Kobelco SK 200 10 Manual

HYDRAULIC EXCAVATOR
MAINTENANCE SPECIFICATIONS
SHOP SK200-10
MANUAL model SK210LC-10
INDEX
1 SPECIFICATIONS SECTION
SYSTEM
2 MAINTENANCE SECTION
3 SYSTEM SECTION
4 DISASSEMBLY SECTION
DISASSEMBLING
5 TROUBLESHOOTING
6 ENGINE SECTION
7 PROCEDURE E / G TROUBLESHOOTING
OF INSTALLING
OPTIONS SECTION OPT.
Book Code No.S5YN0051E01

0-1
Copyright©2016 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YN0051E01] [0122CsCshLbWk]
GENERAL SAFETY INFORMATION 3) CAUTION- Indicates a potentially hazardous
situation which, if not avoided, may result in mi-
nor or moderate injury. It may also be used to
alert against possible damage to the machine
Do not operate or perform any maintenance on this and its components and is represented as fol-
machine until all instructions found in the OPERA- lows:
TOR’S MANUAL and this MANUAL have been thor-
oughly read and understood.
Improper operation or maintenance of this machine (4) It is very difficult to forecast every danger that may
may cause accidents and could result in serious in- occur during operation. However, safety can be en-
jury or death. sured by fully understanding proper operating pro-
Always keep the manual in storage. cedures for this machine according to methods
If it is missing or damaged, place an order with an recommended by Manufacturer.
authorized our Distributor for a replacement.
(5) While operating the machine, be sure to perform
If you have any questions, please consult an autho-
work with great care, so as not to damage the ma-
rized our Distributor.
chine, or allow accidents to occur.
(1) Most accidents, which occur during operation, are (6) Continue studying the manual until all Safety, Oper-
due to neglect of precautionary measures and safe- ation and Maintenance procedures are completely
ty rules. Sufficient care should be taken to avoid understood by all persons working with the ma-
these accidents. Erroneous operation, lubrication chine.
or maintenance services are very dangerous and
may cause injury or death of personnel. Therefore
all precautionary measures, NOTES, DANGERS,
WARNINGS and CAUTIONS contained in the man-
ual and on the machine should be read and under-
stood by all personnel before starting any work with
or on the machine.
(2) Operation, inspection, and maintenance should be
carefully carried out, and safety must be given the
first priority. Messages of safety are indicated with
marks. The safety information contained in the
manual is intended only to supplement safety
codes, insurance requirements, local laws, rules
and regulations.
(3) Messages of safety appear in the manual and on
the machine : All messages of safety are identified
by either word of "DANGER", "WARNING" and
"CAUTION".
1) DANGER- Indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury and is represented as
follows:
2) WARNING- Indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury and is represented as
follows:
0-2
SAFETY PRECAUTIONS stands, capable of supporting the machine, before
performing any disassembly.
The proper and safe lubrication and maintenance

for this machine, recommended by Manufacturer, Do not operate this machine unless you have
are outlined in the OPERATOR’S MANUAL for the read and understand the instructions in the OP-
machine. ERATOR’S MANUAL. Improper machine opera-
Improper performance of lubrication or mainte- tion is dangerous and could result in injury or
nance procedures are dangerous and could result death.
in injury or death. Read and understand the MAN-
(6) Relieve all pressure in air, oil or water systems be-
UAL before performing any lubrication or mainte-
fore any lines, fittings or related items are discon-
nance.
nected or removed. Always make sure all raised
The serviceman or mechanic may be unfamiliar with components are blocked correctly and be alert for
many of the systems on this machine. This makes it possible pressure when disconnecting any device
important to use caution when performing service work. from a system that utilizes pressure.
A knowledge of the system and or components is im- (7) Lower the bucket, dozer, or other attachments to
portant before the removal or disassembly of any com- the ground before performing any work on the ma-
ponent. chine. If this cannot be done, make sure the bucket,
Because of the size of some of the machine compo- dozer, ripper or other attachment is blocked correct-
nents, the serviceman or mechanic should check the ly to prevent it from dropping unexpectedly.
weights noted in this manual. Use proper lifting proce- (8) Use steps and grab handles when mounting or dis-
dures when removing any components. Weight of com- mounting a machine. Clean any mud or debris from
ponents table is shown in the section ; steps, walkways or work platforms before using.
SPECIFICATIONS. Always face to the machine when using steps, lad-
The following is a list of basic precautions that must al- ders and walkways. When it is not possible to use
ways be observed. the designed access system, provide ladders, scaf-
folds, or work platforms to perform safe repair oper-
(1) Read and understand all Warning plates and decal
ations.
on the machine before Operating, Maintaining or
Repairing this machine. (9) To avoid back injury, use a hoist when lifting com-
ponents which weigh 20kg (45lbs) or more. Make
(2) Always wear protective glasses and protective
sure all chains, hooks, slings, etc., are in good con-
shoes when working around machines. In particu-
dition and are the correct capacity. Be sure hooks
lar, wear protective glasses when using hammers,
are positioned correctly. Lifting eyes are not to be
punches or drifts on any part of the machine or at-
side loaded during a lifting operation.
tachments. Use welders gloves, hood/goggles,
apron and the protective clothing appropriate to the (10)To avoid burns, be alert for hot parts on machines
welding job being performed. Do not wear loose fit- which have just been stopped and hot fluids in
ting or torn clothing. Remove all rings from fingers, lines, tubes and compartments.
loose jewelry, confine long hair and loose clothing (11)Be careful when removing cover plates. Gradually
before working on this machinery. back off the last two capscrews or nuts located at
(3) Disconnect the battery and hang a "Do Not Oper- opposite ends of the cover or device and carefully
ate" tag in the Operators Compartment. Remove ig- pry cover loose to relieve any spring or other pres-
nition keys. sure, before removing the last two capscrews or
nuts completely.
(4) If possible, make all repairs with the machine
parked on a firm level surface. Block the machine (12)Be careful when removing filler caps, breathers and
so it does not roll while working on or under the ma- plugs on the machine. Hold a rag over the cap or
chine. Hang a "Do Not Operate" tag in the Opera- plug to prevent being sprayed or splashed by liq-
tors Compartment. uids under pressure. The danger is even greater if
the machine has just been stopped because fluids
(5) Do not work on any machine that is supported only
can be hot.
by lift, jacks or a hoist. Always use blocks or jack
0-3
(13)Always use the proper tools that are in good condi- (19)Loose or damaged fuel, lubricant and hydraulic
tion and that are suited for the job at hand. Be sure lines, tubes and hoses can cause fires. Do not bend
you understand how to use them before performing or strike high pressure lines or install ones which
any service work. have been bent or damaged. Inspect lines, tubes
(14)Reinstall all fasteners with the same part number. and hoses carefully. Do not check for leaks with
Do not use a lesser quality fastener if replacements your hands. Very small (pinhole) leaks can result in
are necessary. a high velocity oil stream that will be invisible close
to the hose. This oil can penetrate the skin and
(15)Repairs which require welding should be per-
cause personal injury. Use card-board or paper to
formed only with the benefit of the appropriate ref-
locate pinhole leaks.
erence information and by personnel adequately
trained and knowledgeable in welding procedures. (20)Tighten connections to the correct torque. Make
Determine type of metal being welded and select sure that all heat shields, clamps and guards are in-
correct welding procedure and electrodes, rods or stalled correctly to avoid excessive heat, vibration
wire to provide a weld metal strength equivalent at or rubbing against other parts during operation.
least to that of the parent metal. Make sure to dis- Shields that protect against oil spray onto hot ex-
connect battery before any welding procedures are haust components in event of a line, tube or seal
attempted. failure must be installed correctly.
(16)Do not damage wiring during removal operations. (21)Do not operate a machine if any rotating part is
Reinstall the wiring so it is not damaged nor will be damaged or contacts any other part during opera-
damaged in operation of the machine by contacting tion. Any high speed rotating component that has
sharp corners, or by rubbing against some object or been damaged or altered should be checked for
hot surface. Do not connect wiring to a line contain- balance before reusing.
ing fluid. (22)Be careful when servicing or separating the tracks
(17)Be sure all protective devices including guards and (crawlers). Chips can fly when removing or install-
shields are properly installed and functioning cor- ing a track (crawlers) pin. Wear safety glasses and
rectly before starting a repair. If a guard or shield long sleeve protective clothing. Tracks (crawlers)
must be removed to perform the repair work, use can unroll very quickly when separated. Keep away
extra caution and replace the guard or shield after from front and rear of machine. The machine can
repair is completed. move unexpectedly when both tracks (crawlers)
are disengaged from the sprockets. Block the ma-
(18)The maintenance and repair work while holding the
chine to prevent it from moving.
bucket raised is dangerous due to the possibility of
a falling attachment. Don’t fail to lower the attach-
ment and place the bucket to the ground before
starting the work.
The copyright of this manual belongs to KOBELCO CONSTRUCTION MACHINERY CO., LTD.
Copy, reproduction, distribution, and delivery (including these actions on the Internet) of all or part of this
manual are prohibited without permission of KOBELCO CONSTRUCTION MACHINERY CO., LTD.
This manual is intended to provide instructions for repair, maintenance, and adjustment of the machine, sold
directly or indirectly by KOBELCO CONSTRUCTION MACHINERY CO., LTD. or KOBELCO authorized dealer,
and any use other than that purpose will not be allowed.
Also, all or part of this manual cannot be transferred, sold, or lent to a third person without permission of
KOBELCO CONSTRUCTION MACHINERY CO., LTD.
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C area in SE Asia (TKCM) INDEX SK200-10
SK210LC-10
Index
Distribution Year–Month Title 1
No. 17 9
MAINTENANCE SPECIFICATIONS
2015-11 OUTLINE 1
2015-11 SPECIFICATIONS 2
2015-11 ATTACHMENT DIMENSIONS 3 2

18 10
2015-11 TOOLS 4
STANDARD MAINTENANCE
2015-11
TIME SCHEDULE
5
MAINTENANCE STANDARD
2015-11
AND TEST PROCEDURE 6
11 3
MECHATRO CONTROL
2015-11
SYSTEM
7
2015-11 HYDRAULIC SYSTEM 8

SYSTEM
2015-11 ELECTRIC SYSTEM 9
12 4
2015-11 COMPONENTS SYSTEM 10
2015-11 AIR-CONDITIONER SYSTEM 11

_
DISASSEMBLING 13 5
DISASSEMBLING
2015-11 12
& ASSEMBLING
2015-11 ATTACHMENT 13
2015-11 UPPER STRUCTURE 14
2015-11 TRAVEL SYSTEM 15 14 6

E / G TROUBLESHOOTING
2015-11 BY ERROR CODES 16
2015-11 BY TROUBLE 17
_
15 7
_
2015-11 ENGINE 18
_
16 8
_
YN15T17101∼/ APPLICABLE MACHINES

YQ15-T3101∼
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NOTE:
This Manual is prepared as a technical material in This Manual may be properly revised due to the im-
which the information necessary for the maintenance provement of products, modification of specifications,
and repairing services of our hydraulic excavators are etc. And there are cases where the system on actual
collected, and is categorized into 7 Chapters, Specifica- machine and a part of the contents of this manual may
tion, Maintenance, System, Disassembly, Trouble- differ due to the variations of specification by countries.
shooting, Engine, and Installation Procedures for For the section in which the description is hardly under-
Optional Attachment. stood, contact our distributor.
• The Chapter "Specification" describes the specifi- The number is assigned to every part handled in this
cations for entire machine and material, which are Manual on account of the description, but the parts,
instructive for replacement and repairing of attach- which cannot be supplied as service parts are con-
ments. tained. Therefore, the order must be placed with re-
spective formal number with due confirmation on the
• The Chapter "Maintenance" describes the material,
Parts Manual for applicable machine.
which is helpful for maintenance service and adjust-
ments for entire machine.
• The Chapter "System" describes the operating sys-
tem like hydraulic system, electric system, compo-
nents, and so on.
• The Chapter "Disassembly" describes the removal
and installing of assembly mounted on the upper
structure and undercarriage, and the assembling
and disassembling of the associated hydraulic
equipment.
• The Chapter "Troubleshooting" describes how to
find the fault equipment.
• The Chapter "Engine" describes the engines mak-
ing use of the "Maintenance Manual" provided by
the suppliers.
• The Chapter "Installation Procedures for Optional
Attachment" describes the supplements added on
request as required.
0-6
［1. OUTLINE］
1. OUTLINE
1.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.................................................................1-3
1.2 GENERAL PRECAUTIONS FOR MAKING REPAIRS .................................................................1-4
1.2.1 PREPARATION BEFORE DISASSEMBLING ..........................................................................1-4
1.2.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING .........................................................1-4
1.2.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT .........................................1-5
1.2.4 ELECTRICAL EQUIPMENT....................................................................................................1-7
1.2.5 HYDRAULIC PARTS..............................................................................................................1-7
1.2.6 WELD REPAIR ......................................................................................................................1-8
1.2.7 ENVIRONMENTAL ISSUES ...................................................................................................1-8
1.3 INTERNATIONAL UNIT SYSTEM ..............................................................................................1-9
1-1
［1. OUTLINE］
1-2
［1. OUTLINE］
1.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL

Copy, reproduction, distribution, and delivery (including these actions on the Internet) of all or part of this manual
are prohibited without permission of KOBELCO CONSTRUCTION MACHINERY CO., LTD.
1
directly or indirectly by KOBELCO CONSTRUCTION MACHINERY CO., LTD. or KOBELCO autorized dealer, and
any use other than that purpose will not be allowed.
Also, all or part of this manual cannot be transferred, sold, or lent to a third person without permission of KOBELCO
CONSTRUCTION MACHINERY CO., LTD.
1-3
［1. OUTLINE］
1.2 GENERAL PRECAUTIONS FOR MAKING REPAIRS

1.2.1 PREPARATION BEFORE DISASSEMBLING
Read Operator's Manual

before disassembling
Knowledge of operating procedure

Read Operator's Manual carefully to understand the operating procedure.
Cleaning machines
Clean machines of soil, mud, and dust before carrying into the service shop.
Carrying a soiled machine into the service shop, causes making less efficient work and damage of parts.
Inspecting machines
Confirm the disassembling section before starting work, determine the disassembly procedure taking the conditions
in work 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, Serial number and Record on hour meter
• Trouble condition, place, cause
• Visible oil leak, water leak and damage
• Clogging of filters, oil level, oil quality, oil contamination and looseness.
• Examine the problems on the basis of monthly operation rate with the last inspection date and records on hour
meter.
Arrangement and cleaning in service shop

• Tools required for repair work.
• Prepare the places to put the disassembled parts.
• Prepare oil pans for leaking oil, etc.
1.2.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING
WARNING
Safety
• Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves.
• Attach "Don't operate" tag to control lever, and begin a meeting before starting the work.
• Before starting inspection and maintenance stop the engine.
• Confirm the position of first-aid kit and fire extinguisher, and also where to make contact for emergency measure
and ambulance to prepare for accidents and fire.
• Choose a hard, level and safe place, and put attachment on the ground without fail.
• Use hoist, etc. to remove parts of heavy weight (23kg [50 lb] or more).
• Use proper tools, and change or repair defective tools.
• Machine and attachment required to work in the lifting condition should be supported with supports or blocks
securely.
1-4
［1. OUTLINE］
1.2.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT
1
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.
• Drain the oil in the removed pipes into pan to prevent the oil from spilling 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 manufacture's side, disassembly, assembly and modification without permission are
strictly prohibited.
• If it is unavoidably necessary to disassemble and modify, it should be carried out by experts or personnel
qualified through service training.
• Make match mark on parts for reassembling.
• Before disassembling, read Disassembling Instruction in advance, and determine if the disassembly and
assembly are permitted or not.
• For parts which are required to use jig and tools, don't fail to use the specified jig and tools.
• For parts which can not be removed in the specified procedure, never force removal. First check for the cause.
• The removed parts should be put in order and tagged so as to install on proper places without confusion.
• For common parts, pay attention to the quantity and places.
Inspecting parts
• Check that the disassembled parts are free from adherence, interference and uneven working face.
• Measure the wear of parts and clearance, and record the measured values.
• If an abnormality is detected, repair or replace the parts.
Reassembling hydraulic equipment

• During the parts cleaning, ventilate the room.
• Before assembly, clean parts roughly first, and then completely.
• Remove adhering oil by compressed air, and apply hydraulic oil or gear oil, and then assemble them.
• Replace the removed O-ring, back-up rings and oil seal with new ones, and apply grease oil on them before
assembling.
• Removes dirt and water on the surface on which liquid sealant are applied, decrease them, and apply liquid
sealant on them.
• Before assembling, remove rust preventives on new parts.
• Use special tools to fit bearings, bushing and oil seal.
• Assemble parts matching to the marks.
• After completion, check that there is no omission of parts.
Installing hydraulic equipment

• Confirm hydraulic oil and lubrication oil.
• Air release is required in the following cases ;
– Change of hydraulic oil
– Replacement of parts on suction pipe side
– Removing and attaching hydraulic pump
1-5
［1. OUTLINE］
– Removing and attaching swing motor

– Removing and attaching travel motor
– Removing and attaching hydraulic cylinder
• 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 comes out. After completion of comes, tighten plug securely.
• 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.
• Air in pilot circuit can be bleed out by only operating digging, swing and traveling motions thoroughly.
• 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 specified level.
How to check oil level of hydraulic oil tank
Im p o r t a n t im fo r m a t io n
LEVEL GAUGE
Oil level of hydraulic oil tank.
If the indicator is within
level marks, the oil quantity
is acceptable.
Checking method for oil level of hydraulic oil tank
WHEN AIR BLEEDING IS REQUIRED

If hydraulic oil and lubricating oil are not filled and also air bleeding is not performed, the hydraulic equipment may
be damaged.
WHEN AIR IS BLED FROM HYDRUALIC CYLIDNER

For cylinder, don't move it to the stroke end at beginning.
1-6
［1. OUTLINE］
1.2.4 ELECTRICAL EQUIPMENT
BATTERY FLUID IS DANGEROUS. 1

The battery fluid is dilute sulfuric acid, and causes scald and loss of eyesight by adhering on eyes, skin and clothes.
When the fluid 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 a lot of water.
• When it has adhered on clothes; Wash it immediately.
• The disassembly of electrical equipment is not allowed.

• Handle equipment with care so as not to drop it or bump it.
• Connector should be removed by unlocking while holding the connector.
Never stress in tension to the caulked section by pulling wire.
• Check that connector is connected and locked completely.
• Engine key off before removing and connecting connector.
• Engine key off before touching terminals of starter and alternator.
• Remove battery grounding terminal before beginning work close to battery and battery relay with tools.
• Wash machine with care so as not to splash water on electrical equipment and connector.
• 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.
1.2.5 HYDRAULIC PARTS
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.
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.
• Tighten it to the specified torque, and check that it is free from twist, over tension, interference, and oil leak.
1-7
［1. OUTLINE］
1.2.6 WELD REPAIR

• The weld repair should be carried out by qualified 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.
• Remove parts which may cause fire due to the entry of spark beforehand.
• 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 flame-proof clothes.
1.2.7 ENVIRONMENTAL ISSUES

• Engine should be started and operated in the place where air can be sufficiently ventilated.
• Waste disposal
The following parts follows the regulation.
– Waste oil and waste container
– Battery
• 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 ;Don't force him to vomit it, but immediately receive medical treatment.
– When it has adhered on skin ;Wash with soap and water.
• Others
For spare parts, grease and oil, use KOBELCO genuine ones.
1-8
［1. OUTLINE］
1.3 INTERNATIONAL UNIT SYSTEM

Introduction (4) De rive d Units be a ring P e culia r De s igna tions
Although this manual uses the SI units system. Outline

Ta b le 1-4 1
of SI units system is described here. QUANTITY UNIT S YMBOL FORMULA
Given hereinunder are an excerpt of the units that are Fre que ncy he rtz Hz 1Hz=1/s
related to this manual : Force ne wton N kg .m/s 2
P re s s ure a nd pa s ca l Pa N/m 2
1. Etymology of SI Units Stre s s
Englis h : Inte rna tiona l S ys te m of units Ene rgy, Work
2. Construction of SI Unit System a nd Qua ntity of joule J N.m
he a t
Base units P owe r wa tt W J /s
Ta ble 1-1 Qua ntity of
Derived units coulomb C A.s
e le ctricity
Supplemen of base units
Ele ctric
SI units tary units Ta ble 1-3
SI unit Ta ble 1-2 pote ntia l
system Derived units diffe re nce ,
bearing peculiar volt V W/A
Derived Volta ge , a nd
units designations
Ta ble 1-4
Ele ctromotive
force
Prefixes of SI Qua ntity of
(n-th power of 10, where n is an integer) s ta tic e le ctricity
Ta ble 1- 5 fa ra d F C/V
a nd Ele ctric
ca pa cita nce
Ele ctric
(1) Ba s ic Units ohm V/A
re s is ta nce
Ta b le 1-1 ce lcius
Ce lcius
de gre e or °C (t+273.15)K
QUANTITIES DES IGNATION S IGN te mpe ra ture
de gre e
Le ngth Me te r m Illumina nce lux lx l m/m 2
Ma s s Kilogra m kg
(5) P re fixe s of S I
Time S e cond s
Curre nt Ampe re A Ta b le 1-5
The rmodyna mic Ke lvin K
P REFIX
te mpe ra ture P OWER
DES IGNATION S IGN
Gra m mole cule Mol mol Giga G 10 9
Luminous inte ns ity Ca nde la cd Me ga M 10 6
Kilo k 10 3
(2) S upple me nta ry Units He cto h 10 2
De ca da 10
Ta b le 1-2 De ci d 10 -1
QUANTITIES DES IGNATION S IGN Ce nti c 10 -2
P la in a ngle Ra dia n ra d Milli m 10 -3
Micro µ 10 -6
S olid a ngle Ste ra dia n sr
Na no n 10 -9
P ico p 10 -12
(3) De rive d Units of Ba s ic Units
(6) Unit Conve rs ion Ta ble
Ta b le 1-3
Ta b le 1-6
QUANTITIES DES IGNATION S IGN
Are a S qua re me te r m2 QUANTITIES J IS SI REMARKS
Volume Cubic me te r m3 Mass kg kg
Force kgf N 1kg f=9.8 07N
Ve locity Me te r pe r s e cond m/s
Torque kgf.m N.m 1kgf.m=9.8 07N.m
Acce le ra tion Me te r pe r s e cond / s e cond m/s 2 P re s s ure kgf/cm 2 MPA 1kgf/cm 2=0.098MP a
De ns ity Kilogra m pe r cubic me te r kg/m 3 Motive powe r PS kW 1P S =0.7355kW
Re volution r.p.m min -1 1r.p.m=1min -1
1-9
［1. OUTLINE］
1-10
［2. SPECIFICATIONS］
2. SPECIFICATIONS
2.2 BASIC COMPONENTS OF THE MACHINE................................................................................2-4
2
2.3 GENERAL DIMENSIONS..........................................................................................................2-6
2.3.1 SK200-10[5.65m(18ft-6in) Boom + 2.94m(9ft-8in) Standard Arm + 0.8m3(1.05cu·yd)
Bucket]............................................................................................................2-6
2.3.2 SK210LC-10[5.65m(18ft-6in) Boom + 2.94m(9ft-8in) Standard Arm + 0.8m3(1.05cu·yd)
Bucket]............................................................................................................2-7
2.4 WEIGHT OF COMPONENTS.....................................................................................................2-8
2.5 SPECIFICATIONS FOR TRANSPORTATION .............................................................................2-9
2.5.1 DIMENSIONS AND WEIGHT OF ATTACHMENT/EQUIPMENT ................................................2-9
2.6 GENERAL SPECIFICATIONS ................................................................................................. 2-11
2.6.1 SPEED AND CLIMBING CAPABILITY .................................................................................. 2-11
2.6.2 ENGINE .............................................................................................................................. 2-11
2.6.3 HYDRAULIC COMPONENTS ............................................................................................... 2-11
2.6.4 WEIGHT .............................................................................................................................. 2-11
2.7 TYPE OF CRAWLER ..............................................................................................................2-12
2.7.1 SK200-10 TYPE OF SHOE ...................................................................................................2-12
2.7.2 SK210LC-10 TYPE OF SHOE...............................................................................................2-12
2.8 TYPE OF BUCKET .................................................................................................................2-13
2.9 COMBINATIONS OF ATTACHMENT .......................................................................................2-14
2.10 ENGINE SPECIFICATION .....................................................................................................2-15
2.10.1 SPECIFICATIONS..............................................................................................................2-15
2-1
2-2

2
2-3
2.2 BASIC COMPONENTS OF THE MACHINE
29 28
30
27
15
31 Indicate the right side
32
26
3 4
13 16
33
19
20
18
21
5
7 1
22 17
8 24
23 34
35 6 12
14
Inside the left side door 10 9 11
25
2-4
No. Name No. Name No. Name

1 Engine 13 Cab 25 Travel motor
2 Hydraulic pump 14 Left side door 26 Boom cylinder
3 Control valve 15 Right side door 27 Boom
4 Hydraulic oil tank 16 Engine hood 28 Arm cylinder
5 Fuel tank 17 Counterweight 29 Arm
6 Swing motor 18 Swing bearing 30 Bucket cylinder
7 Swivel joint 19 Crawler 31 Idler link

2
8 Air cleaner 20 Front idler 32 Bucket link
9 Battery 21 Crawler adjuster 33 Bucket
10 Oil cooler 22 Lower roller 34 Swing flusher
11 Radiator 23 Track guide 35 Battery power-off switch
12 Intercooler 24 Upper roller
2-5
2.3 GENERAL DIMENSIONS

2.3.1 SK200-10[5.65m(18ft-6in) Boom + 2.94m(9ft-8in) Standard Arm + 0.8m3
(1.05cu·yd) Bucket]
Unit: mm(ft-in)
45 (1.77”)
0 R
9 4 ”) (9 2 9 1
R 1 6 ’4 ’7 ” 0
)
(
9600 (31’6”) 2710 (8’1 1”)
2900 (9’6”) 1390 1320
(4’7”) (4’4”)
3010 (9’11”)
2980 (9’9”)
2740 (8’12”)
1060* (3’6”)
450*
(17.7”)
4170 (13’8”) 600
(23.6”)
4990 (16’4”) 2800 (9’2”)
Dimensions marked * do not include the height of the shoe lug.
2-6
2.3.2 SK210LC-10[5.65m(18ft-6in) Boom + 2.94m(9ft-8in) Standard Arm +

0.8m3(1.05cu·yd) Bucket]
Unit: mm(ft-in)
45 (1.77”)
2
0 R
9 4 ”) (9 2 9 1
1
R 6’ 4 ’7 ” 0
( )
9600 (31’6”) 2710 (8’1 1”)
2900 (9’6”) 1390 1320
(4’7”) (4’4”)
3010 (9’11”)
2980 (9’9”)
2740 (8’12”)
1060* (3’6”)
450*
(17.7”)
4450 (14’7”) 600
(23.6”)
5130 (16’10”) 2990 (9’10”)
Dimensions marked * do not include the height of the shoe lug.
2-7
2.4 WEIGHT OF COMPONENTS

Item / Model SK200-10 SK210LC-10
Operating mass (standard specification) kg (lbs) 20,500 (45,200) 20,900 (46,080)
1. Upper structure (including following items) 9,470 (20,880) ←

1.1 Upper frame 1,890 (4,170) ←
1.2 Counterweight 4,320 (9,530) ←
1.3 Cab 389 (858) ←
1.4 Engine 515* (1,140) ←
1.5 Hydraulic oil tank 179* (395) ←
1.6 Fuel tank 151* (333) ←
1.7 Slewing motor (including reduction unit) 188* (415) ←
1.8 Control valve 220* (485) ←
1.9 Boom cylinder 166* (366) x 2 ←
1.10 Pin (for mounting boom) 44 (97) ←
1.11 Hydraulic pump 141* (311) ←
1.12 Radiator (including intercooler) 88* (194) ←
2. Undercarriage (including following items) 6,900 (15,210) 7,270 (16,030)

2.1 Lower frame 2,360 (5,200) 2,520 (5,560)
2.2 Slewing bearing 251 (553) ←
2.3 Travel motor (including reduction unit) 317 (699) x 2 ←
2.4 Upper roller 17 (37) x 2 ←
2.5 Lower roller 37 (82) x 14 37 (82) x 16
2.6 Front idler 105 (232) x 2 ←
2.7 Idler adjuster 101 (223) x 2 ←
2.8 Sprocket 50 (110) x 2 ←
2.9 Swivel joint 24* (53) ←
2.10 Track link with 600mm (23.6in.) shoes assy (STD) 1,260 (2,780) x 2 1,340 (2,950) x 2
Track link with 800mm (31.5in.) shoes assy 1,660 (3,660) x 2 1,750 (3,860) x 2
2.10.1 Track link assy 510 (1,120) x 2 600 (1,320) x 2
3. Attachment (including following items) 4,120 (9,080) ←

{5.65m (18ft-6in.) boom + 2.94m (9ft-8in.) arm}
3.1 Bucket assy (0.80m3 (1.05cu·yd) 660 (1,460) ←
3.2 STD Arm assy (including following items) 1,200 (2,650) ←
3.2.1 STD Arm 807 (1,780) ←
3.2.2 Bucket cylinder 143* (315) ←
3.2.3 Idler link 42 (93) ←
3.2.4 Bucket link 90 (198) ←
3.2.5 Pin(2pcs. for mounting bucket cylinder/ 2pcs. for 84 (185) ←
mounting bucket) 2,260 (4,980) ←
3.3 Boom assy (including following items) 1,430 (3,150) ←
3.3.1 Boom 255* (562) ←
3.3.2 Arm cylinder 51 (112) ←
3.3.3 Pin (Mounting arm - Mounting arm cylinder)
4. Lubricant and water (including following items) 650 (1,430) ←

4.1 Hydraulic oil 230 (507) ←
4.2 Engine oil 21 (46) ←
4.3 Fuel 370 (816) ←
4.4 Water 32 (71) ←
Marks * show dry weight.
2-8
2.5 SPECIFICATIONS FOR TRANSPORTATION

2.5.1 DIMENSIONS AND WEIGHT OF ATTACHMENT/EQUIPMENT
2.5.1.1 BOOM
Item / Type 5.65m (18ft-6in) Boom
Length X Height X Width 5.86 x 1.61 x 0.67

L X H X W: m (ft-in) (19'3" x 5'3" x 2'2")
Weight: kg (lbs) 1,760 (3,880)

2
2.5.1.2 ARM AND BUCKET

Item / Type 2.94m (9ft-8in) arm + 0.80 m3 (1.05cu·yd) Bucket

L X H X W: m (ft-in) (17'4" x 2'11" x 4')
Weight: kg (lbs) 1,860 (4,100)
2.5.1.3 ARM
Item / Type 2.94m (9ft-8in) arm

L X H X W: m (ft-in) (12'11" x 2'9" x 1'10")
Weight: kg (lbs) 1,250 (2,750)
2-9
2.5.1.4 BUCKET
Type Hoe bucket
Length X Height X Width 1.38 x 1.24 x 1.16 1.38 x 1.24 x 1.30 1.37 x 1.26 x 1.46
L X H X W: m (ft-in) (4'6" x 4'1" x 3'10") (4'6" x 4'1" x 4'3") (4'6" x 4'2" x 4'9")
Weight: kg (lbs) 724 (1,600) 782 (1,720) 768 (1,690)
Bucket capacity: m3 (cu·yd) 0.80 (1.05) STD 0.93 (1.22) 1.0 (1.31)
Õ Hoe bucket
2-10
2.6 GENERAL SPECIFICATIONS

2.6.1 SPEED AND CLIMBING CAPABILITY
Item / Area & Model SK200-10 SK210LC-10
Swing speed min-1 (rpm) 13.3 (13.3)
Travel speed (1-speed/2-

km/h (mile/h) 3.6 / 6.0 (2.2 / 3.7)
speed)
Gradeability % (degree) 70 (35)

2
2.6.2 ENGINE
Engine model HINO J05E-TG
Water-cooled, 4 cycle 4 cylinder
Type
direct injection type diesel engine with inter cooler turbo-charger
Number of cylinders-BoreXStroke 4 -112 mm dia. x 130 mm (4.41 in x 5.12 in)
Total displacement 5.123 L (312.61 cu·in)
Rated output / Engine speed 114kW (153 hp) / 2,000 min-1 (rpm) (ISO 9249 : With fan)
Maximum torque / Engine speed 596 N·m (420 lbf·ft) / 1,600 min-1(rpm) (ISO 9249 : With fan)
Starter 24 V / 5.0kW
Alternator 24 V / 60A
2.6.3 HYDRAULIC COMPONENTS

Hydraulic pump Variable displacement axial piston pump x 2 + gear pump x 1
Hydraulic motor (swing) Axial piston motor x 1
Variable displacement axial piston motor x 2 (with counterbalance

Hydraulic motor (travel)
valve)
Control Valve 8-spool control valve x 1
Cylinder (Boom, Arm, Bucket) Double action cylinder
Oil cooler Air-cooled type
2.6.4 WEIGHT
Fully equipped weight kg (lbs) 20,500 (45,200) 20,900 (46,080)
Upper structure kg (lbs) 9,470 (20,880) ←
Travel system
kg (lbs) 6,900 (15,210) 7,270 (16,030)
(600 mm {23.6in} grouser shoe)
Attachment
4,120 (9,080) ←
5.65m (18ft-6in) Boom + 2.94m kg (lbs)
0.8 m3 (1.05cu·yd) Bucket 0.8 m3 (1.05cu·yd) Bucket
(9ft-8in) Arm + Bucket
2-11
2.7 TYPE OF CRAWLER
Use 600mm (23.6in) 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.)
2.7.1 SK200-10 TYPE OF SHOE

Shoe width Overall width of crawler Ground pressure
Shape
mm (in) mm (ft-in) kPa (psi)
Grouser shoe 600 (23.6) 2,800 (9'2") 46 (6.7)
700 (27.6) 2,900 (9'6") 40 (5.8)
800 (31.5) 3,000 (9'10") 35 (5.1)
46 LINKS
2.7.2 SK210LC-10 TYPE OF SHOE

Shoe width Overall width of crawler Ground pressure
Shape
mm (in) mm (ft-in) kPa (psi)
Grouser shoe 600 (23.6) 2,990 (9'10") 46 (6.7)
700 (27.6) 3,090 (10'2") 40 (5.8)
800 (31.5) 3,190 (10'6") 35 (5.1)
46 LINKS
2-12
2.8 TYPE OF BUCKET

Outer width mm (ft-in) Availabili-
Heaped Struck Num- W or
ty Weight
Hoe bucket capacity m3 ber of w/o
With side Without side of face kg (lbs)
m3 (cu·yd) (cu·yd) cutter cutter tooth side cutter
shovel
0.80
0.59 720
(1.05) 1,160 (3'10") 1,060 (3'6") 5 W NO
(0.77) (1,590)
STD
0.93 0.67 780
1,300 (4'3") 1,200 (3'11") 5 W NO
(1.22) (0.88) (1,720)
2
1.05 0.75 770
1,460 (4'9") 1,360 (4'5") 6 W YES
(1.37) (0.98) (1,700)
2-13
2.9 COMBINATIONS OF ATTACHMENT
If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage to the arm and
bucket may occur.
• The marks listed below are specified as follows.

