Used
Bucket
Boom
Arm
50~70
(1.97~2.76)
B
77.5
(3.05)
82.5
(3.25)
92.5
(3.64)
Unit : mm (inch)
C
88
(3.47)
93
(3.66)
103
(4.06)
II118
20~30
(0.787~1.18)
8
(0.315)
1.9.3 WRENCH FOR PISTON NUT

Table 1-9
B
Fig. 1-43
Wrench for piston nut
119
Unit : mm (inch)
Cylinder used
95 (3.74)
Arm
85 (3.35)
Boom
80 (3.15)
Bucket
1.9.4 BUSHING EXTRACTION JIG (SYMBOL A)

(For clevis)
Fig. 1-43
Table 1-10
Cylinder Used
Bucket
Arm
Boom
1.9.5 PISTON (SLIPPER)

(SYMBOL C)
SEAL
FIXING
Unit : mm (inch)
d
80 (3.15)
89 (3.50)
85 (3.35)
100 (3.94)
JIG
Fig. 1-44
Table 1-11
Unit : mm (inch)
Cylinder Used
D1
D2
Bucket
104.6 (4.12)
106 (4.17)
80 (3.15)
23 (0.906)
Boom
114.6 (4.51)
116 (4.57)
90 (3.54)
24 (0.945)
Arm
124.6 (4.91)
126 (4.96)
100 (3.94)
26 (1.02)
II120
L
65 (2.56)
1.9.6 SLIPPER SEAL HOLDING-DOWN JIG

(SYMBOL D)
MATERIAL : NYLON
O RING
Fig. 1-45
Table 1-12
Unit : mm (inch)
Cylinder Used
O ring
Bucket
105 (4.13)
1B P105
Boom
115 (4.53)
1B P115
Arm
125 (4.92)
1B P125
1.9.7 SLIPPER SEAL HOLDING-DOWN JIG

(SYMBOL G)
HARD CHROMIUM PLATING
MATERIAL : SS41
Weld it before
d lathed
Fig. 1-46
Table 1-13
Unit : mm (inch)
Cylinder Used
Bucket
105 (4.13)
120 (4.72)
Boom
115 (4.53)
130 (5.12)
Arm
125 (4.92)
140 (5.51)
II121
L
40 (1.58)
50 (1.97)
E200SR
SECTION 33
UPPER STRUCTURE
TABLE OF CONTENTS
[Part I. Removing and Installing Assy]
1. CAB .......................................................................................................................... I-1
2. OPERATOR SEAT .................................................................................................... I-2
3. BATTERY ................................................................................................................. I-3
4. GUARD..................................................................................................................... I-4
5. UNDER COVER ....................................................................................................... I-9
6. FUEL TANK ............................................................................................................. I-10
7. HYDRAULIC TANK ................................................................................................. I-11
8. HYDRAULIC PUMP ................................................................................................ I-14
9. AIR CLEANER ........................................................................................................ I-18
10. MUFFLER ............................................................................................................. I-19
11. COUNTERWEIGHT .............................................................................................. I-20
12. RADIATOR & OIL COOLER ................................................................................. I-21
13. ENGINE ................................................................................................................ I-25
14. INSTRUMENT PANEL ........................................................................................... I-27
15. CONTROL VALVE ................................................................................................ I-28
16. PILOT VALVE (FOR ATT) ..................................................................................... I-30
17. PILOT VALVE (FOR TRAVEL) ............................................................................. I-31
18. SWING MOTOR UNIT .......................................................................................... I-32
19. SWIVEL JOINT ..................................................................................................... I-34
20. UPPER FRAME .................................................................................................... I-37
1. PUMP ...................................................................................................................... II-1
2. CONTROL VALVE ...................................................................................................II-2
3. PILOT VALVE (FOR ATT) ........................................................................................II-3
4. PILOT VALVE (FOR TRAVEL) ................................................................................ II-4
5. SWING MOTOR UNIT ............................................................................................. II-5
6. SWIVEL JOINT........................................................................................................ II-6
1. CAB
Rotate 90 degrees to remove.

BOLT (25-9)
GROMMET
24
1.1 REMOVAL
(1) Remove floor mat
(2)
1)
2)
3)
4)
COVER
BRACKET
Remove the following parts for air-con cover. 14
CATCH (24)
Five bolts (25-9) for catch (24)
Cover (25-14) assy
25-14
GRILLE
Grille under front seat
Duct from duct (14) to under right duct on
cab inside.
FLOOR MAT
: Cross recessed screw driver
: 13mm
Fig. 1-1 Detaching and attaching air conditioner cover
(3) Remove the following parts for harness and

connector.
1) Antenna cable from back side of tuner
2) Harness for room lamp
3) Harness on cab front right side
4) Harness for gauge cluster
HARNESS FOR ROOM LAMP HARNESS
HARENSESS
FOR
WINDOW
WASHER
GROMMET
DOOR SW.
(4) Remove window washer tube
ANTENNA
(5) Remove the following parts for cab mounting

bolt
1) Five capscrews (A1)M10 (Fig. 1-2 Mark U)
2) Four nuts M16 (Fig. 1-2 Mark c)
: 17mm, 24mm
GROMMET
To instrument panel
Tightening torque
kgfym (lbfyft)
Nut M16
24
19.5 (140)
Capscrew (A1)
17
4.7 (34)
Remove washer
tube at connector
TUBE
NUT
M164 pcs.
Fig. 1-2 Removing and attaching harness

connector and cab mounting bolts
1.2 INSTALLATION
Mount it in reverse procedure of Dismounting
according to the Tightening Torque Table.
Tool
GROMMET
B2
TUBE
A1
M105pcs
(6) Slinging cab

1) Remove two plastic plugs on front side of cab
ceiling, and attach eye bolts M10, and hook
wire three places, two bolts and lifting eye, on
rear left side.
2) Then lift up slowly avoiding interference with
surroundings.
Wire with hook ;
Length 1.5m (4ft 11in) Dia. 8mm (0.315in)
3pcs.
Weight of cab ; Approx. 180kg (400 lbs)
Tightening position
CONNECTOR
HAND RAIL
FOR TUNER
M10 EYE BOLT
A1
Fig. 1-3 Slinging cab

I 1
2. OPERATOR SEAT
2.1 REMOVAL
(1) Remove seat. (Include upper rail.)
1) Remove four M8 capscrews (15) in the upper
rail.
2) Remove seat
[Approx.15kg (33 lbs) with upper rail]
: 6mm
(2)
1)
2)
3)
4)
Remove slide on lower rail of seat.

Remove four capscrews (15)M8.
Remove support (4).
Remove four capscrews (15)M8.
Remove lower rail (3).
: 6mm
M816
15
SEAT
(3) Remove seat stand (1)

1) Remove four capscrews (9)M10.
2) Remove seat stand (1).
: 8mm
Weight of seat stand ; 17kg (37 lbs)
2.2 INSTALLATION
Install it in reverse procedure of removing
according to the tightening torque table.
UPPER RAIL
LOWER RAIL
15
M816
Allen Tightening torque

Tightening position wrench
kgfym (lbfyft)
HEX
Capscrew (9)
Capscrew (15)
8
6
4.7 (34)
2.4 (17)
Reference : Movement on rail

Upper rail Fixed on lower surface of seat
(Forward 80, backward 80)
Lower rail Fixed on seat stand.
Height adjustment lever (L.H)
Seat raise 23mm (0.91inch)
Seat lower 37mm (1.5inch)
M830
13
M816
15
9
M1025
Fig. 2-1
M825
18
PLATE
(STOPPER)
Floor plate
Dismounting and mounting seat
3.
3.1
(1)
1)
2)
3)
4)
BATTERY
REMOVE
Open right cover.
Open it with starter key.
Open cover.
Fix it with stay.
Remove rubber (A7). (See Fig.3-3)
RIGHT COVER
(2) Remove right front deck cover (See Fig.4-8)

1) Remove seven sems bolts (36) M12.
2) Remove deck cover.
: 19mm
RIGHT FRONT DECK COVER
(3) Remove battery cable

1) Remove M8 nut (7). Then disconnect cable (4)
across ground and battery (). (Always remove
() terminal first and install it at last.)
2) Cable (3) (between battery (+) and ())
3) Cable (2) (between battery (+) and battery relay)
: 13mm
Fig. 3-1 Preparation for removing battery
BATTERY RELAY
Follow the battery removal order.

Start removing battery from grounding
side, and finish attaching to grounding
side.
If
this
order
is
GND
missed,
short-circuits may occur.

(4) Remove battery (B1)
1) Remove four capscrews (A3) M10.
: 17mm
2) Remove supports (A1), (A2).
3) Remove battery (B1).
Fig. 3-2
Remove battery cable

A3
A7
A1
3.2 INSTALL
(1) Install the battery in the reverse procedure of
removing.
Battery attaching capscrew (A3)
: 17mm,
Tightening torque : 1.1kgfym (8.0 lbfyft)
(2) Installing grounding cable
Install grounding cable last. Especially care
must be taken that the grounding face is free
from painting, rust, etc.
: 13mm
A2
B1
Fig. 3-3 Removing battery
4. GUARD
4.1 PREPARATION FOR REMOVAL
(1) Remove guard in the following procedure.
When removing the components remove only
the guards that are required for removal. The
order of removal of the engine : (4), (5), (9),
and (10)
1-2
1-1
11
2,3
18
4
52,83
14,25,53,54
8
(2) All the locked cover, open them using starter

key.
17
7
91
Fig. 4-1
4.2
(1)
1)
2)
3)
4)
5)
REMOVE GUARD
Remove cover assy (11)
Unlock cover assy (11) and lift it up
Remove stay for stopper.
Remove gas spring.
Remove two sems bolts (36) M1230.
Remove cover assy (11).
: 19mm
Weight : 18kg (39 lbs)
10
Arrangement of guard assy

(The figures represent the item numbers)
11
36
HINGE
Fig. 4-2
(2) Remove panel assy (2), (3)
1) Remove two sems bolts (37) M1025 and
open the panel assembly.
: 17mm
2) Remove two nuts (70) M12.
3) Remove panel assy (2).
: 19mm
4) Remove three sems bolts (36) M12 30, a
capscrew (80) M1230 and panel assy (3).
: 19mm
37
2
80
36
36
70
Fig. 4-3
Removing cover assy (11)
Removing panel assy (2), (3)
(3)
1)
2)
3)
Remove bonnet assy (10)

Remove snap pin (27) and gas spring (41).
Remove four sems bolts (36) M1230.
Lift up bonnet assy (10) with nylon sling.
: 19mm
35
9
51
10
(4) Remove bonnet assy (9)

1) Remove two sems bolts (35) M1225.
2) Remove capscrew (51) M1025.
: 19mm, 17mm
3) Remove bonnet sssy (9).
27
28
41
28
36
Fig. 4-4
Removing bonnet assy (9), (10)
(5) Remove cover (4)

1) Remove four capscrews (37) M10 25 and
cover (4).
: 17mm
(6)
1)
2)
3)
37
Remove cover assy (5)

Unlock it with the key.
Remove two sems bolts (35) M1225.
: 19mm
5
Fig. 4-5

2) Remove cover (8).
: 19mm
35
Removing cover (4), (5)

8
36
Fig. 4-6
Removing cover (8)
27
(8) Remove cover (1-2)

1) Unlock cover (1-2) and remove snap pin (1-5)
and stay (1-3).
2) Remove two sems bolts (1-6) M1225.
: 19mm
3) Remove cover (1-2).
1-2
1-6
1-3
1-5
36
1-1
36
Fig. 4-7 Removing box (1)
(9)
1)
2)
3)
Remove cover assy (52), (83)

Remove five sems bolts (36) M1230.
Remove two capscrews (61) M1245.
: 19mm
4) Remove four sems bolts (61) M1245.
5) Remove cover assy (83).
: 19mm
52
83
61
36
61
(10) Remove box (1-1)

1) Remove five sems bolts (36) M1230.
: 19mm
2) Remove box (1-1).
Fig. 4-8
49
(11) Remove stay (49)

1) Remove five capscrews (78) M1265 and two
capscrews (62) M1270.
: 19mm
(12) Remove bracket (21)
: 19mm
2) Remove bracket (21).
Removing cover assy (32), (52)
62
36
21
Fig. 4-9
Removing stay (49) and bracket (21)
(13) Remove cover assy (12)

: 19mm
19
35

1) Remove six sems bolts(35) M1235.
: 19mm
36
2) Remove cover assy (18) .

(15) Remove bracket (19)
1) Remove three sems bolts (36) M1230.
: 19mm
35
35
35
2) Remove brackets (19).

(16) Remove cover assy (14), (25), (53) and (54)

located under the boom.
1) Remove all attaching bolts.
: 19mm
18
35
12
Fig. 4-10 Removing cover assy (12),(13),(18),(19)
64
14
35
54
56
53
2) Remove covers (14), (25), (53) and (54), in

that order.
35
35
25
Fig. 4-11 Removing cover assy (14), (25), (53),
(54)
64
(17) Remove guard assy (47)

1) Remove two capscrews (64) M1225.
: 19mm
47
2) Remove guard assy (47).

: 19mm
36

15
Fig. 4-12 Removing cover assy (15)
and guard assy (47)
I 7

1) Remove four sems bolts (69)M820.
: 13mm
35
17
69
35

: 19mm
68
35
(21) Remove bracket assy (17)

: 19mm
2) Lift up bracket assy (17) with nylon sling.
16
Fig. 4-13
Removing cover (16), (68)

and bracket assy (17)
35

1) Remove seven sems bolts (35) M1225.
: 19mm
2) Remove cover assy (20)
20
(23) Remove bracket assy (45)

1) Remove three sems bolts (36) M1230.
2) Remove two capscrews (64) M1225.
: 19mm
3) Remove bracket assy (45).
Fig. 4-14
Removing cover assy (20)
45

1) Remove six sems bolts (36) M1230.
: 19mm
64
Fig. 4-15
1) Open cover (91-1).
2) Remove six sems bolts (36) M1230.
: 19mm
36
Removing bracket assy (45)
36
36
91
7
91-1
4.3 INSTALLATION
(1) Installing is done in the reverse order of
removing.
(2) Tightening torque
: 19mm M12
: 17mm M10
36
36
Fig. 4-16
91-2
Removing cover assy (7), (91)
5. UNDER COVER
5.1
(1)
1)
2)
REMOVAL
Remove under cover (1, 2, 3, 4, 5, 6)
Remove sems bolts (7) M1225.
Remove covers.
: 19mm
1
7
2
7
6
7
5
7
4
Fig. 5-1
5.2 INSTALLATION
(1) Install under cover (1, 2, 3, 4, 5, 6)
: 19mm
Tightening torque : 8.1kgfym (59 lbfyft)
7
Under cover assy
6. FUEL TANK
(1) Draining fuel.
1) Unlock cap (A2) with a starter key and open it.
2) Loosen cock (B8) under the tank.
(Refer to Fig.6-2)
3) Draining fuel
Capacity of tank : 270 (71gal)
A2
RETURN
5,9,12
(2) Open bonnet (10) and cover (5) and remove

covers (8), (15) and guard assy (47). (Refer to
Fig.4-4, 4-5, 4-6, 4-12.)
(3) Remove the connector for level sensor (B4).
(See Fig. 6-2)
(4) Remove cab assy (Refer to 1. CAB.).
(5) Remove guard tube (9), (11) and hose (5), (6)
1) Loosen the clip (12) in the tank return
position and in the tank suction position, and
draw out the hose.
2) Put in plugs that match the hose bore.
SUCTION
6,11,12
Fig. 6-1 Removing fuel hose (5), (6)

A2
6.2 REMOVAL
B20
(1) Remove bracket (B17) and stay (B18) that
connect the tank with the upper frame.
1) Remove two sems bolts (B19) M1230.
2) Remove bracket (B17).
B18
: 19mm
3) Remove four sems bolts (B20) M12 25 and
separate stay (B18).
: 19mm
(2) Remove fuel tank assy (A1)
1) Remove four capscrews (B1) M16 45 and
three shims (B3).
: 24mm
A1
B17 B19
B20
B6
B4
2) Hook the wire to the lifting eye on the fuel

tank assy and remove the fuel tank.
6.3 INSTALLATION
removing.
Tank attaching bolt (B1) M1645
: 24mm, Apply Loctite #262
Tightening torque : 22.0kgfym
(160 lbryft)
B1
B3
Fig. 6-2 Removing fuel tank

B8
(2) Tightening torque
No.
NAME
B1
CAPSCREW
22 (160)
B6
MACHINE SCREW
0.2 (1.4)
B8
COCK
0.5 (3.6)
B19, 20 SEMS BOLT
I10
Tightening torque
kgfym (lbfyft)
8.1 (59)
7. HYDRAULIC TANK
11
2,3

(1) Remove cover assy (11), panel assy (2), (3)
and other guards necessary to remove the
hydraulic oil tank. (Refer to 4. GUARDS.)
Fig. 7-1 Remove guard

(2) Bleeding the tank internal pressure
Push the boot of the cap on breather assy
(A9) by your finger tip, to vent the internal
pressure.
Push
A9
Keep pressing until the hissing stops.
Fig. 7-2 Bleeding internal air of tank

(3) Remove cover (A7).
1) Remove six capscrews (A13) M1020.
: 17mm
2) Remove cover (A7).
A13
A8
A13
3) Remove suction strainer (A2).
A14
A7
A6
(4) Remove cover (A8).
1) Remove six capscrews (A13) M1020.
: 17mm
2) Remove cover (A8).
B
C
A2
A10 A23
A11
3) Remove filter element (A23).

(5) Disassembling filter element
Turn the handle of element assy (B), and
disassemble the removed filter element (A23).
Disassembling parts : (B), (C), (D), (E), (F)
A9
D
E
F
Fig. 7-3 Remove cover (A7), (A8)
I11
(6) Draining hydraulic oil

Place pump in tank and draw up hydraulic
oil.
Capacity of tank : 115 (30gal)
7.2
(1)
1)
2)
REMOVAL
Draw out the suction hose (3)
Remove two clips (16) of the tank side.
Pulling out hose (3).
: Flat-blade screwdriver
PLATE
FOR
LIFTING
(2) Disconnecting the main pipe return hose

1) Remove hose (7).
: 22, 27mm
2) Remove hose (6).
: 22, 27mm
PILOT
RETURN
HOSE
SECTION
3
B3
16
B1
Fig. 7-4
(3) Remove radiator return tube (2)

1) Remove coupling (11) M8 nut.
: 13mm
2) Separate tube (2).
(4) Disconnecting pilot return hose
1) Remove pilot hose (A21).
: 19, 22mm
2) Remove pilot hose (B5).
: 19, 22mm
3) Remove pilot hose (C20).
: 19, 22mm
4) Remove two pilot hoses (D23).
: 17, 19mm
Draining hydraulic oil and

drawing out the suction hose
11
6
7
Fig. 7-5
(5) Remove hydraulic tank attaching bolt

Remove four capscrews (B1) M1640, and a
shim (B3).
: 24mm
Removing main piping return hose
HYDRAULIC TANK
A21
B5
Record the shim locations.

(6) Slinging hydraulic oil tank
Place a wire sling in the lifting plate of the
tank.
Tank weight : Approx : 125kg (276 lbs)
D23
D23
C20
Fig. 7-6
12
Remove pilot drain hose
7.3 INSTALLATION
(1) Cleaning hydraulic oil tank
(2) Cleaning suction hose
(3) Cleaning mount of tank.
Installing is done in the reverse order of
removing.
(4) Install four attaching capscrews (B1) M1640
with Locktite #262. (See Fig. 7-4)
: 24mm
Tightening torque : 22kgfym (160 lbfyft)
If there is any clearance (gap) more
than 1mm (0.04in) between the tank
mount and the frame, adjust shim (B3)
thickness and fasten them together.
(5) Connection of suction hose (3)
Apply PERMATEX on pipe side of hose
connection and insert it.
1) Put the hose with clip (16).
O RING
(6) Assembling return element

Assemble filter element by the use of element
kit (B-2). (See Fig. 7-3, 7-7)
1. Two elements (D) are used as one

set.
2. Replace O ring (C) and packing (F)
with new ones respectively.
(7) Install return element (A23).

(8) Installing suction strainer (A2)
SUCTION
STRAINER
F
FILTER ELEMENT KIT (B-2)
(9) Install tank cover (A7, A8) attaching capscrews

(A13), M1020.
M10 Tightening torque : 4.7kgfym (34 lbfyft)
Fig. 7-7 Strainer & filter
Replace O ring fitted on the backside of

tank cover (A8) with new one.
I13
8. HYDRAULIC PUMP
(1) Remove bonnet and counterweight.
A13
(2) Release pressure in hydraulic oil tank.

(See item Hydraulic Tank.)
A7
SUCTION
STOPPER
(3) Remove six capscrews (A13) M10.

(4) Remove cover (A7)
: 17mm
(5) Take out suction strainer.
SUCTION
STRAINER
(6) Install suction stopper.

For suction stopper, see item Chapter YB 11
Tools.
Note : Pump can be removed even when
counterweight is not removed. But
removal of counterweight facilitates
working, and the working time is also
reduced.
HYDRAULIC TANK
Fig. 12-1 Suction stopper installing
(7) Remove cover (16), (68).

: 19mm
35
68
2) Remove cover (16), (68).

(8) Disconnect drain down pipe installed under
engine muffler.
35
16
Fig. 12-2 Removing guard (18), (19)
HYDRAULIC PUMP
HYDRAULIC
TANK
8.2 REMOVAL
(1) Loosen half clamp (8) on hoses (4), (5) and
capscrews (9) M10 35 and disconnect two
hoses on the delivery side.
: 17mm
(2) Remove suction tube

1) Remove four capscrews (10) M1230.
40mm
(1.57in)
: Special service tool No.6-1 of

opposing flats 10mm
10
2) Remove suction tube (1) from pump.

Fig. 12-3
I14
Removing hose (4), (5)

and suction tube (1)
(3) Removing other hoses

1) Disconnect hoses of the following ports.
(See Fig. 8-4.)
Port
Size
Tool
Dr1
PF1/2
27
Psv1,2 PF1/4
19
A3
PF3/8
22
B3
PF3/4
36
Dr3
PF3/8
22
Connected
to
Tank
Remarks
Drain
Proportional For control

valve block valve
Dr3
A3
Psv1
Gear pump
Line filter delivery port
for pilot
Suction port
Tank
for pilot
Drain port
Tank
for pilot
Psv2
B1
Dr1
A2
A1
B3
Fig. 8-4 Pump port
A4
2) Attach tags to hoses to identify.
(4) Remove main pump
1) Place a wire rope and tension it a little by
utilizing the eye bolt (M10) at the top of the
hydraulic
pump.
Temporarily
loosen
capscrew (4) and remove capscrew (3).
: 14mm, weight : 95kg (209 lbs)
: 17mm
2) Draw out the power take-off assy from the
flywheel housing slowly, adjusting the
tension of the wire rope.
On that occasion, the coupling rubber (2-1)
comes out with the hydraulic pump.
0
4
3) Remove capscrew (2-4) fastening coupling

rubber (2-1) and remove coupling rubber
(2-1).
: 14mm
3
1
4) Remove hub (2-2)

If you loosen two set screws (2-5), hub (2-2)
comes off from the spline shaft of the pump.
: 8mm
5) Remove bracket (1)
If you loosen and remove capscrew (4),
bracket (1) comes off the pump.
: 14mm
2-3
2-4
2-1
2-6
2-2
2-5
Fig. 8-5
15
2
Removing pump
8.3 INSTALLATION
removing.
(1) Installing bracket (1)
Install bracket (1) to the pump and
temporarily fasten them together by means of
socket bolts (4).
: 14mm
(2) Installing hub (2-2)
Insert hub (2-2) into the spline of the pump
till the end face of the spline enters 4mm
(0.16in) inward (Refer to the Detail A.) and
attach two setscrews (2-5).
: 8mm
(3) Installing coupling rubber (2-1)
Insert coupling rubber (2-1) into hub (2-2)
and attach socket bolts (2-4).
On that occasion, do not coat socket bolts
(2-4) with Loctite. (Socket bolts (2-4) are with
micro capsule coating.)
: 14mm
(4) Installing the pump
Lift the pump with bracket level and dock it
in so bolts (2-3) enter the holes in coupling
rubber (2-1).
Re-fit nine cap screws (3) and two cap screws
(6) where they were.
: 17mm
(5) Tighten socket bolts (4) regularly.
: 14mm
(140 lbfyft)
(6) Attach hoses (4), (5) of the delivery side with
half clamp capscrews (9).
: 17mm
(42 lbfyft)
(7) Install the suction tube (1) attaching socket
bolts (10) M12 (4pcs.)
: 10mm, ( Special service tool No.6-1)
(8) Installing the hose Tool
Tightening torque
Tightening position
kgfym (lbfyft)
Cap nut Dr1
27
8.0 (58)
Cap nut Psv1, 2
19
3.0 (22)
Cap nut A3
22
5.0 (36)
Cap nut B3
36
12.0 (87)
Cap nut Dr3
22
5.0 (36)

Do not use Loctite. (The
attached bolts are coated
with micro capsule coating.)
2-4
T=Tightening torque
4
T=19.5kgfym (140 lbfyft)
A
2-5
T=11kgfym
(80 lbfyft)
T=6.6kgfym(48 lbfyft)
3 Apply Loctite #262
2-3
T=22kgfym(160 lbfyft)
Do not use Loctite. (The
attached bolts are coated
with micro capsule coating.)
equivalent
BRACKET
2-1
2-2
2-4
2-5
(0.157)
DETAIL A
VIEW
Fig. 8-6 Installing Hydraulic pump
HYDRAULIC PUMP
HYDRAULIC TANK
10
1
Fig. 8-7
I16
Installing delivery hose (4),(5)

and suction tube (1)
(9) Remove suction stopper

(10) Installing suction strainer
(11) To bleed air in pump, loosen plugs on
pressure measuring ports a1, a2.
(12) Check hydraulic oil level.
(13) Start engine and check it for oil leakage and
noise.
(14) Attach drain down pipe under engine muffler.
a1
a2
(15) Install guards (16), (68)

Tightening position
Sems bolt (35)
Tool
19
Tightening torque
kgfym (lbfyft)
8.1 (59)
Fig. 12-8
Bleed air in pump
After replacing pump, be sure to fill

hydraulic oil to 1 (0.26gal) or more.
35
68
35
16
Fig. 12-9
17
Installing guard (16),(68)
9. AIR CLEANER
(1) Opening bonnet assy (10)
(2) Opening cover assy (5)

(3) Unplug terminals on indicator lines (1-5)
9.2
(1)
1)
2)
(2)
1)
2)
(3)
1)
2)
3)
REMOVAL
Loosen clips (7) on both sides of hose (5).
Pulling out hose (5)
: Flat-blade screw driver
Loosen clips (7) on both sides of hose (2).
Pulling out hose (2)
Removing hoses (3), (4) and intake tube (6)
Loosen clips (8), (9) on both ends of hoses (3),
(4).
Loosen nut (12) and remove U bolt (11).
Separate hoses (3), (4) and intake tube (6).
: 13mm
Fig. 9-1 Preparation for removal
1-6
1-2
7
1-5
(4) Remove air cleaner assy (1)

1) Remove four sems bolts (10) M1025
: 17mm
2) Remove air cleaner assy (1) from guard
bracket.
2
7
10
7
7
5
3 8
9.3 INSTALLATION
(1) Installing is the reverse order of removing
with attention paid to the following items:
1) The insertion depth of air hose (2) shall be
30mm (1.2in).
2) The insertion depth at both ends of air hoses
(3), (4), (5) shall be 40mm (1.6in), provided
that the depth on the turbo side shall be
25mm (1.0in).
10
6
8
8
11
9
4
Fig. 9-2 Removing air cleaner
(2) Replacing parts
3) Tightening torque :
No.
NAME
1-5 INDICATOR
10 SEMS BOLT
Tightening Torque
kgfym (lbfyft)
0.4 (2.9)
4.0 (29) Apply Locktite #262
FILTER ELEMENT (1-2)
I18
O RING (1-6)
12
10. MUFFLER
10

(1) Remove bonnet assy (9) and open (10).
(2) Remove cover (4).
(3) Remove sems bolt (69) and remove cover (68).
16
4
10.2 REMOVAL
(1) Remove U bolt (3).
1) Remove four nuts (5) M8.
2) Remove two U bolts (3).
: 13mm
(2) Remove clamp assy (10)
1) Remove two capscrews (8) M1035
2) Separate clamp assy (10) from muffler (1).
: 17mm
(3) Removing other parts
Remove exhaust tube (7) and brackets (2), (17),
where necessary.
: 13mm, 17mm
Fig. 10-1 Preparation for removal

SPACE
69
68
B
A
16
10.3 INSTALLATION
Installing is the reverse order of removing with attention
paid to the following items:
(1) Procedure of fastening U bolt (3)
1) Tighten four nuts (A) till there is no space and make
sure that the dimension C is even all around.
2) Tighten nuts (A) to specified torque and confirm the
C dimensions on the right and left once again.
3) Tighten nuts (B) to specified torque and make sure
that U bolts (3) are not inclined.
Nut A : 0.9kgfym(6.5 lbfyft)
Nut B : 1.1kgfym(8.0 lbfyft)
C
PROCEDURE OF
FASTENING U BOLT
Fig. 10-2 Removing cover (68)
3
1
12
16
5
19
Procedure of fastening the nuts :

Fasten (5-1) for the flange of exhaust tube (7)
and (5) for U bolt (3). Then fasten (11) for
clamp assy (10).
2 18
(2) Tightening torque :
17
10
18
No.
5-1
NAME
Tightening
torque
kgfym (lbf yft)
NUT ; M8
2.9 (21)
CAPSCREW ; M10
7.2 (52)
12
CAPSCREW ; M10
6.6 (48)
16
CLIP
0.3 (2.2)
(3)19 Replacing
parts
CAPSCREW ; M10
5-1 8
6.0 (43)
REMARK
7
4
Tightening exhaust tube (7)

Apply Locktite #262
Apply Locktite #262
Fig. 10-3 Removing muffler
NAME
MUFFLER (1)
GASKET (4)
I-19
11
11. COUNTERWEIGHT
BONNET

(1) Removing bonnet assy.
Remove bonnet on engine. (See Fig. 4-4.)
(2) Remove cover (4), (5) (See GUARD Fig. 4-5.)
(3) Preparing slinging jig
Remove plug (B5) and install the counterweight
lifting jig (Refer to Chapter YB 11 Tools.)
(Use bolt : M48120)
: 75mm
For an additional weight, use two eye bolts

M24.
11.2 REMOVAL
(1) Lifting up counter weight temporarily
Hook wire rope to slinging jig, and lift it and
stretch wire rope to the degree where it is
providing no slack temporarily.
Weight of counterweight ;
Approx. 4,600kg (10,100 lbs)
Wire more than 16 (0.63) ;
1.5m (4ft 11in)2 pcs.
B7
(2) Removing counterweight
B2
1) Remove two capscrews (B1) M30 140 and
(B7) M30190.
: 46mm
B3
2) Remove shim (B3), (B4).
B4
3) Remove counterweight (A1).
(3) Removing counterweight (Add-on)
1) Attach two eye bolts M24 to the add-on
counterweight and lift it up temporarily.
Weight of counterweight ;
Approx. 1,000kg (2,205 lbs)
2) Remove 3 capscrews M24 (C2,C3) and add-on
counterweight (C1).
4
Fig. 11-1 Lifting up counter weight
7 8 4 10
6
9
B5
A1
C5
B6
C5
C1
C4
C3
C4
C2
COUNTERWEIGHT
(ADD-ON)
B2
B1
11.3 INSTALLATION
(1) Install counterweight in the reverse
Fig. 11-2 Removing counterweight
procedure of removing.
(2) Install shim (B3), (B4) as it was.
(3) Slinging counterweight
B3,B4
Check that the attaching bolts can be
screwed in by hand.
(4) Apply Loctite #242 on capscrews (B1), (B7),
and tighten them with washers (B2).
: 46mm,
Tightening torque : 170kgfym (1,200 lbfyft)
(5) Remove slinging tools, and attach plugs (B5).
(6) Mounting add-on counterweight
1) Apply Loctite #262 on capscrews M24 (C2,C3)
B1,B2
and tighten them with washers (C4).
Fig. 11-3 Installing counterweight rear section
: 36mm
and tightening capscrew
Tightening torque : (C3) 89kgfym (643 lbfyft)
: (C2) 96kgfym (694 lbfyft)
2) Remove eye bolt, and attach plugs (C5).
I20
12.
RADIATOR & OIL COOLER

(1) Bleed air from the hydraulic tank and install
the suction stopper.
7
7
(2) Remove counterweight

(See 11. COUNTERWEIGHT)
Fig. 12-1 Removing air cleaner hose
(3) Remove air cleaner hose

Refer to
1) Loosen clips (7).
9. AIR CLEANER
2) Pulling out hose (5).
(4) Removing under cover installed on lower side
of radiator.
1) Remove eight sems bolts (7) M12 25.
: 19mm
3
7
Fig. 12-2 Removing under cover (3)
(5) Drain down of radiator

Put container 18 (5gal) under drain cock
hose for draining water.
[Water capacity of radiator : 9.5 (2.5gal)]
A4
(6) Remove washer tank (A4)
1) Pulling out hose.
2) Move washer tank.
Fig. 12-3 Removing washer tank (A4)

(7) Remove sub tank (B2) for radiator
1) Loosen clip (B15) on one side of hose (B8) and
pull out hose.
2) Remove four capscrews (B17) M8 25 and
separate sub tank (B2) from bracket assy.
: 13mm
B15
B15
B8
B2
B17
T 1.1kgfm
(8 lbfft))
Fig. 12-4 Removing sub tank (B2)
21
(8) Removing inter-cooler (B1)

1) Loosen clip (B13) on inter-cooler hoses (B5),
(B6).
2) Remove hose (B5), (B6).
3) Remove three capscrews (B18) M1040 and
one capscrew (B22) M1240.
: 17mm, 19mm
4) Remove inter cooler (B1).
B13
B5
B6
B13
B18
B1
B22
Do not loosen the joints of the hoses

related to the air-conditioner. Otherwise
the refrigerant leaks.
Fig. 12-5
Removing inter cooler
CONDENSER
(9) Move air-conditioner condensers.

1) Remove six capscrews (16) M650.
2) Move A/C condenser
: 10mm
14
RECEIVER TANK
(10) Move receiver tank

1) Remove two capscrews (14) M816 which
are used to install receiver tank with bracket.
2) Move receiver tank.
: 13mm
16
16
ig. 12-6
Moving condensers and receiver tank

B14
B3
B14
12.2 REMOVAL
(1) Remove radiator stay (A1), (A2)
1) Remove four sems bolts (A4) M1230.
: 19mm
B14
2) Remove stay (A1), (A2).

(2) Remove water hose (B3)
1) Loosen the clip (B14) for water hose (B3).
2) Remove hose (B3).
3) Loosen the clip (B14) for water hose (B4).
4) Remove hose (B4).
B4
A4
B14
A1
A4
A4
A2
Fig. 12-7
22
Removing radiator assy
(3) Remove wire net (26)

1) Remove three capscrews (27) M820.
2) Remove guard (26).
: 13mm
27
(4) Disconnecting hydraulic oil tube (3), (4)

Place an oil pan under the tube joint. Remove
the coupling (9) that connects tubes (3), (4).
26
Fig. 12-8
(5) Remove radiator body (C1)

Remove four capscrews (A3) M1245.
: 19mm
: 19mm
Removing wire net
C1
(6) Disconnecting hydraulic oil pipe

1) Shift the radiator outwards so the engine fan
do not interfere with it when lifted up.
2) Stop up pipe ends with clean cloth, etc.
A3
4
9
(7) Removing radiator

Place a wire sling in the lifting metals of the
radiator assy and remove the assy by crane.
Weight : Radiator approx. 30kg (66 lbs)

Fig. 12-9
Oil cooler approx. 16kg (35 lbs)
23
Removing hydraulic hose (3), (4)
12.3 INSTALLATION
removing.
C1
(2) Install radiator assy

Place a wire sling in the lifting metals of the
radiator, match the openings of the hydraulic
pipes, match the mounting positions of the
radiator and assemble it temporarily.
Water hose insert allowance 40mm (1.6in)
A3
(3) Radiator attaching bolt

Apply Locktite #262 on four capscrews (A3)
M12 45, and tighten it with washer
respectively.
: 19mm
Tightening torque ; 12.3kgfym (89 lbfyft)
Tightening torque
12.3kgfym
(89 lbfyft)
Apply Locktite
#262
Fig. 12-10
(4) Adjust the clearance between the fan and the

radiator shroud all around the circumference,
as below :
Circumferential direction:
205mm (0.8in0.2in)
Longitudinal direction :
365mm (1.4in0.2in)
Installing radiator
Adjust the engine fan so its rear end sticks

out 36mm (1.42in) from the radiator shroud.
(1.42in)
(5) Clean the plastering area of the insulation

thoroughly before plastering it.
(6) Making up hydraulic oil and LLC (Long Life
Coolant)
After completion of other installation, make
up hydraulic oil and water.
Cooling water volume of engine body
8.5 (2.2gal)
Water capacity of radiator 9.5 (2.5gal)
24
Fig. 12-11
Back-and-forth
adjusting position of radiator
13. ENGINE
13.1 PREPARATION FOR REMOVING
(1) Remove battery ground (See 3. BATTERY)
(7) If necessary, remove pump, muffler and

radiator.
(2) Remove bonnet and cover (See 4. GUARD)

(8)
1)
2)
3)
(3) Remove air cleaner hose

(See 9. AIR CLEANER)
(See 11. COUNTERWEIGHT)
(5) Remove radiator hose and inter cooler hose
(See 12. RADIATOR)
(6) Remove fuel hose and heater hose, and if
necessary air-con hose.
Remove harness connector

Remove E/G ground cable
Starter cable Starter B terminal
Remove the connector that connects the main
harness with the engine.
-CN-318E/G sub harness
-CN-165
MAIN HARNESS
Govenor motor
(See YB23
-CN-166
ELECTRIC
-CN-170 Pump
SYSTEM)
-CN-171 proportional valve
-CN-167E/ G speed sensor
Prepare a stand, which withstands the
weight of the engine assy and can place
the removed engine firmly.
(Refer to YB11 Tools on Page 13.)
SPEED SENSOR
THERMOSTAT
FUEL FILTER
TURBO CHARGER
STARTER MOTOR
WATER TEMP. SENSOR
THERMO SWITCH
OIL PRESSURE SWITCH
OIL FILTER ELEMENT (BYPASS)
ALTERNATOR
OIL FILTER ELEMENT (FULL FLOW)
ISUZU 4BG1TCY(WITH TURBO CHARGER)

Fig. 13-1 General view of engine
I25
T=Tightening torque
13.2 REMOVAL
4
5
8
6 CAPSCREW

Apply Loctite #271
8 WASHER
10 TEMP.SENSOR
4 CAPSCREW
Apply Loctite #271
1
9 PLATE
2 RUBBER MOUNT
RUBBER MOUNT 1
15 SHIM
16 SHIM
3 RUBBER MOUNT
7 NUT
15,16
1,2
+1.0
+ 0.039
)
0 (0.039 0
15
16
15
15
3
7
16
16
3
7
3
7
(1)
1)
2)
3)
Removing attaching bolt to frame

Remove four nuts (7) M18.
Remove rubber mount (3) and shim (15), (16).
Remove four capscrews (4), (5), (6) M1890.
: 27mm
4)
5)
6)
(2)
1)
Remove two washers (8).

Remove two plates (9).
Remove two rubber mounts (1), (2).
Slinging engine body
Sling engine hooking wire to lifting lugs on
the front and rear sides.
Wire
: 6 (0.24)1m (3ft 3in) 2pcs.
+1.0
Adjust to 1 0
+0.04
(0.04 0 )
using shims
No.15, 16.
Clearance Adjustment of Engine Mount

13.3 INSTALLATION
removing.
1) Clearance adjustment of engine mount
Adjust the clearance between the lower
mounting surface of the engine and rubber
Mount (3) to 1.0mm (0.04in), using shims
(15), (16).
2) Refer to the above figure for the tightening
torques and Loctites (Adhesive).
(3) Position engine on the mount stably.

I26
14. INSTRUMENT PANEL

Remove terminal () from battery.
14.2 REMOVAL
(1) Remove RH, LH instrument panel
1) Remove 8 sems bolts (12) M5.
: cross recessed screw driver
12
12
12
12
2) Lift instrument panel.

3) Remove two connectors and antenna cable on
rear side of left instrument panel
1 8P for air-con panel
2 9P for tuner
Fig. 14-1 Around of instrument panel

RH instrument panel
LH instrument panel
12
CAP
4) Remove connectors on rear side of right panel

1 6P for key switch
2 3P for accel dial
3 2P for switch
12 M516
12
12
BRACKET
ANTENNA CABLE
TUNER
(2) Remove control box
Fig. 14-2 Removing instrument panel
1) Remove four sems bolts (19) M8 on right and
left sides.
PILOT VALVE
2) Separate control box from support.
SUPPORT
: 13mm
PILOT
Weight : Left control box 8.5kg (19 lbs) and
19
VALVE
right control box 7kg (15 lbs) including
M825
pilot valve
37
M616
Remove hose referring to Page 1-32.
SUPPORT
14.3 INSTALLATION
Install it in reverse procedure of removing
according to the tightening torque table.
SEAT STAND
Fig. 14-3 Removing control box

Tightening
position
Tool
Tightening torque
kgfym (lbfyft)
Sems bolt (19)
13
2.4 (17)
Sems bolt (12) cross recessed

screw driver
0.27 (2.0)
I27
15. CONTROL VALVE

(1) Remove cover assy (11) (See Fig. 4-2.)
(2) Remove panel assy (2), (3) (See Fig. 4-3.)
(3) Release air in hydraulic oil tank, open cover
of suction element of hydraulic oil, and lower
the level. (See Fig.8-1.)
15.2 REMOVAL
(1) Removing hoses for each piping
Attach tag on hose, and write port name in it,
then remove hoses.
Ports
Functions
Ports on upper sides (on machine)

FRONT SIDE
RIGHT SIDE
PAr
PAr Travel right forward
PAc Bucket dump
PLc1
Boom down lock release
PAb Boom up
Ports
PAL
PAL Travel left forward
PAc
PLc1
PAa
PAb
Drc Drain
Drc
Pcb P1 side cut
Pcb
Pis
PAo2
PAa Arm in
Pis Arm recirculation
PAo2
Ports
Functions
Ports on front sides (on machine)

LOWER SIDE
RIGHT SIDE
Dra Drain
Br
Travel right reverse
Bc
Bucket digging
Bb
Boom down
Functions
REAR SIDE
Ports
Option valve
Functions
UPPER SIDE
PL1 Attach boost pressure

Ar
Travel right forward
Drb Drain
I28
Ac
Bucket dump
Ab
Boom up
Ports
Functions
Ports on rear sides (on machine)

UPPER SIDE
AL
As
PAs
Aa
Ao2
Ports
PBb
Travel left
BL Travel left reverse
forward
Swing (left)
Swing (left)
Arm in
Bs
Swing (right)
Ba
Arm out
Bo2 Option valve
Option valve
Functions
Ports on lower sides (on machine)
Ports
REAR
SIDE
Functions
PBo2 Option valve
Arm conflux
Pca P2 side cut
Boom dowm
Drd Drain
PBa Arm out
Bucket digging
PLc2
PBc
Travel right
Arm in
Lock release
PB1 Boom conflux
PBr
PTb
Functions
LOWER SIDE
RIGHT SIDE
FRONT
SIDE
PA1
Ports
reverse
PBs Swing (right)
Travel straight
PBL Travel left reverse

RIGHT SIDE
(2) Remove control valve

1) Remove four capscrews (3) M12 40 from
upper frame.
2) Remove bracket (1), (2) together with control
valve.
3) Remove three capscrews (4) M12 65 from
bracket.
: 19mm
4) Weight : 220kg (490 lbs) (include bracket)
MACHINE FRONT
A1
15.3 INSTALLATION
remove.
: 19mm,
Tightening torque : 12.3kgfym(89 lbfyft)
(2) Make certain that attachment moves
normally in operation.
(3) Check oil level and that it is free from oil
leakage.
Fig. 15-1 Removing main control valve

I29
16. PILOT VALVE (FOR ATT)

The removing procedure for right and left is the
same, so the preparation for left side is described
here.
(1) Put attachment on ground, stop engine and
release pressure in tank.
PANEL ASSY
28
29
(2) Remove panel assy referring to Section 4.

Instrument Panel.
(3) Remove one sems bolt (12) M5 from lower
side of control box.
12
Fig. 16-1 Removing instrument-panel cover
(4) Remove cover on outer surface.
BOOTS
(5) Remove sems bolt (28) and rubber sheet (29)

securing cover and control box on inner
surface.
A1
PILOT VALVE
(6) Remove cover on inner surface.

(7) Remove harness connector for horn.
PF3/8
Opposing
Flats 22
VALVE SIDE
PF1/4
(8) Attach tag to hoses for identification.
Opposing
Flats 19
MARK F
16.2 REMOVAL
(1) Remove hoses from your side to far side in
order.
: 19mm, 22mm
PF3/8
PF1/4
HOSE SIDE
1~4,5~6,T PORT CONNECTOR
(2) Shift boots.
P PORT CONNECTOR
(WITH FILTER)
Fig. 16-2 Pilot valve connector

FRONT OF THE MACHINE
(3) Remove four socket bolts (A1) M6.

: 5mm
(4) Remove pilot valve.
8 ARM(R)
(GREEN)
SWING
(R)
(RED)
(5) Plug hose ends. Plug PF1/4
4 BOOM(R)
(GRAY)
BUCKET
(R)
(BLUE)
5 SWING(L)
(GRAY)
16.3 INSTALLATION
1
P
Install it in the reverse order of removal and
P BUCKET(H)
(RED)
7 ARM(H)
tighten it to the below tightening torque.
(BLUE)
3 BOOM(H)
: 5mm
(GREEN)
: 19mm T=3.0kgfym (22 lbfyft)
RIGHT SIDE
LEFT SIDE
Fig. 16-3 Port position (Seeing from upper side)
I30
17.
PILOT VALVE (FOR TRAVEL)

(1) Release pressure in hydraulic oil tank
(2) Remove under cover (1) (See 5. UNDER COVER)
TRAVEL
2 SPEED
SWITCH
(3) Remove floor mat

17.2 REMOVAL
(1) Separate pressure sensors (B2) at two places
of the harnesses under the floor.
(2) Remove two pressure sensors (B2).
: 19mm
(3) Separate the lead wires CA103 for the travel

1, 2 speeds, at two places, from the harnesses
of the main body, at two places.
(4) Attach tag, and disconnect connectors and
hoses (B7), (B8), (B9), (B11).
: 19mm (P port)
: 22mm (T port, 1~4 port)
(5) Plug hose ends
Plug PF1/4, PF3/8
CA103
B10
25
24
B2
B1
B2
B8
CONNECTOR
SECTION
B7B9
B9
(6) Remove four sems bolts (7) M1020.
B11
B11
(7) Remove right and left levers (4).

(8) Remove four socket bolts (B10) M1030.
: 8mm
Opposing
PF3/8 flats 22
PF3/8
(9) Remove four sems bolts (25) M1025 and

remove plate (24).
: 17mm
HOSE
SIDE
VALVE
SIDE
T port connector
(10) Remove pilot valve lifting it upward.
Opposing
flats 19
PF1/4
VALVE SIDE
(11) Stop up holes with plugs PF1/4, 3/8.
PF3/8
MARK F
PF1/4
Opposing
flats 22
PF3/8
17.3 INSTALLATION
Install it in the reverse order of removal and
tighten it to the below tightening torque.
Hose
: 8mm
Pressure sensor
P port connector
HOSE SIDE
1~4 port connector
Fig. 17-1 Attaching and detaching pilot V
I31
19.
18. SWING
MOTOR UNIT
(1) Park machine on flat and solid ground and
put attachment on ground.
(2) Remove the under-cover under the engine.

5
8
(3) Stop engine and release pressure in circuit
operating swing control lever.
(4) Remove the air cleaner at the top of the
swing motor.
B10
(5) Bleed air from the hydraulic oil tank and

attach to each hose a tag showing port name
and other information.
B10
(6) Remove guard as necessary to make work

easier. (Refer to 4. GUARD.)
A16
18.2 REMOVAL
(1) Remove hose.
1) Remove hose (8) from the Tee in the makeup
port M.
: 36mm
Fig. 18-1 Removing swing unit piping
2) Remove hose (5), (6) from the Tee in the drain

port Dr.
: 27mm
M PORT
B1
3) Remove one hose (A16) from the elbow of the

PG port (for swing parking brake).
: 19mm
B20
4) Remove two hoses (B10) from the elbows of

the A, B port.
: 36mm
B19
Put in plugs 1" 3/16-12UN, PF1/2, and PF1/4

into the removed ports.
Fig. 18-2 Removing swing unit
I32
(2) Loosen one nut (B20) M10 from upper side of

upper frame and remove drain hose clip (B19)
for reduction unit.
: 17mm
(3) Removing the swing motor unit
1) Remove twelve capscrews (B1) M2055.
: 30mm
2) Fit an eye bolt to the M port, place a wire
sling on it and remove the swing motor unit.
Weight of swing motor unit ;
Approx. 235kg (520 lbs) (include reduction unit)
18.3 PREPARATION FOR INSTALL
(1) Clean mating surfaces of swing motor unit
and upper frame.
Tools : spatula, wash oil
(2) Apply Locktite #515 on entire mounting
surface of swing motor unit.
18.4 INSTALLATION
Install the swing motor unit in the reverse order
of disassembly, confirming the orientation of the
swing motor unit..
1) Tighten capscrews (B1).
: 30mm
Apply Loctite #262
Coat all the mounting surface

of the swing motor with
Locktite #515 or equivalent.
2) Fill inside from motor drain port to casing

with hydraulic oil before piping for drain.
Swing motor unit mount
18.5 PREPARATION FOR DRIVE

(1) Before starting operation, check that gear oil
#90 (API grade GL-4) level of swing reduction
is sufficient.
Amount of charge : 7.5 (2gal)
Apply Loctite #262 or equivalent.

Tightening torque 55kgfym (400 lbfyft)
(2) When starting operation, operate motor in

low idling and at low speed for several
minutes, and check it for possible oil leakage
and noise.
Fig. 18-3 Installing swing motor unit
I33
20. SWIVEL JOINT

20.1 PREPARATION FOR REMOVE
1) Remove boom piping hose
20.2 REMOVAL
(1) Remove travel motor hose and tube
[Refer to Travel section under HYDRAULIC
SYSTEM YN22 (8)]
1) Remove tube (A5), (A6). (E port : PF1/2)
: 32mm
Tightening torque :
2) Remove tubes (A1), (A2). (C, D port : PF1)
: 41mm
Tightening torque :
3) Remove tubes (A3), (A4). (A, B port : PF1)
: 41mm
Tightening torque :
4) Remove two hoses (A7). (F port : PF1/4)
: 19mm
A2
A4
SWIVEL JOINT
B2
A7
A7
A3
A1
A6
A5
Fig. 20-1 Removing piping (lower side)
I34
(2) Disconnecting the hoses on the top part of

swivel joint
[Refer to Swivel Joint under, HYDRAULIC
SYSTEM 22 (3), (4).]
1) Remove drain hose (5). (E port : PF1/2)
: 27mm
2) Remove hoses (A9), (A12).
(C, D port : 1-3/16-12UN)
: 36mm
Tightening torque :
3) Remove hoses (A7), (A22).
(A, B port : 1-3/16-12UN)
: 36mm
Tightening torque :
4) Remove hose (15).
(1, 2-speed select port : PF1/4)
: 19mm
A7
A9
A22
A12
15
Fig. 19-2 Disconnecting the hoses

on the top part of swivel joint
(3) Remove whirl-stop of swivel joint.

1) Loosen the nut (C5) M16.
2) Remove a capscrew (C3)M16110.
: 24mm
C3 T=16kgfym
C5
(120 lbfyft)
Fig. 19-3 Removing whirl-stop nut & the capscrew
(4) Remove joint for piping

(Refer to Fig.20-1, 20-2)
1) Remove two connectors (B2). (F port)
2) Remove elbow (4) for travel 2-speed change
over. (PF1/4)
: 19mm
T=0.69kgfym (5 lbfyft) B9
T=1.5kgfym (11 lbfyft) B8
(5) Remove seal (B4)

1) Remove six capscrews (B8) M1020.
: 17mm
2) Remove clip (B9).
3) Remove seal (B4).
PLATE
Before mounting the seal B4

(B4), apply adhesive to
the adhering surface of
S/J and the upper frame.
Fig. 19-4 Removing seal (B4)

I35
(6) Remove capscrew for installation

Attach eye bolt, lift it up temporarily, and
remove three capscrews (2) M1225.
: 19mm
(See YB11 Tools No.610)
EYE BOLT
LOWER FRAME
2
CAPSCREW
M1225
Loctite #262
SWIVEL JOINT
Fig. 19-5 Removing capscrew for installation
(7) Slinging the swivel joint

Weight : Approx.26kg (57 lbs)
19.3 INSTALLATION
removing.
Piping tightening torque
Size
Tool Tightening torque kgfym(lbfyft)

HEX O ring type joint Hydraulic hose
PF1/4
19
3.7(27)
3.0(22)
PF3/8
22
7.5(54)
5.0(36)
PF1/2
27
11.0(80)
8.0(58)
PF3/4
36
16.5(120)
12.0(87)
PF1
41
26.0(180)
14.0(100)
1-3/16-12UN
36
18.0(130)
(2) Check for oil leakage and the hydraulic oil

level.
(3) Check for operating.
I36
20. UPPER FRAME

(1) Remove attachment
(Refer to Chapter 32 : ATTACHMENT)
WIRE ROPE
162.5m
(0.630) (8ft 2in)
(2) Remove cab (Refer to 1. CAB.)

CHAIN HOISTS
(3) Remove guard (Refer to 4. GUARD)

(Refer to 11. COUNTERWEIGHT)
(5) Remove swivel joint
(Perform the steps (1) thru (7) of 20. SWIVEL
JOINT)
20.2 REMOVAL
(1) Lifting up upper frame temporarily
Install two upper swing body lifting jigs
(Refer to 11 Tool two in the holes into which
the counterweight is placed. Mount two chain
hoists to the boom foot and lift the upper
frame at four points.
Wire rope ; 16 (0.630)2.5m(8ft 2in), 2pcs.
16 (0.630)1.5m(4ft 11in), 2pcs.
Chain hoists ; For 1,000kg (2,200 lbs) 2pcs.
LIFTING JIG No.13 FOR

UPPER FRAME
Fig. 20-1 Temporarily lift upper frame
MATCH
MARK
(2) Marking match marks on swing bearing

Mark match marks on upper frame and
swing bearing.
Fig. 20-2
(3) Removing upper frame attaching bolts

Remove thirty capscrews M20105 and three
reamer bolts used to install swing bearing
and upper frame.
: 30mm
Matching mark on swing bearing

and upper frame
(4) Slinging upper frame

Sling according to Fig.20-1, and remove
upper frame and put it on a stand.
Weight : Approx. 5,100kg (11,200lbs)
Fig. 20-3 Removing upper frame attaching bolts

I37
20.3 INSTALLATION
21.3
removing.
Apply Locktite #515 to the race surface over the whole

circumference (hatched) on the inside of capscrew.
(2) Cleaning mating surfaces of upper frame and

swing bearing.
(3) Apply Locktite #515 to the inside of the
capscrews on the contact surface.
Apply Locktite #262

equivalent.
(4) Slinging upper frame

Match marks and install it with three reamer
bolts (14) temporarily.
13,14
Fig. 20-4
21-4 Bearing mount
Confirm the reamer bolt positions referring to

Fig. 20-5.
21-5.
OUTER (S) ZONE POSITION
: 30mm, Tightening torque :

Tightening40kgf
torque
: 40kgfylbs)
ym (290ft
ym (290 lbfyft)
Apply Locktite
Apply#262
Locktite #262
(5) Install swing bearing
Install thirty capscrews (13) M20105.
: 30mm,
30mm Tightening torque :
ym: (290ft
Tightening40kgf
torque
40kgfyylbs)
m (290 lbfyft))
Apply Locktite
Apply#262
Locktite #262
K
Fig. 20-5
21-5 Reamer bolt position (K)
( )
Apply Locktite on section specified
by slanting lines
I38
Table 1-1
TIGHTENING
TORQUE
kgfym (lbfyft)
REGULATOR
1.1 HYDRAULIC PUMP

1.1.1 STRUCTURAL EXPLODED VIEW
(1) Main pump
531,548
535
789
406
534
792
702
532
732
261
774
710
ENGINE
SIDE
886
808
953
724
728
467
113
127
123
824
490
406
251
401
490
141 CYLINDER BLOCK
151 PISTON
18
152 SHOE
153 PLATE
(RETAINER PLATE)
18
725
466
TIGHTENING
TORQUE
kgfym (lbfyft)
05
211
Refer to Fig.1-34
212
GEAR PUMP
(FOR PILOT)
13 (94)
No.
NAME
QTY
2
18
24 (170)
312 VALVE BLOCK

313 VALVE PLATE
(for CW rotation)
314 VALVE PLATE
(for CCW rotation)
401 SOCKET BOLT ; M16_175
1.2 (8.7)
406 SOCKET BOLT : M6_16
3.7 (27)
466 VP PLUG ; PF1/4
11 (80)
467 VP PLUG ; PF1/2
711
886
157
Refer to Fig.1-2
127 BEARING SPACER
271 PUMP CASING
GEAR PUMP
(FOR DOZER)
141
214
314
151,152
124 NEEDLE BEARING
262 SEAL COVER (R)

886
885
124
153
123 ROLLER BEARING
214 TILTING BUSHING

251 SWASH PLATE SUPPORT
(F)
252 SWASH PLATE SUPPORT
(R)
261 SEAL COVER (F)
885
156
116 1st GEAR
111
719
116
312
717
113 SHAFT (R)
212 SWASH PLATE
710
262
211 SHOE PLATE
901
271
QTY
111 SHAFT (F)
157 CYLINDER SPRING
313
954
127
NAME
719
124
808
No.
1
1
1
1
1
8
725 O RING : 1B_P11
468 VP PLUG ; PF1/2
728 O RING : 1B_P18
0.9 (6.5)
490 PLUG ; NPTF1/16
15
732 O RING : 1B_P16
24 (170)
531 TILT PIN; M20_1.5
774 OIL SEAL
24 (170)
532 SERVO PISTON ; M20_1.5
789 BACKUP RING
534 STOPPER ( L)
792 BACKUP RING
535 STOPPER (S)
808 HEX. NUT ; M16
548 FEED BACK PIN
824 SNAP RING
702 O RING ; 1B_G30
885 VALVE PLATE PIN
886 SPRING PIN
711 O RING : 1B_G95
901 EYE BOLT ; M10
717 O RING ; 1B_G120
953 SET SCREW
719 O RING ; 1B_G115
954 SET SCREW
724 O RING ; 1B P8
18
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Fig. 1-1 Structural exploded view of main pump
II-1-1
1. HYDRAULIC PUMP REGULATOR
12
(2) Gear pump (for pilot)
700
354
433
351
434
728
435
312
311
732
710
361
850
307
353
310
308
309
434
467
466 355
725
Fig. 1-2 Structural of gear pump (for pilot)
Table 1-2
TIGHTENING
TORQUE
No.
kgfym (lbfyft)
3 (22)
NAME
QTY
307
308
309
310
311
POPPET
SEAT
SPRING SEAT
SPRING
ADJUSTING SCREW
1
1
1
1
1
312
351
353
354
355
LOCK NUT ; M14

GEAR CASE
DRIVE GEAR
DRIVEN GEAR
FILTER
361 FRONT CASE
TIGHTENING
TORQUE
No.
kgfym (lbfyft)
1.7 (12)
1.7 (12)
3.4 (25)
1.6 (12)
5.4 (39)
NAME
QTY
433
434
435
466
467
FLANGE SOCKET ; M840

VP PLUG ; PF1/4
ADAPTER ; PF1/2-PF3/8
2
2
2
1
1
1
1
1
1
1
700
710
725
728
732
RING
O RING ; 1B
O RING ; 1B
O RING ; 1B
O RING ; 1B
1
1
1
1
1
850 SNAP RING

II13
G80
P11
P18
P16
1.1.2 DISASSEMBLY AND ASSEMBLY OF MAIN

PUMP
(1) Tools
The following list shows the tools required for
remove and install.
Table 1-3
Tool name
Allen wrench
Dimension
Opposing flats
Eye wrench
Socket wrench
Wrench with double Opposing flats

heads (single head)
19, 27mm
Adjust wrench
Medium size 1pc.
Screw driver
Flat-bladed screw driver 1pc.
Hammer
Plastic hammer 1pc.
Plier
For snap ring
Steel bar
(2) Disassembling procedure
1) Selecting a place for disassembly.
4,5,6,8,14mm
Torque wrench
Steel bar for key

Approx.108200mm
(0.400.310.79)
One that may be fastened to
specified torque
z Choose a clean place.

z Spread rubber sheet or cloth on work
bench to protect parts from
damaging.
2) Cleaning
Remove dust and rust, etc. on pump surface
with wash oil.
3) Drain oil
Drain out the oil in the pump casing by
removing drain port plug (467), (468).
: 27mm
z Drain out oil from the plug of the
front pump and the rear pump.
REGULATOR
4) Removing regulator and PTO gear casing

Remove the socket bolts [415 (See Fig.1-20),
435 (See Fig.1-34.)]. Then remove the
regulator and the PTO gear casing.
: 6mm, 8mm
z Regarding the disassembly of the
regulator, refer to article of
Regulator.
z Regarding the disassembly of the
PTO gear casing, refer to article of
PTO Gear Casing.
Fig. 1-3
14
Removing regulator
5) Remove socket bolt (401)

Loosen socket bolts (401) that fasten swash
plate support (251), pump casing (271) and
valve block (312).
: 14mm
6) Disassembling the pump casing and the valve

block
Place the pump level on a work bench with
its mounting surface of the regulator facing
down. Then separate pump casing (271) and
valve block (312).
312
271
z When facing the mounting surface of

the regulator down, place a rubber
board on a work bench so as not to
score the mounting surface.
z When the pump casing has been
separated from the valve block, draw
out the 1st gear at the same time.
Fig. 1-4 Disassembling the pump casing (271)
and the valve block (312)
7) Drawing out the cylinder assy
Draw out cylinder (141) out of pump casing
(271) in parallel to shaft (111). At the same
time draw out piston (151), plate (153),
spherical bushing (156) and cylinder spring
(157).
271
141(151)
153
156
z Use care so as not to score the

sliding surface of the cylinder,
spherical bushing, shoe and the
swash plate .
Fig. 1-5
15
Drawing out the cylinder assy
406
8) Remove seal cover (F)

Remove socket bolt (406) and seal cover F
(261).
: 5mm
261
z The seal cover (F) may be drawn out

with ease if it is taken out by
tightening bolts in the tapped holes
(M6 tap) of the seal cover (F).
z An oil seal is fitted to seal cover (F).
Therefore, use care so as not to score
the oil seal.
Fig. 1-6
Removing seal cover F (261)

271
9) Remove seal cover (R)

Remove socket bolt (406) and seal cover R
(262).
: 5mm
251
10) Separating the swash plate support and the

pump casing
Knock lightly on the mounting flange of
swash plate support (251) from the pump
casing (271) side and separate the swash
plate support from the pump casing.
Fig. 1-7 Separating the swash plate (251)
support and the pump casing (271)
11) Remove shoe and swash plate
Draw out shoe plate (211) and swash plate
(212) from pump casing (271).
271
212 (211)
Fig. 1-8 Removing shoe (211)

and swash plate (212)
12) Drawing out the shaft
Tap lightly the shaft end (111, 113) by means
of a plastic hammer and draw out the shaft
from the swash plate support.
251
113
Fig. 1-9
16
Drawing out the shaft (111), (113)
13) Remove valve plate

Remove valve plate (313, 314) from valve
block (312).
z The valve plate may come off during
the operation under 6).
312
314
(313:OPPOSITE SIDE)
Fig. 1-10
14) Remove other parts
If necessary, remove stopper (L) (534),
stopper (S) (535), servo piston (532) and
tilting pin (531) from pump casing (271), and
remove needle bearing (124) from valve block
(312).
Removing valve plates (313), (314)

531
808
z When removing the tilting pin, use

care so as not to score the head of
the tilting pin, using a jig.
z It is hard to separate the tilting pin
from the servo piston in some cases
as Locktite is coated on the mating
part between them. Use care so as
not to score the servo piston by
applying unreasonable force.
z Do not draw out needle bearings
except when their service life has
ended.
z Do not loosen hex nuts (808) of valve
block (312) and swash plate support
(251). A set flow rate changes.
534
535
532
808
271
312
251
Fig. 1-11
17
Removing other parts
124
(3) Installing procedure

1) Precautions to be exercised in installation
Assembly is a reverse order of disassembly,
but notice the following.
1. Repair scored parts at disassembly. Get
replacements ready beforehand.
2. Wash parts sufficiently in cleaning oil and
dry them with jet air.
3. Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
4. In principle, replace sealing parts such as O
rings and oil seals.
5. Tighten socket bolts and plugs to specified
torques in this manual, using a torque
wrench.
6. Do not mix up front pump parts with rear
pump parts.
2) Installing swash plate support
Attach swash plate support (251) to pump
casing (271) by tapping the swash plate
support lightly with a plastic hammer.
271
z When the servo piston, the tilting

pin, the stopper (L) and the stopper
(S) have been removed, install them
to the pump casing beforehand.
z When tightening servo piston and
tilting pin, use a jig so as not to
damage the head of the tilting pin
and feedback pin.
Coat the screwed part with Locktite
#262.
251
Fig. 1-12
3) Installing swash plate
Place the pump casing with its mounting
surface of the regulator facing down, insert
the tilting bushing of the swash plate into
tilting pin (531), and fit swash plate (212) to
swash plate support (251) properly.
Installing swash plate support (251)

251
271(531)
z Confirm by the fingers of your both

hands that swash plate moves
smoothly.
z The shaft be installed easily if grease
is applied to the sliding parts of
swash plate and swash plate
support.
212
Fig. 1-13
18
Installing swash plate (212)
4) Installing shaft
Install shaft (111) fitted with bearing (123),
bearing spacer (127) and snap ring (824), to
swash plate support (251).
251
z Do not knock on the shaft with a

hammer or something.
z Fix the bearing by lightly tapping
the outer race of it by means of a
plastic hammer and set it exactly to
the end by using a steel rod and
others.
123
127,824
111
Fig. 1-14 Installing shaft (111)
5) Installing seal cover

Assemble seal cover (F) (261) to pump casing
(271) and fix it with socket bolts (406).
: 5mm,
271
261
406
z Coat the oil seal in seal cover (F)

with a thin film of grease.
z Handle the oil seal with sufficient
care so it is not scored.
z Fit seal cover (R) (262) the same way
as above.
Fig. 1-15 Installing seal cover F (261)

6) Inserting piston cylinder sub
Assemble the piston cylinder sub [cylinder
block (141), piston (151), shoe (152), plate
(153), spherical bushing (156) and cylinder
spring (157)].
Align the spherical bushing with the cylinder
spline and insert them into the pump casing.
141(151,152)
156
153
Fig. 1-16 Inserting piston cylinder sub
II19
7) Installing valve plate

Install valve plate (313), (314) to valve block
(312) by aligning pin.
z Do not mistake the suction and
delivery sides of the valve plate.
312
8) Installing valve block

Install valve block (312) to pump casing (271)
and fasten them together with socket bolts
(401).
: 14mm,
314
(313:OPPOSITE SIDE)
Fig. 1-17
z Work will be promoted if assembly is

started from the rear pump.
z Exercise care so as not to mistake
the direction of the valve block (312).
(Install it so the regulator comes up
as seen from the front side and the
suction flange comes on the right.)
z Insert the 1st gear into the valve
block beforehand and connect it with
the spline of the shaft.
Installing valve plates (313), (314)
271
401
Fig. 1-18
9) Installing regulator and PTO gear casing
Pinch feedback pin of tilting pin in feedback
lever of the regulator and PTO gear casing,
install the regulator and fasten socket bolt.
Refer to [415 (See Fig.1-20.), 435[See
Fig.1-34.)].
Installing valve block (312)
REGULATOR
Socket bolt (415) ........... For regulator

: 6mm,
Socket bolt (435) ........... For PTO gear casing
: 8mm,
Fig. 1-19
z Do not mistake the front regulator
for the rear regulator.
10) Installing drain port plug
The work is complete when drain port VP
plugs (467), (468) have been set.
: 27mm,
110
Installing regulator and PTO gear

casing
1.1.3 MAINTENANCE STANDARDS

(1) Replacement standards for abrasive parts
Replace or readjust parts that exceed the
following standards of wear.
However, always replace such parts that

show excessive damage on appearance.
Unit: mm (in)
Standard
dimension
Recommended
value for
replacement
Clearance between piston and

cylinder bore (Dd)
0.028
(0.0011)
0.056
(0.0022)
Replace piston or cylinder.
Gap between piston and caulked part

of shoe ()
00.1
(0.004)
0.3
(0.012)
Replace piston shoe assy.
Thickness of shoe (t)
3.9
(0.154)
3.7
(0.146)
Replace piston shoe assy.
Free height of cylinder spring (L)
31.3
(1.23)
30.2
(1.19)
Replace cylinder spring .
Combined height of retainer plate and

spherical bushing (Hh)
10.5
(0.413)
9.8
(0.386)
Replace a set of spherical

bushing or retainer plate.
Part name and inspection item
Remedy

cylinder bore: Dd
Combination of retainer plate and spherical

bushing Height=H-h
Gap between piston and shoe :

thickness of shoe: t
Free height of cylinder spring: L
(2) Repair standards for cylinder, valve plate and swash plate (shoe plate face)
Valve plate (sliding section)
Swash plate (shoe plate face)
Cylinder (sliding section)
Roughness of each surface
Surface roughness requiring correction

Standard surface roughness
(correction value)
111
3Z
Less than 0.4Z (lapping)
1.1.4 TROUBLESHOOTING
(1) Locating causes of troubles
The pump is usually fitted with a regulator,
auxiliary valves and auxiliary pumps, and
this makes fault location extremely difficult.
However, faults would be found out easily if
the following check items were attended to.
1) Inspecting the filter and drain oil
Inspect the filter element to check for
abnormal contaminations. Some metallic
particles will be deposited on it as the shoe
and the cylinder wear off. In case metallic
particles are found in large quantity, the
elements may be damaged. In that case check
the drain oil in the pump casing as well.
2) Checking for abnormal vibration and sound
Check that the pump does not vibrate and
make an abnormal sound.
Check that the hunting of the regulator and
the attached valves relief valve are of regular
frequency. In case vibration and sound are
abnormal, the pump may be making a
cavitation or internally broken.
3) When two pumps are used

In case two single pumps or motors are used
or when a double pump is used. change pump
pipelines. This will make clear that the
pumps are faulty or the circuit after the
pumps is faulty.
4) Pressure measurements
If the problem is related to control functions,
avoid disassembling the pumps carelessly,
but look for causes by measuring pressures.
(2) Troubleshooting
1) Overloading to engine
Cause
1. Revolution and pressure are
higher than set values.
2. Regulator torque is set higher
than normal.
3. Pumps internal parts are
seized or broken.
Remedy
1) Set pressure to specified
value.
2) Readjust regulator.
3) Replace damaged parts.
4. Regulator is piped incorrectly. 4) Pipe regulator correctly.
112
Remarks
2) Refer to Regulator Manual.

3) Check filter and drain oil to see if
abnormal wear particles are
present.
(2) Pumps oil flow rate is extremely low and delivery pressure is not available.
Cause
1. Regulator is out of order
Remedy
1) Repair regulator.
Remark
1) Refer to Regulator Manual.
2. Pumps internal parts are

2) Replace damaged parts. 2) Check filter and drain oil.
seized or broken.
3. Attached pump is out of order. 3) Replace damaged parts. 3) Remove attached pump and check
shaft joint.
4. Attached valve is out of order. 4) Check attached valve.
4) Refer to Manual for Attached
Particularly poppet,
Valve.
seat and spring.
5. Regulator is piped incorrectly. 5) Pipe correctly.
(3) Abnormal Sound and Vibration

Cause
Remedy
Remark
1. Cavitation
1) Prevent cavitation.
1-1) The boost pressure is low.
Check that hydraulic oil 1-2) The attached pump is in trouble.
is not clouded.
1-3) The suction pipe is inhaling air.
1-4) The suction resistance is high.
2. Caulked part of shoe is broken. 2) Replace piston shoe and
shoe plate.
3. Cylinder is cracked
3) Replace cylinder.
4. Pump is installed improperly.
4) Correct installation.
5. Regulator is hunting.
5) Repair regulator,
5) See Regulator Manual.
6. Relief valve in attached valve

is hunting.
6) Repair attached valve.
6) See the Manual for Attached

Valve.
113
1.2 REGULATOR
656 402
733
627
646
624
496
601
801
924
415
543
545
541
079
756
755
614
733
887
658
325
724
418
708
652
496
897
Table
651
643
611
631
TIGHTENING
TORQUE
No.
kgfym (lbfyft)
755
466
TIGHTENING
TORQUE
No.
kgfym (lbfyft)
NAME
Q
TY
643 PISTON
646 SPRING
1.2 (8.7)
651 SLEEVE
1.2 (8.7)
652 SPOOL
3.0 (22)
656 COVER
0.7 (5.1)
658 PLUG ; NPTF1/16
1.6 (12)
466 VP PLUG ; PF1/4
708 O RING ; 1B
G75
0.9 (6.5)
496 PLUG
724 O RING ; 1B
P8
541 SEAT
731 O RING ; 1B
P25
543 STOPPER
733 O RING ; 1B
P18
545 BALL
755 O RING ; 1B
P11
601 CASING
756 O RING ; 1B
P12.5
611 FEEDBACK LEVER
801 HEX. NUT ; M8
614 FULCRUM PLUG ; PF1/4
887 PIN
624 SPRING SEAT
897 PIN
627 PLUNGER
924 SET SCREW
631 SLEEVE
3.7 (27)
Fig. 1-20
Q
TY
PROPORTIONAL
079 SOLENOID
REDUCING VALVE
325 VALVE CASING
731
407
NAME
1-4
Structural exploded view of regulator
0.9 (6.5)
1.6 (12)
114
1.2.2 DISASSEMBLY AND ASSEMBLY

(1) Tools
The right list shows the tools required for
remove and install.
Table 1-5
Tool name
Dimension
Allen wrench

Opposing flats
Eye wrench
Socket wrench

heads (single head)

damaging.
2) Cleaning
Remove dust and rust, etc. on regulator
surface with wash oil.
4,5,6,8mm
19mm
Adjust wrench
Medium size 1pc.
Screw driver
Flat-bladed screw driver 1pc.

Plunger (627),
for drawing out (M4)
One that may be fastened to
specified torque
Socket bolt
Torque wrench
3) Remove regulator
Remove socket bolts (415) and separate the
regulator from the pump body.
: 6mm
REGULATOR
z Exercise care so as not to lose O

rings and check valve sub (541),
(543), and (545).
Fig. 1-21
Removing regulator
4) Remove valve casing

Remove socket bolts (407) and remove valve
casing (325) with solenoid proportional
reducing valve (079).
: 5mm
325 (079)
407
Fig. 1-22
115
Removing valve casing (325)
5) Remove cover
Remove socket bolt (402) and cover (656).
: 5mm
l The cover is assembled with set
screw (924) and hex nut (801), but do
not loosen them. If they are
loosened, the pressure settings
change.
801
402 924 656

Fig. 1-23 Removing cover (656)
6) Remove sleeve and pilot piston
Draw out sleeve (631) and pilot piston (643)
from the regulator body.
631(643)
Fig. 1-24 Removing sleeve (631)
and pilot piston (643)
7) Remove feedback lever
Remove fulcrum plug (614) and feedback
lever (611).
: 19mm
611
8) Drawing out the spool and the sleeve

Draw out spool (652) and sleeve (651) from
the sleeve hole of the regulator casing.
HOLE FOR FULCRUM PLUG (614)
Fig. 1-25
9) Remove plunger, pilot spring and spring seat
Draw out plunger (627). Then take out pilot
spring (646) and spring (624).
Removing feedback lever (611)
627(624,646)
l The plunger comes off easily if an

M4 bolt is used.
Fig. 1-26 Removing plunger (627)

1 16
10) Drawing out the check valve

The disassembly is complete when the check
valve [seat (541), ball (545), and stopper
(543)] have been drawn out.
541
543 (545)
z The check valves are placed on two
places; the mating surface of the
pump casing and on the matching
surface of the valve casing.
Fig. 1-27
601
Drawing out the check valve.

1. Do not fail to correct parts damaged during
disassembly and get replacement parts ready
beforehand.
2. Entry of foreign matter causes faulty
functions; clean parts thoroughly, dry them
with jet air and work in a clean place.
3. Tighten bolts and plugs to specified torques.
4. Do not fail to coat the sliding parts with clean
hydraulic oil, before proceeding to assembly.
5. In principle, replace seals such as O rings
with new ones.
541
1) Placing the check valve

Fit the check valve to casing (601).
z Assemble the check valve into the
matching surface of the pump casing
and the matching surface of the
valve casing.
543 (545)
601
Fig. 1-28
2) Fitting the sleeve and the spool
Place sleeve (651) and spool (652) into the
sleeve hole of casing (601).
Placing the check valve.
601
z Make sure that the spool and the

sleeve slide smoothly in the casing
without interference.
z Beware of the direction of the spool.
651(652)
Fig. 1-29 Fitting the sleeve (651)
and the spool (652).
117
611(897)
3) Installing feedback lever

Insert pin (897) of feedback lever (611) into
the pin hole of the sleeve and fix the feedback
lever with fulcrum plug (614).
: 19mm,
z Operate the feedback lever and
make sure that it does not have
much looseness and that it operates
without catching.
614
Fig. 1-30
Installing feedback lever (611)

646(627)
4) Installing spring seat, pilot spring and

plunger
Place spring seat (624), pilot spring (646) and
plunger (627) into the hole in the sleeve.
Fig. 1-31 Installing spring seat (624),

pilot spring (646) and plunger (627)
5) Installing cover
Attach cover (656) to casing (601) and fasten
them together with socket bolts (402).
: 5mm,
z The cover is fitted with set screw
(924) and hex nut (801).
601
656
Fig. 1-32
402
Installing cover (656)
6) Assembling the sleeve and the pilot piston

Assemble sleeve (631) and pilot piston (643)
into casing (601).
7) Installing valve casing
Attach valve casing (325) fitted with solenoid
proportional reducing valve (079) to casing
(601) and fasten them together with socket
bolts (407).
: 5mm,
631
643
Fig. 1-33 Assembling the sleeve (631)
and the pilot piston (643).
This completes assembly.
118
1.3 PTO GEAR CASING

414
117
128
435
126
826
128
886
711
326
414
115
886
827
262
728
125
468
118
125
825
435
435
Fig. 1-34
Structural exploded view of PTO gear casing
Table 1-6
TIGHTENING
TORQUE
No.
kgfym (lbfyft)
3.4 (25)
NAME
Q
TY
TIGHTENING
TORQUE
No.
kgfym (lbfyft)
NAME
Q
TY
115 IDLE SHAFT
3.4 (25)
435 FLANGE SOCKET ; M1020
117 2nd GEAR
7.5 (54)
468 VP PLUG ; PF3/4
118 3rd GEAR
711 O RING ; 1B
G85
125 BALL BEARING
728 O RING ; 1B
P24
126 ROLLER BEARING
825 SNAP RING
128 BEARING SPACER
826 SNAP RING
262 COVER
827 SNAP RING
326 GEAR CASING
886 PIN
2
119

(1) Tools
The right list shows the tools required for
remove and install.
Table 1-7
Tool name
Dimension
Allen wrench

Opposing flats
Eye wrench
Socket wrench

heads (single head)

damaging.
8mm
27mm
For snap ring RR-20

For snap ring RR-72
Plier
2) Cleaning
Remove dust and rust, etc. on pump surface
with wash oil.
3) Drain oil
Drain out the oil in the pump casing by
removing drain port plug (467), (468).
: 27mm
FLANGE SOCKET (M10)

TIGHTENING TORQUE : 3.4kgfym (25ftylbs)
z Drain out the oil from the plugs of

the front pump and the rear pump.
4) Remove gear pump and cover
Remove the flange socket and the socket
bolts. Then remove the gear pump and the
cover.
: 8mm
GEAR PUMP
(FOR DOZER)
COVER
PTO GEAR CASING
435
GEAR PUMP
Fig. 1-35
5) Remove PTO gear casing
Remove flange socket (435) and PTO gear
casing.
: 8mm
Removing gear pump
HOLE FOR FLANGE

SOCKET (435)
PTO
GEAR CASING
Fig. 1-36
120
Removing PTO gear casing
6) Removing the 2nd gear, the roller bearing

and the bearing spacer
Remove snap ring (827) and idle shaft (115).
Then draw out 2nd gear (117), roller bearing
(126) and bearing spacer (128).
HOLE FOR
IDLE SHAFT (115)
117(126,128)
z Roller bearing (126) can not be

separated from 2nd gear (117).
Fig. 1-37
Removing 2nd gear (117)
7) Removing the 3rd gear and the ball bearing

Remove snap ring (825) and draw out 3rd
gear (118) and ball bearing (125).
z Ball bearing (125) can not
separated from 3rd gear (118).
125
be
118
Fig. 1-38 Removing 3rd gear (118)

and ball bearing (125)
1. Repair scored parts at disassembly. Get
replacements ready beforehand.
2. Wash parts sufficiently in cleaning oil and
3. Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
4. In principle. replace sealing parts such as O
rings and oil seals.
5. Tighten socket bolts and plugs to specified
torques in Service Standard, using a torque
wrench.
6. Do not mix up front pump parts with rear
pump parts.
1.3.3 MAINTENANCE STANDARDS

In case a pitching (1 pit is more than 1mm
(0.039in), while the area ratio is more than 5%.) is
seen on the gear tooth surface of 2nd gear (117)
and 3rd gear (118), replace the gears. Replace the
gears also in case they show excessive damage.
121
122
2.
CONTROL VALVE
2.1 GENERAL PRECAUTIONS

1) As all the hydraulic components are precisely
machined, it is essential to carry out
disassembly and reassembly in an especially
clean location.
2) When handling the control valve, take special
care to prevent the entry of foreign matter,
such as dust or sand.
3) Cap each port of the control valve before
removing the valve from the machine. Before
disassembly, confirm that each cap is in place
and then clean the exterior of the assembly.
Use an appropriate workbench. Lay a clean
sheet of paper, rubber mat, or the like over
the workbench.
4) When carrying or moving the control valve,
hold the body, and never put pressure on a
lever, an exposed spool, or the end cover.
Handle the valve with care.
5) Tests(for
relief
characteristics,
leaks,
overload valve setting, flow resistance, etc.)
that are desired after disassembly and
reassembly
require
hydraulic
testing
apparatus.
For this reason, do not disassemble hydraulic
units that you are capable of disassembling
but cannot test or adjust.
Prepare beforehand washing fluid, hydraulic
oil, grease, etc. .
2.3 DISASSEMBLY
Regarding the construction of the control valve,
refer to 4.2 Construction, 4. Control Valve under
YB24 Components System.
The figures in parentheses after part names in
the
contents
represent
those
in
the
above-mentioned Fig.4 structural exploded view
on YB24, 4 Control valve.
Place the control valve on the workbench with the
ports facing upward.
Disassemble the valve in a clean
location, and be careful not to damage
flange surfaces or plate mounting
surfaces.
Fig. 2-1 Preparation for disassembly

(valve upper side)
2.2 TOOLS
Prepare the following tools before disassembling
the control valve.
No.
Name
Table
2-1
QTY
Remarks
a Vise
1
Box
end
wrench
1
of
each
8,22,24,27,30,32mm
b
size
1 of each 4,5,6,8,10,12,14,22mm
c Allen wrench
size
e Locktite #262
1
f Spatula
g Tweezers
h Adjust wrench
Fig. 2-2 Preparation for disassembly

(valve lower side)
21
214
(1) Remove option valve block (Section H-H)

1) Loosen the socket bolts (272) and remove the
plate (214) and the option valve (213).
: 10mm
213(272)
Regarding the disassembly of the

optional valve block, refer to the
Disassembling option valve under (20).
Fig. 2-3 Removing option valve

(2) Remove plate
plate (214).
: 10mm
(3) Disassembling arm recirculation spool

(Section G-G)
spring cover (204) and the O ring (262) for
arm recirculation.
: 6mm
271
214
Fig. 2-4 Removing plate (214)

273
204(262)
Fig. 2-5 Removing arm recirculation

spool spring cover (204)
2) Draw out, from casing A (101), the assy of
arm recirculation spool (310), spring seat
(332), springs (325), (326), stopper (337) and
bolt (333).
310
When drawing out the spool assy, use

care so as not to score casing A (101).
Fig. 2-6 Drawing out arm recirculation spool

II22
3) Fix the arm recirculation spool assy with vise

via a protective plate (aluminum plate, etc.)
and remove bolt (333). Then separate spring
seat (332), springs (325), (326) and stopper
(337) from arm recirculation spool (310).
333
332
326(337)
325
310
Fig. 2-7 Disassembling arm recirculation

spool assy
273
204(262)
(4) Disassembling cut spool (Section G-G)

1) Loosen socket bolt (273) and separate spring
cover (204) and O ring (262) from the cut
spool.
: 6mm
Fig. 2-8
Removing cut spool spring cover (204)
2) Draw out the assy of cut spool (309), spring

seat (332), springs (325), (326), stopper (337)
and bolt (333) from casing A (101) or casing B
(102).
309
When drawing out the spool assy, take

care so as not to score casing A (101) or
casing B (102).
Fig. 2-9
3) Fix the cut spool assy with vise via a
protective plate (aluminum plate, etc.) and
remove bolt (333). Then separate spring seat
(332), springs (325), (326) and stopper (337)
from cut spool (309).
Drawing out cut spool assy
333
332
326(337)
325
309
Fig. 2-10
23
Disassembling cut spool assy
273
(5) Disassembling the arm spool (Section F-F)

1) Loosen socket bolts (273) and remove spring
cover (201) for arm and O ring (262).
: 6mm
201(262)
Fig. 2-11
Removing arm spool spring cover (201)
2) Draw out the assy of arm spool (302), spring

and bolt (333) from casing A (101).
302

Fig. 2-12
3) Fix the arm spool assy with vise via a
from arm spool (302).
: 6mm
Drawing out arm spool assy
333
332
324(337)
329
4) Do not disassemble the arm spool (302)

further unless there is any problem.
(See Fig. 4-5)
302
Take care so as not to distort arm spool

(302) by overtightening it in the vise.
Fig. 2-13
Disassembling arm spool assy

273
(6) Disassembling the boom spool (Section F-F)

cover (201) for boom and O ring (262).
: 6mm
Fig. 2-14
24
201(262)
Removing boom spool spring cover
301
2) Draw out the assy of boom spool (301), spring

and bolt (333) from casing B (102).
care so as not to score casing B (102).
Fig. 2-15
3) Fix the boom spool assy with vise via a
from boom spool (301).
Drawing out boom spool assy
333
332
324(337)
329
301
Fig. 2-16
4) Do not disassemble the boom spool (301)
further unless there is any problem.
(See Fig. 4-6)
Disassembling boom spool assy

301(352,353)
Take care so as not to distort boom

spool (301) by overtightening it in the
vise.
(7) Disassembling the boom conflux spool

(Section E-E)
cover (201) for boom conflux and O ring (262).
: 6mm
Fig. 2-17
Disassembling boom spool (301)

201(262)
273
Fig. 2-18 Removing boom conflux
spool spring cover (201)
25
2) Draw out the assy of boom conflux spool

(305), spring seat (332), springs (325), (326),
stopper (337) and bolt (333) from casing A
(101).
305

Fig. 2-19 Drawing out boom conflux spool assy

3) Fix the boom conflux spool with vise via a
from boom conflux spool (305).
333
332
326(337)
325
305
Fig. 2-20 Disassembling boom conflux spool assy

273
(8) Disassembling bucket spool (Section E-E)

1) Loosen socket bolts (273) and remove bucket
spring cover (201) and O ring (262).
: 6mm
201(262)
Fig. 2-21 Removing bucket spool spring cover

2) Draw out the assy of bucket spool (304),
spring seat (332), springs (328), (329), stopper
(337) and bolt (333) from casing B (102).
304

Fig. 2-22
2 6
Drawing out bucket spool assy
3) Fix the bucket spool assy with vise via a

from bucket spool (304).
333
332
328(337)
329
304
Fig. 2-23
Disassembling bucket spool assy
(9) Disassembling the swing spool (Section D-D)

cover (202) and O ring (262).
: 6mm
273
Fig. 2-24
202(262)
Removing swing spool spring cover
2) Draw out the assy of swing spool (303), spring

and bolt (333) from casing A (101).
303

care so as not to score casing A (101) or
casing B (102).
Fig. 2-25
3) Fix the swing spool assy with vise via a
from swing spool (303).
Drawing out swing spool assy
333
332
324(337)
329
303
Fig. 2-26
27
Disassembling swing spool assy
(10) Disassembling the travel spool (left travel

and right travel) (Section C-C, D-D)
travel.
: 6mm
273
201(262)
Fig. 2-27 Removing travel (right)

spool spring cover
2) Draw out the assy of travel spool (306),
spring seat (332), springs (325), (327), stopper
(338) and bolt (333) from casing A (101) or
casing B (102).
306

care so as not to score the casing A
(101) or the casing B (102).
Fig. 2-28
3) Fix the travel spool assy with vise via a
protective plate (aluminum plate, etc.).
Remove bolt (333) and separate spring seat
from travel spool (306).
Drawing out travel (right) spool assy
333
332
327(338)
325
306
Fig. 2-29
(11) Disassembling travel straight spool
(Section C-C)
travel straight.
: 6mm
Disassembling travel (right) spool

(306)
273 201(262)
Fig. 2-30 Removing travel straight
l
i
28
2) Draw out the assy of travel straight spool

(307), spring seat (332), springs (325), (326),
stopper (337) and bolt (333) from casing B
(102).
307

care so as not to score the casing B
(102).
Fig. 2-31 Drawing out travel straight spool assy

3) Fix the travel straight spool assy with vise
via a protective plate (aluminum plate, etc.).
Remove bolt (333) and separate spring seat
(332), springs (325), (326) or (322),(323) and
stopper (337) or (339) from travel spool (307).
333
332
326(337)
325
307
Fig. 2-32 Disassembling travel straight spool

assy
(12) Remove lock valve selector sub (Section F-F)
Loosen socket bolts (L171) and remove lock
valve selector (211).
: 5mm
L171
211
Do not disassemble the lock valve

selector sub assy.
Fig. 2-33 Removing lock valve selector sub assy

(13) Disassembling the arm conflux spool
(Section G-G)
cover (204) and O ring (262) for arm conflux.
: 6mm
273
204(262)
Fig. 2-34 Removing arm conflux

spool spring cover
II29
308
2) Draw out the assy of arm conflux spool (308),

spring seat (332), spring (325), (326), stopper
(337) and bolt (333) from casing B (102).
Fig. 2-35
Drawing out arm conflux spool assy
3) Fix the arm conflux spool assy (308) with vise

via a protective plate (aluminum plate, etc.)
and remove bolt (333). Then separate spring
seat (332), springs (325), (326) and stopper
(337) from arm conflux spool (308).
333
332
326(337)
325
308
Fig. 2-36
Disassembling arm conflux spool assy
(14) Removing spool cover

Loosen the socket bolts (273) for the travel,
arm, boom, bucket, swing, travel straight and
boom conflux sections. Then remove spool
cover (206) and O ring (265).
: 6mm
273
206(265)
Fig. 2-37
Removing spool covers (206)
(15) Removing relief valve

Remove the main relief valve (601) and over
load relief valve (602) from the casing.
Regarding the disassembly of the relief valve,
refer to the disassembling Main and Port
relief valve. Refer to (18) and (19).
: 30mm
Fig. 2-38
210
601
Removing main relief valve(601)
602
Fig. 2-39
Removing over load relief valve (602)

552
(16) Remove check valve (Section G-G)

1) Arm recirculation check valve (CAr)
Loosen plug (552) and remove poppet (512)
and spring (522).
Remove the load check valve the same way.
(CT2,CP2,LCs,CCb,LCa)
(CP1,LCc,LCb,CCa)

check valve plug (552)
512(522)

check valve poppet (512)
2) Check valve in the lock valve section.
(Arm ; CRa, Boom ; CRb) (Section F-F)
556
Loosen plug (556) and remove poppet (514)

and spring (524).
Exercise care so as not to mistake parts
as they all differ in kind from 1) above.
Fig. 2-42
211
Removing arm lock valve plug (556)
514
524
Fig. 2-43 Removing arm lock valve poppet (514)
3) Check valve in the travel straight section
(CT1)
Remove plug (552). Then remove poppets
(512) and spring (522).
: 10mm
552
CT1
522
512
SECTION H -H
Fig. 2-44 Removing check valve
in the travel straight section
4) Check valve in the main relief valve section
(CMR1,CMR2)
Remove plug (552) and remove poppet (513)
and spring (522).
: 10mm
513
522
CMR1
552
552
Those plugs that are not mentioned in

the foregoing disassembly procedure
are blind for extra holes and cast-on
holes; do not remove them unless
necessary.
CMR2
522
513
SECTION C-C
Fig. 2-45 Removing check valve
in the main relief valve section
(17) Disassembling casing

1) Loosen socket bolts (973), (974) and separate
casing A (101) and casing B (102).
: 12mm
973
Fig. 2-46 Disassembling casing

II212
(18) Disassembling main relief valve (See Fig.4-3.)

1) Remove plug (103) and seat (541) by pulling
them by hand as C ring (121) is fixed.
2) Draw out spring (521) and plunger (512) from
inside seat (541).
3) Remove locknut (671) and adjust screw (651).
Remove spring plate (612), spring (621) and
poppet (611).
4) Separate C ring (121), spacer (122), O ring
(561) and backup ring (562) from plug (103).
541
Filter (125) and filter stopper (124) are

assembled with plug (103) by means of
C ring (123).
Therefore, it can not be disassembled
any further.
Fig. 2-47
121
103
Disassembling main relief valve
(19) Disassembling port relief valve (See Fig.4-4.)

1) Loosen plug (102), remove springs (521),
(522) and seat (541) out of body (101) and
draw out piston (301) and plunger (511) out
of seat (541).
: 30mm
102
2) Separate locknut (671) and adjust screw (651)
from plug (102) and remove spring seat (612),
spring (621) and poppet (611).
Filter (125) and filter stopper (124) are
assembled with plug (103) by means of
snap ring (123).
Therefore, it can not be disassembled
any further.
101
Fig. 2-48
213
Disassembling over load relief valve
(20) Disassembling option valve (See Fig.4-7 on 24

H4-6 (6)).
1) Loosen the socket bolts (S271) and remove
the spring cover (S202) and the O ring (S261)
for option.
: 6mm
2) Draw out the assy of option spool (S301),
spring seat (S337), springs (S323), (S324),
stopper (S333) and bolt (S334) from casing
(S101).
care so as not to score the casing
(S101).
3) Fix the option spool assy with vise via a
protective plate (aluminum plate, etc.).
Remove bolt (S334) and separate spring seat
(S337), springs (S323), (S324) and stopper
(S333) from option spool (S301).
: 6mm
4) Loosen the socket bolts (S271) and remove
the spool cover (S204) and the O ring (S262)
for option.
: 6mm
5) Remove the over load relief valve (S603) from
the casing (S101).
Regarding the disassembly of the relief valve,
refer to the disassembling main and over load
relief valve. Refer to (18) and (19).
6) Loosen the plug (S551) and remove the
poppet (S512) and spring (S522).
: 12mm
7) Remove the plug (S552).
: 10mm
II214
2.4 INSPECTION AFTER DISASSEMBLY

Thoroughly clean all disassembled parts with
wash oil, and dry them with jet air. Place each
part on a clean sheet of paper or cloth for
inspection.
7) Remove any slight defects found during the

above inspection by lapping.
8) If any abnormal part is found, replace the
relief valve as an assy.
(1) Control valve

1) Inspect the entire surface of each part for
burrs, scratches, cuts, and other defects.
2) Confirm that the O ring groove surface of the
casing or the block is free from foreign
matter, dents or rust.
3) If the check valve seat of the casing or the
block has dents or damage on its surface,
smooth it by lapping.
2.5 REASSEMBLY
1) Here, only the reassembly procedures are
described. Regarding drawings, refer to the
disassembly procedures.
Take care not leave lapping compound

behind in the casing or block.
4) Confirm that O ring or the outer
circumference of the sliding part of a manual
spool is free from scratches, dents, and the
like. Remove any small defects with an oil
stone or lapping compound.
5) Manually confirm that all sliding and fitted
parts move smoothly. Confirm that all
grooves and passages are free from foreign
matter.
6) Replace any broken or deformed spring with
new one.
7) If a relief valve malfunctions, repair it by
following the relief valve disassembly and
reassembly procedures.
8) Replace all O ring with new ones.
(2) Relief valve
1) Confirm that the seating face of each poppet
and each seat edge is free from defects and is
a uniform contact surface.
2) Manually confirm that the main poppet slides
smoothly onto and off the seat.
3) Confirm that the outer circumference of the
main poppet and the inner circumference of
its seat are free from defects such as
scratches.
4) Confirm that each spring is free from
breakage, deformation, and excessive wear.
5) Confirm that the orifices of the main poppet
and its seat are not clogged.
6) Replace all O rings with new ones.
2) The figures in parentheses after part names

in the contents represent those in 4. Control
Valve under 24 Components System.
3) Precautions on reassembling O ring
1. Confirm that O rings are free from defects
caused by poor handling.
2. Apply thin coat of grease or hydraulic oil to O
rings and their mating parts.
3. Do not stretch O rings to the extent that they
become permanently set.
4. When installing O rings, do not roll them into
place. Twisted O rings do not easily untwist
by themselves after installation, and can
cause oil leaks.
5. Use a torque wrench to tighten each
attaching bolt. Tighten to the torque in
Maintenance Standards.
(1) Casing
1) Fix O rings (162,163) to casing B (102). Then
fasten socket bolts (973,974) against casing A
(101) to the specified torque.
Confirm that the mating surface is free
from foreign matter such as dust, and
that each O ring is securely installed in
its groove.
(2) Assembling check valve
1) Load check valve, conflux check valve, etc.
Fit poppet (512) and spring (522), put O ring
(562) in plug (552) and fasten it to the
specified torque. (10 places)
2) Lock valve (CRa, CRb)
Fix poppet (514) and spring (524), put O ring
specified torque. (2 places)
II215
Plugs (552) and (556) look similar; use

care of the parts combination and
assembling position.
3) Travel straight sections (CT1)
Fit poppets (512) and spring (522), put O ring
specified torque.
(5) Assembling travel straight spool

1) Put a mouthpiece (aluminum plate, etc.) in
the vise and hold the center of travel straight
spool (307) in it. Set spring seat (332), springs
(325), (326) or (322), (323) and stopper (337)
or (339) and tighten bolts (333) to the
specified torque.
z When tightening bolts (333), coat
them with Loctite #262.
z Be careful so as not to distort travel
straight
spool
(307)
by
over-tightening it in the vise.
4) Main relief valve sections (CMR1, CMR2)

Fit poppets (513) and spring (522), put O ring
specified torque.
(3) Installing relief valve
1) Tighten main relief valve (601) and over load
relief valves (602) to the specified torques in
correct positions.
Regarding the reassembly of the relief
valve, refer to the (15), (16) assembling
main and over load relief valve.
(4) Assembling arm conflux spool
1) Put a mouthpiece (aluminum plate, etc.) to a
vise. Hold the center of arm conflux spool
(308) in the vise, set spring seat (332),
springs (325), (326) and stopper (337) and
tighten bolts (333) to the specified torque.
z Before tightening bolts (333), coat
z Be careful so as not to distort arm
conflux spool (308) by overtightening
it in the vise.
2) Assemble the travel straight spool assy in 1)

into casing B (102).
When assembling the travel straight
spool assy into casings B (102), do it
slowly and carefully ; never force it in.
3) Fit O ring (262) to the spring side of the
travel straight spool assy. Then attach spring
cover (201) to the assy and tighten socket
bolts (273) to the specified torque.
(6) Assembling travel spool
the vise and hold the center of travel spool
(306) in it. Set spring seat (332), springs
(325), (327) and stopper (338) and tighten
z Be careful so as not to distort travel
spool (306) by overtightening it in
the vise.
2) Fix the arm conflux spool assy in 1) into

casing B (102).
Fix the arm conflux spool assy into
casing B (102) slowly and carefully and
never force it in.
2) Assemble the travel spool assy in 1) into

casing A (101), B (102).
3) Attach spring cover (204) with O ring (262) to

the spring side of the arm conflux spool assy.
Then fasten socket bolts (273) to the specified
torque.
When assembling the travel spool assy

into casings A (101), B (102), do it
travel spool assy. Then attach spring cover
(201) to the assy and tighten socket bolts
II216
(7) Assembling swing spool

1) Put a mouthpiece (aluminum plate, etc.) to
the vise and hold the center of swing spool
(303). Set spring seat (332), springs (324),
(329) and stopper (337) and tighten bolts
(9) Assembling boom conflux spool

1) Put a mouthpiece (aluminum plate, etc.) and
hold the center of boom conflux spool (305) in
the vise. Set spring seat (332), springs (325),

them with Locktite #262.
z Be careful so as not to distort swing
the vise.

z Use care so as not to distort boom
conflux spool (305) by overtightening
it in the vise.
2) Assemble the swing spool assy in 1) into

casing A (101).
2) Fix the boom conflux spool assy in 1) into

casing A (101).
When assembling the swing spool assy

into casing A (101), do it slowly and
carefully ; never force it in.
When assembling the boom conflux

spool assy into casing A (101), do it
3) Put O ring (262) to the spring side of the

swing spool assy and attach spring cover
(202) to the assy. Then tighten socket bolts
3) Fit O ring (262) to the spring side of the boom

conflux spool assy and attach spring cover
(8) Assembling bucket spool

1) Put a mouthpiece (aluminum plate, etc.) to
the vise and hold the center of bucket spool
(304) in it. Set spring seat (332), spring (328),
(10) Assembling boom spool

1) Assemble plunger 1 (315), plunger 2 (316),
plunger 3 (317), spring B1 (320), spring B2
(330) and spring B3 (340) in boom spool (301).
Then tighten plugs (352), (353) to the
specified torque.

z Be careful so as not to distort bucket
the vise.
Use care so parts are assembled in

correct positions and make sure that
each plunger slides lightly in boom
spool (301).
2) Assemble the bucket spool assy in 1) into

casing B (102).
When assembling the bucket spool assy
into casing B (102), do it carefully and
slowly ; never force it in.
2) Put a mouthpiece (aluminum plate, etc.) in a

vise and hold the center of boom spool (301)
in the vise. Set spring seat (332), springs
(324), (329) and stopper (337) and tighten
z Be careful so as not to distort boom
the vise.

bucket spool assy and attach spring cover
3) Install the boom spool assembly reassembled

in Article 2) above in casing B (102).
217
When assembling the boom spool assy

into casing B (102), do it slowly and

the spring side of the cut spool assy. Then
fasten socket bolts (273) to the specified
torque.
4) Attach O rings (262) to the spring side of the

boom spool assy. Then fit spring cover (201)
to the assy and tighten socket bolts (273) to
the specified torque.
(11) Assembling arm spool
1) Put a mouthpiece (aluminum plate) in the
vise and hold the center of arm spool (302) in
z Take care so as not to distort arm
the vise.
(13) Assembling arm recirculation spool

1) Put a mouthpiece (aluminum plate) in the
vise and hold the center of arm recirculation
spool (310) in the vise. Set spring seat (332),
springs (325), (326) and stopper (337) and
tighten bolts (333) to the specified torque.
z Take care so as not to distort arm
recirculation
spool
(310)
by
over-tightening it in the vise.
2) Fit the arm recirculation spool assy in 1) to
casing A (101).
When assembling the arm recirculation
spool assy into casing A (101), do it
2) Fit the arm spool assy in 1) to casing A (101).