◎Standard: combination
○General: operation Excavation or loading of sand, gravel, and clay
△Light operation: Mainly loading of loose gravel (e.g., cultivation or loading of sand or gravel)
×Prohibited combination: Do not use this combination because this is not included in the warranty.
• When installing the attachment to this machine, install the genuine or KOBELCO recommended attachment.
Note that if a failure occurs in this machine or the attachment because of installation of an attachment other than
the specified attachment, it is not included in the manufacturer warranty.
Bucket Available Arm

Heaped capacity m3
Type Struck m3 (cu·yd) 2.94m (9ft-8in) arm
(cu·yd)
STD
0.59 (0.77) ◎
0.80 (1.05)
Hoe bucket
0.93 (1.22) 0.67 (0.88) ○
1.05 (1.37) 0.75 (0.98) ○
Breaker ― ― ○
Nibbler ― ― ○
2-14
2.10 ENGINE SPECIFICATION

2.10.1 SPECIFICATIONS
Engine model HINO J05E-TG
4cycle, water-cooled, OHC, and inline-vertical type, direct injection
Type
engine equipped with turbo charger with intercooler
Number of cylinder - Bore X Stroke 4-112mm (4.41in) diameter×130mm (5.12in)
Total displacement 5,123cc (313cu·yd)
Compression ratio 18.0 2

Rated output (ISO 9249: With fan) 114 kW (153 hp) at 2,000 min-1 (rpm)
Maximum torque (ISO 9249: With fan) 596 N·m (420 lbf·ft) at 1,600 min-1 (rpm)
No load high idle 2,170 to 2,230 min-1 (rpm)
No load low idle 800 min-1 (rpm)
Thermostat action Start 344 K (160F degrees) / Full open 358 K (185F degrees)
Firing order 1 -3 -4 -2
Valve clearance Open Close
0.3mm (0.012in) at 14 deg. before top 30 deg. after bottom

Intake valve
Valve clearance cool dead point dead point
0.45mm (0.018) at 54 deg. before top 13 deg. after top

Exhaust valve
cool dead point dead point
Starter capacity (V X Kw) 24 X 5.0

Generator capacity (Alternator) (V X A) 24 × 50
650 dia. (25.6 in) X suction type 7 fans, V-belt drive, pulley ratio 0.89
Cooling fan drive method
Full level 18L (4.76 gal)

Engine oil quantity Low level 15L (3.96 gal)
Total 20.5L (5.42 gal)
Dry weight Approximately 530kg (1,170 lbs)
Specific fuel consumption (at rated power) 208 g / kw·h (155 g / hp·h)
Allowable inclination(degrees) Front / Rear and Right / Left : 35
Dimension (overall length X overall width X overall 1.011mm×737mm×1.045mm

height) (3ft-4 in X 29.0 in X 3ft-5in)
Rotating direction Clockwise rotation when seeing from fan
2-15
2-16
［3. ATTACHMENT DIMENSIONS］
3. ATTACHMENT DIMENSIONS
3.2 BOOM......................................................................................................................................3-4
3.2.1 BOOM DIMENSIONAL DRAWING..........................................................................................3-4
3.2.2 BOOM MAINTENANCE STANDARD ......................................................................................3-5
3.3 ARM ........................................................................................................................................3-8
3.3.1 ARM DIMENSIONAL DRAWING.............................................................................................3-8
3.3.2 ARM MAINTENANCE STANDARD .......................................................................................3-10 3
3.4 BUCKET ................................................................................................................................3-13
3.4.1 BUCKET DIMENSIONAL DRAWING ....................................................................................3-13
3.4.2 BUCKET DIMENSIONAL TABLE..........................................................................................3-13
3.4.3 LUG SECTION DIMENSIONAL DRAWING ...........................................................................3-14
3.4.4 BOSS SECTION DIMENSIONAL DRAWING .........................................................................3-15
3-1
3-2

3-3
3.2 BOOM
3.2.1 BOOM DIMENSIONAL DRAWING
d2
J
SECTION X-X
Boom Dimensional Drawings
5.65m (18ft-6in) boom Standard specification
No. Name Dimensions: mm (ft-in)
A Boom length 5,650 (18'6")

B Boom foot width 670 (26.4")
C Boom end inner width 347 (13.7")
D Boom end outer width 482 (19")
E Height of boom cylinder rod pin 1,008.5 (3'4")
F Height of arm cylinder (head side) pin 1,203.5 (3'11")

G Distance between pins of boss R2,589 (8'6")
H Distance between pins of bracket R2,829.5 (9'3")
I Arm cylinder (head side) inner width 126 (4.96")
J Outer width of bracket on the boom cylinder (rod side) mounting 468 (18.4")
d1 Boom foot pin dia. 90 dia. (3.54")

d2 Boom cylinder (rod side) pin dia. 85 dia. (3.35")
d3 Pin dia. of boom end. 90 dia. (3.54")
d4 Arm cylinder (head side) pin dia. 85 dia. (3.35")
3-4
3.2.2 BOOM MAINTENANCE STANDARD

Clearance of pin and bushing on boom section
A
C
B
3
Clearance of pin and bushing on boom section
Unit:mm (in)
Standard value Clearance
No. Item Pin part No. Bushing Repair- Remedy

Pin dia. Standard Service
Pin dia. i.d. able
tolerance value limit
tolerance level
+ 0.020 + 0.216 + 0.236
ø 90 (+0.0008) (+0.0085) (+0.0093)
A Boom foot YN02B02495P2
(3.5433) - 0.020 + 0.071 + 0.051
(-0.0008) (+0.0028) (+0.0020)
+ 0.250 + 0.290
Boom 0
ø 85 (+0.0098) (+0.0114)
B cylinder YN02B02457P1 - 0.040
(3.3465) + 0.050 + 0.050
(Head side) (-0.0016) Replace
(+0.0020) (+0.0020) 2.0 2.5
bushing
+ 0.020 + 0.250 + 0.270 (0.08) (0.1)
Boom or pin
ø 85 (+0.0008) (+0.0098) (+0.0106)
C cylinder YN02B01721P1
(3.3465) - 0.020 + 0.050 + 0.030
(Rod side)
(-0.0008) (+0.0020) (+0.0012)
+ 0.030 + 0.250 + 0.280

Arm
ø 85 (+0.0012) (+0.0098) (+0.0110)
D cylinder YN02B02436P1
(3.3465) - 0.030 + 0.050 + 0.020
(Head side)
(-0.0012) (+0.0020) (+0.0008)
3-5
Clearance in thrust direction on the boom cylinder installation section
D
D C
B A
SECTION C-C
SECTION D-D
SECTION A-A
SECTION B-B
Clearance in thrust direction on the boom cylinder installation section
3-6
Unit:mm (in)
Clearance X adjusted with shim

Standard value Pin length
(total of both sides)
Sec. Item Repair- Remedy
Standard Service
No. Size able No. Size
value limit
level
Boom 670 (26.4) 0.5 (0.02) 839
A-A Boom foot L1 PL1
Upper frame 676 (26.6) or less (33.0)
2.0 2.5
Boom Boom cylinder 105 (4.13) (0.08) (0.10)
0.6 to 1.0 234
B-B cylinder L2 PL2
Upper frame 111 (4.37) (0.02 to 0.04) (9.2)
(Head side) Shim
adjust-
Boom Boom cylinder L3 105 (4.13)
0.6 to 2.0 3.0 4.0 736 ment
C-C cylinder PL3
Boom L3' 468 (18.4) (0.02 to 0.08) (0.12) (0.16) (29.0)
(Rod side)
Arm Arm cylinder 120 (4.72)

0.6 to 1.0 2.0 2.5 252
D-D cylinder
(Head side) Boom
L4
126 (4.96) (0.02 to 0.04) (0.08) (0.10)
PL4
(9.9) 3
3-7
3.3 ARM
3.3.1 ARM DIMENSIONAL DRAWING
VIEW J
SECTION X-X
SECTION Y-Y SECTION Z-Z
Arm dimensional drawing
3-8
2.94M (9ft-8in) Arm standard specification
Dimension Dimension
Code Part Name Code Part Name
mm (ft-in) mm (ft-in)
C Arm length 2,940 (9'8") M Boss width 342 (13.5")
Distance between pins of boss

D R874 (34.4") N Bracket inner width 126 (4.96")
and bracket
D1 I.D of boss ø110 (4.33") O Bracket inner width 111 (4.37")
D2 I.D of boss ø85 (3.35") P Idler link dimension 630 (24.8")
D4 I.D of boss ø105 (4.13") Q Bucket link dimension 610 (24")
Distance between pins of boss Height between pins of boss and

E R2,169 (7'1") R 31 (1.22")
and bracket center
Distance between pins of boss
F R420 (16.5") d1 Pin dia. ø80 (3.15")
and boss
Height between pins of boss and
665.5 (26.2") ø70 (2.76")
G
bracket
d2 Pin dia.
3
Height between pins of boss and
H 312 (12.3") d3 Pin dia. ø85 (3.35")
bracket
K Arm top end boss width 325 (12.8") d4 Pin dia. ø90 (3.54")
L Arm link section boss width 323 (12.7") d5 Pin dia. ø80 (3.15")
3-9
3.3.2 ARM MAINTENANCE STANDARD

Clearance of pin and bushing
E
F
D, D'
B
C
G
Clearance of pin and bushing on arm section
Unit:mm (in)
Standard value Clearance
No. Item Pin part No. Bushing Stand- Remedy

Pin dia. Standard Service
Pin dia. i.d. ard
tolerance value limit
tolerance value
+ 0.254 + 0.314
(+0.0100) (+0.0124)
A Arm point
- 0.020 + 0.083 + 0.103
ø80 (-0.0008) (+0.0033) (+0.0041)
YN12B02407P1
Bucket link (3.1496) - 0.060 + 0.241 + 0.301
(Connecting (-0.0024) (+0.0095) (+0.0119)
B
part of + 0.084 + 0.104
bucket) (+0.0033) (+0.0041)
+ 0.020 + 0.239 + 0.279

Idler link
ø70 (+0.0008) (+0.0094) (+0.0110)
C (Connecting YN12B11522P1
(2.7559) - 0.040 + 0.173 + 0.153
part of arm)
(-0.0016) (0.0018) (+0.0060)
+ 0.231 + 0.291
Bucket link
(+0.0091) (+0.0115)
D (Idler link
+ 0.020 + 0.161 + 0.161
connection) Replace
ø80 (+0.0008) (+0.0063) (+0.0063) 2.0 2.5
YN12B11520P1 bushing
(3.1496) - 0.040 + 0.250 + 0.290 (0.08) (0.01)
Bucket or pin
(-0.0016) (+0.0098) (+0.0114)
D' cylinder
+ 0.050 - 0.030
(Rod side)
(+0.0020) (-0.0012)
+ 0.030 + 0.250 + 0.280

Bucket
ø80 (+0.0012) (+0.0098) (+0.0110)
E cylinder YN12B11518P1
(3.1496) - 0.030 + 0.050 - 0.020
Head side
(-0.0012) (+0.0020) (+0.0008)
+ 0.030 + 0.250 + 0.280

Arm cylinder ø85 (+0.0012) (+0.0098) (+0.0110)
F YN02B02436P1
(Rod side) (3.3465) - 0.030 + 0.050 + 0.020
(-0.0012) (+0.0020) (+0.0008)
+ 0.020 + 0.235 + 0.255

ø90 (+0.0008) (+0.0093) (+0.0100)
G Arm foot YN12B11620P2
(3.5433) - 0.020 + 0.074 + 0.054
(-0.0008) (0.0029) (+0.0021)
3-10
Clearance of arm and cylinder installing sections in thrust direction
E
D, D'
B
F
E
B C
D, D' F
A A
C G
G
X1 L1
X3 L3 PL5
X6 L6
X5 L5
PL1 PL3
3
PL6
SECTION A-A SECTION C-C SECTION E-E SECTION F-F
PL7
X2 L2 X7 L7
X4 L4
X4' L4'
PL2 PL4
SECTION B-B SECTION D-D SECTION G-G
Clearance of arm and cylinder installing sections in thrust direction
3-11
Unit:mm (in)
Standard Clearance X adjusted with shim

Pin length
value (total of both sides)
Sec. Item Repair- Remedy
Standard Service
No. Size able No. Size
value limit
level
325
Arm
(12.79) 0.5 to 1.5
A-A Arm point L1 ― PL1
327 (0.02 to 0.06)
Bucket
(12.87) 481
325 (18.9)
Link side
(12.79)
B-B Bucket link L2 ― ― PL2
327
Bucket
(12.87)
Idler link 323 2.5

Arm 0.5 1.0
C-C (Arm L3 (12.72) (0.10) PL3
(0.02) (0.04)
connection) Link side ―
Bucket link Rod side ―

D-D (Idler link L4 323 428
connection) Link side (16.9)
(12.72)
0.6 to 1.0 2.0 Shim
105 PL4
Rod side (0.02 to 0.04) (0.08) adjust-
Bucket link (4.13)
ment
D'-D' L4'
(Rod side) 11 1
Bucket link
(4.37)
105
Head side
Bucket cylinder (4.13) 227
E-E L5 PL5
(Head side) 11 1 (8.9)
Arm
(4.37) 0.6 to 2.0 3.0 4.0
120 (0.02 to 0.08) (0.12) (0.16)
Rod side
Arm cylinder (4.72) 252
F-F L6 PL6
(Rod side) 126 (9.9)
Arm
(4.96")
342
Arm
(13.46) 0.5 1.0 2.5 508
G-G Arm foot L7 PL7
347 (0.02) (0.04) (0.10) (20.0)
Boom
(13.66)
3-12
3.4 BUCKET
3.4.1 BUCKET DIMENSIONAL DRAWING
Hoe bucket
Bucket dimensional drawing
No. Name No. Name

A Distance between pin and bracket G Inner width of bucket bottom
B Distance between bucket pin and tooth end H Bucket outer width of front side
C Inner width of bucket top end I Pitch between teeth
D Inner width of lug Io Pitch between teeth
E Inner width of bracket d1 Outer dia. of bushing
F Outer width of side cutter d2 Pin dia.
3.4.2 BUCKET DIMENSIONAL TABLE

Unit:mm (ft-in)
Type Hoe bucket

Capacity [STD] 0.80 m3 (1.05 cu·yd) 0.93 m3 (1.22 cu·yd)
A R430 (16.9") ←
B R1,440 (4'9") ←
C 1,003 (3'3") 1,146 (3'9")
D 399 (15.7") ←
E 327 (12.9") ←
F 1,157 (3'10") 1,300 (4'3")
G 938 (36.9") 1,081 (3'7")
H 1,057 (3'6") 1,200 (3'11")
I 224 (8.82") 260 (10.2")
IO 224 (8.82") 260 (10.2")
d1 ø95 (3.74") ←
d2 ø80 (3.15") ←
3-13
3.4.3 LUG SECTION DIMENSIONAL DRAWING

Unit : mm (ft-in)
X B
J
A
Installation of three bolts M16 should be possible. M BOSS

28
(1.10) Apply rust prevention oil
19
(0.748)
3-G
bb
F
N
D E
H Insert this pin flush BOSS

SHIM t=1 (0.039") with surface
(Five shims arm SECTION X-X
installed at shipping) DETAIL bb
Dimension of lug section
Unit:mm (ft-in)
Type of bucket Hoe bucket

Capacity of bucket [STD] 0.80 m3 (1.05 cu·yd) 0.93 m3 (1.22 cu·yd)
A Pin hole dia. ø80 (3.15") ←
B Lug plate thickness 25 (0.984") ←
D Hole dia. ø95 (3.74") ←
E Spring pin dia. ø13 (0.512") ←
F Boss outer dia. ø180 (7.09") ←
G Screw dia. M16 ←
H Boss width. 25 (0.984") ←
J Boss outer dia. ø170 (6.69") ←
M Boss width 36 (1.42") ←
N Screw hole P.C.D 140 (5.51") ←
3-14
3.4.4 BOSS SECTION DIMENSIONAL DRAWING

Unit : mm (ft-in)
bb
H 5
(0.197" )
- G
I
m 0 .2 0 8 "
.0 0 . x
(0 R a
R 0 .0
ax
08 2
m
(
")
.0 .5
- A - B - C- D
(0 -C 0
")
)
20
30r
2
15 (0.591")
3
DETAIL bb
E
Dimension of boss section
Unit:mm (ft-in)
Type of bucket Hoe bucket

Capacity of bucket [STD] 0.80 m3 (1.05 cu·yd) 0.93 m3 (1.22 cu·yd)
øA 114.3 (4.50") ←
øB 84 (3.31") ←
øC 105.5 (4.15") ←
øD 111.5 (4.39") ←
E 23 (0.91") ←
F 38 (1.50") ←
øG 17 (0.669") ←
H 13 (0.512") ←
I 2.5 (0.098") ←
3-15
3-16
［4. TOOLS］
4. TOOLS
4.2 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS ..........................................................4-4
4.3 SCREW SIZE AND NOMINAL SIZE OF TOOL ...........................................................................4-6
4.3.1 CAPSCREW (HEX HEAD BOLT) ............................................................................................4-6
4.3.2 CAPSCREW (HEX HEAD SOCKET BOLT) .............................................................................4-6
4.3.3 SET SCREW (HEX HEAD SOCKET SET SCREW) ..................................................................4-6
4.4 TIGHTENING TORQUE FOR HOSE AND FITTING ....................................................................4-7
4.4.1 JOINT (O-RING TYPE)...........................................................................................................4-7
4.4.2 HYDRAULIC HOSE (30 DEG. FLARE TYPE) ..........................................................................4-7
4.4.3 ORS FITTNIG ........................................................................................................................4-7
4.4.4 SPLIT FLANGE .....................................................................................................................4-7
4.5 TIGHTENING TORQUES FOR NUTS AND SLEEVES ................................................................4-8
4.6 PLUG.......................................................................................................................................4-9 4
4.6.1 PLUG FOR BYTE TYPE TUBE FITTING .................................................................................4-9
4.6.2 PLUG FOR HYDRAULIC EQUIPMENT .................................................................................4-10
4.7 SPECIAL SPANNER FOR TUBE .............................................................................................4-12
4.8 SPECIAL TOOLS....................................................................................................................4-13
4.9 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND....................4-15
4.10 SUCTION STOPPER ............................................................................................................4-16
4.10.1 COMPONENTS..................................................................................................................4-16
4.10.2 DIMENSION.......................................................................................................................4-16
4.11 COUNTER WEIGHT LIFTING JIG..........................................................................................4-17
4.12 ENGINE MOUNTING PEDESTAL ..........................................................................................4-18
4.13 TRACK SPRING SET JIG .....................................................................................................4-19
4-1
［4. TOOLS］
4-2
［4. TOOLS］

4-3
［4. TOOLS］
4.2 TIGHTENING TORQUES FOR CAPSCREWS AND

NUTS
Tables Table "Metric coarse thread (Not plated)" and Table "Metric fine thread (Not plated)" 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.
Insufficient tightening may lead to a loosening or loss of bolts. Always tighten bolts to proper torques.
Tightening torque for metric coarse threads (not plated)
Unit : N·m (lbf·ft)
Strength
4.8T 7T 10.9T
classification
Size
Use No Oil No Oil No Oil
classification lubrication lubrication lubrication lubrication lubrication lubrication
4.4±0.5 3.7±0.4 9.6±1.0 8.1±0.8 17.4±1.8 14.7±1.5
M6 P=1
(3.2±0.4) (2.7±0.3) (7.1±0.7) (6.0±0.6) (12.8±1.3) (10.8±1.1)
10.7±1.1 9.0±0.9 23.5±2.0 19.6±2.0 42.2±3.9 35.3±3.9

M8 P=1.25
(7.9±0.8) (6.6±0.7) (17.3±1.5) (14.5±1.5) (31.1±2.9) (26.0±2.9)
21.6±2.0 17.9±1.8 46.1±4.9 39.2±3.9 83.4±8.8 70.6±6.9

M10 P=1.5
(15.9±1.4) (13.2±1.3) (34.0±3.6) (28.9±2.9) (61.5±6.5) (52.1±5.1)
36.3±3.9 31.4±2.9 79.4±7.8 66.7±6.9 143±15 121±12

M12 P=1.75
(26.8±2.9) (23.2±2.1) (58.6±5.8) (49.2±5.1) (105±11) (89.2±8.9)
57.9±5.9 49.0±4.9 126±13 106±10 226±20 191±19

M14 P=2
(42.7±4.4) (36.1±3.6) (92.9±9.6) (78.2±7.4) (167±15) (141±14)
88.3±8.8 74.5±6.9 191±20 161±16 343±39 284±29

M16 P=2
(65.1±6.5) (55.0±5.1) (141±15) (119±12) (253±29) (209±21)
122±12 103±10 265±29 226±20 481±49 402±39

M18 P=2.5
(90.0±8.9) (75.8±7.2) (195±21) (167±15) (355±36) (297±29)
172±17 144±14 373±39 314±29 667±69 559±59

M20 P=2.5
(127±13) (106±10) (275±29) (232±21) (492±51) (412±44)
226±20 192±20 500±49 422±39 902±88 755±78

M22 P=2.5
(167±15) (142±15) (369±36) (311±29) (665±65) (557±58)
294±29 235±29 637±69 520±49 1160±118 941±98

M24 P=3
(217±21) (173±21) (470±51) (383±36) (856±87) (694±72)
431±39 353±39 941±98 765±78 1700±167 1370±137

M27 P=3
(318±29) (260±29) (694±72) (564±58) (1250±123) (1010±101)
588±59 490±49 1285±127 1079±108 2300±235 1940±196

M30 P=3.5
(434±44) (361±36) (948±94) (796±80) (1700±173) (1430±145)
794±78 667±69 1726±177 1451±147 3110±314 2610±265

M33 P=3.5
(586±58) (492±51) (1270±131) (1070±108) (2290±232) (1930±195)
1030±98 863±88 2226±226 1863±186 4010±402 3360±333

M36 P=4
(760±72) (637±65) (1640±167) (1370±137) (2960±297) (2480±246)
4-4
［4. TOOLS］
Tightening torques for metric fine threads (not plated)
Unit : N·m (lbf·ft)
Strength
4.8T 7T 10.9T
classification
Size
Use No Oil No Oil No Oil
classification lubrication lubrication lubrication lubrication lubrication lubrication
11.3±1.1 9.5±1.0 24.5±2.0 20.6±2.0 44.1±3.9 37.3±3.9
M8 P=1
(8.3±0.8) (7.0±0.7) (18.1±1.5) (15.2±1.5) (32.5±2.9) (27.5±2.9)
22.6±2.0 18.7±1.9 48.1±4.9 41.2±3.9 87.3±8.8 73.5±6.9

M10 P=1.25
(16.7±1.5) (13.8±1.4) (35.5±3.6) (30.3±2.9) (64.4±6.5) (54.2±5.1)
39.2±3.9 33.3±2.9 85.3±8.8 71.6±6.9 154±16 129±13

M12 P=1.25
(28.9±2.9) (24.6±2.1) (62.9±6.5) (52.8±5.1) (114±12) (95.2±9.6)
92.2±8.8 77.5±7.8 196±20 169±17 363±39 304±29

M16 P=1.5
(68.0±6.5) (57.2±5.8) (145±15) (125±13) (268±29) (224±21)
186±19 155±16 402±39 333±29 726±69 608±59

M20 P=1.5
(137±14) (114±12) (297±29) (246±21) (535±51) (448±44)
314±29 265±29 686±69 569±59 1240±118 1030±98

M24 P=2
(232±21) (195±21) (506±51) (420±44) (915±87) (760±72)
637±59 530±49 1390±137 1157±118 2500±255 2080±206

M30 P=2
(470±44) (391±36) (1030±101) (853±87) (1840±188) (1530±152)
853±88 706±70 1860±186 1550±155 3350±334 2790±275

M33 P=2
(629±65) (521±52) (1370±137) (1140±114) (2470±246) (2060±203)
4
1070±108 892±88 2330±226 1940±196 4200±422 3500±353
M36 P=3
(789±80) (658±65) (1720±167) (1430±145) (3100±311) (2580±260)
4-5
［4. TOOLS］
4.3 SCREW SIZE AND NOMINAL SIZE OF TOOL

4.3.1 CAPSCREW (HEX HEAD BOLT)
Nominal B mm Nominal B mm
screw size screw size
(d) Tool size (d) Tool size
M6 10 M36 55
M8 13 M42 65
M10 17 M45 70
d
M12 19 M48 75
(M14) 22 M56 85
M16 24 (M60) 90
(M18) 27 M64 95 B
M20 30 (M68) 100
(M22) 32 M72 105
M24 36 M76 110
(M27) 41 M80 115
M30 46
4.3.2 CAPSCREW (HEX HEAD SOCKET BOLT)

(d) Tool size (d) Tool size
(M3) 2.5 M20 17

(M4) 3 (M22) 17 d
(M5) 4 M24 19
M6 5 (M27) 19
M8 6 M30 22
B
M10 8 M36 27
M12 10 M42 32
M14 12 (M45) 32
M16 14 M48 36
(M18) 14 M52 36
4.3.3 SET SCREW (HEX HEAD SOCKET SET SCREW)

(d) Tool size (d) Tool size d
M2.5 1.27 M8 4
M3 1.5 M10 5
M4 2 M12 6
M5 2.5 M16 8 B
M6 3 M20 10
4-6
［4. TOOLS］
4.4 TIGHTENING TORQUE FOR HOSE AND FITTING

4.4.1 JOINT (O-RING TYPE)
Size of screw diameter Wrench Tightening torque
(PF) (mm) N·m (lbf·ft)
1/8 14 17±2 (13±1.5)
1/4 19 36±2 (27±1.5)
3/8 22 74±5 (55±4)
1/2 27 108±9.8 (80.0±7)
3/4 36 162±9.8(119±7)
1 41 255±9.8(188±7)
4.4.2 HYDRAULIC HOSE (30 DEG. FLARE TYPE)

Size of screw diameter Wrench Tightening torque
(PF) (mm) N·m (lbf·ft)
UNION NUT
1/8 17 15±2.0 (11±1.5)
1/4 19 29±4.9 (21±3.6)
3/8 22 49±4.9 (36±3.6)
1/2 27 78±4.9 (58±3.6) 4

3/4 36 118±9.8 (87±7.2)
1 41 137±15 (101±11)
4.4.3 ORS FITTNIG

Tightening torque
Unified screw size Opposing flats
N·m (lbf·ft) CONNECTOR O-R ING FITTING
1-14 UNS 30, 32 137±14 (101±10)
36 177±18 (131±13)
1 3 / 16-12 UN
41 206±21 (152±15)
41 206±21 (152±15)
1 7/ 16-12 UN NUT
46 206±21 (152±15)
4.4.4 SPLIT FLANGE

Tightening torque N·m (lbf·ft)
Nominal Standard Hi pressure
size Bolt Bolt
pressure series series
size size
20.6 MPa (2987 psi) 41.2 MPa (5974 psi)
3/4 33.9±5.6 (25±4) M10 39.5±5.6 (29±4) M10
1 42.4±5.6 (31±4) M10 62.2±5.6 (46±4) M12
11 / 4 55.1±7.1 (41±5) M10 93.3±8.4 (69±6) M14
11 / 2 70.6±8.4 (52±6) M12 169±11 (125±8) M16
2 81.9±8.4 (60±6) M12 282±11 (208±8) M20
4-7
［4. TOOLS］
4.5 TIGHTENING TORQUES FOR NUTS AND SLEEVES

Table below indicates standard tightening torques applicable to cases where no particular note is given.
Overtightening or undertightening of nuts and sleeves in FLARELESS JOINT may develop oil leaks through pipe
connections.
Always tighten nuts and sleeves to proper torques.
Working Opposing No lubrication:

Manufacturer's Tube size
pressure flats Tightening torque
name OD X thickness mm (in)
MPa (psi) (HEX) mm N·m (lbf·ft)
ø10 X 1.5 (0.394 X 0.059) 19 49.0±9.8 (36±7.2)
ø15 X 2.0 (0.591 X 0.079) 27 118±12 (87±8.7)
Nippon A.M.C. 29.4 (4270) ø18 X 2.5 (0.709 X 0.098) 32 147±15 (110±11)
ø22 X 3.0 (0.866 X 0.118) 36 216±22 (160±16)
ø28 X 4.0 (1.10 X 0.157) 41 275±27 (200±20)
Ihara Science 29.4 (4270) ø35 X 5.0 (1.38 X 0.197) 55 441±44 (330±33)
SLEEVE NUT
B
d
d
Parts No. Opposing Parts No.

Tube size Tube size
flats
ød Ihara Science Nippon A.M.C. ød Ihara Science Nippon A.M.C.
(HEX) mm
6 ZF96S06000 — 6 14 ZF96N06000 —
8 ZF96S08000 — 8 17 ZF96N08000 —
10 ZF96S10000 ZA93S10000 10 19 ZF96N10000 ZA93N10000
12 ZF96S12000 — 12 22 ZF96N12000 —
15 ZF96S15000 ZA93S15000 15 27 ZF96N15000 ZA93N15000
18 ZF96S18000 ZA93S18000 18 32 ZF96N18000 ZA93N18000
22 ZF96S22000 ZA93S22000 22 36 ZF96N22000 ZA93N22000
28 ZF96S28000 ZA93S28000 28 41 ZF96N28000 ZA93N28000
32 ZF96S32000 — 32 50 ZF96N32000 —
35 ZF96S35000 ZA93S35000 35 55 ZF96N35000 ZA93N35000
38 ZF96S38000 — 38 60 ZF96N38000 —
4-8
［4. TOOLS］
4.6 PLUG
4.6.1 PLUG FOR BYTE TYPE TUBE FITTING
Cap nut (Joint plug)
Applicable Opposing
tube Cap nut parts No. T screw flats
O.D:A H1 H
6 ZF83H06000 M12 X 1.5 14 14
A
8 ZF83H08000 M14 X 1.5 17 17
10 ZF83H10000 M16 X 1.5 17 19
12 ZF83H12000 M18 X 1.5 19 22
15 ZF83H15000 M22 X 1.5 24 27
18 ZF83H18000 M26 X 1.5 27 32
22 ZF83H22000 M30 X 1.5 32 36
H1 T s cre w H
28 ZF83H28000 M36 X 1.5 38 41
Plug (Tube plug)
Applicable
tube Plug parts No.
O.D:A 4
6 ZF83P06000
8 ZF83P08000
A
10 ZF83P10000
12 ZF83P12000
15 ZF83P15000
18 ZF83P18000 S le e ve Nut
Type
22 ZF83P22000
joint body
28 ZF83P28000
Nut
Applicable
Opposing
tube Nut parts No. d screw
flats
O.D:A
6 ZF93N06000 M12 X 1.5 14
8 ZF93N08000 M14 X 1.5 17
10 ZF93N10000 M16 X 1.5 19
12 ZF93N12000 M18 X 1.5 22
A
d s cre w
15 ZF93N15000 M22 X 1.5 27
18 ZF93N18000 M26 X 1.5 32
22 ZF93N22000 M30 X 1.5 36
28 ZF93N28000 M36 X 1.5 41
32 ZF93N32000 M42 X 1.5 50
35 ZF93N35000 M45 X 1.5 55
38 ZF93N38000 M48 X 1.5 60
4-9
［4. TOOLS］
4.6.2 PLUG FOR HYDRAULIC EQUIPMENT

PF screw
PF
Plug parts No. B mm O-ring parts No. Nominal O-ring B
screw O-ring
PF1/4 ZE72X04000 19 ZD12P01100 1B P11
PF3/8 ZE72X06000 22 ZD12P01400 1B P14
PF1/2 ZE72X08000 27 ZD12P01800 1B P18
PF3/4 ZE72X12000 36 ZD12P02400 1B P24
PF1 ZE72X16000 41 ZD12P02900 1B P29 P F s cre w
PT screw
PT screw Plug parts No. B mm

PT1/8 ZE82T02000 5
B
PT1/4 ZE82T04000 6 P T s cre w
PT3/8 ZE82T06000 8
PT1/2 ZE82T08000 10
PT3/4 ZE82T12000 14
PT1 ZE82T16000 17
PT1 1/4 ZE82T20000 22
PT1 1/2 ZE82T24000 22
Plug for(F)flare hose
PF screw Plug parts No. B mm

P F s cre w
PF1/4 2444Z2728D1 14
PF3/8 2444Z2728D2 17
60
PF1/2 2444Z2728D3 22
PF3/4 2444Z2728D4 27
PF1 2444Z2728D5 36 Oppos ing fla ts B
PF screw Plug parts No. E mm F mm

PF1/4 2444Z2729D1 14 19
PF3/8 2444Z2729D2 17 22
PF
60
PF1/2 2444Z2729D3 23 27 screw
PF3/4 2444Z2729D4 27 36
PF1 2444Z2729D5 36 41
Opposing Oppos ing
PF1 1/4 2444Z2729D6 40 50 flats F flats E
4-10
［4. TOOLS］
Plug for ORS joints
Male
Opposing
Screw Applicable O-ring Nominal
Plug parts No. flats
size A hose O.D parts No. O-ring
(HEX)
1-14UNS ø21.7 YN01H01001P1 27 ZD12A01600 1B A16

1 3/16-12UN ø27.2 YN01H01002P1 36 ZD12A01800 1B A18
1 7/16-12UN ø34.0 YN01H01003P1 41 ZD12A02100 1B A21
Female
Applicable Opposing
Screw size A Plug parts No.
hose O.D flats (HEX)
1-14UNS ø21.7 YN01H01004P1 32

A
1 3/16-12UN ø27.2 YN01H01005P1 36
1 7/16-12UN ø34.0 YN01H01006P1 41
Plug for half clamp
For standard pressure : 20.6 MPa (2990 psi) 4

Nominal Plug O-ring
C mm D mm G mm H mm 4-oH
size part No. parts No.
25.53 to
1/2 ZE12Q08000 38.10 17.48 9 45Z91D2
25.40
31.88 to
3/4 ZE12Q12000 47.63 22.23 11 ZD12P02600
31.75 C
39.75 to
1 ZE12Q16000 52.37 26.19 11 ZD12P03400
39.62
44.58 to
1 1/4 ZE12Q20000 58.72 30.18 11 ZD12P03800 D
44.45
For high pressure : 41.2 MPa (5970 psi)
Nominal Plug O-ring

C mm D mm G mm H mm
size part No. parts No.
25.53 to
1/2 ZE13Q08000 40.49 18.24 9 2445Z831D1
25.40 G
31.88 to
3/4 ZE13Q12000 50.80 23.80 11 ZD12P02600
31.75
39.75 to
1 ZE13Q16000 57.15 27.76 13 ZD12P03400
39.62
44.58 to
1 1/4 ZE13Q20000 66.68 31.75 15 ZD12P03800
44.45
4-11
［4. TOOLS］
4.7 SPECIAL SPANNER FOR TUBE

Applicable tube Width across flats of
Parts No. Drawing of a special spanner mm (in)
diameter mm (in) nut (mm)
70(2 .76)
16 8 PART-No. 22
15 (0.591) 2421T160 27 (0.3 15)
(0.6 30) (0.8 66)
HEX27
40(1 .57) 12.7
(0.500 )
70(2 .76)
42(1 .65)
18 (0.709) 2421T138 32 19 PART-No. 22

(0.7 48)
(0.8 66)
HEX32 12.7
22(0 .866)
(0.500 )
70(2 .76)
11.5 (0.453)
22 (0.866) 2421T130 36 23 PART-No. 22

(0.9 06) (0.8 66)
48(1 .89)
HEX36 12.7
(0.500 )
60(2 .36) 109 (4.29)

14.5 (0.571)
28 (1.10) 2421T115 41 29 PART-No. 22

(1.1 42) (0.8 66)
12.7
HEX41 (0.500 )
28 (1.10) 2421T231 46 PART-No.
32 (1.26) 2421T232 50 PART-No.
HEX50
35 (1.38) 2421T314 55 PART-No.
HEX55
4-12
［4. TOOLS］
4.8 SPECIAL TOOLS

No. Tools name Tools No. Shape Applicabie
Allen wrench
ZT22A10000 Pump
1 Nominal
suction
B:10, C:11.3
Commercial tool len gth (L1) - cut le ngth = Re quire d le ngth

40 (1.57") - 10 (0.39") = 30 (1.18")
Spanner or socket
2 General tools Pump install
Nominal size:17
CUT
Spanner ZT12A36000 Swing motor

3
Nominal S:36 A,B port
Com merc ia l tool oute r width (D) - cut le ngth = Re quire d le ngth
81 (3.19") - 16 (0.63") = 65 (2.56")
Additiona l M10 X 22
ta pping
4
for M10 e ye bolt
For slinging
Plug ZE72X12000
4 the swing
PF3/4
motor
PF3/4 O-ring
M12 Eye bolt
Eye bolt ZS91C01200 For slinging

5 M12 X 22 or commercial the swing
equivalent motor
22
M12
M8 Eye bolt
Plug ZF83P22000
(Nominal size 22)
6 Reference Re fe re nce nut Flare hose
Eye bolt ZS91C00800
Nut ZF93N22000
M8 X 18
Addtiona l ta pping
4-13
［4. TOOLS］
No. Tools name Tools No. Shape Applicabie
M8 Eye bolt
M8 X 18
Additional
threading
Plug YN01H01001P1
Nominal 1-14UNS
7 HEX 27 Flare hose
Eye bolt ZS91C00800
1-14UNS
M8 X 18 M8 Eye bolt
Additional
threading
Plug
YN01H01002P1
Nominal 1 3/16-
8 12UN HEX 36 Flare hose
ZS91C00800
Eye bolt
1 3/16-12UN
M12 Eye nut
Plug ZE25F08000
PF1/2 We ld For slinging
9
Coupling the swivel joint
half Coupling ha lf
PF 1/2
5.49
TORX driver
For instrument
(with tamper proof) Point shape
10 — panel cover
T30
(RH)
(For M6)
4-14
［4. TOOLS］
4.9 APPLICATION OF SCREW LOCKING COMPOUND

AND SEALING COMPOUND
For general use
Manufacturer
Service Features
Loctite Three-Bond
Low
#242 1360K
strength
Screw locking Middle

#262 1374
compound strength
High
#271 1305
strength
Sealing compound #515 1215 Sealing
For specific location

No. Use Manufacturer Name Equivalent Applicable
(Manufacturer ; Loctite)
# 1901 Anti-seizure Cylinder
Three-Bond # 1215 gray # 5699 Swing motor
# 1211 white # 5301J Swing motor

4
# 1303B # 211 Main pump
Sealing (Manufacturer ; Three-Bond)

compound Loctite Main pump
1 # 222 # 1344N
&
adhesive # 277 # 1307N Pilot valve
(Manufacturer ; Three-Bond)
Loctite Parmatex 98D # 1121 Hydrualic oil tank and hose
Sumitomo
Chemical Co., Cyano Bond P0-1 Swing bearing and seal
Ltd.
Shell petroleum Shell Alvania EP2 New Molyknock Grease 2 Grease bath of swing bearing
4-15
［4. TOOLS］
4.10 SUCTION STOPPER

4.10.1 COMPONENTS
No. NAME PARTS No. Q'TY

SUCTION STOPPER ASSY 24100P978F2
1 ROD 2420T4660D1 1
1
2 NUT ZN16C08007 1
3 COVER 2414T2123D2 1
4 O-RING 45Z91D6 1
2
3
Components of suction stopper
4.10.2 DIMENSION
50
(1.97")
R
(1 8 O113 (4.45")
.3
15" 2
) M8 NUT (0.08")
O8 (1.315")
600 (23.6")
+0.5
M8 O100 0
(0.787")
(3.94 +0.0197
0 )
O108
20
(4.25")
ROD COVER
Dimension of suction stopper
4-16
［4. TOOLS］
4.11 COUNTER WEIGHT LIFTING JIG

Standard eye bolt
Size Vertizal lifting load
Part No.
d L kg (lbf)
M8 15 ZS91C00800 80 (176)
M10 18 ZS91C01000 150 (331)
M12 22 ZS91C01200 220 (485)
M16 27 ZS91C01600 450 (992)
M20 30 ZS91C02000 630 (1390)
M24 38 ZS91C02400 950 (2090)

L
L
M30 45 ZS91C03000 1500 (3310) dd
M36 55 ZS91C03600 2300 (5070)
M42 65 ZS91C04200 3400 (3400) Eye bolt
M48 70 ZS91C04800 4500 (9920)
4-17
［4. TOOLS］
4.12 ENGINE MOUNTING PEDESTAL

245 (9.65) Material : Wood
Unit ; mm (inch)
6 1
175(6.89)
375 (14.8)
2
400 (15.7)
240 (9.45)
(4.72) (4.72)
750 (29.5)
120 120
375 (14.8)
175(6.89)
6 6
744 (29.3) 100
(3.94)
945 (37.2)
6 6
275 300
(10.8) (11.8)
2 X 1 piece 4 X 1 piece 1 X 1 piece

400 (15.7) 670 (26.4)
200 (7.9) 430 (16.9)
25
55 (0.98)120
(2.2) (4.72)
5(0.2)
50(2.0)
352 (13.9)
250(9.84)
0
213(8.39)
750 (29.5)
R5 .0)
200(7.87)
t 50 (2
(2.0) t 24 (0.95)
t 24 (0.95)
5 X 1 piece
3 X 1 piece 670 (26.4)
400 (15.7) 120
(4.72)
200 (7.87) 945 (37.2)
55 145
352 (13.9)
(2.2) (5.71)
6 X 5 pieces
R5
352 (13.9)
100(3.94)
(2. 0
(3.5)
10(0.39)
90
t 24 (0.95) 0)
t 24
10(0.39)
(7.48)
(0.95)
190
t50
(2.0)
Engine stand
4-18
［4. TOOLS］
4.13 TRACK SPRING SET JIG

M30
Retainer nut
Retainer plate
)
.6"
(12
(27.6")
Stand
(15.0")
Hydraulic jack
Base 4
Track spring set jig
4-19
［4. TOOLS］
4-20
［5. STANDARD MAINTENANCE TIME TABLE］
5. STANDARD MAINTENANCE TIME

TABLE
5.2 PREFACE ................................................................................................................................5-4
5.3 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ....................5-5
5.3.1 Attachment(01) .....................................................................................................................5-6
5.3.2 Cab & guard(02)....................................................................................................................5-8
5.3.3 Swing frame(03)..................................................................................................................5-10
5.3.4 Travel system(04) ...............................................................................................................5-15
5.3.5 Electric equipment(06)........................................................................................................5-17
5-1
5-2

5-3
5.2 PREFACE
Working Conditions
• Workers:
More than one worker shall be 1st class service technician (having five years or more of field experience and
having received training in the operation).
• Equipment:
Jigs, tools, apparatuses and testers used in field service work shall be available commercially.
The maintenance plant shall be equipped with a service shop, a crane and inspection apparatuses necessary for
specific self inspection activities.
• Place:
A flat land where work may be performed and to which a service car or a truck crane is accessible.
Range of standard maintenance time

• Standard maintenance time=Direct maintenance time X Preparation time
• Direct maintenance time: Net time actually spent for maintenance
• Spare time:Time needed to move machines for service, prepare safety operations, discuss work, and process
the needs of the body.
Extra time (not included in the standard service time)

• Repair time:Machining, sheet metal, welding, melt cutting, folding and extracting bolts, servicing parts, and
painting.
• tems excluded from service time because of uncertainty in time:
Receiving a vehicle into shop, transfer, delivery, inspection on completion, investigation of causes of faults,
diagnosis, and inspection.
• Indirect time:
Time for; field work, preparation of necessary parts before leaving for work, return for field work, waiting time
because of user's convenience in the field, paper work after returning to shop, and preparation of bills.
• Special time: Work at early morning, at midnight and on holidays are to be calculated separately.
• Separate calculation: The operating time for service cars, trucks with a crane and crane trucks.
Applicable machine for estimation of standard maintenance time

• Standard machine
• A well maintained and controlled machine with a standard combination of attachments which is used in a general
environment.
5-4
5.3 STANDARD WORKING TIME TABLE FOR THE

MAINTENANCE OF EXCAVATOR
The time required for works specified in this Chapter shows the total time for maintenance.
Standard maintenance time table

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

No. GROUP REMARKS
Indicates installing, removing, replacement and
01 Attachment
overhaul.
02 Cab & Guard
03 Swing frame 5
04 Travel system
Electric Indicates the installing, removing and

06
equipments replacement of single items.
Indicates overhaul of the single engine.