When assembling the arm spool assy
into casing A (101), do it slowly and
the spring side of the arm spool assy. Then
tighten socket bolts (273) to the specified
torque.
(12) Assembling cut spool
1) Put a mouthpiece (aluminum plate, etc.) in a
vise and hold the center of cut spool (309) in
(326) and stopper (337) and fasten bolts (333)
to the specified torque.
z Before tightening bolts (333), coat
z Use care so as not to distort cut spool
(309) by overtightening it in the vise.
2) Fit the cut spool assy in 1) into casing A (101)
and casing B (102).

the spring side of the arm recirculation spool
assy. Then tighten socket bolts (273) to the
specified torque.
(14) Assembling spring covers
1) Travel, boom, bucket, swing and arm.
Fit O ring (265) to spool cover (206) and
torque.
2) Travel straight and boom conflux
Fit O ring (265) to spool cover (206) and
torque.
(15) Assembling main relief valve (See Fig.4-3.)
1) Fit spacer (122), C ring (121), O rings (163),
(561) and backup ring (562) to plug (103).
2) Fix poppet (611) and spring (621) to plug
(103) in 1) above. Then fix spring seat (612)
in 2) fitted with O rings (661).
When assembling the cut spool assy

into casing A (101), B (102), do it slowly
with care ; never force it in.
Make sure that poppet (611) is snugly

placed in the seat of plug (103).
218
3) Temporarily assemble adjust screw (651) and

lock nut (671) to plug (103).
4) Assemble plunger (512) and spring (521) into
seat (541).
5) Assemble the seat in 4) to the plug (103) assy
under 3) and fix it with snap ring (121).
6) Pressure adjustment is performed in accordance with Maintenance Standard and Test
Procedure. Leave adjust screw (651) temporarily assembled.
(16) Assembling Over load Relief Valve
(See Fig.4-4.)
1) Assemble spring seat (612) with poppet (611),
spring (621) and O ring (661), into plug (102)
that is fitted with O rings (162), (561) and
backup ring (562). Then temporarily assemble adjust screw (651) and locknut (671).
(17) Assembling option valve

1) Tighten plug (S552) with O ring (S562) to
casing (S101) and fasten it to the specified
torque.
2) Assemble poppet (S512) and spring (S522) to
casing (S101) and fasten plug (S551) with O
ring (S561) to the specified torque.
the vise and hold the center of option spool
(S301) in it. Set spring seat (S337), springs
(S323), (S324) and stopper (S333) and tighten
bolts (S334) to the specified torque.
z When tightening bolts (S334), coat
z Be careful so as not to distort option
spool (S301) by overtightening it in
the vise.
4) Assemble the option spool assy in 3) into
casing (S101).
Make certain that poppet (611) is

snugly fitted in the seat of plug (102).
When assembling the option spool assy

into casing B (102), do it carefully and
slowly ; never force it in.
2) Fit O ring (563) and backup ring (564) to seat

(541) and attach the seat to plunger (511) and
assemble piston (301) and springs (521),
(522).
3) Assemble the seat (541) assy in 2) into body
(101) and tighten the plug (102) assy in 1) to
Confirm that springs (521), (522) are
guided properly.
5) Put O ring (S261) to the spring side of the

option spool assy, attach spring cover (S202)
to the assy and tighten socket bolts (S271) to
6) Install spool cover (S204) with O ring (S262)
and fasten socket bolt (S271) to the specified
torque.
7) Install over load relief valve (S603) to casing
(S101) and fasten it to the specified torque.
4) Pressure adjustment is performed in accordance with Maintenance Standard and Test

Procedure and adjust screw (651) is left temporarily assembled.
219

(1) Inspection of components
Part name
Inspection item
scratches,
Criterion and remedy
Casing
1) Look for
corrosion.
rusting
and 1) If any of the following parts are

damaged, replace the casing.
z Sliding part of casing hole and spool,
particularly the land, to which holding
pressure is applied.
z Part of sealing pocket through which
spool is inserted.
z Area of sealing part that is in contact
with O ring.
z Sealing and seating part of main or over
load relief valve.
z Defects of other parts that seem to
prevent normal function.
Spool
1) Look for scratches, galling, rusting 1) If a defect detectable with your

and corrosion.
fingernail is found on the sliding part of
the outer circumference, replace the
spool.
2) Inspect ends that are sealed with an 2) If the sliding part is damaged, replace
O ring.
the spool.
3) Insert the spool in the casing bore, 3) If the spool damages the O ring or does
and move it while turning it.
not move smoothly, repair or replace
the spool.
Poppet
1) Look for damage on the poppet and 1) If sealing is incomplete, correct or

the spring.
replace the seal.
2) Insert the poppet in the casing, and 2) If the poppet moves lightly without
move it.
catching, it is normal.
Spring and
related parts
1) Look for rust, corrosion, deformation, 1) If damaged heavily, replace.

and breakage of the spring, spring
seat, plug and cover.
Spool seal and

related parts
1) Look for external oil leak.

1) Repair or replace.
2) Look for rust, corrosion and deformation 2) Repair or replace.
of sealing plate.
Main relief valve 1) Look for rust and damage on outer

surface.
Over load relief
2)
Inspect
the contact face of the valve
valve
seat.
3) Inspect the contact face of the poppet.
4) Look for spring abnormality.
5) Inspect the O ring, backup ring, and
seal.
220
1) Replace.
2) If damaged, replace.
3) If damaged, replace.
4) Replace.
5) As a general rule, replace all parts with
new ones.
2.7 TROUBLESHOOTING
1) If an abnormal condition is noticed, check to
see if the problem is with the control valve
itself, one of the main pumps, the gear pump,
or a circuit. To this end, you will need to
measure pilot pressure, pump delivery
pressure, load pressure, etc. If any part of the
system is to be disassembled for inspection,
follow the disassembly and reassembly
procedures in this manual.
2) Dust is the enemy of hydraulic components.
Pay strict attention to protection from dust.
If any part of the system is to be

disassembled, take dust protection measures
beforehand.
3) Moving parts must be handled with care. If
they are damaged, smooth the damage using
an oil stone or the like.
4) Take care not to damage the contact face of
O rings. A damaged contact face will
certainly cause oil leaks.
(1) Control valve

Trouble
1. Travel does not
occur.
Slow to start up
(or poor power).
Slow response.
Cause
Remedy
1) Malfunctioning main relief valve.

1) Measure travel relief valve pressure
z Foreign matter between main z Disassemble and clean. If damaged
poppet and seat.
heavily, replace the assy as a unit.
z Foreign matter between poppet z Same as above.
and seat.
Sticking
main poppet.
z
z Smooth sticking part with oil stone.
z Broken or deformed spring.
z Replace spring.
z Clogged main poppet throttle.
z Remove foreign matter.
z Loosened adjusting screw.
z Readjust, and tighten lock nut to
specified torque.
2. Machine does not 1) Malfunctioning travel straight 1) Measure pilot pressure.

travel straight
valve.
during
z Sticking spool.
simultane-ous
z Replace spring.
travel and operate z Clogged small hole in spool.
attachment.
2) Malfunctioning
right
or left 2) Measure pilot pressure.
neutral cut valve.
z Sticking spool.
z Replace spring.
z Excessive clearance between right z Replace spool.
or left casing and spool.
z Clogged small hole in spool.
3) Malfunctioning main relief valve.
See item 1. 1) above.
221
3) Replace main relief valve.
Trouble
Cause
Remedy
3. Excessive natural 1) Excessive clearance between 1) Replace spool.

falls of attachment
casing and spool.
under its own
2) Spool is not completely in 2) Measure secondary pilot pressure.
weight when spool
neutral position.
is in neutral.
z Foreign matter between casing z Disassemble, clean and smooth sticking
and spool, or sticking spool.
part with oil stone.
z Replace spring.
z Clogged pilot circuit.
3) Malfunctioning port relief valve. 3) Measure over load relief valve pressure.
Refer to item 1. 1) above.
4) Malfunctioning anti-cavitation 4) Checking the over load relief valve
check valve.
z Foreign matter between poppet z Disassemble and clean.
and casing.
z Replace spring.
5) Lock valve function is faulty.
5)
z Foreign matter between poppet z Disassemble and clean. In case
and casing.
scratches are excessive, replace casing.
z Poppet is stuck.
z Correct stuck part with oil stone.
z Replace spring.
z Selector spool is stuck.
z Replace lock valve selector sub assy.
z Dirt is included between selector z Replace lock valve selector sub assy.
spool and bushing.
z O ring in bushing is worn out.
z Replace lock valve selector sub assy.
4. When raising
attachment, at
first it drops.
1) Malfunctioning load check valve. 1)

z Foreign matter between poppet z Disassemble and clean. If heavily
and casing.
damaged, replace control valve.
z Sticking poppet.
z Replace spring.
5. Bucket, boom, arm 1) Malfunctioning main spool.

1) Measure secondary pilot pressure.
or swing does not
z Excessive clearance between z Replace spool.
operate.
casing and spool.
z Foreign matter between casing z Disassemble and clean.
Slow to start up
and spool.
(or poor power).
z Sticking spool.
z Smooth stuck part with oil stone.
Slow response.
z Broken or deformed return z Replace spring.
spring.
z Clogged pilot circuit.
2) Malfunctioning
main
relief 2) Measure main relief valve pressure.
valve. Refer to item 1. 1) above.
3) Malfunctioning over load relief 3) Measure over load relief valve pressure.
valve. Refer to item 1. 1) above.
4) Malfunctioning pilot valve.
Refer to Pilot valve section.
222
4) Refer to Pilot valve section.
Trouble
Cause
Remedy
6. Swing priority
function does not
operate.
1) Operating fault of arm recirculation 1) The same way as 5.1).
7. Boom or arm
conflux does not
operate.
1) Malfunctioning conflux valve.
spool [the same way as 5.1) below].
Refer to item 5.1) above.
1) Measure pilot pressure.

Refer to item 5.1) above.
(2) Relief valve

Trouble
Cause
Remedy
1. No pressure rise.
Main or pilot poppet of relief valve is

sticking and valve is open, or there is
foreign matter on valve seat.
z Check for foreign matter on each

poppet.
z Confirm that each component slides
smoothly.
z Clean all components thoroughly.
2. Unstable relief
pressure.
Damaged pilot poppet seat of relief

valve. Pilot piston sticks against main
poppet.
z Replace damaged component.

z Clean all components thoroughly.
z Smooth surface damage.
3. Irregular relief
pressure.
1) Wear due to foreign matter.
1) Disassemble and clean.
2) Loosened lock nut or adjusting 2) Adjust pressure.

screw.
4. Oil leak.
1) Damaged seat.
Worn out O ring.
1) Replace
damaged
component.
Confirm
or
worn
that
each
component operates smoothly before

reassembling.
2) Sticking component due to foreign 2) Confirm that there are no scratches,
matter.
scores, or foreign matter present

before reassembling.
223
224
4.
4.1 CONSTRUCTION
(1) Sectional view
PILOT VALVE (FOR TRAVEL)

Z
12
13
33 2
36
19
37
1,3
20
34
22
20
39
32
44,16
6
18
24
41
14
26
30
15
21
20
42
25
25
42
17
40
7
8
25,42
36 33
28
9 31 5
29
33 36
SECTION
27
10,11
33
AA
35
4-M10
T=4.30.4
(312.9)
38
24,41
VIEW
SECTION
Z
Fig. 4-1
TIGHTENING
TORQUE
NO.
kgfym (lbfyft)
1
1.5 (11)
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Sectional view of pilot valve (for travel)
NAME
ORIFICE (SHIM)
SEAT
ORIFICE (SHIM)
SPOOL
BODY
STOPPER
SPRING
SPRING
NAME PLATE
SHIM t=0.2
SHIM t=0.1
CAM
BOOTS
PIN
COVER
PISTON
GUIDE
SLEEVE
HOLDER
RING
ORIFICE (SHIM)
TIGHTENING
TORQUE
QTY
NO.
kgfym (lbfyft)
4
22
2
1.0 (7.2)
24
4
2.5 (18)
25
4
6.0 (43)
26
1
0.5 (3.6)
27
4
1.5 (11)
28
4
29
4
30
1
31
4
32
4
33
2
34
2
35
2
36
2
37
4
38
4
39
4
40
4
41
12
42
4
44
41
BB
Apply Locktite #262

NAME
QTY
SPRING
PLUG ; PF1/8
PLUG ; PF1/4
SOCKET BOLT ; M1060
FLANGE BOLT
SET SCREW ; M8
WASHER
WASHER
RIVET
PIN ; 5
BALL
BALL
BALL
BALL
U PACKING
O RING ; 1A P5
O RING ; 1A P24
O RING ; 1A P26
O RING ; 1B P8
O RING ; 1B P11
PISTON ASSY
4
3
3
2
4
4
4
2
2
4
6
4
4
6
4
4
4
4
3
3
4
(2) Explosion view

13
30
26
28
12
LIP DETAIL
14
37
15
6
27
18
19
1,3
16,44
20
21
34
22
20
39
20
17
10,11,29
REDUCING VALVE SECTION
DAMPER SECTION
36
7
40
32
38
24
41
Fig. 4-2
Explosion view of travel pilot valve

42
1. Tools used
Tool name
Vise
Small vise
(Place a copper plate on
the mouthpiece.)
Allen wrench
Scriber
(or a sharp point rod of
the same shape)
Hex rod for torque
wrench
Use
For fixing the valve
body
For disassembling the
reducing valve spool
3, 4, 5, 6, 8mm
For disassembling the
U-packing
3, 4, 5, 6, 8mm
Torque wrench
Magnet bar
For picking up ball (36)

and holder (19)
3. Disassembling the damper (See Fig.4-3.)

(1) Draw out piston assy (44) and guide (17) from
cover (15).
z The damper is drawn out easily if it is pushed
from the ball side (36).
(2) Draw out four balls (36), holders (19) and
orifices (1), (3) from piston assy (44).
z On that occasion, align the hole in the cover,
the piston assy and the guide as a set as each
part is shop fitted. Therefore, if parts for
different locations are assembled, functional
faults may occur in some cases.
z Ring (20), orifice (21), spring (22) and ball
(34) can not be separated from the piston
assy as they are assembled with ring (20)
pressed in.
z Disassembly and assembly procedures

It is usual that disassembly and assembly are
executed at the makers factory, but in
unusual cases, do the work at a service shop
where skilled technicians are available.
Hydraulic parts are precision products of
small clearance. Therefore, disassembly and
assembly work shall be performed in a clean
place where there is little dust in the
following manner:
Never knock on precision parts in case they
do not operate smoothly.
Replace seal parts such as O rings and U
packings with new ones.
37
15
36
19
1,3
2. Disassembly
(1) Put a plug into each port (P,T,1,2,3,4,5,6) of
the valve and clean the outside.
(2) Fix the valve after cleaning it in a vise.
(3) Remove two boots (13).
(4) Loosen 22 places of socket head set screws
(28) and remove them from cam (12).
: 4mm
(5) Draw out two pins (14) from cover (15). On
that occasion, the pins may be drawn out
with ease if the pins are pushed out of the
inside by the use of an allen wrench 4mm.
(6) Remove two cams (12).
(7) Loosen socket bolts (26) and remove two of
them with washers (30).
: 8mm
(8) Remove two dampers from the reducing
valve.
43
44,16
20
34
22
20
39
17
Fig. 4-3
21
20
Disassembling the damper
4. Disassembling the reducing valve section

(See Fig.4-4.)
(1) Separate three socket plugs (24) from body
(5).
: 5mm
(3) Draw out two balls (36) from body (5) by

attracting the balls to a magnet.
z Balls (33), (35) are for circuit plugs and press
fitted to body (5). Therefore, they are not
separable.
(2) Separate O ring (41) from socket plug (24).

(3) Remove four reducing valve spool assemblies
from body (5).
(4) Remove stopper (6) from the reducing valve
spool assy.
(5) Remove four springs (7); parallel pins (32), O
rings (38), (40) from body (5).
7
40
32
5. Disassembling the reducing valve spool assy

(See Fig.4-5.)
z The outer diameter of reducing valve spool (4)
is finished with a small clearance against the
hole of body (5). Therefore, put a copper plate
on the mouthpiece of the vise at disassembly
so as not to score the outer diameter.
Note that the spool is deformed if the vise is
tightened too much.
(1) Fix spool (4) in a vise (Put a copper plate
against the mouthpiece.) and loosen four
socket flange bolts (27).
: 3mm
38
24
5
41
Fig. 4-4
Disassembling the reducing valve
27
18
(2) Draw out socket flange bolt (27), sleeve (18),

spring (8), shims (10), (11) and washer (29)
from spool (4), in that order.
z On that occasion, mate the disassembled
parts with mating parts as sets.
6. Disassembling the shuttle (See Fig.4-6.)
z The shuttle is unseparable basically as seat
(2) is fixed with adhesive agent (Locktite
#262.).
(1) Remove two socket plugs (25) from body (5).
: 6mm
REDUCING VALVE SPOOL ASSY
(3) Separate four O rings (39) from guide (17).

(4) Remove four U packings (37) from cover (15),
using a scriber.
10,11,29
4
Fig. 4-5
Disassembling the reducing spool assy

33
36
2
33
36
2
33
33
(2) Remove two seats (2) from body (5).

: 5mm
z On that occasion, the Locktite comes off.
Remove it including that adhered to the
neighboring area of the screw.
44
42
Fig. 4-6
42
25
25
Disassembling the shuttle
8. Assembling the shuttle. (See Fig.4-7.)

(1) Put two balls (36) into body (5).
(2) Coat the screwed part of seat (2) with
Locktite#262 and fit two of them to body (5).
1.50.1kgfym(110.7 lbfyft)
11. Assembling the damper (See Fig.4-3.)

(1) Fit four U packings (37) to cover (15).
z On that occasion, place the cover so the lip of
the U packing faces down (damper chamber
side).
(2) Insert four piston assemblies (44) into cover
(15).
z In that case, make sure that each piston is
set in the same hole where it was before
disassembly.
The performances of the piston are not
affected at all if it is placed in any direction
on the circumference.
(3) Fit O ring (39) to guide (17). Install four
guides to cover (15).
z Fix the guide in the same hole where it was
set before disassembly.
(3) Set O rings (42) to socket plugs (25) and

fasten two plugs to body (5).
2.50.2kgfym (181.4 lbfyft)
9. Assembling the reducing valve spool assy
(See Fig. 4-5.)
(1) Fix spool (4) in a vise. (Put copper plates
against the mouthpiece.) Set washer (29),
shims (10), (11), spring (8) and sleeve (18), in
that order, and tighten them with four socket
flange bolts (27).
0.50.1 kgfym (3.60.7 lbfyft)
z On that occasion, pair parts with the
disassembled parts as sets, before performing
assembly work. Incorrect pairing may change
the secondary pressure.
10. Assembling the reducing valve (See Fig.4-8.)
(1) Fit four O rings (38), (40), parallel pins (32)
and springs (7) to body (5).
(2) Fit four reducing valve spool assemblies and
stoppers (6). On that occasion, use care as
stopper (6) has a direction in which it should
be installed; Place it so the concave surface of
it faces down (reducing valve spool side).
(3) Set O rings (41) to socket plugs (24). Fasten
three plugs to body (5).
10.1 kgfym (7.20.7 lbfyft)
33
36
2
33
36
2
33
33
42
Fig. 4-7
6
25
Assembling the shuttle
7
40
32
38
24
41
Fig. 4-8
45
42
25
REDUCING VALVE
SPOOL ASSY
7. Assembly
z Clean and degrease parts before assembly. In
particular, clean the body with a nylon brush
or something.
Foreign matter intruded into the valve causes
functional faults to occur.
z Prepare new seals (O rings and U packings)
and coat the surface with hydraulic oil or a
thin film of grease.
Assembling the reducing valve
In case such scratches and burrs can not be

corrected with ease, replace the parts with
new ones in pairs.
(3) If you feel the moving parts of the reducing
valve, body (5) and spool (4) unsmooth,
correct them to be free from scratches and
burrs, using #1000 emery paper. If it is
difficult to correct, replace the parts with new
ones in pairs.
(4) If you feel the moving parts of the cam
assembly such as, cam (12), pin (14) and
cover (15), correct them to be free from
scratch and burr, using #1000 emery paper. If
it is hard to correct, replace the parts with
new ones.
13
28
36 12
14
19
37
16,44
20
22
39
32
6
27
34
20
17
40
18
24
41
35
15
26
30
1,3
21
38
8
7
20
10,11,29
25,42
13
Fig. 4-9
28
12
30
26
14
DAMPER
(4) Set orifices (1), (3) to piston assy (44) that is

set in the cover.
l The orifices absorbs rattles that are made
when cam (12) is in neutral: either orifice
may be at the top or at the bottom.
l In case the cam rattles very much because
the cam and the pin are worn out after long
hours of use, increase the number of orifices.
However, if many orifices are set when there
is no gap, the reducing valve spool is actuated
at neutral and pressure is built up in the
secondary pressure port. When there is no
gap on the cam at neutral, do not increase the
orifices.
(5) Set four holders (19) and balls (36) to piston
assembly (44).
(6) Install two dampers on the reducing valve
and fasten them with socket bolts (26) with
washers (30).
In that case, parallel pin (32) set in body (5)
is placed in the hole of cover (15) to position
the reducing valve and the damper in place.
6 0.5kgfm (43 3.6 lbfft)
(7) Set cam (12) to cover (15) and insert pin (14).
On that occasion, check the gap of the cam
and if the gap is large, increase orifices (1),
(3) according to item (4) above.
l Ball (36) and holder (19) can be drawn out
easily by magnet bar. If a magnet bar is not
available, place the valve on its side and give
vibration to it.
(8) When the gap adjustment of the cam has
been finished, apply grease to the moving
parts of cam (12), pin (14), cover (15) and ball
(36).
(9) Attach 2 2 pcs. set screws to cam (12) and
tighten them.
1.5 0.1kgfm (11 0.7 lbfft)
(10) Fit two boots (13).
REDUCING
VALVE
12. Standard for the judgement of serviceability

of parts
(1) Replace seals with new ones at disassembly
and reassembly.
(2) If you feel the moving parts of the damper,
cover (15), piston assy (44) and guide (17)
unsmooth, correct the sliding surfaces and
corners to be free from scratches and burrs,
using #1000 emery paper.
4 6
5. SWING MOTOR UNIT

5.1 CONSTRUCTION
(1) Swing motor
488
992
469
355
401
ANTI CAVITATION
PLUNGER
051 RELIEF VALVE
351
051-1
391 390
VALVE CASING SECTION
SWING SHOCKLESS
VALVE BLOCK
052
V171
161,
152 162
163
V162
053
303
(400-1)
981 111 984 131 451
(400-2)
444
981
485
438
464
472
706
712
743
742
121
052
400
SECTION_A_A
V981
V162 V163
V164
113 V154
707
980
V252
V262
122
702
123
(053)
114
118
V301
116
V154
V101
117
V164
301
443 491 305
101
437 124
994
V261 V251 V981

SECTION_B_B
Fig. 5-1 Swing motor

II-5-1
V324
TIGHTENING
TORQUE
kgfym (lbfyft)
18 (130)
TIGHTENING
No.
PARTS
051 RELIEF VALVE ; M33-P1.5
7 (51)
PARTS
QTY
438
SNAP RING
443
ROLLER BEARING
052
SWING SHOCKLESS VALVE SUB ASSY
444
ROLLER BEARING
053
BYPASS VALVE BLOCK SUB ASSY
451
PIN
100
CASING FOR SHOCKLESS VALVE
3.7(27)
464
VP PLUG ; PF1/4
34 (250)
469
ROMH PLUG ; M30-P1.5
2
1
111 CYLINDER
472
O RING
485
O RING ; 1B
P11
114 CYLINDER SPRING
488
O RING ; 1B
P28
116 PUSH ROD
12
491
OIL SEAL
117 SPACER F
702
BRAKE SPRING
118 SPACER
706
O RING
121 PISTON
707
O RING
122 SHOE
712
BRAKE SPRING
24
123 SET PLATE
742
FRICTION PLATE
124 SHOE PLATE
743
SEPARATOR PLATE
131 VALVE PLATE
0.09 (0.65)
980
PLUG ; PF1/4
152 PLUG
0.45 (3.3)
981
PLUG ; PF3/4
161 O RING ; 1B
P11
0.17 (1.2)
984
PLUG ; PF3/8
162 O RING ; 1B
P12
6.6 (48)
992
PLUG ; PT1/2
163 O RING ; 1B
P6
10 (72)
994
PLUG ; PT3/4
CASING FOR BYPASS VALVE
V101
301 CASING
V154 PLUG
303 VALVE CASING
V162 O RING
305 SEAL COVER
V163 O RING
3.7 (27)
351 PLUNGER
V164 O RING
355 SPRING
3.0 (22)
V171 SOCKET BOLT ; M890
390 NAME PLATE
17 (120)
V251 PLUG 1
391 RIVET
11 (80)
V252 PLUG 2
400
V261 O RING
V262 O RING
SWING SHOCKLESS VALVE ; M22-P1.5
400-1 O RING ; 1B
P20
400-2 BACKUP RING
44 (320)
No.
101 DRIVE SHAFT
3.0 (22)
TORQUE
kgfym (lbfyft)
G30
051-1 O RING ; 1B
3.7 (27)
QTY
V301 SPOOL
V304 SPRING
437 SNAP RING
V981 PLUG
II52
0.09 (0.65)
(2) Swing reduction unit
33
19
29 28 27 26
25
18
22
17
23
16
24
22
14
20
15
21
13
10
12
11
37
36
34
35
9
8
6
2
Fig. 5-2
TIGHTENING
TORQUE
kgfym (lbfyft)
3.4 (25)
QTY No.
NAME
1
1
1
1
1
19
20
21
22
23
7 RETAINER
8 SOCKET BOLT; M825
9 BEARING
10 HOUSING
11 SPACER
1
12
1
1
1
24 NEEDLE BEARING
25 THRUST WASHER
26 #1 PINION
27 ROLLER
28 THRUST WASHER
12
13
14
15
16
BEARING
SNAP RING
#2 SPIDER
#2 SUN GEAR
RING GEAR
1
1
1
1
1
29
33
34
35
36
SNAP RING
SNAP RING
SET SCREW; M2020
CONNECTOR
HOSE
3
1
2
1
1
17
#1 SPIDER ASSY
37
PLUG
SOCKET BOLT ; M14130
10
Apply Three-Bond #1360K

II53
#1 SUN GEAR
SPRING PIN
SHAFT
THRUST WASHER
#2 PINION
QTY
PINION SHAFT
SLEEVE
PLUG (Not shown)
O RING
OIL SEAL
18.5 (130) 18
Cross-sectional view of swing reduction unit
NAME
No.
1
2
4
5
6
1
4
4
8
4
4
3
3
102
3
5.2 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR

5.2.1 TOOL
Tools
Remarks
Socket
wrench
VP plug
Allen
wrench
M8,M14,M20,M20(Set screw)
6,10,12,17mm
Plier
For bearing fixing locking rings
Snap ring for hole 60, 52
PF1/4
19mm
Screwdriver
Flat-bladed type, medium size 2 pcs.

108200 (0.390.317.87 )
Steel bar
(key material) 1 pc.
Hammer
Torque wrench
Plastic hammer
kgfym(lbfyft)
1 pc.
1.04.5 (7.233)
4.018 (29130)
1248 (87350)
40
(1.57)
Slide hammer bearing puller
100(4)
(0.433 )
BORE DIA.11
M10
150(5.91)
175.5(6.91)
200(7.87)
54
(0.2)
M8
10 (0.4)
Brake piston drawing tool

(Bolt M875 2pcs.)
250(10)
40 (1.57)
Place this
claw in the
groove of
brake piston.
5.2.2 DISASSEMBLY
(1) General cautions
1) Hydraulic components are precision products
and have small clearance. Therefore,
assemble and disassemble in a less dusty
clean place. Use clean tools and cleaning oil
and handle components with full care.
2) If a component is removed from the main
body, clean the area around the ports
thoroughly and plug them up so no dust and
water do not enter. When fitting them back to
the body, do not remove the plugs till piping
is completed.
3) Study the structural drawing before the work
begins and prepare necessary parts according
to your purpose and the scope of work. Seals
and O rings once removed can not be used
again.
Some parts can not be supplied as single
parts and available only in sub assy. Prepare
such parts according to the parts manual.
4) The piston and the cylinder block are shop
fitted when new. If you intend to reuse them,
put a matching mark on the piston and the
cylinder block.
(2) Disassembly procedure
The figures in parentheses after part names
in this manual represent those item numbers
in Fig. 5-1.
1) Draining oil
Remove the drain plug and drain hydraulic
oil from casing (301).
2) Preparation for removing the valve casing
Fix the motor on a work bench so the drive
shaft (101) end comes down. On that
occasion, put a matching mark on the mating
parts of casing (301) and valve casing (303).
053
303
z Choose a clean place, and lay with a

rubber sheet or a cloth on a work
bench. Handle the valve casing with
care so parts do not have dents.
052
051
712
702
301
Fig.5-3
55
101
Removing valve casing (303)
052
3) Loosen relief valve (051) and separate it from

valve casing (303).
: 41mm
4) Loosen swing shockless valve sub assy (052)
& bypass valve block sub assy (053) and
separate it from valve casing (303).
: 6mm
355
303
469
5) Separate RO plug (469) from valve casing

(303) and draw out spring (355) and plunger
(351).
: 14mm
6) Loosen socket bolt (401) and separate valve
casing (303) from casing (301). If the socket
bolt (401) are loosened, the valve casing floats
off casing (301) by the force of brake spring
(712).
Then separate valve plate (131) from valve
casing (303).
: 17mm
351
401
051
Fig. 5-4 Removing relief valve (651), swing
shockless valve (052), anti-cavitation
plunger (351) and valve casing (303)
BRAKE PISTON
DRAWING JIG
131
7) Draw out brake spring (712) from brake

piston (702).
8) Put the claw of the brake piston removing jig
in the concaved part of brake piston (702).
Hold the cylindrical part of the jig and pull it
straight up at once by reaction.
Draw out the brake piston with the jig, from
the casing.
702
301
Fig. 5-5
Removing brake piston (702)

117
9) Lay the motor on its side again and draw out

cylinder block (111) from drive shaft (101).
Then draw out piston (121), retainer plate
(123), spherical bushing (113), spacer F (117)
and shoe plate (124).
Handle the parts with care so as not to
score the sliding surfaces of cylinder
block (111), spherical bushing (113)
and shoe (122).
101
124
122 121 743

113
301
111
123
742
Fig. 5-6 Drawing cylider block (111), piston sub
assy, friction plate (742) and separator plate
56
10) Draw out friction plate (742) and separator

plate (743) from casing (301).
301
11) Draw out drive shaft (101) from casing (301),

while lightly tapping the side face of valve
casing (303) in drive shaft (101), using a
plastic mallet.
PLASTIC
MALLET
101
Fig. 5-7
443
Removing drive shaft (101)
z Do the following work as required.

PRESS
1. Drawing the inner race of roller bearing (443)

from drive shaft (101), using a press.
101
z Do not reuse the removed bearing.

443
2. Remove snap ring (437) with pliers. Then

draw out seal cover (305) from casing (301).
Put a bolt in the screwed hole (M40.7) of oil
seal (491). Then draw out oil seal (491) from
casing (301).
3. Drawing out the outer race of roller bearing
(443) from casing (301), by lightly tapping the
steel rod from the oil seal (491) housing side.
(Do not reuse the bearing.)
4. Separate the outer race of roller bearing (444)
from valve casing (303), using a slide
hammer bearing puller.
57
Put the inner race

on the press bench.
Fig. 5-8
Removing inner race of roller

bearing (443)
5.2.3 ASSEMBLY
1) Repair
those
parts
damaged
after
disassembly and prepare replacement parts
beforehands.
2) Clean all parts thoroughly in cleaning oil and
3) Always coat the moving parts with clean
hydraulic oil, before assembly.
4) Replace such seals as O ring and oil seal in
principle.
OUTPUT SHAFT SIDE
444
5) Tighten socket bolts and plugs to specified

torques, using a torque wrench.
(2) Assembly procedure
The figures in parentheses after part names
in this manual represent those item numbers
in the Fig. 5-1.
1) Preparation for assembly
Place casing (301) on a work bench so its
valve casing (303) side faces upward.
443
101
z This operation is necessary only

when the roller bearing is removed.
Fig.5.9
Assembling the inner race of

bearings (443), (444)
2) Shrinkage fit the inner race of roller bearing

(443) into drive shaft (101).
3) Shrinkage fit the inner race of roller bearing
(444) to drive shaft (101).
z This operation is necessary only
when the oil seal is removed.
Fit snap ring (437) to casing (301),
put in seal cover (305) and fix oil seal
(491) by the use of the jig. On that
occasion, coat the lip of the oil seal
with grease and check the direction
of it, before fixing it.
4) Assemble the outer race of roller bearing
(443) into casing (301), by lightly tapping the
steel rod.
5) Attach drive shaft (101) to casing (301).
301
101 491
443 437 305
Fig.5.10 Fitting snap ring (437), seal cover (305),
oil seal (491), outer race of roller
bearing (443), and drive shaft (101)
58
6) Place casing (301) as shown in Fig. 5-11 and

insert shoe plate (124).
On that occasion, the shoe plate does not
come off if it is coated with grease.
The larger
chamfer side
124
301
443
Fig. 5-11
Inserting shoe plate (124)
7) Fix spacer (118) and spring to cylinder (111),

fit snap ring (438) to it and insert push rod
(116) into cylinder (111).
Then mount the spherical bushing (113) with
spacer F (117) on the cylinder.
8) Place piston sub assy (121, 122) on retainer
plate (123).
9) Assemble piston sub assy (121, 122) fixed in
retainer plate (123) into cylinder (111). Match
it to the spline of drive shaft (101) and insert
it in place.
On that occasion, drive shaft (101) is easy to
be inserted if the phase of spherical bushing
(113) is aligned with that of the spline of
cylinder (111).
117
123
116
118
122
113
114
121
111
101
438
Fig. 5.12
Inserting cylinder assy
10) Replace casing (301) with seal cover facing

downward and assemble separator plate
(743) and friction plate (742) into casing
(301), in that order.
Assemble four separator plates and three
friction plates.
Assemble the same phases of four slits
in the gears of friction plate (742).
Assemble four slits in the four claws of
separator plate (743) in the position of
Fig.5-13.
PG PORT
Fig. 5-13
59
Mounting position of separator plate
702
11) Fit O rings (706), (707) to casing (301). In that case,

if the O rings are coated with grease, they are hard to
tear off when brake piston (702) is inserted.
12) Assemble brake piston (702) into casing (301).
13) Assemble brake spring (712) into brake piston (702).
In that case, make sure that a spring is placed
correctly in the spot faced part of the brake piston.
SLIT (OPPOSITE SIDE)
l This operation is necessary only where

roller bearing (444) is removed.
PG PORT
14) Insert the outer race of roller bearing (444) into

valve casing (303), while lightly tapping the steel
rod placed on the outer race, using a hammer.
Fig. 5-14
15) Assemble valve plate (131) into valve casing (303)

and fit O ring (472) in it.
16) Install valve casing (303) to casing (301) and fasten
them with socket bolts (401).
: 17mm,
Tightening torque : 44kgfm (320 lbfft)
17) Fit plunger (351) and spring (355) to valve casing
(303). Then tighten RO plug (469) fitted with O ring
(488) against valve casing (303).
: 14mm,
18) Fit relief valve (051) to valve casing (303).
: 41mm,
19) Fit swing shockless valve (052) & bypass valve
block sub assy (053) to valve casing (303).
: 6mm,
20) Fit O ring (485) to plug (464) and fasten the plug
against casing (301).
: 19mm,
Tightening torque : 3.7kgfm (27 lbfft)
10
Assembling brake piston
5.3 DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT

5.3.1 TOOLS
50mm
Material : SS41
Jig
(for press fitting bearing )
(0.394)
Remarks
10mm
Tool name
(1.97)
Code
910.5mm
(3.5830.020)
1400.5mm
(5.5120.020)
Snap ring plier
For shaft
(0.591)
Oil seal fitting jig
140mm
(5.51)
15mm
Material : SS41
208 0.5 mm
0
(8.189 0.020
)
Plastic hammer (Wooden hammer)
Press
Flat screwdriver
Metal bar
Class 14kgfym (100 lbfyft)
Class 10ton (22000 lbs )
(0.787)
Torque wrench
20mm
3 pcs.
155mm
(6.10)
j
k
General tools
Allen key wrench and steel rod
Screw lock compound
Three-Bond 1360K
Sealing compound
Locktite #515
5.3.2 DISASSEMBLY
The figures in parentheses correspond to the ones
in construction drawings (Fig. 5-2).
3) Disconnect the drain hose.
(1) Preparation
1) Before disassembly, clean the outside of the
reduction unit thoroughly and check for no
damage and scoring.
2) Drain gear oil from the reduction unit.
4) Matching Mark
To facilitate the reassembly of the unit, put
matching mark on the maiting parts of the
housing before disassembly.
511
(2) Separating swing motor from reduction unit

1) Preparation for disassembly
Place the reduction unit assy on a stable
work bench as shown in Fig.5-15, remove
plug (32), drain out oil put a matching mark
on the matching surface of the figure on the
right.
2) Removing swing motor assy
Loosen all socket bolt (18) (M14). Attach eye
bolts (M12 1.75) in the lifting bolt holes in
the top surface of the swing motor and lift the
assy by crane.
If it is hard to remove the swing motor assy
from the reduction unit, float it by inserting a
flat-blade screwdriver (h) in the groove of the
flange.
: 12mm
SWING MOTOR
18
h
32
MATCHING
MARK
160
290
(6
(12)
)
Fig. 5-15
Removing swing motor assy
17
19
16
(3) Disassembling reduction unit
1) Remove #1 sun gear (19).
2) Removing #1 spider assy (17).
The spider assy (17) [consisting of thrust
washer (28), #1 pinion (26), needle bearing
(27) and snap ring (29)] can be removed from
the spline easily if it is lifted up in that
condition.
10
Fig. 5-16 Removing #1 sun gear and
#1 spider assy
3) Removing ring gear (16)

Attach eye bolts (M14) to the top surface of
ring gear (16) and lift the ring gear lightly by
a wire sling.
Put a flat-blade screwdriver (h) into the
matching surface of ring gear (16) and
housing (10) and remove ring gear (16) by
lightly tapping the outer circumference of the
ring gear with a plastic mallet.
4) Remove #2 sun gear and separate the #2
spider assy.
Draw out #2 sun gear (15) and separate the
#2 spider assy.
Regarding the disassembly of the #2 assy,
refer to par. (4) which will come up later.
#2 SPIDER ASSY
16
h
10
Fig. 5-17 Removing ring gear (16)

#2 SPIDER ASSY
15
Fig. 5-18
5 12
Removing #2 spider assy
5) Turn over the housing so gear side of pinion

shaft faces up, as shown in Fig. 5-19.
180 (7 )
35010(140.4)
Fig. 5-19
Turning over housing
6) Remove all socket bolts (8).

: 6mm
8
Fig. 5-20
Removing socket bolts (8)
7) Remove retainer (7) with oil seal (6).
6
7
Fig. 5-21
513
Removing retainer (7)
M10
8) Removing pinion shaft assy

Attach an M10 eye bolt to the end of the
pinion and lift it upright : The pinion shaft
assy (1,2,5,9,11,12,13) can be lifted up easily.
11
12
13
Fig.5-22
(4)
1)
1.
2.
Disassembling spider assy

Disassembling #1 spider assy
Remove snap ring (29) with a plier (b).
Remove thrust washers (25,28), pinion (26)
and roller (27).
17
z The shaft attached to spider assy

(17) is caulked. When replacing
parts, replace the spider assy as a
whole.
z The pinion can not be replaced as a
piece. For replacement, do it in a set
of three.
Removing the pinion shaft assy
26
29
27
28
25
Fig.5-23
2) Disassembling #2 spider assy

1. Draw out spring pin (20).
2. Draw out shaft (21) from spider (14) and
remove thrust washer (22), pinion (23) and
needle bearing (24).
22
21
24
z Pinions (23) can not be replaced

singly. Replace them in a set of four.
23
22
20
14
Fig.5-24
514
(5) Disassembling pinion shaft assy

1) Remove snap ring (13), using pliers (b).
13
Fig. 5-25
Removing snap ring
2) Removing pinion shaft (1)

Erect three supporting metal bars (i) at equal
intervals in the grooves in the teeth of pinion
shaft (1), place sleeve (2) on them and draw
down the pinion shaft by press in Fig. 5-26.
Pressing force : about 1011 tons
(2200024000 lbs)
Bind the supporting metal bars (i)
around their outside with a steel wire
when performing press operation.
2
1
i
Fig. 5-26
3) Draw out the pinion shaft (1) and
remove
O ring (5) from sleeve (2). Then the pinion
shaft is disassemlbed into the parts in Fig.
5-27.
Removing pinion shaft (1)

7
12
11
9
5
2
Fig. 5-27
515
Disassembling pinion shaft assy
5.3.3 ASSEMBLY
(1) Preparation
1) Clean parts thoroughly in cleaning oil and
2) Check that parts are not faulty.
(2) Assembling pinion shaft assy

1) Apply grease
Apply a thin film of grease over O ring (5)
and the O ring seat of pinion shaft (1).
2) Insert sleeve
Heat sleeve (2) to 100120 (212248
F),
fit O ring (5) and fix it into pinion shaft (1).
Fig. 5-28
Inserting sleeve to pinion shaft
3) Coat the outer surface of the sleeve with a

thin film of grease.
4) Coat the gear oil
Coat the outer circumference of pinion shaft
(1) with a thin film of gear oil to prevent
seizure.
a
13
12
5). Fill grease in the groove of the oil seal lip in

contact with the oil seal till about 1/3 of the
groove is filled with grease.
19
9
6) Assembling bearing
Heat bearings (9,12) to 100120 (212
248
F), fit the bearings with spacer (19) into
pinion shaft (1). Push them in, using jig (a)
and fix snap ring (13).
Pressing force : 1112ton
(2400026500 lbs)
516
1
OIL SEAL
Fig. 5-29
Assembling pinion shaft assy
(3) Assembling spider assy

1) Assembling #1 Spider Assy
1. Coat the bore surface of pinion (26) with
grease. Put pinion (26) on thrust washer (25)
and assemble roller (27) into the bore surface.
17
26
29
27
28
2. Fit thrust washers (25,28) and pinion (26) as

in Fig. 5-30, 5-31 and fit snap ring (29) by
means of pliers (b).
25
Fig. 5-30
Assembling #1 spider assy
Fix the snap ring with the sharp edge

on the motor side (top side in the
position of Fig.5-31 ).
MOTOR SIDE
SNAP RING (29)
25, 28
17
29
Fig. 5-31
2) Assembling #2 Spider Assy
1. Coat the bore surface of pinion (23) with
grease. Put pinion (23) on thrust washer (22)
and fit needle bearing (24) to the bore
surface.
26
Fixing snap ring

GEAR SIDE
CAULK TWO
POINTS WITH
A PUNCH.
2. Fit thrust washer (22) and pinion (23) as in

Fig. 5-32, insert shaft (21) into spider (14)
and fix spring pin (20).
67mm
(0.240.28in)
z Make sure that the oil hole (A in

Fig. 5-32) in shaft (21) faces the
outside as shown in the figure.
z Insert shaft (21) into spider (14) so
spring pin hole (20) is aligned.
VIEW
67mm
(0.240.28in)
22
21
24
23
22
20
14
Fig. 5-32
517
Assembling #2 spider assy
(4) Assembling reduction unit assy

1) Mounting pinion assy
Place housing (10) on a work bench. Lift the
pinion assy and lower it slowly into the
housing till it is set in place.
z Take care on this step so that outer

race of bearing (9) is installed
straight along the inner face of
housing (10).
z Outer races of bearings (9,12) can
normally be installed in the housing
(10) easily as enough clearance is
provided between the two parts. If
they cannot be inserted easily, check
to see whether or not the outer race
of bearings (9,12) are positioned
correctly and if there is any damage
to housing (10). Pressing them in
with undue force may damage these
parts.
12
10
Fig. 5-33
2) Attaching retainer
1. Fit the oil seal to retainer (7), making sure of
its direction and set it in place by using oil
seal fixing jig (c).
2. Apply sealing compound (Locktite #515) to
the retainer (7) with oil seal and the
matching surface of housing (10). Then fit it
to sleeve (2).
10
Fig. 5-34
Installing pinion assy
M825
8
7
Assembling retainer (7)
#2 SPIDER ASSY
Use care when assembling so as not to

score the oil seal by the gear teeth of
pinion (1)
3. Tighten socket bolt (8)
: 6mm,
Tightening torque 3.4kgfym (25 lbfyft)
3) Turning over housing (10)
Place pinion shaft (1) on a stable work bench,
with its spline facing up.
Fig. 5-35
Installing #2 spider assy

19
4) Attaching #2 spider Assy

Insert the #2 spider assy into the spline shaft
of pinion shaft (1).
5) Attaching #2 sun gear (19)
Install #2 sun gear (19) with its spline facing
up.
Fig. 5-36
518
Installing #2 sun gear (19)
6) Installing ring gear (16)

Apply a thin film of sealing compound
(Locktite #515) to the matching surface of
housing (10) and ring gear (16) and assemble
them, aligning the gear teeth and according
to the matching marks given.
#2 SPIDER ASSY
16
ALIGN
MATCHING MARKS.
10
Fig. 5-37
7) Installing #1 spider assy
1. Mesh the #1 spider assy with ring gear (16)
and set them in place.
2. Mesh #1 sun gear (19) with #1 pinion (26)
and set them in place.
Installing ring gear (16)
#1 SPIDER ASSY
19
8) Fit drain hose (36) and plug (37).

: 12mm
16
26
9) Filling Lube Oil

Fill in 7.5 (2.0gal) of Extreme pressure gear
oil SAE90 (API Service Grade GL4).
10
10) Installing swing motor assy

Attach eye bolts (M121.75) in the tapped
holes of the swing motor and put a wire sling
in them.
Coat the matching surface of ring gear (16)
with sealing compound (Locktite #515), insert
the spline joint of the swing motor and match
the matching marks.
Coat socket bolts (18) with screw lock
compound (Three-Bond 1360K) and fasten
them.
: 12mm,
Tightening torque 18.5kgfym (130 lbfyft)
Fig.5-38
Installing #1 spider assy
SWING MOTOR
M14130
18
MATCHING
MARKS
160
(6)
Fig. 5-39
519
290
(12)
Installing swing motor assy

5.4.1 SWING MOTOR
(1) Replacement standards for parts
The following are the standards to determine
whether or not parts may be reused from
values taken at disassembly. These are only
general standards and in case the motor
displays poor performance or parts shows
extreme
damage
and
discoloration
before
Item
disassembly, it is most important to

determine which parts should be replaced,
depending upon the purpose of disassembly
and the remaining service life of the motor
that the user expects.
Standard
Dimension
mm (in)
Recommended
Value for
Replacement
mm (in)
0.027
(0.00160)
0.052
(0.00205)
Replace piston or cylinder.
0.3
(0.0112)
Replace piston and shoe assy.
5.5
(0.217)
5.3
(0.209)
Replace piston and shoe assy.
5.5
(0.217)
5.0
(0.197)
Replace a spherical bushing and a

retainer plate as a pair.
1.8
(0.0709)
1.6
(0.0630)
Replace.
Remedy

cylinder bore
(D-d)
Gap between piston and caulked

part of shoe
()
Thickness of shoe
(t)
Assembled height of retainer plate

and retainer
(H-h)
Thickness of friction plate

t
520
(2) Standard for correcting sliding surfaces

If the surface roughness of the sliding surface
of parts exceeds the following standard,
correct it or replace the parts.
Standard for correcting sliding surfaces
Parts
Shoe
Shoe plate
Cylinder
Valve plate
Standard surface
roughness
Surface roughness
requiring correction
0.8Z
(Ra=0.2)
(lapping)
3Z
(Ra=0.8)
0.4Z
(Ra=0.1)
(lapping)
3Z
(Ra=0.8)
1.6Z
(Ra=0.4)
(lapping)
12.5Z
(Ra=3.2)
0.8Z
(Ra=0.2)
(lapping)
6.3Z
(Ra=1.6)
z Lap each sliding surface to

standard roughness level or finer.
z If the sliding surface of the cylinder

block, valve plate, retaining plate or
spherical bushing is roughened,
replace parts in set.
521
5.4.2 SWING REDUCTION GEAR

(1) Inspection at disassembly
1) Spacer and thrust washer
1. Inspect that the parts are not seized or worn
abnormally or unevenly.
2. Inspect and measure the parts to see that the
wear does not exceed the allowable values.
2) Gears
1. Inspect that the gear teeth do not show
pitching and seizure.
2. Inspect by dye penetrant examination that
the bottom of the teeth does not show cracks.
(2) Inspection after assembly

1) Function
Check to see that #1 sun gear (19) is not
faulty when turned by hand.
2) Checking for oil leakage and oil quality
Check for oil leakage.
Check the oil level by level gauge and confirm
that the oil is not dirty. If the oil is short,
replenish gear oil SAE90 (API Service Grade
GL-4).
3) Bearing
Turn the bearing and check that it does not
develop abnormal sound, catching and other
faults.
4) O rings and oil seals
Do not reuse O rings and oil seals; always
replace them with new ones at reassembly.
522
(3) Maintenance standards
(H)
LUBE OIL LEVEL
D
C
APPLY LOCKTITE #515.
D
B
APPLY LOCKTITE #515.
Unit : mm (in)
Code
Item
Serviceability
Limit
Standard Value
0.021
No flaking
Replace four
shafts as a set.
Condition of tooth face

Condition of tooth flank
There should be no cracks.
Gears
Wear in sleeve (Diameter of part coming

in contact with oil seal )
2.00.1
(0.0790.004)
0
160 0.063
0
(6.29920 0.00248
Extreme pressure gear oil

SAE90(API Service Grade GL4)
II523
7.5
(2.0gal)
Replace
(Planetary pinion
should be replaced
in a set of four.)
1.8
(0.0709 )
Replace
159.5
(6.28)
Replace
M83.4 kgfym(25 lbfyft)

M1418.5 kgfym(130 lbfyft)
Capscrew tightening torque

Lube
oil
Replace entire
spider assy.
There should be no pitching

exceeding 1.6mm (0.0630in) dia,
abnormal wear or seizure.
Thickness of thrust washer
0.00083
(1.55315 0.00126
0
29 0.009
0
(1.14173 0.00035
Wear in #2 planetary shaft
G
(H)
39.45 0.032
Wear in #1 planetary shaft
Remedy
Apply Three-Bond
1360K and tighten
to specified torque.
Replenish or
replace.
5.5 TROUBLESHOOTING
5.5.1 SWING MOTOR
(1) Hydraulic motor does not rotate.
Trouble
Pressure does not
rise.
Pressure rises.
Cause
Remedy
1. Relief valve pressure in circuit is not 1. Set to correct value.

adjusted correctly.
2. Malfunction of relief valve.
2.
2-1. Sticking plunger.
2-1. Correct the stuck areas or
replace the plunger.
2-2. Orifice on plunger is clogged.
2-2. Disassemble and clean.
3. Plunger seat is faulty.
3. Check the seat surface and
replace the plunger if scored.
4. Swing shockless valve seat is faulty.
4. Replace the swing shockless
valve cartridge or block.
5. Bypass valve seat is faulty,
5. Replace
malfunction.
1. Overload.
1. Reduce the load.
2. Moving parts are seized.
2. Inspect and repair piston, shoe
and cylinder valve plate.
3. Brake release pressure is not 3. Check circuit and correct it.
working on the motor
4 Brake piston is stuck.
4. Disassemble and check.
5. Friction plate is seized.
5. Disassemble, check and repair.
Replace one that is seized.
(2) Rotating direction is opposite.

Trouble
Cause
Remedy
Rotating direction 1. Motors assembling direction is reversed. 1. Assemble correctly.

is opposite.
2. Piping inlets and outlets are reversed.
2. Pipe correctly.
524
(3) Revolution does not rise to set value.

Trouble
Cause
Remedy
Revolution does not 1. Oil inflow is deficient.

rise to set value
2. Oil leaks are excessive due to high
temperature.
3. Sliding surfaces are worn or broken.
4. Malfunction of bypass valve.
1. Check pumps delivery rate and

circuits to motor.
2. Lower oil temperature.
3. Replace.
4. Replace.
(4) Brake torque is insufficient.

Trouble
Brake torque is
insufficient.
Cause
Remedy
1. Friction plate is worn.

2. Brake piston is stuck.
3. Brake release pressure is
released.
4. Spline of friction plate is broken.
1. Disassemble and check. Replace if

wear is beyond standard value.
not 3. Check and correct circuit.
Replace broken part.
(5) The swing motor drifts much.

Check the drain rate of the hydraulic motor.
If it is less than 200cc/min(12cuyin/min), you
should think that the motor is not faulty.
Trouble
Cause
Remedy
The
swing
motor 1. Relief valve malfunctions.
1.
drifts much when it is
Same as (1).
actuated by external 2. Plunger seat is faulty.
2.
torques. (e.g. Machine 3. Seat of the swing shockless valve is 3.
is on a slope.)
no good.
4. Bypass valve seat is faulty,
4.
malfunction.
525
Same as (1).
Replace.
Replace the swing shockless valve
cartridge or block.
Replace.
(6) Oil leaks

1) Oil leak from oil seal
Trouble
Cause
Remedy
Oil leaks from oil 1. Lip of seal contains dirt

seal
damaged.
2. Shaft is damaged or worn.
and 1. Replace oil seal.

2. Shift the lip and shaft positions or
replace oil seal.
3. Repair drain piping if clogged up.
3. Casing inner pressure has risen
abnormally high, with the result that
lip of oil seal has turned up.
4. Disassemble and correct.
4. Shaft is rusted.
2) Oil leak from matching surface

Trouble
Oil leak from
matching surface
Cause
Remedy
1. O ring is missing.
2. O ring has a scratch.
3. Seal surface has a scratch.
4. Bolt is loose or broken.
526
1. Set O ring correctly and assemble

it.
2. Replace.
3. Disassemble and correct.
4. Tighten to specified torque or
replace.
5.5.2 REDUCTION UNIT

Cause
Trouble
Remedy
1)Reduction unit does not rotate.

Hydraulic motor inlet pressure has risen.
Overloaded
Reduce the load of
Reduction unit is broken.
Replace reduction unit.
Parking brake of the

hydraulic motor is not
released.
Inspect the release

pressure and the brake.
Check the release
command pressure.
Hydraulic motor inlet pressure has not
Rotating sound is heard from

hydraulic motor.
Rotating sound is not heard

from hydraulic motor.
Motor shaft is broken.
Replace hydraulic motor.
Reduction unit is broken.
Pump and valve are out of

order.
Check for fault and

correct.
2) Oil leakage
Oil leaks through matching surface.
Liquid packing is not applied.
Disassemble and apply

liquid packing.
Bolts are not fastened tight.

The matching surface is
slipping because of loosening.
Disassemble, apply
liquid packing and
reassemble as specified.
The
matching
surface
is
scored.
Oil leaks from shaft.
Replace faulty parts.
Oil seal is damaged.
Disassemble reduction
unit and replace oil
The gear oil is not filled up or

the oil level is low.
Check oil level and fill oil

up to a specified level.
The amount of grease is small.
Fill up grease.
Gear and bearing are

damaged.
3) Temperature is high.
Temperature of reduction unit casing
is high.
527
528
6. SWIVEL JOINT
6.1 CONSTRUCTION VIEW
Y
E
D
B
C
E
2
X
X
D
VIEW
C
12
B
A
5
7
SECTION
XX
3
9
13
8
Tble 6-1
No.
PART NAME
QTY No.
PART NAME
QTY
1 BODY
7 O RING ; 1A G95
2 STEM
3 THRUST PLATE
5 SEAL ASSY
12 PLUG
6 SEAL ASSY
13 COVER
Fig.6-1
Construction of swivel joint

61
6.2 DISASSEMBLY AND ASSEMBLY

6.2.1 TOOLS
Code
Tool Name
Hammer
Rubber mat
Wrench
Table 6-2
Used for
Remarks
1. Steel hammer
2. Wooden or plastic mallet
750mm (30in) square or more
1. Allen wrench
2. Double-ended and single-ended wrench
3. Extension pipe
Torque wrench
Assembly
10kgfym (72 lbfyft)

Grind the tip ofa nailto shape
as a screwdriver.
Pin
Disassembly
Made from a hack-saw blade
Disassembly
f
Approx. 120mm (4.72 in)
Spatula
Assembly
Vinyl tape
Disassembly
Remove the edge completely

and make corner round smooth.
Vise
Locktite
#242
Lubricating oil
Hydraulic oil or vaseline
Cleaning oil
Assembly
6.2.2 APPARATUS
(1) Hoist or crane
The lifting device should be capable of lifting
the swivel joint assy.
(2) Work bench
The work bench should have an area of 1.2m
1.5m (4ft5ft).
(3) Others
Also prepare waste cloth, wooden block and
oil pan.
Vise movable over 150mm (6in)
6.2.3 CLEANING OUTSIDE

Clean the swivel joint to be free from dirt and
dust, using steam and cleaning oil.
62
z Keep all ports plugged up while

cleaning.
6.2.4 DISASSEMBLY
The part numbers used in this disassembly
procedure correspond to those of a construction
drawing in Fig.6-1.
13
(1) Removing cover

1) Mark cover (13) and body (1) with matching
marks for convenient reassembly.
2) Place a V-block on a work bench, place a
swivel joint set on the side, fix it and loosen
socket bolt (9) by means of a pipe and
wrench. Alternately, the swivel joint may be
fixed by holding stem (2) in a vise.
: 6mm
ALLEN
WRENCH
PIPE
V-BLOCK
Fig. 6-2
Removing cover (13)
3) Remove cover (4) from body (1) and draw out

O ring (7) from cover (13).
13
Fig. 6-3 Removing O ring (7)
1 BODY
3 THRUST PLATE
8 SOCKET BOLT
(2) Removing thrust plate

Loosen socket bolt (8) fastening thrust plate
(3), in the same manner as the removing of
the above-mentioned cover.
z When removing thrust plate (3) by
fixing body (1), support stem (2) so it
may not fall down.
: 6mm
PIPE
(3) Removing stem

Place body (1) on a Vblock. Put a wooden
block against stem (2) via the body so about
half of the stem is covered by the wooden
block and knock it out using a mallet.
By hitting out the stem over about 1/2 from
the body, it can be easily pulled out by hand.
STEM
Fig. 6-4 Removing thrust plate (3)

WOODEN BLOCK
FOR PROTECTOR
Secure
with hands.
1
2
Stem weight ; 12kg(26 lb)
WORK BENCH
V-BLOCK
Fig. 6-5 Drawing out stem (2)

63
BACK-UP RING
(4) Removing sealing parts

1) Pierce slipper ring of seal assemblies (6) and
(5) with pin (e) and remove them from the
seal groove. Fig. 6-6 shows only one pin, but
use two pins to remove it securely.
Pay attention to the body (1) not to be
damaged by pin (e).
SLIPPER RING
DETAIL(5), (6)
1 BODY
PIN(e)
6
SEAL ASSY
GROOVES
FOR HYD. OIL
5
SEAL ASSY
Fig. 6-6 Removing out seal assy (5)(6)

2) Remove backup rings of seal assemblies (6)
and (5) with spatula (f).
SPATULA(f)
Pay attention to the body (1) not to be

damaged by the top edge of spatula (f).
Fig. 6-7 Removing back-up ring

6.2.5 ASSEMBLY
Prior to assembly, clean each parts (excluding the
O ring and slipper ring), and arrange in the
sequence of assembly.
(1) Assembling seals to body

1) Make sure that oiliness, such as hydraulic oil
and grease, has been completely removed.
2) Apply grease on the groove of seal to be
installed on seal assemblies (6).
3) Slipper ring is assembled, after first inserting
the backup ring, by slightly-distorting the
shape as shown in Fig.6-8. Also after
inserting all of the seals, be certain that these
are installed in the seal groove by use of the
spatula.
64
SLIPPER RING
Fig. 6-8 Inserting seal assy (5),

and slipper ring(6)
(2) Assembling stem

Lightly coat the outer circumference of stem
(2) and the inner surface of body (1) with
grease or vaseline and slowly insert stem (2)
into body (1).
Press in by applying your weight

by your both hands.
2 STEM
If stem (2) is pressed in too fast, the
seal may be damaged. Do it slowly.
The clearance between body (1) and
stem (2) is about 0.1mm (0.004in).
Push stem straight along the shaft
center.
SEAL 6
1 BODY
5
SEAL ASSY
WORK BENCH
Fig. 6-9
(3) Assembling thrust plate
1) While holding stem (2) and body (1), match
the hole of thrust plate (3) and the stem (2)
hole.
2) Next, after removing any oil from the thread
of socket bolt (8), coat it with Locktite #242
and tighten to stem (2).
: 6mm,
Inserting stem (2)
Fig. 6-10 Tightening socket bolt (8)
(4) Assembling cover

After installing O ring (7) to cover (4) and
aligning the matching marks of the cover (4)
and body (1), coat socket bolt (9) with
Locktite #242 and tighten it which will then
complete assembly.
: 6mm,
MATCHING MARK
9
4
ALLEN
WRENCH
PIPE
Fig. 6-11 Tightening socket bolt (9)
6 5

6.3.1 INSPECTION PROCEDURE AND REMEDY
Table 6-3
Interval
2,000Hrs.
Check Item
Checking Procedure
Seal for oil

Check oil leakage outside
leakage outside
4,000Hrs. All sealing

In principle, parts
disassemble
and
check All sliding parts Check abnormal wear, scoring
or corrosion caused by foreign
re-gardless of
matters or seizure.
oil leakage or
not.
When
All parts
disassembled
for repair
Remedy
Replace O ring or dust seal , if any oil
leakage can be found.
Replace all sealing parts such as slipper
seal with back-up ring and O ring.
Repair or replace referring to their limit
of service.
Check them for seizure, foreign Repair or replace referring to their limit
matters, abnormal wear, and
of service.
defect of seals.
O rings and dust seal should be
replaced.
6.3.2 SERVICE LIMIT OF THE PARTS

Table 6-4
Parts
Sliding surface with
sealing sections
Body,
Stem
Cover
Sliding surface
between body and
stem other than
sealing sections
Maintenance Standards
Remedy
Plating worn or peeled due to seizure or contamination. Replace

1) Worn abnormally or damaged more than 0.1mm Replace
(0.004in) in depth due to seizure or contamination.
2) Damaged less than 0.1mm (0.004in) in depth.
Smooth with
oilstone.
1) Worn more than 0.5mm (0.02in) or abnormality.
Replace
Sliding surface
2) Worn less than 0.5mm (0.02in).
Smooth
with thrust plate
3) Damage due to seizure or contamination repairable Smooth

within wear limit 0.5mm (0.02in).
1) Worn more than 0.5mm (0.02in) or abnormality.
Replace
Sliding surface
2) Worn less than 0.5mm (0.02in).
Smooth
with thrust plate
3) Damage due to seizure or contamination repairable Smooth

within wear limit 0.5mm (0.02in).
66
Parts
Maintenance Standards
Remedy
1) Protruded excessively from seal groove.

Replace
PROTRUSION
(With
back-up
ring)
BACK-UP RING
2) Slipper ring 1.5mm (0.06in) narrower than seal

groove, or narrower than back-up ring.
Replace
(With
Slipper ring
back-up
1.5mm (max.)
(0.06in)
ring)
BACK-UP RING
3) Worn unevenly more than 0.5mm (0.02in)

0.5mm (max.)
(0.02in)
Replace
(With
back-up
ring)
67
6.6.3 INSPECTION AFTER ASSEMBLY

After completion of assembly, inspection for oil
leakage, pressure resistance, etc., using a device
as shown in the figure right.
(1) High pressure port (A,B,C,D port)
Install a directional valve and pressure gauge
to the stem side port and body side port
respectively, and while watching the pressure
gauge (for high pressure) installed on the
body side and also by regulating high
pressure relief valve (7), gradually increase
the pressure and when the pressure has
reached 1.5 times the maximum working
pressure, close stop valve (3) and lock in the
hydraulic oil in the swivel. Keep stop valve
(6) on the low pressure relief valve side closed
at this time.
Check that it is free from looseness,
deformation, breakage, etc. under three
minutes pressurizing.
And, the oil leakage must be checked for the
first 1 minute, and if there be a pressure drop
for any reason, the pressure drop should be in
10% of the trapped pressure.
This checking must be carried out for every
circuit.
(2) Low pressure port
(Drain port, return port : E,F port.)
Similar to the high pressure port, install a
directional valve and pressure gauge on each
port of the stem side and body side.
Open stop valve (6) on the side of low
pres-sure relief valve (5) and while watching
the pressure gauge (for low pressure)
connected to the body side and also by
regulating low pressure relief valve (5),
gradually increase the pressure and check for
outside leakage with a color check at a
pressure of 5 kgf/cm2 (71psi).
9
Connect to
body side
2
Connect to
stem side
3
8
Hydraulic
source
Fig. 6-12 Hydraulic circuit for inspection equipment
Table 6-5
Item
Description
1 Pressure Gauge
Remarks
High and Low Pressures
are required.
2 Swivel Joint
3 Stop Valve
5
Relief Valve for

low pressure
Setting Pressure :
5kgf/cm2 (71psi)
6 Stop Valve
7
Relief Valve for

high pressure
8 Directional Valve
9 Piping, etc.
68
Setting Pressure
(Working pressure1.5times)
6.4
TROUBLESHOOTING
Table 6-6
Trouble
Cause
Remedy
1. External leakage of
hydraulic oil
Defective O ring & seal Replace all seals.
2. Internal leakage of
hydraulic oil
1) Defective slipper seal 1) Replace all seals.

2) Sliding face worn 2) Replace assy.
excessively
1) Stem
and
body 1) Grind and hone.
seized
Replace assy, if stem and body
are too loose and causing oil
leakage.
2) Inappropriate swivel 2) Reinstall
stopper bracket
Secure 2 3mm (0.08 0.12in)
allowance for bolt stopper.
Socket bolt tightened
Retighten.
insufficiently.
3. Swivel stem seized
4. Loose swivel stem and

cover
69
610
E200SR
SECTION 34
TRAVEL SYSTEM
TABLE OF CONTENTS
[Part I. Removing and Installing]
1. TRAVEL SYSTEM .................................................................................................... I-1
2. CRAWLER
2.1 Removing crawler ................................................................................................................ I-1
2.2 Installing ............................................................................................................................... I-2
2.3 Construction ........................................................................................................................ I-3
2.4 Maintenance standard ......................................................................................................... I-4
2.5 Tools and jigs ....................................................................................................................... I-4
3.UPPER ROLLER
3.1 Upper roller assy.................................................................................................................. I-5
3.2 Removing ............................................................................................................................. I-5
3.3 Installing ............................................................................................................................... I-5
3.4 Construction ........................................................................................................................ I-6
3.5 Disassembly and Assembly .................................................................................................. I-6
3.6 Maintenance standard ......................................................................................................... I-9
3.7 Tools and jigs ....................................................................................................................... I-9
4. LOWER ROLLER (TRACK ROLLER)

4.1 Lower roller assy................................................................................................................ I-11
4.2 Removal ............................................................................................................................ I-11
4.3 Installation .......................................................................................................................... I-11
4.4 Construction ...................................................................................................................... I-12
4.5 Disassembly and Assembly ................................................................................................ I-12
4.6 Maintenance standard ....................................................................................................... I-16
4.7 Tools and jigs ..................................................................................................................... I-17

INDEX
5. FRONT IDLER
5.1 Front idler assy ..................................................................................................... I-18
5.2 Removing .............................................................................................................. I-18
5.3 Idler assy .............................................................................................................. I-19
5.4 Idler adjuster assy ................................................................................................ I-23
6. SPROCKET
6.1 Removing .............................................................................................................
6.2 Installing...............................................................................................................
6.3 Maintenance standard .........................................................................................
6.4 Sprocket tooth profile gauge ................................................................................
I-27
I-27
I-28
I-28
7. TRAVEL REDUCTION UNIT

7.1 Travel motor ........................................................................................................ I-30
7.2 Removing ............................................................................................................. I-30
7.3 Installing............................................................................................................... I-31
8. SWING BEARING
8.1 Swing bearing assy .............................................................................................
8.2 Removing .............................................................................................................
8.3 Installing...............................................................................................................
8.4 Construction .........................................................................................................
8.5 Disassembly and Assembly .................................................................................
8.6 Maintenance Standard .........................................................................................
I-32
I-32
I-33
I-33
I-33
I-34

1. TRAVEL MOTOR ................................................................................................... II-1
[Part ; Removing and Installing]
1. TRAVEL SYSTEM
8. SWING BEARING
2. CRAWLER
7. TRAVEL MOTOR
5. FRONT IDLER
6. SPROCKET
GUARD
LOWER FRAME
GREASE NIPPLE OF THE

TRACK SPRING ADJUSTER
3. UPPER ROLLER
4. LOWER ROLLER
Fig. 1-1
Designation and location of undercarriage
2. CRAWLER
2.1 REMOVING CRAWLER
(1) Position the machine to remove crawler.
(2) Pushing out master pin.

1) Find the master pin and place it in its
removing/fixing position in Fig.2.2.
2) Loosen the grease nipple and slacken crawler.
: 19mm
z When loosening the grease nipple of
the adjuster, do not loosen it more
than one turn.
z Where grease does not come out
well, travel the machine back and
forth. The over loosening of grease
nipple may cause it to jump out
incurring danger of injury. So be
careful not to over loosen the grease
nipple.
3) Pushing out master pin
Apply jig on master pin and strike it out with
a mallet.
(Refer to Fig.2-6 Fixing the master pin.)
z When using a big hammer, wear
protective goggles and a long-sleeved
uniform so you do not injure yourself
by flying objects.
Fig. 2-1
Crawler removing position
Removing/fixing
position of master pin
Fig. 2-2
Removing/fixing position of master pin
(3) Removing crawler

Put attachment on ground so that weight is
not loaded to the lower frame, and remove
track link assy by means of rotating sprocket.
Removing
master pin
Crawler end section may fall on the

ground just before extending it on the
ground incurring danger of injury.
Please keep well away from the
equipment.
Fig. 2-3
Removing crawler
2.2 INSTALLING
removing.
(1) Checking crawler installation direction.
Place the track links on the ground so they
converge, facing the front idler, as shown in
the figure on the right.
(2) Installing crawler
1) Preparation for installation
Treat paint flaking protection with care not
to damage lower flame.
Front
idler side
Fig. 2-4
Installing direction of crawler
2) Winding crawler
Insert a crowbar into the master pin hole, lift
the lower frame 1 to 2cm above the ground
level by holding it by hand so the machine
body weight is not exerted on the shoe.
Reverse the sprocket to help push the back
winding of the crawler.
(3) Preparation for press fitting master pin
1) Preparing for installation
Put square wood under the shoe plate.
2) Aligning master pin holes
Aligning master pin holes through fine
adjustment turning sprocket.
Fig. 2-5
Winding crawler
z When using a big hammer, exercise

care so you are not injured by flying
objects the same way as when
pushing out the master pin.
z Coat
the
master
pin
with
molybdenum disulfide grease, before
pressing it in.
(4) Press fitting of master pin
Apply press fitting jig on master pin, and
strike it with a mallet to press fit.
2
Press fitting jig

on master pin
Fig. 2-6
Press fitting of master pin
(5) Adjusting crawler tension(See Fig. 2-8)

After installing, adjust tension of crawler.
: 19mm
Standard dimension
A
Dimension of iron crawler in
a max. slackened condition
320350mm
(12.613.8in)
Fig. 2-8 Adjusting crawler tension

2.3 CONSTRUCTION
No.
1
1-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
2
3
4
PARTS
LINK ASSY
TRACK LINK R
TRACK LINK L
BUSHING
PIN
MASTER BUSHING
MASTER PIN
COLLAR
SEAL
SHOE 600mm
BOLT 2420Z1292
NUT 2420Z1293
1-1
STD
LC
QTY QTY
1
1
46
49
46
49
45
48
45
48
1
1
1
1
2
2
90
96
46
49
184
196
184
196
1-4
1-8
1-8
1-3
1-7
1-7
1-2
1-5
1-1
1-2
Fig. 2-9 Track link assy
Fig.2-10
Shoe plate
1-6
2.4 MAINTENANCE STANDARD
Fig. 2-10
Table 1-1
No.
ITEM
A Link pitch
B O.D. of bushing
C Height of link
Interference
D between bushing
and link
Interference
E between track pin
and link
STANDARD VALUE
1900.1 (7.48030.0039)
58.780.05 (2.31420.0020)
1060.3 (4.17320.0118)
Basic
Tolerance
dimension
58.78
0.05
(2.3142) Shaft (0.0020)
36.63
(1.4421)
Shaft
0.05
(0.0020)
Unitmm(in)
REPAIRABLE
LEVEL
SERVICE LIMIT
REMEDY
194 (7.64)
55 (2.17)
100 (3.94)
198 (7.80)
54 (2.13)
98 (3.86)
Replace the link

assy if the
service limit is
exceeded
Fit
Fit
Interference
0.05 (0.0020)
Interference
0
Interference
0.05 (0.0020)
Interference
0
0.03
36.50
Interference
0.088
Shaft
(1.43701)
0.05 (0.0020)
0.00118
0.00315
Clearance between
1.5 (0.06)
8 (0.32)
G links
(both side)
(both side)
Tightening torque
H
87kgfym (630 lbfyft)
of shoe bolt
Interference
F between master
pin and link
2.5 TOOLS AND JIGS

(1) Tightening tools
NAME
Socket
Unit : mm
Interference
0
Replace
Link
10 (0.39)
(both side)
Replace
Retighten
(2) Jig
OPPOSING FLATS
NAME
30
Master pin
fixing jig
for iron
crawler
Replace
SHAPE
3. UPPER ROLLER
3.1 UPPER ROLLER ASSY
UPPER ROLLER ASSY No.
NAME
ITEM
ASSY
QTY
ROLLER
CAPSCREW
NUT
WASHER
3 4
4
3.2 REMOVING
(1) Preparation for removal
Remove crawler (Above mentioned).
(2) Removing upper roller (1)

1) Remove nuts on support tightening section,
and also remove capscrew (2) M20120.
: 30mm
Fig. 3-1
Removing upper roller
3.3 INSTALLING
removing.
(1) Inspection
Before reassembling, check it that it rotates
smooth manually and for leakage.
Countersinking
(2) Installing upper roller (1)

1) To install the upper roller, turn up socket
bolts (2) toward the center of machine.
2) Insert it until collar comes in contact with
support.
VIEW
3) Fit it directing the countersinking mark of

shaft end upward.
Center of machine
4) Apply Locktite #262 on capscrew M20120,

and tighten it to the specified torque.
: 30mm,
2,4
Fig. 3-2
5
3,4
Installing upper roller
3.4 CONSTRUCTION
No. NAME
QTY
No. NAME
11
QTY
1 ROLLER
7 FLOATING SEAL
2 SHAFT
8 O RING : 1A
3 COLLAR
9 SOCKET BOLT
4 PLATE
10 PLUG
5 COVER
11 SNAP RING
6 BUSHING
P65
10
Fig. 3-3
(1) Disassembly
1) Draining out oil
Remove plug (10) and drain out oil.
: 6mm
1
5
9
Construction of upper roller
11
10
8
5
1
2) Removing snap ring (11)

Mount the upper roller (1) on stand jig (f) and
separate snap ring (11), using snap ring
pliers.
3) Removing cover (5)

Take off cover (5) upwards, utilizing the
screwed hole for the plug.
Fig. 3-4
4) Removing O ring (8)
Separate O ring (8) from cover (5).
Preparation for disassembly

Push with press
5) Removing plate (4)

Loosen two socket bolts (9) and draw out
plate (4) from roller (1).
: 8mm
2
7
6) Removing shaft (2)

Put the extrusion jig (h) against the end face
of shaft (2) and push shaft (2) with collar (3)
for floating seal (7), using a press or hammer.
Fig. 3-5
6
Extruding shaft
7) Removing floating seal (7).

Take out floating seal (7) from roller (1).
8) Removing floating seal (7).

Remove from collar (3), floating seal (7) that
is located on the side from which shaft (2)
was disparted.
Fig. 3-6
Removing out floating seal

g
Collar (3) is press fitted into shaft (2).

Therefore do not disassemble it.
9) Removing bushing (6)
Since the bushing is thin, machine it on a
lathe or scrape it off, exercise care so as not
to damage the bore of roller (1).
If the bushing is not worn much, mount
upper roller (1) on jig (f), insert jig (g) into the
end face of bushing (6) and push it out with a
press.
3
f
Fig. 3-7
Removing
floating seal
Fig. 3-8
Extruding bushing
Push with press (e)
(2) Assembly
Assembly of the upper roller is done in the
reverse order of disassembly.
1) Place upper roller (1) on the top end face of
jig ( f ) , with its floating seal setting side
facing down.
2) Confirm that the outer surface of bushing (6)
is not seized and coat the outer surface of the
inserting side of the bushing, with
molybdenum disulfide grease.
3) Put jig (i) into bushing (6) and press it in,
using the bore of the bushing and the bore of
the roller as guides.
i
6
1
Fig. 3-9
If you fail in this operation by pressing
the bushing unevenly, the bushing is
distorted and gets unserviceable. In
that case, do not re-use the bushing as
it may develop malfunctioning after
assembly.
Pushing in bushing
2
7
7
3
Fig. 3-10
7
Fixing floating seal
4) Installing floating seals (7).

Two floating seals (7) make a pair. Attach one
floating seal to retainer fixed in shaft (2), and
another to the inside of upper roller (1).
Push with press
z Prior to placing floating seal (7) in,

apply engine oil lightly to seal
surface.
5) Inserting shaft (2).

Coat shaft (2) with a thin film of oil and
insert it into upper roller (1).
Fig. 3-11
6) Installing plate (4).
Mount upper roller (1) on the stand jig ( f )
and attach plate (4) to the end face of the
shaft with bolt (9).
: 8mm,
Tightening torque : 11.7kgfym (85
lbfyft)
Inserting shaft
11
8
5
4
1
7) Installing O ring (8).

Fit O ring (8) to the groove of cover (5).
z Apply grease to O ring.
f
8) Installing cover (5).

Attach cover (5) to upper roller (1). Use a
press in this operation as a press fit is used.
9) Installing snap ring (11).
Fix snap ring (11) into upper roller (1), using
snap ring pliers.
Fig. 3-12
Installing cover
10) Filling oil

Fill in 30cc (1.83cuyin) of engine oil API grade
CD#30 through the plug hole in cover (4).
11) Installing plug (10).

Wind seal tape around plug (10) and screw it
into the plug hole of cover (4).
: 6mm,
z After assembling the upper roller,

confirm that oil is not leaking from it
and that it rotates smoothly by hand.
Fig. 3-13
8
Filling oil
D
B
Table 3-1
No.
ITEM
Dia.
Width
Tread dia.
Tread width
Clearance
between shaft and
bushing
Interference
between roller
and bushing
Tightening torque
of socket bolt
Oil
Roller rotation
Unit : mm (in)
REPAIRABLE
LEVEL
SERVICE LIMIT
160 (6.30)
150 (5.91)
130 (5.12)
128 (5.04)
Fit
Fit
Clearance
0.7 (0.028)
Clearance
1.0 (0.039)
Interference
0
Clearance
0.01 (0.0004)
STANDARD VALUE
140 (5.51)
33 (1.30)
Basic
dimension
Tolerance
50
(1.96850)
Shaft
55
(2.16535)
Hole
0.025
0.050
0.00098
0.00197
0.030
0
0.00118
0
REMEDY
Replace
Replace bushing.
11.7kgfym(85 lbfyft)
Engine oil API grade CD #30, 30cc (1.83cuyin)
Refill
Roller rotates smoothly by hand.
Reassembly
3.7 TOOLS AND JIGS

Unit : mm
NAME
OPPOSING FLATS
Socket
30
Allen wrench
6,8
(2) Jigs
Unit : mm (in)
No.
NAME
SHAPE
140 (5.51 )
160 (6.30 )
100 (3.94 )
Stand jig
18
(0.71 )
For
extruding
bushing
30
(1.18 )
52.5 (2.07 )
Bushing
fixing jig
49
20
(0.79 )
(1.93 +0.004
)
0
For
extruding
shaft
(2.36 )
+0.1
0
49 (1.93 )
50
(1.97 )
70
(2.76 )
10
4.
LOWER ROLLER (TRACK ROLLER)
4.1 LOWER ROLLER ASSY

ITEM
NAME
1
2
3
4
LOW ROLLER
CAPSCREW
TRACK GUIDE
CAPSCREW
STD LC
Q
TY
4 Apply Locktite #262
REMARKS
14 16
56 64 M1880(P=1.5)
2
2
8
8 M1840(P=1.5)
2
Apply Locktite #262
Fig. 4-1
Lower roller assy and track guide
4.2 REMOVAL
1) Loosen the tension of the crawler, lift up the
lower frame by the front attachment and stop
the engine in that condition.
2) Place a safety block (wooden) at the front and
back of the lower frame.
(2) Removing track guide
Remove capscrews (4) and remove track guide.
: 27mm
Weight of track guide : Approx.24kg (52 lbs)
SAFETY BLOCK
(Square timbers)
Fig. 4-2
Preparation for removal
(3) Remove lower roller

Remove capscrews (2) and remove lower roller
(1).
: 27mm
Weight of lower roller : Approx.35kg (77 lbs)
4.3 INSTALLATION
(1) Installation of lower roller
Coat mounting capscrews (2) with Locktite #262
and fasten all four capscrews temporarily. Then
tighten them to a specified torque.
: 27mm
Fig. 4-3 Installing lower roller
(2) Installation of track guide

Capscrews (4) with Locktite #262 and fasten all
four capscrews temporarily. Then tighten them
to a specified torque.
: 27mm
GREASE NIPPLE
(3) Adjusting tension of crawler.

Tighten grease nipple and fill it with grease.
: 19mm,
Tightening torque : 6kgfym(43 lbfyft)
Fig. 4-4
11
Adjusting tension of crawler
4.4 CONSTRUCTION
No.
NAME
ROLLER
COLLAR
SHAFT
4
5
6
BUSHING
PIN
2
2
2
O RING
1A,G60
PLUG
PT1/4
FLOATING
SEAL
4 1 6 2 7 5
QTY REMARKS
3
Fig. 4-5
Construction of lower roller

(1) Disassembly
1) Drain oil
Remove plug (8) and drain out oil.
: 6mm
2
2) Removing pin (5)

Put both ends of lower roller assy on the
V-shaped blocks (K), apply push-out bar ( )
on upper end face of pin (5), and push pin (5)
out striking with mallet.
3) Removing collar (2), O ring (7)

Put lower roller on jig (m) for repair stand so
that the shaft (3) is perpendicularly located,
apply push-out jig (P) on shaft end on upper
side, and push shaft (3) until the O ring (7)
separate from collar (2) with press or mallet,
and take out collar (2) and O ring (7).
Fig. 4-6
Pushing out collar fixing pin (5)
JIG P
2
1
4) Removing shaft (3)

In addition, push out and remove shaft (3)
together with the lower collar (2) and O ring
(7).
3
JIG m
The shaft (3) extrusion operation may

cause the remaining lube oil to flow
out.
Prepare
an
oil
container
beforehand.
Fig. 4-7
12
Removing shaft (3), collar (2), O ring (7)
5) Removing collar (2), O ring (7)

Remove O ring (7) from shaft (3) that was
drawn out in the previous par.(1).
6
6) Removing floating seal (6)
Remove floating seal (6) from collar (2).
2
7) Removing floating seal (6)

Remove floating seal (6) from roller (1).
Fig. 4-8
Removing floating seal (6)
Fig. 4-9
Removing floating seal (6)

Since thickness of bushing (4) is thin
[thickness is 2.0mm (0.079in)], remove it
through lathe or strip it with care not
damage inner hole of roller. When the wear of
bushing is not large, place upper roller (1) on
jig (m) for repair stand and apply the end of
push-out jig on the end face of bushing (4)
end, and push it out striking it with mallet.
n
1
Hammer the inside surface of roller

lightly so as not to damage the surface.
Put the extrusion jig (n) uniformly over
the circumference of bushing (4) and
extrude it perpendicularly little by
little.
JIG m
Fig. 4-10
13
Extruding bushing (4)
(2) Installing
1) Attach O ring (7) to one side
Install O ring (7) to groove on shaft.
z Grease O ring.
z Replace O ring with new one without
fail at reassembling.
Fig. 4-11
Attach O ring (7) to one side
2) Press fitting bushing (4)

Align inner hole of roller (1) and bushing (4)
and press fit it vertically in capacity of press
fit load, 5ton (11000 lbs), in the condition that
bushing push-in jig (Q) is inserted into
bushing (4).
JIG Q
z Apply molybdenum disulfide grease

on press-fit section of bushing, and
press fit it in ordinary temperature.
z Bushing which fails to press-fit
because of the uneven pressing
should not be fitted.
Fig. 4-12
3) Press fitting collar (2)

Fit O ring (7) to the one side of shaft (3)
mating pin hole of collar (2) on which floating
seal (6) is fit with pin hole of shaft (3) in
advance. Use the press of capacity 17 ton
(37500 lbs) or more.
Press fitting bushing (4)
z Care should be taken not to damage

O ring (7) while press-fitting collar
(2) to shaft (3).
7
Fig. 4-13
Inserting pin (5)
4) Inserting pin (5)

Press-fit pin (5) to pin hole on aligning pin
holes of shaft (3) and collar (2).
5) Attach floating seal (6) to roller side
Fit floating seal (6) to inner holes on both
ends of roller (1).
z Check that the seal surface is free
from flaws, rusts, etc. before reusing
the floating seal.
6) Inserting roller (1)
Insert roller (1) from the side where collar (2),
O ring (7) is not press-fitted to the shaft (3).
3
2
Fig. 4-14
14
Inserting roller (1)
7) Installing O ring (7)

Install O ring (7) to groove on shaft.
Press
z Grease O ring.
z Replace O ring with new one without
fail at reassembling.
Pin hole
2
7
8) Press fitting collar (2)

Press-fit collar (2) to shaft (3).
z Press-fit collar (2) on aligning pin (5)
hole.
9) Inserting pin (5)

Press-fit pin (5) in to the pin hole mating pin
hole of collar (2) with pin hole on the end side
of shaft (3).
Fig. 4-15
Installing O ring (7), collar (2)
10) Filling oil

Remove plug (8) and fill in 160cc (9.8cuyin) of
engine oil API grade CD#30.
11) Check it for leakage
Before tightening plug (8), check it for
leakage in the condition of air pressure
2.0kgf/cm2 (28psi).
8
Tightening
torque
2.4kgfym
(17 lbfyft)
12) Installing plug (8)

Apply oil resistant sealant on plug (8), and
tighten it in the plug hole on the collar (2)
end face.
: 6mm,
Fig. 4-16
After assembling the lower roller,

confirm that oil is not leaking and that
the roller rotates smoothly by hand.
15
Installing filling oil plug (8)
Fig. 4-17
Lower roller (Track roller)
Table 4-1
No.
ITEM
STANDARD VALUE
Unit : mm (in)
REPAIRABLE LEVEL
SERVICE LIMIT
O.D. of flange
185 (7.28)
Tread dia.
150 (5.91)
134 (5.28)
128 (5.04)
Flange width
23.5 (0.925)
18 (0.709)
16.5 (0.65)
Fit
Fit
Clearance
0.7 (0.276)
Clearance
1.0 (0.394)
Basic
Clearance between
shaft and bushing
(Wrapped bushing)
Interference
between roller and
bushing
Oil
Plug (8)
Roller rotation
Reinforcement
Tolerance
dimension
65
(2.55905)
0.060
Shaft
REMEDY
0.090
0.00236
0.00354
0.030
Interference
Clearance
0.020
Hole
0.00118
0
0.01 (0.0004)
0.00079
Engine oil API grade CD #30, 160cc (9.8cuyin)
weld, repair or
replace
Replace
bushing.
69
(2.71653)
Execute air leak test at
2.0kgf/cm2
(28psi) before tightening the plug.
Rotates smoothly by hand.
16
Refill
Reassembly
4.7 TOOLS AND JIGS

Unit : mm
NAME
OPPOSING
Socket
19,27
Allen wrench
FLATS
(2) Jigs
Unit : mm (in)
SHAPE
V-block
Pin (5)
100 (3.94 )
extrusion
(0.55 )
NAME
14
No.
Bushing
n
16
(0.63 )
rod
200
extrusion
rod
270
extrusion
jig
64.5
(2.54 )
94.5
(3.72 )
30
86
(1.18 ) (2.52 )
Shaft
125
(4.92 )
Stand jig
64
160
(6.30 )
290
Bushing
fixing jig
+0.1
64.6 0
(2.54 +0.004
)
0
17
5. FRONT IDLER (IDLER ADJUSTER ASSY)

5.1 FRONT IDLER ASSY
No.
1
2
3
4
NAME
IDLER ASSY
IDLER ADJUSTER ASSY
GREASE NIPPLE
CAPSCREW
Q
TY
2
2
2
4
Apply Loctite#262 or equivalent

REMARKS
M1645
3
Fig. 5-1 Front idler assy
5.2 REMOVING
Remove crawler. (Above mentioned)
CROWBAR
(2) Removing idler assy

Sling idler assy, and push it forward with
crowbar.
Weight of crawleridler assy : 420kg (926 lbs)
(Sum total of both sides.)
Keep away from the front side of front

idler.
(3) Installing
removing.
Fig. 5-2
idler
Removing
and
installation
the
(4) Where idling assy (1) has to be separated

Loosen capscrew (4), and separate idler assy
(1) from idler adjuster assy (2).
: 24mm
Weight of idler assy : 107kg (236 lbs)
Weight of idler adjuster assy : 103kg (227 lbs)
z The separated idler assy should be

placed on square timbers.
Fig.
18
5-3
Separating idler assy

from idler adjuster
(1)
front
5.3 IDLER ASSY

5.3.1 CONSTRUCTION
No.
NAME
Q
TY
IDLER
BUSHING
COLLAR
FLOATING SEAL
PIN
SHAFT
O RING
PLUG
1
2
3
7
8
6
5
4
Fig. 5-4
Idler assy
5
R
5.3.2 REMOVING AND INSTALLING

(1) Removing
1) Drain oil
Remove plug (8) on the side of collar (3) to
drain.
: 5mm
2) Removing pin (5)
Apply pin push bar (jig R) to the top of pin,
and push out striking bar (jig R) lightly by
hammer.
Fig. 5-5
Removing pin (5)
Push with press
3) Removing collar (3)

Put idler (1) on repair stand (U), apply
push-out jig (S) on shaft (6), push out shaft
(6) with collar (3), then remove collar (3).
3
Fig. 5-6
Removing collar (3)

Push with press
4) Removing collar (3) from shaft (6)

If removal of collar (3) on the opposite side is
required, turn over front idler and proceed
with the procedure described in Par. 3).
S
6
Fig. 5-7
19
Removing collar (3)

With idler (1) mounted on the stand, tap
bushing (2) lightly by hammer, while placing
the bushing drawing rod (T) against the end
face of bushing (2) evenly all round, till it
comes out.
6) Removing floating seals (4)
Take out floating seals (4) from idler (1),
collar (3). If you intend to re-use floating
seals (4), confirm that there is no scoring and
rusting on the contact surface and store the
floating seals in pairs by placing card board
between the sealing faces.
7) Removing O ring (7)

Separate O ring (7) from shaft (6).
Fig. 5-8
(2) Assembly
1) Pressing in bushing (2)
Align inner hole of idler (1) and bushing (2)
and press fit it vertically with press so that
jig (V) for bushing press-fitting is inserted
into bushing (2).
Removing bushing (2)
2 Push with press
2) Installing O ring (7)

Fit O ring (7) to groove on shaft (6).
z Apply grease to O ring
Fig. 5-9
3) Installing collar (3) (See Fig. 5-10)

Press fit the O ring (7) installed side of shaft
(6) into collar (3), and drive pin (5).
Pressing
6
4) Installing floating seal (4)

Fit the half of floating seal (4) on each side of
collar (3) and idler (1).
5) Inserting idler (1)
Insert floating seal (4) fitted side of idler (1)
into shaft (6).
3
5
Fig. 5-10
Installing collar (3), shaft (6)

6
6) Installing floating seal (4)

Fit floating seal (4) on the other side of idler
(1).
4
1
Fig. 5-11
20
Pressing in bushing (2)
Inserting idler (1) and installing

floating seal (4)
7) Installing collar (3)

Fit the half of floating seal (4) on the other
collar (3), press fit it in shaft (6), and drive
pin (5) in with hummer.
3
5
8) Filling oilInspection
Fill in 200cc (12.2cuyin) of engine oil API
grade CD #30 through the plug hole of collar
(3), wind seal tape and tighten plug (8).
: 5mm
Fig. 5-12
Installing collar (3) and filling oil
z After installing the idler assy to the

idler adjuster assy, make certain
that no oil leaks from floating seal
and plug (8) and that idler (1)
rotates smoothly.
160 (6.30)
C
A
Fig. 5-13
5.3.3 MAINTENANCE STANDARD
Front idler
Table 5-1
No.
STANDARD VALUE
REPAIRABLE LEVEL
SERVICE LIMIT
Dia. of idler
projection
535 (21.1)
Tread dia.
497 (19.6)
490 (19.3)
487 (19.2)
Flange width
840.5 (3.3070.020)
78 (3.07)
76 (2.99)
Fit
Fit
Clearance
1.5 (0.059)
Clearance
2.0 (0.079)
Interference
0
Clearance
0.01 (0.0004)
ITEM
Unit : mm (in)
Clearance
between shaft
and bushing
Interference
between idler
and bushing
Oil
Idler rotation
Basic
dimension
75
(2.95275)
83
(3.26771)
Tolerance
Shaft
Hole
0.030
0.060
0.00118
0.00236
0.036
0
0.00142
0
REMEDY
Replace
Replace
bushing.
Engine oil API grade CD#30, 200cc (12.2cuyin)
Refill
Rotates smoothly by hand.
Reassemble
21
5.3.4 TOOLS AND JIGS

Unit : mm
NAME
OPPOSING
Socket
24
Allen wrench
FLATS
(2) Jigs
Unit : mm (in)
SHAPE
20
striking jig
70
Bushing
Press fitting
jig
(2.91 )
Shaft
push out jig
74
340 (13.4 )
(0.79 )
(2.76 )
90
(3.54 )
Pin
SHAPE
105 (4.13 )
15
105
(4.13 ) (0.59 )
+0.
74.61
(2.94 +0.004
)
0
Bushing
drawing rod
About. 150 (5.91 )

About. 600
(23.6 )
Stand
About.
400
(15.7 )
2 pcs.
22
Collar Press
fitting jig
30
(0.63 )
300 (11.8 )
16
103 (4.06 )
(1.18 )
NAME
30
(1.18 )
No.
(0.59 )
NAME
15
No.
5.4 IDLER ADJUSTER ASSY

5.4.1 CONSTRUCTION
No.
NAME
Q
TY
1 GREASE CYLINDER
2 BRACKET
3 NUT
4 SPRING PIN
5 SPRING
6 PISTON
7 COLLAR
8 O RING
9 OIL SEAL
10 PIN
11 COVER
REMARKS
9 8
880
11
1B
10
G80
Fig. 5-14

(1) Disassembly
1) Spring set special jig
Before disassembling and assembling the
idler adjuster assy, prepare spring setting jig
(V).
M30
Holding-down nut
Retainer plate
Capacity of hydraulic jack : more than 20

tons (44000 lbs)
: 46mm
Large power is needed to set the
spring. Prepare a special jig before
disassembly and assembly.
Idler adjuster assy
V
Hydraulic jack
BASE
Fig. 5-15
2) Preparation for working
Place a hydraulic jack between the jig base
and the stand.
Loosen the holding-down nuts of the jig and
draw out the retainer plate upward.
: 46mm
3) Draw out grease cylinder (See Fig. 5-14)
Draw out piston (6) from grease cylinder (1)
of the idler adjuster assy.
4) Removing oil seal (9), O ring (8)
(See Fig. 5-14)
Taken out oil seal (9) and O ring (8) from
grease cylinder (1).
5) Slinging work idler adjuster

Set the idler adjuster assy on the stand of
the jig, with its bracket side facing up.
V
Fig. 5-16
23
Spring set special jig (V)
Slinging idler adjuster
6) Fixing idler adjuster assy

Fit retainer plate to bracket (2), tighten
holding-down nuts alternately, and secure
idler adjuster assy.
Holding-down nut
: 46mm
Retainer plate
3,4
Fig. 5-17
Fixing idler adjuster assy
7) Compression of spring (5)

Remove spring pin (4), press spring (5) lifting
it with jack so that nut (3) can be turned
freely, and remove nut (3).
: 46mm
: 75mm
Fig. 5-18
Compression of spring (5)
8) Removing bracket (2)

Allow the hydraulic jack to retract slowly till
the spring is extended to its free length.
Remove the retainer plate and take off
bracket (2), cover (11).
The free length of the spring :
About 531.1mm(20.9in)
Retainer plate
2
11
: 46mm
Fig. 5-19
9) Removing spring (5), grease cylinder (1)
Hook lifting eye nut (W) to screw M48P2 on
grease cylinder (1) top end and hoist it. Then,
remove the set of grease cylinder (1) and
spring (5) using crane from the jig.
Remove spring (5), collar (7), grease cylinder
(1), in that order.
Removing retainer plate, bracket (2)

W
Fig. 5-20 Removing spring (5), grease cylinder (1)
24
(2) Assembly
Assembly is done in the reverse order of
disassembly.
1) Installing spring (5), grease cylinder (1)
Insert grease cylinder (1), collar (7) into
spring (5) and attach lifting eye nut (W) to
screw M48 P2 at the tip of the grease
cylinder. Lift the grease cylinder by crane
and erect it in the center of the jig stand
upright.
2) Fixing idler adjuster assy

Install bracket (2), cover (11) on top of spring
(5). Center the rod of grease cylinder (1) and
the holes in bracket (2). Attach the retainer
plate and four holding-down nuts. Fasten the
nuts evenly all round and fix the idler
adjuster assy to the jig body.
W
1
Fig. 5-21 Attach spring (5) and grease

cylinder (1) to the jig
Holding-down nut
Retainer plate
: 46mm
2
4
3
3) Compressing spring (5) and installing nut (3)

Extend the hydraulic jack, compress spring
(5) to a set length and screw in nut (3) to the
screwed part at the tip of grease cylinder (1).
11
1
5
Set length of the spring : 429mm (16.9in)

4) Installing spring pin (4)
Tighten nut (3) till the holes for locking
spring pins (4) are aligned. Then fit spring
pin (4).
Fig. 5-22 Compression of spring (5), and

attaching nut (3) and spring pin (4)
: 46mm
: 75mm
5) Removing idler adjuster assy
Remove idler adjuster assy from jig.
Fig. 5-23 Removing idler adjuster assy
25
6) Installing oil seal (9), O ring (8)

Fit oil seal (9) and O ring (8) to grease
cylinder (1).
z Grease oil seal (9) and O ring (8).
7) Filling grease cylinder(1) with grease.