09 E/G relation
(Materials prepared by manufacturer)
Conditions for standard service time of the engine

• Tools designated by E/G maker are used
• Genuine parts are changed
• Correct working procedures are observed.
5-5
5.3.1 Attachment(01)
Group Work to Unit:
Location Unit Remarks
No. be done Hour
See Paragraph "BUCKET" in Chapter
00 Bucket related parts
"ATTACHMETNTS"
Detach/
01 Bucket assy 1 pc. Include adjustment 0.6
attach
02 • Bucket attaching and detaching position Preparation 1 pc. 0.1
Detach/
03 • Bucket attaching pin 1 Include stopper pin. 0.1
attach
Detach/
04 • Bucket drive pin 1 0.1
attach
05 • Bucket sling and movement Preparation 1 pc. 0.2
06 • Bucket (single) O/H 1 pc. Not include attaching and detaching 2.4
07 • Tooth Replace 1 pc. 0.6
08 • Side cutter Replace 1 pc. 1.2
09 • Bushing Replace 1 pc. 0.6

See Paragraph "ARM" in Chapter
10 Arm related parts
"ATTACHMETNTS"
Detach/
11 Arm assy 1 pc. 1.2
attach
• Bucket cylinder attaching and detaching
12 Preparation 1 pc. 0.4
position and piping
Detach/
13 • Bucket cylinder rod pin 1 pc. Include stopper pin. 0.1
attach
Detach/
14 • Bucket cylinder head pin 1 pc. Include stopper pin. 0.1
attach
Detach/
15 • Bucket cylinder assy 1 pc. 0.1
attach
Detach/
16 • Arm cylinder rod pin 1 pc. Include stopper pin. 0.1
attach
Detach/
17 • Boom top pin 1 pc. Include wire stop pin 0.1
attach
Detach/
18 • Arm sling and movement 1 pc. 0.2
attach
See Paragraph "BOOM" in Chapter
30 Boom related parts
"ATTACHMETNTS"
Detach/
31 • Boom assy 1 pc. 1.4
attach
32 • Boom attaching and detaching position Preparation 1 pc. 0.1
33 • Boom cylinder temporary slinging Preparation 2 pcs. 0.2

Detach/
34 • Boom cylinder rod pin 2 Include stopper pin. 0.2
attach
Detach/
35 • Boom cylinder piping 2 pcs. 0.2
attach
Detach/
36 • Arm & bucket piping 1 pc. 0.2
attach
Detach/
37 • Boom assy temporary slinging 1 pc. 0.1
attach
5-6
Group Work to Unit:

No. be done Hour
Detach/
38 • Boom foot pin 1 Include stopper pin. 0.2
attach
Detach/
39 • Boom assy slinging 1 pc. 0.2
attach
Detach/
40 Arm cylinder attaching and detaching 1 pc. 0.4
attach
Detach/
41 • Arm cylinder piping 1 pc. 0.2
attach
Detach/
42 • Arm cylinder head pin 1 Include stopper pin. 0.1
attach
Detach/
43 • Arm cylinder slinging 1 pc. 0.1
attach
Detach/
50 Boom cylinder attaching and detaching 2 pcs. 0.7
attach
Detach/
51 • Boom cylinder piping 2 0.3
attach
Detach/
52 • Boom cylinder head pin 2 0.2
attach
Detach/
53 • Boom cylinder slinging 2 0.2
attach
60 Bucket cylinder O/H 1 3.6
61 • Pin bushing Replace 1 Include seal. 1.2
70 Arm cylinder. O/H 1 3.6
71 • Pin bushing Replace 1 set Include seal. 1.2
80 Boom cylinder O/H 2 7.0
81 • Pin bushing Replace 1 set Include seal. 1.2 5
5-7
5.3.2 Cab & guard(02)

Group Work to be Unit:
No. done Hour
10 Cab related parts See Paragraph "CAB" in Chapter
"UPPER SLEWING STRUCTURE"
Detach/
11 Cab assy 1 pc. 1.4
attach
Detach/ 1 pc.
12 • Front lower glass, floor mat 0.1
attach each
12
Detach/
13 • Cover mounting bolt pla- 1.2
attach
ces
Detach/
14 • Cover (including air conditioner duct) 5pcs. 1.0
attach
Detach/
15 Panel 2 pcs. 0.4
attach
Detach/
16 • Cable and harness (electricity) 6 pcs. 0.2
attach
Detach/
17 • Controller related parts 1 set 1.0
attach
Detach/
18 • Cab mounting bolt 8 0.3
attach
4
Detach/
19 • Cab slinging pla- 0.2
attach
ces
See Paragraph "GUARD" in Chapter
20 Guard related parts
Detach/
21 Bonnet assy (B1) 1 pc. 0.2
attach
Detach/
22 Cover assy(B3) 1 pc. 0.2
attach
Detach/
23 Panel assy (C1), (C2) 1 pc. 0.4
attach
Detach/
24 Guard (D1), (D2) 1 pc. 0.4
attach
Detach/
25 Guard assy (C5) 1 pc. 0.2
attach
Detach/
26 Bracket (C4), (C6), (C7), (C8) 1 pc. 0.8
attach
Detach/
27 Cover assy (D3), (D4), (D5) 1 pc. 0.6
attach
Detach/
28 Cover (D13), (D14) 1 pc. 0.4
attach
Detach/
29 Bracket assy (D12) 1 pc. 0.2
attach
Detach/
30 Pillar (D7), (D8) 1 0.4
attach
Detach/
31 Bracket (D6) 1 0.2
attach
Detach/
32 Beam (D11), (D17) 1 0.4
attach
Detach/
33 Pillar (D9), (D10) 1 pc. 0.4
attach
5-8

No. done Hour
Detach/
34 Beam (A5), (A6) 1 pc. 0.4
attach
Detach/
35 Pillar (A1), (A2) 1 pc. 0.4
attach
Detach/
36 Guard assy (A3) 1 pc. 0.2
attach
Detach/
37 Cover (A4) 1 pc. 0.2
attach
Detach/
38 Cover assy (F1), (F2) 1 pc. 0.4
attach
Detach/
39 Handrail (E1) 1 0.2
attach
See Paragraph "UNDER COVER" in
40 Under cover related parts Chapter "UPPER SLEWING
STRUCTURE"
Detach/
41 Cover (1) 1 pc. 0.1
attach
Detach/
42 Cover (2) 1 pc. 0.1
attach
Detach/
43 Cover (3) 1 pc. 0.1
attach
Detach/
44 Cover (4) 1 pc. 0.1
attach
Detach/
45 Cover (5) 1 pc. 0.1
attach
Detach/
46 Cover (6) 1 pc. 0.1
attach
Cover (7)
Detach/
1 pc.
5
47 0.1
attach
5-9
5.3.3 Swing frame(03)

No. done Hour
See Paragraph "AIR CLEANER" in
10 Intake related parts Chapter "UPPER SLEWING
STRUCTURE"
Detach/
11 Precleaner assy 1 pc. 0.2
attach
Detach/
12 Air cleaner assy 1 pc. 0.4
attach
Detach/
13 • Hose (3) 1 0.1
attach
Detach/
14 • Air cleaner mounting bolt 4 0.2
attach
15 • Element Replace 1 0.1
See Paragraph "MUFFLER" in
20 Exhaust related parts Chapter "UPPER SLEWING
STRUCTURE"
Detach/
21 Muffler assy 1 pc. 0.5
attach
Detach/
22 • Clamp assy (3) 1 pc. 0.2
attach
See Paragraph "RADIATOR AND
30 Radiator related parts OIL COOLER" in Chapter "UPPER
SLEWING STRUCTURE"
Detach/
31 • Radiator assy 1 pc. 4.0
attach
32 • Coolant (LLC) Replace 1 pc. 0.3
Measure-
33 • Concentration of coolant 1 pc. 0.2
ment
Remove/
34 • A/C condenser 1 pc. 0.3
move
Detach/
35 • Stay 1 pc. 0.1
attach
Detach/
36 • Bracket 1 0.3
attach
Detach/
37 • Sub tank hose 1 pc. 0.1
attach
Detach/
38 • Fan guard 1 pc. 0.3
attach
Detach/
39 • Water hose (radiator ~ E/G) 2 0.5
attach
Detach/
40 • Radiator mounting bolts removing 1 pc. 0.2
attach
Detach/
41 • Under cover 1 pc. 0.1
attach
Detach/
42 • Hydraulic oil tank suction stopper 1 pc. 0.2
attach
Detach/
43 • Hydraulic oil piping 1 pc. 0.6
attach
• Inter cooler hose & tube Detach/
44 2 0.5
(E/G to inter cooler) attach
5-10

No. done Hour
Detach/
45 • Radiator lifting or hoisting 1 pc. 0.2
attach
46 • Radiator inter cooler core & oil cooler Cleaning 1 pc. 1.0
See Paragraph "FUEL TANK" in
50 Fuel related parts Chapter "UPPER SLEWING
STRUCTURE"
Detach/
51 Fuel tank assy 1 pc. 1.8
attach
52 • Fuel Drain out 1 pc. 0.3
Detach/
53 • Hose (water separator side) 2 0.1
attach
Detach/
54 • Tube (tank side) 1 0.1
attach
Detach/
55 • Fuel tank installing bolts 1 pc. 0.3
attach
Detach/
56 • Tank slinging 1 pc. Removing and installing guard 0.3
attach
Detach/
Other necessary works 1 pc. 0.4
attach
See Paragraph "HYDRAULIC OIL
60 Hydraulic oil tank related parts TANK" in Chapter "UPPER
SLEWING STRUCTURE"
Detach/
61 Hydraulic oil tank assy 1 pc. 3.0
attach
Detach/
65 • Cover 1 pc. 0.2
attach
66 • Hydraulic oil Replace 1 pc. 0.5 5
Detach/
68 • Pilot drain hose 1 pc. 0.2
attach
Detach/
69 • Pump suction hose 1 0.5
attach
Detach/
70 • Mounting bolt 1 pc. 0.2
attach
Detach/
71 • Hydraulic oil tank slinging 1 pc. 0.3
attach
72 • Return filter Replace 1 0.2
73 • Suction filter Cleaning 1 0.2

See Paragraph "HYDRAULIC PUMP"
80 Pump related parts in Chapter "UPPER SLEWING
STRUCTURE"
Detach/
81 Pump assy 1 pc. 3.2
attach
Detach/
82 • Hydraulic oil tank cover 1 pc. 0.2
attach
Detach/
83 • Strainer & stopper 1 pc. 0.3
attach
Detach/
84 • Piping 1 set 1.0
attach
Detach/
85 • Guard 5pcs. 1.0
attach
5-11

No. done Hour
Detach/
86 • Pump slinging 1 pc. 0.5
attach
87 • Cleaning Cleaning 1 pc. 0.1
88 • Vent air Adjust 1 pc. 0.1
89 • Pump assy O/H 1 pc. 4.0

See Paragraph "SWING MOTOR
90 Swing motor unit related parts UNIT" in Chapter "UPPER SLEWING
STRUCTURE"
Detach/
91 Swing motor assy 1 pc. 2.4
attach
Detach/
attach
Detach/
attach
Detach/
94 • Unit slinging 1 pc. 0.5
attach
95 • Cleaning and sealant Cleaning 1 set 0.2
96 • Swing motor O/H 1 pc. 3.6
97 • Swing reduction gear O/H 1 pc. 4.2

See Paragraph "REMOVING AND
INSTALLING SWIVEL JOINT" in
100 Swivel joint related parts
Chapter "UPPER SLEWING
STRUCTURE"
Detach/
101 Swivel joint assy 1 2.6
attach
Detach/
102 • Piping (Top part only) 1 set 0.5
attach
Detach/
103 • Whirl stop bolt 1 0.2
attach
Detach/
104 • Cover 1 0.4
attach
Detach/
105 • Joint & elbow 1 set 0.4
attach
Detach/
106 • Mounting bolt 1 set 0.4
attach
Detach/
107 • Swivel joint 1 0.4
attach
108 • Cleaning Cleaning 1 set 0.3
109 Swivel joint O/H 1 set Removing and installing guard 3.6
Detach/
Other necessary works 1 set Lower piping 0.6
attach
See Paragraph "CONTROL VALVE"
110 Main control valve in Chapter "UPPER SLEWING
STRUCTURE"
Detach/
111 Main control valve assy 1 pc. 2.5
attach
112 • Attach tag to port name of pipe Preparation 1 pc. 0.6
Detach/
attach
5-12

No. done Hour
Detach/
114 • Bracket mounting bolt 1 pc. 0.1
attach
Detach/
115 • Valve slinging 1 pc. 0.1
attach
116 Main control valve assy O/H 1 set Guard 6.0
Detach/
Other necessary works 1 set 0.4
attach
120 Valve related parts OPT
Detach/
121 Solenoid valve assy 1 pc. 1.0
attach
122 • Attach tag to port name of pipe Preparation 1 pc. 0.2
Detach/
attach
Detach/
attach
See Paragraph "ENGINE" in Chapter
130 Engine (E/G) mounting related parts
Detach/
131 Engine assy 1 pc. After removing pump & radiator 1.8
attach
• Harness connector & grounding & cable Detach/
132 1 pc. 0.3
connection attach
Detach/
133 • Fuel hose 1 pc. 0.1
attach
Detach/
134 • Others 1 set 0.5
attach
Detach/
135 • Mounting bolt
attach
1 pc. 0.5 5
Detach/
136 • Engine slinging 1 set 0.2
attach
138 Engine O/H 1 set Reference for engine (Chapter 51)
Detach/
Other necessary works 1 set Removing and installing guard 0.6
attach
Detach/ Removing and installing
1 set 0.6
attach Counterweight
Detach/
1 set Removing and installing pump 3.2
attach
Detach/
1 set Removing and installing air cleaner 0.4
attach
Detach/
1 set Removing and installing muffler 0.4
attach
Detach/
1 set Removing and installing radiator 4.0
attach
See Paragraph "UPPER FRAME" in
140 Upper frame Chapter "UPPER SLEWING
STRUCTURE"
Detach/
141 Upper frame assy 1 pc. After removing swivel joint 1.3
attach
5-13

No. done Hour
Detach/
142 • Mounting bolt 1 set 0.4
attach
Detach/
143 • Upper frame slinging 1 pc. 0.4
attach
145 • Sealant Apply 1 pc. 0.2

Detach/
Other necessary works 1 set Cab 1.4
attach
Detach/
1 set Guard 0.4
attach
Detach/
1 set Counterweight 0.6
attach
Detach/
1 set Boom 1.4
attach
5-14
5.3.4 Travel system(04)

No. done Hour
00 Travel related parts INSTALLING CRAWLER" in Chapter
"TRAVEL SYSTEM"
Detach/ One
01 Track link assy Include adjustment of tension 1.5
attach side
• Track link attaching and detaching One
02 Preparation 0.1
position side
Detach/ One
03 • Master pin 0.5
attach side
Detach/ One
04 • Track link extending and winding 0.5
attach side
05 Shoe plate Replace 1 pc. 0.4
10 Upper roller related parts INSTALLING UPPER ROLLER" in
Chapter "TRAVEL SYSTEM"
Detach/
11 Upper roller assy 1 After removing track link 0.2
attach
12 Upper roller O/H 1 1.0
20 Lower roller related parts INSTALLING LOWER ROLLER" in
Detach/
21 Lower roller assy 1 0.2
attach
22 Lower roller O/H 1 1.0
Front idler related parts
INSTALLING FRONT IDLER 5
30
ASSEMBLY" in Chapter "TRAVEL
SYSTEM"
Detach/ One
31 Front idler assy After removing track link 0.6
attach side
Detach/ One
32 Front idler assy slinging 0.3
attach side
One
33 Front idler assy Detaching 0.3
side
One
34 Idler assy O/H 1.0
side
One
35 Idler adjuster assy O/H Replace spring 2.4
side
One
36 • Grease cylinder O/H 0.6
side
40 Sprocket INSTALLING SPROCKET" in
One
41 Sprocket Replace After removing track link 0.6
side
50 Travel motor related parts INSTALLING TRAVEL MOTOR" in
5-15

No. done Hour
Detach/ One
51 Travel motor assy After removing track link 1.7
attach side
Detach/ One
52 • Motor cover 0.1
attach side
Detach/ One
53 • Hydraulic piping 0.9
attach side
Detach/ One
54 • Motor mounting bolt 0.5
attach side
Detach/ One
55 • Motor slinging 0.1
attach side
One
56 Motor cleaning Cleaning 0.1
side
One
57 Travel motor O/H 3.6
side
One
58 Travel reduction gear O/H 3.6
side
60 Swivel joint related parts
Detach/ Include bonnet assy removing and

61 Pipe on swivel joint travel side 1 pc. 0.6
attach installing.

INSTALLING SWIVEL JOINT" in
62 Swivel joint O/H 1 pc. 3.6
Chapter "UPPER SLEWING
STRUCTURE"
70 Swing bearing INSTALLING SWING BEARING" in
Detach/
71 Swing bearing assy 1 pc. After removing upper frame 0.7 0.7
attach
Detach/
72 Swing bearing mounting bolt 1 pc. 0.5
attach
Detach/
73 Swing bearing slinging 1 pc. 0.3
attach
5-16
5.3.5 Electric equipment(06)

No. done Hour
Controller
C-1 Controller (TC0-63-1A (hard)) Replace 1 0.5
C-2 Cluster gauge Replace 1 1.0
C-4 Air conditioner amplifier Replace 1 2.0
C-5 Engine coolant level controller Replace 1 0.5
C-8 Engine controller Replace 1 0.8

Diode
D-4 Diode Replace 1 0.3

Electric equipment
E-1 Fuse & relay box Replace 1 0.3
E-2 Alternator Replace 1 1.0

5
E-5 Horn (high) Replace 1 0.3
E-6 Horn (low) Replace 1 0.3
E-8 Speaker left Replace 1 0.3
E-9 Speaker right Replace 1 0.3
E-10 Receiver dryer Replace 1 Include gas charging. 1.0

Include removing and installing
E-11 Air conditioner compressor Replace 1 1.0
counterweight.
E-12 Battery Replace 2 0.4
E-15 Fusible link Replace 1 0.2
E-27 Accel redundant volume Replace 1 0.5
E-35 Glow Replace 1 0.5
E-38 Resistor Replace 1 0.5
E-65 24V power socket Replace 1 0.5
E-101 CAN resistor 1 Replace 1 -
E-102 CAN resistor 2 Replace 1 -
E-103 Engine controller check connector Replace 1 -
E-104 9P connector Replace 1 -
5-17

No. done Hour
Light
L-1 Boom working light left Replace 1 Bulb 0.2
L-2 Deck working light (RH) Replace 1 0.2
L-5 Room light Replace 1 0.2
L-7 Cab working light front 1 Replace 1 0.2
L-9 Boom cylinder working light Replace 1 0.2

Motor
M-1 Starter motor Replace 1 1.0
counterweight.
M-3 Wiper motor Replace 1 0.5
M-4 Washer motor Replace 1 0.5

Proportional valve
PSV-A Arm two-speed inverse proportional sol. Replace 1 0.5

PSV-B P2 unload proportional sol. Replace 1 0.5
proportional valve block.
PSV-C Travel straight proportional sol. Replace 1 0.5
PSV-D P1 unload proportional sol. Replace 1 0.5

PSV-
Boom 3 proportional sol. Replace 1 0.5
23
PSV-
Boom 2 proportional sol. Replace 1 0.5
24
PSV-
P1 pump proportional sol. Replace 1 0.5
P1
PSV-
P2 pump proportional sol. Replace 1 0.5
P2
Relay
R-1 Battery relay Replace 1 0.3
R-2 Starter relay Replace 1 0.3
R-3 Glow relay Replace 1 0.3
R-4 Safety relay Replace 1 0.1
R-5 Horn relay Replace 1 0.1
R-6 Work light relay Replace 1 0.1
R-9 Cab working light relay 1 Replace 1 0.1
R-11 Cab working light relay 2 Replace 1 0.1
R-23 Auto idle stop relay 1 Replace 1 0.1
R-24 Auto idle stop relay 2 Replace 1 0.1
R-25 E/G emergency stop relay Replace 1 0.1
R-26 Lever lock relay Replace 1 0.1
5-18

No. done Hour
R-28 Alternator relay Replace 1 0.1
R-29 Wiper motor relay (normal rotation) Replace 1 0.1
R-30 Wiper motor relay (reverse rotation) Replace 1 0.1
R-31 Wiper motor arc prevention relay Replace 1 0.1
R-32 Washer motor relay Replace 1 0.1
R-45 Boom cylinder working light relay Replace 1 0.1
R-94 Neutral stop relay Replace 1 0.1
R-145 Key ON holding relay Replace 1 0.1

Sensor
SE-1 Pressure sensor : Bucket digging Replace 1 0.3
SE-2 Pressure sensor : Bucket dump Replace 1 0.3
SE-3 Pressure sensor : Boom up Replace 1 0.3
SE-4 Pressure sensor : Boom down Replace 1 0.3
SE-7 Pressure sensor : Arm in Replace 1 0.3
SE-8 Pressure sensor : Arm out Replace 1 0.3

Include removing and installing under
SE-9 Pressure sensor : Travel right Replace 1 0.5
cover.
SE-10 Pressure sensor : Travel left Replace 1 0.5
cover.
SE-11 Pressure sensor : P2 side opt. Replace 1 0.5
cover.
SE-13 Engine speed sensor Replace 1 0.5
cover.
5
SE-15 Fuel level sensor Replace 1 0.5
guard.
Include removing and installing panel

SE-16 Accel potentio Replace 1 0.5
in cab.
SE-20 Pressure sensor : P1 side opt. Replace 1 0.5
cover.
SE-21 Hyd. oil temp. sensor Replace 1 0.3
SE-22 Pressure sensor : P1 pump Replace 1 0.3
SE-23 Pressure sensor : P2 pump Replace 1 0.3
SE-40 Press. sensor : Swing right Replace 1 0.3
SE-41 Press. sensor : Swing left Replace 1 0.3
SE-60 Hyd. oil filter clogging sensor Replace 1 0.3
SE-99 Swing speed sensor Replace 1 0.3
SE- Engine coolant temperature sensor (for

Replace 1 0.3
102 ECU)
Solenoid
SV-1 Swing parking sol. Replace 1 0.5
SV-2 Attachment boost pressure sol. Replace 1 0.5
SV-3 2-speed travel sol. Replace 1 0.5
5-19

No. done Hour
SV-4 Lever lock sol. Replace 1 0.5
SV-105 Boom meter in cut sol. Replace 1 0.5

Switch
SW-1 Key switch Replace 1 0.3
SW-4 Swing parking release switch Replace 1 0.3
SW-7 Engine oil pressure switch Replace 1 0.3
SW-8 Clogged air filter switch Replace 1 0.3
SW-10 Horn switch (left) Replace 1 0.3
SW-11 Lever lock switch Replace 1 0.3
SW-19 Wiper interlock switch Replace 1 0.3
SW-20 Attachment power boost switch (right) Replace 1 0.3
SW-22 Release switch (KPSS) Replace 1 0.3
SW-26 Cab working light switch Replace 1 0.3
SW-27 Radiator coolant level switch Replace 1 0.3
SW-55 Boom and deck working light switch Replace 1 0.3
5-20
［6. MAINTENANCE STANDARD AND TEST PROCEDURE］
6. MAINTENANCE STANDARD AND

TEST PROCEDURE
6.2 HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS...........................................6-4
6.3 PERFORMANCE INSPECTION STANDARD TABLE..................................................................6-5
6.4 MEASUREMENT OF ENGINE SPEED.......................................................................................6-7
6.4.1 WARMING UP OF ENGINE ....................................................................................................6-7
6.4.2 ENGINE SPEED MEASURED VALUE THROUGH SERVICE DIAGNOSIS ................................6-8
6.5 MEASUREMENT OF HYDRAULIC PRESSURE .........................................................................6-9
6.5.1 OVERVIEW OF MEASURING HYDRAULIC PRESSURE .........................................................6-9
6.5.2 PLACE TO INSTALL PRESSURE GAUGE..............................................................................6-9
6.5.3 PRESSURE ADJUSTMENT POSITION.................................................................................6-10
6.5.4 PROCEDURE FOR ADJUSTING RELIEF VALVE ..................................................................6-12
6.6 MEASURING TRAVEL PERFORMANCES...............................................................................6-14
6.6.1 TRAVEL SPEED ..................................................................................................................6-14
6.6.2 TRAVEL DEVIATION ...........................................................................................................6-15
6.6.3 PERFORMANCE OF PARKING BRAKE ...............................................................................6-16
6.6.4 DRAIN RATE OF TRAVEL MOTOR ......................................................................................6-17
6.7 MEASURING SWING PERFORMANCES ................................................................................6-18
6.7.1 Swing speed .......................................................................................................................6-18
6.7.2 PERFORMANCE OF SWING BRAKE ...................................................................................6-19
6.7.3 PERFORMANCE OF SWING PARKING BRAKE ...................................................................6-20
6.7.4 DRAIN RATE OF SWING MOTOR ........................................................................................6-21
6.8 MEASURING ATTACHMENT OPERATING PERFORMANCES.................................................6-22
6.8.1 OPERATING TIME OF CYLINDERS .....................................................................................6-22
6
6.8.2 OIL TIGHTNESS OF CYLINDERS ........................................................................................6-23
6.9 MEASURING PERFORMANCES OF SWING BEARING...........................................................6-24
6.10 MECHATRO CONTROLLER .................................................................................................6-26
6.10.1 ENGINE CONTROL INPUT / OUTPUT ................................................................................6-26
6.10.2 OVERVIEW OF ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C
ADJUSTMENT) ..............................................................................................6-26
6.10.3 MECHATRO CONTROL ADJUSTMENT (A-B-C ADJUSTMENT) PROCEDURES .................6-27
6.10.4 MEASURES WHEN MECHATRO CONTROL ADJUSTMENT IS IMPOSSIBLE .....................6-32
6.10.5 OPERATIONS WHEN OCCURS FAILURE OF MECHATRO CONTROLLER .........................6-33
6-1
6-2

6-3
6.2 HOW TO USE MAINTENANCE STANDARDS AND

PRECAUTIONS
Application
• When the machine is new; Confirm that the performances are in accordance with standard specifications as
compared to the performance standards.
• 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.
• When main components are replaced; For example, use data to restore performances of pumps and others.
Terminology
• 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).
• Reference values for remedy; 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.
• 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.
Cautions to be Exercised at Judgment

• 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.
• 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.
Other Cautions to be Exercised

• 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.
• 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.
• 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.
6-4
6.3 PERFORMANCE INSPECTION STANDARD TABLE
When turning on the power, the work mode is the "S" mode. Unless otherwise specified, measure the inspection
items by the "H" mode.
Measured location Tolerance Measurement

Inspection item Standard value Unit Adjusting
Location Size Port Upper limit Lower limit point Condition and operation
Hydraulic oil cleanliness Hydraulic oil inside tank NAS 8 or less — — Class — Sampling
Standard measurement condition
Surface temperature near 50 (122) + 5 (41) - 5 (23)

Hydraulic oil temperature Temperature
relief valve of control valve Degrees C — 50 to -10 degrees C
Upper tank surface of (F) (122 to 14 degrees F)
Water temperature 75 (167) +15 (59) - 15 (5)
radiator
H mode Lo idle 1150 + 30 - 30 LOW throttle
Engine speed
FULL throttle
H mode Hi idle 2170 + 30 - 30
Adjustment (HI idle)
See measured value from min-1
Decel 1200 + 30 - 30 not required
gauge cluster
Perform all measurement
S mode Hi idle 1950 + 30 - 30 with air conditioner "OFF".
ECO mode Hi idle 1950 + 30 - 30
Pilot primary pressure circuit G pump a3 5.0 (725) + 0.5 (+73) 0 PR1 HI idle
P1 a1
valve pressure
ATT 34.3 (4970) + 0.7 (+100) - 0.5 (-73) MR1 Boom up

Main relief
P2 a2
P1 a1
Power boost 37.8 (5480) + 1.0 (+145) - 0.5 (-73) MR1
P2 a2
R 37.8 (5480) + 0.5 (+73) - 0.5 (-73) OR4 Boom down
Boom a1
H 39.7 (5760) + 0.5 (+73) - 0.5 (-73) OR3 Boom up
High pressure circuit
Main pump
Overload relief valve pressure
R 39.7 (5760) + 0.5 (+73) - 0.5 (-73) OR8 Arm out

Arm a2
H PF1/4 37.8 (5480) + 0.5 (+73) - 0.5 (-73) OR7 Arm in
MPa
R 37.8 (5480) + 0.5 (+73) - 0.5 (-73) (psi) OR2 Bucket dumping
Bucket a1
H 39.7 (5760) + 0.5 (+73) - 0.5 (-73) OR1 Bucket digging
RH 29.0 (4205) + 2.5 (+363) - 0.7 (-102) OR6 Swing RH
Swing a2
LH 29.0 (4205) + 2.5 (+363) - 0.7 (-102) OR5 Swing LH
FWD —
Right a1 34.3 (4970) + 1.7 (+247) 0
— 6
Travel
RWD Right and left

FWD — simultaneous operation
Left a2 34.3 (4970) + 1.7 (+247) 0
RWD —
6-5
Inspection item Standard value Unit

No. of sprocket rotations 1st speed 29.9 to 33.1
min-1
(Right and left) 2nd speed 49.6 to 54.4
Up 2.7 to 3.3
Boom
Down 2.1 to 2.7
Operation speed
Cylinder operation time In 3.0 to 3.6

Arm sec
(no load) Out 2.3 to 2.9
Digging 2.1 to 2.7
Bucket
Dumping 1.7 to 2.3
Right
Swing speed 4.2 to 5.4 sec / rev
Left
1st speed Iron crawler 19.5 to 21.5 sec / 20 m
Travel speed (66ft)
2nd speed Iron crawler 11.9 to 13.1
0 to 240 mm / 20 m
Amount of travel deviation 2nd speed
(0 to 9.45) (inch / 66ft)
0 mm / 5 min
Parking brake performance 15 degrees slope
(0) (inch / 5 min)
Neutral position after
Performance
Swing brake performance 180 degrees full speed swing 106 to 126 degree
Swing parking 0
15 degrees slope mm (inch)
brake performance (0)
Tip of bucket tooth 96 (3.8)
mm / 5 min
ATT lowering amount Boom cylinder 7.2 (0.28) (No load)
(inch / 5 min)
Arm cylinder 5.4 (0.21)
30 to 50
Amount of horizontal play at bucket tooth mm (inch)
(1.18 to 1.97)
Note
The port re lie f va lve s No.OR1 to OR8 on the control s e ction a re a djus te d to the following ope ra tion numbe rs .
(1) Bucke t digging, (2) Bucke t dumping, (3) Boom up, (4) Boom down,
(5) S wing le ft, (6) S wing right, (7) Arm in, (8) Arm out
Left Right
Control levers
6-6
6.4 MEASUREMENT OF ENGINE SPEED

6.4.1 WARMING UP OF ENGINE
Start engine to raise the coolant temperature of engine 1
to 60 to 90C degrees (140 to 194F degrees) at surface of
radiator upper tank. 2
The E/G coolant tem-perature gauge is used to
measure. The range in white color shows the
temperature of approx. 65 to 105 C degrees (149 to
221F degrees), so confirm that the pointer indicates the 3
temperature within the white range.
(1)Red
(2)White
(3)Blue
6-7
6.4.2 ENGINE SPEED MEASURED VALUE THROUGH SERVICE

DIAGNOSIS
1. Turn "ON" the starter switch with buzzer stop switch (1) pressed.
2. A program No. and an actual engine revolution are displayed as the No.2 Item.
3. The screen advances like No.2, No.3....each time "Up arrow switch" (2) on the gauge cluster is pushed.
4. The screen returns like No.45, No.44....each time "Down arrow switch" (3) is pushed.
5. The display does not disappear unless the starter switch is turned to"OFF".
Switch for E/G speed indication
NO.2 ENG
G-3 SPEED SET 2205
MEAS 1 2201
MEAS 2 2201
G-5 ENG OIL PRS. LIVE
WATER TEMP. 100 OFF
F
MODE HM
ATT MODE BRK
H-1 ACCEL. VOLT. 4.2V
POS 100%
ECU OUTPUT 0.5V
Service diagnosis for E/G speed measuring