Fill up grease in cylinder (1), remove the
grease nipple from piston (6) to discharge the
inside air, and press in the piston by hand.
z Direct grease nipple hole downward
to make air discharge easier.
Grease Nipple
Fig. 5-24
Grease cylinder (1)
8) Installing grease nipple

Tighten grease nipple to piston (6).
: 19mm,
5.4.3 MAINTENANCE STANDARD

No.
ITEM
STANDARD
VALUE
A Installed length of spring
429mm (16.9in)
B Free length of spring
About. 531.1mm
(20.9in)
C Stroke
50mm (1.97in)
D Set length
630mm (24.8in)
E Outside view of piston

Tightening torque of
F grease nipple
Nor scoring
and rusting
6kgfym
(43 lbfyft)
C
E
A, B
D
26
6. SPROCKET
6.1 REMOVING
Remove crawler referring to Section 2.
"Crawler", lift up crawler frame with
attachment, and put it on square timbers to
float and stabilize.
Fig. 6-1
Preparation for removal
(2) Removing sprocket

Loosen twenty two capscrews (2) M1850,
for the attaching of the sprocket, and remove
the sprocket (1).
Weight of sprocket : 57kg (126 lbs)
: 27mm
Fig. 6-2
1
Removing sprocket
6.2 INSTALLING
(1) Check before installing
Check the mating portion of the travel
reduction unit and the sprocket, eliminate
burrs and contamination thoroughly and
install the sprocket.
(2) Securing sprocket temporarily
Coat the sprocket attaching capscrews with
Locktite #262 and fasten the sprocket
temporarily.
(3) Securing sprocket completely
Remove the wooden blocks under the track
frame, bring the machine down on the ground
and tighten the sprocket.
: 27mm,
Fig. 6-3
27
Securing sprocket temporarily
6.3
MAINTENANCE STANDARD
Table 6-1
96.07mm
PITCH
(3.78in)
SPECIFICATION
ROLLER 58.72
DIA.
(2.31in)
NUMBER
21
OF TEETH
PITCH
644.602
DIA.
(25.333in)
Fig. 6-4
Sprocket
Table 6-2
No.
NAME
STANDARD VALUE
REPAIRABLE LEVEL
SERVICE LIMIT
REMEDY
664
(26.1)
656
(25.8)
654
(25.7)
Reinforcement weld,
repair or replace.
704 (2.7510.157 )
64 (2.52)
62 (2.44)
586 (23.1)
578 (22.8)
576 (22.7)
A O.D. of sprocket
B
Width of
sprocket teeth
O.D. of sprocket
C bottom
6.4 TOOLS AND JIGS

Unit : mm
NAME
Socket
Unit:mm(in)
OPPOSING
FLATS
27
28
Replace.
Reinforcement weld,
repair or replace.
(2) Sprocket tooth profile gauge : W

Unit : mm (in)
Fig. 6-5
Tooth profile gauge (Full scale)
29
7. TRAVEL
MOTOR
Apply Loctite #262
or equivalent
7.1 TRAVEL MOTOR

No.
NAME
Q
TY
REMARKS
TRAVEL MOTOR ASSY
SPROCKET
CAPSCREW
44 M1855
CAPSCREW
34 M2060
Apply Loctite #262

or equivalent
1
0
Fig. 7-1
Installing travel motor
7.2 REMOVING
Remove crawler, lift up crawler frame using
attachment, and put it on square timbers to
float and stabilize.
7
(2) Removing cover (1)

Remove sems bolt (7) M12 25 and also
remove covers (1).
: 19mm
Fig. 7-2
Removing and installing cover (1)
(3) Preparation of oil pan
(4) Removing hydraulic pipe

Bleed air in hydraulic oil tank, remove all
pipes connecting to travel motor. Then plug
up all pipes and joint section to protect them
from entry of dust.
: 19mm, 27mm, 32mm, 41mm
Refer to tool 4.plug (1).
Hydraulic pipe plug 4-1
11 See tools
ORS plug 4-1
Fig. 7-3 Removing and installing hydraulic pipe

30
(5) Removing sprocket

Removing forty four (both side) capscrews (2)
M1850.
: 27mm
2
Fig. 7-4
Removing and installing sprocket
(6) Loosening travel motor attaching bolts (3)

Apply match marks on travel motor and
lower frame, and remove thirty four (both
side) capscrews (3) M2060.
Remove pipes.(Disconnect)
: 30mm
3
(7) Slinging travel motor assy

Sling travel motor with nylon sling applied on
the side close to sprocket installing section
and remove the motor.
Weight of
Fig. 7-5 Removing and installing travel motor

attaching bolts
motor : About. 240kg (529 lbs)
7.3 INSTALLING
Installing of the travel motor piping is performed
in the reverse order of removal.
1) Cleaning
Check that contact surface of travel motor
and lower frame is free from burr and stain.
Tighten capscrew and hydraulic pipes to the
torque specified in "Tightening Torque".
Fig. 7-6
Tightening
RE-MA
Torque
RKS
kgfym(lbfyft)
NAME
SIZE
Tools
HEX
No.
Sems bolt
M12
19
M18
27
M20
30
55 (400)
5 (36)
15 (110)
28 (200)
3.7 (27)
11 (80)
26 (190)
Capscrew
3) Fill inside from motor drain port to casing with
hydraulic oil before piping for drain. When
starting operation, operate motor in low idling
and at low speed for several minutes, and check
it for possible oil leakage and noise.
Slinging travel motor
Flareless
nut for 101.5 19
182.5 32
pipes,
41
28
sleeve
PF1/4 19
Connector PF1/2 27
41
PF1
31
8.5 (61)
Apply
40.5 (290) Loctite

#262
8.
SWING
BEARING
8.1 SWING BEARING ASSY

No.
NAME
QTY
SWING BEARING
CAPSCREW
36
REMARKS
M20P1.565
FRONT
Inner S zone position of

swing bearing
SECTION AA
Fig. 8-1 Swing bearing assy
8.2 REMOVING
(1) Matchmarks
Remove upper structure, apply matchmarks
on inner race of swing bearing and lower
frame.
Swing bearing
Outer race
(2) Remove thirty six capscrews (2) M2065 for

installation inner race.
: 30mm
Inner race
Matchmarks
(3) Drawing out grease

Remove grease in grease bath.
Fig. 8-2 Matchmarks
(4) Removing swing bearing
Attach eyebolt on swing bearing and sling it.
Weight of swing bearing : 220kg (485 lbs)
Swing bearing
Eye bolt
Grease bath
Fig. 8-3 Removing and installing swing bearing
32
8.3 INSTALLING
(1) Cleaning
Clean it completely so that installing surfaces
of swing bearing and lower frame are free
from dust and stain.
FRONT
(2) Installing
Install swing bearing on lower frame meeting
the matchmarks and positioning the S mark
on inner race as shown in the figure.
(3) Temporary fastening of inner race
Coat the threads of the capscrews (2) with
Locktite #262 and tighten all the capscrews
(2) temporarily.
: 30mm
Inner S zone position of

swing bearing
Fig. 8-4
Location of S mark on swing bearing
(4) Regular tightening of inner race

Tighten the capscrews (2) at 180 degrees
intervals alternately to a specified torque.
:30mm,
Tightening torque :
2 Locktite #262 or equivalent

to be applied
(5) Filling grease.

Fill grease bath with 8.3kg (18 lbs) of grease
NLGI-2 (containing molybdenum disulfide) or
equivalent.
SECTION
Fig. 8-5
AA
Removing and installing capscrew (2)
8.4 CONSTRUCTION
No.
1
2
3
4
5
NAME
QTY
1
1
BALL
104
RETAINER 104
SEAL
1
OUTER RACE
INNER RACE
No.
6
7
8
9
NAME
SEAL
TAPER PIN
PLUG
GREASE NIPPLE
QTY
1
1
1
1
(PT1/8)
6
1
9
8
7
3,4
5
2

(1) Disassembly
1) Take out seal (5) fitted in the groove in the
outer circumference under inner race (2) and
seal (6) fitted in the groove in the inner
circumference on top of outer race (1) and
place them level on a square wooden block or
something.
2) Draw out taper pin (7), using a hammer and
an extrusion rod.
3) Draw out plug (8), utilizing an pull bolt
inserted in the screwed hole (M10) in the
center of the plug and using a puller.
33
Fig. 8-6
Cross-sectional view of swing bearing
EYE BOLT
7
1
Square wooden
block
8
5
Fig. 8-7
Removing swing bearing
4) While rotating outer race (1) little by little,

take out ball (3) and retainer (4) through plug
hole, in that order.
3
Fig. 8-8
(2) Installing
1) Thoroughly degrease the groove for seal (6)
located on the inner surface of outer race (1)
and the groove for seal (5) located on the
outer surface of inner race (2). Coat the
grooves with adhesive Cyano Bond PX-3000
or equivalent, fit seal (5) and place it on a
surface plate.
2) Lower outer race (1) to the position where
upper surface of inner race (2) and lower
portion of seal groove is mated, put adjusting
washer under outer race (1) so that outer
raceway surface of ball (3) aligns with inner
raceway, and support it.
3) Insert ball (3) and retainer (4), on which
grease is applied, through plug (8) hole on
outer race (1), alternately.
To insert ball (3) and retainer (4), use a
push rod, etc., to protect persons from
injury from inserting fingers into plug
hole.
Removing balls (3) and retainers (4)
1
6
Push rod
2
Square
wooden block
Fig. 8-9
Fitting balls (3)
Eye bolt
Hooked rod
4) Fit plug (8) to outer race (1) while checking it

for direction and position of taper pin hole.
5) Coat seal (6) with adhesive Cyano Bond
PX-3000 equivalent and fit it in the groove of
outer race (1).
6) Check that grease nipple (7) is properly
fitted, and fill it with grease. Then, check
bearing for smooth rotation and flaws on seal
lip portion.
z Shell Alvania EP#2 ; 160cc (9.8cuyin)
Maintenance standard concerning wear of swing
bearing is described in the section Maintenance
Standard and Test Procedure in the separate
volume.
34
4
Square
wooden block
Fig. 8-10
Fitting retainer (4)
1.1 CONSTRUCTION OF TRAVEL MOTOR

35
12 13 3 7 5
37
40 24
28
* : Apply Locktite #242

Tightening
torque
36
20
kgfym(lbfyft)
Opposing
flats
mm
33
32
17
26
38
18
40
39 _Z
41
10
2
19
30
8
25
22
11
44
50
15 16
4 27
42 45 48 47
49
43
42
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
27
28
29
30
21
23
29
1. REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT
14
46
NAME
Tightening
torque
QTY
CASING
REAR COVER
CYLINDER BLOCK
SHOE RETAINER
FRICTION PLATE
BRAKE PISTON
SEPARATOR PLATE
VALVE PLATE
SHAFT
COUPLING
SHOE PLATE
BALL JOINT
SPRING RETAINER
PISTON ASSY
D RING (SMALL)
D RING (LARGE)
CHECK VALVE
SNAP RING
SNAP RING
TILTING PISTON
BALL
PIVOT
PISTON SEAL
M6 ORIFICE_0.6
OIL SEAL
SPRING
SPRING(CYLINDER)
SPRING(BRAKE)
BEARING
BEARING
1
1
1
1
3
1
4
1
1
1
1
1
1
9
1
1
3
1
1
1
1
2
1
2
1
3
9
2
1
1
kgfym(lbfyft)
Opposing
flats
mm
23.5 (170)
14
1.4 (10)*
1.5 (11)
3.0 (22)
5
6
11 (80)
32
5.5 (40)
22
5.5 (40)
2.8 (20)
10 (72)
10
No.
NAME
SOCKET BOLT ; M1645
SHIM
PARALLEL PIN ; 612
___
PLUG ; NPT1/16
PLUG ; NPT1/16(Meck : TB)
PLUG
PLUG ; PF1/8
PLUG ; PF1/4
ORING ; 1B P8
ORING ; 1B P11
ORING ; 1B P14
ORING ; 190.172.62
31
32
33
_
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
OVER LOAD RELIEF VALVE_M27
SPOOL
PLUG ; PF3/8
SPRING RETAINER
PIN
SPRING
CONNECTOR
SPOOL ASSY
COVER
SPRING
SPRING RETAINER
RESTRICTOR VALVE
SPRING
PLUG
ORING ; 42.522.62
ORING ; 1B P9
SOCKET BOLT ; M1235
QTY
8
1~2
1
_
1
10
1
3
2
5
4
2
1
2
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
8
58
54
44-3
44-2
44-1
44-4
44-12 44-13
44-9
44-8 44-12
44-10 44-11 44-6
44-7
44-5
60
53
52
57
41
31
51
59
Note) Quantities are worth one overload relief valve.

Tightening
torque
kgfym(lbfyft)
Opposing
flats
mm
11 (80)
32
16 (120)
35
55 56
VIEW_Z (Shows part of the cross-sectional view)

Fig.1-1 Construction of travel motor
No.
44-1
44-2
44-3
44-4
44-5
44-6
44-7
NAME
SOCKET
VALVE
VALVE SEAT
CONNECTING PISTON
PLUG
PILOT BODY
PISTON
QTY
1
1
1
1
1
1
1
Tightening
torque
kgfym(lbfyft)
Opposing
flats
mm
No.
44-8
44-9
44-10
44-11
44-12
44-13
NAME
SHIM
ADJUSTMENT SPRING
O RING ; 1BP7
BACK UP RING
O RING ; 1BG25
BACK UP RING
QTY
1
1
1
2
2
1
II - 1
1.2 CONSTRUCTION OF REDUCTION UNIT
24
15
14 13
16
12
18
25
20
4
7
3
5
10
6
Clearance:0.08 to0.02mm (0.0031 to0.0008in)

Adjust it with only one shim.
1.1mm
0.42.4mm
(0.016 0.094 )
(0.043 )
Storage this unit in condition

that the axis is horizon.
8
1
2
11
26
17
21
22
Fig.1-2
19
23
Construction of reduction unit

Apply Locktite #242
Tightening
torque
kgfym(lbfyft)
Opposing
flats
mm
No.
NAME
QTY
Tightening
torque
kgfym(lbfyft)
Opposing
flats
mm
No.
NAME
QTY
1
2
3
4
5
COVER
CARRIER 1
CARRIER PIN 1
NEEDLE BEARING
THRUST WASHER 1
1
1
3
3
6
14
15
16
17
18
PLANETARY GEAR 2
SPRING PIN840
THRUST WASHER 2
RING GEAR
HOUSING
3
3
6
1
1
PLANETARY GEAR 1
19
BEARING
7
8
9
10
SPRING PIN532
THRUST PLATE
SUN GEAR 1
SUN GEAR 2
3
1
1
1
20
21
22
23
SHIM
LOCK WASHER
SUPPORT RING
FLOATING SEAL
1
2
1
1
11
12
13
CARRIER 2
CARRIER PIN 2
NEEDLE BEARING
1
3
3
24
25
26
SOCKET BOLTM1025
8.0 (58)
28.0 (200)
1.0 (7.2) SEAL
TAPE
8
14
14
SOCKET BOLTM1680
SOCKET PLUGPT3/4
15
19
2
1.3 TRAVEL MOTOR DISASSEMBLY

1.3.1 TOOLS
Table 1-1
TOOLS
Unitmm
SPECIFICATION
Allen wrench
Opposing flats
5, 6, 10, 14
Spanner
Opposing flats
19, 27, 32, 35
Plier for snapring
For shaft 45
Plier for snapring
For hole 3280
Plastic hammer
Torque wrench
23.5kgfym (170 lbfyft) max.
Gear (Bearing) puller
Effective opening dimension: diameter 75 width 45
Holding-down metal fitting
Ex. L160 (6.3)W70 (2.76)H37 (1.46),

20 (0.79)100 (3.94) oval hole:
2 tools are needed.
L
Flat-bladed (), Medium size 2pc.
20
(0.79 )
Screw driver
52
(2.05 )
(0.39 )
90
(3.54 )
10
Oil seal fitting jig
10
(0.39 )
100
(3.94 )
Others
Seal tape
Cleaning oil (Kerosene)
170
(6.69 )
Grease
190
(7.48 )
Hydraulic oil
Rag
250
(9.84 )
Compressed air
22
(0.87 )
DRILL THROUGH 2-18 (0.71)
PCD220
(8.66 )
10
(0.39 )
Brake piston fitting jig
1.3.2 DISASSEMBLY
1) In general, the hydraulic components are
made to precision and have very little
clearance. For this reason, disassemble and
assemble them in a less dusty clean place.
Use clean tools and cleaning oil and handle
them with care.
2) When the motor has been separated from the
machine , clean the ports and the neighboring
areas thoroughly and put plugs into ports so
no dirt, water and other foreign matter enter
the motor.
3) Study the assembly drawing before starting
the work and prepare
necessary parts
according to the purpose and the scope of
disassembly. Seals and O rings once
disassembled can not be used again. Some
parts cannot be supplied singly, but must be
supplied as sub-assemblies. Prepare such
parts beforehand according to the parts
manual.
Separate spring (53), spring retainer (54) and

spool assembly (51).
Put a matching mark on spool
assembly (51) and rear cover (2) so
they are reassembled in correct
directions. (Right and left directions)
Since the screw threads of spool
assembly (51) is coated with
adhesive, further disassembly is not
possible.
Draw out plug (57), O ring (41), spring (56)
and restrictor valve (55).
Remove overload relief valve (44).
: 32mm
Remove coupling (10).
4) Pistons and cylinders do not have specific

combinations when new. If you expect to use
disassembled pistons again, put a matching
mark on each piston and cylinder so they are
reassembled where they were.
10
5) Use care so you do not pinch your finger

between parts and drop parts on your foot.
(2) Disassembly procedure

1) Removing the attached valves.
Remove
the
attached
valves
disassembling the motor.
44
before
58
60
Do not remove such valves that are

not supposed to be taken off because
of the purpose of disassembly.
However, you can not disassemble
the motor without removing the
brake valve.
52
53
54
Loosen socket bolts (60) and take off O rings

(58), (59).
: 10mm
57 41 56 55 59
Fig. 1-3
51
Removing the attached valves
2) Disassembling the motor

Place the motor shaft level and remove all
bolts (31) except two vertically diagonal ones.
: 14mm
AIR SUPPLY 28
Loosen two remaining bolts slowly at the

same time.
Remove rear cover (2) and spring (28), taking
care so cylinder block (3) does not come off
with rear cover (2).
3
In that case, do not drop valve plate

(8), brake spring (28) or O ring (43).
Fig.1-4
8 30 43
31
Removing the rear cover
Remove valve plate (8) so cylinder block (3)

does come off together.
Put a matching mark on valve plate
(8) and rear cover (2) so they are
reassembled correctly. (so the face
and the back are not reversed.)
Push in cylinder block (3), using removed bolt
(31) in the holding-down metal so the
cylinder block is not damaged, till the inner
race of rear bearing (30) sticks out.
Remove the inner race of rear bearing (30) by
putting the gear (bearing) puller in the inner
race.
30
Fig.1-5
5
Removing the rear bearing
Hold down brake piston (6) by hand and

press it out by blowing air through the brake
releasing oil hole.
AIR SUPPLY
7 5
13
Use care as the brake piston pops up

by air pressure.
Put such a bar (marked) that does not score

cylinder block (3) (such as a coiled paper
shaped like a pipe) into the hole of piston (14)
and give a matching mark on the outer
surface of cylinder block (3).
Remove cylinder block (3), spring retainer
(13) and spring (27).
Remove separator plate (7) and friction plate
(5).
Take off nine piston assy (14), shoe retainer
(4) and ball joint(12) at the same time.
With piston assy (14) and shoe
retainer (4) removed, match the
mark with the matching mark and
put them into the cylinder block.
This operation is to insure that the
pistons are reassembled where they
were.
14
MARK
MATCHING MARK
12
Fig.1-6
Take care so as not to score the

moving surfaces. Scored ones can not
be used again.
The piston and the shoe are caulked
together and can not be separated.
(Reference)
The above-mentioned explanations are associated
with a single motor, but the motor with a
reduction gear may be separated the same way.
The motor with a reduction gear may be
disassembled more easily in some cases as the
shaft does not swing too much.
4 27
Removing the cylinder block
Remove shoe plate (11).
Do not remove tilting piston (20). In case it

must be removed for unavoidable reason,
hold down tilting piston (20) by hand and
push it out by blowing air through the hole in
the figure.
Shaft (9) comes off.
Take off snap ring (19) and oil seal (25).
When replacing the bearing, remove the

inner race and the outer race with a bearing
puller and replace them as an assembly.
AIR SUPPLY
25
19
29
Shim (32) is placed under the outer

race of bearing (30). Put it in as it is
at reassembly.
22
Fig.1-7
When replacing such parts that are

related with the fastening allowance
of the bearing such as bearings (29,
30), shaft (9), casing (1) and rear
cover (2), the thickness of shim (32)
needs adjustment.
Measure
the
shim
clearance
correctly when the shim is placed
lightly, replace it with a proper one
and adjust the clearance of the
bearing to 0 to 0.1mm.
A special jig is required to determine
the shim thickness.
Do not take off pivot (22). In case it
must be taken off for indispensable
reason, put a matching mark on shoe
plate (11).
Do not take off oil seal (25). Replace
it with a new one in case it was
taken off.
Removing the shoe plate
20
11
Determining the shim thickness for taper

roller bearing
This operation is necessary when
any of casing (1), rear cover (2), shaft
(9) and bearings (29), (30) has been
replaced.
1. Measure
the
dimension
E
as-assembled condition in Fig.1-8.
Make sure that shaft
perpendicularly positioned.
(Not tilted).
in
(9)
the
9
30
is
2. Measure the dimension F on the rear cover

side.
Measure four diagonal points on the
circumference and make a mean
value.
F
1
3. Suppose the thickness of shim (32) to be used

is "S", the clearance "Y" is as below:
YF(ES)
Fig.1-8
Determining the shim thickness
4. Choose one or two shims that make the

clearance "Y" 00.1mm (00.004 ).
3) Disassembling the overload valve
Remove the overload valve as an assembly,
utilizing the opposing faces of the hexagon of
socket (44-1).
In principle, the overload valve is handled as
an assembly, but in case it must be
disassembled for unavoidable reason, remove
plug (44-5) from socket (44-1) and pull out the
internal parts.
44-3
44-2
44-1
44-4 44-12 44-13 44-9
Fig.1-9
44-8 44-12 44-10 44-11 44-6
Disassembling the overload relief

8
44-7
44-5
1.4 ASSEMBLING THE TRAVEL MOTOR

1.4.1 GENERAL PRECAUTIONS TO BE EXERCISED
(1) Clean the parts in cleaning oil and blow them
with jet air.
(2) Coat the moving parts with clean hydraulic
oil before proceeding to assembly.
(3) Take care so you do not pinch your hand
between parts and you do not drop parts on
your foot.
1.4.2 ASSEMBLY PROCEDURE
(1) Coat the outer surface of oil seal (25) and the
inner surface of casing(1) with grease. Insert
oil seal (25) into casing (1) by lightly tapping
it so it does not tilt, using the fixing jig.
(2) Fix oil seal (25) with snap ring (19).
(3) Put the outer race of bearing (29) into casing
(1) (clearance fit) and press the inner race
into shaft (9). (interference fit).
25
The inner race is set more easily if it

is heated below 100.
Fixing jig of oil seal
(4) Put shaft (9) in casing (1). In that case, coat

the contact surface of oil seal with grease.
(5) Put in tilting piston (20).
(6) Fit pivot (22).
z In that case, put it on the side on
which the matching marks of the
shoe plate are aligned. If the motor
is run for a long time, put the shoe
plate where the traces on the
spherical part match the contact
marks of shoe plate (11).
Fig.1-10
19
25
29
Oil seal fixing
20
22
Fig.1-11
9
Installing the shoe plate
11
(7) Coat the three spherical areas of shoe plate

(11) with a thick film of grease.
(8) Assemble piston assy (14), shoe retainer (4),
ball joint (12), spring retainer (13) and
cylinder spring (27) into cylinder block (3), as
shown in the figure. Then put the whole
assembly into shaft (9).
14
13
Do not fail to bring back each piston

assy (14) into the hole in which the
assy was set.
(9) Install the inner race of bearing (30) to the
end of shaft (9) by lightly tapping it with a
mallet.
(10) Assemble separator plate (7) and friction
plate (5) by turns till all of them are put
together. The first and the last are separator
plates (7).
12
Fig.1-12
27
Assembling the piston assy
(11) Fit brake piston (6) with D rings (15, 16) to

casing (1), using a fixing jig.
The brake piston is equipped with
two D rings (15, 16), large and small.
The larger D ring (16) enters the
hole first and the small D ring (15)
enter the hole later.
You can not check visually that the
smaller D ring (15) is entering.
In some cases, the D ring is scraped
off by the hole of casing (1).
1 14 7 5
15 16
31
30
Fig.1-13
10
BRAKE
PISTON
FIXING JIG
Assembling the brake piston
(12) Put valve plate (8) into rear cover (2)

according to the matching marks left at
disassembly. Fit brake spring (28) and O ring
(43) to the rear cover, insert rear cover (2)
into casing (1), and fasten them together with
socket bolts (31).
: 14mm,
Tightening torque: 23.5kgfym (170 lbfyft)
In case the outer race of bearing (30)
was removed, do not forget to fit
shim (32).
15
18 10
(13) Attach coupling (10).
16
6
28
8
(14) Install overload relief valve (44).

30 32
(15) Put restrictor valve (55) and spring (56) in

cover (52). Then fix the cover with plug (57)
that is fitted with O ring (41).
: 22mm,
Tightening torque: 2.8kgfym (20 lbfyft)
42 2
Fig.1-14
31
Assembling the rear cover
(16) Fit O rings (58), (59) to cover (52).

(17) Put spool assy (51) into rear cover (2)
according to the matching marks left at
disassembly. Then assemble spring retainer
(54) and spring (53).
Exercise care of the orientation of
spool assy (51).
(18) Install cover (52) with socket bolts (60).
: 10mm,
Tightening torque: 10kgfym (72 lbfyft)
44
52 60 58
54
51
57 41 56 5559 53
Fig.1-15
11
60 52
54
53
Assembling the brake valve
1.5 TRAVEL MOTOR

1.5.1 PARTS MAINTENANCE STANDARDS
The following are reference values by which
serviceability of the disassembled parts are
determined. These are general values and the
extent of disassembly should be determined
depending upon the performances, extreme
external damage and discoloration, the purpose of
disassembly and the expected service life.
Table
1-2
Inspection Item / Method

(1) Sliding
surface
of
Criterion and Remedy
cylinder
block, valve plate and swash

plate
Measure the surface roughness
of the sliding surface of the
cylinder,
valve
plate
and
Inspection item
Standard Surface Allowable surface

roughness
roughness
Cylinder block
valve plate
surface roughness
Remedy
Replace
0.4-Z max.
3.0Z max.
or
correct.
of shoe plate
swash plate, using a surface

roughness meter.
Measure the hardness of the
To correct the surface roughness of the cylinder block and the

valve plate,lap them together. (lapping powder # 1200 )
Inspection item
sliding surface of the valve

plate and swash plate, using a
Shoe plate
hardness meter.
(2)
Piston and cylinder block

clearance
Inspection item
Piston O.D. dd1
Allowable hardness
Standard hardness requiring
replacement
Higher than
HS78
Standard
0.01mm(0.0004 )
HS74
Remedy
Replace.
Allowable value Remedy

0.05(0.0020 )
Replace
piston or
of pistons and the bore of the Cylinder bore DD1 0.01mm(0.0004 ) 0.022(0.00087 )
cylinder
0.0350.045mm 0.065(0.0026 )
cylinders
at
least
three Clearance Dd
block.
(0.00140.0018 )
locations longitudinally by
Measure the outside diameter
means of a micrometer, and let

the maximum O.D. value be d,
the minimum O.D. value be d1,
the maximun bore value be D,
When any piston is to be replaced, replace nine pistons

altogether.
and the minimum bore value

be D1.
12
Inspection Item/Method

Part name and
inspection item
(3) Gap of piston shoe

Hold down the shoe to the
surface plate by means of jig,
draw out the piston upward
Standard
dimension
Allowable
value
Remedy
Gap of caulked part

between piston and
shoe
and measure the gap between
00.1mm
0.3mm
(00.004 )
(0.012 )
Replace piston
the piston and the shoe.
DIAL INDICATOR
PISTON
JIG
MAGNET
SHOE
SURFACE
PLATE
Fig.1-16
40
(1.58
27+0.2
+0.1
Measure
70
(2.76 )
(1.06 +0.008
+0.004 )
Fig.1-17
Gap of caulked part
Fig.1-18
(4) Negative brake force

Inspection item
After the end of assembly, place
a torque wrench in the end of
the output shaft, apply torque
to it and measure the torque Brake torque
reading when the motor begins
to turn.
13
Standard
value
Jig
Allowable
value
50kgfym
41kgfym
(360 lbfyft)
(300 lbfyft)
Remedy
Replace all of
separator
plate, friction
plate and
spring.
Inspection Item/Method
(5) Shaft
Measure the wear of the shaft
seal by means of a roughness
meter.
(6) Bearing
Replace bearing

Allowable stepped wear is up to 0.05mm (0.002in).
When the shaft is to be replaced. replace the oil seal (25)
at the same time.
When replacing the shaft, the thickness of shims (32)
must be adjusted.
Replace bearing (29) and bearing (30) within 10,000
hours on the hour meter.
When replacing the bearings, replace the inner race and
the outer race at the same time.
When the bearings have been replaced, the thickness of
shims (32) must be adjusted.
(7) Spline
Replace spline if it is worn
beyond its allowable limit.
(8) Overload relief valve section

This is the overload relief
valve section. Pressure can
not be checked and regulated
without a special test bench.
Serviceable stepped wear is up to 0.3mm (0.012in) on the

contact surface.
Replace the sub assembly every 10,000 hours on the

hour meter.
14
1.6 TRAVEL MOTOR TROUBLESHOOTING

The following are corrective actions to be taken in
case the motor is in trouble.
1.6.1 GENERAL PRECAUTIONS
(1) Cautions to be exercised before work
Before proceeding to work, determine the
kind of abnormality and think if a similar
symptom occurred before.
Think once again if the fault really comes
from the motor.
(2) Beware of dust.
Many faults are caused by dust. Therefore,
take dustproofing measures at disassembly.
(3) Handling parts

Handle parts with due care, particularly the
moving portions, so as not to damage the
moving parts.
(4) Handle O rings so as not to score the seat
surfaces.
At removal, replacing O rings with new ones
is recommended.
1.6.2 TROUBLESHOOTING
(1) Motor does not start.
Symptom
Pressure does not
rise.
Pressure rises.
Cause
Remedy
Built-in relief valve is out of order.
Repair or replace relief valve.
1. Negative brake is not released.

(Orifice in release pressure path is
clogged.)
1. Check if orifice is not clogged.

Clean or replace orifice.
2. Negative brake is not released.

(The spool is assembled the other
way in terms of right and left.)
2. Assemble the spool in correct

orientation.
3. Friction plate or separator plate in

Negative brake is stuck.
3. Replace friction plate and separator

plate.
4. Negative brake piston in mechanical 4. Recondition O. D. of brake piston of

brake section is stuck.
replace brake piston.
5. Sliding area is seized.
5. Repair or replace piston, shoe, shoe

plate, cylinder block and valve plate.
6. Spool malfunctions
(Spool is stuck.)
(The hole in the restrictor valve is
clogged.)
6. Correct or replace
(2) Motor does not start powerfully.

Symptom
Cause
Remedy
Correct or replace
A set pressure is
Spool malfunctions
(Spool is stuck.)
normal, but brake
release lags behind.
15
Symptom
Cause
Remedy
Negative brake is
released but the
motor is late to
start.
The viscosity of hydraulic oil is too high. Raise the oil temperature.
Negative brake is
released but the
motor starts feebly.
1. Negative brake is not released

completely.
(The orifice in the release pressure
path is clogged with dirt.)
1. Investigate to see if orifice is not

clogged.
2. Dirt is included in relief valve.
2. Clean relief valve.

Inspect seat surface or replace relief
valve.
3. Sliding surfaces are seized.
3. Inspect and repair sliding surface or

replace relief valve.
(3) Revolution does not reach a set value.

Symptom
Pressure does not
reach a set value.
Cause
Remedy
1. Oil flow is insufficient.
1. Inspect pump, delivery rate and the

oil path to motor.
2. Shoe, cylinder block and valve plate

are worn off or scratched much.
2. Inspect and repair faulty parts or

replace faulty parts.
(4) Brake does not work.

Symptom
Brake does not
work.
Cause
Remedy
Negative brake malfunctions.
Inspect and repair or replace brake

piston, friction plate and spring.
1. Friction plate is worn off.

2. Spring is broken.
Reverse brake
works.
Spool malfunctions
Correct or replace
1. Spool and the body are stuck

together.
2. Check valve is stuck or includes dirt.
3. The hole in the restrictor valve is
clogged.
(5) Oil leaks.

Symptom
Oil leaks.
Cause
Remedy
1. Bolts and plugs are loosen.
1. Tighten bolts or plugs to a specified

torque.
2. O rings are galled.
2. Replace O ring.
3. Oil is leaking into gear casing.
3. Replace oil seal.
16
(6) The motor speed does not change from high to low.
Trouble
Cause
Remedy
Spool of pilot valve is stuck.

Motor does not
change from high to
low speed.
Check and repair pilot valve.
(7) Abnormal sound occurs.

Trouble
Intense vibration
and sound occur
when brake is
operated slowly or
with other circuits.
Cause
Remedy
Spool malfunctions.
Bleed air.
Air remains in circuit and valve.

Spool is stuck.
Correct or replace.
(8) Hunting occurs when machine goes down a slope.

Trouble
Hunting is intense
during inching.
Cause
Remedy
Spool malfunctions.
Correct or replace.
Spool and body are stuck.

Seat of restrictor valve is poor.
Interference with negative brake
Spring at end of spool is fatigued or
broken.
17
Correct or replace.
1.7 REDUCTION UNIT DISASSEMBLY

1.7.1 TOOLS
Before removal and installation, prepare tools,
jigs and measuring instruments.
No.
Tools
Application
Torque wrench
50kgfm (0
360 lbfft)
Allen wrench
Opposing flats 8mm, 14mm
Stand
180
(7.09 )
More than 420 (16.5 )

340
(13.4 )
t=16 (0.63 )
Micro depth meter
15mm
Caliper
150mm
Eye bolt
M10 M18
Pin
Spring pin 3.5 75, 5 55
Press machine
Others
It is used to insert the angular bearing and fix the lock

washer.
Capacity 3 tons (6610 lbs)
Cleaning oil, Detergent, Gear oil, Grease,
Locktite#242, #515, Seal tape, rag and others
1.7.2 DISASSEMBLY
(1) Preparation before removal
1) The travel unit removed from the machine
has dust and mud. Wash them with cleaning
oil.
2) Loosen drain or oil filling plug (26) and drain
the oil out of the reduction unit.
When oil is hot, pressure is built up
inside. Take care as the oil gushes
out in some cases.
3) Leaving matching marks
Put a matching mark on the outside of each
matching surface so it may be installed where
it was.
l The numbers in the parentheses after
part names correspond to those in the
assembly drawing on page II-2.
18
3pcs. each
(2) Mounting the travel unit to the stand.

1) Remove three M10 socket bolts (24) in cover
(1) at equal spacings. Put eye bolts and lift it.
Then install the travel unit so the cover
comes up and the motor faces down.
: 8mm
COVER
MATCHING MARK
Take care so you do not pinch your

hand between parts and drop parts.
Fig.1-19
(3) Removing the cover

1) Take off the remaining M10 socket bolts (24).
: 8mm
2) The contact surfaces of cover (1) and ring
gear (17) are coated with sealing compound.
Therefore, remove cover (1) by placing a
wooden piece on the area of the cover
protruded from ring gear (17) and knocking it
with a hammer.
24
1
Fig.1-20
1
17
Fig.1-21
19
(4) Removing Carrier 1 Assy

1) Remove thrust plate (8).
2) Remove sun gear 1 (9).
3) Place three M10 eye bolt in carrier 1 (2) and

remove carrier 1 assy (2, 3, 4, 5, 6, 7).
6
(3,4,5,7)
Fig.1-22
(5) Removing carrier 2 assy
1) Remove sun gear 2 (10).
11
2) Place three M10 eye bolt in carrier 2 (11) and

remove carrier 2 assy (11, 12, 13, 14, 15, 16).
14
(12,13,15,16)
Fig.1-23
(6) Removing housing assy
1) Remove support ring (22).
2) Remove lock washer (21) by hammering on
something like a screwdriver that is placed in
the split.
22
3) Place an eye bolt in each of the three M10

threaded holes in ring gear (17). Then remove
housing assy [ring gear (17), housing (18),
bearing (19), and floating seal (23)].
Fig.1-24
21
Fig.1-25
20
(7) Removing housing assy

1) Place the housing assy with ring gear (17) facing
downward and housing (18) upward. Leave a
matching mark on the outer surface of the housing
and the ring gear.
2) Separate floating seal (23) from housing (18).
3) Take off all M16 socket bolts (25), except two in
diagonal directions.
: 14mm
4) With the remaining two loosened, knock the head of
them with a hammer. Then ring gear (17) comes off
from housing (18) easily.
25
300 (11.8_) or more
19
Use care so as not to score the moving

surface of the floating seal (23) and the O
ring.
17
Fig.1-26_Three stands of same height
The outer circumference of the bearing

(19) is engaged with the bore diameter of
the housing (18) by a very close fit. Do not
remove them except when necessary.
When the bearing has been separated from
the housing, do not use it again, but
replace it with a new one.
(8) Removing the floating seal
1) Remove the floating seal (23) on the motor side.
23

When reusing a carrier pin 1 (3), store it
by putting a mark in the carrier 1 (2) hole
and the carrier pin 1 (3) so they are
assembled the same way before they were
removed.
Fig.1-27_Removing floating seal (23)
Fig.1-28_Carrier 1 assy
II-21
18
1) Drive in spring pin (7) into carrier pin 1 (3).

2) Remove carrier pin 1 (3) from carrier 1 (2).
3) Separate thrust washer 1 (5), planetary gear
1 (6), and needle bearing (4).
4) Remove spring pin (7) from carrier pin 1 (3).
7
3
When replacing the carrier pin 1 (3)

or the planetary gear 1 (6), always
replace a set of three at one time.
Fig.1-29
2
Removing carrier 1 assy
5
6
4
6
Fig.1-30

When reusing a carrier pin 2 (12),
store it by putting a mark in the
carrier 2 (14) hole and the carrier
pin 2 (12) so they are assembled the
same way before they were removed.
15
1) Drive in spring pin (15) into carrier pin 2

(12).
2) Remove carrier pin 2 (12) from carrier 2 (11).
3) Separate thrust washer 2 (16), planetary gear
2 (14), and needle bearing (13).
4) Remove spring pin (15) from carrier pin 2
(12).
12
11
11
Fig.1-31
When replacing the carrier pin 2 (12)

or the planetary gear 2 (14), always
replace a set of three at one time.
14
11
16
13
Fig.1-32
22
1.8 INSTALLATION
(1) General precautions
1) Clean parts thoroughly in cleaning oil and
dry it up by jet air. Degrease areas to coated
with Locktite, using thinner or something.
2) Check that parts are free from fault.
3) Coat socket bolt with Locktite #242, before
tightening them.
4) Coat the parts with a thin film of gear oil,
before proceeding to assembly operation.
5) Use care so you do not pinch your hand
between parts and you do not drop parts.
(2) Installing carrier 2 assy
1) Install planetary gear 2 (14), needle bearing
(13), and thrust washer 2 (16) into carrier 2
(11).
2) Insert carrier pin 2 (12) into carrier 2 (11),
matching the carrier pin in the direction of
the spring pin hole.
3) Drive spring pin(15) into carrier 2 (11) and
carrier pin 2 (12).
[Drive in the spring pin 1 to 2mm (0.04
0.08in) below the surface into which it is
placed.]
4) Caulk two places 180diagonally located.
11
14(13,16)
Fig.1-33
Installing carrier assy
14(13,16)
15
11
Fig.1-34
(See carrier 2 in the figure.)
1) Install planetary gear 1 (6), needle bearing
(4), and thrust washer 1 (5) into carrier 1 (2).
2) Insert carrier pin 1 (3) into carrier 1 (2),
matching the carrier pin in the direction of
the spring pin hole.
3) Drive spring pin (7) into carrier 1 (2) and
carrier pin 1 (3).
[Drive in the spring pin 1 to 2mm (0.04
0.08in) below the surface into which it is
placed.]
4) Caulk two places 180diagonally located.
CAULKING
POSITION
15
Fig.1-35
23
Install spring pin
Caulking the spring pin
(4) Installing floating seal

1) Install floating seal (23) on the motor side.
23
Fig.1-36
Installing floating seal (23)
(5) Installing housing assy

1) Apply Locktite #515 to the matching surface
of housing (18) and ring gear (17).
18
2) Attach three eye bolt M18 in housing (18), lift

it with a wire sling, align the matching
marks, and install the housing to ring gear
(17).
3) Apply Locktite #242 to nineteen socket bolts
M1680 (25) and tighten them up.
: 14mm,
LOCKTITE #515
Fig.1-37
Installing housing assy
4) Install floating seal (23) to the housing side.

HOUSING SIDE
Clean the floating seal to be free

from oil, dirt, paint and other foreign
matter.
23
25 18
17
Coat the moving part of the floating

seal (23) with a thin film of gear oil.
Fix the O ring so it is not twisted.
Confirm that the floating seal (23) is
fixed parallel to the housing (18) and
the motor, as illustrated.
GOOD
BAD
BAD
Fig.1-38
24
Install floating seal (23)
(6) Deciding the shim thickness for angular

bearing
z This operation is needed when the
motor
(casing),
housing
(18),
bearing(18), bearing (19) or lock
washer (21) is replaced. If any of the
above parts was not replaced, use
the original shim (20) as it is.
1) Press the inner races of two bearings (19)
evenly and measure the assembled width (A)
of the inner races.
2) Measure the width (B) of the assembled part
of the motor bearing.
3) Measure the width (C) of groove on the
motor.
4) Measure the thickness (D) of lock washer
(21).
In
the
above
measurements,
measure four diagonally intersecting
points on the circumference and get
a mean value.
A
B
D
C
17 21 22
5) Suppose the thickness of shim (20) being used

is (S), the clearance (X) is as follows :
X(BC)(ADS)
6) For this unit, choose one shim that makes the
clearance X;0.08mm to0.02mm
(0.00310.0008in).
(A plus value is a clearance fit and a minus
value is a interference fit.)
Fig.1-39
18
20
Deciding a shim thickness
(7) Pressing fit the motor

1) Place the motor on a level stand with its shaft
facing up. Then place shims (20) selected
under 6) above, on the end face in which
motor bearing is inserted.
2) Attach three M10 eye bolts to ring gear (17)
and lift it up, bring it down slowly vertically
matching it to the center of the motor and
insert bearing (19) fixed in the bore of
housing (18) into the motor. Press the inner
race of the bearing (19) to full depth, using a
press.
3) Fix lock washer (21) into the groove, pressing
the flange of housing (18).
4) Fix support ring (22) in the outside of lock
washer (21).
21
Fig.1-40
25
19
22
Pressing fit the motor
PLANETARY GEAR 2

1) Place the carrier 2 assy in ring gear (17) and engage
it with the motor spline so that three planetary gears
2 (14) are placed in the illustrated position Fig.1-41.
2) Insert sun gear 2 (10).
BRAKE VALVE
The reason why the carrier 2 assy is

assembled in the illustrated position is to
promote oil lubrication; do not fail to observe
it.
Fig.1-41
11

1) Put the carrier 1 assy into ring gear (17). Turn the
planetary gear (6) by hand to correct position and
engage it with sun gear 2 (10).
2) Insert sun gear 1 (9).
3) Put thrust plate (8) into carrier 1 (2).
SUN GEAR 2(10)
Fig.1-42
Assembling carrier 2
(10) Installing cover

1) Apply Locktite #515 to the matching surface
between cover (1) and ring gear (17). Then install
cover (1) to ring gear (17).
2) Apply Locktite #242 to
fifteen socket
bolts
(24) and tighten them up.
: 8mm,
Tightening torque 8kgfm (58 lbfft)
SUN GEAR 1(9)
(11) Filling gear oil

1) Fill in gear oil (SAE90, API Grade GL-4, 5.5 lit.)
through the socket plug PT3/4 (26), place seal tape
on the plug and attach it to cover (1).
: 14mm,
Fig.1-43
Assembling carrier 1
1
LOCKTITE #515
17
26
Fig.1-44
26
Installing cover (1)

1.9.1 INSPECTION BEFORE REASSEMBLY
(1) Thrust washer
1) Check to see that there is no seizure,
abnormal wear and uneven wear.
2) Check that the wear does not exceed an
allowable value.
(3) Bearing
Turn it by hand and check to see that it turns
without unusual sound and resistance.
(4) Floating seal
Inspect that the moving parts and O rings
are not scored.
(2) Gears
1) There is no pitching and seizure on the gear
tooth surface.
2) Inspect that the root of gears is not cracked
by liquid penetrant examination technique.
1.9.2 SERVICING PARTS
The following are reference values by which the
serviceability of used parts is determined. Since
these serve as general reference, it is
recommended that the extent of disassembly be
decided depending upon performances, excessive
damage or discoloration of components, the
purpose of disassembly and remaining service life
that is expected.
Fig.1-45
Maintenance Standard
Code
Item
Reference value
Allowable value
Remedy
Replace 3 shafts as
a set.
Planetary shaft is worn.
To be smooth, no abnormal
wear and seizure.
Tooth face and root

condition
To be smooth, no abnormal No pitching over

Replace3 planetary
wear and seizure.
1.6mm (0.063) and no gears as a set.
crack at root of gear.
Thrust clearance of angular 0.08mm (0.0032 ) [Interferance]

bearing inner race
to0.02mm (0.0008) [Clearance]
Replace shims.
[See.1.8 (6)]
D Thickness of thrust washer 1
1.80.2mm
(0.0710.008 )
Wear
0.1mm
(0.004 )
Replace
0.70.06mm
(0.0280.002 )
Wear
0.1mm
(0.004 )
Replace
Thickness of thrust washer 2
27
1.9.3 TIGHTENING TORQUE

Fasten with a torque wrench.
No.
Part name
Size
Tightening torque
24
Socket bolt
M10_25
8kgfym (58 lbfyft) [Apply Locktite #242]
25
Socket bolt
M16_80
28kgfym (200 lbfyft) [Apply Locktite #242]
26
Socket plug
PT3/4
10kgfym (72 lbfyft) [Coil seal tape.]
1.9.4 INSPECTION AFTER ASSEMBLY

(1) Checking the oil level
After assembling the travel unit, place the shaft level
and direct the drain port of the cover downward.
Loosen the level plug and check that gear oil comes
out.
(2) Rotation test
Install the assembled travel unit on a hydraulic test
bench and run it at no load. On this occasion, check
that there is no abnormal sound and oil leakage. You
may carry out this checkup by installing the travel
unit on the machine, bringing the attachment down
on the ground and lifting up the crawler.
II-28
E200SR
SECTION 41
TROUBLESHOOTING (MECHATRO CONTROL)
TABLE OF CONTENTS
1. OUTLINE ................................................................................................................... 1
2. TABLE OF ACTUATOR FOR TROUBLESHOOTING ................................................. 3
3. TROUBLESHOOTING OUTLINE ............................................................................... 4
4. CHECK POINT FOR MECHATRO SYSTEM ............................................................. 5
1. OUTLINE
Troubleshooting provides process locating for the
cause of trouble in the order that trouble
occurred. This manual describes how to solve the
specific phenomenon systematically as early as
possible. For troubleshooting concerning the
inside of equipment, refer to troubleshooting for
each manual of equipment.
1.1 JUDGMENT OF ACTUAL THING AT SITE
(1) Get to the site as quickly as possible.
Verify model, serial number, situation of
trouble and field, and notify person of arrival
time.
(2) Verify background of trouble occurred
1) Model name and serial number
2) Kind of attachment
Check that the combination of attachment is
proper or that the operating method is not
unreasonable.
3) Operating time by hour-meter
4) History of trouble occurred and additional
works.
5) Recurrence of past trouble, or problems on
the additional modification.
YR-B76
Attending the field to verify actual thing.
(3)
1)
2)
3)
How to diagnose trouble

Verify defective part
Make the condition of trouble again
Where defective parts can not be verified,
surmise causes systematically.
4) Verify reasons for surmise
5) Report methods, procedure, and period for
repairing to user.
YR-B76
Verifying background of trouble occurred.
(4) Explanation of the cause of trouble

1) Explain the cause of trouble to clients. For
example, oil leak through piston is caused by
flaws on the piston rod. And the method of
using the machines should be explained so
that the same kind of trouble does not
reoccur.
2) Treatment of damaged parts
The damaged parts to be claimed and
returned are evidence so they should be
handled with care. Protect them from entry of
water, soils, etc. into port of hydraulic unit,
etc. and return them. And also use care not to
flaw and damage those surfaces.
YT-B87
Confirm the symptoms of the trouble.
YR-B76
Diagnosing fail by means troubleshooting.