(Example)
6-8
6.5 MEASUREMENT OF HYDRAULIC PRESSURE

6.5.1 OVERVIEW OF MEASURING HYDRAULIC PRESSURE
Hydraulic pressure measuring device
6.9 MPa (1000 psi) pressure gauge: 1 unit
49 MPa (7100 psi) pressure gauge: 2 units
Pressure measuring device and instrument for analysis: 1 set
Measuring cleanliness of hydraulic oil
ABOUT HANDLING OF HYDRAULIC OIL TANK

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 standard value, replace the return filter or
change the hydraulic oil.
6.5.2 PLACE TO INSTALL PRESSURE GAUGE

• Main circuit
a3
After releasing the pressure in hydraulic oil tank and
system, replace plugs PF1/4 of main pump gauge
ports (a1) (a2) with plugs for pressure measurement,
and attach pressure gauge 49 MPa (7100 psi).
• Pilot circuit
Replace pilot gauge plug (a3) with plug PF1/4 for
pressure measurement, and attach pressure gauge
6.9 MPa (1000 psi).
a2
a1
Gauge port on main pump

6
6-9
6.5.3 PRESSURE ADJUSTMENT POSITION

Main control valve
OR8 : ARM (R)
MACHINE
FRONT
MR1 : MAIN RELIEF OR3 : BOOM (H) OR2 : BUCKET (R)

(ATT & TRAVEL)
VIEW FROM THE TOP OF THE MACHINE
OR1 : BUCKET (H)

OR4 : BOOM (R)
MACHINE
FRONT
OR7 : ARM (H)
VIEW FROM THE BOTT OM OF THE MACHINE
Relief valve position on main control valve
6-10
Pilot relief valve

The pilot relief valve PR1 is located on the gear pump that is attached to the main pump.
A3
a3
B3
PR1 ADJUST SCREW
FOR PILOT RELIEF
Pilot relief valve position
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 "Gauge port on main pump" Fig.)
SWING LEFT SWING RIGHT

OR5 OR6
PB
PA
Swing over load relief position
6-11
6.5.4 PROCEDURE FOR ADJUSTING RELIEF VALVE

Pilot relief valve
Adjust it with adjust screw (311).
Tools: Spanner: 24 mm,
Tightening torque: 29.4 N·m (22 lbf·ft)
Tools: Allen wrench: 6 mm
LOCK NUT HEX24

311
Pilot relief valve
No. of turns of adjust screw Pressure change MPa (psi)
1 turn Approx. 2.1 (305)

2-stage main relief valve (Commom for travel and HEX30
ATT sections) 1
2 HEX19
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 standard
side with adjusting screw (4) and tighten nut (3) after
completion of the adjustment. 4 3
Tools: Spanner: 30mm HEX22
Tightening torque: 46 to 52 N·m (34 to 38 lbf·ft)
Tools: Spanner: 22mm Main relief valve (Travel section, ATT section)
Tools: Spanner: 19mm, Adjust screw
Tools: Allen wrench: 6mm

Boosting side 1 turn Approx. 17.6 (2560)
STD side 1 turn Approx. 17.6 (2560)
Over load relief valve (Boom, bucket, arm sections)
Loosen lock nut (1) and adjust it with adjust screw (2).
Tools: Spanner: 22mm
Tightening torque: 27.4 to 31.4 N·m (20 to 23 lbf·ft)
2 1
H E X 2 2
Over load relief valve (Boom, bucket, arm

sections)
1 turn Approx. 17.7 (2560)
6-12
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).
2
Tools: Allen wrench: 6mm 1
Travel over load relief valve
6-13
6.6 MEASURING TRAVEL PERFORMANCES

6.6.1 TRAVEL SPEED
Purpose
Measure the travel sprocket revolution and confirm the
performances between the hydraulic pump and the
travel motor of the travel drive system.
Conditions
Hydraulic oil temperature: 45 to 55 degrees C (113 to
131 degrees F)
The crawlers on the right and left sides are tensed
evenly.
One side lifted position
Preparation
Attach the reflection panel with a magnet to the travel
motor cover. REFLECTION
PANEL
Swing the swing frame through 90C degrees as shown
in Fig. "One side lifted position" and make the crawler on
one side take off the ground, using the attachment.
Adhering position of reflection panel
Measurement
Number of sprocket rotations Unit: min -1
Engine speed: High idle
Measurement item Standard value Reference value for remedy Service limit
2-speed travel switch: 1st speed and 2nd speed
Measuring points: Right and left H mode 1st speed 33.1 to 29.9 25.8 to 23.3 21.1 or less
RH & LH
Method, example 1: H mode 2nd speed 54.4 to 49.6 42.4 to 38.7 34.8 or less
Measure revolution with a stroboscope
Method, example 2:
Measure the revolutions per minute visually.
6-14
6.6.2 TRAVEL DEVIATION

Purpose
BOOM FOOT
Measure the amount of deviation at 20 m (66 ft) travel PIN
and confirm the horizontal balance between the
hydraulic pump and the travel motor of the travel drive
system.
Condition ARM TOP

Hydraulic oil temperature: 45 to 55 degrees C (113 to PIN
131 degrees F)
RH and LH crawlers are tensed evenly.
Firm, level ground Travel position
Preparation
• Straight course more than 30 m (108 ft)
• Travel position in which the bottom of the bucket is
lifted by about 30 cm (1 ft). A
20m (66ft)
Measuring Method
Measurement
Tra ve l de via tion Unit : mm (in) / 20m (66ft)
1. Measure the max. deviation distance of the circular Measuring
Standard value
Reference value
Service limit
position for remedy
arc in the 20 m (66 ft) length, excluding the
A 240 (9.45) or less 480 (18.9) 720 (28.4)
preliminary run of 3 to 5 m (10 to 16 ft).
2. Operate the travel lever at the same time.
6-15
6.6.3 PERFORMANCE OF PARKING BRAKE

Purpose
Confirm that the parking brake holds a stopped condition
of the machine in a no-load travel position and on a 15
degree slope.
BOOM FOOT PIN
Condition
A slope with (Approx. 15 deg) gradient and a stopped
condition in a no-load travel position ARM TOP P IN
15 degree slope
Parking brake operating position
Preparation
Place an angle meter on the shoe plate and confirm that
it makes an angle more than 15 degree.
Hang a perpendicular in parallel with the guide frame rib
on the track frame and put a mark (matching mark) on
the shoe plate.
C ANGLE
GUIDE FRAME METER
Measuring Method
Measurement
Parking brake Unit : mm(in)/5min
Five minutes after the engine stops, measure the Measuring
Standard value
Reference value
Service limit
position for remedy
movement distance of the matching mark.
C 0 1 (0.04) 2 (0.08) or more
6-16
6.6.4 DRAIN RATE OF TRAVEL MOTOR

Purpose FOR WARD 90 10 DIA.
(3.54") (0.394")
To measure the drain rate of the travel motor and to
22 DIA. 40
confirm the performances of the travel motor. PIPE (1.57")
(0.866")
Condition RIB "A" 150
S TOP P ER (5.91")
Hydraulic oil temperature: 45 to 55 degrees C (113 to "B"
131 degrees F)
Engine speed: High idle 80 DIA.
(3.15")
ROTARY DIRECTION
Location of stopper applied to travel sprocket
Preparation
1. Place a stopper under the RH and LH travel
sprockets.
2. Stop the engine and release pressure from the
hydraulic circuit.
3. Connect a hose with the drain port of the travel
motor and take drain in a container.
Method of measuring the drain rate of travel motor
Measurement: At Travel Lock Drain rate of travel motor Unit : L(gal )/30sec
Measuring Reference value
position Standard value for remedy Service limit
Drain rate 9 (2.4) 16 (4.2) 23 (6.1) or more
ROTARY FORCE DIRECTION AT TRAVEL LOCK

Unless you observe the rotary force direction at travel lock, rib "A" may be broken by stopper "B" in some cases. 6
(See the figure of "Location of stopper applied to travel sprocket")
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.
Perform measurement on each side at the forward rotation for three times and the average value of the results
is the measurement value.
6-17
6.7 MEASURING SWING PERFORMANCES

6.7.1 Swing speed
Purpose
Measure the swing time and confirm the performances
between the hydraulic pump and the swing motor of the
swing drive system.
Conditions
131 degrees F)
Firm, level ground
Preparation
Make the bucket empty and extend the boom, arm and
bucket cylinders fully. (Minimum reach) Swing speed measuring position (at the min.
reach)
Measurement Swing speed Unit : sec/rev

Swing the machine by bringing the swing lever to its full Me a s uring Reference value
pos ition Standard value for remedy Service limit
stroke. Measure the time required to make two swings S wing s pe e d a t
min. re a ch 4.2 to 5.4 5.4 to 6.9 7.2 or more
after one turn of preliminary swing and calculate the time
required for one swing.
6-18
6.7.2 PERFORMANCE OF SWING BRAKE

Purpose
Confirm the braking torque performances by the swing relief valve.
Conditions
Hydraulic oil temperature: 45 to 55 degrees C (113 to 131 degrees F)
Firm, level ground, no load bucket
Preparation
• Make the bucket empty, retract the arm cylinder fully ARM TOP
BOOM FOOT
and extend the bucket cylinder fully. And move the PIN
PIN
boom so that the arm top pin is positioned at same
height with the boom foot pin.
• Put a matching mark on the outer circumference of
the swing bearing of the upper frame side and of the
track frame side. Place two poles (flags) on the front
and back of the extended line of the matching mark.
Measuring position of swing brake performances
Measurement MEASURING THE LENGTH OF THE ARC OVER

THE OUTER CIRCUMFERENCE OF OUTER RACE
1. When operating in regular swing speed, by shifting
MATCHING MARKS ON
lever to neutral position at pole position the swing OUTER RACE
operation stops.
2. Calculate the swing drift angle by the following
equation, after the upper swing body stops, using
the amount of deflection m(ft-in) of the matching
marks on the swing race and the length m(ft-in) of
the circumference of the swing race: MATCHING MARKS
ON INNER RACE
Measuring position of swing brake performances
Amount of deflection of
Swing drift matching marks [m (ft-in)]
angle (degrees) = Circumferential length of X 360
degrees
swing race [m (ft-in)]
6
Swing brake performance Unit: degrees
Measurement item Standard value Reference value for remedy Service limit
Swing 180 Within 126 117 to 139 151 or more
6-19
6.7.3 PERFORMANCE OF SWING PARKING BRAKE

Purpose
To confirm the mechanical performances of the swing
parking brake that is fitted to the inside of the swing
motor.
Conditions
On a slope of 15 degree incline.
Stop the machine at right angles with the slope. Make
the bucket empty, retract the arm cylinder fully and
extend the bucket cylinder fully. And move the boom so
that the arm top pin is positioned at same height with
boom foot pin.
Measuring position of swing parking brake

performance
Preparation MEASURING THE LENGTH OF THE ARC OVER

THE OUTER CIRCUMFERENCE OF OUTER RACE
Put the angle meter on the shoe plate and make sure
MATCHING MARKS ON
that the angle is more than 15 degree. OUTER RACE
Put a matching mark on the outer race side and on the
inner race side.
MATCHING MARKS
ON INNER RACE
Measuring position of swing parking brake

performances
Measurement Performance of swing parking brake Unit : mm(in)/5min

When five minutes has passed after the engine stops, Measuring Reference value
measure the length of the movement of the matching C 0 1 (0.04) 2 (0.08) or more
marks.
6-20
6.7.4 DRAIN RATE OF SWING MOTOR

Purpose
Measure the drain rate of the swing motor and confirm
the performances of the swing motor.
Conditions
131 degrees F)
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.
Measurement: At Swing Lock
Drain rate of swing motor Unit : L(gal)/30sec
1. Start the engine and put the side faces of bucket Measuring
Standard value
Reference value
Service limit
position for remedy
against the inside of the right or left shoe plates.
Drain rate 2.1 (0.55) 5.2 (1.4) 6.2 ( 1.6 ) or more
2. Relieve the swing motor at full stroke of the swing
motion.
3. Collect the amount of drained oil in a container for 30 seconds.
6-21
6.8 MEASURING ATTACHMENT OPERATING

PERFORMANCES
6.8.1 OPERATING TIME OF CYLINDERS
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.
Condition
3 0 c m (1 ft)
131 degrees F)
Measuring position for bucket digging and dump
Operating time excluding cushion stroke
Preparation C o n d itio n :
A r m c y lin d e r m o s t r e tr a c te d
Firm level ground with the bucket empty B u c k e t c y lin d e r m o s t e x te n d e d
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.
Measuring position for boom up and down

motions
ABOUT MEASUREMENT OF TIME OF BOOM DOWN OPERATION

When lowering the boom, allow the bucket onto a soft ground or cushioning such as rubber tires ; never put the
bucket against concrete or other solid material.
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 30 cm (1ft) above ground, measure the full
stroke operating time required with the arm and bucket
operating levers at full stroke. 30cm (1ft)
Measuring position for arm in and out motions
Cylinder operation time Unit: sec

Measurement position Standard value Reference value for remedy Service limit
(1) 2.1 to 2.7 2.7 to 3.5 3.6 or more
(2) 1.7 to 2.3 2.2 to 2.9 3.0 or more
(3) 2.7 to 3.3 3.5 to 4.2 4.5 or more
(4) 2.1 to 2.7 2.7 to 3.5 3.6 or more
(7) 3.0 to 3.6 3.8 to 4.6 5.0 or more
(8) 2.3 to 2.9 2.9 to 3.7 3.9 or more
6-22
6.8.2 OIL TIGHTNESS OF CYLINDERS

Purpose B
Confirm that the cylinder oil tight by checking the moving BOOM FOOT
length of the cylinder rods. C PIN
A
Condition
Hydraulic oil temperature: 45 to 55 degrees C (113 to ARM TOP D
131 degrees F) PIN
Firm, level ground
After cylinders are replaced, bleed off air from the cylinders, before checking for oil tightness.
Extend the arm cylinder rod 50 mm (2 inch) from the most retracted position so that the piston is not in a same
range of the cushioning mechanism.
Preparation
Oil tightness of cylinder Unit : mm(in)/5min
Put the bucket empty. Extend the arm cylinder rod 50 Measuring Reference value
mm (2in) from the most retracted position. And extend
the bucket cylinders fully. Then hold the boom so that the A 7.2 (0.28) 9 (0.35) 12 (0.47) or more
arm top pin is positioned at same height with boom foot B 5.4 (0.21) 6.8 (0.27) 9 (0.35) or more
pin. C - - -
D 96 (3.8) 120 (4.7) 160 (6.3) or more
Measurement
Measure the items five minutes after the engine is turned off.
6-23
6.9 MEASURING PERFORMANCES OF SWING BEARING

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.
Condition
Firm, level ground
The swing bearing mounting bolts are not loosened.
The swing bearing is lubricated well, not making abnormal sound during turning.
Preparation
LOCATION OF BEARING
1. Install a dial indicator to the magnetic base and fix it MOUNTING BOLTS
to the lower frame.
2. Direct the upper swing body and the lower frame SWING BEARING
toward the travel direction, bring the probe of the A
dial indicator in contact with the bottom surface of
the outer race on the swing body side and set the
reading at zero. DIAL INDICATOR
How to measure the axial play of swing bearing
Measurement 1 (Measuring position I and II)

Measure the displacement of the outer race in the axial
direction in position I [The arm at 90 degrees to 110
9 0 ~ 1 0 0
degrees and the crawler front is lifted by attachment
about 30cm (1ft)] and in position II, using a dial indicator.
3 0 c m (1 ft)
Measuring position I
ARM TOP
PIN BOOM FOOT
PIN
Measuring position II
Axial play of swing bearing Unit : mm (in)

0.8 to 1.8 2.3 to 3.3 3.6 or more
A (0.03 to 0.07) (0.09 to 0.13) (0.14)
6-24
Measurement 2 (Measuring position III)

Retract the arm cylinder fully and extend the bucket ARM TOP
PIN BOOM FOOT
cylinder fully. And move the boom so that the arm top pin PIN
is positioned at same height with boom foot pin. Then
swing the bucket right and left by man power. But in this
case, the gap of the attachment is included.
Measuring position III
Right and left movement of the tip of bucket Unit : mm (in)

30 to 50
Bucket (1.18 to 1.97) 80 (3.15) 120 (4.72) or more
6-25
6.10 MECHATRO CONTROLLER

6.10.1 ENGINE CONTROL INPUT / OUTPUT
INJEC TOR
C-8:
ENGINE
C-2: CONTROLLER
GAUGE CLUSTER
C-1: ENGINE ENGINE

MECHATRO SPEED
SENSOR
CONTROLLER
PUMP
PROPO RTIONAL
VALVE
S TARTER E-1:
SWITCH FUSE&REL AY BOX EMERGENCY E-27:
ACCEL
ACCEL DIAL ENGINE THROTTLE FOR
POTENTIO METER REDUNDANT MODE
INPUT / OUTPUT
6.10.2 OVERVIEW OF ADJUSTMENT OF MECHATRO CONTROLLER

OUTPUT (A-B-C ADJUSTMENT)
PURPOSE OF THE ADJUSTMENT
There are 3 kinds of adjustment of mechatro controller as shown below; every adjustment is an essential function to
ensure performance of machine.
• Adjustment of engine ("A" adjustment)
This adjustment is performed to set the relationship between the acceleration command voltage output from the
mechatro controller to the engine controller and the engine speed.
• Adjustment of pump ("B" adjustment)
This adjustment is performed to correct the output variation by coordinating the output hydraulic pressure with
engine rated output.
• Adjustment of unloading valve ("C" adjustment)
This adjustment is performed to correct the open variation of unloading valve to improve the operability further.
IN CASES WHERE THE ADJUSTMENT OF MECHATRO CONTROLLER IS REQUIRED

When the following parts are replaced or repaired, carry out the adjustment without fail.
• Mechatro controller
• Engine or engine controller
• Hydraulic pump or hydraulic pump proportional valve
• Unloading proportional valve, spool of unloading valve
6-26
6.10.3 MECHATRO CONTROL ADJUSTMENT (A-B-C ADJUSTMENT)

PROCEDURES
(1)MULTI DISPLAY
(2)WORK MODE SELECT SWITCH
(3)BUZZER STOP SWITCH 1
(4)UP ARROW SWITCH

(5)MENU SWITCH
(6)DOWN ARROW SWITCH
2 4
Gauge cluster
6.10.3.1 ADJUSTMENT OF ENGINE ("A" ADJUSTMENT)
Preparation
• Raise the oil temperature to approximately 50 degrees C (122 degrees F) to warm up the engine.
• Turn the air-con OFF.
• Turn the starter key switch OFF to stop the engine.
When the mechatro controller was replaced, the following error code is displayed because the adjustment data
is not entered.
A215, A225, A015, A025, A035
As the error codes other than those shown above may suggest failures of machine, repair the machine into the
ordinary operating condition according to Error Code List.
6
1. For machines equipped with lifting magnet, turn the generator OFF.
2. For the adjustment items not included in the specifications, "- - -" is displayed.
1. Turn starter key switch ON keeping the work mode MULTI DISPLAY
select switch on the gauge cluster pressed, and hold (EXAMPLE)
it for 5 to 10 seconds, and then release it. (If the S 12:15
engine is started, the following indication is not

displayed. Therefore do not start the engine.)
6-27
2. Keep buzzer stop switch on gauge cluster pressed

for 5 seconds and release it and the screen for
selecting adjustment is displayed. When adjustment
ADJUST OUTPUT FIN
data is not entered in mechatro controller, "READY" ADJUST UNLOAD READY
is indicated. If the adjustment operation is once ADJUST CRANE
ADJUST 0 CRANE
READY
READY
performed, "FIN" is indicated. ADJUST LMN READY
ADJ INTERFE PREV READY

And the lever lock solenoid is automatically ADJUST INITIAL READY
released, disabling all operations.
3. Press menu switch on gauge cluster to display

"START ENGINE". START
ENGINE
The "ENGINE" speed, "P1 PRESSURE" and "P2
PRESSURE", and "STEP" (acceleration command ENGINE
STEP
0
voltage) are displayed. ECU OUTPUT 80
P1 PUMP 350
P2 PUMP 350
P1 UNLOAD 200
P2 UNLOAD 200
P1 PRESSURE 0
P2 PRESSURE 0
4. After starting the engine, when you press the menu

switch on the gauge cluster, "MEMORY ENGINE" is MEMORY
ENGINE
indicated. Then the engine speed is automatically
increased and adjustment of the engine is ENGINE
STEP
0
performed. ECU OUTPUT 80
P1 PUMP 350
(To restrict the engine speed, press the menu switch P2 PUMP 350
on the gauge cluster when a desired engine speed P1 UNLOAD 200
P2 UNLOAD 200
is obtained. Then adjustment of the engine is P1 PRESSURE 0
completed. Later torque adjustment and unload P2 PRESSURE 0
adjustment are not performed, and the default

values are written.)
5. When a high idle engine speed is detected normally,
adjustment is completed. FINISH
ENGINE
(Press the buzzer stop switch on the gauge cluster
while this display is present. Then, the engine ENGINE
STEP
0
adjustment is completed. Later torque adjustment ECU OUTPUT 80
P1 PUMP 350
and unload adjustment are not performed, and the P2 PUMP 350
default values are written.) P1 UNLOAD 200
P2 UNLOAD 200
P1 PRESSURE 0
P2 PRESSURE 0
6-28
6.10.3.2 ADJUSTMENT OF PUMP ("B" ADJUSTMENT)

1. The operation automatically shifts from "MEMORY
ENGINE" to "MEMORY PUMP" and the engine MEMORY
PUMP
speed shifts from the low idle speed to the high idle
speed. And the unload proportional valve and the ENGINE
STEP
0
pump proportional valve start working to increase ECU OUTPUT 80
P1 PUMP 350
the load on the pump. P2 PUMP 350
The "ENGINE" speed, "P1 PRESSURE" and "P2 P1 UNLOAD 200
P2 UNLOAD 200
PRESSURE", and the current (command value) of P1 PRESSURE 0
"P1 PUMP" and "P2 PUMP" proportional valves are P2 PRESSURE 0
displayed.
2. After detection of the engine rated speed, the
adjustment of pump is automatically completed. FINISH
PUMP
(Press the buzzer stop switch on gauge cluster
while this display is appeared and the adjustment is ENGINE
STEP
0
completed. The unloading adjustment required later ECU OUTPUT 80
P1 PUMP 350
is not performed, and the default value is written.) P2 PUMP 350
P1 UNLOAD 200
P2 UNLOAD 200
P1 PRESSURE 0
P2 PRESSURE 0
6.10.3.3 ADJUSTMENT OF UNLOADING VALVE ("C" ADJUSTMENT)

1. The adjustment shifts from pump to unloading, and
the unloading valve actuates, accordingly the pump MEMORY
UNLOAD
pressure is detected. And "MEMORY UNLOAD" is
displayed. ENGINE
STEP
0
The "ENGINE" speed, "P1 PRESSURE" and "P2 ECU OUTPUT 80
P1 PUMP 350
PRESSURE", and the current (command value) of P2 PUMP 350
"P1 UNLOAD" and "P2 UNLOAD" proportional P1 UNLOAD 200
P2 UNLOAD 200
valves are displayed. P1 PRESSURE 0
P2 PRESSURE 0
2. When the unloading valve operates to the specified

value, the adjustment of unloading proportional FINISH
UNLOAD
valve is automatically terminated. And "FINISH
UNLOAD" is displayed.
6
ENGINE 0
STEP 0
The speed is shifted to the speed corresponding to ECU OUTPUT 80
P1 PUMP 350
acceleration potentiometer. P2 PUMP 350
The adjusting current value is indicated on the P1 UNLOAD 200
P2 UNLOAD 200
display of current of P1, P2 unloading proportional P1 PRESSURE 0
valves. The adjusting range is usually 520 to 635 P2 PRESSURE 0
mA.
Stop the engine. (The adjusted data is automatically
stored.)
6-29
6.10.3.4 ADJUSTMENT OF UNLOADING VALVE ("C" ADJUSTMENT)

When the unloading valve and unloading proportional valve are replaced, perform the adjustment of unloading
valve.
1. Turn the starter key switch ON keeping the work MULTI DISPLAY
mode select switch on the gauge cluster pressed, (EXAMPLE)
and hold it for 5 to 10 seconds, and then release it. S 12:15
(If the engine is started, the following indication is

not displayed. Therefore do not start the engine.)
2. Keep buzzer stop switch on gauge cluster pressed

for 5 seconds and release it and the screen for
selection of adjustment type is displayed. And
"ADJUST" is displayed. ADJUST OUTPUT FIN
ADJUST UNLOAD FIN

When adjustment data is not entered in mechatro ADJUST CRANE ---
controller, "READY" is indicated. If the adjustment ADJUST 0 CRANE
ADJUST LMN
---
---
operation is once performed, "FIN" is indicated. ADJ INTERFE PREV ---
ADJUST INITIAL ---

And the lever lock solenoid is automatically
released, disabling all operations.
3. Change the adjusting items with up arrow switch ()

and down arrow switch (▼), and select "ADJUST
UNLOAD". (See Fig. "Gauge cluster")
Like the output adjustment, when adjustment data is ADJUST OUTPUT
ADJUST UNLOAD
FIN
FIN
not entered in mechatro controller, "READY" is ADJUST CRANE ---
ADJUST 0 CRANE ---

indicated. If the adjustment operation is once ADJUST LMN ---
performed, "FIN" is indicated. ADJ INTERFE PREV ---
ADJUST INITIAL ---
4. Press menu switch on gauge cluster to display

"START ENG". START
ENGINE
"ENGINE SPEED", P1, P2 "PUMP PRESSURE"
and "STEP" (acceleration command voltage) are ENGINE
STEP
2040
indicated. ECU OUTPUT 120
P1 PUMP 350
P2 PUMP 350
P1 UNLOAD 750
P2 UNLOAD 750
P1 PRESSURE 250
P2 PRESSURE 11
5. After starting engine, press menu switch on gauge

cluster and "MEMORY UNLOAD" is indicated, the MEMORY
UNLOAD
engine speed is automatically increased and the
ENGINE 2290
adjustment of unloading valve is performed. STEP 0
"ENGINE SPEED", P1, P2 "PUMP PRESSURE" ECU OUTPUT 360
P1 PUMP 390
and "PROPO-VALVE" (acceleration command P2 PUMP 390
current) are indicated. P1 UNLOAD 360
P2 UNLOAD 360
P1 PRESSURE 341
P2 PRESSURE 340
6-30
6. When the unloading proportional valve operates to

FINISH
the specified value, the adjustment of unloading UNLOAD
proportional valve automatically completes. ENGINE 2040
The speed is shifted to the speed corresponding to STEP 0
ECU OUTPUT 120

acceleration potentiometer. P1 PUMP 350
The value of adjusting current is indicated on the P2 PUMP 350
P1 UNLOAD 750
display of current of P1 and P2 unloading P2 UNLOAD 750
proportional valves. The adjusting range is usually P1 PRESSURE 250
P2 PRESSURE 11
520 to 635 mA.
Stop the engine. (The adjusted data is automatically
stored.)
6-31
6.10.4 MEASURES WHEN MECHATRO CONTROL ADJUSTMENT IS

IMPOSSIBLE
1. When adjustment of engine is impossible
Judging condition: The read value of the engine ERROR
ENGINE
speed is 50 rpm or more lower than the previous
ENGINE 0
value. STEP 0
An engine speed reading error and application of ECU OUTPUT 80
P1 PUMP 350
pump load during adjustment and an error of the P2 PUMP 350
acceleration command voltage to the engine P1 UNLOAD
P2 UNLOAD
200
200
controller are suspected. P1 PRESSURE 0
P2 PRESSURE 0
1) Check of rotation sensor: Check for abnormal
reading of the engine speed caused by engine
vibration.
2) Check of pump load: Check for abnormal rise of the pump pressure during engine adjustment in the
adjustment screen.
3) Check of acceleration command voltage: Measure the acceleration command voltage that is output from the
mechatro controller and input to the engine controller. Measure the voltage actually or use the failure
diagnosis tool of the engine controller to check that the signal is input to the engine controller correctly.
2. When adjustment of pump is impossible
Judging condition 1: P1 and P2 average pump
pressure at the time when the adjustment is ERROR
PUMP
completed is less than 25 MPa (3625 psi).
Judging condition 2: The adjustment does not ENGINE
STEP
0
complete although the pump proportional valve ECU OUTPUT 80
P1 PUMP 350
current reaches to the specified value. P2 PUMP 350
The P1 and P2 pump pressures usually increase to P1 UNLOAD 200
P2 UNLOAD 200
33 to 38 MPa (4785 to 5510 psi). P1 PRESSURE 0
When the pressure does not increase; P2 PRESSURE 0
1) Identify the reason why the pressure does not

increase.
• Check that the relief valve operates normally.
• Check that the hydraulic circuit is free from leak of pressure.
• Check that the pressure sensor functions normally. And so on.
2) Identify the reason why the actual flow rate does not increase.
• Check that the pump proportional valve operates normally.
• Check that the pump regulator operates normally. And so on
3. When adjustment of unload valve is impossible
Judging condition 1: The pump pressure does not
increase. Or the increased pressure is held as it is. ERROR
UNLOAD
Judging condition 2: The pressure sensor of either
P1 or P2 pump is failed. ENGINE
STEP
0
Normally the pump pressures of P1 and p2 pumps ECU OUTPUT 80
P1 PUMP 350
gradually increase to 10 to 25 MPa (1450 to 3625 P2 PUMP 350
psi). (It may be affected by the hydraulic oil P1 UNLOAD 200
P2 UNLOAD 200
temperature.) P1 PRESSURE 0
When the pump pressure does not increase; P2 PRESSURE 0
1) Identify the reason why the pressure does not

increase.
• Check that the relief valve operates normally.
• Check that the hydraulic circuit is free from leak of pressure.
• Check that the pressure sensor functions normally. And so on.
4. Other precautions
6-32
• In the event of a failure, the adjustment may not be performed normally. First service the machine, and perform
the adjustment work.
• In the condition where a large load is constantly applied to the engine, the adjustment could not be performed
normally.
For machines equipped with the lifting magnet, turn the generator OFF.
6.10.5 OPERATIONS WHEN OCCURS FAILURE OF MECHATRO

CONTROLLER
Engine emergency mode
When the trouble occurs and the control of engine is impossible, the engine speed can be controlled by operating
emergency acceleration (E-27) provided on the seat rear side.(See the figure in "ENGINE CONTROL INPUT/
OUTPUT".)
Operating procedure:
1. Set the emergency acceleration to NORMAL position.
2. Start engine.
3. Turn the emergency acceleration to HI side and control the engine speed.
4. When stopping the engine, set the emergency acceleration to NORMAL position before stopping.
Never increase the engine speed immediately after starting engine. It is dangerous.
To avoid this danger, repeat the above procedure, or the engine speed does not increase.
When the machine does not operate, set the emergency acceleration to NORMAL position.
Pump emergency mode

When a failure of the mechatro controller occurs, command by a current for positive control of the pump and the P1
and P2 bump proportional valves, which is based on total horsepower control, may not be performed causing slow
movement of all operations (the pump is fixed at the minimum rotation of the swash plate).
In this case, by operating the KPSS release switch to the release side, the hydraulic emergency mode starts and
the operation speed of the pump becomes a certain speed.
However, during the hydraulic emergency mode, the accuracy of inching performance becomes poor, the engine
speed is decreased further, and the engine stalls at LOW idle speed. Be careful about these.
6
The hydraulic emergency mode should be used in only case of emergency. Repair the failure part by
troubleshooting as early as possible.
6-33
6-34
［7. MECHATRO CONTROLLER］
7. MECHATRO CONTROLLER
7.2 FOREWORD ............................................................................................................................7-4
7.3 SUMMARY OF MECHATRO CONTROL SYSTEM......................................................................7-6
7.3.1 MECHATRO CONTROL SYSTEM IN GENERAL .....................................................................7-6
7.3.2 UNLOAD VALVE CONTROL ..................................................................................................7-8
7.3.3 POSITIVE CONTROL AND P-Q CONTROL ..........................................................................7-10
7.3.4 BOOM UP CONFLUX CONTROL .........................................................................................7-12
7.3.5 CONTROL OF ARM-IN RECIRCULATION AND CONFLUX ...................................................7-14
7.3.6 ARM-IN ANTI-CAVITATION CONTROL.................................................................................7-16
7.3.7 ARM-OUT CONFLUX CONTROL .........................................................................................7-17
7.3.8 BOOM DOWN AND ARM-OUT CONTROL............................................................................7-20
7.3.9 BUCKET DIGGING AND ANTI-CAVITATION CONTROL .......................................................7-22
7.3.10 SWING PRIORITY CONTROL ............................................................................................7-24
7.3.11 TRAVEL STRAIGHT CONTROL .........................................................................................7-26
7.3.12 PRESSURE RELEASE CONTROL .....................................................................................7-28
7.3.13 WARNING OF RETURN FILTER CLOGGING ......................................................................7-30
7.4 MECHATRO CONTROLLER ...................................................................................................7-32
7.4.1 SUMMARY OF MULTI-DISPLAY...........................................................................................7-32
7.4.2 SELF DIAGNOSIS DISPLAY FUNCTION ..............................................................................7-39
7.4.3 SERVICE DIAGNOSIS DISPLAY FUNCTION ........................................................................7-43
7.4.4 TROUBLE HISTORY DISPLAY FUNCTION...........................................................................7-52
7.4.5 CHANGE PROCEDURES OF REPLACEMENT INTERVAL....................................................7-53
7.4.6 VARIOUS ADJUSTMENT FUNCTION (USER MENU)............................................................7-55
7.4.7 VARIOUS ADJUSTMENT FUNCTION (SERVICE MENU) ......................................................7-63
7.4.8 MECHATRO CONTROL DEVICES .......................................................................................7-74
7-1
7-2

7-3
7.2 FOREWORD
This chapter explains the control related to hydraulic to electric power conversion or vice versa as mechatro control
and explains only the summary of the mechatro system and mechatro controller related devices and functions.
Regarding the conditions before and after each conversion, refer to Chapters "HYDRAULIC SYSTEM" and
"ELECTRICAL SYSTEM".
7-4
This page is blank for editing convenience.
7-5
7.3 SUMMARY OF MECHATRO CONTROL SYSTEM

7.3.1 MECHATRO CONTROL SYSTEM IN GENERAL
ELECTRIICITY HYDRAULIC POWER
CONTROLLER INPUT SIGNAL PILOT SECONDAR Y P RES S URE
SECONDAR Y P RES S URE OF P ROP. S OLENOID VALVE
PILOT PRIMARY P RES S URE
MAIN CIRCUIT
LH RH LH RH
PILOT VALVE PILOT VALVE

FOR ATT FOR TRAVEL
SE-9 NOTE:
SE-10 FOR NOR TH AMERICA:
WITH BHL MULTI SELECT OR VALVE
NOTE FOR EUROPE:
WITHOUT MULTI SELECT OR VALVE
GAUGE CLUSTER
LOW PRESSURE SENSOR
LCD FOR SELECITION SE-4
AND DISPLAY (4)
FUEL LEVEL METER SE-3
COOLANT TEMP.
(3)
GAUGE SE-2 L2
(2) L3
LOWER SW.
SCREEN CHANGE SW. SE-1
(1)
BUZZER STOP SW.
WORK MODE SELECT SE-8
S W. (H, S, AND ECO) (8)
WASHER SW. SE-7
(7)
WIPER SW. L4
OUTPUT VOLTAGE
TRAVEL SPEED (6)

S ELECT SW.
DIGGING MODE SW. SE-41
(5)
NIBBLER MODE SW.
BREAKER MODE SW.
SE-40
MENU SW.
CAN COMMUNICATION
ENGINE
THROTTLE
SE-16
SE-23
PROP. VOLTAGE
HIGH PRESSURE
SENSOR SE-22
L5
C-1
MECHATRO CONTROLLER A1 A2 A3
ENGINE
INJECT OR SPEED SENSOR
SE-13
PSV-P1
SE-21
P1 PUMP PROPOR TIONAL VALVE
: HIGH PRESSURE SENSOR
(P1, P2, BOOM HEAD, AND BOOM ROD) PSV-P2
P2 PUMP PROPOR TIONAL VALVE
: INJECT OR
CAN COMMUNICATION
: E/G SPEED SENSOR C-8
ENGINE CONTROLLER L6
ENGINE SPEED
: LOW PRESSURE SENSOR COMMAND CURRENT
(ATT: 6 PCS., SWING: 2PCS. AND TRAVEL: 2 PCS.) VOLTAGE OF 24V
PROP . COMMAND CURRENT L7
: ENGINE THROTTLE POTENTIOMETER E-27
ENGINE THROTTLE FOR REDUNDANT MODE
7-6
MAIN CONTROL VALVE
ARM-OUT DUMP DOWN FOR WARD FOR WARD LEFT ARM-OUT

(8) (2) (4) (3) (6) (8)
P1 UNLOAD
CONFLUX
BOOM 2
BOOM UP
BOOM METER IN CUT
PL1(POWER BOOST)
ARM-IN SPEED 2
ARM-IN SPEED 1
TRAVEL RIGHT
TRAVEL LEFT
BUCKET
P2 UNLOAD
STRAIGHT
BOOM 3
SWING
BOOM
TRAVEL
P1 P2
(1) (3) (5) (7)
DIGGING UP REVERSE REVERSE RIGHT ARM-IN
L2
L3
L4
RELEASE OF SWING MOT OR

PARKING BRAKE
2-SPEED SELECTION OF
TRAVEL MOTOR
TRAVEL 2-SPEED SELECTION
BOOM CYLINDER
BOOM UP CONFLUX
SWING PARKING BRAKE
SE-24
BOOM METER IN CUT
L5
TRAVEL STRAIGHT
ARM-IN SPEED 2
POWER BOOST
LEVER LOCK
P2 UNLOAD
P1 UNLOAD
BOOM 2
BOOM 3
SE-25
ARM CYLINDER
ARM-OUT CONFLUX
ARM-IN CONFLUX RECIRCULATION
7
PSV PSV PSV PSV PSV S V PSV S V SV SV SV
-A -23 -24 -B -C -1 -D -4 -105 -3 -2
(7)
L6 ARM-IN BUCKET CYLINDER
DIGGING / DUMP CONFLUX
L7
SE-60
CLOGGING SENSOR
SOLENOID OPERA TED DIRECTIONAL
CONTROL VALVE AND PROP. SOLENOID VALVE ) BLOCK
7-7
7.3.2 UNLOAD VALVE CONTROL
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
TRAVEL LEFT
ARM 2 SPEED
ARM 1 SPEED
BUCKET
SWING
BOOM
STRAIGHT
BOOM METER IN CUT

P2 UNLOAD
BOOM 3
TRAVEL
P2 P1
BOOM CYLINDER
PILOT PILOT
(LEFT) (RIGHT) OPTIONAL VALVE VALVE
PILOT VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
SE-11 PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1 | 4 SE-40,41,7,8
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROP. VALVE
PSV-B
PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
P1 UNLOAD
PROCESS PROP. VALVE
PSV-D
MECHATRO pi :
PILOT SECONDARY PRESSURE CONTROLLER SECONDARY PRESSURE
OF PROPORTIONAL VALVE
1. On starting any one of operations, the control pilot secondary pressure switches spools and enters in each low
pressure sensor.
2. The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller
processes pilot signals and outputs the command values to each unload proportional valve according to the
input voltage.
3. Each unload proportional valve outputs the pilot secondary pressure according to the command output by the
mechatro controller and switches each unload spool.
4. With this operation, the bleed opening is obtained according to the lever displacement, and the pump pressure
which actuates each actuator is delivered, so that each actuator starts working.
7-8
7-9
7.3.3 POSITIVE CONTROL AND P-Q CONTROL
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
ARM 2 SPEED
ARM 1 SPEED
TRAVEL LEFT
BUCKET
BOOM
SWING
STRAIGHT
BOOM METER IN CUT

P2 UNLOAD
TRAVEL
BOOM 3
OPTIONAL
PILOT VALVE
P2 P1
SE-23 SE-22
SE-11
BOOM CYLINDER
PILOT PILOT
(LEFT) (RIGHT) VALVE VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1 | 4 SE-40,41,7,8
pi
PILOT SIGNAL
PROCESS COMMAND TO P2 PUMP
P2 PUMP PROP. PROP. VALVE
VALVE PSV-P2
pi
pi
COMMAND TO P1 PUMP
P1 PUMP PROP. PROP. VALVE
PILOT SIGNAL VALVE PSV-P1
PROCESS pi :
MECHATRO SECONDARY PRESSURE
CONTROLLER OF PROPORTIONAL VALVE
Positive control
1. On starting any one of operations, the control pilot secondary pressure switches spools and enters in each low
pressure sensor.
processes pilot signals and outputs command values to each pump proportional valve according to the input
voltage.
3. Each pump proportional valve outputs the pilot secondary pressure according to the command value output by
the mechatro controller and changes the swash plate angle of each pump to control the delivery rate.
7-10
4. With this operation, the delivery rate is supplied to the actuator according to the lever displacement, and the
working speed changes according to the lever displacement.
P−Q control
1. The output voltage of the high pressure sensor at each pump line is input to the mechatro controller and the
mechatro controller processes pilot signals and calculates the command value according to the input voltage
(load pressure).
2. A lower value between the command value calculated by positive control and command value (1) calculated by
P-Q control (calculated value in 1.) is selected and is output to each pump proportional valve as the command
value.
3. Each pump proportional valve outputs the pilot secondary pressure according to the command value output by
the mechatro controller and changes the swash plate angle of each pump to control the delivery rate of
pressure oil.
4. With this operation, the actuator load becomes high and even when the pump load becomes high, the machine
can keep working without engine stall.
POSITIVE CONTROL P-Q CONTROL
PILOT SIGNAL PROCESS PILOT SIGNAL PROCESS

S ECONDARY P RES S URE
S ECONDARY P RES S URE

OF P UMP P ROP . VALVE
Pi OF P UMP P ROP . VALVE Pi
PILOT PRESSURE PUMP DELIVERY PRESSURE
7-11
7.3.4 BOOM UP CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
ARM 2 SPEED
ARM 1 SPEED
TRAVEL LEFT
BUCKET
SWING
BOOM
P2 UNLOAD
BOOM METER IN CUT

STRAIGHT
BOOM 3
TRAVEL
PILOT
VALVE P2 P1
BOOM CYLINDER
SE-3
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2
PILOT SECONDARY PRESSURE OF BOOM UP

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROP. VALVE
PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROP. VALVE
PSV-B

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROP. VALVE
MECHATRO PSV-D
CONTROLLER pi :
PILOT SECONDARY PRESSURE OF BOOM UP SECONDARY PRESSURE
1. On starting boom up operation, the pilot pressure or boom up operation switches the boom spool and the boom
up conflux spool and is input to the low pressure sensor.
processes pilot signals and outputs the command values to the P1 and P2 pump proportional valves and the
P1 and P2 unload proportional valves according to the input voltage.
3. Each proportional valve outputs the pilot secondary pressure of the proportional valve according to the
command value output by the mechatro controller and changes the P1 and P2 pump delivery rates and
switches the P1 and P2 unload valves.
7-12
4. The boom main spool and the boom up conflux spool are switched by the original hydraulic pressure
command, and also the P1 and P2 pumps and the P1 and P2 unload valves are switched by the command of
the mechatro controller, and the delivery oil of the P1 pump joins the delivery oil of the P2 pump during boom
up operation.
7-13
7.3.5 CONTROL OF ARM-IN RECIRCULATION AND CONFLUX
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
ARM 2 SPEED
ARM 1 SPEED
TRAVEL LEFT
BUCKET
BOOM
SWING
BOOM METER IN CUT

P2 UNLOAD
STRAIGHT
BOOM 3
TRAVEL
PILOT
VALVE
P2 P1
BOOM CYLINDER
LOW
PRESSURE LOW PRESSURE
SENSOR SENSOR
SE-1 | 4,40,41 SE-7
CONTROL PROCESS
OF 2-SPEED
pi PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2
PILOT SECONDARY PRESSURE OF ARM-IN
P1 PUMP
PROP. VALVE
PSV-P1

PILOT SIGNAL
PROCESS P2 UNLOAD
PROP. VALVE
PSV-B
P1 UNLOAD
PROP. VALVE
pi PSV-D
PILOT SECONDARY PRESSURE PILOT SIGNAL

PROCESS
pi
CONTROL PROCESS ARM-IN SPEED 2
OF ARM-IN SPEED 2 INVERSE PROP.
INVERSE PROP. VALVE PSV-A
VALVE
PILOT SECONDARY
PRESSURE OF ARM
P2 PUMP PRESSURE MECHATRO pi :

CONTROLLER SECONDARY PRESSURE
Recirculation and conflux (low load)

1. On starting arm-in operation, the pilot secondary pressure of arm operation is input to the arm speed 1 and 2
spools, and the low pressure sensor.
7-14
processes pilot signals and outputs the command values to the P1 and P2 pump proportional valves, the P1
and P2 unload proportional valves, and the arm-in speed 2 inverse proportional valve according to the input
voltage.
In case of combined operation, the pilot pressure of other than arm-in operation is input to the low pressure
sensor and the output voltage is input to the mechatro controller. And the mechatro controller processes the
pilot signals according to the combined operation and outputs the command values to the P1 pump
proportional valve, the P1 unload proportional valve, and the arm-in speed 2 inverse proportional valve,
differently from arm-in independent operation.
3. The primary pressure of the arm-in speed 2 inverse proportional valve is the pilot secondary pressure of arm-in
operation and the arm 2 spool is switched by the secondary pressure of the proportional valve according to the
command value. (The arm 2 spool controls recirculation rate and conflux rate.)
The other proportional valves output the secondary pressure of the proportional valve according to the
command value of the mechatro controller, change the delivery rate of the P1 and P2 pumps, and switch the
P1 and P2 unload spools.
4. The arm speed 1 spool is switched by the original hydraulic pressure command, and the P1 and P2 pumps, the
P1 and P2 unload spools, and the arm speed 2 spool are switched by the command of the mechatro controller
to recirculate the return oil from the arm cylinder rod side and mix it with the delivery oil from the P1 and P2
pumps during arm operation.
Recirculation cut
The voltage output value from the high pressure sensor at the P2 side is input to the mechatro controller, and when
load becomes high during arm-in operation, the mechatro controller processes the pilot signals according to the
pressure detected by the high pressure sensor and outputs the command value to the arm-in speed 2 inverse
proportional valve to command recirculation cut on the arm-in speed 2 function.
The arm-in speed 2 inverse proportional valve outputs the pilot secondary pressure according to the command
value of the mechatro controller and switches the arm 2 spool to the recirculation cut position to block the
recirculation passage.
7-15
7.3.6 ARM-IN ANTI-CAVITATION CONTROL
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
BUCKET
BOOM
SWING
BOOM METER IN CUT

STRAIGHT
P2 UNLOAD
BOOM 3
TRAVEL
PILOT
VALVE
P2 P1
BOOM CYLINDER
LOW ENGINE THROTTLE

PRESSURE POTENTIOMETER
SENSOR
SE-7
pi pi
PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2

pi PILOT SIGNAL
PROCESS P2 UNLOAD
PROP. VALVE
PSV-B pi

pi
COMMAND TO ARM-IN ARM-IN SPEED 2
SPEED 2 INVERSE INVERSE PROP.
PROP. VALVE VALVE PSV-A pi
pi :
ENGINE SPEED (COMMAND VALUE) MECHATRO
SECONDARY PRESSURE
CONTROLLER
1. On starting arm-in operation, the pilot secondary pressure of arm-in operation switches the arm speed 1 spool
and is input to the low pressure sensor.
2. The engine speed command output by the engine throttle potentiometer is input to the mechatro controller.
3. The output voltage of the low pressure sensor is input to the mechatro controller, and the mechatro controller
processes the pilot signals and outputs the command value to the P2 pump proportional valve and the P2
unload proportional valve according to the input voltage.
4. And also the mechatro controller outputs the command value to the arm-in speed 2 inverse proportional valve
according to the input voltage from the engine throttle potentiometer.
5. Each proportional valve outputs the pilot secondary pressure according to the command value of the mechatro
controller, and spool stroke of the arm-in speed 2 inverse proportional valve is controlled according to the
engine speed. By changing the recirculation rate, cavitation can be prevented even when a pump delivery rate
is low due to a low engine speed.
7-16
7.3.7 ARM-OUT CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
TRAVEL LEFT
ARM 2 SPEED
ARM 1 SPEED
BUCKET
BOOM
SWING
BOOM METER IN CUT

P2 UNLOAD
STRAIGHT
BOOM 3
TRAVEL
PILOT
P2 P1
VALVE
BOOM CYLINDER
LOW PRESSURE
SENSOR
SE-8
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2
PILOT SECONDARY PRESSURE OF ARM-OUT

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROP. VALVE
PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROP. VALVE
PSV-B

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROP. VALVE
MECHATRO PSV-D
CONTROLLER pi :
PILOT SECONDARY PRESSURE OF ARM-OUT SECONDARY PRESSURE
OF PROPORTIONAL VALVE 7
1. On starting arm-out operation, the pilot pressure of arm-out operation switches the arm speed 1 and 2 spools
processes pilot signals and outputs the command values to the P1 and P2 pump proportional valves and the
P1 and P2 unload proportional valves according to the input voltage.
switches the P1 and P2 unload valves.
7-17
4. The arm speed 1 and 2 spools are switched by the original hydraulic pressure command, and also the P1 and
P2 pumps and the P1 and P2 unload valves are switched by the command of the mechatro controller, and the
delivery oil of the P1 pump joins the delivery oil of the P2 pump during arm-out operation.
7-18
7-19
7.3.8 BOOM DOWN AND ARM-OUT CONTROL
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
ARM 2 SPEED
TRAVEL LEFT
ARM 1 SPEED
BUCKET
BOOM
SWING
BOOM METER IN CUT

STRAIGHT
P2 UNLOAD
BOOM 3
TRAVEL
P2 P1
BOOM CYLINDER
LOW
PRESSURE
SENSOR LOW PRESSURE
SE-4
SENSOR
SE-8
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROP. VALVE
PSV-P1
PILOT PRESSURE OF BOOM DOWN

pi PILOT SIGNAL
PROCESS P1 UNLOAD
PROP. VALVE
PSV-D

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2
PILOT PRESSURE OF ARM-OUT

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROP. VALVE
PSV-B
PILOT PRESSURE OF ARM-OUT
pi
BOOM 2 PSV-23
BOOM DOWN AND
ARM-OUT PROCESS
BOOM 3 PSV-24

PILOT PRESSURE OF ARM-OUT BOOM METER IN CUT
SV-105
7-20
1. When arm-out operation is performed during boom down operation (or boom down operation is performed
during arm-out operation), the pilot secondary pressure of the boom down operation switches the boom spool
and is input to the low pressure sensor and also that of arm-out operation switches the arm spool and is input
to the low pressure sensor.
and P2 unload proportional valves, the boom 2 and 3 proportional valves, and the boom meter in cut solenoid
valve according to the input voltage.
3. Each proportional valve outputs the pilot secondary pressure according to the command value output by the
mechatro controller and changes the P1 and P2 pump flow rates and switches the P1 and P2 unload spools,
the boom 2 and 3 spools, and the meter in cut valve.
4. The boom spool, and the arm speed 1 and 2 spools are switched by the original hydraulic pressure command,
and also the P1 and P2 unload spools, the boom 2 and 3 spools, and the boom meter in cut valve are switched
by the command of the mechatro controller. With this operation, the return oil from the boom head can be
supplied to the arm-out side.
7-21
7.3.9 BUCKET DIGGING AND ANTI-CAVITATION CONTROL
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
BUCKET
SWING
BOOM
BOOM METER IN CUT
STRAIGHT
P2 UNLOAD
BOOM 3
TRAVEL
PILOT
VALVE P2 P1
BOOM CYLINDER
LOW
PRESSURE
SENSOR
SE-1(2) pi
PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2
PILOT SECONDARY PRESSURE OF BUCKET DIGGING

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROP. VALVE
PSV-P1

pi
ENGINE PILOT SIGNAL
THROTTLE PROCESS P2 UNLOAD
POTENTIOMETER PROP. VALVE
PSV-B

pi PILOT SIGNAL
PROCESS P1 UNLOAD
PROP. VALVE
PSV-D

pi
PILOT SIGNAL
PROCESS TRAVEL STRAIGHT
PROP. VALVE
PSV-C

PILOT SIGNAL
pi PROCESS
POWER BOOST
BUCKET CAVITATION SOLENOID VALVE
PREVENTION PROCESS SV-2
ENGINE SPEED (COMMAND VALUE)
pi :
MECHATRO SECONDARY PRESSURE
P1 PUMP PRESSURE CONTROLLER OF PROPORTIONAL VALVE
1. On starting bucket digging operation, the pilot pressure of bucket digging operation switches the bucket spool
7-22
2. The engine speed command output by the engine throttle potentiometer is input to the mechatro controller.
and P2 unload proportional valves, and the travel straight proportional valve according to the input voltage.
switches the P1 and P2 unload valves and the travel straight valve in the control valve.
5. The tandem passage at the P1 side communicates with the P2 port due to the switched travel straight valve
and the P1 pump delivery oil and P2 pump delivery oil join together because of the switched P2 unload valve.
6. The power boost solenoid valve turns the solenoid valve on according to the engine speed, outputs the
secondary pressure, actuates the stroke limiter, and limits stroke of the bucket spool.
By limiting the spool stroke, cavitation can be prevented even when a pump delivery rate is low due to a low
engine speed.
7. When the P1 pump pressure is increased due to cylinder stroke end, etc., the solenoid valve turns OFF
according to the pump pressure, and when the pump pressure is high, the power boost solenoid valve does not
limit stroke of the bucket spool.
7-23
7.3.10 SWING PRIORITY CONTROL
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
PILOT
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
VALVE
BUCKET
SWING
BOOM
BOOM METER IN CUT
STRAIGHT
P2 UNLOAD
BOOM 3
TRAVEL
P2 P1
LOW
PRESSURE BOOM CYLINDER
SENSOR
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2
P1 PUMP
PILOT SECONDARY PRESSURE OF ARM-IN PROP. VALVE
pi PSV-P1
PILOT SIGNAL
PROCESS P2 UNLOAD
PROP. VALVE
PSV-B
P1 UNLOAD
PROP. VALVE
PILOT SECONDARY PRESSURE OF ARM-IN PSV-D
pi
COMMAND TO TRAVEL TRAVEL STRAIGHT
STRAIGHT PROP. PROP. VALVE
VALVE PSV-C
COMMAND TO ARM-IN ARM-IN SPEED 2

PILOT SECONDARY PRESSURE OF SWING SPEED 2 INVERSE INVERSE PROP.
pi PROP. VALVE VALVE PSV-A
pi :
PILOT SECONDARY PRESSURE OF SWING MECHATRO SECONDARY PRESSURE
1. When swing operation is performed during arm-in operation (or arm-in operation is performed during swing
operation), the pilot secondary pressure of arm operation switches the arm spool and is input to the low
pressure sensor and also the pilot secondary pressure of swing operation switches the swing spool and is
input to the low pressure sensor.
and P2 unload proportional valves, the travel straight proportional valve, and the arm-in speed 2 inverse
proportional valve according to the input voltage.
3. Each proportional valve outputs the pilot secondary pressure according to the command value output by the
mechatro controller and changes the P1 and P2 pump delivery rates and switches the P1 and P2 unload
spools, the travel straight spool, and the arm speed 2 spool.
4. The arm speed 1 spool and the swing spool are switched by the original hydraulic pressure command, and the
P1 and P2 unload spools, the travel straight spool, and the arm speed 2 spool are switched by the command of
the mechatro controller to supply the flow rates of two pumps to the arm cylinder head side and recirculate the
return oil from the arm cylinder rod side to the arm cylinder head side.
7-24
5. The return oil from the arm rod side is recirculated and it makes the working pressure increase and the pump
delivery rate be used for swing operation preferentially. The arm is operated by the recirculated oil and
because of this, the operation at a speed decreased by a minimum range becomes possible.
7-25
7.3.11 TRAVEL STRAIGHT CONTROL
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
BUCKET
SWING
BOOM
OPTIONAL
PILOT VALVE
BOOM METER IN CUT

STRAIGHT
P2 UNLOAD
BOOM 3
TRAVEL
(LEFT) (RIGHT)
BOOM
CYLINDER P2 P1
PILOT VALVE
FOR TRAVEL
PILOT PILOT
VALVE VALVE
SE-11 LOW
SE-10 SE-9 PRESSURE
SENSOR
S E-1~4,
7,8,40,41
TRAVEL STRAIGHT SIGNAL
pi
PILOT SIGNAL TRAVEL STRAIGHT
PROCESS PROP. VALVE
PSV-C

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROP. VALVE
PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROP. VALVE
PSV-B

pi
PILOT SIGNAL
P1 UNLOAD
PROCESS PROP. VALVE
PSV-D pi :
MECHATRO SECONDAR Y PRESSURE
PILOT SECONDARY PRESSURE CONTROLLER OF PROPORTIONAL VALVE
7-26
Judging travel straight

1. When carrying out attachment/equipment operation (boom, arm, bucket, swing, and option) during travel
operation (right and left), the pilot pressure switches each spool and is input to each low pressure sensor.
2. The mechatro controller judges the operation as travel straight on receiving the input combination shown in the
table below from the low pressure sensor and turns a travel straight signal on.
3. After the travel straight signal is turned on, the following command values are output to each proportional
valve.
Operation of each proportional valve

(Basically the attachment operation is actuated by the P1 pump and the travel operation is actuated by the P2
pump in the travel straight condition.)
1. Travel straight proportional valve
This outputs a switching pressure according to the pilot pressure of the attachment system in operation, which
is selected by high value selection.
2. P1 unload proportional valve
3. P2 unload proportional valve
This outputs a switching pressure according to the pilot pressure of travel in operation, which is selected by
high value selection.
4. P1 pump proportional valve
5. P2 pump proportional valve
This outputs a switching pressure according to the pilot pressure of travel in operation, which is selected by
high value selection.
Boom Arm Bucket Swing Option
Travel right (P1) ○ ○
Travel left (P2) ○ ○ ○
7-27
7.3.12 PRESSURE RELEASE CONTROL
BOOM UP CONFLUX
P1 UNLOAD
BOOM 2
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
BUCKET
SWING
BOOM
BOOM METER IN CUT
STRAIGHT
P2 UNLOAD
PILOT
BOOM 3
TRAVEL
VALVE
GAUGE CLUSTER
P2 P1
SE-23 SE-22
BOOM
CYLINDER ENGINE
PRESSURE
RELEASE ENGINE SPEED
CONTROL CONTROL
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROP. VALVE
PSV-P2
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROP. VALVE
PSV-P1
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROP. VALVE
PSV-B
pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROP. VALVE
PSV-D
MECHATRO pi : SECONDARY PRESSURE
1. Change the mechatro controller to the pressure release mode by operating switches on the gauge cluster.
For details of mode switching method, refer to "How to switch to 'Pressure release mode'" in Chapter
"HYDRAULIC SYSTEM".
2. Once the mechatro controller judges the operation as pressure release control, regardless of each input signal
(operation pilot and engine throttle potentiometer, etc.), the mechatro controller;
1) Outputs the command value of the minimum swash plate angle to the P1 and P2 pump proportional valves
and fixes the swash plate angle of the P1 and P2 pumps at the minimum.
2) Outputs the command value of pressure release to the ECU and fixes the engine speed to a pressure
release control speed.
3) Outputs the maximum command value to the P1 and P2 unload proportional valves and each pilot
secondary pressure fixes the P1 and P2 unload valves at the maximum opening.
7-28
3. The mechatro controller senses the output voltage from the high pressure sensor of the main pump, judges the
pump pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on the gauge cluster.
4. By operating each control lever and switching spools with the unload valve opened, each pump delivery oil is
unloaded to the tank passage enabling the remained pressure (trapped pressure) of each actuator to be
released.
7-29
7.3.13 WARNING OF RETURN FILTER CLOGGING

Clogging of the return filter is checked automatically.
Check the differential pressure between the backpressure of the filter case of the hydraulic oil tank and the
pressure of the tank suction chamber (the pressure applied to the bypass valve of the return filter) and count the
number of times that the pressure sensor turns ON to judge whether the return filter is clogged or not.
SUCTION
CHAMBER SIDE
FILTER CASE SIDE
PRESSURE SENSOR (SE-20)
M4 NUT
TIGHTENING TORQUE:
0.49 N .m (0.36 lbf .ft) OR LESS
HYD. OIL TEMP.SENSOR(SE-21)
WIDTH ACROS S FLATS :

HIGH PRESSURE 27mm(1.06 inch)
SENSOR
WARNING DISPLAY
(0.64 inch)
16.2
LOW PRESSURE CONTACT CIRCUIT AT DIFFERENTIAL

SENSOR P RES S URE 0 MP a (0 ps i)
COM NC
CONTACT CIRCUIT AT DIFFERENTIAL

P RES S URE 0.1 MP a (14.5 ps i)
COM NC
PRESSURE SENSOR (SE-20)
7-30
Pressure sensor
• This is a normal close, voltage detection type sensor.
• At 0 MPa (0 psi), it turns OFF (close), and at 0.1 MPa (14.5 psi) or more, it turns ON (open).
Detection mode
During normal operation, even when the pressure sensor turns ON, it does not affect detection.
When the operation under the condition that the oil temperature is 30 degrees C (86 degrees F) or more and the
engine speed is 1600 min–1 or more is performed for total 60 seconds or more, the pump flow rate increases to the
maximum automatically for approximately 3 seconds while each control lever, pedal, and switch are at the neutral
position to detect ON/OFF of the pressure sensor.
Count
When the pressure switch turns ON during the detection mode, if the starter switch is turned off with that condition,
ON is counted as 1 time. If ON is counted for three times continuously, the return filter is judged as being clogged.
But, even if ON of the pressure sensor is detected during the detection mode, if OFF is detected at the next
detection mode during a continuous operation, ON of the previous time can be cancelled. In other words, ON just
before turning off the starter switch is only applied for count.
Warning display
When the return filter is judged as being clogged due to the third count at the time of starter switch OFF, "CHANGE
HYD. OIL FLTR" appears on the gauge cluster at the time of the next starter switch ON.
Furthermore, the warning display for filter replacement appears not only when clogging occurs but also when the
remaining time for maintenance set from the gauge cluster becomes zero.
Canceling warning
When the return filter is clogged or the replacement interval of the return filter has been reached, replace the filter.
At that time, the warning can be cancelled by either of the following method.
1. Reset the maintenance interval of the return filter from the gauge cluster. (Default value: 1,000 hours)
2. Set the machine in the detection mode to make the pressure sensor OFF, and then turn the starter switch off.
7-31
7.4 MECHATRO CONTROLLER

7.4.1 SUMMARY OF MULTI-DISPLAY
Electro-hydraulic converted information is displayed on the multi-display of the gauge cluster.
7.4.1.1 CONTROLS
5 12
11
3 2
1
6
8
10
4
9
DETAILA
No. Name No. Name

1 Left control lever (with horn switch) 7 Engine throttle
2 Right control lever 8 Swing parking brake release switch
3 Pilot control shut-off lever 9 Engine throttle for redundant mode
4 Fuse and relay box 10 KPSS release switch
5 Cluster gauge 11 Mechatro controller
6 Starter switch 12 Engine controller
7-32
7.4.1.2 GAUGE CLUSTER

(1)Engine coolant temperature meter
(2)Fuel level meter
(3)Screen change switch
1 S
K
2
(4)Buzzer stop switch
(5)Work mode select switch
(6)Washer switch 18
(7)Wiper switch
(8)Travel speed select switch L/h
50
(9)Auto acceleration switch 9 40

30
20
(10)Menu switch 10
6
11 30
9
MIN
25 20 15 10 5
11
0
0
(11)Digging switch 24.4 L/h
(12)Nibbler switch
(13)Breaker switch 8 7
5 13
(14)Up arrow switch 4 16
(15)Down arrow switch 10
(16)Right arrow switch
(17)Left arrow switch
17 3 14 15 12
(18)Multi-display (LCD)
7-33
7.4.1.3 DISPLAY ACCORDING TO SELECTION OF WORK MODE SELECT SWITCH

The work mode is switched into three modes, "S" → "E"
→ "H" in order, each time work mode select switch (1) is
pressed.
S
Select a proper work mode according to the work K
condition and purpose.

The selected work mode is displayed on the left upper
corner of the multi-display.
The work mode after engine start always starts from the "S" mode.
Control mode Display Summary
S
K
S: S mode The "S mode" is suitable for a standard digging work and loading
(for standard digging operations. It provides good fuel consumption and is well-balanced
work) with a workload.
E
K
E: ECO mode
(for digging work with The "ECO mode" focuses on a low fuel consumption operation.
low fuel consumption)
H
K
H: H mode
The "H mode" is suitable for a heavy duty digging work with high
(for heavy duty digging
speed, which gives priority to a workload.
work)
7.4.1.4 GREEN MARK TURNING ON CONDITION

When the fuel consumption value is 90 % or less of that
of relief operation at the H mode, the green mark turns
on. This is lighting logic of the green mark. (common at
each mode)
1
(1)Green mark
7-34
7.4.1.5 DISPLAY ACCORDING TO SELECTION OF ATTACHMENT MODE SELECT SWITCH

This switch is used to select the attachment mode.
Attachment mode display screen
Select an appropriate mode corresponding to the
S
attachment from two modes: "digging" or "breaker". K
Before operation, always check that the attachment

mode is appropriately set.
When digging switch (1) is pressed, the attachment
mode is switched to the digging mode, and the icon of
the selected digging mode is displayed.
When breaker switch (3) is pressed, the attachment
mode is switched to the breaker mode, and the icon of 2
the selected breaker mode is displayed.
(1)Digging switch
(2)Nibbler switch
(3)Breaker switch 3
1
Attachment mode Switch position Display Work contents
S
K
Digging mode This is mode for digging or loading work.
S
K
Nibbler mode Do not use this mode.
S
K
Be sure to select breaker mode when

Breaker mode
performing breaker work.
If you perform work with "nibbler mode" selected, it may lead to damage of the components.
Do not use "nibbler mode".
7
7-35
7.4.1.6 MAINTENANCE SCREEN

This screen displays the remaining time to the end of the
recommended replacement interval specified for the
filter/oil.
After turning the starter switch "ON" or starting the S INTERVAL REMAINDER
EXCHANGE
DAY
engine, press "menu switch" (8) to enter user menu K
USER MENU ENGINE OIL 500Hr 500Hr 14/12/12
K
screen (b). Move the cursor to "MAINTENANCE" and MAINTENANCE FUEL FILTER 500Hr -100Hr 14/12/12
SWITCH STATUS HYD. FILTER 1000Hr 500Hr 14/12/12

while keeping it in that position, press the right arrow OPTION SETTING HYD. OIL 3000Hr 3000Hr 14/12/12
switch to enter the maintenance information screen. CONSUMPTION

SCREEN SETTING
This screen shows the recommended replacement CLOCK SETTING
interval of the engine oil, fuel filter, hydraulic oil filter, and
EXCHANGE
hydraulic oil, the remaining time until the next ENGINE OIL
INTERVAL REMAINDER
500Hr 500Hr
DAY
14/12/12
replacement interval, and the date of the previous BACK
HOME
UP
DOWN
NEXT
FUEL FILTER 500Hr -100Hr 14/12/12
replacement. HYD. FILTER 1000Hr 500Hr 14/12/12

(a) (b)
HYD. OIL 3000Hr 3000Hr 14/12/12
EXCHANGE EXCHANGE
INTERVAL REMAINDER INTERVAL REMAINDER
DAY DAY
ENGINE OIL 500Hr 500Hr 14/12/12 ENGINE OIL 500Hr 500Hr 14/12/12
FUEL FILTER 500Hr -100Hr 14/12/12 FUEL FILTER 500Hr -100Hr 14/12/12
HYD. FILTER 1000Hr 500Hr 14/12/12 HYD. FILTER 1000Hr 500Hr 14/12/12
HYD. OIL 3000Hr 3000Hr 14/12/12 HYD. OIL 3000Hr 3000Hr 14/12/12
Default setting of recommended replacement interval
Item Default
Engine oil 250 Hr
Fuel filter 500 Hr
Hydraulic oil filter 1,000 Hr
Hydraulic oil 2,000 Hr
7-36
7.4.1.7 EXPLANATION OF GAUGE CLUSTER DISPLAY

After the key is turned on and the logo mark disappears, the screen for the operator is displayed on the multi-
display. The multi-display has the following functions.
(1)Clock display
(2)Self diagnosis display 1
4
(3)Warning display S
K
(4)Machine condition display
2,3
1. Display function for operator: Screen usually displayed during operation.

1) Clock display function: Current time is displayed.
2) Self-diagnosis display function:
When abnormality is detected on the mechatro system like a sensor, or proportional valve etc., this displays
error codes.
3) Warning display function:
When the machine becomes a dangerous condition or a failure occurs, warning contents with the symbol
and texts are displayed.
. Wa rning
SELECT OR VALVE FAILURE CLOGGED AIR FLTR

W009 W008
POWER BOOST ON ENGINE ST OP
LIFT UP LOCK LEVER

WARM FINISH WARM-UP
BEFORE ENGINE ST ART
DATA
CPU COMMUNICATION ERROR
CHANGE HYD. OIL
SWING BRAKE DISENGAGED PREHEA T

W001 W011
CHANGE FUEL FLTR CHARGE ERROR
CHANGE HYD. OIL FLTR LOW FUEL LEVEL
LOW ENG OIL PRESS. WARM AUTO WARMING UP

W005
HIGH ENG W ATER TEMP. CHANGE ENG OIL

W006
LOW ENG W ATER LEVEL

W004
7
• W001, W004, W005, W006, W008, W009, and W011 are error codes.
• Error codes are stored as trouble history, and displayed on the multi-display by the trouble history display
function.
4) Machine condition display: The machine operating condition is displayed.
7-37
2. Display function for maintenance:

By pressing screen change switch (3), the remaining time to the next replacement of the following items are
displayed.
1) Engine oil
2) Fuel filter
3) Hydraulic oil filter
4) Hydraulic oil
3. Trouble history display function:
Abnormality that occurred on the mechatro system in the past is stored and displayed in the order of the recent
occurrence by operating the starter switch and buzzer stop switch (4).
4. Mechatro adjustment display function:
By operating work mode select switch (5), the starter switch, and buzzer stop switch (4), the procedures are
displayed at mechatro system adjustment such as output adjustment.
5. Service diagnosis display function:
By operating buzzer stop switch (4) and the starter switch, information from the mechatro controller such as a
detection value of the pressure sensor is displayed.
7-38
7.4.2 SELF DIAGNOSIS DISPLAY FUNCTION

7.4.2.1 SUMMARY
This self-diagnoses any failure in the control input/output signals of the pressure sensors, proportional valves, and
others when the machine is running. Any failed items are displayed on the multi-display in the gauge cluster. For
the connector and pin numbers, refer to the after-mentioned C-1 MECHATRO CONTROLLER. The wire numbers
and the wire colors can be confirmed by the electrical schematics or the harnesses.
7.4.2.2 INPUT-OUTPUT CONFIGURATION
CONTROL
Pressure sensor, Engine controller CAN COMMUNICATION
INPUT Proportional valve, Battery relay Gauge cluster
Selector valve (SOL) (Buzzer sound)
7-39
7.4.2.3 SELF DIAGNOSIS DISPLAY ITEMS

The clock display remains the same (normal main screen). When a failure occurs, the failure part and the type of
failure can be identified by the error codes.
S
12h
Alphabet: Decides in which system failure occurs.
Last 2nd and 3rd digits: Specifies failure section.
Last 1 digit: Specifies failure type.