1
TABLE OF ACTUATOR FOR TROUBLESHOOTING ; MECHATRO CONTROL

Hydraulic
Heavy duty arm in full lever

operation
Bucket digging
Bucket dump
Swing operation
Travel LH / RH operation
(1st. speed)
Travel LH / RH operation
(2nd speed)
Arm lock valve
Arm in full lever operation
Other
Boom lock valve
Bucket
Arm
Boom
Swing motor
Travel left motor
Arm in slight lever operation
Travel right motor

valve
Safety lock lever

Solenoid valve
Travel 1-2speed
Solenoid valve
Swing parking brake

Solenoid valve
Low pressure sensor
Arm conflux valve
Arm out full lever operation
Boom conflux valve
Travel straight valve
Arm out slight lever operation
Cylinder
Motor
P2 bypass cut valve
P1 bypass cut valve
Travel left
Boom lowering operation
S
V
Travel right
Operating condition
S
V
Swing
P
S
V
S
V
Bucket
P
S
V
Arm
Boom raising full lever operation
P
S
V
P
S
V
Actuator
Boom
P
S
V
P2 Pump proportional
valve
P
S
V
Control valve
P1 Pump proportional
valve
P1 bypass cut
proportional valve
Boom raising slight lever

operation
Travel straight
proportional valve
S
E
23
P2 bypass cut
proportional valve
Hi pressure sensor (P2)
S
E
22

Proportional valve
Hi pressure sensor (P1)
Electric
Independent operation
2.
TROUBLESHOOTING OUTLINE ; MECHATRO CONTROL
Pilot secondary pressure
Location
Lever position
Att
Travel
Operation
Pressure sensor
High pressure
(Pump)
Low pressure
(Pilot)
Pump proportional valve
P1
P2
ATT
Proportional valve
Arm variable recirculation valve
Bucket digging
Bucket dump
Boom raise
Neutral ; 642mA
Control lever at
full stroke
Max
Max
Approx 35kgf/cm2 Approx 24kgf/cm2
(500psi)
(340psi)
More than
2.9V
More than
3.7V
Min ; 303mA
Max 750 mA
Max 750 mA
Boom lower
Neutral ; approx 350mA
Swing left
Max ; 642mA
Swing right
Arm in
Arm out
TRAVEL
Forward
Reverse
Lever at neutral
Approx6.0kgf/cm2
(85psi) or less
Approx
6.0kgf/cm2
(85psi) or less
Less than
0.5V
Less than
0.5V
Neutral
(Hi idle)
Neutral
(Hi idle)
350mA
350mA
Max ; 700mA (When releasing pressure)

(513mA Except when releasing pressure)
Max ; 642mA
3.
4. CHECK POINTS FOR MECHATRO SYSTEM

4.1 ATTACHING POSITION OF SENSOR AND ELECTRIC EQUIPMENTS
(1) Location of under floor harness and low pressure sensor
GROUND
TRAVEL TWO SPEED SW
PRESSURE SENSOR
(OPTION 1) (SE-11)
PRESSURE SENSOR
(BUCKET DIGGING) (SE-1)
PRESSURE SENSOR
(TRAVEL RIGHT) (SE-9)
PRESSURE SENSOR
(TRAVEL LEFT) (SE-10)
PRESSURE SENSOR
(OPTION 2) (SE-20)
PRESSURE SENSOR
(ARM OUT) (SE-8)
Fig. 1
To the front side of floor plate
Under floor harness
Location of under floor harness and low pressure sensor

(View from the front of floor plate)
(2) Location
P
of high pressure sensor and pump proportional valve
PRESSURE SENSOR(P1 PUMP)(SE-22)
PROPORTIONAL
VALVE (P1 PUMP)
(PSV-P1)
Fig. 2
PRESSURE SENSOR (P2 PUMP)(SE-23)

PROPORTIONAL VALVE
(P2 PUMP)(PSV-P2)
Location of high pressure sensor and pump proportional

5
(3) Location of low pressure sensor
(SE-5)
PRESSURE SENSOR
(SWING)
(SE-2)
PRESSURE SENSOR
(BUCKET DUMP)
(SE-7)
PRESSURE
SENSOR
(ARM PULL)
(SE-4)
PRESSURE SENSOR
(BOOM DOWN)
(SE-3)
PRESSURE SENSOR
(BOOM UP)
Fig. 3
Location of low pressure sensor on C/V and multi C/V
(4) Location of solenoid valve block

CONTROL VALVE
Fig.4
SOLENOID VALVE BLOCK
Location of solenoid valve block

6
4.2 EQUIPMENT
(1) Solenoid proportional valve block
HYDRAULIC SYMBOLS
Fig. 5
Proportional valve block

(3) High pressure sensor
(2) Low pressure sensor

A
AMP MQS-TYPE 3P (B-TYPE)

OTHER PARTY CONNECTOR(FEMAIL)
HOUSING2-967642-1
TERMINAL (GOLD PLATING)965906-5
CONNECTER TERMINAL
ARRANGEMENT
TERMINAL NO.
1-COMMON
2-OUT PUT(+)
3-POWER SUPPLY(+)
VIEW
1921.9 HEX
HEX 22
O RING P11
O RING
PF1/4
PF3/8
DETAIL OF SENSOR
7
P14
E200SR
SECTION 42
TROUBLESHOOTING (HYDRAULIC)
TABLE OF CONTENTS
1. TROUBLE DIAGNOSIS TABLE ................................................................................ 1
2. TROUBLESHOOTING .............................................................................................. 3
1.
1.1 HYDRAULIC SYSTEM
TROUBLE DIAGNOSIS
Oil pressure
No operation is possible.
(1) Machine operates unexpectedly
Speed is low.
Power lacks
9 10
Raise
Lower
Arm in
Arm out
All motions
Bucket digging
Boom
Arm in
Bucket digging and dump
Boom
Swing
Arm in and out
(4)
(5)
Travel 1, 2 speed change

impossible
Raise
(6) Travel speed is low.
(7)
Travel power is low.
(8)
Machine cannot travel straight

or deviates in one direction or
zigzags.
(9)
Machine does not stop still on a

slope.
(10) Swing motion does not work.
(11) Swing speed is low.
(12)
(13)
Swing power is poor.
Swing motion drifts very large.

Abnormal sound is heard during
swing motion.
Safety lock lever sol. valve
Bucket digging and dump
Raise
11
Boom
Travel 1-2speed sol. valve
Boost pressure sol. valve
Proportional valve block
Swing parking sol. valve
Swivel joint
Pilot valve (travel)
Bucket cylinder
Pilot valve (ATT)
Arm cylinder
Pilot valve (1-2speed select)
Counter balance check valve
Parking brake
Motor
Reduction parts
Swing motor
Check valve of relief valve
Lock valve
Load check valve
P1 bypass cut valve
P2 bypass cut valve
Arm conflux valve
Boom conflux valve
Bucket spool
Arm spool
Boom spool
Swing spool
Counter balance valve
Other valve
All actions
Fine operation
impossible.
Attachment operation
Travel operation
Swing operation
Hydraulic systems
(3)
Cylinder
even though lever is in neutral.
(2)
Travel spool
Travel straight spool
Pilot pump
Pilot relief valve
Travel motor
Boom cylinder
Trouble Device No.
P2 pump
P1 pump
E/G revolution
Group No.
Classification
Component
Parking brake
Swing
motor
Control valve
Pump
2. TROUBLESHOOTING
(1)-1
Note: (1)-1 matches the Groupe No. on page 1.
No operation is possible.
NO
24V is alive across white/blue and black terminals of connector

(CN-253F) of safety lock lever solenoid (SV-4).
YES
Only the hydraulic pilot system
(ATT and travel motion) not
operative?
Is the main relief valve pressure
NO within a standard value?
YES
To electric
troubleshooting
NO Pilot relief valve
pressure is about
50kgf/cm2 (710psi).
P1,P2 ; 350kgf/cm2(4980psi)
(OPT)-P4 ; 250kgf/cm2(3550psi)
YES
YES
NO Replace relief
valve.
Inspect or replace pump.
Also inspect pump
coupling.
Inspect if there is any other cause.
Travel straight valve port PTb

pressure is about 7kgf/cm2(100psi).
YES
NO
Machine does not operate if

connector(CN-258F) for travel
straight proportional valve(PSV-C) is
disconnected 7kgf/cm2(100psi).
YES
NO
Replace proportional valve

for travel straight.
The primary pressure of pilot pump is about 50kgf/cm2 (710psi).
YES
The pilot valve P port inlet pressure is approx. 50kgf/cm2 (710psi).
YES
NO
NO
NO
The secondary pressure of pilot valve is approx. 50kgf/cm2
To electric troubleshooting
NG Replace proportional valve

block.
Inspect or replace pilot pump and pilot relief valve.
Inspect or replace safety lock lever solenoid valve.
Inspect or replace pilot valve.
(1)-2
Machine moves unexpectedly with levers in neutral.
Machine stops moving unexpectedly if the connector (CN-257F,CN-259F)
for proportional valve P1,P2 bypass cut is disconnected.
YES
To electrical troubleshooting
NO
Pump
delivery
pressure in
unloaded
condition is
approx.
5kgf/cm2
(71psi) or
lower.
YES
NO The secondary pilot pressure of the system
YES
that is moving unexpectedly is generated

when the lever is in neutral.
NO
The spool returning spring of the circuit that
is moving unexpectedly is broken.
NO
Inspect or replace pilot

valve.
YES
Inspect or replace spool

assy and pilot cover.
NO The outer
The spool of the system that is operating

unexpectedly moves smoothly by hand.
(Remove pilot cover.)
circumference of
spool is scratched.
YES
NG
NO
YES
Replace spool assy.
Replace control valve.
YES Inspect or replace the proportional valve for bypass cut
Pilot pressure at ports PCa, PCb (P1, P2

bypass cut valve) is approx. 7kgf/cm2
(100psi).
valve that is defective.
NG
NO
Inspect or replace proportional valve block.
YES Inspect or replace bypass cut valve spool assy and pilot
Return spring of bypass cut valve spool is

broken.
cover.
NO
NO Spool is scored on
Bypass cut valve spool moves smoothly by

hand. (together with P1 and P2 bypass cut
valves)
YES Replace bypass cut valve

spool assy.
inspection.
NO
YES
NG
Boom or
arm?
NO
YES When the lock valve, body seat and selector YES Replace lock valve and correct body seat or replace
parts were inspected, faults such as scratch
body or replace selector.
were discovered.
NO
Faults such as scratch are discovered in load
check valve and seats in conflux passage and
recirculation passage.(CCb,CCa, CAr)
YES
Replace check valve, correct body seat or replace body.
NO
Spool of the circuit that operates unexpectedly is scored on inspection.
NO
Inspect or replace
overload relief valve.
YES
NG Inspect the cylinder of the circuit that

operates unexpectedly and replace if faulty.
(Inside leak)
Replace spool assy.
NG Inspect or replace control

valve.
(2)-1
All attachment motions are slow.
(Service diagnosis 24,25)
Command current readings of pump
proportional valve are at standerd levels(below)
during operation.
P1 ; approx. 750mA by bucket operation.
P2 ; approx. 750mA by swing operation.
NO
The sum of pump

pressures(P1+P2)during check
operation is
460kgf/cm2 (6540psi).
YES
YES
Do motions get normal if the coupler(PSV-C) for
travel straight proportional valve is
disconnected?
NO
Primary pilot pressure is 50kgf/cm2 (710psi).
YES
Secondary pilot pressure at PTb port (travel
straight) is approx. 5.7kgf/cm2 (81psi).
YES
NO To electric
troubleshooting.
Inspect or replace boost

check, bypass check piping.
To electric troubleshooting.
NO
Inspect or replace pilot pump

and pilot relief valve.
YES
Inspect or replace travel

straight proportional valve.
NO
NG
Inspect or replace
proportional valve block.
Return spring of travel straight spool is broken.
YES
Travel straight spool moves smoothly by hand.
(Remove the pilot cover.)

straight spool assy and pilot
cover.
NO
NO
Outside of travel straight

spool is scored.
NO
YES
YES Replace travel straight spool

assy.
NG
Main relief pressure lies within standard level

P1,P2 ; 350kgf/cm2 (4980psi).
NO
Inspect or replace main relief

valve.
YES
NG Replace control valve or

pump.
(2)-2
Only the bucket motion is slow.
Is the motion normal if connector (CN-257F) for
bypass cut proportional valve is disconnected?
P2
NO
YES
To electrical troubleshooting.
NO
Secondary pilot pressure at PBc, PAc ports (bucket

digging and dump ports) is 50kgf/cm2 (710psi).
YES
(Service diagnosis 24)
Command current readings of pump
proportional valve are within standard
levels(below) during full lever operation.
Bucket digging / dumping operation : 750mA
YES
NO
Pump pressure during check operation lies

within standard value(below).
P1 ; digging approx 80kgf/cm2(1140psi)
dump approx 200kgf/cm2(4980psi)
P2 ; approx 5kgf/cm2(71psi)
NO
Relief pressure lies within standard levels(below)

when bucket operation is changed.
Digging / dumping : 350kgf/cm2(4980psi).

NO Relief pressures for both
digging and dump operations

are abnormal.
NO
YES
Return spring for bucket spool is broken.
NO
Bucket spool moves smoothly by hand. (Remove
pilot cover.)
NG
YES
Confirm the check valve

before main relief valve for
control valve. Check the seat
of it as well. (CMR1,CMR2)
YES
NO
YES To electrical
troubleshooting.
Inspect or replace control valve.
Inspect overload relief valve

on the faulty pressure side
and replace valve if defective.
NG
Replace bucket spool assy.

Outside of bucket spool is
scored.
YES
YES
NG
NO

Is the motion slow if coupler for travel straight
proportional valve is disconnected?
YES
Pilot pressure at port PTb (travel straight) is
approx. 7kgf/cm2 (100psi).
NO
(toAll motions are slow.)
NO

YES
NG
Inspect or replace
Return spring for travel straight spool is broken.
NO
YES
Inspect travel straight spool

assy and pilot cover and
replace them if faulty.
NO

spool is scored.
YES
NO
YES
Replace travel straight spool

assy.
NG
Is the motion slow if pump delivery ports P1 and

P2 are exchanged.
NO
Inspect or replace pump.
YES

Inspect bucket cylinder for oil
tightness and replace if
defective.
(2)-3
Only the boom raise motion is slow.
Control current of P2 bypass cut proportional
valve is approx. 640mA when full lever
operation is performed for boom raise motion.
YES
Secondary pilot pressure at port PCa (P2 bypass
cut valve) is approx. 25kgf/cm2 (360psi).
YES
Pilot pressure at PAb, PB1 ports (boom raise
and boom conflux) is 50kgf/cm2 (710psi).
NO
NO
Inspect or replace P2 bypass

cut proportional valve.
NG
NO
Inspect or replace
Inspect or replace ATT pilot
valve.
YES
(Diagnosis 24,25)
Command current readings for pump
proportional valve lie within standard levels
(below) during the above operation.
P1 ; approx. 670mA
P2 ; approx. 670mA
NO
Does the pump delivery

pressure lie at normal levels
during check operation?
Normal values for P1 & P2 ;
approx. 150kgf/cm2(2130psi).
YES
NO
Change ATT to normal one

and reconfirm.

NG
Inspect or replace control

valve.
Adjust boom port relief

pressure.
NG
Replace overload relief valve

at port Ab (boom head side).
Hasn't the weight changed by

the change of ATT's?
YES
NO
YES
Relief pressure lies within standard level

(below) when boom up lever is turned to the full.
350kgf/cm2(4980psi)
NO
YES
Return spring for P2 bypass cut valve spool is
broken.
NO
P2 bypass cut valve spool moves smoothly by
hand. (Remove pilot cover.)
YES
NO
YES

cut spool assy and pilot cover.
Outer circumference of P2
bypass cut valve spool is
scored.
YES
Replace P2 bypass cut spool

assy.
NG
NO

Return spring of boom spool is broken.
NO
Boom spool moves smoothly by hand.
YES
NO
Inspect or replace boom spool

Outer circumference of boom
spool is scored.
YES
NG
NO
YES
Replace boom spool assy.

Return spring for boom conflux spool is broken.
NO
Boom conflux spool moves smoothly by hand.
YES
NO

assy and Pilot cover.
Outer circumference of boom
conflux spool is scored.
YES
NO
YES
Replace boom conflux spool

assy.
NG
(2)-4
Only boom lower action is slow.
Control current for travel straight proportional
valve is approx. 350mA.
(Are the motions slow if coupler (PSV-C) for travel
straight proportional valve is disconnected?)
YES
Pilot pressure at port PTb (travel straight) is
approx. 7kgf/cm2(100psi).
NO
Return spring for travel straight spool is broken.
NO
NO
YES

NG

cover.
YES
NO
YES
Inspect or replace

spool is scored.
YES
NO

assy.
(2)-5
Only arm in action is slow.
Control current readings for arm recirculation
proportional valve are about 480mA when
H-mode arm in lever is turned to the full.
NO
YES
Pilot pressure at arm variable recirculation is
port Pis approx. 15kgf/cm2(210psi).
NO
YES
P1 ; approx. 350mA
P2 ; approx. 750mA
NO
YES
Secondary pilot pressure at PAa, PLC2 ports
(arm in, lock valve release) is approx. 50kgf/cm2
(710psi).
YES
Relief pressure lies within standard levels
when arm in is operated.
350kgf/cm2(4980psi).
YES
Arm spool or recirculation spool return spring is
broken.
NO
Arm spool or recirculation spool moves smoothly
by hand. (Remove pilot cover.)
Inspect or replace arm

variable recirculation
proportional valve.
NG
Does the pump delivery pressure

lie at normal levels during check
operation?
Normal values for
P1 ; approx. 5kgf/cm2(71psi)
P2 ; approx. 100kgf/cm2(1420psi)
YES
NO
Inspect or replace

NO
NO
Adjust or replace overload

relief valve on the arm head
(H) side.
YES
Inspect or replace arm spool,

recirculation spool and pilot
cover.
NO
Outside of arm spool or

recirculation spool is scored.
NO
YES
YES
Replace arm spool or

recirculation spool assy.
NG
(2)-6
Only arm out operation is slow.
Command current for P1 bypass cut proportional
valve is approx. 640mA when arm out lever is
shifted to the full.
NO
YES
Secondary pilot pressure at port Pcb
(P1 bypass cut valve) is approx. 25kgf/cm2
(360psi).
YES
Secondary pilot pressure at port PBa (arm out)
is approx. 50kgf/cm2 (710psi) or over.
NO

NG
NO
Inspect or replace
YES
(Service diagnosis 24,25)
P1 ; approx. 550mA
P2 ; approx. 550mA
NO
YES
(below) when arm out is turned to the full.
350kgf/cm2(4980psi)
YES
Arm spool return spring is broken.
NO
Arm spool moves smoothly by hand.
Pump delivery pressure lies

within standard level during
the above operation.
P1,P2 ; approx. 200kgf/cm2
(2840psi).
YES

NO
NO
Inspect or replace overload

relief valve at port Ba (arm
rod side).
YES
Inspect or replace arm spool

NO
Outside of arm spool is

scored.
YES
Replace arm spool assy.
NG
NO
YES
Return spring of P1 bypass cut valve spool is

broken.
YES
P1 bypass cut valve spool moves smoothly by
hand.(Remove pilot cover.)
NO
NO
Inspect or replace P1 bypass cut

valve spool assy and pilot cover.
Outside of P1 bypass cut
valve spool is scored.
YES Replace P1 bypass cut valve

spool assy.
NG
NO
YES
Arm conflux spool return spring is broken.
YES
Arm conflux spool moves smoothly by hand.

conflux spool assy and pilot
cover.
NO
NO
Outside of arm conflux spool

is scored.
NO
YES
YES Replace arm conflux spool

assy.
NG
(3)-1
All ATT operating power is poor.
Each independent operating speed is within a
standard value.
YES
P1,P2 ; 350kgf/cm2(4980psi).
YES
Primary pilot pressure is approx. 50kgf/cm2
(710psi).
YES
Travel straight spool return spring is broken.
NO
NO
NO
NO
Refer toAll motions are

slow..
Adjust main relief pressure
of control valve.
NG
Replace pilot pump and relief

valve.
Adjust pilot relief pressure.

cover.
YES
NO
Replace the relief valve of

main control valve.

spool is scored.
YES Replace travel straight spool

assy.
NO
YES
NG
valve or pump.
(3)-2
Bucket digging power is poor.
No-load independent operating speed is within a
standard value.
YES
NO

(below) when bucket digging lever is turned to
the full.
(
)
NO
Secondary pilot pressure at port PBC (bucket

digging) is approx. 50kgf/cm2 (710psi).
NO
Refer to Only bucket motion

is slow.
Adjust overload relief valve
on bucket digging side.
NG
Replace overload relief valve

at port BC (bucket head side).
YES
YES
Bucket spool return spring is broken.
NO
Bucket spool moves smoothly by hand. (Remove
pilot cover.)
YES
NO
Inspect or replace bucket

spool assy and pilot cover.
Outside of bucket spool is
scored.
NO
YES
YES
NG
Replace control valve or
pump.
10
(3)-3
Boom raise operating power is poor.
standard value.
NO
Refer toOnly boom raise motion

is slow.
YES
(below) when boom up lever is turned to the full.
P1, P2 ; 350kgf/cm2(4980psi).
YES
Secondary pilot pressure at boom raise PAb port
and boom conflux PB1 port is 50kgf/cm2(710psi)
YES
Boom spool return spring is broken.
NO
Boom spool moves smoothly by hand.
NO
Adjust main relief on control

valve.
NG
NO
YES
NO
YES
Adjust or replace overload relief

valve at port Ab (boom head
side).

Outside of boom spool is
scored.
YES
NG
NO
Boom conflux spool return spring is broken.
NO
Boom conflux spool moves smoothly by hand.
YES
YES
NO

Outside of boom conflux
spool is scored.
NO
YES
Replace boom conflux spool
NG
Inspect or replace control valve
or pump.
11
(3)-4
Arm in power is poor.
standard value.
NO
Refer toOnly arm in is

slow..
YES
Relief pressure during arm in for both P1 and
P2 pumps lies within standard levels.
P1,P2 ; 350kgf/cm2(4980psi).
YES
NO
Adjust main relief on control

valve.
NG
Adjust or replace overload

relief valve at port Aa (on
arm head side).
Control current readings for arm recirculation

proportional valve are about 480mA when
H-mode arm in lever is turned to the full.
NO
To electric trouble shooting.

Refer toOnly arm in is
YES
Pilot pressure at arm variable recirculation port
Pis is about 15kgf/cm2(210psi)
NO
YES
Secondaly pilot pressure at arm in port PAa and
arm lock valve release PLC2 port is
50kgf/cm2(710psi)
YES
Arm spool return spring is broken.
NO
Arm spool moves smoothly by hand.

variable recirculation
proportional valve.
NG
NO
YES
NO

Outside of arm spool is
scored.
YES
NG
NO
YES
Inspect or replace
Arm variable recirculation spool return spring is

broken.
NO
Arm variable recirculation spool moves smoothly
by hand. (Remove pilot cover.)
YES
NO

Outside of arm variable
recirculation spool is scored.
NO
YES
YES
Replace arm variable

recirculation spool assy.
NG
Replace control valve or
pump.
12
(4)-1
Machine can not perform fine operation of bucket digging and dump.
Machine returns normal if connector of P1 bypass cut proportional
valve (PSV-D) is disconnected.
YES
NO
Unload pressure of P1
pump is less than 5kgf/cm2
(71psi) when bucket digging
lever is at neutral.
YES
NO No-load independent operating NO
Refer toOnly bucket motion

is slow..
speed is within a standard

value.
YES
Secondary pilot pressure at
port PCb (P1 bypass cut valve)
is approx. 7kgf/cm2 (100psi)
when lever is at neutral.
NO
P1 bypass cut spool return
spring is broken.
YES Inspect or replace P1
bypass cut proportional

valve.
YES
NG Inspect or replace

NO
P1 bypass cut spool moves
smoothly by hand. (remove
pilot cover.)
NO Outside of P1 bypass
cut spool is scored.
NO
YES
YES Replace P1 bypass cut

spool assy.
NG
Secondary pressure of pilot

valve is approx. 5.5kgf/cm2
(78psi) when bucket digging
lever is just shifted a little.
YES
Pilot spool return spring is
broken.
NO
Bucket spool moves
smoothly by hand. (Remove
pilot cover.)
YES
NO
YES
Inspect or replace bucket

spool assy or pilot cover.
NO Outside of bucket spool is
YES
scored.
NG
NO

13
(4)-2
Machine can not perform fine operation of boom raise and lower.
Machine gets normal if connector of P1 bypass cut proportional
valve (PSV-D) is disconnected.
YES
NO
pump is less than 5kgf/cm2
(71psi) when boom lever is
at neutral.
NO Secondary pilot pressure at
port PCb (P1 bypass cut valve)

is approx. 7kgf/cm2 (100psi).
NO
YES
Return spring of P1 bypass cut

spool is broken.
NO
YES Inspect or replace
proportional valve for

P1 bypass cut valve.
YES
YES
proportional valve
block.

smoothly by hand.
YES Replace P1 bypass

cut spool assy.
NG
NO

Secondary boom pilot pressure is approx.
5.5kgf/cm2 (78psi) when lever is just shifted.
YES
NO
NO
YES
YES
Return spring of boom spool is broken.

Boom spool moves smoothly
by hand.
NO

Outside of boom spool is scored.
YES
NG
NO

Does boom lock valve move
smoothly by hand?
NO
Inspect or replace lock valve.
YES
14
(4)-3
Machine can not perform fine swing operation.
YES
Machine gets normal if connector (CN-257F) for P2 bypass cut

proportional valve (PSV-B) is disconnected.
NO
YES
Machine gets normal if connector (CN-254F) for swing parking

brake solenoid (SV-1) is disconnected.
NO
Secondary pressure of swing pilot valve is approx. 6kgf/cm2
(85psi), while pilot pressure of parking brake solenoid valve is
0kgf/cm2 (0psi).

swing parking solenoid
NO
pump is approx. 5kgf/cm2
(71psi) or less when swing
Pilot pressure of port PCa (P2
NO bypass cut valve) is approx.

7kgf/cm2 (100psi) when swing

NO
YES
Return spring for P2 bypass cut

spool is broken.
YES
proportional valve
block.
proportional valve
block.
cut spool and pilot cover.
NO
smoothly by hand. (Remove
pilot cover.)

cut spool assy.
NO
YES
NG
Secondary pilot pressure of parking brake solenoid valve is

when secondary pressure of pilot valve is
0kgf/cm2 (0psi)
NO
Inspect or replace swing

parking solenoid valve.
proportional valve
block.
YES
Secondary pressure of pilot
valve at startup is approx.
5.5kgf/cm2 (78psi).
YES
Return spring for swing
spool is broken.
NO
Swing spool moves
smoothly by hand.
YES
NO
YES
NO
Replace swing spool assy.
YES
Outside of swing spool is
NG
NO

15
(4)-4
Machine can not perform fine operation of arm in and out.
YES
Machine gets normal if connector (CN-257F) of P2 bypass cut

proportional valve (PSV-B) is disconnected.
NO
P2 pump unload pressure is
less than 5kgf/cm2 (71psi)
when arm lever is at
neutral.
port PCa (P2 bypass cut valve)

YES
YES
Return spring of P2 bypass cut

spool is broken.
NO Inspect or replace

YES
proportional valve
block.

NO
smoothly by hand.

cut spool assy.
NO
YES
NG
Secondary pressure is
approx. 5.5kgf/cm2 (78psi)
when arm lever is shifted a
little.
YES
Return spring of arm spool
is broken.
NO
Arm spool moves smoothly
by hand.
NO
YES
NO
Outside of arm spool is scored.
YES
NG
NO
YES

Arm lock valve moves
smoothly by hand.
NO
Inspect or replace lock valve.
YES
(5)
Travel 1st and 2nd speeds can not be changed over.
24V is alive across light green/black and black
of connector (CN-255F) for travel 1-2 speed
solenoid (SV-3).
YES
Pilot pressure of travel 1-2 speed select solenoid
(SV-3) is approx. 50kgf/cm2 (710psi).
NO
NO
Inspect or replace travel 1-2

speed select solenoid valve.
YES
Travel 1-2 speed select can not be done in heavy
duty condition on a slope or on a muddy land.
YES
NO Inspect travel motor (throttle in passage to 1-2 select valve, inclusion of

foreign matter in shuttle valve, etc.) or replace it.
Since the delivery rate of pump is small at heavy duty, the difference
between 1st and 2nd speeds gets smaller. This makes you feel sometimes
that speed is not changed. But this is normal.
16
(6)
Travel independent speed is low.
Is the travel motion in both speeds slow
at no load?
(H-mode, Hi idle, 1st-speed, sprocket
revolution ; approx. 28rpm)
NO
Refer to Travel independent

deviates..
YES
Machine is slow on slopes and in muddy
fields?
Since the pump delievery

rate is decreased at high
load, travel speed is
decreased, but it is normal.
YES
NO
Current readings of pump proportional
valve lie within standard levels during
both travel speeds.
P1,P2 ; approx. 750mA
NO
boost check, bypass

check piping.
Secondary pressure for travel

pilot valve is approx.
24kgf/cm2 (340psi).

Control current of travel straight
proportional valve is approx. 350mA.
Is the machine slow even if connector
for travel straight proportional valve
is disconnected.
YES
NO
YES
control valve.
Inspect or replace pilot valve

for travel.
NO
port PTb (travel straight valve)

YES
YES
YES
Is the pivot turn possible?

(in both directions)
Pump pressure
during travel idling
is 50~70kgf/cm2
(710~1000psi).
NO
Return spring of travel straight
spool is broken.
NO
Travel straight spool moves
smoothly by hand.
NG
travel straight
proportional valve.
Inspect or replace
proportional valve
block.

cover.
YES
NO Outside of travel
straight spool is scored.
YES Replace travel

straight spool assy.
NO
YES
NG
Return spring of travel

spool is broken.
NO
Travel spool moves
smoothly by hand.
YES
NO Outside of travel spool is
YES
scored.
YES
Relief pressure during both
travel speeds lies within
standard value.
; 350kgf/cm2 (4980psi)

spool assy and pilot cover.
Replace travel spool assy.
NG
NO
NO

motor relief valve.
YES

motor.
17
(7)
Travel power is poor.
Both travel speeds are slow during idle
traveling.
(H-mode, Hi idle, 1st-speed, sprocket
revolution ; approx. 28rpm)
NO
Refer to Travel independent

is slow..
YES
Command current for travel straight
proportional valve is approx. 350mA.
YES
Power lack is felt on a slope or in muddy
fields.
NO
Since the delivery rate of pump is small and travel speed is
low in heavy duty condition, power lack is felt in some cases,
but it is normal.
YES
NO
Is the secondary pilot
pressure for travel approx.
24kgf/cm2 (340psi)?
YES
Is a pivot turn possible?
(in both directions)
NO
Inspect or replace travel pilot

valve.
NO Pilot pressure at port PTb
(travel straight valve) is

YES
travel straight
proportional valve.
YES
Return spring of travel straight
spool is broken.
NO
smoothly by hand.
proportional valve
block.

cover.
YES
NO Outside of travel
straight spool is scored.
NO
YES
YES Replace travel

straight spool assy.
NG

spool is broken.
NO
Travel spool moves
smoothly by hand.
YES
NO Outside of travel spool is
YES
scored.
YES
Relief pressure lies within
standard value in both
travel speeds.
; 350kgf/cm2 (4980psi)

straight spool and pilot cover.
Replace travel spool assy.
NG
NO
NO

motor relief valve.
YES
motor.
18
(8)-1
Machine does not travel straight.
Control current for travel
NO
straight proportional valve
(PSV-C) is 515mA.
YES
Secondary pilot pressure at
port PTb (travel straight
valve) is approx. 17kgf/cm2
(240psi).
NO Secondary pressure of travel
pilot valve is approx. 24kgf/cm2

(340psi).
YES
YES
straight spool is broken.
NO
smoothly by hand.
YES
NO
Inspect or replace
travel straight
proportional valve.

valve.
cover.
YES
NO Outside of travel straight spool YES

assy.
is scored.
NG
NO

(8)-2
Machine deviates in travel independent motion.
In idle run, the right and the left crawlers rotate
at different speeds. (H-mode, Hi idle,
1st-speed)
NO
YES
Control current for travel straight proportional
valve (PSV-C) is 515mA.
Does the machine deviates

from former direction if
delivery ports are
exchanged?
NO

valve.
NO

valve.
NO

valve.
YES
NO
YES
Pump pressure for P1 and P2

lies within
50~70kgf/cm2 (7101000psi)
during travel idling.
YES
Secondary pilot pressure for
travel is 24kgf/cm2 (340psi).
YES
Machine deviates from former direction if the right

and left pipes between control valve and travel
motor are exchanged.
Relief pressure lies within
NO standard value in both travel NO

speeds.
; 350kgf/cm2 (4980psi)
YES
Return spring of travel straight spool is broken.
NO
YES
YES

motor relief valve.
motor.
cover.
YES
NO Outside of travel straight
spool is scored.
NO
YES
NG
19
(9)
Machine drifts on a slope. (Machine can not be held on a slope.)
Machine can not be held on a slope when engine
is off.
NO
Secondary pilot pressure for travel is 0kgf/cm2
(0psi).
YES
Return spring of travel spool is broken.
NO
Travel spool moves smoothly by hand.
YES
YES

motor.
NO
Inspect or replace remote

control valve.
YES
Inspect or replace travel spool

NO
Outside of travel spool is

scored.
NO
YES
Replace travel spool.
NG
20
(10)
Swing motion dose not work.
Machine moves if connector(CN-254F) of swing

parking SOL(SV-1) is disconnected.
YES
NO
Is the pilot pressure of parking SOL reduce to
0kgf/cm2 (0psi)when the secondary pressure of
pilot valve is 6kgf/cm2(85psi)? .
NO Inspect or replace swing
NO Dirt or something is stuck in YES

the restrictor of slow return
valve.
YES
Return spring of swing spool is broken.
Inspect or replace
Reference
In case of a machine with a
multi control valve, check if
the condition returns normal
by changing swing lever back
& forth operation.
YES
Secondary pressure of swing pilot valve is

50kgf/cm2(710psi) for both directions.
NG
parking solenoid.
NO
Inspect or replace slow return

valve.
YES
Inspect or replace swing spool

NO
Swing spool moves smoothly by hand.
NO Outside of swing spool is
YES
scored.
YES
NG
NO
Return spring of P2 bypass cut spool is broken..
YES
Inspect or replace P2 bypass cut

valve spool assy and pilot cover.
NO
P2 bypass cut spool moves smoothly by hand.
NO
YES

spool is scored.
NO
YES
Replace P2 bypass cut assy.
NG
Swing relief pressure lies within standard level.

285kgf/cm2(4050psi).
NO

motor relief.
YES
Machine can be held on a slope during swing
motion.
NG
NO

reduction unit and swing motor.
YES
Machine drifts largely when swing parking
brake is released (arm in action) on a slope.
YES

motor.
NO

reduction unit and swing motor.
21
(11)
Swing speed is slow.
Command current of P2 bypass cut proportional
valve (PSV-B) is 640mA when swing lever is
turned to the full.
NO
YES
Secondary pilot pressure for swing motion is

approx. 50kgf/cm2 (710psi) when lever is turned
to the full in either direction.
Reference
In case of a machine with a multi
control valve, check if the condition
returns normal by changing swing
lever back & forth operation.

valve.
NG
NO
YES

valve.

Secondary pilot pressure at PCa port (P2 bypass
cut valve) is approx. 25kgf/cm2 (360psi) when
swing lever is shifted to the full.
YES
Return spring of P2 bypass cut spool is broken.
NO
NO Inspect or replace P2 bypass NG

YES

NO Outside of P2 bypass cut
YES
spool is scored.
YES
Inspect or replace
NO

assy.
NG

; 285kgf/cm2(4050psi).
NO

motor relief.
YES
is released (arm in action) on a slope.
NG
YES

motor.
NO
NO
YES
YES


scored.
NO
YES
NG
22
(12)-1
Swing power is
Swing speed lies within standerd level

; (H-mode HI idle is approx. 11.3rpm or over.)
YES
Return spring of P2 bypass cut spool is broken.
NO
NO
Refer toSwing speed is

slow..
YES

NO Outer circumference of P2
YES
bypass cut spool is scored.
YES
NO
NG
Reference
In case of a machine with a
multi control valve, check if
the condition returns normal
by changing swing lever back
& forth operation.
Secondary pilot pressure for swing motion is
approx. 50kgf/cm2 (710psi) when lever is turned
to the full in both directions.

; 285kgf/cm2(4050psi)

valve.
NO
YES

valve.
Inspect or replace pilot valve .
NO

motor relief.
YES

assy.
NG
YES

motor.
NO
The pressure at the P/B (PG) port of swing
motor is 50kgf/cm2(710psi) when swing lever is
turned to the full or during arm in action.
NO Inspect or replace P2 bypass NG

Inspect or replace
YES
NO
YES
YES


scored.
NO
YES
NG
23
(12)-2
Swing motion drifts very large.
; 285kgf/cm2(4050psi)
NO

motor relief valve.
YES
Command voltage
Machine can be held on a
slope during swing motion.
YES
NO of swing parking
brake releasing
acts on swing
parking solenoid.
YES Replace the lining of swing NG

motor parking brake.
NO


motor and reduction unit.
YES
NO
Secondary pilot pressure in swing motion

decreases quickly when swing lever is brought
to neutral.

motor.
Reference
In case of a machine with a multi
control valve, check if the condition
returns normal by changing swing
lever back & forth operation.

valve.
YES

valve.
NO
Inspect or replace pilot valve .
NO
YES
YES


scored.
NO
YES
NG
24
(13)
Abnormal sound is heard
during swing motion.
YES
Abnormal sound occurs during swing relief

action.

motor relief valve.
NO
Abnormal sound occurs when swing motion stops.
YES

shockless valve.
NO
; 285kgf/cm2(4050psi)
Control current for P2
NO bypass cut proportional valve NO

is approx. 640mA.
YES
YES
Pressure at P2 bypass cut port PCa
is about 25kgf/cm2(360psi)during
swing operation.
P2 bypass cut
proprotional valve.
proprotional valve
block.
YES
Main relief pressure lies
within standard level.
; 350kgf/cm2(4980psi)
YES Inspect or replace NO Inspect or replace

swing motor relief
valve.
swing motor.
NO
Outside of P2 cut valve spool
is scored.
Inspect or replaceP2 bypass

cut valve spool assy and pilot
cover.
YES
NO
smoothly by hand.
(Remove pilot cover)
YES
Inspect or replace main relief

valve.
NO
valve spool is scored.
YES
Replace P2 bypass cut valve

spool assy.
NO
NG
NO
(Remove pilot cover)
YES

YES
scored.
NO
YES
NG
Machine can be held on a slope during swing

motion.
YES
NO
Inspect or replace swing motor
pinion gear, swing bearing race
and swing bearing gear.
25

motor or reduction unit.
E200SR
SECTION 43
TROUBLESHOOTING (ELECTRIC)
TABLE OF CONTENTS
1. TROUBLE DIAGNOSIS TABLE ................................................................................. 1
2. SELF DIAGNOSIS TABLE ......................................................................................... 4
3. SERVICE DIAGNOSIS TABLE .................................................................................. 4
4. TROUBLESHOOTING ............................................................................................... 5
TROUBLE DIAGNOSIS TABLE ; ELECTRIC
(1)
Machine moves freely when

4 6

5 7
Speed is slow
Power is poor
Power supply grounding
Battery relay
Swing parking SOL
Travel 1-2speed SOL
Boom raising
Arm in
Bucket digging, dumping
Fine operation
impossible
(6)
(7)
Travel power is poor
Boom raising, lowering
Swing
Arm in, out
ATT travel combined and

travel straight are
impossible.
Travel deviates, zigzags.
(at combined
operation with
ATT swing)
Attachment operation
Travel operation
Swing operation
Bucket digging
(5)
Machine drifts on a downhill

and does not stop still on a slope
(10) Swing motion does not work
(11)
Swing speed is slow
(12) Swing power is poor
(13)
Governor motor B phase
All operate
Travel 1-2 speeds can not be

changed
(8)
8 10 12 14 15 17 19 21 22 23 24 25

9 11 13
16 18 20
26
Only bucket speed is

slow.
Only boom raise speed is
slow.
Motions are slow except
boom raise and arm out.
Only arm in motion is
slow.
Only arm out motion is
slow.
(4)
(9)
Others
Electric systems
(3)
Battery backup
CN-15
13 15 16 25 28 1
26
2
27
No motions operate.
Power supply +24V
CN-14
All operate
(2)
Arm variable recirculation proportional valve A
P2 bypass cut proportional valve B

C
P1 bypass cut proportional valve D
Shield grounding
Governor motor A phase
Shield grounding
Gauge cluster
Front working light relay
Governor motor & proportional & SOL
Washer motor relay
ATT boost pressure SW
Wiper motor relay
Conflux / single select SW (OPT)
Fuel level thermister
Air filter clogging LS
CN-13
7 13 14 15 16 17 18 19 20 22 1
8
21
2
9
3
Travel alarm SW
Engine oil pressure low LS
Option 1 pressure sensor
Shield grounding
Engine speed sensor
KPSS release SW
Swing P/B release SW
Travel 1-2speed SW
Key SW GLOW
CN-12
Engine water temp high LS
CN-11
1 4

2 5
Pin No.
3 6
Key SW ON
Auto idle stop select SW
Alternator voltage
Option 2 pressure sensor
P2 pump pressure sensor
Accelerator potentio
Accel motor start point indexing LS
Travel left pressure sensor
Swing pressure sensor
Travel right pressure sensor
Bucket dump pressure sensor
Bucket digging pressure sensor
31 34 1 4

32
2 5

33
3 6
Arm out pressure sensor
28
29
30
Connector
No.
C1 mechatro controller
Switch & relay
Power supply & other signal
7 10 13 16 19 25

8 11 14 17 20 26

9 12 15 18 21 27
Arm in pressure sensor
Boom lowering pressure sensor
Group No
System
Component
Boom raising pressure sensor
Low pressure sensor
Trouble
1.
Swing leftright
Swing can not be held on a slope
(14) Auto idle stop is not actuated
(1)

Others
(8)
(9)
Speed is slow
Power is poor
All operate
Bucket digging
Boom raising
Arm in

Swing
Arm in, out

changed

ATT travel combined
and travel straight are
impossible.
Travel
deviates,
zigzags.

(11) Swing speed is slow
(13)

slow.
slow.
slow.
slow.
(at combined
operation with
ATT swing)
(5)
(6)
(7)
Fine operation
impossible
Attachment opration
Travel operation
(4)
Swing operation
Electric systems
2
(3)
Swing leftright
(14) Auto idle stop is not actuated
M
7
M
8
M M
9 10
Cab working light relay (OPT)
M
6
Wiper relay assy
M
5
Working light relay
Fuel pump
M
4
Horn relay
Roof wiper motor
M
3
Washer motor relay
Power window look motor (right, OPT)
M
2
Wiper motor relay
Power window look motor (left, OPT)
M
1
Safety relay
Power window motor (OPT)
L
3
Glow relay
Washer motor
L
2
Battery relay
Wiper motor
L
1
Wiper motor (rise up, OPT)
Governor motor
E E E E
10 11 12 14
Starter motor
E
9
Room light
E
8
Relay
Working light (right)
E
7
Resistor
E
7
Motor
Boom working light (left)
E
4
E
5
Heater (OPT)
E
3
Air compressor
E
2
Horn
E
1
Receiver dryer
D
5
Speaker right
D
4
Speaker left (OPT)
D
3
Tuner AM
D
2
Light
Tuner AM&FM (OPT)
D
1
Hourmeter
C
5
Alternator
C
4
Fuse box
Power window controller
C
2
Diode
B
1
No motions operate.
All operate
(2)
P P
S S
V V

P P
1 2
Gauge cluster
P
S
V
Battery
P
S
V
P P
S S
V V

A B
Pin
No.
Trouble
Group No
System
Component
Electrical equipments
Diode
Controller
R
1
R
3
R
4
R
5
R
6
R
7
R
8
R
9
R
10
Proportioal valve
(1)
No motions operate.
ATT boost pressure SW
S
W
5
S
W
4
Single/Conflux select SW (OPT)
S
W
3
Work light switch (OPT)
S
W
1
Horn switch (right)
S
V
4
Heater & A/C switch
S
V
3
Safety lock lever SW
KPSS release switch
S
V
2
Horn switch (left)
Swing P/B release SW
S
V
1
Engine water temperature, oil pressure,

filter clogging
Travel 1-2 speed SW
S S S S S S S S S
E E E E E E E E E
10 11 13 14 15 16 20 22 23
Key switch
S
E
9
S
E
8
S
E
7
S
E
5
Swing parking SOL
Travel left
S
E
4
Option 2
Travel right
S
E
3
Accelerator
Arm out
S
E
2
Fuel sensor
Arm in
Engine water temperature sensor
Swing
Engine speed sensor
Boom lower
S
E
1
Option 1
Boom raise
Pin
No.
Bucket dump
Trouble
Switch
Pressure
sensor
Bucket digging
Group No
System
Component
Solenooid
Senser
Low pressure sensor
S S S S S S S S S
W W W W W W W W W
6 10 11 12 20 21 22 23 34
7
13
(8)
Speed is slow

slow.
slow.
slow.
slow.
Bucket digging
Boom raising
Arm in

Swing
Arm in, out

ATT travel combined
and travel straight are
impossible.


(11) Swing speed is slow
(13)

changed
Travel deviates, zigzags.
(9)
All operate
(at combined
operation with
ATT swing)
Travel operation
Swing operation
(5)
(6)
(7)
Power is poor
(3)
Fine operation
impossible
(2)
(4)
Others
Electric systems
Attachment opration
All operate
Swing leftright
(14) Auto idle stop is not actuated.
Regarding the C-1 mechatro controller, refer to two pages back.

3
3.
SELF DIAGNOSIS TABLE
The self diagnosis detects errors in the control I/Os of the pressure sensors and the proportional valves
while the machine is in operation and shows them on the multi display of the gauge cluster.
DISPLAY ITEM
No.
Contents
Mechatro controller fail
16
P1 by-pass cut
propo-valve fail
ROM data
17
P2 by-pass cut
propo-valve fail
Mechatro set error
18
Travel priority
propo-valve fail
Boom raising
Arm variable
19 recircula-tion
propo-valve fail
Boom lowering
20
Pump P1 pressure
sensor fail
Arm in pressure
sensor fail
21
Pump P2 pressure
sensor fail
Arm out pressure

sensor fail
22
ATT boost pressure

Solenoid valve fail
Bucket digging
23
Travel two-speed
solenoid valve fail
Bucket dump
24
Swing parking solenoid

valve fail
10
Swing pressure
sensor fail
25
Governor motor current

fail
12
Travel right pressure

sensor fail
26
Governor motor starting

point indexing fail
Travel left pressure

13
sensor fail
Display of monitor
No.
Contents
27 Accel potentio meter fail
14
Pump P1 pressure
sensor fail
Gauge cluster
28 Mechatro controller
communication failure
15
Pump P2 pressure
sensor fail
29 Battery relay fail
Display of monitor
The results of service diagnosis are displayed in up to 23 items according to data from the mechatro
controller.
Displaying procedure:
1) TurnONthe starter switch with the buzzer stop switch pressed.
2) A mechatro controller parts number and a program version are displayed as the No.1 item.
3) The diagnosis advances like No.2, No.3.... each time the display select switch is pressed.
4) The diagnosis returns like No.40, No.39... each time the buzzer stop switch is pressed.
5) The display does not disappear unless the starter switch is turnedOFF.
No.1
PROGRAM VERSION
Buzzer stop switch

Returns the screen
SERVICE DIAGNOSIS DISPLAY

No.
DISPLAY
No.
No.1
PROGRAM VER
VER 5.60
No.2
E/G
Display select switch

Advances the screen
VER 5.60
30 Draining hyd. pressure

31 Fail drain hyd. pressure
SERVICE DIAGNOSIS TABLE
E/G
KPSS
No.3
H1
ACCEL
SET
MEAS
PRS.
SW
VOLT.
POS.
MOTOR STEP
POS.
2420
2420
LIVE
H
4.2V
100%
256
100%
No.4
GOVERNOR MOTOR
G1
COIL A
0.9A
G1
COIL B
1.0A
G2
LIMIT
OFF
No.5
SOL.VALVE
F2
SWING-BRAKE
COMP.
OFF
MEAS.
OFF
RELEASE SW
OFF
No.6
SOL.VALVE
F3
1/2-TRAVEL
COMP.
OFF
MEAS.
OFF
SWITCH
OFF
10
11
12
DISPLAY
No.7
SOLENOID
F1 POWER UP
COMP.
MEAS.
SWITCH
No.8
RELAY
I2 BAT. RELAY
COMP.
MEAS.
KEY SWITCH
No.
OFF
OFF
OFF
OFF
OFF
OFF
No.9
PRESS. SENSOR
B1
BOOM RAISE
3.5V 35k
B2
BOOM LOWER
3.5V 35k
No.10
PRESS. SENSOR
B3
ARM OUT
3.5V 36k
B4
ARM IN
3.5V 36k
No.11
PRESS. SENSOR
B5
BUCKET DIG
3.5V 37k
B6
BUCKET DUNP
3.5V 37k
No.12
PRESS. SENSOR
B7
SWING (R)
3.5V 38k
B8
SWING (L)
3.5V 38k
13
14
15
20
21
22
DISPLAY
No.
No.13
PRESS. SENSOR
B9
TRAVEL (R)
3.5V 39k
B10 TRAVEL (L)
3.5V 39k
No.14
PRESS. SENSOR
C1 PUMP P1
3.5V
42k
C2 PUNP P2
3.5V
42k
23
24
No.15
PRESS. SENSOR
B16 P1 OPT.
3.5V
36k
B17 P2 OPT.
3.5V
36k
25
No.20
PROPO-VALVE
D1 P1 BYPASS
COMP. 600mA 45k
MEAS. 600mA 45k
No.21
PROPO-VALVE
D2 P2 BYPASS
COMP. 600mA 45k
MEAS. 600mA 45k
No.22
PROPO-VALVE
D3 S-TRAVEL
COMP. 600mA
MEAS. 600mA
45k
45k
39
40
DISPLAY
No.23
PROPO-VALVE
D6 A-RECIRCULAT
COMP. 600mA 45k
MEAS. 600mA 45k
No.24
PROPO-VALVE
E1 P1 PUMP
COMP. 600mA
45k
MEAS. 600mA
45k
POWER SHIFT 100mA
No.25
PROPO-VALVE
E2 P2 PUMP
COMP. 600mA
45k
MEAS. 600mA
45k
POWER SHIFT 100mA
No.39
MECHATRO ADJT.
CONT. SW
TEST
CONT. VOL
100%
PROG. SW
OFF
No.40
RELEASE SW
KPSS
SWING BRAKE
TEST
OFF
2.
4. TROUBLESHOOTING
(1)-1
Note: (1)-1 matches the Groupe No. on page
1.
No motions operate.
Lever stand down

24V is alive across
YES
white/blue and black of
connector (CN-253F) for
safety lever lock solenoid.
To hydraulic
troubleshooting
NO
24V is alive across white

and blue of connector
(CN-46F) for safety lever
lock switch (SW-11).
YES
NO

and black of connector
(CN-46F) for safety lever
lock switch (SW-11).
YES
NO
Fuse No.15 is blown.
YES
Safety lever lock switch

(SW-11) is faulty.
YES
Safety lever lock switch

(SW-11) is attached
improperly.
YES
Inspect harness.
Replace switch (SW-11).
YES
NO

and black of connector
(CN-38M) on fuse box.
Harness between safety

lever lock switch (SW-11)
and safety lever lock
solenoid (SV-4) is
disconnected.
YES
Harness between fuse box

and safety lever lock
switch (SW-11) is
disconnected.
Harness shorted to frame.
YES
YES
Adjust and replace.
Inspect harness.
Inspect the shorted point

of harness.
NO
Inspect if there is no
disconnection in fuse box.
(1)-2
Machine moves unexpectedly when lever is at neutral.
(P1 bypass cut proportional valveandP2 bypass cut
proportional valveare displayed on the gauge cluster.)
The machine operates unexpectedly if the
connector (CN-257F) for the P1 bypass
cut proportional valve is removed.
YES
To hydraulic
troubleshooting
NO
(Service diagnosis No.10)
Arm out operation pressure sensor
YES Trouble disappears if arm out operation
(SE-8) shows more than 1.3V even
pressure sensor (SE-8) is replaced.
NO
NO
Arm out pilot pressure is 6kgf/cm2 (85psi)

Arm out operation
YES pressure sensor (SE-8) is

faulty.
YES
NO
Arm in operation pressure sensor
YES
(SE-7) shows more than 1.3V when
NO
C-1 controller is faulty.
Trouble disappears if arm in operation

NO
Arm in pilot pressure is 6kgf/cm2 (85psi)
YES Arm in operation
pressure sensor (SE-7) is

faulty.
YES
NO
The machine operates unexpectedly if the
connector(CN-257F) for the P2 bypass cut
proportional valve is removed.
Inspect ATT pilot valve.