B013
Error code ta ble

Proportional Proportional
Last 2,3 Controller Low pressure High pressure valve of valve of pump Solenoid Potentiometer Communication
digits memory sensor sensor valve system system selector valve Speed sensor etc. system Battery relay Engine ECU Relay output
Engine Wiper ark Common rail
adjustment data Boom up P1 pump P1 unload P1 pump Power boost Acceleration Battery relay prevention relay pressure
Torque Wiper forward
adjustment data Boom down P2 pump P2 unload P2 pump Swing parking Boom angle rotation relay Fuel
Unload Travel Travel 1,2 Speed sensor for Wiper reversePump flow
adjustment data Arm out Boom head straight Option relief 1 speed machine Arm angle rotation relay
rate
Boom up Option Speed sensor for Clogging of
both machine
adjustment data Arm in Boom rod Boom up Option relief 2 selector and ECU Offset angle Washer motor hydraulic oil
Arm-in Inter boom Bucket
adjustment data Bucket digging Overload Boom down Fan pump angle limitation
Arm-out Arm-in Left and right
adjustment data Bucket dump Spare 1 speed 2 Spare 1 tilt angles
Offset right Front and rear
adjustment data Swing right Spare 2 Arm out Boom M/I cut tilt angles
Offset left Coolant
adjustment data Swing left Arm in temperature
sensor
Inter up
adjustment data Travel right Offset right Fuel sensor
Inter down Hydraulic oil
adjustment data Travel left Offset left temperature
sensor
Inclinometer front Detection of P1 travel CAN
and rear
adjustment data selector position independent communication
Inclinometer left
S e e Cha pte r "ENGINE".

and right Clamp up P2 travel CAN
adjustment data and down independent Swing speed communication
Arm variable Swing flasher
Offset left recirculation right relay
Swing flasher
Offset right Fan drive left relay
Travel rear Travel alarm
right Bypass valve relay
P1 side
option Spare 1 AIS relay 2
P2 side Boom Engine stop
option recirculation relay
Lever lock
Dozer up Boom M/O relay
Dozer down
Travel rear
left
Adjustment CAN
data sector 1 communication Safety relay
Adjustment CAN
data sector 2 communication
Hour meter
sector 1
Hour meter
sector 2
Proportional valve
adjustment data
Cluster
communication
Expansion
controller
communication
Last 1
digit
Larger than Larger than
normal range normal range Abnormal
S e e Cha pte r "ENGINE".
Transistor
OFF failure
/GND short GND short CAN error
Abnormal Abnormal Transistor Transistor
output output ON failure ON failure Overrun
Transistor
ON failure
Disconnection Disconnection Disconnection Disconnection /disconnection Disconnection Disconnection Time out
Contact point
Power short Power short Power short adhesion due Power short
circuit circuit circuit to melting circuit
Failure value
*H11 Temperature sensor for clogging of hydraulic oil
7-40
ENGINE SYSTEM ERROR CODE LIST
Error Code Possible cause of failure Error Code Possible cause of failure
Injector common 1 ground
P0217 Engine overheat P1211
short
Atmospheric pressure sensor Injector related Injector common 2 ground
P2228 P1214
circuit low input errors short
Atmospheric pressure sensor Injector common 1 power
P2229 P1212
circuit high input source line short
Common rail pressure sensor Injector common 2 power
P0192 P1215
circuit low input source line short
Common rail pressure sensor Injector common 1 open
P0193 P1212
circuit high input circuit
Common rail pressure sensor Injector common 2 open
Sensor related P0191 P1215
malfunction circuit
errors &
related dialogs Boost pressure sensor circuit Injector circuit malfunction
P0237 P0201
low input -cylinder 1
Boost pressure sensor circuit Injector circuit malfunction

P0108 P0202
high input -cylinder 2
Coolant temperature sensor Injector related Injector circuit malfunction

P0117 P0203
circuit low input errors -cylinder 3
Coolant temperature sensor Injector circuit malfunction

P0118 P0204
circuit high input -cylinder 4
Fuel temperature sensor Cylinder 1 contribution/

P0182 P0263
circuit low input balance fault
Fuel temperature sensor Cylinder 2 contribution/
P0183 P0266
circuit high input balance fault
Accelerator sensor 1 and 2 Cylinder 3 contribution/
P2120 P0269
malfunction balance fault
Accelerator sensor circuit 1 Cylinder 4 contribution/
P2122 P0272
low voltage balance fault
Accelerator sensor circuit 1 Turbo related
P2123 P0234 Turbocharger over boost
Accelerator high voltage errors
sensor related
errors Accelerator sensor circuit 2 ECU charge circuit low
P2127 P0611
low voltage input
Accelerator sensor circuit 2 ECU charge circuit high

P2128 P0200
high voltage input
Emergency accelerator
P1133 P0605 Flash ROM error
sensor malfunction high input ECU body
Engine speed main and sub related errors CPU malfunction (Hard
P0335 P0606
sensor circuit malfunction detection) 7
Abnormal engine main Monitoring IC malfunction
Rotation P0336 P0607
rotation sensor pulse count in CPU
sensor related
errors Engine speed sub sensor
P0340 P1601 QR code failure
circuit malfunction
Abnormal engine auxiliary
P0341 P0540 Preheat circuit malfunction
rotation sensor pulse count
Machine
Supply pump SCV related errors
Supply pump
P0629 malfunction (Power source P0686 Main relay malfunction
related errors
line short)
7-41
Error Code Possible cause of failure Error Code Possible cause of failure
Supply pump SCV
P0628 malfunction (Full discharge P0219 Engine overrun
mode)
Excessive common rail

P0088 P0617 Starter signal malfunction
pressure
Excessive common rail Communica-

Engine ECU CAN
P0088 pressure, supply pump tion related U110A
communication
excess forced feed errors
Supply pump abnormal
P2635 pressure record
Supply pump SCV sticking
7-42
7.4.3 SERVICE DIAGNOSIS DISPLAY FUNCTION

The present service diagnosis based on the data from the mechatro controller can be displayed on the multi-
display.
This chapter shows operation methods and each screen sample. However, the displayed values vary according to
the engine speed status and the position of the attachment.
7.4.3.1 OPERATION METHOD OF SERVICE DIAGNOSIS SCREEN

1. Turn the starter switch on while pressing the buzzer stop switch.
Buzzer stop switch
2. After the logo mark appears, the screen enters service diagnosis mode. The service diagnosis screen "Mode
No.1", and "Screen No.1" are displayed first. The service diagnosis is classified into two modes, 1, and 2, and
the present mode is displayed on "Screen No.1".
The screen numbers on the screen differ according to each mode. The screen numbers displayed at each
mode are as follows.
• Mode No.1: Screen No.1 to 22
• Mode No.2: Screen No.1, Screen No.23 to 30
3. After that, the screen is switched every time you press each switch.
Up arrow switch
The screen changes to the next number.
(No.2→No.3→No.4→...)
Down arrow switch

The screen changes to the previous number.
(No.30→No.29→No.28→...)
Right arrow switch

Service diagnosis mode changes to the next number.
(No.1→No.2→No.1→No.2→...)
Left arrow switch

Service diagnosis mode changes to the previous number.
(No.2→No.1→No.2→No.1→...)
4. Turn the key switch "OFF" and the display of service diagnosis mode is closed.
To switch the service diagnosis mode to No. 3, turn the swing parking brake release switch ON for 1 second or
more with the service diagnosis screen No.1 displayed and then turn OFF that switch.
7-43
7.4.3.2 SERVICE DIAGNOSIS DISPLAY SCREEN (EXAMPLE)

The following is a list of service diagnosis display screens. (The conditions for the example are at the H mode,
engine low speed and neutral lever position.)
Service diagnosis mode No.1

No. Display Contents No. Display Contents
1 NO.1 6 NO.5 PRESS. SENSOR
HOUR METER 35.3h HOUR METER 35.3h
MAIN CONT. P/N B-1 BOOM RAISE
YN22E00632F1 P/No. indication 3.5V 2.6M Sensor voltage/pressure converted value
PROGRAM VERSION B-2 BOOM LOWER
1-VER 01.00 Mechatro controller program version 3.5V 2.6M Sensor voltage/pressure converted value
2-VER 00.00 Machine operation management B-3 ARM OUT
system program version 3.5V 2.6M Sensor voltage/pressure converted value
B-4 ARM IN
SER VICE DIAG 1 Service diagnosis mode 3.5V 2.6M Sensor voltage/pressure converted value
B-5 BUCKET DIG
CLUSTER GAUGE P/N Gauge cluster P/No. indication 3.5V 2.6M Sensor voltage/pressure converted value
YN59S00038F2 B-6 BUCKET DUMP
PROGRAM VERSION Gauge cluster P/No. indication 3.5V 2.6M Sensor voltage/pressure converted value
01.00 B-7 SWING
ENGINE CONT . P/N ECU P/No. indication 3.5V 2.6M Sensor voltage/pressure converted value
J05EUN138 3A40 B-9 TRAVEL (R)
ENGINE SERIAL NUMBER Engine serial No. indication 3.5V 2.6M Sensor voltage/pressure converted value
J05ET A001001 B-10 TRAVEL (L)
3.5V 2.6M Sensor voltage/pressure converted value
B-16 P1 OPT .
B-17 P2 OPT .
2 NO.2 ENG
7 NO.6 SENSOR PROPO-V
G-3 SPEED SET 2205 No load set speed C-1 P1 PUMP
MEAS.1 2201 Actual speed 1 3.5V 2.6M Sensor voltage/pressure converted value
MEAS.2 2201 Actual speed 2 (engine controller) C-2 P2 PUMP
G-5 ENG PRS LIVE Engine oil pressure 3.5V 2.6M Sensor voltage/pressure converted value
W ATER TEMP 100¥¥ OFF Coolant temperature sensor E-1 P1 PUMP
MODE H Work mode COMP . 600mA 4.5M Command value/pressure converted value
ATT MODE BRK Attachment mode MEAS. 600mA 4.5M Measured value/pressure converted value
H-1 ACCEL VOLT. 4.2V Potentiometer voltage POWER SHIFT 100mA Amount of horse power reduction
POS. 100% Volta ge % dis pla y FLOW RA TE 100L P1 pump flow rate
ECU OUTPUT 0.5V Acceleration output voltage to engine controller E-2 P2 PUMP
FIN. ACCEL POS. 100% Final acceleration openin COMP . 600mA 4.5M Command value/pressure converted valu e
CAN COMMAND ENG SPEED Final target speed MEAS. 600mA 4.5M Measured value/pressure converted value
2500 POWER SHIFT 100mA Amount of horse power reduction
ACCEL SENSOR 1 VOL. 5.0V Acceleration voltage FLOW RA TE 100L P2 pump flow rate
COMP . FUEL CONS. Final injection quantity
500mm /VV W .cyl.
3
COMP . FUEL CONS. Final injection quantity
H-10 HYD. OIL TEMP 100 ¥ Hydraulic oil temperature 500mm 3 /VV W .cyl.
PERCENT TORQUE 100% Percent torque
ENG SPEED 2350 Input speed from ECU
BOOST PRESS. 400 Intake air pressure
ENG RAIL PRESS. 200.0M Common rail pressure
EGR V ALVE P OS . 100.0% EGR valve actual opening
SCV CURRENT 900mA SCV drive current
VNT POS. 100.0% VNT opening
EXHAUST TEMP 100 ¥ Exhaust gas temperature
TURB SPEED 50000 Turbo s pe e d
INTAKE AIR 500k J /h Intake air amount
100 ¥ Intake air temperature
4 NO.3 SOL. V ALVE 8 NO.7 PROPO-V ALVE

F-1 POWER BOOST D-1 P1 UN-LOAD(BP-CUT)
COMP . OFF Command value COMP . 600mA 4.5M Command value/pressure converted value
MEAS. OFF Measured value MEAS. 600mA 4.5M Measured value/pressure converted value
SWITCH OFF Switch D-2 P2 UN-LOAD(BP-CUT)
F-2 SWING-BRAKE COMP . 600mA 4.5M Command value/pressure converted value
COMP . OFF Command value MEAS. 600mA 4.5M Measured value/pressure converted value
MEAS. OFF Measured value D-3 S-TRA VEL
RELEASE SW Switch COMP . 600mA 4.5M Command value/pressure converted value
F-3 1/2-TRA VEL MEAS. 600mA 4.5M Measured value/pressure converted value
COMP . OFF Command value D-6 ARM IN-2-SPEED
MEAS. OFF Measured value COMP . 600mA 4.5M Command value/pressure converted value
SWITCH OFF Switch MEAS. 600mA 4.5M Measured value/pressure converted value
E-3 OPT RELIEF 1
COMP . 600mA 14.5M Command value/pressure converted value
5 NO.4 RELAY MEAS. 600mA 14.5M Measured value/pressure converted value
HOUR METER 35.3h E-4 OPT RELIEF 2
K-1 AIS RELAY2 OFF Command value COMP . 600mA 14.5M Command value/pressure converted value
K-2 SAFETY RLY OFF Command value MEAS. 600mA 14.5M Measured value/pressure converted value
K-3 ENG ST OP OFF Command value
KEY SWITCH ON Key switch
ST ART S WITCH OFF Start switch
CHARGE LIVE Alternator
K-4 LEVER OFF Command value
SWITCH OFF Switch
K-5 POWER CONSER V. RLY ON Key power holding relay
7-44

9 NO.8 SENSOR, SWITCH 15 NO.14 DIGITAL INP UT
H-9 FUEL LEVEL DI1 OFF ON / OFF display
4.5V 90% Fuel level DI2 OFF ON / OFF display
H-10 HYD. OIL TEMP DI3 OFF ON / OFF display
4.5V 90 ¥ Hydraulic oil temperature DI4 OFF ON / OFF display
GLOW OFF Glow switch DI5 OFF ON / OFF display See list of
AIR FILTER LIVE Clogging of air filter DI6 OFF ON / OFF display connectors in
W ATER S EPA. LIVE Clogging of water separator DI7 OFF ON / OFF display Paragraph
ENG OIL FILTER LIVE LIVE Clogging of engine oil filter DI8 OFF ON / OFF display "MECHATRO
FRONT WINDOW SW OFF Front window open/close switch DI9 OFF ON / OFF display CONTROLLER".
DOUBLE FLOW SW ON Conflux/single flow select switch DI10 OFF ON / OFF display
KPSS SW OFF KPSS switch DI11 OFF ON / OFF display
HEA TER OFF Air heater command DI12 OFF ON / OFF display
ENG OIL LEVEL LIVE Engine oil level DI13 OFF ON / OFF display
COOLANT LEVEL LOW Coolant level DI14 OFF ON / OFF display
FUEL DIST. 9999 Fuel distinction DI15 OFF ON / OFF display
FUEL TEMP. -100¥¥ Fuel temperature DI16 OFF ON / OFF display
DI17 OFF ON / OFF display
10 NO.9 SOL. V ALVE

16 NO.15 DIGITAL INP UT
F-4 OPT SELECT DI27 OFF ON / OFF display
COMP . OFF Command value DI28 OFF ON / OFF display
MEAS. OFF FB value DI29 OFF ON / OFF display
SPOOL POS. BRK Spool position DI30 OFF ON / OFF display
SELECT SWITCH BRK Mode of selector valve DI31 OFF ON / OFF display
F-5 F AN PUMP DI32 OFF ON / OFF display
MEAS. OFF Measured value DI34 OFF ON / OFF display
F-6 DI35 OFF ON / OFF display
MEAS. OFF Measured value DI37 OFF ON / OFF display
14
NO.13 PRESS. SENSOR DI41 OFF ON / OFF display
HOUR METER 35.3h DI42 OFF ON / OFF display
B-11
B-12
C-3 BOOM HEAD
C-4 BOOM ROD
B-15
B-18 DOZER 1
B-19 DOZER 2
B-20 17 NO.16 DIGITAL OUTP UT
3.5V 12.6M Sensor voltage/pressure converted value HOUR METER 35.3h
C-5 DO1 COMP . OFF Command value
3.5V 12.6M Sensor voltage/pressure converted value MEAS. OFF Measured value
DO5 COMP . OFF Command value
MEAS. OFF Measured value
MEAS. OFF
DO10 COMP . OFF
Measured value
Command value
7
7-45

18 NO.17 DIGITAL OUTP UT 23 NO.22 ENG CONT .
DO14 COMP . OFF Command value TRANS. COUNT . 100 Counter value of transmission error
MEAS. OFF Measured value RECEIVE COUNT . 100 Counter value of reception error
DO15 COMP . OFF Command value DIAG STATUS 0 Diagnosis status
MEAS. OFF Measured value NUMBER OF DIAG 100 Number of errors
DO16 COMP . OFF Command value BOOST PRESS. 100 Boost pressure
MEAS. OFF Measured value BOOST TEMP. -100 ¥ Boost temperature
DO17 COMP . OFF Command value BAROMETRIC P . 100 Atmospheric pressure
MEAS. OFF Measured value FUEL TEMP. -100 ¥ Fuel temperature
DO18 COMP . OFF Command value FUEL CONS. 200 Fuel consumption
MEAS. OFF Measured value INTAKE TEMP. -100 ¥ Intake air temperature
DO19 COMP . OFF Command value ENG PRESS. 300 Engine oil pressure
MEAS. OFF Measured value GLOW OFF Glow output
DO20 COMP . OFF Command value ENG ST OP OFF Engine stop command
MEAS. OFF Measured value TORQUE 1000 Torque
DO21 COMP . OFF Command value DPF BUZZER --- Information alarm buzzer of ECU
MEAS. OFF Measured value DPF CLOG 9 DPF clogging amount information of ECU
DO22 COMP . OFF Command value DPF REGENE NO ON Prevention information of DPF regeneration
MEAS. OFF Measured value DPF FORCED REGENE ON Information of DPF forcible regeneration
DO23 COMP . OFF Command value ENG RAI PRESS 1000 Common rail pressure
MEAS. OFF Measured value UREA LEVEL 100 DEF/AdBlue level
DO24 COMP . OFF Command value UREA TEMP. 100 ¥ DEF/AdBlue temperature
19 NO.18 DIGITAL OUTP UT

24 NO.23 BOOM
DO27 COMP . OFF Command value C-1 P1-PRES 13.9M Pump pressure sensor
MEAS. OFF Measured value C-2 P2-PRES 13.9M Pump pressure sensor
DO28 COMP . OFF Command value E-1 P1-PSV 600mA Command value
MEAS. OFF Measured value E-2 P2-PSV 600mA Command value
D-1 P1-UL(BPC) 600mA Command value
D-2 P2UL(BPC) 600mA Command value
B-1 BOOM RAISE 1.9M Boom up pressure sensor
B-2 BOOM LOWER 1.9M Boom down pressure sensor
G-3 ENG SPEED 2205 Engine speed
POWER SHIFT 100mA Horse power reduction current
20 NO.19 WIPER SYSTEM 25 NO.24 ARM SWING

WIPER SW OFF Wiper switch C-1 P1-PRES 13.9M Pump pressure sensor
RISEUP SW OFF Wiper rise-up switch C-2 P2-PRES 13.9M Pump pressure sensor
REVERSE SW OFF Wiper reverse rotation switch E-1 P1-PSV 600mA Command value
PREVENT ARC OFF Wiper motor ark prevention relay E-2 P2-PSV 600mA Command value
CW MOT OR RLY OFF Wiper normal rotation relay D-1 P1-UL(BPC) 600mA Command value
CCW MOT OR RLY OFF Wiper reverse rotation relay D-2 P2-UL(BPC) 600mA Command value
WASHER SW OFF Wa s he r s witch D-3 S-TRA VEL 600mA Command value
MOTOR RELAY OFF Wa s he r motor re la y D-6 ARM-IN-2 600mA Command value
B-3 ARM OUT 13.9M Arm-out pressure sensor
B-4 ARM IN 13.9M Arm-in pressure sensor
B-1 BOOM RAISE 13.9M Boom up pressure sensor
B-7 SWING R 13.9M Swing right pressure
B-8 SWING L 13.9M Swing left pressure
22 NO.21 IT SYSTEM 26 NO.25 BUCKET

COMMUNICATION MC-IT OFF Communication status between controller of C-1 P1-PRES 13.9M Pump pressure sensor
machine operation management system C-2 P2-PRES 13.9M Pump pressure sensor
COM ANTENNA ON Communication antenna status E-1 P1-PSV 600mA Command value
NETWORK CONNECTION --- Network connection status E-2 P2-PSV 600mA Command value
RADIO WAVE INTENS ITY 0 Communication radio field intensity D-1 P1-UL(BPC) 600mA Command value
GPS ANTENNA ON Connection status of GPS antenna D-2 P2-UL(BPC) 600mA Command value
GPS CONDITION OFF Positioning condition of GPS D-3 S-TRA VEL 600mA Command value
SIM CONDITION ON SIM card condition B-5 BUCKET DIG 1.9M Bucket digging pressure sensor
COM PERMISSION OFF Communication permission status B-6 BUCKET DUMP 1.9M Bucket dump pressure sensor
AUTHENTICATION OFF Initial authentication status G-3 ENG SPEED 2205 Engine speed
REMOVAL DETECTION OFF Removal condition POWER SHIFT 100mA Horse power reduction current
LOCK CONDITION 0 Lock condition
INTERNAL ERROR 0 IT controlle r dia gnos is informa tion
IT VERS ION 0 Version number of IT controller software
7-46
Service diagnosis mode No.2

27 NO.26 TRAVEL 30 NO.29 INJECT OR ADJUSTMENT
C-1 P1-PRES 13.9M Pump pressure sensor ENG SPEED 2350 Input speed from ECU
C-2 P2-PRES 13.9M Pump pressure sensor WATER TEMP 100 ¥ Coolant temperature
E-1 P1-PSV 600mA Command value 1CYL 50.0mm 3 /st .cyl. Amount of inter-cylinder calibration (1 cylinder)
E-2 P2-PSV 600mA Command value 2CYL 50.0mm 3 /st .cyl. Amount of inter-cylinder calibration (2 cylinder)
D-1 P1-UL(BPC) 600mA Command value 3CYL 50.0mm 3 /st .cyl. Amount of inter-cylinder calibration (3 cylinder)
D-2 P2-UL(BPC) 600mA Command value 4CYL 50.0mm 3 /st .cyl. Amount of inter-cylinder calibration (4 cylinder)
D-3 S-TRA VEL 600mA Command value 5CYL 50.0mm 3 /st .cyl. Amount of inter-cylinder calibration (5 cylinder)
B-9 TRAVEL(R) 13.9M Tra ve l right pre s s ure s e ns or 6CYL 50.0mm 3 /st .cyl. Amount of inter-cylinder calibration (6 cylinder)
B-10 TRAVEL(L) 13.9M Tra ve l le ft pre s s ure s e ns or SPEED DEVIA. TIME
Pi-P1 13.9M P1 side pilot pressure sensor 1CYL 254 Cylinder speed change deviation time (1 cylinder)
Pi-P2 13.9M P2 side pilot pressure sensor 2CYL 254 Cylinder speed change deviation time (2 cylinder)
G-3 ENG SPEED 2205 Engine speed 3CYL 254 Cylinder speed change deviation time (3 cylinder)
POWER SHIFT 100mA Horse power reduction current 4CYL 254 Cylinder speed change deviation time (4 cylinder)
5CYL 254 Cylinder speed change deviation time (5 cylinder)
28 6CYL 254 Cylinder speed change deviation time (6 cylinder)
NO.27 OPT
HOUR METER 35.3h
C-1 P1-PRES 13.9M Pump pressure sensor
C-2 P2-PRES 13.9M Pump pressure sensor
E-1 P1-PSV 600mA Command value
E-2 P2-PSV 600mA Command value
D-3 S-TRA VEL 600mA Command value
E-3 OPT RELIEF 600mA Command value
B-16 P1 OPT 1.9M P1 side option pressure sensor
B-17 P2 OPT 1.9M P2 side option pressure sensor
F-4 OPT SELECT CRS Option selector solenoid
DOUBLE FLOW SW CRS Conflux/single selector switch
31
NO.30 STUDY PUMP DIFFERENCE
HOUR METER 35.3h
CONDITION FLAG DONE1 Pump dif ference study finish flag
FIN. ACCEL POS. 100% Final acceleration opening
S TARTER S W ON Starter switch of ECU side
COMP. FUEL CONS. 500mm 3 /st .cyl. Final injection quantity
ENG RAIL PRESS 200.0M Common rail pressure
WATER TEMP 100 ¥ Coolant temperature
FUEL TEMP. 100 ¥ Fuel temperature
ECU OUTPUT 4.8V Acceleration output voltage to ECU
CAN COMMAND ENG SPEED 2350 Final target speed
DPR REGENE MODE ON DPF regeneration information
PUMP DIAG.
29
NO.28 ENG S TART CHECK
HOUR METER 35.3h
WATER TEMP 100 ¥ Coolant temperature
OIL TEMP 100 ¥ Hydraulic oil temperature
E-1 P1 PUMP P1 pump proportional valve
MEAS. 700mA 25.0M Measured value/pressure converted value
E-2 P2 PUMP P2 pump proportional valve
MEAS. 700mA 25.0M Measured value/pressure converted value
ECU OUTPUT 4.8V Acceleration voltage to ECU
COMP. FUEL CONS. Final injection quantity
500mm 3 /st .cyl.
ENG RAIL PRESS 200.0M Actual common rail pressure
FIN. ACCEL POS. 100% Final acceleration opening
BAROMETRIC P . --- Atmospheric pressure
S TARTER S W --- Starter switch of ECU side
KEY SWITCH ECU --- Key switch of ECU side
7-47
7.4.3.3 SERVICE DIAGNOSIS DATA LIST

Preface and precaution
The following data is service diagnosis data at each operation when the machine is in a normal condition and the
service diagnosis data is used for judging whether the machine is in a normal or abnormal condition at machine
inspection.
• The values in following display are reference values with a standard attachment attached.
• The values of the pressure sensors are calculated taking variation into accounts. When comparing the values to
the performance check reference criteria, perform measurement by calibrated measuring instruments.
• The current of the proportional valve is not a measured value, but a command value in the computer. Regarding
the measured value, confirm it by the display of each proportional valve.
• The current value of the pump proportional valve is a reference value because it varies according to the pump
pressure and the adjusted torque value.
• The value in the display during operation shows the value in a steady state but not at start of operation.
• Perform inspection after sufficiently warming up the machine.
• The value in the display may differ according to the software version. Contact your KOBELCO authorized dealer
about it.
Operation No.1: No operation Operation No.2: No operation
H mode Hi idle S mode Hi idle
No.24 ARM, SWING No.24 ARM, SWING
C-1 P1-PRES 0.2 to 1.5 M C-1 P1-PRES 0.2 to 1.5 M

E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
D-1 P1-UL(BPC) 750 mA D-1 P1-UL(BPC) 750 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING R 0.0 M B-7 SWING R 0.0 M
B-8 SWING L 0.0 M B-8 SWING L 0.0 M
G-3 ENG SPEED 2070 to 2130 G-3 ENG SPEED 1870 to 1930
POWER SHIFT 0 mA POWER SHIFT 0 mA
Operation No.3 : Operation No.4 :

Boom up in full lever operation & relief Boom up in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.23 BOOM No.23 BOOM
E-1 P1-PSV 415 to 525 mA E-1 P1-PSV 560 to 750 mA
B-2 BOOM LOWER 0.0 M B-2 BOOM LOWER 0.0 M
7-48
Operation No.5 :
Boom down in full lever operation & in operation
H mode Hi idle
No.23 BOOM
C-1 P1-PRES 12.5 to 16.0 M
C-2 P2-PRES 0.2 to 1.5 M
E-1 P1-PSV 600 to 617 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 427 to 477 mA
D-2 P2-UL(BPC) 750 mA
B-1 BOOM RAISE 0.0 M
B-2 BOOM LOWER 3.0 M
G-3 ENG SPEED 1770 to 1860
POWER SHIFT

Arm-in in full lever operation & relief Arm-in in full lever operation & in operation

Arm-out in full lever operation & reliefH mode Arm-out in full lever operation & in operation
B-3 ARM OUT 3.0 M B-3 ARM OUT 3.0 M 7
*The values are measured 5 minutes after engine start or release of low temperature mode.
7-49

Swing in full lever operation & relief Swing in full lever operation & in operation
E-2 P2-PSV 528 to 750 mA E-2 P2-PSV 750 mA

Bucket digging in full lever operation & relief Bucket digging in full lever operation & in operation
No.25 BUCKET No.25 BUCKET

Bucket dump in full lever operation & relief Bucket dump in full lever operation & in operation
No.25 BUCKET No.25 BUCKET
B-5 BUCKET DIG 3.0 M B-5 BUCKET DIG 3.0 M
B-6 BUCKET DUMP 0.0 M B-6 BUCKET DUMP 0.0 M
7-50

P2 side option in full lever operation & relief P2 side option in full lever operation & relief
Nibbler mode Hi idle Breaker mode Hi idle
No.27 OPT No.27 OPT
E-3 OPT RELIEF 0 mA E-3 OPT RELIEF 0 mA
B-16 P1 OPT 0.0 M B-16 P1 OPT 0.0 M
B-17 P2 OPT 2.0 to 2.6 M B-17 P2 OPT 2.0 to 2.6 M
F-4 OPT SELECT NIB F-4 OPT SELECT BRK
DOUBLE FLOW SW. — DOUBLE FLOW SW. —
* The relief set pressure is a factory default value. * The relief set pressure is a factory default value.

Travel right in full lever operation & travel idling Travel left in full lever operation & travel idling
No.26 TRAVEL No.26 TRAVEL
B-9 TRAVEL(R) 2.0 to 2.5 M B-9 TRAVEL(R) 0.0 M
B-10 TRAVEL(L) 0.0 M B-10 TRAVEL(L) 2.0 to 2.5 M
Pi-P1 0.0 M Pi-P1 0.0 M
Pi-P2 0.0 M Pi-P2 0.0 M
7-51
7.4.4 TROUBLE HISTORY DISPLAY FUNCTION

• The items detected as failed items by the self diagnosis function of the mechatro controller are stored in the
mechatro controller as history and can be displayed on the multi-display.
• A part of the warning contents is stored in the "trouble history screen".
• Error codes of the self diagnosis are stored.
7.4.4.1 DISPLAY METHOD OF TROUBLE HISTORY

1. Turn the starter switch "ON" while pressing buzzer (Example)
stop switch (1). Service diagnosis screen (a) TURN ST ARTER KEY
SWICH ON (a) (b)
appears. + HOUR METER 0.0h
MAIN CONT. P/N
2. During pressing buzzer stop switch (1), press menu YN22E00632F1

PRIGRAM VERSION
1-VER 01.01
+ SER VICE MENU
2-VER 00.00
switch (2) three times. "SERVICE MENU" screen (b) SER VICE DIAG 1
SER VICE DIAGNOSIS
TROUBLE HIST ORY

appears. CLUSTER GAUGE P/N
YN59S00038F2
PROGRAM VERSION
LANGUAGE & LOGO SETTING
02.00
SER VICE ADJUST 1
3. Use "up" arrow switch (3) or "down" arrow switch (4)

ENGINE CONT . P/N
MIS FF SER VICE ADJUST 2
ENGINE SERIAL NUMBER
MIS FF FACTORY PRESET
to move the cursor to "TROUBLE HISTORY" on FAULT DIAG MODE
screen (b). Press "right" arrow switch (5) to display

"trouble history " screen (C).
BACK ON NEXT
4. The trouble history data (one or many) and the hour DOWN
meter data are displayed on the gauge cluster.

• The data of the hour meter and ten failures are
displayed on the screen. (c)
No errors NO ERROR
• In case the failure data exceed ten, confirm the
data by the next page.
5. Turning page Error detected
• Press "up" arrow switch (3) to move the item up. in the past
• Press "down" arrow switch (4) to move the item

down.
6. Turn the starter switch "OFF" to cancel the display.
7.4.4.2 HOW TO CLEAR TROUBLE HISTORY
All the stored trouble history items are deleted and cannot be deleted partially.
1. Display the "TROUBLE HISTORY" screen.

2. Press the work mode select switch and buzzer stop switch (1) at the same time for five seconds or more.
3. When the display is changed to "NO ERROR", deletion is completed.
4. Turn the starter switch "OFF".
7-52
7.4.5 CHANGE PROCEDURES OF REPLACEMENT INTERVAL
The Intervals of replacement are as follows.

• Engine oil: 250 hrs.
• Fuel filter: 500 hrs.
• Hydraulic oil filter: 1,000 hrs.
• Hydraulic oil: 2,000 hrs.
• When the remaining time to engine oil replacement becomes 20 hrs. or less, the display for forecasting
replacement appears on the multi-display and after that, when 250 hrs. has been reached, the warning appears
but the buzzer does not sound.
• When the remaining time to fuel filter replacement becomes 20 hrs. or less, the display for forecasting
• When the remaining time to hydraulic oil filter replacement becomes 20 hrs. or less, the display for forecasting
• When the remaining time to hydraulic oil replacement becomes 20 hrs. or less, the display for forecasting

6 7 4 5
3 10
(4)Washer switch
(5)Wiper switch
(6)Travel speed select switch
(7)Auto acceleration switch
(8)Menu switch
2
(9)Arrow switch
(10)Attachment mode select switch
1 9 8
7-53
EXCHANGE EXCHANGE
S INTERVAL REMAINDER DAY INTERVAL REMAINDER DAY
12h
USER MENU ENGINE OIL 500Hr 500Hr 08/12/12 ENGINE OIL 500Hr 500Hr 08/12/12
MAINTENANCE
FUEL FILTER 500Hr -100Hr 08/12/12 FUEL FILTER 500Hr -100Hr 08/12/12
SWITCH ST ATUS HYD. FILTER 1000Hr 1000Hr 08/12/12 HYD. FILTER 1000Hr 1000Hr 08/12/12
OPTION SETTING HYD. OIL 5000Hr 5000Hr 08/12/12 HYD. OIL 5000Hr 5000Hr 08/12/12
CONSUMPTION
SCREEN SETTING
CLOCK SETTING
EXCHANGE
INTERVAL REMAINDER DAY
ENGINE OIL 500Hr 500Hr 08/12/12
FUEL FILTER 500Hr -100Hr 08/12/12

BACK UP NEXT
HOME DOWN HYD. FILTER 1000Hr 500Hr 08/12/12
(a) (b) HYD. OIL 5000Hr 3000Hr 08/12/12
EXCHANGE EXCHANGE
INTERVAL REMAINDER DAY INTERVAL REMAINDER DAY
ENGINE OIL 500Hr 500Hr 08/12/12 ENGINE OIL 500Hr 500Hr 08/12/12
FUEL FILTER 500Hr -100Hr 09/01/12 FUEL FILTER 500Hr 500Hr 09/01/12
HYD. FILTER 1000Hr 500Hr 08/12/12 HYD. FILTER 1000Hr 1000Hr 08/12/12
HYD. OIL 5000Hr 3000Hr 08/12/12 HYD. OIL 5000Hr 5000Hr 08/12/12
1. Turn the starter switch "ON" to display main screen (a). Press menu switch (8) to enter user menu screen (b).
2. Using the up or down arrow switch, move the cursor to "MAINTENANCE". Press the right arrow switch to enter
the maintenance information setting.
3. Using the up or down arrow switch, move the cursor to one of the items from "ENGINE OIL", "FUEL FILTER",
"HYD.FILTER" or "HYD.OIL".
4. Press the right arrow switch. The background color of "REMAINDER" turns blue.
5. Press "menu switch" (8) to reset the remaining time.
To set "REMAINDER" to a desired value, press the up or down arrow switch to set the desired value between
the recommended replacement time and zero.
At this time, "EXCHANGE DAY" is updated.
6. Press the right arrow switch to store the value.
At this time, "REMAINDER" turns black.
7. Press "screen change switch" (1) to return to main screen (a).
7-54
7.4.6 VARIOUS ADJUSTMENT FUNCTION (USER MENU)

7.4.6.1 AUTO IDLING STOP SETTING
(1) Screen Change Switch
6 7 4 5
(2) Buzzer Stop Switch
(3) Work Mode Select Switch
3 10
(4) Washer Switch
(5) Wiper Switch
(6) Travel Speed Select Switch
(7) Auto Acceleration Switch
(8) Menu Switch
2
(9) Arrow Switch
(10) Attachment Mode Select Switch
1 9 8
S
12h
USER MENU USER MENU SWITCH ST ATUS SWITCH ST ATUS
MAINTENANCE MAINTENANCE SWING FLASHER OFF SWING FLASHER OFF

SWITCH ST ATUS SWITCH ST ATUS AUTO IDLING ST OP OFF AUTO IDLING ST OP OFF
OPTION SETTING OPTION SETTING AUTO WARM-UP OFF AUTO WARM-UP OFF
CONSUMPTION CONSUMPTION
SCREEN SETTING SCREEN SETTING
CLOCK SETTING CLOCK SETTING
BACK UP NEXT BACK UP NEXT BACK UP NEXT BACK UP NEXT

HOME DOWN HOME DOWN HOME DOWN HOME DOWN
(a) (b) (c) (d) (e)
SWITCH ST ATUS SWITCH ST ATUS SWITCH ST ATUS
SWING FLASHER OFF SWING FLASHER OFF SWING FLASHER OFF

AUTO IDLING ST OP ON AUTO IDLING ST OP ON AUTO IDLING ST OP OFF
AUTO WARM-UP ON AUTO WARM-UP ON AUTO WARM-UP OFF
BACK UP NEXT BACK UP BACK UP

HOME DOWN HOME DOWN HOME DOWN
(h) (g) (f)
2. Using the Up or Down arrow switch, move the cursor to "SWITCH STATUS". Press the Right arrow switch to
enter the switch setting.
3. Using the Up or Down arrow switch, move the cursor to "AUTO IDLING STOP".
4. Press the Right arrow switch to enter display (f). The background color of "OFF" turns blue.
7
5. Using the Up or Down arrow switch, select "ON".
6. Press "Menu Switch" (8) to set the status.
At this time, the background color of "ON" turns black.
7. Turn "OFF" the starter key switch once to store the status.
7-55
7.4.6.2 CLOCK SETTING

6 7 4 5
3 10
(4) Washer Switch
(5) Wiper Switch
(8) Menu Switch
2
(9) Arrow Switch
1 9 8
S
12h
USER MENU USER MENU CLOCK CLOCK
SETTING SETTING
MAINTENANCE MAINTENANCE YEAR 10 YEAR 10
SWITCH ST ATUS SWITCH ST ATUS MONTH 01 MONTH 01
OPTION SETTING OPTION SETTING DATE 01 DATE 01
CONSUMPTION CONSUMPTION HOUR 13 HOUR 13
SCREEN SETTING SCREEN SETTING MINUTE 25 MINUTE 25

(a) (b) (c) (d) (e)
CLOCK CLOCK
SETTING SETTING
YEAR 11 YEAR 11
MONTH 01 MONTH 01
DATE 01 DATE 01
HOUR 13 HOUR 13
MINUTE 25 MINUTE 25
BACK UP NEXT BACK

HOME DOWN HOME OK
(g) (f)
2. Using the Up or Down arrow switch, move the cursor to "CLOCK SETTING". Press the Right arrow switch to
enter the clock setting.
3. Using the Up and Down arrow switches, select any of "YEAR/MONTH/DAY/HOUR/MINUTE" as display (d).
4. Press the Right arrow switch to enter display (e). The background color of the value turns blue.
5. Using the Up and Down arrow switches, select the desired value.
6. Press menu switch (8) to set the desired value.
At this time, the background color of the value turns black.
7. Press "Screen Change Switch" (1) to return to main screen (a).
7-56
7.4.6.3 CONTRAST ADJUSTMENT

6 7 4 5
3 10
(4) Washer Switch
(5) Wiper Switch
(8) Menu Switch
2
(9) Arrow Switch
1 9 8
S
12h
USER MENU USER MENU SCREEN SCREEN
SETTING SETTING
MAINTENANCE MAINTENANCE CONTRAST 5 CONTRAST 5
SWITCH ST ATUS SWITCH ST ATUS Brightness(day) 100 Brightness(day) 100
OPTION SETTING OPTION SETTING Brightness(night) 50 Brightness(night) 50
BACK UP NEXT BACK UP NEXT BACK UP NEXT BACK UP

(a) (b) (c) (d) (e)
SCREEN SCREEN
SETTING SETTING
CONTRAST 6 CONTRAST 6
Brightness(day) 100 Brightness(day) 100
Brightness(night) 50 Brightness(night) 50
BACK UP NEXT BACK

HOME DOWN HOME OK
(g) (f)
2. Using the Up or Down arrow switch, move the cursor to "SCREEN SETTING". Press the Right arrow switch to
enter the screen setting.
3. Using the Up or Down arrow switch, move the cursor to "CONTRAST".
4. Press the Right arrow switch to enter display (e). The background color of the value turns blue.
5. Using the Up and Down arrow switches, select the desired values. 7
The adjustable range is from 1 (Faint) to 10 (Clear).
* The default value is 5.
7-57
7.4.6.4 BRIGHTNESS (DAY) ADJUSTMENT

6 7 4 5
3 10
(4) Washer Switch
(5) Wiper Switch
(8) Menu Switch
2
(9) Arrow Switch
1 9 8
S
12h
SETTING SETTING

(a) (b) (c) (d) (e)
SCREEN SCREEN SCREEN

SETTING SETTING SETTING
CONTRAST 5 CONTRAST 5 CONTRAST 5
Brightness(day) 80 Brightness(day) 80 Brightness(day) 100
Brightness(night) 5 Brightness(night) 50 Brightness(night) 50
BACK UP BACK BACK UP

HOME DOWN HOME OK HOME DOWN
(h) (g) (f)
3. Using the up and down arrow switches, move the cursor to "Brightness (day)" as display (e).
4. Press the Right arrow switch to enter display (f). The background color of the value turns blue.
5. Using the Up and Down arrow switches, select the desired values.
Adjustable Range: 1 (Dark) to 100 (Bright)
7-58
7.4.6.5 BRIGHTNESS (NIGHT) ADJUSTMENT

6 7 4 5
3 10
(4) Washer Switch
(5) Wiper Switch
(8) Menu Switch
2
(9) Arrow Switch
1 9 8
S
12h
SETTING SETTING

(a) (b) (c) (d) (e)
SCREEN SCREEN SCREEN

SETTING SETTING SETTING
CONTRAST 5 CONTRAST 5 CONTRAST 5
Brightness(day) 100 Brightness(day) 100 Brightness(day) 100
Brightness(night) 60 Brightness(night) 60 Brightness(night) 50
BACK UP BACK BACK UP

HOME DOWN HOME OK HOME DOWN
(h) (g) (f)
3. Using the up and down arrow switches, move the cursor to "Brightness (night)" as display (e).
4. Press the Right arrow switch to enter display (f). The background color of the value turns blue.
5. Using the Up and Down arrow switches, select the desired values. 7
Adjustable Range: 1 (Dark) to 100 (Bright)
7-59
7.4.6.6 CONSUMPTION
Use the indicated average fuel consumption for reference.