YES
To hydraulic
troubleshooting.
NO

Boom raise operation pressure sensor
YES Trouble disappears when boom raise
ope-ration pressure sensor (SE-3) is
NO
NO
Boom raise pilot pressure is more than

6kgf/cm2 (85psi) when lever is at neutral.
Boom raise operation

faulty.
YES
NO

Swing operation pressure sensor
YES Trouble disappears when swing ope-ration
(SE-5) shows more 1.3V when lever is
at neutral.
NO
NO
Swing pilot pressure is more than 6kgf/cm2

(85psi) when lever is at neutral.
NO
Swing operation

faulty.
YES

(2)-2
Only bucket motion is slow.
The bucket operating pressure sensor value
is more than 4.0V when the bucket
operating lever is turned to the full.
YES
To hydraulic
troubleshooting
YES
Bucket opration pressure

sensor (SE-1,or SE-2) is
faulty.
NO
Trouble disappears if bucket operation
pressure sensor (SE-1,or SE-2)is changed.
NO
If the harness for the bucket operation
pressure sensor is connected another
pressure sensor, the pressure sensor gets
out of order.
YES
Bucket pilot pressure is more than approx.
35kgf/cm2 (500psi) when lever is at full.
Harness between bucket

opeeration pressure sensor
and controller is faulty.
NO
YES
NO
To hydraulic
troubleshooting
(2)-3
Only boom raise speed motion is slow.
The boom raise operation pressure sensor
(SE-3) value is more than 4.0V when the
boom raise operating lever is turned to the
full.
YES
To hydraulic
troubleshooting
YES
Boom reise operation

fauly.
NO
Trouble disappears if boom raise operation
pressure sensor is replaced.
NO
If the harness for the boom raise operation
out of order.
(2)-4
YES
NO
To hydraulic
troubleshooting
Except for boom raise and arm out motions are slow.
Command current for travel straight
proportional valve is approx. 350mA or over
at boom raise or arm in motions.
NO
YES (Service diagnosis No.13)

Travel right operation pressure sensor
(SE-9) shows more than 1.3V when travel
right lever is at neutral.
YES Trouble disappears when travel right
NO
To hydraulic
troubleshooting
operation pressure sensor (SE-9) is

replaced.
NO
Travel right pilot pressure is more than
6kgf/cm2 (85psi) when lever is at
YES Travel right operation

faulty.
YES Inspect travel pilot valve.

Inspect harness between
travel right operation
pressure sensor (SE-9) and
controller.
NO
Travel left operation pressure sensor

(SE-10) shows approx. 1.3V or over when
travel left lever is at neutral.
NO
YES Trouble disappears if travel left
YES Travel left operation

faulty.
opera-tion pressure sensor (SE-10) is
NO
Travel left pilot pressure is more than
NO
YES
Inspect travel pilot valve.

travel left operation
pressure sensor (SE-10)
and C-1 controller.
(2)-5
Only arm in motion is slow.
Arm in operation pressure sensor shows
4.0V or over when arm in lever is shifted to
the full.
NO
Trouble disappears if arm in operation
YES
To hydraulic
troubleshooting
YES
Arm in operation pressure

sensor (SE-7) is faulty.
NO
Faulty symptom changes if the harness for
the arm in operation pressure sensor is
connected with another pressure sensor.
Harness between arm in

operation pressure sensor
YES
NO
Arm in pilot pressure is approx. 35kgf/cm2
(500psi) or over when arm in lever is shifted
to the full.
(2)-6
YES
NO
To hydraulic
troubleshooting
Only arm out motion is slow.

Arm out operation pressure sensor shows
4.0V or over when arm out lever is shifted to
the full.
NO
Trouble disappears if arm out operation
YES
To hydraulic
troubleshooting
Arm out operation
faulty.
YES
NO
If the harness for the arm out operation
out of order.
Harness between arm out

YES
NO
Arm out pilot pressure is approx. 35kgf/cm2
(500psi) or over when arm out lever is
(4)-1
YES
NO
To hydraulic
troubleshooting
Fine operation of bucket digging and dump motions can not be performed.
Bucket digging (dump)
Trouble gets normal if
operation pressure
NO
NO connector on P1 bypass
sensor shows
cut proportional valve
0.7V or over when
(PSV-D) is disconnected.
YES
Trouble disappears if arm
YES in operation pressure
sensor (SE-7) shows
approx. 1.3V or over when
sensor (SE-7) is replaced.
YES Arm in operation pressure

NO
NO
Arm in pilot pressure is

6kgf/cm2 (85psi) or over
NO
Continued on the P9.
To hydraulic
troubleshooting.
Continued on the P9.
YES

arm in operation pressure
sensor (SE-7) and C-1
controller.
Continued from P8.
Continued from P8.
NO
YES
Arm out operation pressure

sensor (SE-8) shows approx.
1.3V or over when lever is at
neutral.
YES Trouble disappears if arm

out operation pressure
YES Arm out operation

faulty.
NO
NO
Arm out pilot pressure is

more than 6kgf/cm2 (85psi)
YES

arm out operation pressure
sensor (SE-8) and
C-1 controller.
NO
Replace C-1 controller.

Trouble disappears if bucket digging
(dump) operation pressure sensor SE-1
(SE-2) is changed.
YES
Bucket digging (dump) operation pressure

sensor is faulty.
YES
Harness between bucket digging (dump)

operation pressure sensor and controller is
faulty.
NO
If the harness for the bucket digging
operation pressure sensor is connected
another pressure sensor, the pressure
sensor gets out of order.
(4)-2
NO
Fine operation of boom raise and lower motions can not be performed.
(Service diagnosis No. 9)
Boom raise (lower)
operation pressure
sensor shows 0.7V
or over when lever
is at neutral.
YES
(
P1 bypass cut proportional valve is displayed on the gauge cluster.)
NO connector of P1 bypass cut
NO
To hydraulic
troubleshooting
proportional valve
(PSV-D) is disconnected.

YES Trouble disappears if arm in
sensor (SE-7) shows
(SE-7) is replaced.
NO

NO

YES
NO
YES Trouble disappears if arm
sensor (SE-8) shows
NO
NO
If the harness for the bucket
digging(dump) operation pressure sensor
is connected to another pressure sensor,
the faulty symptom changes.

sensor (SE-7) and
C-1 controller.

NO

NO
Trouble disappears if boom raise (lower)

operation pressure sensor SE-3 (SE-4) is
changed.
Inspect ATT pilot.valve
YES

sensor (SE-8) and
C-1 controller.
YES
Boom raise (lower) operation pressure sensor

SE-3 (SE-4) is faulty.
YES
The harness between bucket digging operation

pressure sensor SE-1 and the bucket dump
operation pressure sensor SE-2 is faulty.
NO
(4)-3
Fine operation of swing motion can not be performed.
(P2 bypass cut proportional valve is displayed on the gauge cluster.)
Trouble gets
Swing operation pressure
Trouble is corrected if swing
YES sensor (SE-5) shows approx. YES operation pressure sensor
normal if
connector of P2
(SE-5) is replaced.
bypass cut
neutral.
NO
proportional
NO
Swing pilot pressure is more
valve (PSV-B) is
than 6kgf/cm2 (85psi) when
disconnected.
NO
YES Swing operation pressure

YES

swing operation pressure
controller.
NO
YES Trouble disappears if boom
raise operation pressure
shows approx. 1.3V or over
YES Boom raise operation

faulty.
NO
NO
Boom raise pilot pressure is

YES
YES Swing operation pressure

NO
NO

YES
NO
sensor (SE-7) shows 1.3V or
over when lever is at
neutral.

YES Trouble disappears if arm in YES Arm in operation pressure

(SE-7) is replaced.
NO
NO

NO
connector of swing parking
solenoid (SV-1) is
disconnected.

boom raise operation
C-1 controller.
NO
sensor (SE-8) shows 1.3V or YES out operation pressure
over when lever is at
neutral.
NO
YES

To hydraulic
troubleshooting
YES
Trouble disappears if swing
sensor (SE-5) shows approx. NO
4.0V or over when lever is
(SE-5) is replaced.
YES
YES

NO
Swing pilot pressure is

approx. 35kgf/cm2 (500psi)
or over when lever is shifted
to the full.
NO
YES

controller.
10
(4)-4
Fine operation of arm in and out motions is not possible.
(Displays Service Diagnosis No21.)
NO
connector of P2 bypass cut
proportional valve (PSV-B) is
disconnected.
To hydraulic
troubleshooting

Trouble gets normal if swing
sensor (SE-5) shows approx. YES
(SE-5) is replaced.
neutral.
YES
NO
NO

YES

Trouble disappears if boom
YES
Boom raise sensor (SE-3)

shows approx. 1.3V or over
NO
YES

Arm out operation pressure YES Trouble disappears if arm
over when lever is at neutral.
YES

C1 controller.
YES
NO
YES
NO
over when lever is at neutral.
Boom raise sensor (SE-3)

is faulty.
NO
NO
NO

swing sensor (SE-5) and
C-1 controller.
NO
NO

Arm out operation

faulty.
YES Trouble disappears if arm in YES

(SE-7) is replaced.

NO
Arm in pilot pressure is more
NO
YES
11
(5)
Travel 1-2 speeds can not be changed.
24V is alive across light green/black
and black wires of connector
(CN-255F) for travel 1-2 speed select
solenoid (SV-3).
YES
To hydraulic
troubleshooting
NO
If Switch travel 1-2 speed select
switch(SW-3) is pressed in the
service diagnosis No.6, ON is
displayed, and if the switch is not
pressed, OFF is displayed.
Each time the switch turns ON
YES and OFF by turns in the service
diagnosis No.6, the 2nd digit and 1st

digit numbers turn to 1 and 0
alternately.
NO
NO
If the plugs(two females) connecting
the travel 1-2 speed select
switch(SW-3) with the main harness
are connected together, the switch is
turned ON and if the plugs are
disconnected, the switch is
turned OFF .
YES
YES

Inspect harness (light
green and black) between
travel 1-2 speed select
solenoid (SV-3) and
C-1 controller.
Replace travel 1-2 speed
select switch (SW-3).
NO
Harness (pink and blue) between
travel 1-2 speed select switch
(SW-3) and C-1 controller is
disconnected.
YES
Repair harness.
NO
12
(6)
Command current of travel straight
NO
proportional (PSV-C) is more than
349mA during traveling.
To hydraulic
troubleshooting
YES
Bucket digging operation pressure
sensor (SE-1) shows 1.3V when lever
is at neutral.
YES Trouble disappears if bucket digging YES

replaced.
Bucket digging operation

faulty.
NO
NO
Bucket digging pilot pressure is

more than 6kgf/cm2 (85psi) when
YES
NO


Bucket dump operation pressure
YES Trouble disappears if bucket dump
sensor (SE-2) shows more than 1.3V
replaced.
YES
Bucket dump operation

faulty.
NO
NO
Bucket dump pilot pressure is more

than 6kgf/cm2 (85psi) when lever is
at neutral.
YES
NO


Boom raise operation pressure
NO
YES Trouble disappears if boom raise

replaced.
YES
NO
Boom raise pilot pressure is more
at neutral.
YES
NO
Boom lower operation pressure
NO

YES Trouble disappears if boom lower

replaced.
YES
Boom lower operation

faulty.
NO
Boom lower pilot pressure is more
at neutral.
YES
NO

Swing operation pressure sensor
YES Trouble disappears if swing
replaced.
NO

faulty.
YES

NO
Swing pilot pressure is more than
neutral.
NO
YES
Continued on the P14
13
Continued from P13
NO (Service diagnosis No.10)

Arm in operation pressure sensor
Trouble disappears when arm in
YES
replaced.
NO
YES

NO
Arm in pilot pressure is more than
neutral.
YES
NO

Arm out operation pressure sensor
YES Trouble disappears if arm out
replaced.
YES
Arm out operation

faulty.
NO
NO
Arm out pilot pressure is more than

neutral.
YES
NO

(8)
Machine does not travel straight.
YES
Command current of travel straight

proportional valve (PSV-C) is 650mA or
NO
TRAVEL PROP-VALV is displayed on
gauge cluster.
NO
Machine deviates
to the left.
To hydraulic
troubleshooting
Check harness (green / black and gray /
black) between travel straight proportional
valve (PSV-C) and C-1 controller.
YES
YES
NO

sensor (SE-5) shows more
than 4.0V when lever is
YES
NO Trouble disappears if swing YES Swing operation pressure

(SE-5) is replaced.
NO
than approx. 35kgf/cm2
(500psi) when lever is
NO
NO Trouble disappears if arm
YES
NO

to the full.
NO
14
Check harness between
YES swing operation pressure

controller.
YES Arm out operation

faulty.
YES arm out operation pressure

sensor (SE-8) and
C-1 controller.
Continued from P14
NO
Continued from P14

NO in operation pressure

NO
YES

to the full.
YES arm in operation pressure

controller.
NO
Boom raise
operation pressure
sensor (SE-3) shows
more than 4.0V
when lever is shifted
to the full.
YES

faulty.
NO Trouble disappears if boom YES

NO
to the full.

C-1 controller.
YES
NO

Boom lower
operation pressure
sensor (SE-4) shows
approx. 4.0V or over
to the full.
YES
NO Trouble disappears if boom YES

lower operation pressure
Boom lower operation

faulty.
NO
Boom lower pilot pressure is
to the full.
YES
NO

boom lower operation
C-1 controller.

Bucket digging
operation pressure
sensor (SE-1) shows
to the full.
YES
NO Trouble disappears if bucket YES

digging operation pressure
NO
Bucket digging pilot
pressure is
approx.35kgf/cm2 (500psi) or
over when lever is shifted to
the full.
YES
NO
YES

bucket digging operation
and C-1 controller.

Bucket dump
operation pressure
sensor (SE-2) shows
to the full.
Bucket digging operation

faulty.
NO Trouble disappears if bucket YES

dump operation pressure
Bucket dump operation

faulty.
NO
Bucket dump pilot pressure
is approx. 35kgf/cm2
(500psi) or over when lever
is shifted to the full.
YES
NO

bucket dump operation
C-1 controller.
15
(10)
Swing motion does not work.
Swing motion works if connector

(CN-254F) of swing parking
solenoid (SV-1) is disconnected.
NO
To hydraulic
troubleshooting
YES

Swing operation pressure sensor NO Trouble disappears if swing
(SE-5) shows approx. 1.3V or
operation pressure sensor (SE-5)
over when lever is shifted to the
is replaced.
full.
YES

NO
YES
Swing pilot pressure is approx.

35kgf/cm2 (500psi) or over when
lever is shifted to the full.
YES
NO

controller.
(11)
Swing speed is low.
Actual current readings of P2
pump proportional valve are
more than 619mA when the
swing lever is turned to the full.
YES
To hydraulic
troubleshooting
NO
Command current of P2 pump
proportional valve are more than
619mA when the swing lever is
turned to the full.
YES
NO
The swing operation pressure
sensor value is more than 4.0V
when the swing operation lever
is turned to the full.
NO

operation pressure sensor (SE-5)
is replaced.
YES

sensor is faulty.
NO
YES

operating pressure sensor is put
into another pressure sensor, the
pressure sensor gets out of order.
YES
Harness between swing

YES
Inspect or replace ATT

pilot valve
NO
NO
P1 or P2 pump pressure sensor
shows more than 0.7V when
Check piping
YES Trouble disappears if P1 or P2

pump pressure sensor is
changed.
NO
P1 or P2 pump pressure
sensor is faulty.
NO
Faulty symptom changes if the
harnesses for P1 and P2 pump
pressure sensors are exchanged.
NO
Swing operating pressure is
normal.
YES
YES
Harness between pressure

sensor and controller is
faulty.
YES
NO
To hydraulic
troubleshooting
16
(12)
Swing power is poor.
Actual current readings of P2
pump proportional valve are
more than 619mA when the
swing lever is turned to the full.
YES
To hydraulic
troubleshooting
NO
Command current of P2 pump
proportional valve are more than
619mA when the swing lever is
turned to the full.
YES
NO
The swing operation pressure
sensor valve is more than 4.0V
when the swing operation lever
is turned to the full.
NO

operation pressure sensor is
replaced.
YES

sensor is faulty.
NO
YES

operating pressure sensor is put
into another pressure sensor, the
pressure sensor gets out of order.
YES
Harness between swing

YES
Inspect or replace ATT

pilot valve
NO
NO
P1 or P2 pump pressure sensor
shows more than 0.7V when
Check piping
YES Trouble disappears if P1 or P2

pump pressure sensor is
changed.
NO
P1 or P2 pump pressure
sensor is faulty.
YES
Harness between pressure

sensor and controller is
faulty.
NO
Faulty symptom changes if the
harnesses for P1 and P2 pump
pressure sensors are exchanged.
NO
Swing operating pressure is
normal.
YES
YES
NO
To hydraulic
troubleshooting
17
(13)
Swing motion can not be held on a slope.
24V is alive across

pink/black and black wires
of connector (CN-254F) for
swing parking solenoid
(SV-1).
YES
To hydraulic
troubleshooting
NO
switch (SW-4) is at
NORMAL.
NO
Turn to NORMAL.
YES
YES Trouble gets normal if
than 1.3V when lever is at
neutral.
YES
NO
NO

than 6kgf/cm2 (85psi) is
YES
Trouble gets normal if arm
YES in operation pressure sensor
YES
(SE-7) is replaced.

NO
NO

YES

sensor (SE-7) and
C-1 controller.
NO
If swing right (or swing left,

or arm in) lever is operated,
SWINGBRAKE SOLENOID
is indicated.

controller.
NO

than 1.3V when lever is at
neutral.

Inspect that harness (pink

and black) between swing
parking brake solenoid
(SV-1) and C-1 controller is
not disconnected.
YES
NO
18
(14)
Auto idling stop (AIS) does not function. (E/G does not stop after an
elapse of 60 seconds after the lock lever was moved upward to locked
ii )
Is WARM-UP displayed?
YES
NO
Is E/G water temperature

warning indicated?
When
overheating
is
detected, AIS does not
work to protect E/G.
Check on it in normal
operation condition.
YES
NO
Is AIS selector SW off?
When AIS selector SW is

off, it does not work.
Switch AIS SW on and
check on it.
YES
NO
Are mechatrocontroller
12-14 pin and grounding
connected?
In auto warm-up (OPT)

operation, AIS does not
work. Switch warm-up SW
off or check on it after
completion of warming up.
Check the line between

grounding - AIS selector
SW - controller.
NO
YES
Is E/G speed indication on
E/G speed display or
Service diagnosis display
normal. (About 2200 rpm
in high idling, about 1000
rpm in low idling)?
Check speed sensor gap, or

check between controller
and speed sensor for
continuity.
NO
YES
Is ATT operation possible
even if the lock lever is
moved upward to locked
position ?
YES
Adjust or replace
lever limit switch.
YES
Check the line between

lock lever limit switch and
controller.
YES
Replace fuse, or check the

line around the fuse.
lock
NO
Is 24 V loaded on mechatro
controller 17-11 when the
lock lever is moved
downward to locked
position?
NO
Is fuse No.15 blown?
NO
* Is set time (60 seconds) YES
Replace controller.
until the AIS is tripped

correct?
NO
*Adjust set time.

NOTE :
1. AIS is Auto Idling Stop.
2. For checking and adjusting method of AIS set time shown by mark *,
contact KOBELCO Field Support Group.
19
E200SR
SECTION 44
TROUBLESHOOTING (ENGINE)
TABLE OF CONTENTS
1. TROUBLE DIAGNOSIS TABLE ................................................................................. 1
2. TROUBLESHOOTING ............................................................................................... 3
Other trouble
Drop in output
Rotation trouble
(3)
(7)
(8)
Starting trouble
Trouble
(1)
Starter does not run.
(2)
Starter runs but does not

start.
Over heat
Exhaust gas is white

(In cold state, white smoke does
not disappear after idling.)
(9)
Excessive oil consumption.
(10)
Excessive fuel consumption.
(11)
Engine does not stop when

key is turned off.
(12)
The key is turned to OFF,

but power does not shut off.
Component
Idling unsmooth
High speed unsmooth
E/G deficiency in output
Exhaust gas is black
Does not reach max

revolution.
Medium speed hunting
Knocking occurs after

warming-up E/G
Max. revolution is too high.
(4)
Revolution does not change

if work modes are changed.
(5)
Accel potentiometer does

not work properly.
Flywheel gear damaged.
Head gasket faulty.
Check fuel feed.
Internal parts stuck.
Valve spring fatigued.
Piston ring worn.
Piston liner worn.
Cooling
Crank shaft oil seal no good.
Governor spring fatigued.
Control rack movement unsmooth.
Compression pressure low.
Oil cooler element damaged.
Lubrication
system
Check thermostat.
Service man
Fuel is mixed.
Oil strainer clogged.
Check relief valve.
Intake /
exhaust
system
Check if engine oil level goes into combustion
chamber.
Air cleaner & muffler
Valve spring is fatigued.
Fuel
system
Valve clearance
Injection pump
Inspect nozzle.
Engine side
Electrical fittings
Check injection timing
Feed pump function
Alternator
Starter relay
Starter motor
Glow
Glow relay
Machine side
Electrical fittings
Safety relay
Connector and electric wiring
Accel potentiometer
Governor motor
Mechatoro A adjust.
Mechatoronic controller
Gas / fluid
Battery relay
Visual check
Starter key
Fuse
Battery fluid level
Engine oil is too much.
Fluid
Gas leaks from valve and gasket.
Inspection
Blowby gas is much.
Poor quality fuel is used or heavy oil is

used.
Viscosity of engine oil is not suited, engine oil is

leaking, or the engine oil level not proper.
Specific gravity of battery fluid
Filters
Fuel is of poor quality or leaking.
Cooling water level
Breather hose bent.
V-belt slips.
Fuel filter clogged.
Gauze filter clogged.
Air cleaner clogged.
Oil filter clogged.
Fuel system trouble(Air or water entered.)
Oil cooler element clogged.
Fuel not filled up or leaking.
Group No.
System
TROUBLE DIAGNOSIS TABLE ; ENGINE

Engine dealer
Main structure
Engine
1.
(6)
Stop
position
2. TROUBLESHOOTING
(1)
Starter does not run.
Check battery voltage.
NO
Check battery fluid level

and specific gravity.
Charge or replace battery.
OK
Check battery relay B1
voltage.
OK
Check fuse box voltage.
OK
The voltage at B1
terminal of battery is
24V ore more.
The voltage at outlet
side of 20A fuse for
keyswitch is 24V or
more.
NO
OK
Check voltage of battery
relay A. Also check
voltage of battery relay
A1.
Replace fuse.
Measure the voltage at

L terminal of battery
relay instead of M
terminal of keyswitch to
check the voltage of the
M terminal.
Measure the voltage at
S terminal of safety
relay on wire No.63
instead of ST terminal of
keyswitch to check the
voltage at ST terminal.
YES
The voltage at L
terminal of battery relay
is 24V or more.
Check electric wiring and

connectors.
NO Check electric wiring

and connector.
Check key switch.
NO Check electric wiring

and connector.
NO
Check electric wiring
and connector.
OK
Check voltage of battery
relay.
Replace fusible link 60A.
OK
The voltage at inlet side
of 20A fuse for
keyswitch is lower than
Check key switch

voltage.
NO
YES
Replace battery relay.
24V is alive on A side,

but not on A1.
Replace fusible link 60A.
OK
Check voltage of starter
motor.
24V is alive on terminal

B of starter motor.
OK
OK
Check voltage of starter
motor.
Replace starter motor.

S of starter motor.
OK
Check voltage of safety
relay.

S of safety relay.
YES
OK
Check voltage of safety
relay.
Replace safety relay.

The voltage across
safety relay and starter
motor(across coil) is
NO
Condition ; Check keyswitch in START position.

Emergency stop knob (for engine stop) is back in normal position.
3
(2)
Starter turns but engine is hard to start.
Check starter power is strong or
weak.
WEAK
Check battery fluid level and

specific gravity.
Charge or replace battery.
OK
Check compression
pressure and valve
clearance. Check that
valve spring is not
fatigued, that piston
liner is not worn, that
piston ring is not worn,
that head gasket is not
faulty and that flywheel
gear is not damaged.
Also check radiator and
thermostat.
Check engine itself.

Check that air filter clogged
lamp lights.
Check air intake system.
OK
OK
Check that air cleaner clogged
sensor.
E/G side
Check gauze filter.
Machine
side
Check fuel gauge and water

separator. Check that poor
quality fuel is not used.
E/G side
24V is alive on glow plug.
Check fuel feed system.
Check electric system.
Check feed pump
OK performance, injection
pump, injection nozzle
and injection timing.
YES
NO
24V is alive on wire No. 66 (5W)
of CN-153F on glow relay (R-3).
NO
24V is alive on wire No.53 (5Y)
of CN-154F on glow relay (R-3).
YES
Harness between glow

relay and glow plug is
faulty.
NO
Harness between glow

relay and battery relay
is faulty.
OK
24V is alive across wire No. 62
of CN-155F on glow relay (R-3)
and earth.
NO
Ground connection is poor.
Check E/G oil of viscosity if it is

suited to ambient temperature.
Check viscosity of E/G oil.
Glow plug is faulty.
YES
NO
NO
Replace glow relay.

Harness between key
switch and glow relay is
faulty.
Replace engine oil.
Checking condition ; E/G starter key is in ON position.
CN-154F
CN-153F
CN-155F
CN-155F
Internal
connection
Fig.1 Glow relay terminals and connector
(3)
E/G revolution is faulty.
Check high pressure pipe
and injection nozzle. Check
that compression
pressures in cylinder are
equal. Check injection
pump and thermostat.
Idling not smooth.
Idling is faulty.
Medium revolution is
faulty.
Idling revolution is too

high.
Adjust mechatroA.
Hunting occurs at medium

revolution.
Check control rack.

Change over governor
spring.
Check that air is not mixed

in fuel.
YES
Bleed air.
OK
Check air intake system.
Check that air cleaner is

not clogged.
OK
Check fuel feed system.
OK
High idling is faulty.
Check fuel gauge, water

separator and gauze filter.
Check also that poor
quality fuel is not used.
Check injection nozzle,
injection pump and
injection timing.
E/G does not reach max.

revolution.
1
Adjust mechatroA.
Max revolution is too high.
Checking condition ; E/G water temperature is 505 (1229

F).
1 ; Refer to Electric Troubleshooting.
Note ; (6) matches the group No. on page 1. The same is true on the following pages.
(6)
E/G output is insufficient.
Overheat
Check that E/G water

temperature lamp is on and
that buzzer sounds.
OK
NO
Check the contents of

excavating.
Check E/G water
temperature switch, gauge
cluster, electric wiring and
connectors.
Inspect electric system.
OK
Check cooling water level.

Check that fan belt does
not slip.
Check thermostat.
Also check that radiator.
Oil cooler is not clogged.
Check cooling system.
OK
Check that poor quality

fuel is not used.
Check fuel system.
OK
Check E/G oil system.
Check air intake
system.
Check E/G oil filter.
Check that air filter clogged

display of warning
OK
Check that air cleaner is

not clogged.
OK
Check fuel feed
system.
Check that air is not mixed in

fuel.
OK
Check E/G oil.
OK
Check engine
itself.
OK
Bleed air.
Check water separator and

gauze filter. Check also that
poor quality fuel is not used.
Check feed pump

performance, injection
pump, injection nozzle and
injection timing.
Check E/G oil of viscosity if it

is suited to ambient
temperature.
Replace engine oil.
Check that blowby gas is not

much, that gas does not leak
from gasket, and that engine
oil level does not go into
combustion chamber.
Checking condition ; High idling

(7)
Check compression
pressure and valve
clearance. Check that
valve spring is not
fatigued. Check that
control rack moves
smoothly. Check that
piston ring is not worn.
Check also that head
gasket is not faulty.
Knocking occurs after warming-up E/G.
OK
Check fuel system.
Check that poor quality fuel is

not used.
Replace fuel.
Check E/G itself.
Check that engine oil goes into

combustion chamber.
Judge it if oil is there on

exhaust port.
OK
Check that blowby gas is not
much and that gas does not
leak from gasket.
Checking condition ; E/G water temperature is 505 (1229F).
Check compression
pressure, injection timing
and injection nozzle.
(8)
Exhaust is abnormal.
Exhaust gas is black.
Check that air cleaner is not

clogged.
Replace air element.
OK
Check engine oil viscosity.
Check that engine oil is not too
much.
OK
Check that gas is not leaking
from head gasket.
Exhaust gas is white.
Check that water is not mixed

in fuel.
Check injection nozzle,

injection timing, injection
pump and valve clearance.
Check that valve spring is not
fatigued and that piston ring is
not faulty.
Check water separator.
OK
Check that engine oil goes
into combustion chamber.
Blowby gas is much. A lot of
gas leaks from gasket.
Check compression pressure

and injection timing.
Checking condition ; Engine water temperature is 505 (1229

F).
(9)
Excessive oil consumption.
Check that engine oil is not
leaking.
(Check that engine oil is not
filled up too much.)
Check leakage by checking the

ground under E/G or by placing
an oil pan under E/G.
Retighten.
Replace packing and seal.
OK
Check that breather hose is not
bent or clogged.
Replace breather hose.
OK
not used.
Advise to replace fuel.
OK
Check viscosity of engine oil.
OK
Checking condition ; No engine oil leaks.
Check that engine oil goes into

combustion chamber.
(10)
Advise to replace engine oil.

Check that; CR shaft oil seal is
not faulty, piston liner is not
worn, or piston ring is not
worn.
Excessive fuel consumption.
Check fuel leakage.

not used.
Advise to replace fuel.
OK
Blowby gas is much.
Check that gas does not leak
from gasket.
Check nozzle function.
Check injection timing.
Check compression pressure.
Checking condition ; Use proper fuel.
(11)
E/G does not stop
when starter key is
turned off.
Check that governor

motor link
connecting bolts are
not loose.
Check if governor
motor is not faulty
mechanically.
Confirm governor
lever stop bolt
position.
OK
Check that terminal
M of starter key
switch shows 0V.
Wire number 60C of

instrument panel
right harness
CN-43F shows 0V.
Check resistance
NG across terminals M
and B on starter
key.
Replace starter key

if resistance across
M and B is 0.
See Fig.3.
Check C1 controller.
Does resistance
across C1 controller
terminals 11-1 and
14-22 measure 72
?
OK
Check that battery
relay terminal B2
measures 0V four
seconds after key is
turned off.
(12)
Wire No.857 of main

harness CN-150F
measures 0V.
NG
Does battery
terminals A and B
measure 0?
NG Replace battery
OK
When starter key is

turned off, power
does not shut off.
Check that battery

relay operates.
relay.
See Fig.2.
Replace C1
controller if
resistance measures
0.
Checking condition ; Starter key is off.

CN-152F
TERMINAL A1
Flowing direction of
main current
TERMINAL A1
LOCK
B B1 TERMINAL
FLW
2.0sq
TERMINAL B1
FLW
2.0sq
VIEW
TERMINAL A
FLW2.0sq
GW
WG
B2
L
TERMINAL B
FLW2.0sq
P COIL
H COIL
BRACKET
TERMINAL B2
Circuit diagram
L TERMINAL
GROUND CABLE
AVS1,25B
Fig. 2
Fig. 3
AVS1,25G
L TERMINAL GW
AVS1,25L
B2 TERMINAL
GROUND
TERMINAL
WD
Battery relay
Key SW. terminal
CN-150M
E200SR
SECTION 51
ENGINE
TABLE OF CONTENTS
1. GENERAL INFORMATION .................................................................................... 1-1
2. MAINTENANCE ..................................................................................................... 2-1
3. DISASSEMBLY ..................................................................................................... 3-1
4. INSPECTION & REPAIR ....................................................................................... 4-1
5. REASSEMBLY ...................................................................................................... 5-1
6. LUBRICATING SYSTEM ....................................................................................... 6-1
7. COOLING SYSTEM .............................................................................................. 7-1
8. FUEL SYSTEM ...................................................................................................... 8-1
9. TURBOCHARGER ................................................................................................. 9-1
10. AIR COMPRESSOR ........................................................................................... 10-1
11. ENGINE ELECTRICALS ..................................................................................... 11-1
12. TROUBLESHOOTING ........................................................................................ 12-1
13. SPECIAL TOOL LIST ......................................................................................... 13-1
14. CONVERSION TABLE ........................................................................................ 14-1
E200SR
SECTION 63
MOUNTING THE BREAKER AND

NIBBLER & BREAKER
TABLE OF CONTENTS
1.LIST OF ADDITIONAL PARTS
1.1 Additional Parts for the Modification of the Nibbler & Breaker ............................................ 1-2
1.2 Additional Parts for the Modification of the Breaker ............................................................ 1-8
2. SUMMARY
2.1 General Precautions .......................................................................................................... 2-1
2.2 Basic Method to be taken when Mounting ......................................................................... 2-1
2.3 Outline of Modification ....................................................................................................... 2-2
3. HYDRAULIC CIRCUIT DIAGRAM

3.1 Hydraulic Circuit for Nibbler & Breaker .............................................................................. 3-1
3.2 Hydraulic Circuit for Breaker .............................................................................................. 3-3
3.3 Hydraulic Components ....................................................................................................... 3-4
4. ELECTRIC SYSTEM DIAGRAM FOR NIBBLER & BREAKER............................... 4-1

5. MODIFICATION PROCEDURE FOR NIBBLER & BREAKER
5.1 Modification Item ................................................................................................................
5.2 Floor Mat (Nibbler & Breaker) ............................................................................................
5.2a Modification of the Control Valve ......................................................................................
5.2b Replacement of return filter of the Hydraulic Tank ............................................................
5.3 Remote Control Piping ; P/V ..............................................................................................
5.4 Control Block Piping ..........................................................................................................
5.5 Main Remote Control Piping ; C/V ......................................................................................
5.6 Upper Hydraulic Piping ......................................................................................................
5.7 Modification of the Instrument Panel ..................................................................................
5.8 Install of the Name Plate ....................................................................................................
5-1
5-1
5-1
5-2
5-3
5-3
5-4
5-5
5-6
5-6
6. MODIFICATION PROCEDURE FOR BREAKER

6.1 Modification Item ................................................................................................................
6.2 Floor Mat ...........................................................................................................................
6.2a Modification of the Control Valve (Same as N&B, See item 5.2a) .....................................
6.2b Modification of the Hydraulic Tank (Same as N&B, See item 5.2b) ..................................
6-1
6-1
6-2
6-2

INDEX
6.3 Remote Control Piping .......................................................................................................

6.4 Remote Control Block (Same as N&B, See item 5.4) .........................................................
6.5 Main Remote Control Piping ; C/V......................................................................................
6.6 Upper Hydraulic Piping ......................................................................................................
6.7 Install of the Name Plate ....................................................................................................
6-3
6-4
6-4
6-5
6-6
7. MODIFICATION PROCEDURE FOR ATTACHMENT .............................................. 7-1

8. REMINDERS ON THE USE OF NIBBLER & BREAKER ......................................... 8-1
9. PRECAUTIONS TO BE EXERCISED ON BREAKERS OF DIFFERENT
MANUFACTURES................................................................................................... 9-1
10. REFERENCE ....................................................................................................... 10-1
1. LIST OF ADDITIONAL PARTS

How to utilize the list of additional modification parts
This manual describes the parts which are added and canceled on
the basis of
Parts Manual
for standard machines when the
machine is modified into the machines equipped with N&B or
breaker.
The manual is divided into five parts, 1. Upper structure, 2. Boom,
3. STD arm, 4. LONG arm, 5. Connector, each being assigned a kit
number. In the case of connector, select for ordering. But ( ) of
quantity are appropriate for the parts of standard machine.
COMPARISON TABLE FOR KIT AND ASSY NO. BY COUNTRY

Table 1
CLASSIFI-CAT
ION
NAME
Upper structure modification kit No.

Modification of the control valve
UPPER STRUCTURE
Modification of the hydraulic tank

Remote control piping (P/V)
Remote control block
HYDRAULIC Remote control piping (C/V)
(C/V) with Boom safety

(C/V) with B&A safety
BOOM
Upper hydraulic piping

ELEC
Modification of the instrument panel
LABEL
Install of the name plate
Boom modification kit No.

Modification of the 5.05M (16 7 ) boom
STD BOOM
5.05M (16 7 ) boom hydraulic piping
2.6M (8 6 ) Arm modification kit No.
Modification of the 2.6M (8 6 ) STD arm
ARM
STD ARM 2.6M (8 6 ) STD arm hydraulic piping

Reinforcing of the idler link
3.0M (9 10 ) Arm modification kit No.
Modification of the 3.0M (9 10 ) LONG arm
LONG
ARM
3.0M (9 10 ) LONG arm hydraulic piping

Reinforcing of the idler link
CONNECTOR
1 1
1.1 ADDITIONAL PARTS FOR THE MODIFICATION OF THE NIBBLER & BREAKER
(1) UPPER STRUCTURE
No.
NAME
QTY REMARK
,A Upper structure modification kit No. N&B

HYDRAULIC TANK ASSY
REPAIR KIT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
REMOTE CONTROL PIPING (P/V)

PILOT VALVE
PRESSURE SENSOR
CONNECTOR
PLUG
ELBOW
ELBOW
WASHER
HOSE
HOSE
HOSE
HOSE
PIN
PEDAL
RUBBER
LOCK ASSY
CAPSCREW
CAPSCREW
CAPSCREW
LOCK WASHER
WASHER
NUT
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
2
2
2
2
4
1
4
11
12
13
15
CONTROL BLOCK PIPING

ELBOW
CONNECTOR
ELBOW
ELBOW
TEE
1
1
1
1
1
MAIN CONTROL PIPING (C/V)

2 CONNECTOR
12 ELBOW
1
1
23-100
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
UPPER HYDRAULIC PIPING

TUBE
TUBE
HOSE
HOSE
CONNECTOR
CONNECTOR
SELECTOR VALVE
ELBOW
O RING
HALF CLAMP
ELBOW
BRACKET
SUPPORT
CLAMP
CAPSCREW
1
1
1
1
1
1
1
1
3
4
1
1
1
1
4
12
N&B
Applicable
Machines
(3) 2.6M (86) ARM

No.
NOTE) COMMON TO BREAKER

NAME
QTY REMARK
N&B
Applicable
Machines
(C) 2.6M (86) Arm modification kit No. N&B, BREAKER

1
2
3
4
5
6
7
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
2.6M(86) ARM ASSY

2.6M(8'6) ARM ASSY
TAPPED BLOCK
TAPPED BLOCK
TAPPED BLOCK
PLATE
PLATE
PLATE
(1) With bushing

2
2
2
1
1
1
2.6M(86) ARM HYDRAULIC PIPING

TUBE
TUBE
HOSE
STOP VALVE
CONNECTOR
O RING
O RING
BRACKET
HALF CLAMP
CLAMP
BUSHING
CAPSCREW
CAPSCREW
CAPSCREW
CAPSCREW
LOCK WASHER
LOCK WASHER
WASHER
WASHER
WASHER
WASHER
1
1
2
2
2
2
2
2
4
8
4
4
8
8
8
4
8
4
8
8
8
IDLER LINK REINFORCEMENT

1 PLATE
RH, LH
(4) CONNECTOR ASSY

No.
N&B
NAME
QTY REMARK
Kit No. is not given because it is provided after selection.

CONNECTOR ASSY
1 CONNECTOR
2 PLUG
3 O RING
1
1
1
14
Applicable
Machines
(3) 2.6M (86) ARM

No.

NAME
QTY REMARK
N&B
Applicable
Machines
(C) 2.6M (86) Arm modification kit No. N&B, BREAKER

1
2
3
4
5
6
7
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
2.6M(86) ARM ASSY

2.6M(8'6) ARM ASSY
TAPPED BLOCK
TAPPED BLOCK
TAPPED BLOCK
PLATE
PLATE
PLATE
(1) With bushing

2
2
2
1
1
1
2.6M(86) ARM HYDRAULIC PIPING

TUBE
TUBE
HOSE
STOP VALVE
CONNECTOR
O RING
O RING
BRACKET
HALF CLAMP
CLAMP
BUSHING
CAPSCREW
CAPSCREW
CAPSCREW
CAPSCREW
LOCK WASHER
LOCK WASHER
WASHER
WASHER
WASHER
WASHER
1
1
2
2
2
2
2
2
4
8
4
4
8
8
8
4
8
4
8
8
8

1 PLATE
RH, LH
(4) CONNECTOR ASSY

No.
N&B
NAME
QTY REMARK

CONNECTOR ASSY
1 CONNECTOR
2 PLUG
3 O RING
1
1
1
14
Applicable
Machines
(5) UPPER STRUCTURE

No.
N&B
NAME
QTY
F Upper structure modification kit No. N&B

MODIFICATION OF THE CONTROL VALVE
1 OPTION VALVE
2 CAPSCREW
HYDRAULIC TANK ASSY
18-4 RETURN FILTER
1
4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

PILOT VALVE
PRESSURE SENSOR
CONNECTOR
PLUG
ELBOW
ELBOW
WASHER
HOSE
HOSE
HOSE
HOSE
PIN
PEDAL
RUBBER
LOCK ASSY
CAPSCREW
CAPSCREW
CAPSCREW
LOCK WASHER
WASHER
NUT
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
2
2
2
2
4
1
4
11
12
13
15

ELBOW
CONNECTOR
ELBOW
ELBOW
TEE
1
1
1
1
1
REMOTE CONTROL PIPING (C/V)

2 CONNECTOR
12 ELBOW
1
1

TUBE
TUBE
HOSE
HOSE
CONNECTOR
CONNECTOR
SELECTOR VALVE
ELBOW
O RING
1
1
1
1
1
1
1
1
3
1
2
3
4
5
6
7
8
9
1 5
REMARK
Applicable
Machines
N&B
No.
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
NAME
QTY
HALF CLAMP
ELBOW
BRACKET
SUPPORT
CLAMP
CAPSCREW
CAPSCREW
CAPSCREW
WASHER
WASHER
NUT
O RING
O RING
CAPSCREW
CAPSCREW
LOCK WASHER
INSTAL OF THE NAME PLATE

20 LABEL
21 LABEL
22 LABEL
1
1
1
(6) BOOM

NAME
QTY
H Boom modification kit No. N&B , BREAKER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Applicable
Machines
4
1
1
1
1
4
5
2
4
9
2
2
2
4
8
12

39 SWITCH
No.
REMARK
5.05M(16 7 ) BOOM HYDRAULIC PIPING

TUBE
TUBE
TUBE
TUBE
PLUG
O RING
O RING
O RING
CLAMP
CLAMP
CLAMP
CAPSCREW
CAPSCREW
CAPSCREW
LOCK WASHER
LOCK WASHER
HALF CLAMP
HOSE
CLIP
CLAMP
1
1
1
1
2
1
1
4
5
1
2
4
13
16
17
16
8
2
1
1
REMARK
Applicable
Machines
N&B
1.2 ADDITIONAL PARTS FOR THE MODIFICATION OF THE BREAKER

(1) UPPER STRUCTURE
No.
NAME
QTY REMARK
(I) Upper structure modification kit No. BREAKER

HYDRAULIC TANK ASSY
REPAIR KIT
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

HOSE
HOSE
HOSE
NUT
PIN
WASHER
CAPSCREW
WASHER
BRACKET
PIN
PIN
CONNECTOR
ELBOW
ELBOW
PILOT VALVE
CUSHION RUBBER
CAPSCREW
LOCK ASSY
PEDAL
COVER
WASHER
PLATE
PRESSURE SENSOR
CONNECTOR
TEE
1
1
1
1
1
3
2
2
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
4
11
12
13
15

ELBOW
CONNECTOR
ELBOW
ELBOW
TEE
1
1
1
1
1
2
12
17
28
MAIN CONTROL PIPING (C/V)

CONNECTOR
ELBOW
TEE
HOSE
1
1
1
1
1
2
4
5
6
7
9
10
11
12
13

TUBE
TUBE
HOSE
PLUG
CONNECTOR
BLOCK
O RING
HALF CLAMP
ELBOW
BRACKET
SUPPORT
1
1
1
1
1
1
2
2
1
1
1
23-100
17
Applicable
Machines
No.
14
15
16
17
18
19
20
21
22
23
24
25
NAME
QTY REMARK
CLAMP
CAPSCREW
CAPSCREW
CAPSCREW
WASHER
WASHER
NUT
O RING
O RING
CAPSCREW
CAPSCREW
LOCK WASHER
1
4
5
2
4
9
2
1
2
4
4
8
INSTAL OF THE NAME PLATE

20 LABEL
21 LABEL
22 LABEL
2)
BOOM
No.
Applicable
Machines
1
1
1
NOTE) COMMON TO NIBBLER & BREAKER

NAME
QTY REMARK
BRAKER
Applicable
Machines
(B) Boom modification kit No. N&B , BREAKER

1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
5.05M(167) BOOM ASSY

5.05M(167) BOOM ASSY
TAPPED BLOCK
TAPPED BLOCK
TAPPED BLOCK
TAPPED BLOCK
TAPPED BLOCK
(1) With bushing

2
3
1
2
1
5.05M(167) BOOM HYDRAULIC PIPING

TUBE
TUBE
TUBE
TUBE
PLUG
O RING
O RING
O RING
CLAMP
CLAMP
CLAMP
CAPSCREW
CAPSCREW
CAPSCREW
LOCK WASHER
LOCK WASHER
HALF CLAMP
HOSE
CLIP
CLAMP
1
1
1
1
2
1
1
4
5
1
2
4
13
16
17
16
8
2
1
1
18
(3) 3.0M (910) LONG ARM

No.
BREAKER
NAME
QTY REMARK
Applicable
Machines
(J) 3.0M (910) Arm modification kit No. BREAKER

1
2
3
4
5
6
7
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
3.0M(910) LONG ARM ASSY

3.0M(910) LONG ARM ASSY
TAPPED BLOCK
TAPPED BLOCK
TAPPED BLOCK
PLATE
PLATE
PLATE
(1) With bushing

2
2
2
1
1
1
3.0M(910) LONG ARM HYDRAULIC PIPING

TUBE
TUBE
HOSE
STOP VALVE
CONNECTOR
O RING
O RING
BRACKET
HALF CLAMP
CLAMP
BUSHING
CAPSCREW
CAPSCREW
CAPSCREW
CAPSCREW
LOCK WASHER
LOCK WASHER
WASHER
WASHER
WASHER
WASHER
1
1
2
2
2
2
2
2
4
8
4
4
8
8
8
4
8
4
8
8
8

1 PLATE
RH, LH
(4) CONNECTOR ASSY

No.
BREAKER
NAME
QTY REMARK

CONNECTOR ASSY
1 CONNECTOR
2 PLUG
3 O RING
1
1
1
CONNECTOR ASSY
1 CONNECTOR
2 PLUG
3 O RING
1
1
1
19
Applicable
Machines
110
2. SUMMARY
2.1 GENERAL PRECAUTIONS
(1) Applications of Breaker or Nibbler & Breaker
Breaker piping ................... Applicable only when
a breaker is mounted.
Nibbler & breaker piping .. Applicable only when
a nibbler and a
breaker are mounted.
(2) Modifying a Breaker and a Nibbler &
Breaker
There are specific procedures to be followed
when modifying a breaker and a nibbler &
breaker. Therefore, when they are to be
modified at our service shop, contact the
nearest breaker and nibbler manufacturers
office, and obtain instructions, so that you
install the pipes and handle the machinery
correctly.
(2) Functions of the option valve :

The option valve is equipped with spool which
functions to send the pressure oil into nibbler
and breaker, and also to switch the flow
direction to the rod side or head side of the
nibbler cylinder.
(3) Action of the single / conflux flow switch :
The single/conflux flow select switch is
provided on the instrument panel and is
connected to the harness to actuate the
single/conflux flow select spool.
(4) Installing the operation pedal :
A pedal and a pilot valve are mounted to the
floor plate and a remote control piping is
placed between the option valves and pedal,
in order to operate the breaker or the nibbler.
(3) Differences between a Breaker Piping and a

Nibbler & Breaker Piping
z Breaker Piping
There is a single oil flow from pump
P2 to the breaker. The oil returns to
the hydraulic tank directly. The flow
is single flow.
(5) Installing the selector valve :

For the machines equipped with nibbler and
breaker, the selector valve which functions to
change the oil flow direction according to the
use of breaker or nibbler is provided on the
main C/V in the inside of guard on the right
side of slewing motor.
If the return oil from the breaker is fed back to the

control valve, the pulsation of the breaker is
transmitted to the oil cooler. This causes the
machine to break down.
(6) Reinforcement of the attachment :

Reinforcement plates are welded to the
standard arm (civil engineering services : for
general use) and to the idler links of the
nibbler & breaker attached machine.
z Nibbler Piping
The oil flows to the nibbler is conflux
flow ; the oil flow is changed to the
rod and the head of the nibbler
cylinder.
(7) Replace the return filter with new standard

filter.
2.2 BASIC METHOD TO BE TAKEN WHEN

MOUNTING
(1) For specifications for nibbler & breaker,
the modification of control valve is not
required.
21
2.3 OUTLINE OF MODIFICATION

(1) Nibbler & Breaker specification
ARM HYDRAULIC
PIPING
HYDRAULIC PIPING FOR BOOM
SELECTOR VALVE
RETURN HYDRAULIC PIPING
STOP
VALVE
RETURN FILTER
ARM
BRACKET
MAIN CONTROL
VALVE
ARM TOP
PIPING
HYDRAULIC
BREAKER
OPTION VALVE
(ADD-ON VALVE)
Replacing the
breaker with the
nibbler is possible.
OPERATING
PEDAL
FLOOR MAT
REMOTE CONTROL PIPING
SINGLE / CONFLUX
FLOW SELECT SWITCH
Fig. 1
Outside view of Nibbler & Breaker-attached machine
(2) Breaker specification

ARM HYDRAULIC
PIPING

RETURN FILTER
STOP
VALVE
MAIN CONTROL
VALVE
ARM
BRACKET
ARM TOP
PIPING
HYDRAULIC
BREAKER
OPTION VALVE
(ADD-ON VALVE)
OPERATING
PEDAL
FLOOR MAT
Fig. 2
Outside view of Breaker-attached machine

22
HYDRAULIC CIRCUIT DIAGRAM
3.1 HYDRAULIC CIRCUIT DIAGRAM OF NIBBLER

& BREAKER (2 WAY P/V)
z Conflux / single select switch
Spec.
Conflux / single
select switch
CONFLUX
ON
SINGLE
OFF
Use of
SINGLE
breaker
OFF
Use of
nibbler
NOTE :
1. Marking of selector valve (51.)
Stamped N : NIBBLER, Stamped B : BREAKER
2. Selection condition and proportional valve command when any of nibbler single & conflux flow or
breaker is in service.
z 2 way P/V pedal

Step on pedal
direction
Mechatro function
Refer to selection
conditions and
proportionality valve
instructions at the time
of Nibbler conflux and
SINGLE
breaker use of notes
FLOW SIDE
2.
NIbbler
Breaker
Trip condition
Toe step (Front step) Nibbler (catch)

Heel step (Rear step) Nibbler (release)
Pedal neutrality
Breaker stopping
Heel step (Rear step) Breaker impacting
NIBBLER & BREAKER SPEC.
HYDRALUIC
PUMP
No.
NAME
50
CONTROL VALVE ASSY
51
SELECTOR VALVE
52
STOP VALVE
53
PILOT VALVE
54
RETURN FILTER
HYDRALUIC
OIL TANK
53
52
51
NIBBLER
BREAKER
P1 BYPASS CUT
P2 BYPASS CUT
50
NOTE :
1. This hydraulic circuit is used in combination with the standard circuit diagram.
2. Return filter of number 54 shows before modification.
After modification, the filter that is available for N&B is equipped as standard
Fig.1
COMMAND SIGNAL OF SOLENOID PROPORTIONAL VALVE

(W : , W/O : )
SINGLE/CONFLUX SELECTOR VALVE
TRAVEL
P1 PUMP
P2 PUMP
P1 CUT
P2 CUT
SELECT SWITCH (No.51)
STRAIGHT
NIBBLER
CONFLUX FLOW
N
CONFLUX FLOW (ON)

NIBBLER SINGLE CONFLUX FLOW
N
FLOW
(OFF)
CONFLUX FLOW
BREAKER
B
(OFF)
CONDITIONS FOR SELECTION
Select Conflux or single flow according to the nibbler type.
54
TRAVEL
STRAIGHT
VALVE
3.
(1) Nibbler conflux circuit operation

1) Mechatro of switch operation and pedal operation
If the conflux/single select switch is turned to the Conflux of the nibbler and the nibbler &
breaker pedal is stepped on, secondary pilot pressure enters the low-pressure sensor (SE-11).
The output voltage of the low-pressure sensor is put into the mechatronic controller. The
mechatronic controller processes the pilot signal and puts out command signals to the solenoid
proportional valves for the travel straight valve, the P2 bypass cut valve and the P1 bypass cut
valve, according to the input voltage levels. And the solenoid proportional valve secondary
pressure switches the travel straight valve of C/V, P1 bypass cut valve and P2 by-pass cut valve.
2) Pilot circuit
Depress N&B pilot valve (53), the pilot secondary pressure flows into PA02 port of C/V through B
port and switches the N&B spool.
3) Main circuit
P1,P2 pump delivery oil is confluxed in the C/V, is discharged through A02 port and is fed into
nibbler head side, and consequently the nibbler starts the closing action.
The return oil from the nibbler rod side flows into the hydraulic tank through B02 port of C/V.
NOTE : Single flow is selected when it is operated with the travel action.
(2) Nibbler single circuit operation
1) Mechatro of switch operation and pedal operation
If the conflux/single select switch is turned to the Single of the nibbler and the nibbler &
breaker pedal is stepped on, secondary pilot pressure enters the low-pressure sensor (SE-11).
The output voltage of the low-pressure sensor is put into the mechatronic controller. The
mechatronic controller processes the pilot signal and puts out command signals to the solenoid
proportional valves for the P2 bypass cut valve according to the input voltage levels. And the
solenoid proportional valve secondary pressure switches the P2 by-pass cut valve.
2) Pilot circuit
Depress N&B pilot valve (53), the pilot secondary pressure flows into PA02 port of C/V through B
port and switches the N&B spool.
3) Main circuit
P2 pump delivery oil is confluxed in the C/V, is discharged through A02 port and is fed into
nibbler head side, and consequently the nibbler starts the closing action.
The return oil from the nibbler rod side flows into the hydraulic tank through B02 port of C/V.
Hydraulic circuit for Nibbler & Breaker (At nibbler operating)

31
Impacting with the breaker is attained with
N & B SPECIFICATION
No.
NAME
the 2-way pedal. If the heel of the 2-way pedal
50
51
52
53
54
CONTROL VALVE ASSY

SELECTOR VALVE
STOP VALVE
PILOT VALVE
RETURN FILTER
is stepped on, the secondary pilot pressure

enters the low-pressure sensor (SE-11). A
voltage output from the low-pressure sensor
enters
the
mechatronic
controller.
The
controller processes the signal and puts out a

command to the solenoid proportionate valve
for the P2 bypass cut valve according to the
HYDRAULIC PUMP
54
53
HYDRAULIC TANK
TRAVEL
STRAIGHT
VALVE
52
51
BREAKER
P1
BYPASS CUT
P2
BYPASS CUT
50
NOTE :
After modification, the filter that is available for N&B is equipped as standard.
Fig. 2
32
Hydraulic circuit for Nibbler & Breaker (Breaker operation)
input voltage.
Then the secondary pressure of the solenoid
proportionate valve changes the P2 bypass
cut valve of the control valve.
2) Pilot circuit
If the heel of the 2-way pilot valve (53) is
stepped on, pressure comes out of the A-port,
enters the PB02 port of the control valve, and
changes the spool of the option valve.
3) Main circuit
The oil discharged by the P2 pump comes out
of the B02 port of the control valve and is
supplied to the breaker to give impact to the
breaker. The oil returned from the breaker
returned directly to the hydraulic tank via
the control valve because the selector valve
(51) is changed.
(3) Breaker operation

1) Mechatro control with switches and pedals
BREAKER SPECIFICATION
No.
NAME
50
51
52
53
CONTROL VALVE ASSY

STOP VALVE
PILOT VALVE
RETURN FILTER
HYDRAULIC PUMP
53
52
HYDRAULIC TANK
51
3.2 Hydraulic circuit for breaker (1way P/V)
(1) Breaker impacting operation

1) Mechatro control with pedals
Impacting with the breaker is attained with
the 1-way pedal. If the 1-way pedal is steeped
on, secondary pilot pressure enters the low
pressure sensor (SE-12) from which a voltage
output is put into the mechatro controller.
The controller processes the signal, puts out a
command to the P2 bypass cut solenoid
proportionate valve according to the input
voltage, and changes the p2 bypass cut valve.
2) Pilot circuit
If the toe of the 1-way pilot valve (52) is
stepped on, secondary pilot pressure enters
the PA02 port of the control valve and enters
the breaker spool.
3) Main circuit
The P2 pump delivery oil flows out through
A02 port of C/V and reaches to the breaker.
The return oil from the breaker flows into the
tank directly.
In the breaker independent operation, the
delivery rate of the P2 pump rises only to a
value set in the breaker mode.
BREAKER
P2
BYPASS C/UT
50
NOTE :
After modification, the filter that is available for N&B is equipped as standard.
Fig. 3
Hydraulic circuit for breaker

33
3.3 HYDRAULIC COMPONENTS

(1) Control valve assy
Option valve (Breaker, Nibbler & Breaker)
STD
With OPT. P2
BREAKER
N&B
TRAVEL
PTb
TRAVEL
STRAIGHT
STRAIGHT
TRAVEL
RIGHT
PBr
PAr
BUCKET
PBc
PAc
PA1
PAb
P1 CUT
ARM
CONFLUX
PCb
TRAVEL LEFT
PAL
TRAVEL
LEFT
PBL
Dra,Drb
TRAVEL
RIGHT
BUCKET
BOOM
PBb
P1 (P2)
BOOM
P1 CUT
(P4)
SWING
SWING
BOOM
CONFLUX
ARM
Pss
BOOM
CONFLUX
PB1
PLc2
ARM
PAa
ARM
Pis
RECIRCULATION
OPTION P2
PBs1
PAs
Drd
ARM
RECIRCU-L
ATION
PCa
PA02
PB02
(P3)
Fig.5
34
Control valve (Breaker, Nibbler & Breaker)
(2) Pilot valve
OPERATING FORCE
SECONDARY PRESSURE
SECONDARY
PRESSURE OPERATING TORQUE
STROKE
CIRCUIT DIAGRAM
CONTROL DIAGRAM
Fig. 8
Pilot valve (Breaker)
(3) Pilot valve
CIRCUIT DIAGRAM
4-PF1/4
JISB2351 O
2-11THROUGH
Fig. 9
Pilot valve (Nzibbler & Breaker)

35
OPERATING FORCE
SECONDARY PRESSURE
SECONDARY
PRESSURE OPERATING TORQUE
OPERATING ANGLE
CONTROL DIAGRAM
4. ELECTRIC SYSTEM DIAGRAM FOR NIBBLER & BREAKER
Fig. 1 Single / Conflux flow select switch
4-1
MODIFICATION PROCEDURE FOR NIBBLER & BREAKER
5.1 MODIFICATION ITEM

The main items that are needed to modify the
standard machine into a nibbler & breaker
mounted machine are as follows :
Table 1-1
FRAME
ITEM
5.2
NAME
Modification of the floor mat
HYDRAULIC
5.2a Modification of the control valve
5.2a MODIFICATION OF THE CONTROL VALVE

(BREAKER, NIBBLER & BREAKER)
5.2a.1 MODIFICATION PROCEDURE
Install the additional parts listed in Table 1-2
to the control valve of the standard machine,
as shown in Fig. 1-2. On that occasion, some
parts become unnecessary.
Table 1-2
MODIFICATION OF
THE CONTROL VALVE
No.
Floor mat
Option valve, capscrew
Replacement of return filter of the

5.2b hydraulic tank
Replace return filter
5.3
Remote control piping ; P/V
Add on 2 way valve
5.4

Remote control piping ; C/V
Block, Elbow,
Connector
Connector
Remote control piping ; B&A safety
Connector
5.6
Hose, Connector
5.7
Modification of the instrument panel Add on the switch
5.8
5.5
LABEL ELEC
Modification items to
be added and change
NAME
QTY REMARK
CONTROL VALVE
(1) machine
1
OPTION VALVE
CAPSCREW
Standard
M1290
Fig. 1-2
Label
Cautions to be exercised in modification

1) Before starting the modification work, check
parts according to the additional parts list.
2) When disconnecting and reconnecting pipes,
take care, so as not to allow dirt and foreign
matter to enter.
3) When the O ring type joint is removed,
always replace it with a new one.
4) At assembly, use care of O rings do not come
off.
5) Regarding the tightening torque of O ring
type joints, hydraulic hoses, refer to the
tightening torque table.
6) Apply Loctite #242 to the clamp mounting
bolts.
(2) Weld
1) Use weld symbol B welding rod (mild steel
50kg grade).
2) Seal the unwelded areas of the tapped block.
5.
5.2 FLOOR MAT (NIBBLER & BREAKER)

Make slits to face of the standard floor mat
according to Fig. 1-1 and cut out the hatching.
Modification of control valve
5.2a.2 PARTS TO BE DISUSED

When the option valve is installed, the parts
shown in Table 1-3 and Fig. 1-3 are disused
from the standard machine.
Table 1-3
No.
NAME
271 CAPSCREW
QTY REMARK
4
M1225
CUT OUT
271
Fig. 1-3
Fig. 1-1
Parts to be disused
Modification of floor mat

51
5.2b REPLACEMENT OF RETURN FILTER OF

THE HYDRAULIC TANK
When the standard machine is modified to nibbler
& Breaker machine, replace the return filter with
new one.
VALVE
z Be sure to release the internal pressure

remaining in the hydraulic tank and hydraulic
oil circuit before inspection, maintenance and
repair.
Supplementary Explanation :
The internal pressure in the hydraulic tank can be
released by pushing the valve with the rubber cap
on the upper surface of the tank 5 or 6 times.
Fig.1-4
Drain pressure for hydraulic tank
CAPSCREW
WASHER
5.2b.1 REPLACING PROCEDURE

Remove the capscrew, on the hydraulic tank and
take out the spring, check valve and filter
element.
Replace them with return filters shown below
according to the procedure shown in table 1-4 and
Fig.1-5. Replace it by the reverse procedure of
disassembly.
COVER
8
SPRING
CHECK VALVE
Table 1-4
HYDRAULIC TANK ASSY
No.
23-100
NAME
QTY
REMARK
REPAIR KIT
O RING
PACKING
FILTER ELEMENT
O RING
PLATE
Fig.1-5
52
REMOTE CONTROL
PIPING
No.
1
2
3
4
5
6
7
8
9
10
11
(2) Parts to be disused

Concerning the remote control piping, the
parts listed in table 3 and Fig. 3 are disused
Table 3
No.
NAME
A2
A4
A8
SUPPORT
COVER
SEMS BOLT
CONTROL
BLOCK
QTY REMARK
1
1
2
11
QTY
PILOT VALVE
1
1
1
1
3
1
3
1
1
1
1
PRESSURE SENSOR
CONNECTOR
PLUG
ELBOW
ELBOW
WASHER
HOSE
HOSE
HOSE
HOSE
REMARK
PF1/4
PF1/4 L=23
PF1/4
PF1/4
PF1/4
PF1/4
L=300
PF1/4
L=350
PF1/4
L=4100
PF1/4
L=2650
No.
12
13
14
15
16
17
18
19
20
21
NAME
PIN
PEDAL
RUBBER
LOCK ASSY
CAPSCREW
CAPSCREW
CAPSCREW
LOCK WASHER
WASHER
NUT
QTY
REMARK
1
1
1
1
2
2
2
2
4
1
18
12
21
19
20
14
8
7
16
7
12
Establishied article
Re-use
5.4 CONTROL BLOCK PIPING

(NIBBLER & BREAKER)
(1) Modification procedure
Assemble the additional parts listed in Table
4 to the control block piping of the standard
machine, as shown in Fig. 4.
Table 4
15
17
20
15
2
13
4
11
12
13
15
NAME
ELBOW
CONNECTOR
ELBOW
ELBOW
TEE
1
1
1
1
1
CONTROL
BLOCK
13
6
11
9
5
QTY
4
3
No.
CONTROL
VALVE
10
Table 2
NAME
5.3 REMOTE CONTROL PIPING

(NIBBLER & BREAKER)
2 to the remote control piping of the standard
machine, as shown in Fig. 2.
10
REMARK
PF1/4
PF3/8
PF1/4
10
A4
Fig. 4 Control block piping (Nibbler & Breaker)
PF3/8 PF1/4
C8
PF3/8
C2
C5
A2
Fig. 2 Remote control piping (Nibbler &

Breaker)
A8

Concerning the control block piping, the parts
listed in table 5 and Fig. 5 are disused from
the standard machine.
Table 5
No.
C2
C5
C8
NAME
CONNECTOR
ELBOW
PLUG
QTY REMARK
1
1
1
PF1/4
PF3/8
PF1/4
Fig. 5
Parts to be disused
Fig. 3
Parts to be disused
53
5.5 MAIN REMOTE CONTROL PIPING

(NIBBLER & BREAKER)
(1) Modification Procedure
Assemble the additional parts listed in Table 6
to the main remote control piping of the
standard machine, as shown in Fig. 6.
12
MACHINE
FRONT
Table 6
MAIN REMOTE
CONTROL PPING
No.
2
12
NAME
QTY REMARKS
CONNECTOR
PF1/4-PF3/8
ELBOW
PF1/4-PF3/8
CONTROL
VALVE
OPTION VALVE
2
Fig.6
Remote control piping (Nibbler & Breaker)

parts listed in Table 7 and Fig. 7 are disused
Table 7
No.
NAME
2 PLUG
54
QTY REMARKS
2
2
Fig. 7
Parts to be disused
CHANGING OVER PROCEDURE OF THE SELECTOR VALVE
TO TANK
Thread size
Spanner
(mm)
Hydraulic hose
(ORS Type)
Tightening torque
kgfym (lbfyft)
13/16-12UN
36
18 (130)
O ring type coupling
TO TANK
TO
ATTACHMENT
TO
ATTACHMENT
TO CONTROL
VALVE
TO CONTROL
VALVE
Thread size
(PF)
Spanner
(mm)
Tightening torque
kgfym (lbfyft)
3/4
1
36
41
16.5 (119.3)
STAMP
USE NIBBLER
USE BREAKER
NAME
TUBE
TUBE
HOSE
HOSE
CONNECTOR
CONNECTOR
Hydraulic hose
(30flare)
Tightening torque
kgfym (lbfyft)
14 (101)
Thread size
Capscrew
Tightening torque
kgfym (lbfyft)
M10
M12
7.2 (52.1)
12.3 (89.0)
3
2
Table 8-1
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
5.6 UPPER HYDRAULIC PIPING (NIBBLER & BREAKER)

(1-1) Modification Procedure
Tightening torque
Fit the additional parts in table 8-1, according
to Fig. 8-1.
QTY REMARK
1
1
1
1
1
1
1
1
3
4
1
1
1
SELECTOR VALVE
ELBOW
O RING
HALF CLAMP
ELBOW
BRACKET
SUPPORT
13/16-12UN
PF1
PF3/4
13/16-12UN
13/16-12UN
1
1
PF1
No.
NAME
14 CLAMP
15 CAPSCREW
16 CAPSCREW
17 CAPSCREW
18 WASHER
19 WASHER
20 NUT
21 O RING
22 O RING
23 CAPSCREW
24 CAPSCREW
25 LOCK WASHER
QTY
1
4
5
2
4
9
2
2
2
4
8
12
REMARK
M1030
M1230
M1285
50 PLUG
24
1 PLUG
20
23
7 9
13
1
11
25
10
12
NAME
14
1
Parts to be disused
(3) Parts to be disused ; only

parts listed in table 10 and in Fig. 10 are
disused from the standard machine.
Table 10
No.
25
10
Fig. 9
19
QTY REMARK
17
21
50
NAME
21
M1270

Concerning upper hydraulic piping, the parts
listed in table 9 and in Fig. 9 are disused
Table 9
No.
22
22
QTY REMARK
2
Fig. 10
1
Parts to be disused
16
19
18
15 25
24
Fig. 8-1 Upper hydraulic piping (Nibbler & Breaker)

55
5.8 INSTALL OF THE NAME PLATE

(NIBBLER & BREAKER)
Fit the label shown in table 13 to the cab of the
standard machine, according to Fig. 13 & 14.
Table
No.

NAME
QTY
39 SWITCH
22
13
INSTALL OF THE NAME PLATE
Table 11
No.
5.7 MODIFICATION OF THE INSTRUMENT PANEL

(NIBBLER & BREAKER)
Install the additional parts listed in Table 11
to the instrument panel assy of the standard
machine, as shown in Fig. 11. On that
occasion, some parts become unnecessary.
REMARK
For single / conflux
switching
NAME
QTY
20 LABEL
21 LABEL
22 LABEL
REMARK
20
Fig. 13
21
Right hand view of cab interior
21
Fig. 11
20
39
Modification of instrument panel
Fig. 14

Concerning instrument panel, the parts listed
in table 12 and in Fig. 12 are disused from
the standard machine.
Table 12
No.
13 CAP
NAME
QTY REMARK
22
Fig. 12
13
Parts to be disused
Attachment operation by foot pedal.

Always check the foot pedal control pattern
before operation.
Always read operators manual before
operating machine.
PY20T01062P1
56
The cover left & rear side view

of operator seat
6. MODIFICATION PROCEDURE FOR BREAKER

6.1 MODIFICATION ITEM
The main items that are needed to modify the
standard machine into a breaker-mounted
machine are as follows :
Table 1
LABEL
HYDRAULIC
FRAME
ITEM
6.2
NAME
Modification of the floor mat
Modification items to
be added and change
Floor mat
6.2a Modification of the control valve
Same as N&B (5.2a)
6.2b Modification of the hydraulic tank
Same as N&B (5.2b)
6.3
Remote control piping ; P/V
Add on 1 way valve
6.4
Same as N&B (5.4)
6.5
Remote control piping ; C/V
6.6
6.7
B&A safety
Label

matter to enter.
off.
bolts.
(2) Weld
50kg grade).
6.2 FLOOR MAT (NIBBLER)

Make slits to face of the standard floor mat
according to Fig. 1 and cut out the hatching.
CUT OUT
Fig. 1
61
Modification of floor mat
6.2a MODIFICATION OF THE CONTROL VALVE

(SAME AS N&B, SEE ITEM 5.2a)
6.2b MODIFICATION OF THE HYDRALUIC TANK

(SAME AS N&B, SEE ITEM 5.2b)
62
Tightening torque
Thread
size
Spanner
(mm)
Capscrew
Tightening torque
kgfym (lbfyft)
M8
13
3.6 (26)
1/4
No.
20
Tightening torque
kgfym (lbfyft)
Hydraulic hose
(30flare)
Tightening torque
kgfym (lbfyft)
3.7 (26.8)
3.0 (21.7)
19
HOSE
HOSE
HOSE
NUT
PIN
WASHER
CAPSCREW
WASHER
BRACKET
PIN
PIN
CONNECTOR
ELBOW
QTY REMARK
1
1
1
1
1
3
2
2
1
1
1
1
1
PF1/4
PF1/4
PF1/4
PF1/4
With filter
No.
14
15
16
17
18
19
20
21
22
23
24
25
17
22
18
NAME
CUSHION RUBBER
CAPSCREW
LOCK ASSY
PEDAL
COVER
WASHER
PLATE
PRESSURE SENSOR
CONNECTOR
TEE
QTY REMARK
1
1
1
2
1
1
1
1
2
1
1
1
14
PF1/4
16
10
ELBOW
PILOT VALVE
11
21
Table 2
NAME
1
2
3
4
5
6
7
8
9
10
11
12
13
19

Thread size Spanner
(PF)
(mm)
REMOTE CONTROL
PIPING
6.3 REMOTE CONTROL PIPING (BREAKER)

2 to the remote control piping of the standard
machine, as shown in Fig. 2,3. On that
occasion, some of the existing parts must be
used and some of them become unnecessary.
15
CONTROL
BLOCK
12
13
R.H
3
2
2
PF1/4
25
23
24
PF1/4
PF1/4
PF1/4
Fig. 3
Remote control piping (Breaker)

parts listed in table 3 and in Fig.4 are
4
2
Table 3
CONTROL
BLOCK
No.
NAME
QTY REMARK
SUPPORT
COVER
SEMS BOLT
1
2
Fig. 4
Fig. 2
Remote control piping (Breaker)
Parts to be disused
63
6.5 MAIN REMOTE CONTROL PIPING ;

C/V (BREAKER)
Install the additional parts listed in Table 4
to the remote control piping as shown in Fig.
5.
17
12
Table 6
28
No.
NAME
2 PLUG
MACHINE FRONT
QTY REMARK
TableCONTROL
4
MAIN REMOTE
PIPING
No.
2
12
17
28
NAME
QTY REMARK
CONNECTOR
ELBOW
TEE
HOSE
1
1
1
1
1
1
1
1
PF1/4-PF3/8
PF1/4-PF3/8
PF1/4
PF1/4
CONTROL VALVE
2
Fig. 5
OPTION VALVE
Main remote control piping (Breaker)
2
Fig. 7

disused.
No.
NAME
11 ELBOW
C11
Table
5
QTY REMARK
1
PF1/4
CONTROL VALVE
64
Fig. 6
Parts to be disused
Parts to be disused

6.4 REMOTE CONTROL BLOCK

(SAME AS N&B, SEE ITEM 5.4)
Tightening torque
Thread size
Spanner
(mm)
Hydraulic hose
(ORS Type)
Tightening torque
kgfym (lbfyft)
13/16-12UN
36
18 (130)
Thread size Spanner

(PF)
(mm)
3/4
1

No.
1
2
4
5
6
7
9
10
11
12
13
14
NAME
QTY REMARK
TUBE
1
TUBE
1
HOSE
1 PF1
PLUG
1 PF3/4
CONNECTOR 1 13/16-12UN
BLOCK
1
O RING
2 1
HALF CLAMP 2 1
ELBOW
1 PF1
BRACKET
1
SUPPORT
1
CLAMP
1
Tightening torque
kgfym (lbfyft)
36
41
4
CONTROL VALVE
Hydraulic hose
(30flare)
Tightening torque
kgfym (lbfyft)
16.5 (119.3)
14 (101)
Thread size
Capscrew
Tightening torque
kgfym (lbfyft)
M10
M12
7.2 (52.1)
12.3 (89.0)
2
1
Table 7
No.
15
16
17
18
19
20
21
22
23
24
25
NAME
QTY REMARK
CAPSCREW
4 M1030
CAPSCREW
5 M1230
CAPSCREW
2 M1285
WASHER
4
WASHER
9
NUT
2
O RING
1
O RING
2
CAPSCREW
4 M1270
CAPSCREW
4
LOCK WASHER 8
22
22
CONTROL
VALVE
2
17
19
16
19
13
19

Concerning upper hydraulic piping, the parts
listed in table 8 and in Fig. 9 are disused.
Table 8
4
25
10
9
50
NAME
PLUG
QTY REMARK
Fig. 9
24
PLUG
23
11
25
12
1
19
18
16
15
NAME
20
Parts to be disused

Table 9
No.
14
1
21
50
No.
6.6 UPPER HYDRAULIC PIPING (BREAKER)

Fit the additional parts in table 7, according
to Fig. 8.
QTY REMARK
Fig. 10
1
Parts to be disused
Fig. 8 Upper hydraulic piping (Breaker)

65
Table
6.7 INSTALL OF THE NAME PLATE

(BREAKER)
Fit the label shown in table 10 to the cab of the
standard machine, according to Fig. 11 & 12.
22
10
INSTALL OF THE NAME PLATE

No.
NAME
QTY
20 LABEL
21 LABEL
22 LABEL
REMARK
20
Fig. 11
21
Right hand view of cab interior
21
20
Fig. 12
The cover left & rear side view

of operator seat
22
Attachment operation by foot pedal.

Always check the foot pedal control pattern
before operation.
Always read operators manual before
operating machine.
66
7.
MODIFICATION PROCEDURE FOR ATTACHMENT
7.1 MODIFICATION ITEM FOR NIBBLER & BREAKER, BREAKER ATTACHMENT

The main item that are needed to modify the standard boom and standard arm into a breaker and a
nibbler & breaker-mounted machine are as follows:
Table 1
BOOM
ITEM
Types of attachment
Modification
item
Spec.
7.2 Modification of the 5.05M (167) boom
N&B
Tapped block
7.3 5.05M (167) boom hydraulic piping
N&B
Tube
7.4 Modification of the 2.6M (86) STD arm N&B

7.5 Modification of the 3.0M (910) long arm
2.6M (86 ) STD arm hydraulic piping
N&B
3.0M (910) long arm hydraulic piping
N&B
N&B
N&B
ARM
7.6
Tapped block
7.7 Connector assy
7.8 Reinforcing of the idler link

matter to enter.
off.
bolts.
Tapped block
Tube
Tube
Connector
Plate
(2) Weld
50kg grade).
71
7.2 MODIFICATION OF THE 5.05M (16ft-7in) BOOM

(NIBBLER & BREAKER, BREAKER)
Weld the additional parts listed in Table 2 to
the boom of the standard specification,
according to Fig. 1.
Table 2
5.05M (167 )
BOOM ASSY
No.
1
2
3
4
5
6
NAME
BOOM ASSY
TAPPED BLOCK
TAPPED BLOCK
TAPPED BLOCK
TAPPED BLOCK
TAPPED BLOCK
QTY
(1)
2
3
1
2
1
SECTION
AA
VIEW
6
SECTION
DD
3
SECTION
BB
Fig. 1
SECTION
SECTION
CC
EE
Modification of the 5.05M (16ft-7in) boom (Nibbler & Breaker, Breaker)

72
REMARK
STD
7.3 HYDRAULIC PIPING FOR 5.05M (16ft-7in) BOOM

Install the additional parts listed in table 3 to the
5.05m (16ft-7in) boom modified according to Fig. 2.
9,13,15
No.
1
2
3
4
5
6
7
8
9
10
NAME
TUBE
TUBE
TUBE
TUBE
PLUG
O RING
O RING
O RING
CLAMP
CLAMP
QTY
REMARKS
1
1
1
1
2
1
1
4
5
1
z Tightening torque for M-threads

Thread size
Tightening torque
M12
M12 (Hexagon socket head) 8.5kgfym (61.5 lbfyft)
z Tightening torque for PF, PT-threads
Thread size
Tightening torque
PF,PT1
z Tightening torque for ORS-joint nut
Thread size
Tightening torque
13/16-12UN
17/16-12UN
9,13,15
11,12,15
Table 3
No.
NAME
QTY
11
12
13
14
15
16
17
18
19
20
CLAMP
CAPSCREW
CAPSCREW
CAPSCREW
LOCK WASHER
LOCK WASHER
HALF CLAMP
HOSE
CLIP
CLAMP
2
4
13
16
17
16
8
2
1
1
REMARKS
13,15,20
SECTION
AA
9,13,15
9,13,15
SECTION
SECTION
DD
BB
8,14,16,17
1
4
8,14,16,17
8,14,16,17
2
5
18
NOTE :
z Remove item 5 plug as necessary,
and
install
an
accumulator
recommended by the breaker maker.
5
11,12,15
19
9,13,15
9,13,15
SECTION
SECTION
EE
CC
Fig.2
Hydraulic piping for 5.05M (16ft-7in) boom (Breaker, Nibbler & Breaker)
73
7.5 MODIFICATION OF THE 3.0M (9ft-10in)

LONG ARM (BREAKER)
Finish by grinder
MODIFICATION OF THE 3.0M (9ft-10in) ARM
MODIFICATION OF THE 2.6M (8ft-6in) ARM

Weld the additional parts listed in Table 4 to the arm of
the long specification, acording to Fig. 3.
Table 4
Weld the additional parts listed in Table 5 to the arm of

the long specification, acording to Fig. 4.
Table 5
DETAIL E
3.0M (9_10_) ARM ASSY
2.6M (8_6_) ARM ASSY
No.
No.
(1)
NAME
(1)
NAME
(1)
QTY REMARK
ARM
STD
QTY REMARK
ARM
(1) STD
TAPPED BLOCK
TAPPED BLOCK
TAPPED BLOCK
TAPPED BLOCK
TAPPED BLOCK
TAPPED BLOCK
PLATE
PLATE
PLATE
PLATE
PLATE
7.4 MODIFICATION OF THE 2.6M (8ft-6in)

STANDARD ARM
(NIBBLER & BREAKER, BREAKER)
PLATE
SECTION_D_D
5
DETAIL E
4
(1)
7
(1)
SECTION_A_A
5
2
2
3
SECTION_B_B
SECTION_C_C
Fig. 3_Modification of the 2.6M (8ft-6in) standard arm (Nibbler & Breaker, Breaker)
SECTION_A_A
SECTION_B_B
Fig. 4_Modification of the 3.0M (9ft-10in) Long arm (Breaker)

7-4
Finish by grinder
SECTION_D_D
SECTION_C_C
2.6M (8ft-6in)
1
2
3
4
5
6
7
8
9
10
NAME
TUBE
TUBE
HOSE
HOSE
STOP VALVE
CONNECTOR
O RING
O RING
BRACKET
HALF CLAMP
CLAMP
11
13,19
DETAIL OF CLAMP
6
7,9,15,17
7, 9,15,17
Table 6
ARM HYDRAULIC PIPING

3.0M (9ft-10in)
ARM HYDRAULIC PIPING
No.
10
QTY
1
1
2
2
2
2
2
2
4
8
1
1
2
2
2
2
2
2
4
8
REMARKS
No.
NAME
11
12
13
14
15
16
17
18
19
20
BUSHING
CAPSCREW
CAPSCREW
CAPSCREW
CAPSCREW
LOCK WASHER
LOCK WASHER
WASHER
WASHER
WASHER
QTY REMARKS
4
4
8
8
8
4
8
4
8
8
4
4
8
8
8
4
8
4
8
8
4
10,11
13,19
13,19
10,11
14,20
12,16,18
4
8
14,20
12,16,1
SECTION
8
SECTION
BB
AA
Fig. 5 2.6M (8ft-6in) STD arm, 3.0M (9ft-10in) long arm hydraulic piping
75
7.6 ARM HYDRAULIC PIPING

(1) 2.6M (8ft-6in) Standard arm hydraulic piping
(Nibbler & Breaker, Breaker)
(2) 3.0M (9ft-10in) Long arm hydraulic piping
(breaker)
This hydraulic piping applies to both the nibbler
& breaker machine and the breaker machine.
Install the additional parts listed in Table 6 to the
arm body as shown in Fig. 5.
M451.5
3
PF1-1/4
7.7 CONNECTOR ASSY

(1) For nibbler & breaker
When using the machine with a nibbler &
breaker, attach the below parts to the tip of
the stop valve.
Table 7
CONNECTOR
ASSY
No.
NAME
QTY REMARK
1
CONNECTOR
1
2
PLUG
1
3
O RING
1 1B P38
7.8 RCING THE IDLER LINK

When using the machine as a nibbler & breaker,
breaker machine, the right and left idler links
need reinforcement. Reinforce them according to
Table 10 and Fig. 9.
Table 10
IDLER LINK (R.H)
IDLER LINK (L.H)
No.
Fig. 6
Connector assy (Nibbler & Breaker)

1-5/16-UNF
(2) For breaker

Select application from the breaker maker.
NAME
QTY
REMARK
IDLER LINK
(1)
(LH) STD
IDLER LINK
(1)
(RH) STD
PLATE
IDLER LINK (L.H)
LH, RH
Table 8
CONNECTOR ASSY
FOR NPK
No.
1
2
3
NAME
CONNECTOR
PLUG
O RING
QTY REMARK
1
1
1
NPK
1B
PF1-1 1/4
P38
1
IDLER LINK (R.H)
Fig. 9
Fig. 7
Connector assy (NPK)
PF1 1
PF1-1/4
Table 9
CONNECTOR ASSY
FOR TOKU, KRUPP
No.
1
2
3
76
NAME
CONNECTOR
PLUG
O RING
QTY REMARK
1
1
1
1B
P38
TOKU,
Fig. 8
KRUPP
Connector assy (TOKU, KRUPP)
Reinforcing the idler link
8. REMINDERS ON THE USE OF NIBBLER & BREAKERS

8.1 CHANGING OVER THE SELECTOR VALVE
A nibbler & breaker-attached machine is
equipped with a selector valve in both the
operation circuit and the main circuit. When
running the machine after completion of
modification, always set the selector
valves
according to a nibbler or a breaker used.
N&B
LOW PRESSUSE SIDE
(RETURN)
N&B
HIGH PRESSUSE
SIDE
NOTE : Incorrect setting of the selector valves not

only deteriorates operating efficiency and
decreases speed but also causes failure of
the machine. Therefore, confirm completion
of the modification and give proper advice
to the user.
z Tools used
For main circuit changeover
: 5mm
: 24mm
CHANGING OVER PROCEDURE OF THE SELECTOR VALVE
Changing over procedure of the selector valve

1) Remove socket bolt with allen wrench.
2) Turn the nibbler or the breaker to its
operating position, using a spanner.
3) Stop it at a specified position and tighten the
setscrew.
TO TANK
Fig. 1
TO
ATTACHMENT
TO
ATTACHMENT
TO CONTROL
VALVE
TO CONTROL
VALVE
STAMP
ALLEN WRENCH (HEX 5mm)
SPANNER (HEX 24mm)
TO TANK
USE NIBBLER
Fig. 2
Changing over procedure of the selector

valve
81
USE BREAKER
Changing over procedure of the selector

valve
8.2 FLUSHING METHOD

After completion of piping work, connect the high
pressure side and the low pressure side, as shown
in Fig. 3, open the stop valves on both sides and
depress the operating pedal to perform flushing.
(ON)
(OFF)
CONNECTOR(PF3/4)
z Before beginning flushing, run the

engine at low speed, depress the
breaker operating pedal and then
run the engine at high speed.
z Perform flushing operation for at
least 40 minutes, and during the
operation, make sure of no oil
leakage from each of the connections
of the newly attached breaker circuit
and the nibbler & breaker circuits.
STOP VALVE
HOSE
An example of flushing time (23min.) in a single

process
8.3 REPLACING HYDRAULIC OIL AND RETURN

FILTER
Contamination and deterioration of hydraulic oil
may develop malfunctioning of the control valve,
early wear and seizure of the hydraulic pumps
and malfunctioning of the entire hydraulic
circuits : always replace hydraulic oil at regular
intervals, based on table 1.
5 min
Flushing
1 min
Stop
5 min
Flushing
Fig. 3
5 min
Flushing
1 min
Stop
1 min
Stop
5 min
Flushing
Flushing method
Table 1
Inspection /
maintenance points
Item
Hydraulic oil
Return filter
Replacement intervals
First replacement
2nd replacement
Regular replacement
Hydraulic oil tank

Hydraulic oil tank
50h
Every 600h
Every 250h
250h
8.4 OPERATING PROCEDURE

This machine is provided with breaker single
circuit and nibbler and breaker conflux (bi-flow)
circuit. To use breaker or nibbler, select circuit
appropriate to the specification through single /
conflux select switch on the left console.
(1) Switch operating
(Nibbler & breaker specification)
Specification
Breaker (
Nibbler (
)
)
Switch position
Circuit
OFF
ON
Single flow
Conflux flow
Never turn switch on (conflux) to operate

breaker. It may cause trouble of machine.
NIBBLER & BREAKER SPECIFICATION
Fig.4
82
(2) Throttle potentiometer

When operating the machine with a
hydraulic
breaker,
do
the
following
operations :
Use the throttle potentiometer on the high
idle side. (Refer to Fig. 5.)
(3) Control pedal

1) Hydraulic breaker single circuit
Release pedal lock on the right front side of
drivers seat to operate pedal.
Fig. 5 Throttle potentiometer position
Precaution for pedal operation

The operation varies in the specifications, so
before operating, read the Operator Manual
carefully.
Foot pedal
Operating condition.
depressing section
Depress toe section
Breaker starts operation.
Pedal in neutral position. Breaker stops operation.
2) Nibbler and breaker conflux (bi-flow) circuit.
Release pedal lock on the right front side of
drivers seat to operate pedal.
l Hydraulic breaker
PUSH LOCK ROD

FORWARD
TO RELEASE
Foot pedal
depressing section
Depress heel section.
Breaker starts operation.
Pedal in neutral position. Breaker stops operation.
PULL LOCK ROD

BACKWARD
TO LOCK PEDAL
l Nibbler
Foot pedal
depressing section
Depress toe section
Depress heel section
DEPRESS PEDAL
WITH TOE TO
ACTIVATE
Nibbler close
Nibbler open
8 3
84
9. PRECAUTIONS TO BE EXERCISED ON BREAKERS

OF DIFFERENT MANUFACTURERS
There
are
some
differences
between
manufac-turers as to the piping to breakers and
the handling of breakers. For this reason, consult
with the manufacturer when mounting a breaker
in the field. The following is a summary of how
breakers should be handled that is extracted from
manu-facturers catalog use and operation
manuals.
NOTE : This is a general outline of how breakers
should be used and may differ with
excavator models. Always contact the
breaker
manufacturer
before
field
mounting.
Low pressure : Measure the inlet pressure of the

side
line filter on the breaker side by
actuating
the breaker at full
engine revolution in the H mode,
and in case the maximum
2
pressure exceeds 55kgf/cm (780
psi), install a low pressure
accumulator.
2
Max. < 55kgf/cm (780 psi)
Regarding the capacity and the
charge pressure of accumulators,
contact the breaker manufacturer
before installation.
(1) Placing high and low pressure accumulators

NPK
They must be placed basically
(depending upon models).
(2) Installation of a relief valve

NPK
Installation is not necessary.
(Contact the breaker manufacturer
as it is necessary depending upon
models.)
K R U P P
O K A D A
FURUKAWA
Check the oscillation of the

pulsation of the breaker
pressure and if pulsation is
large,
always
install
accumu-lators.
Standard of judgment on the installation of

accumulators
Measure the pulse oscillation by
pressure on the high pressure
High
side of the breaker at the
pressure :
inspection port for the pumps
delivery pressure by actuating the
breaker at the full revolution of
the engine in mode H and set the
maximum pressure difference to
within 20% of the excavators
system
pressure
350kgf/cm2
(4980psi).
In case it exceeds 20%, install a
high pressure accumulator.
20%=
NOTE : The pulse oscillation is 350
2
70kgf/cm (1000psi). Therefore, if it is more
than this level, an accumulator must be
installed.
Install accumulator referring to the
result of verification test.
Installation is necessary.
A relief valve is specified by
each breaker manufacturer.
K R U P P
Since the method of pressure
O K A D A
setting of the relief valve
differs
with
breaker
T A I S E I
manufac-turers, install a relief
FURUKAWA
valve
according
to
the
manufac-turers instructions.
NOTE : Only the B series TOKU machine requires
a relief valve to be installed.
T
N&B
LOW PRESSUSE SIDE
(RETURN)
N&B
HIGH PRESSUSE
SIDE
max
ACCUMULATOR
min
Fig. 1
9 1
Accumulator mounting
(4) Changing over the breaker to high and low

speeds
(PF1)
TO TANK
RETURN SIDE
TO BREAKER
(3) Restriction of engine speed

NPK
Full engine speed may be used.
T
K R U P P
O K A D A
T A I S E I
There are restriction on the

engine
speed.
Since
a
specified speed differs with
breakers, follow the breaker
manufacturers instructions.
K
K
T A I S E I
These breakers are not so

constructed as to be switched
over to high and low speed.
FURUKAWA
KRUPP
OIL SUPPLY SIDE
1. HIGH PRESSURE HOSE 4. PLUG

2. NIPPLE
5. ELBOW
3. ADAPTER
6. RELIEF VALVE
Fig. 2
Breakers larger than MKB1200 are

constructed with a switching function.
It can be operated from inside the cab
by the installation of a solenoid valve.
For piping work, consult with the
breaker manufacturer.
NOTE : Piping work is not required in some cases if

a high-low changeover function is not
necessary at users request.
On that occasion, it is necessary to fix the
changeover valve contained in the breaker
to the low speed side beforehand. Consult
with the breaker manufacturer in that case.
It is prohibited to use the high-low speed
changeover valve without laying high-low
speed piping and without fixing the high-low
speed changeover valve.
FURUKAWA
HIGH-LOW SPEED
CHANGEOVER VALVE
NOTE : In the case of a breaker for which the

engine revolution is limited, the breaker
does not increase impact power and cycles
even at full engine revolution.
HYDRAULIC
Since extra hydraulic oil returns to the
RELIEF VALVE
BREAKER
hydraulic oil via the relief valve, it causes
the hydraulic oil temperature to rise and the TO CONTROL VALVE
fuel consumption to increase. Plaster the
label (furnished by the breaker maker)
TO TANK
indicating the revolution (Check the engine
revolution.), to the throttle potentiometer
position. Always observe the indicated
CHECK VALVE
revolution.
Fig. 3
92
10. REFERENCE
Typical combinations are quoted from breaker
manufacturers catalog use as below, but
concerning applicable breaker models, decide it
after consultation with the breaker manufacturer.
Working press
Applicable
Manufacturer
kgf/cm2
breaker
(psi)
120140
H-10XB
(1,7101,990)
N
P
K
130150
H-4XE
(1,8502,130)
100140
TNB-10B
(1,4201,990)
120140
TNB-14B
(1,7101,990)
100160
T O K U TNB-6E
(1,4202,280)
120170
TNB-10E
(1,7102,420)
130170
TNB-14E
(1,8502,420)
150160
MKB1100
(2,1302,280)
K R U P P
150180
MKB1200
(2,1302,560)
150180
UB 11
(2,1302,560)
O K A DA
130160
OUB 310
(1,8502,280)
150170
T A I
S ETF-150
(2,1302,420)
160180
FURUKAWA HB20G
(2,2802,560)
When fitting a breaker, read through reminders

on the use of breakers and cautions instructed by
breaker manufacturers.
Table 1
Oil volume
used /min
(gal/min)
160200
(42.252.8)
3560
(9.2415.8)
110140
(29.037.0)
140160
(37.042.2)
4580
(11.921.1)
100140
(26.437.0)
130170
(34.344.9)
80110
(21.129.0)
90130
(23.834.3)
110
(29.0
)
110155
(29.040.9)
100120
(26.431.7)
125150
(33.039.6)
Total weight
kg
(lbs)
1,450
(3,200)
410
(900)
1,000
(2,210)
1,400
(3,100)
391
(860)
997
(2,200)
1,550
(3,400)
1,1001,250
(2,4302,760)
1,1201,200
(2,4702,650)
1,450
(3,200)
1,070
(2,360)
1,330
(2,930)
1,400
(3,100)
Total length
mm
(in)
2,156
(84.9 )
1,644
(64.7 )
1,476
(58.1 )
1,850
(72.8 )
2,190
(86.2 )
2,278
(89.7 )
Bucket
capacity m3
(cuyd)
0.550.70
(0.720.92)
0.700.90
(0.921.18)
0.250.35
(0.330.46)
0.550.70
(0.720.92)
0.700.90
(0.921.18)
0.500.90
(0.651.18)
0.551.00
(0.721.31)
0.70
(0.92
)
0.550.70
(0.720.92)
0.600.90
(0.781.18)
2,240
(88.2)
2,040
(80.3 )
1,596
(62.8 )
2,119
(83.4 )
[
] Excludes chisels.
General precautions to be exercised on the installation of breakers by different manufacturers

Table 2
Installation of Installation of Restriction of
engine
Manufacturer
accumulators a relief valve
speed
NPK
TOKU
Series B
TOKU
Series E
High-low speed changeover
changeover type not available.

changeover type available for large
machines.
changeover type available on
special request.
KRUPP
OKADA
FURUKAWA
TAISEI
Adaptation test completed.

One that must be installed.
One that does not need to be installed.
One that must be adjusted at installation.

Capacity 1 liter, pressure is 70kgf/cm2 (1,000psi)
101

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- For any question or comment, or in case you

- Read this manual carefully for correct

NEW HOLLAND KOBELCO CONSTRUCTION

ADDITIONAL REFERENCE MANUALS

DESCRIPTION OF THE COMPLETE

equipment, information on maintenance standards,

- E200SR Workshop Manual "Excavator"

The complete Workshop Manual for the excavator

"Excavator" and "Engine" Workshop Manuals

Copyright New Holland

On machines having hydraulically, mechanically and/or cable controlled

All rights reserved. Reproduction of text and illustrations in whole or in part, is

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Copyright New Holland

The proper and safe lubrication and maintenance for

Read and understand all Warning plates and

Always wear protective glasses and protective

Disconnect the battery and hang a Do Not

If possible, make all repairs with the machine

Do not operate this machine unless you have read

Relieve all pressure in air, oil or water systems

Lower the bucket, dozer, or other attachments to

Use steps and grab handles when mounting or

To avoid back injury, use a hoist when lifting

The following is a list of basic precautions that must

Do not work on any machine that is supported

10. To avoid burns, be alert for hot parts on machines

Copyright New Holland

greater if the machine has just been stopped

21. Do not operate a machine if any rotating part is

16. Do not damage wiring during removal operations.

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1. GENERAL PRECAUTIONS FOR MAKING REPAIRS

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7) The removed parts should be put in order and

3) For air bleed of hydraulic pump and swing

(4) Reassembling hydraulic equipment

How to check oil level of hydraulic oil tank

1.4 ELECTRICAL EQUIPMENT

(5) Installing hydraulic equipment

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(9) When water has entered in the waterproofed

Tighten it to the specified torque,

1.6 WELD REPAIR

Battery electrolyte is dangerous.

1.7 ENVIRONMENTAL ISSUES

1.5 HYDRAULIC PARTS

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2. INTERNATIONAL UNIT CONVERSION SYSTEM

(1) Basic Units

(3) Derived Units of Basic Units

(6) Unit Conversion Table

Units that are allowed to use

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do not include the height of

'((

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'(

% 3# '

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# $%%&'( )*+

1" 2 )*+ 3&%4

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