6 7 4 5
3 10
(4) Washer Switch
(5) Wiper Switch
(8) Menu Switch
2
(9) Arrow Switch
1 9 8
S
12h
USER MENU USER MENU CONSUMPTION CONSUMPTION
L/h L/h
MAINTENANCE MAINTENANCE 50 50
40 40
SWITCH ST ATUS SWITCH ST ATUS 30 30
20 20
OPTION SETTING OPTION SETTING
10 10
CONSUMPTION CONSUMPTION 0 0
30 25 20 15 10 5 0 30 25 20 15 10 5 0
MIN MIN
WORKTIME 100 HOURS WORKTIME 0 HOURS
CONSUMPTION 100 L CONSUMPTION 0L
AVERAGE 24.4 L/h AVERAGE 0 L/h
BACK UP NEXT BACK UP NEXT BACK BACK

HOME DOWN HOME DOWN HOME RESET HOME RESET
(a) (b) (c) (d) (e)
2. Using the up and down arrow switches, move the cursor to "CONSUMPTION" as display (c). Press the Right
arrow switch to enter the fuel efficiency setting.
3. The graph indicates the average fuel consumption by 2 hours for this 12 hours. The values of the operating
time, fuel consumption and average fuel consumption are also displayed.
4. To reset these values, press the down arrow switch.
7-60
7.4.6.7 PUMP FLOW RATE SETTING (NIBBLER MODE/BREAKER MODE) AND SELECTION OF
OPTION RELIEF PRESSURE
If there is no switch operation for 20 seconds, the display returns to the main screen.

6 7 4 5
3 10
(4)Washer switch
(5)Wiper switch
(8)Menu switch
2
(9)Menu switch
1 9 8
In nibbler mode
S S
12h 12h
USER MENU USER MENU NIBBLER
SETTING
FLOW RATE 780 L/min MAINTENANCE MAINTENANCE SET1 440
MPa
PRESSURE A 50 Mpa SWITCH ST ATUS SWITCH ST ATUS SET2 396

MPa
OPTION SETTING OPTION SETTING SET3 352

PRESSURE B 50 Mpa MPa
CONSUMPTION CONSUMPTION SET4 308

MPa
SCREEN SETTING SCREEN SETTING SET5 264

MPa
CLOCK SETTING CLOCK SETTING SET6 220

MPa
L/min
SET7 198
MPa
30
SET8 176
MPa
15 SET9 154
MPa
SET10 132
0 MPa
30 25 20 15 10 5 0
MIN BACK UP NEXT BACK UP NEXT BACK UP
AVERAGE 0.0 L/h RESET HOME DOWN HOME DOWN HOME DOWN OK
(a) (b) (c) (d) (e)
In breaker mode
S
12h
USER MENU USER MENU BREAKER
SETTING
FLOW RATE 480 L/min MAINTENANCE MAINTENANCE SET1 220
MPa
PRESSURE A 50 Mpa SWITCH ST ATUS SWITCH ST ATUS SET2 198

MPa
OPTION SETTING OPTION SETTING SET3 176

MPa
CONSUMPTION CONSUMPTION SET4 154

MPa
SCREEN SETTING SCREEN SETTING SET5 132

MPa
CLOCK SETTING CLOCK SETTING SET6 110

MPa
L/min
SET7 88
MPa
30
SET8 66
MPa
15 SET9 44
MPa
SET10 30
0 MPa
30 25 20 15 10 5 0
MIN BACK UP NEXT BACK UP NEXT BACK
AVERAGE 0.0 L/h RESET HOME DOWN HOME DOWN HOME OK
(b) (c) (d) (e)

7
1. Turn the starter switch "ON" to display main screen (a).

2. From main screen (a), change the attachment mode from the "digging mode" to the "nibbler mode" or "breaker
mode". The flow rate indication screen (b) appears.
3. When the display is flow rate indication screen (b), press "menu switch" (8) to enter "USER MENU" screen (c).
4. Using the up or down arrow switch, move the cursor to "OPTION SETTING". Press the right arrow switch to
enter option setting screen (e).
7-61
5. When the display is option setting screen (e), move the cursor to a desired flow rate. Press menu switch (8) to
set the desired flow rate value.
7-62
7.4.7 VARIOUS ADJUSTMENT FUNCTION (SERVICE MENU)

The table below shows the adjustment functions for service.
Item Contents
Language Language selection
Idle stop Adjustment of time (sec) until auto idle stop function starts.
P1 side option pressure sensor ON/OFF of self diagnosis for P1 option pressure sensor
P2 side option pressure sensor ON/OFF of self diagnosis for P2 option pressure sensor
Swing alarm ON/OFF of swing alarm (ON/OFF of adjustment for user)
Selection of using left pedal for rotation or not. (Unload valve does not actuate because
Left pedal for rotation
P4 pump is equipped. Europe specification.)
Optional flow rate limitation, relief pressure limitation, adjustment for combination of
Option adjustment setting
return selector.
Engine speed display ON/OFF of engine speed display
Rise-up wiper Switching wiper control(Changed when cab is changed to new demolition cab )
Auto acceleration Adjustment of auto deceleration of instant blow up type
Start mode Change of start mode
Forcible release of low

Release of low temperature mode
temperature mode
Inter-cylinder calibration Inter-cylinder variation calibration
Pressure release For pressure release
Flow rate setting of nibbler

Pump flow rate setting for using nibbler (crusher)
(crusher)
Flow rate setting of breaker Pump flow rate setting for using breaker
Camera 1 setting ON/OFF of rearview camera 1 display
Fuel efficiency display ON/OFF of fuel efficiency graph display
Fuel consumption gauge display ON/OFF of fuel consumption gauge (eco mark) display
Logo display setting ON/OFF of KOBELCO logo display
Engine cylinder suspension Suspension of specific engine cylinder
Input of injector code Code is input to ECU when injector is replaced
Pump difference study Clearance and restudy of ECU difference study contents
Quick coupler ON(operational)/OFF(inoperable) of quick coupler function
• Some of these are described from the next page. 7
7-63
7.4.7.1 PUMP FLOW RATE SETTING (NIBBLER MODE/BREAKER MODE)

(2)Menu switch
(3)Nibbler switch
S
K
(4)Breaker switch
(5)Up arrow switch
(6)Down arrow switch
(7)Right arrow switch
(8)Left arrow switch
1 7
2
8 5 6
According to the attachment to be installed, the flow rate of the service circuit needs to be reduced.
Regarding the flow rate of the nibbler service circuit, there are 10 patterns of setting.
SET 1 SET 2 SET 3 SET 4 SET 5 SET 6 SET 7 SET 8 SET 9 SET 10
Nibbler Flow
L/min 440 396 352 308 264 220 176 132 98 30
(crusher) rate
Flow
Breaker L/min 220 198 176 154 132 110 88 66 49 15
rate
The flow rate of the nibbler service circuit is set at "SET6" of the above table as a factory-set value when the
machine is shipped from a factory.
The flow rate of the breaker service circuit is set at "SET1" of the above table as a factory-set value when the
machine is shipped from a factory.
Refer to the following procedure when setting the flow rate. Set values of above-mentioned adjustment can be
selected from the user menu of "the pump flow rate at the nibbler or breaker mode".
7.4.7.1.1 WHEN USING NIBBLER (CRUSHER)

S TARTER KEY S WICH
ON (a) (b) (c) (d) (e)
+ No.1
HOUR METER 28.1h SER VICE MENU SER VICE ADJUST1-2 NIBBLER or NIBBLER
MAIN CONT. P/N + 28.1h 28.1h
SETTING 28.1h
SETTING 28.1h
LQ22E00344F2
PROGRAM VERSION
1-VRE 02.02
SER VICE DIAGNOSIS AUTO ACCEL 18 SET1 440L/min
SET1 440
L/min
2-VRE 00.00 TROUBLE HIST ORY START MODE X SET2 443 SET2 443
L/min L/min
SER VICE DIAG 1 LANGUAGE & LOGO SETTING CANCEL LOW TEMP ON SET3 394L/min
SET3 394
L/min
CLUSTER GAUGE P/N SER VICE ADJUST 1 CANCEL MODE SET4 344L/min
SET4 344
L/min
YN59S00033F1 SER VICE ADJUST 2 CHECK INJECT OR SET5 295 SET5 295
PROGRAM VERSION L/min L/min
01.00 FACTORY PRESET PRESS DRAIN OFF SET6 246L/min

SET6 246
L/min
ENGINE CONT . P/N
MIS FF FAULT DIAG MODE NIBBLER SETTING SET7 221L/min
SET7 221
L/min
MIS FF
BREAKER SETTING SET8 197L/min
SET8 197
L/min
CAMERA 1 SETTING ON SET9 172L/min

SET9 172
L/min
CAMERA 2 SETTING OFF SET10 148L/min

SET10 148
L/min
BACK UP NEXT BACK UP NEXT BACK UP BACK UP

HOME DOWN HOME DOWN HOME DOWN OK HOME DOWN OK
1. Turn the starter switch "ON". Press nibbler switch (3) to select the nibbler mode, then turn the starter switch
"OFF".
7-64
2. With holding down buzzer stop switch (1), turn the starter switch "ON". Service diagnosis screen (a) is
displayed.
3. Start the engine.
4. With holding down buzzer stop switch (1), press menu switch (2) 3 times. "SERVICE MENU" screen (b) is
displayed.
5. Using up arrow switch (5) or down arrow switch (6), point the cursor to "SERVICE ADJUST 1" of screen (b).
Press right arrow switch (7), and the "SERVICE ADJUST 1-1" screen is displayed. Then press down arrow
switch (6) several times and "SERVICE ADJUST 1-2" screen (c) is displayed.
6. Using up arrow switch (5) or down arrow switch (6), point the cursor to "NIBBLER SETTING" of screen (d).
Press right arrow switch (7), and "NIBBLER SETTING" screen (e) is displayed.
7. There are 10 step settings from "SET 1" to "SET 10". Using up arrow switch (5) or down arrow switch (6),
select a desired set number. To set the desired set number, press right arrow switch (7).
8. Using up arrow switch (5) or down arrow switch (6), select a desired flow rate and press menu switch (2) and
confirm it.
9. After that, press left arrow switch (8) to return to "SERVICE ADJUST 1-2" screen (c).
7.4.7.1.2 WHEN USING BREAKER

S TARTER KEY S WICH
ON (a) (b) (c) (d) (e)
+ No.1
HOUR METER 28.1h SER VICE MENU SER VICE ADJUST1-2 BREAKER or BREAKER
MAIN CONT. P/N + 28.1h 28.1h
SETTING 28.1h
SETTING 28.1h
LQ22E00344F2
PROGRAM VERSION
1-VRE 02.02
SER VICE DIAGNOSIS AUTO ACCEL 18 SET1 246
L/min
SET1 246
L/min
2-VRE 00.00 TROUBLE HIST ORY START MODE X SET2 221 SET2 221
L/min L/min
SER VICE DIAG 1 LANGUAGE & LOGO SETTING CANCEL LOW TEMP ON SET3 197
L/min
SET3 197
L/min
CLUSTER GAUGE P/N SER VICE ADJUST 1 CANCEL MODE SET4 172
L/min
SET4 172
L/min
YN59S00033F1 SER VICE ADJUST 2 CHECK INJECT OR SET5 148 SET5 148
PROGRAM VERSION L/min L/min
01.00 FACTORY PRESET PRESS DRAIN OFF SET6 123

L/min
SET6 123
L/min
ENGINE CONT . P/N
MIS FF FAULT DIAG MODE NIBBLER SETTING SET7 98
L/min
SET7 98
L/min
MIS FF
BREAKER SETTING SET8 74
L/min
SET8 74
L/min
CAMERA 1 SETTING ON SET9 49

L/min
SET9 49
L/min
CAMERA 2 SETTING OFF SET10 15

L/min
SET10 15
L/min
BACK UP NEXT BACK UP NEXT BACK UP BACK UP

HOME DOWN HOME DOWN HOME DOWN OK HOME DOWN OK
1. Turn the starter switch "ON". After pressing breaker switch (4) to select the breaker mode, turn the starter
switch "OFF".
2. With holding down buzzer stop switch (1), turn the starter switch "ON". Service diagnosis screen (a) is
displayed.
4. With holding down buzzer stop switch (1), press menu switch (2) 3 times. "SERVICE MENU" screen (b) is
displayed.
5. Using up arrow switch (5) or down arrow switch (6), point the cursor to "SERVICE ADJUST 1" of screen (b).
Press right arrow switch (7), and the "SERVICE ADJUST 1-1" screen is displayed. Then press down arrow
switch (6) several times and "SERVICE ADJUST 1-2" screen (c) is displayed.
6. Using up arrow switch (5) or down arrow switch (6), point the cursor to "BREAKER SETTING" of screen (d). 7
Press right arrow switch (7), and "BREAKER SETTING" screen (e) is displayed.
7. There are 10 step settings from "SET 1" to "SET 10". Using up arrow switch (5) or down arrow switch (6),
select a desired set number. To set the desired set number, press right arrow switch (7).
8. Using up arrow switch (5) or down arrow switch (6), select a desired flow rate and press menu switch (2) and
confirm it.
9. After that, press left arrow switch (8) to return to "SERVICE ADJUST 1-2" screen (c).
7-65
7.4.7.2 INTER-CYLINDER CALIBRATION

6 7 4 5
3 10
(4)Washer switch
(5)Wiper switch
(8)Menu switch
2
(9)Arrow switch
1 9 8
S TARTER KEYS WICH

ON (a) (b) (c) (d) (e)
+ No.1
or or
HOUR METER 5.0h SER VICE MENU SER VICE MENU SER VICE ADJUST1-1 SER VICE ADJUST1-2
MAIN CONT. P/N
LQ22E00344F2
+ 5.1h 5.1h 5.1h 5.1h
PROGRAM VERSION
SER VICE DIAGNOSIS SER VICE DIAGNOSIS AUTO IDLE ST OP 60 AUTO ACCEL 18
1-VER 02.02
2-VER 00.00 TROUBLE HIST ORY TROUBLE HIST ORY P1 OPT SENSOR ACT. OFF START MODE 8
SER VICE DIAG 1 LANGUAGE & LOGO SETTING LANGUAGE & LOGO SETTING P2 OPT SENSOR ACT. OFF CANCEL LOW TEMP OFF

CLUSTER GAUGE P/N SER VICE ADJUST 1 SER VICE ADJUST 1 SWING ALARM OFF CANCEL MODE
YN59S00033F1 SER VICE ADJUST 2 SER VICE ADJUST 2 PRIORITY MODE CHECK INJECT OR
PROGRAM VERSION
01.00 FACTORY PRESET FACTORY PRESET LEFT PEDAL ACTIVE ON PRESS DRAIN OFF
ENGINE CONT . P/N
MIS FF FAULT DIAG MODE FAULT DIAG MODE SELECT OPT SYSTEM 1 NIBBLER SETTING
ADJ OVERLOAD BREAKER SETTING
MIS FF
ENG SPEED DISPLAY OFF CAMERA 1 SETTING OFF
RISE-UP WIPER ON CAMERA 2 SETTING OFF
DOWN DOWN DOWN DOWN
Start the engine with

the above screen
displayed.
(f)
CYLINDER BALANCING(FCCB)
HOUR METER 99999.4h
ENG SPEED 799

CYL1 -0.1mm3/s t.cyl.
CYL3 0.0mm3/s t.cyl.
CYL1 SPEED DEVIA. TIME 2
CYL2 SPEED DEVIA. TIME -8
CYL4 SPEED DEVIA. TIME -4
OK
1. With holding down buzzer stop switch (2), turn the starter switch "ON". Service diagnosis screen (a) appears.
2. With holding down buzzer stop switch (2), press menu switch (8) 3 times. "SERVICE MENU" screen (b)
appears.
3. Using the up or down arrow switch, point the cursor to "SERVICE ADJUST 1" of screen (c). Press the right
arrow switch, and the "SERVICE ADJUST 1-1" screen is displayed.
4. Start the engine and using the up or down arrow switch, point the cursor to "CHECK INJECTOR" of screen (e).
Press the right arrow switch, and the "CYLINDER BALANCING (FCCB)" screen is displayed and inter-cylinder
calibration starts.
5. The engine speed is fixed at approximately 800 rpm.
6. When the value of [mm3/st.cyl] for each cylinder becomes stabled, the inter-cylinder calibration is completed.
Press menu switch (8) to return to the service adjust screen.
7-66
7.4.7.3 ENGINE CYLINDER SUSPENSION

6 7 4 5
3 10
(4)Washer switch
(5)Wiper switch
(8)Menu switch
2
(9)Arrow switch
1 9 8
S TARTER KEY S WICH

ON (a) (b) (c) (d) (e)
+ No.1
or or
MAIN CONT. P/N
LQ22E00344F2
+ 5.1h 5.1h 5.1h 5.2h
PROGRAM VERSION
SER VICE DIAGNOSIS SER VICE DIAGNOSIS AUTO IDLE ST OP 60 CAMERA 3 SETTING OFF
1-VER 02.02
2-VER 00.00 TROUBLE HIST ORY TROUBLE HIST ORY P1 OPT SENSOR ACT. OFF CONSUMPTION GRAPH ON
SER VICE DIAG 1 LANGUAGE & LOGO SETTING LANGUAGE & LOGO SETTING P2 OPT SENSOR ACT. OFF MILEAGE GAGE ON

CLUSTER GAUGE P/N SER VICE ADJUST 1 SER VICE ADJUST 1 SWING ALARM OFF LOGO DISPLA Y ON
YN59S00033F1 SER VICE ADJUST 2 SER VICE ADJUST 2 PRIORITY MODE BACKGROUND COLOR
PROGRAM VERSION
01.00 FACTORY PRESET FACTORY PRESET LEFT PEDAL ACTIVE ON ADJUST F AN
ENGINE CONT . P/N
MIS FF FAULT DIAG MODE FAULT DIAG MODE SELECT OPT SYSTEM 1 STOP CYLINDER
ADJ OVERLOAD INPUT INJ ECTOR CODE
MIS FF
ENG SPEED DISPLAY OFF STOP PUMP DIFFERENCE
RISE-UP WIPER ON
DOWN DOWN DOWN DOWN
Start the engine with

2 the above screen
displayed.
STOP ENG CYLINDER STOP ENG CYLINDER STOP ENG CYLINDER STOP ENG CYLINDER STOP ENG CYLINDER
HOUR METER 3.0h HOUR METER 3.0h HOUR METER 3.0h HOUR METER 3.0h HOUR METER 3.0h
STOP CYLINDER No. 4 STOP CYLINDER No. 3 STOP CYLINDER No. 2 STOP CYLINDER No. 1 1 STOP CYLINDER No. +
ENG SPEED 1134 ENG SPEED 1127 ENG SPEED 1134 ENG SPEED 1129 ENG SPEED 1149
COMP. FUEL CONS. 24mm3/s t .cyl. COMP. FUEL CONS. 20mm3/s t .cyl. COMP. FUEL CONS. 24mm3/s t .cyl. COMP. FUEL CONS. 20mm3/s t .cyl. COMP. FUEL CONS. 16mm3/s t .cyl.
ENG RAIL PRESS 57.0M ENG RAIL PRESS 57.0M ENG RAIL PRESS 57.0M ENG RAIL PRESS 56.0M ENG RAIL PRESS 53.0M
BOOST PRESS 104 BOOST PRESS 104 BOOST PRESS 104 BOOST PRESS 104 1 BOOST PRESS 102
EGR VALVE POS. No.1 0.0% EGR VALVE POS. No.1 0.0% EGR VALVE POS. No.1 0.0% EGR VALVE POS. No.1 0.0% EGR VALVE POS. No.1 0.0%
EGR VALVE POS. No.2 100.0% EGR VALVE POS. No.2 100.0% EGR VALVE POS. No.2 100.0% EGR VALVE POS. No.2 100.0% EGR VALVE POS. No.2 100.0%
SCV CURRENT 1020mA SCV CURRENT 1040mA SCV CURRENT 1120mA SCV CURRENT 1920mA SCV CURRENT 1020mA
INTAKE AIR FLOW 0g/h INTAKE AIR FLOW 0g/h INTAKE AIR FLOW 0g/h INTAKE AIR FLOW 0g/h INTAKE AIR FLOW 0g/h
INTAKE AIR TEMP 0¥¥ INTAKE AIR TEMP 0¥¥ INTAKE AIR TEMP 0¥¥ INTAKE AIR TEMP 0¥¥ INTAKE AIR TEMP 0¥¥
PERCENT TORQUE 0.2% PERCENT TORQUE 0.2% PERCENT TORQUE 0.2% PERCENT TORQUE 0.2% PERCENT TORQUE 0.1%
P1-PRES 0.0M P1-PRES 0.0M P1-PRES 0.0M P1-PRES 0.0M P1-PRES 0.0M
P2-PRES 0.2M P2-PRES 0.2M P2-PRES 0.2M P2-PRES 0.2M P2-PRES 0.2M
P1-PSV 338mA P1-PSV 339mA P1-PSV 339mA P1-PSV 338mA P1-PSV 339mA
P2-PSV 341mA P2-PSV 341mA P2-PSV 341mA P2-PSV 340mA P2-PSV 340mA
1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
4 OK 4 OK 4 OK 4 OK 4 OK
2. During pressing buzzer stop switch (2), press menu switch (8) three times. "SERVICE MENU" screen (b) 7
appears.
4. Using the up or down arrow switch, point the cursor to "STOP CYLINDER" of screen (e).
Start the engine and press the right arrow switch to display the "STOP ENG CYLINDER" screen.
5. Referring to the display, select the number of a desired cylinder (1 to 4) to be stopped. The selected cylinder is
stopped.
7-67
6. At the time of the cylinder stop, check the value of COMP.FUEL CONS. (If the command injection quantity has
been changed significantly or has not been changed from the command injection quantity of when stopping the
cylinder under a normal machine condition, the stopped injector can be failed.)
7. Press the switch of the same number of the stopped engine cylinder and then the stopped cylinder works
again.
8. Press menu switch (8) to finish the "STOP ENG CYLINDER" screen and return to the "SERVICE ADJUST
SCREEN 1-3" screen.
7-68
7.4.7.4 INPUT OF INJECTOR CODE
• Even if "READ INJECTOR CODE" is not performed, the injector codes can be input but in this case, "F" is input
to all of the boxes of each "injector no." first and it takes a lot of times to rewrite them.
• If a wrong value of the injector code is input, "WRITING FAILED" is displayed.
In this case, the input injector code is not stored. Input the injector code again.
• When replacing the ECU, display the injector code by following the procedure 10. and write the injector code
down, and then input that code. Otherwise, input the code displayed on the tag attached to the injector body.
• When replacing the injector, perform the procedures of 1. to 5. to allow the injector to read the code.

6 7 4 5
3 10
(4)Washer switch
(5)Wiper switch
(8)Menu switch
2
(9)Arrow switch
1 9 8
7-69
S TARTER KEY S WICH

ON (a) (b) (c) (d) (e)
+ No.1
or or
MAIN CONT. P/N
LQ22E00344F2
+ 5.1h 5.1h 5.1h 5.6h
PROGRAM VERSION
1-VER 02.02
PROGRAM VERSION
ENGINE CONT . P/N
MIS FF
ENG SPEED DISPLAY OFF STOP PUMP DIFFERENCE
RISE-UP WIPER ON
BACK NEXT BACK NEXT BACK NEXT BACK NEXT
Example:
When is input (h) (g) (f)
INPUT CODE INJECT OR No.1 INPUT CODE INJECT OR No.1 INPUT CODE INJECT OR No. SELECT INJECT OR SELECT INJECT OR
5.7h 5.6h 5.6h 5.6h 5.7h
A 1 0 0 0 0 E 4 2 1 0 0 0 0 E 4 2 1 0 0 0 0 E 4
INJECT OR No.1 INJECT OR No.1

0 0 0 0 F 2 0 0 0 0 0 0 F 2 0 0 0 0 0 0 F 2 0 0

E 9 E 4 0 0 0 0 E 9 E 4 0 0 0 0 E 9 E 4 0 0 0 0 INJECT OR No.5 INJECT OR No.5

0 0 0 0 3 A 0 0 0 0 3 A 0 0 0 0 3 A READ INJECT OR CODE READ INJECT OR CODE
1 2 3 4
5 6 7 8
9 A B C
BACK NEXT D E F 0 BACK NEXT BACK BACK
OK OK OK OK
or
INPUT CODE INJECT OR No.1 SELECT INJECT OR or SELECT INJECT OR

5.7h 5.6h 5.7h
A 1 0 0 0 0 E 4

0 0 0 0 F 2 0 0

E 9 E 4 0 0 0 0 INJECT OR No.5 INJECT OR No.5

0 0 0 0 3 A READ INJECT OR CODE READ INJECT OR CODE
BACK NEXT BACK BACK

OK OK OK
appears.
4. Using the up or down arrow switch, point the cursor to "INPUT INJECTOR CODE" of screen (e). Press the right
arrow switch, and the "SELECT INJECTOR" screen is displayed.
5. Using the up or down arrow switch, point the cursor to "READ INJECTOR CODE" of screen (f) and press menu
switch (8). The injector code is read from the ECU and the value is read by each "injector no. n" (n is an
arbitrary number).
6. Using the up or down arrow switch, point the cursor to a desired "injector no. n" of screen (g). Press menu
switch (8) to display "INPUT CODE INJECTOR No. n" (h).
7. Using the up or down arrow switch, point the cursor to a desired box of screen (h). Press the right arrow switch,
and input a desired code referring to the screen of the gauge cluster.
8. After inputting the code, the cursor is moved to the next right box. Input a code again following the same
procedure of 7.
7-70
9. After inputting the codes to the all boxes, press menu switch (8) to register the input codes. At this time, the
screen returns to "SELECT INJECTOR".
10. Finally, perform "READ INJECTOR CODE" once again and display "INPUT CODE INJECTOR No. n" to check
that the injector codes are input correctly.
7-71
7.4.7.5 PUMP DIFFERENCE STUDY
By pressing menu switch (8) under any condition of "CLEARED" or "DONE" in the procedure of 7., the screen shifts
to screen (k) and each condition information is stored.

6 7 4 5
3 10
(4)Washer switch
(5)Wiper switch
(8)Menu switch
2
(9)Arrow switch
1 9 8
S TARTER KEY S WICH
ON (a) (b) (c) (d) (e)
+ No.1
or or
MAIN CONT. P/N
LQ22E00344F2
+ 5.1h 5.1h 5.1h 5.9h
PROGRAM VERSION
1-VER 02.02

PROGRAM VERSION
ENGINE CONT . P/N
MIS FF
ENG SPEED DISPLAY OFF STUDY PUMP DIFFERENCE
RISE-UP WIPER ON
DOWN DOWN DOWN DOWN
(j) (i) (h) (g) Start (f)

STUDY PUMP DIFFERENCE STUDY PUMP DIFFERENCE STUDY PUMP DIFFERENCE STUDY PUMP DIFFERENCE the Engine
HOUR METER 3.2h HOUR METER 3.2h HOUR METER 3.2h HOUR METER 3.2h STUDY PUMP DIFFERENCE
CONDITION FLAG DONE CONDITION FLAG LEARNING1 CONDITION FLAG LEARNING2 CONDITION FLAG CLEARED 3.1h
ENG SPEED 783 ENG SPEED 807 ENG SPEED 808 ENG SPEED 779
COMP. FUEL COMS. 14mm3/s t .cly COMP. FUEL COMS. 14mm3/s t .cly COMP. FUEL COMS. 14mm3/s t .cly COMP. FUEL COMS. 14mm3/s t .cly STUDY PUMP DIFFERENCE
ENG RAIL PRESS 42.0M ENG RAIL PRESS 42.0M ENG RAIL PRESS 42.0M ENG RAIL PRESS 42.0M CONDITION CLEARED
WATER TEMP 73.0¥¥ WATER TEMP 73.0¥¥ WATER TEMP 73.0¥¥ WATER TEMP 73.0¥¥
FUEL TEMP 31¥¥ FUEL TEMP 31¥¥ FUEL TEMP 32¥¥ FUEL TEMP 32¥¥
POWER SUPPLY VOLTAGE 0.0V POWER SUPPLY VOLTAGE 0.0V POWER SUPPLY VOLTAGE 0.0V POWER SUPPLY VOLTAGE 0.0V
ACCEL POS. 0% ACCEL POS. 0% ACCEL POS. 0% ACCEL POS. 0%
STARTER SW 0% STARTER SW 0% STARTER SW 0% STARTER SW 0%
CAN COMMAND ENG SPEED 0 CAN COMMAND ENG SPEED 0 CAN COMMAND ENG SPEED 0 CAN COMMAND ENG SPEED 0
DPR REGENE MODE DPR REGENE MODE DPR REGENE MODE DPR REGENE MODE
BACK
OK OK OK OK OK
(k)
STUDY PUMP DIFFERENCE
3.1h
STUDY PUMP DIFFERENCE
CONDITION DONE
BACK
OK
7-72
appears.
4. Using the up or down arrow switch, point the cursor to "STUDY PUMP DIFFERENCE" of screen (e). Press the
right arrow switch, and the "STUDY PUMP DIFFERENCE" screen is displayed.
5. Confirm that "STUDY PUMP DIFFERENCE CONDITION" is "CLEARED" by screen (f). If it is "DONE", press
menu switch (8) to change it to "CLEARED".
6. Start the engine and press menu switch (8) to start pump difference study.
7. The contents of "CONDITION FLAG" shifts through "CLEARED", "LEARNING 2", "LEARNING 1", and
"DONE". When it becomes "DONE", the pump difference study is completed.
8. By pressing menu switch (8), the study result is stored and shifts to screen (k).
7-73
7.4.8 MECHATRO CONTROL DEVICES

7.4.8.1 MECHATRO CONTROLLER (CODE C-1)
7.4.8.1.1 GENERAL VIEW
CIRCUIT NUMBER
CN105 CN104 CN103 CN102 CN101

~134 ~99 ~67 ~32 ~1
167~ 133~ 98~ 66~ 31~

CN105 CN103 CN101
CN104 CN102
List of connectors
Connector No. P in No. P ort na me Function Input/output S igna l le ve l

CN101 1 S HG Chassis ground - Ground
2
3
4 Reserved - -
5 C1(DO1) Wiper ark prevention relay Output EARTH/OPEN
6 C2(DO2) Wiper normal rotation relay Output EARTH/OPEN
7 C3(DO3) Wiper reverse rotation relay Output EARTH/OPEN
8 A1G 0V
9 A1S Boom up pressure sensor Input 0.5 to 4.5V
10 A1V 5V
11 A2V 5V
12 A2S Boom down pressure sensor Input 0.5 to 4.5V
13 A2G 0V
14 A3G 0V
15 A3S Arm-in pressure sensor Input 0.5 to 4.5V
16 A3V 5V
17 A4V 5V
18 A4S Arm-out pressure sensor Input 0.5 to 4.5V
19 A4G 0V
20 A5G 0V
21 A5S Bucket digging pressure sensor Input 0.5 to 4.5V
22 A5V 5V
23 A6V 5V
24 A6S Bucket dump pressure sensor Input 0.5 to 4.5V
25 A6G 0V
26 A8G 0V
27 A8S Travel right pressure sensor Input 0.5 to 4.5V
28 A8V 5V
29 A9V 5V
30 A9S Travel left pressure sensor Input 0.5 to 4.5V
31 A9G 0V
7-74

CN102 32 C7(DO7) Travel 1/2 speed selector valve Output +24V/OP EN
33 C8(DO8) Swing parking brake selector valve Output +24V/OP EN
34 C9(DO9) Power boost selector valve Output +24V/OP EN
35 C11(DO11) Option selector switching valve Output +24V/OP EN
36 C12(DO12) DPF forcible regeneration signal Output +24V/OP EN
37 C16(DO16) AIS 2 relay Output EARTH/OPEN
38 A10 G 0V
39 A10 S Acceleration potentiometer Input 0.5 to 4.5V
40 A10 V 5V
41 A13 V 5V
P1 side option pressure sensor Input
42 A13 S 0.5 to 4.5V
43 B1(DI1) Working light switch Input +24V/OP EN
44 B4(DI4) Front window open/close switch Input EARTH/OPEN
45 A14 S 0.5 to 4.5V
P2 side option pressure sensor Input
46 A14 V 5V
47
48
49
50 B2(DI2) Key switch (ON) Input +24V/OP EN
51 B3(DI3) Key switch (glow) Input +24V/OP EN
52 B6(DI6) Engine start Input +24V/OP EN
EARTH/OPEN(7mA)
53 B16(DI16) Wiper rise-up switch Input
(Interruption)
54 B18(DI18) Power boost switch Input EARTH/OPEN
55 A13 G P1 side option pressure sensor Input 0V
56 A18 G Swing left pressure sensor Input 0V
57 A14 G P2 side option pressure sensor Input 0V
58 B7( DI7) Dozer pressure sensor Input EARTH/OPEN
EARTH/OPEN(7mA)
59 B17 (DI7) Wiper reverse rotation switch Input
(Interruption)
60 CANL2 CAN
Gauge cluster communication
61 CANH2
62 A18 V 5V
Swing left pressure sensor Input
63 A18 S 0.5 to 4.5V
64 B23(DI23) Lever lock switch Input +24V/OP EN
65 C17 (DO 17 ) Engine stop relay Output EARTH/OPEN
66 C18 (DO 18 ) Lever lock relay Output EARTH/OPEN
7-75

CN103 67 D5+ +0 to 800mA
P1 pump proportional valve Output
68 D5- -0 to 800mA
69 D6+ +0 to 800mA
P2 pump proportional valve Output
70 D6- -0 to 800mA
71 D3+ +0 to 800mA
Travel straight proportional valve Output
72 D3- -0 to 800mA
73 GND Battery (-) - 0V
74 A11G 0V
75 A11S P1 pump pressure sensor Input 0.5 to 4.5V
76 A11V 5V
77 A12V P2 pump pressure sensor Input 5V
78 A23G (Hydraulic oil temperature) Input 0V
79 A12G P2 pump pressure sensor Input 0V
80 A20G Pressure sensor for 0V
81 A20S detection of selector Input 0.5 to 4.5V
82 A20V valve position 5V
83 B22 Spare2 Input EARTH/OPEN
84 TXD1 Handy checker Transmission RS232 communication
85 A22G GP Input 0V
86 A22S (Fuel level) Input 0.5 to 4.5V
87 A23S (Hydraulic oil temperature) Input 0.5 to 4.5V
88 A12S P2 pump pressure sensor Input 0.5 to 4.5V
89 A17G 0V
90 A17S Boom rod pressure sensor Input 0.5 to 4.5V
91 A17V 5V
92 E1+ Input 2.8Vp-p or more
93 GP Engine speed sensor - 0V
94 SHG - Shielded ground cable
95 B19 Hand control of nibbler Input EARTH/OPEN
96 RXD1 Reception RS232 communication
97 DL Handy checker - EARTH/OPEN
98 GP - 0V
7-76

CN104 99 D1+ P1 unload proportional valve Output +0 to 800m A
100 D1- -0 to 800m A
101 D2+ +0 to 800m A
P2 unload proportional valve Output
102 D2- -0 to 800m A
103 D4+ Arm-in speed 2 inverse +0 to 800m A
Output
104 D4- proportional valve -0 to 800m A
105 C10(DO10) Boom M/I cut Output +24V/OP EN
106
107
108 C13(DO13) Swing flasher right relay Output EARTH/OP EN
109 C14(DO14) Swing flasher left relay Output EARTH/OP EN
110 B5(DI5) Swing parking brake release Input EARTH/OP EN
111 B9(DI9) Engine oil pressure switch Input EARTH/OP EN(7mA)
112 B10(DI10) Air filter switch Input EARTH/OP EN(7mA)
113 B13(DI13) Engine coolant level Input EARTH/OP EN(7mA)
114 B20(DI20) ECU main relay Input EARTH/OP EN(7mA)
115 B8(DI8) Hand control of breaker Input EARTH/OP EN(7mA)
116 B11(DI11) Charge Input +24V/OP EN
117
118
119 B21(DI21) Rotation nibbler (crusher) and breaker Input EARTH/OP EN
120
121 D10- Option relief proportional valve 1 Output -0 to 800m A
122 D11+ +0 to 800m A
Option relief proportional valve 2 Output
123 D11- -0 to 800m A
124 B12 (DI12) Manual regeneration signal Input EARTH/OP EN
125 TXD2 Transmission RS232 communica tion
126 GP - 0V
IT terminal
127 RXD2 Reception RS232 communica tion
128 S HG - Shie lde d ground ca ble
129 D10+ Option relief proportional valve 1 Output +0 to 800m A
130 CANL1 CAN communica tion
ECU -
131 CANH1 CAN communica tion
132 H1+ Acceleration signal 1 - 0 to 5V
133 H2+ Acceleration signal 2 - 0 to 5V
7-77

CN105 134 +24V Battery (+) 20 to 32V
-
135 +24V (for dynamic force ) 20 to 32V
136 GND 0V
137 GND Battery (-) - 0V
138 GND 0V
139 +24V 20 to 32V
Battery (-) (for control) -
140 +24V 20 to 32V
141 C21 (DO21) Safety relay Output EARTH/OP EN
142 C15 (DO15) Travel alarm relay Output EARTH/OP EN
143
144
145 C4 (DO4) Washer motor relay Output EARTH/OP EN
146
147 A16G 0V
148 A16S Boom head pressure sensor Input 0.5 to 4.5V
149 A16V 5V
150 A7V 5V
151 A7S Swing right pressure sensor Input 0.5 to 4.5V
152 A7G 0V
153
154
155 A19G Swing speed Input 0V
156 D8+ Boom recirculation +0 to 800mA
Output
157 D8- proportional valve -0 to 800mA
158 A19V Swing speed Input 5V
Differential pressure EARTH/OP EN
159 B14 (DI14) Input
of hydraulic oil filter (Re a ding fre que ncy)
160 D12 + Output +0 to 800mA
161 D12- -0 to 800mA
162 +24V Battery (+) (for clock IC) - 20 to 32V
163 D7+ - +0 to 800mA
Boom 3 proportional valve
164 D7- -0 to 800mA
165 A19S Swing speed Input 0.5 to 4.5V
166 D9+ Output +0 to 800mA
Arm cushion proportional valve
167 D9- -0 to 800mA
7-78
7.4.8.2 GAUGE CLUSTER (CODE C-2)
7.4.8.2.1 GENERAL VIEW

NIBBLER
SWITCH
BREAKER
SWITCH
CN-600
MULTI
DISPLAY(LCD) 1 2 3 4
5 6 7 8
HARNESS SIDE
DIGGING SWIHCH AMP 040 (8P)
HOUSING : 174044-2
TERMINAL : 173681-2
WORK MODE
SELECT SWIHCH
BUZZER STOP
SWITCH
LEFT ARROW
SWITCH RIGHT ARROW SWITCH
MENU SWITCH CN-601
SCREEN CHANGE HARNESS SIDE
DOWN ARROW SWITCH 1 2 3 4 5 6 AMP 040 (12P)
SWITCH
UP ARROW SWITCH 7 8 9 10 1112 HOUSING : 174045-2
TERMINAL : 173681-2
Connector CN-600 (Harness side)

No. Item name Wire color No. Item name Wire color
1 Reserved - 5 Source (+24V) White
2 Reserved - 6 GND Black
3 Reserved - 7 Source (+24V) White
4 Reserved - 8 Reserved -
Connector CN-601 (Harness side)

No. Item name Wire color No. Item name Wire color
4 Rearview camera video signal White 10 GND Black

5 Reserved - 11 Reserved - 7
Mechatro-controller → Gauge cluster →
6 Gauge cluster (CAN Red 12 Mechatro-controller (CAN White
communication) communication)
Function
• Signals from communication between the gauge cluster and the mechatro controller are processed and they are
displayed by the lamps, LCD and sound the buzzer.
• Coolant temperature signals, fuel level signals and panel switch signals are output to the mechatro controller
through the communication ports.
7-79
Summary of display and drive item

No. Item Remarks
1 Monitar display LCD dot 120X168
2 -
3 -
4 Buzzer Piezo-electricity type
5 Screen change switch
6 Buzzer stop switch
7 Work mode select switch

8 Digging switch
9 Nibbler switch
10 Breaker switch
11 Up arrow switch
12 Down arrow switch

13 Right arrow switch
14 Left arrow switch

15 Back light LED
7-80
7.4.8.3 RELAY AND FUSE BOX (CODE E-1)
7.4.8.3.1 GENERAL VIEW AND CONSTRUCTION
(This figure s hows condition tha t re la ys

a nd fus e s a re fully ins ta lle d.)
Label
Internal section
Connecter position (seeing from backside)
Relay & fuse position
Detail of label
7-81
Circuit schematic
No. Name Device name
diagram No.
1 FS1 LEVER LOCK MINI FUSE(10A) ○
2 FS2 REVOLUTION/NIBBLER RELAY MINI FUSE(5A) ○
3 FS3 ENG CONTROLLER MINI FUSE(15A) ○
4 FS4 OPT MINI FUSE(10A) ○
5 FS5 CIGARETTE LIGHTER MINI FUSE(10A) ○
6 FS6 HORN MINI FUSE(10A) ○
7 FS7 RESERVE MINI FUSE(20A) ○
8 FS8 A/C(MAIN) MINI FUSE(15A) ○
9 FS9 A/C (COMPRESSOR) MINI FUSE(5A) ○
10 FS10 CAB WORK LIGHT 1 MINI FUSE(20A) ○
11 FS11 CAB WORK LIGHT 2 MINI FUSE(20A) ○
12 FS12 KEY SWITCH MINI FUSE(20A) ○
13 FS13 FUEL SUPPLY PUMP MINI FUSE(15A) ○
14 FS14 ROOM LIGHT MINI FUSE(5A) ○
16 FS16 MECHATRO CONTROLLER MINI FUSE(20A) ○
17 FS17 MECHATRO CONTROLLER MINI FUSE(5A) ○
18 FS18 ENG CONTROLLER MINI FUSE(15A) ○
19 FS19 TUNER MINI FUSE(10A) ○
20 FS20 RADIATER COOLANG LEVEL MINI FUSE(5A) ○
21 FS21 FLASHER MINI FUSE(20A) ○
23 FS23 TRAVEL ALARM MINI FUSE(20A) ○
24 FS24 AC(AMP) MINI FUSE(5A) ○
25 FS25 CLUSTER GAUGE MINI FUSE(5A) ○
26 FS26 DC-DC CONVERTER MINI FUSE(10A) ○
27 FS27 WIPER MINI FUSE(20A) ○
28 FS28 BUCKET CONTROL MINI FUSE(10A) ○
29 FS29 WORK LIGHT MINI FUSE(20A) ○
31 FS31 CLUSTER BACK UP MINI FUSE(5A) ○
32 FS32 MECHATRO BACK UP MINI FUSE(5A) ○
33 RLY1 AUTO IDLE STOP 2 MICRO RELAY(V23074A2002A403) ○
34 RLY2 SAFETY MICRO RELAY(V23074A2002A403) ○
35 RLY3 HORN MICRO RELAY(V23074A2002A403) ○
36 RLY4 ENG EMERGENCY STOP MICRO RELAY(V23074A2002A403) ○
37 RLY5 WIPER MOTOR REVERSING MINI RELAY(V23134A053C643) ○
38 RLY6 WINDOW WASHER MOTOR MINI RELAY(V23134A053C643) ○
39 RLY7 CAB WORKING LIGHT 1 MICRO RELAY(V23074A2002A403)
7-82
Circuit schematic
No. Name Device name
diagram No.
40 RLY8 CAB WORKING LIGHT 2 MICRO RELAY(V23074A2002A403)
41 RLY9 KEEP KEY ON MICRO RELAY(V23074A2002A403) ○
42 RLY10 LEVER LOCK MICRO RELAY(V23074A2002A403) ○
43 RLY11 ALTERNATOR MICRO RELAY(V23074A2002A403) ○
44 RLY12 AUTO IDLE STOP 1 MICRO RELAY(V23074A2002A403) ○
45 RLY13 TRAVEL ALARM MICRO RELAY(V23074A2002A403)
46 RLY14 WIPER MOTOR MINI RELAY(V23134A053C643) ○
47 RLY15 PREVENT SPARK MINI RELAY(V23134A053C643) ○
48 RLY16 BUCKET CONTROL MICRO RELAY(V23074A2002A403)
49 RLY17 WORK LIGHT MICRO RELAY(V23074A2002A403) ○
50 RLY18 NEUTRAL STOP MICRO RELAY(V23074A2002A403) ○
51 SP1 SPARE MINI FUSE(5A) ○
Note: The mark "○" shows a standard part.
7-83
7.4.8.3.2 CIRCUIT DIAGRAM
7-84
7-85
7-86
7-87
7.4.8.4 HIGH PRESSURE SENSOR

YN52S00103P1 (with orifice)
YN52S00104P1 (without orifice)
ECONOSEAL SERIES MARK (+)> SPECIFICA TION :

3POLES CAP
MATING HOUS ING174357-2 PRESSURE RANGE : 0 50 MPa (0 7250 psi)
POWER SOURCE VOL TAGE : 5.0+0.5V DC
COMMON OUTPUT : 1/10Vs-9/10Vs
OUTPUT (+) (Vs=5V DC 0.5 4.5V DC)
POWER SOURCE (+) INSURANCE RESIST ANCE : 100M OR MORE
(BETWEEN CASING AND ALL IN/OUT
TERMINALS AT 50V DC MEGGER)
O-RING P14
JIS B2401 CLASS1B
PF 3/8
Tighte ning torgue
73.5N .m (54.2lbf .ft)
7.4.8.5 LOW PRESSURE SENSOR

LC52S00019P1
A AMP MQS CONNECTOR 3 POLE (B TYPE)
OPPOSITE CONNECTOR (FEMALE)
HOUSING 8 2-967642-1
TERMINAL (GOLD PLATED) 8 965906-5
CONNECTOR TERMINAL POSITION

TERMINAL No.
1-COM
2-OUT PUT (+)
3-POWER (+)
VIEW A
19mm - 21.9mm HEX

(0.75 inch - 0.86 inch)
SPECIFICA TION :
O-RING P11 PRESSURE RANGE : 0 3.0 MPa (0 435 psi)
PF1/4 RATED VOLTAGE : 5.0+0.5V DC
Tighte ning torgue
32 N .m (23.6 lbf .ft) INSURANCE RESIST ANCE : 100M OR MORE
DETAIL OF SENSOR CONNECTOR (BETWEEN BODY AND EACH TERMINAL AT
50V DC MEGGER)
7-88
［8. HYDRAULIC SYSTEM］
8. HYDRAULIC SYSTEM
8.2 SUMMARY ...............................................................................................................................8-4
8.3 HYDRAULIC CIRCUITS AND COMPONENTS ...........................................................................8-5
8.3.1 PART NUMBER OF HYDRAULIC COMPONENT.....................................................................8-5
8.3.2 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS ...................................................8-5
8.3.3 STANDARD SPECIFICATION ............................................................................................... 8–7
8.3.4 N&B (FOOT) SPECIFICATION .............................................................................................. 8–8
8.4 NEUTRAL CIRCUIT................................................................................................................8-10
8.4.1 OPERATION OF UNLOAD VALVE AND BY-PASS CUT VALVE HOUSED IN CONTROL
VALVE ...........................................................................................................8-10
8.4.2 SAFETY LOCK LEVER AND PILOT CIRCUIT .......................................................................8-10
8.4.3 PUMP POSITIVE FLOW CONTROL .....................................................................................8-10
8.4.4 PUMP P-Q CURVE CONTROL OPERATION.........................................................................8-10
8.5 TRAVEL CIRCUIT...................................................................................................................8-12
8.5.1 TRAVEL FORWARD PILOT SIMULTANEOUS OPERATION CIRCUIT....................................8-12
8.5.2 2-SPEED TRAVEL SOLENOID COMMAND CIRCUIT AND AUTO 1st SPEED RETURN
FUNCTION.....................................................................................................8-12
8.5.3 TRAVEL MAIN CIRCUIT ......................................................................................................8-12
8.5.4 TRAVEL MOTOR FUNCTION ...............................................................................................8-12
8.6 BUCKET CIRCUIT..................................................................................................................8-14
8.6.1 PILOT CIRCUIT FOR BUCKET DIGGING .............................................................................8-14
8.6.2 AUTO ACCELERATION OPERATION ..................................................................................8-14
8.6.3 STAND-BY CURRENT CONSTANT CONTROL.....................................................................8-14
8.6.4 BUCKET DIGGING AND TRAVEL STRAIGHT CONFLUENCE (CONFLUX) MAIN
CIRCUIT ........................................................................................................8-14
8.6.5 BUCKET SPOOL STROKE LIMITER ....................................................................................8-14
8.7 BOOM CIRCUIT .....................................................................................................................8-16
8.7.1 BOOM UP PILOT CIRCUIT ..................................................................................................8-16
8.7.2 BOOM UP 2 PUMPS CONFLUX MAIN CIRCUIT IN C/V .........................................................8-16
8.7.3 BOOM DOWN PILOT CIRCUIT.............................................................................................8-18
8.7.4 PREVENTION OF NATURAL FALL BY LOCK VALVE AND ACTUATION AT
LOWERING....................................................................................................8-18
8.7.5 BOOM DOWN MAIN CIRCUIT..............................................................................................8-18
8.8 SWING CIRCUIT ....................................................................................................................8-20
8.8.1 PILOT CIRCUIT FOR LEFT SWING ......................................................................................8-20
8.8.2 SWING AUTO PARKING BRAKE .........................................................................................8-20
8.8.3 SWING MAIN CIRCUIT ........................................................................................................8-20 8
8.8.4 SWING MOTOR FUNCTION.................................................................................................8-20
8.9 ARM CIRCUIT ........................................................................................................................8-22
8.9.1 ARM IN, LIGHT-LOAD OPERATING PILOT CIRCUIT ............................................................8-22
8-1
8.9.2 ARM-IN, LIGHT-LOAD VARIABLE NORMAL RECIRCULATION, INTERNAL CONFLUX MAIN

CIRCUIT .............................................................................................................8-22
8.9.3 ARM IN, HEAVY LOAD OPERATING PILOT CIRCUIT................................................................8-24
8.9.4 ARM IN, HEAVY LOAD OPERATING RECIRCULATION CUT MAIN CIRCUIT .............................8-24
8.9.5 ARM OUT PILOT CIRCUIT........................................................................................................8-26
8.9.6 ARM OUT 2 PUMPS CONFLUX MAIN CIRCUIT.........................................................................8-26
8.9.7 NATURAL FALL PROTECTION WITH ARM LOCK VALVE.........................................................8-26
8.10 COMBINED CIRCUIT ................................................................................................................8-28
8.10.1 BOOM UP / TRAVEL, PILOT CIRCUIT.....................................................................................8-28
8.10.2 BOOM UP / TRAVEL, MAIN CIRCUIT ......................................................................................8-28
8.10.3 SWING / ARM IN LIGHT LOAD, PILOT CIRCUIT .....................................................................8-30
8.10.4 SWING / ARM IN, SWING PRIORITY MAIN CIRCUIT ...............................................................8-30
8.11 PRESSURE DRAINING .............................................................................................................8-32
8.11.1 PRESSURE DRAIN (RELEASING) PILOT CIRCUIT .................................................................8-32
8.11.2 PRESSURE DRAIN MAIN CIRCUIT .........................................................................................8-32
8-2

8-3
8.2 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.
Device Function Features

Easy operability and safety
• Travel straight • Travel straight at combined operation

• Travel 2-speed change & Auto 1st (low) • 1-2 travel speed change and low speed / high torque at heavy
speed return duty
Travel
• Auto parking brake • Automatic braking when parking
• Motor overrun protection • Prevents overrunning of travel motor on the down hill slope.
• Travel pilot operation • Prevents hunting by the built in travel shockless mechanism
• Reverse rotation protective function • Easy positioning to protect it from swinging back when stops
swinging.
• Swing priority circuit (simultaneous
Swing operation of arm in and swing motions) • Easy operation of stable swing speed, arm slanted leveling,
swing press digging
• Automatic swing parking brake
• Swing parking brake when operating at on a slope
• Hydraulic pilot control system • Light action with operating lever

Attachment • Pilot safety lock system with timer • Cut out of pilot circuit by safety lock lever.
• Lock valve (boom / arm) • Protect boom and arm from unexpected drop (Natural fall).
• Pressurized hydraulic oil tank • To prevent hydraulic oil from entering dust 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
Others • Return circuit • To prevent hydraulic oil from contamination
• Cooling hydraulic oil by oil cooler • To prevent hydraulic oil from being deteriorated.
• Pressure draining circuit • To release the main circuit pressure for piping repair work.
• Switching of return line for N&B • Switching of return line for N&B machine is possible from
machine from inside cab inside cab
Mass handling capability
• Electric flow controlled variable • Pump delivery rate control by a current command to the
Pump displacement pump solenoid proportional valve of the variable displacement pump
• Positive flow rate control • Flow control by positive pilot control pressure
• Boom up conflux circuit • Speed up of boom up operation

• Arm conflux circuit • Speed up of arm operation
Attachment • Bucket conflux circuit • For speed-up of bucket operation (digging & dump)
• Optimum operation by work mode • Efficient operation in all work modes
select (H,S,E,ECO)
Low fuel consumption
Micro • Auto accel • Reduce fuel consumption and noise by lowering engine speed
computer when control lever is in neutral position.
8-4
8.3 HYDRAULIC CIRCUITS AND COMPONENTS

8.3.1 PART NUMBER OF HYDRAULIC COMPONENT
Standard Specification YN01Z00266P1
No. Component Name Part Number Model Number
1 Pump YN10V00070F1 K7V125DTP (Without PTO.)
2 Control valve assy (main) YN30V00161F1 KMX15YF
3 Swing motor YN15V00078F1

4 Travel motor YN15V00051F5 MAG-170VP
5 Boom cylinder mm (ft-in) YN01V00151F2 85 (3.34") dia. x 120 (4.72") dia. x 1355 (4'5")
6 Arm cylinder mm (ft-in) YN01V00175F4 95 (3.74") dia. x 135 (5.32") dia. x 1558 (5'1")
7 Bucket cylinder mm (ft-in) YN01V00153F2 80 (3.15") dia. x 120 (4.72") dia. x 1080 (3'7")
8 Swivel joint YN55V00059F1
9 Pilot valve (ATT) LQ30V00043F1 PV48K2110
10 Pilot valve (travel) YN30V00105F2 6TH6 NRZ

11 Inline filter YN50V00020F1 SS03950A005A
12 Suction strainer LQ50V00004F1 SB281J0A027A
13 Solenoid valve LQ35V00007F1 16882-00000
14 Solenoid valve LQ35V00008F1 8KWE5A-30
15 Return filter YN52V01025F1 FZ1F183S054A
16 Air breather YN57V00013F1 AB0210GA016B
17 Check valve YN21V00005F2 0033-07580
18 Check valve YN21V00024F2 16886-00000
19 Check valve YN21V00024F1 16670-00000
The part numbers may be changed due to modification, so use the table above only as references.
8.3.2 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS

Blue……Feed, drain circuit
0.44 MPa (64 psi) or less
Green……Return, make up circuit
0.44 to 0.59 MPa (64 to 86 psi)
Purple……Secondary pilot pressure, (including proportional valve)
0.59 to 5 MPa (86 to 725 psi)
Red……Primary pilot pressure, (including proportional valve)
5 MPa (725 psi)
Orange……Main pump drive pressure
5 to 34.3 MPa (725 to 4974 psi)
Blue tone………At valve operation
Red valve………When solenoid proportional valve (reducing) is operating
Red solenoid…In active and exciting 8
Displaying the flow circuit and standby circuit when operating. Regarding the electrical symbols in this manual, refer
to the electric circuit diagram.
8-5
8-6
8.3.3 STANDARD SPECIFICATION
YN01Z00266P1 02
8–7
8.3.4 N&B (FOOT) SPECIFICATION

N&B(FOOT) SPECIFICA TION LQ01Z00094P1
ITEM NAME P/No. TYPE
60 CONTROL VALVE LQ30V00046F1 VBY-191
61 PILOT VALVE YN30V00080F1 16030-00000
62 RELIEF VALVE AS S Y YN22V00035F1 KRBP13C-21/21B40-15/30A
61
62
60
LQ01Z00094P1 01
8–8
8–9
8.4 NEUTRAL CIRCUIT 8.4.3 PUMP POSITIVE FLOW 8.4.4 PUMP P-Q CURVE CONTROL
CONTROL OPERATION
This section describes the following functions.
• Bypass cut valve and unload valve control Type: Type:
• Safety lock lever and pilot circuit Electrical flow control type variable pump Electrical flow control type variable pump
• Pump positive flow control
Principle: Principle:
• Pump positive flow control
The current command I to the pump's solenoid proportional Perform an operation of the value from pump high pressure
valve controls the delivery rate of the pump. sensor to P-Q curve control value, and send a command to
8.4.1 OPERATION OF UNLOAD the pump solenoid proportional valve.
VALVE AND BY-PASS CUT Operation:
VALVE HOUSED IN CONTROL • Flow rate rise operation (Eg. P1 pump)
Operation:
VALVE By operating any of control levers, the operating The pump high pressure sensor converts the pressure to
secondary pressure of pilot valve rises, and the rising the output voltage corresponding to the pump delivery
• Unloading valve
pressure is transformed to the rise of output voltage pressure.
On starting engine, like by-pass cut valve, the secondary
corresponding to the pressure input by the low pressure The mechatro controller converts the voltage output by the
pressures output by P1 and P2 unloading proportional
sensor. Mechatro controller signal-processes this high pressure sensor to the P-Q curve control value. On the
valves (PSV-D, PSV-B) exert on PCb and PCa ports,
change of voltage, resulting in rise of command current other hand, select the pump positive control command
consequently the P1 and P2 unloading valves are
value I to the pump proportional solenoid valve and current value from the low pressure sensor in lower order,
switched to OPEN side.
consequently the pump flow rate rises. This is called and the values are output to respective pump proportional
• By-pass cut valve "Positive Control System". As the pump command valve as a command current.
When machine is under normal conditions, by-pass cut current value rises, the secondary pressure of With this operation, the pump power is controlled so as not
valve is closed normally. If pilot pressure sensor or proportional solenoid valve also rises. On the regulator to be exceed the engine power, therefore engine dose not
unloading proportional valve is disconnected or attached on the pump, the spool (652) through piston stall.
malfunctioned, the unloading valve closes completely. (643) is pushed rightward, and stops at the position
Even if control valve is in neutral position, hydraulic oil is where being in proportion to the force of pilot spring
trapped. As a result, the pump relieves due to pressure (646).
increase. The tank port connected to the large bore of servo
In such the case, before the machine is repaired, open piston (532) opens, and the piston moves leftward by
the by-pass cut valve manually. And the machine is delivery pressure P1 of the small bore resulting in the
operable by draining excess oil to hydraulic tank. increase of tilt angle (α). The servo piston and spool
(652) are connected to feedback lever (611). Therefore
8.4.2 SAFETY LOCK LEVER AND when servo piston moves leftward, the spool (652) also
PILOT CIRCUIT moves rightward by means of feedback lever." With this
movement, the opening of spool sleeve closes gradually,
Purpose: and the servo piston stops at the position the opening
To protect attachment from unexpected movement for closed completely.
safety. • Operation to decrease current flow rate
As the current value I of mechatro controller reduces, the
Principle: secondary pressure of solenoid proportional valve
Cut pressure source of pilot valve for operation. reduces, and spool (652) is moved leftward by the force
of pilot spring (646). With the movement of spool, the
Operation: delivery pressure P1 usually flows into the large bore of
piston through the spool.
If the safety lock lever (red) is pushed forward after the
The delivery pressure P1 flows in the small bore of servo
engine starts, the limit switch (SW-11) is turned on. The
piston, but the servo piston moves rightward due to the
timer relay is actuated one second later which causes the
difference of area, resulting in the reduction of tilt angle.
solenoid (SV-4) of the solenoid valve block (14) to be
Similarly, when the servo piston moves rightward, the
energized and makes the pilot operating circuit to stand by.
spool (652) is moved leftward by the feedback lever.
The operation is maintained until the opening of spool
sleeve is closed.
8-10
YN01Z00266P1 02
NEUTRAL CIRCUIT : Positive control function at safety lock lever down (unlocked position)
8-11
8.5 TRAVEL CIRCUIT 8.5.2 2-SPEED TRAVEL SOLENOID

COMMAND CIRCUIT AND
AUTO 1st SPEED RETURN
• Travel forward pilot simultaneous operation circuit
FUNCTION
• 2 speed travel solenoid command circuit and auto LOW
(1st) speed return function Purpose:
• Travel main circuit Change travel motor speed with switch.
• Travel motor function
Principle:
8.5.1 TRAVEL FORWARD PILOT It excites the 2-speed travel solenoid which in turn converts
the primary pilot pressure and the self pressure to a tilting
SIMULTANEOUS OPERATION
angle of the variable displacement motor.
CIRCUIT
Operation:
Purpose:
If the rabbit marked switch on the gauge cluster is pressed,
Light operating force and shockless operation
the solenoid (SV-3) of the proportional valve block (14) is
Operation: excited and changes the proportional valve. Then the
solenoid command pressure is issued from port A3, enters
1. If the travel lever with damping mechanism is operated the P port of the travel motor (4), opens the oil passage to
for travel right, left and forward motions, the secondary the 2nd speed select piston, and causes the motor to run in
pilot proportional pressure comes out of the 3, 1 ports the 2nd speed tilting mode by its self pressure. However,
of P/V (10). The higher of the pressures is selected, when the main circuit pressure rises above 28 MPa (4060
comes out of the 6, 5 ports and acts upon the low psi), the motor's self pressure pushes the 2nd speed select
pressure sensors (SE9) (SE-10). piston back to the 1st speed.
2. The pilot secondary pressure flows to PAr and PAL
ports of the control valve (2), moves the travel spool, 8.5.3 TRAVEL MAIN CIRCUIT
and switches the main circuit.
3. The low pressure sensor output voltage is input into Operation:
mechatro controller. The mechatro controller performs The delivery oil from Pump A1 and A2 ports by changing
signal processing, and outputs flow rate increase the travel spool with the operation of travel pilot flows in
current to P1 pump proportional valve (PSV-P1) and each P1 port on the left side of travel motor (4) and P2 port
P2 pump proportional valve (PSV-P2). At the same on the right side of travel motor (4) through C,D ports of
time, it outputs command current to P1 unloading swivel joint (8) from AL, AR ports of C/V, and rotates the
proportional valve (PSV-D) and P2 unloading travel motor.
proportional valve (PSV-B).
4. The secondary pressures output by P1 pump 8.5.4 TRAVEL MOTOR FUNCTION
proportional valve (PSV-P1) and P2 pump proportional
valve (PSV-P2) exert on pump regulator, actuating the Function:
pump on the delivery flow rate increase side. • Prevents the motor from over running on a slope.
5. The secondary pressure delivered in P1 unloading • Check valve that prevents cavitation of the hydraulic
valve (PSV-D) and P2 unloading valve (PSV-B) is fed motor.
to Pcb and PCa ports provided in control valve (2).
• Shockless relief valve and anti cavitation valve when
The secondary pressure from proportional valve which
inertia force stops.
has exerted on PCb and PCa ports switches the
unloading spool in CLOSE side. • High/Low 2 step speed change mechanism and auto 1st
speed return at high load.
• Travel parking brake.
8-12
YN01Z00266P1 02
TRAVEL CIRCUIT : Travel 2nd speed, RH & LH simultaneous operation
8-13
8.6 BUCKET CIRCUIT 8.6.2 AUTO ACCELERATION 8.6.4 BUCKET DIGGING AND
OPERATION TRAVEL STRAIGHT
CONFLUENCE (CONFLUX)
• Bucket digging pilot circuit Principle:
MAIN CIRCUIT
• Auto acceleration operation Auto acceleration actuates according to signals from low
• Stand-by current constant control pressure sensor. Operation:
• Bucket digging and travel straight confluence (conflux) 1. The oil delivered through A1 port of P1 pump goes into
Operation:
main circuit P1 port of C/V (2), opens load check valve LCc through
• When lever is set to neutral position parallel circuit and enters in bucket spool.
• Bucket spool stroke limiter
In the event where the sensor does not receive signal for
2. On the other hand, the oil delivered through P2 port of
4 seconds or more even though the acceleration dial is
P2 pump goes into P2 port of C/V (2), confluences with
8.6.1 PILOT CIRCUIT FOR BUCKET set to MAX position, the engine speed should be raised
oil from P1 pump through travel straight valve, and
DIGGING to 1000 rpm.
goes into bucket spool. (Confluence of oil from 2
• When lever is operated pumps)
Operation:
When the pressure 0.6 MPa (87 psi) is input to low
3. With the function of pilot circuit, the oil flow is switched
1. When the operation for bucket digging is performed, pressure sensor in STD specification (travel, bucket,
from bucket spool, and is fed into bucket cylinder head
the pilot proportional secondary pressure is delivered swing, arm), proportional voltage from low pressure
(H) side through AC port of C/V (2). On the other hand,
through port 1 of the right pilot V (9), flows to PAc port, sensor inputs in mechatro controller, and then the engine
the return oil from cylinder rod (R) side is throttled by
and acts on the low pressure sensor (SE-1), and at the speed returns to the dial set position corresponding to
bucket spool and returns to tank circuit from BC port of
same time the bucket spool is switched. the lever operation.
C/V (2).
2. The low pressure sensor output voltage is input into
mechatro controller. The mechatro controller performs 8.6.3 STAND-BY CURRENT Reference:
signal processing, and outputs command current of CONSTANT CONTROL • In bucket dumping operation, the travel straight valve
pump flow rate increase to the electromagnetic
also switches like digging operation, resulting in
proportional valves (PSV-P1) and (PSV-P2) on the P1 Principle:
confluence with travel straight.
and P2 pump sides. At the same time, it outputs
When the engine speed is intermediate speed or lower, • When the bucket operation and other operation are
command current to P1 unloading proportional valve
command current value to have the pump delivery rate simultaneously performed, the travel straight valve does
(PSV-D), P2 unloading proportional valve (PSV-B) and
constant is output. not actuate, resulting in single flow of bucket circuit.
travel straight proportional valve (PSV-C).
In the following pages, the relation of operation of low Operation:
pressure sensor to both the increase of pump flow rate 8.6.5 BUCKET SPOOL STROKE
Even if the engine speed specified by acceleration
and unloading proportional valve is the same.
potentiometer is low speed, as the delivery rate
LIMITER
Therefore the explanation is omitted."
corresponds to the intermediate speed, the actuator moves Purpose:
3. The secondary pressure output by P1 pump earlier than the movement equivalent to the control lever
proportional valve (PSV-P1) and P2 pump proportional angle rate in light load operation. To secure simultaneous operability of boom and arm and to
valve (PSV-P2) exerts on pump regulator, actuating the prevent cavitations at low engine speed.
pump onto the delivery flow increase side.
Operation:
4. The secondary pressure delivered in P1 unloading
valve (PSV-D) and P2 unloading valve (PSV-B) is led On boosting up attachment pressure, pilot primary pressure
to PCb and PCa ports provided in control valve (2). exerts on PCc port of C/V(2) through attachment booster
The secondary pressure from proportional valve which solenoid valve, operates stroke limiter of bucket spool, and
has exerted on PCb and PCa ports switches the throttle oil path of spool. As a result, P1 pump pressure
unloading spool in CLOSE side. increases, making the simultaneous operation of boom up
5. The secondary pressure delivered in travel straight and bucket digging possible.
proportional valve (PSV-C) is led to PTb port provided Even though the engine speed is low, similarly the
in control valve (2) and shifts the travel straight valve. cavitations can be prevented by actuating the stroke limiter.
8-14
YN01Z00266P1 02
BUCKET CIRCUIT : Bucket digging (travel straight conflux), auto-acceleration and standby flow rate constant control function
8-15
8.7 BOOM CIRCUIT

This section describes about boom up conflux function.
• Boom up pilot circuit
• Boom up 2 pumps conflux main circuit in C/V
8.7.1 BOOM UP PILOT CIRCUIT

Operation:
1. If boom up operation is performed, the secondary pilot
proportional pressure from the right pilot valve (9) gets
out of port 3 and acts upon the low pressure sensor
(SE3). At the same time, the pressure acts upon the
PAb and PB1 ports.
2. The secondary pressure which enters the PAb port of
C/V (2) shifts the boom spool. The secondary pressure
which enters the PB1 port shifts the boom conflux
spool.
8.7.2 BOOM UP 2 PUMPS CONFLUX

MAIN CIRCUIT IN C/V
Purpose:
Boom up 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. Since P1 unloading valve is closed, the
boom spool is moved and bypass circuit is closed, the
oil opens load check valve LCb1 through parallel circuit
and flows into boom spool.
2. Then the oil passes through boom spool, opens lock
valve of boom lock valve CRb1, and is led into H side
of boom cylinder through C/V (2) Ab port.
3. Meanwhile, the oil delivered from the A2 port of the P2
pump enters the P2 port of C/V (2) and due to shut off
the P2 unloading valve, 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 CRb2 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.
8-16
YN01Z00266P1 02
BOOM CIRCUIT : Boom up operation, conflux function
8-17
This section describes boom lower operation. 8.7.5 BOOM DOWN MAIN CIRCUIT
• Boom down pilot circuit
Operation:
• Prevention of natural fall by lock valve and actuation at
lowering During boom down operation, the hydraulic oil delivered
from hydraulic pump P1 is supplied to the boom cylinder
• Constant recirculation function of boom down main
rod (R) side through port (Bb).
circuit
On the other hand, the oil returned from the boom cylinder
head (H) side enters the C/V through port (Ab). The lock
8.7.3 BOOM DOWN PILOT CIRCUIT valve poppet is pushed and opened because holding of the
lock valve poppet is released.
Operation:
Then the return oil flows the boost check valve and returns
1. If the boom down operation is performed, the to the hydraulic oil tank through tank port T1.
secondary pilot proportional pressure comes out of
port (4) of right pilot valve (9) and acts upon the low
pressure sensor (SE-4). At the same time, the
pressure acts upon the PBb port of C/V (2).
2. The voltage output of the low pressure sensor (SE-4)
enters the mechatro controller and processed in it.
3. Then, the proportionl secondary pressure fed into C/V
(2) PBb port and branches off in two lines and switches
boom spool and releases boom lock valve.
8.7.4 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:
In the boom down action, the selector valve is changed
over by the secondary proportional pressure of PBb port.
Then the poppet spring chamber of the lock valve CRb1
gets through the drain line (Dr) and makes the lock valve
poppet open. When the boom lever is at neutral, the drain
line on the lock valve CRb1 poppet spring chamber is
closed which causes the poppet closed.The result is that
the oil returning from the boom cylinder head (H) to the
boom spool is held and makes the leak from the boom
spool zero.Thus the boom cylinder is prevented from
making a natural fall.
8-18
YN01Z00266P1 02
BOOM CIRCUIT : Boom down operation & prevention of natural boom falling by boom lock valve
8-19
8.8 SWING CIRCUIT 8.8.3 SWING MAIN CIRCUIT

This section describes the following operations. Operation:
• Pilot circuit for left swing The oil delivered from the A2 port of the P2 pump enters the
• Swing auto parking brake P2 port of C/V (2) and is branched off into the bypass line
and the parallel circuit. However, since the bypass line is
• Swing main circuit
closed as the swing spool is shifted, the oil pushes the load
• Swing motor function check valve LCs open through the parallel circuit, enters
the B port of the swing motor via the Bs port of C/V (2), and
8.8.1 PILOT CIRCUIT FOR LEFT rotates the swing motor counterclockwise.
SWING
8.8.4 SWING MOTOR FUNCTION
Operation:
• Anti-cavitation circuit at swing deceleration
1. When the left swing operation is performed, the pilot
proportional secondary pressure is delivered through • Preventing the swing motor from being reversed circuit
port (5) of left pilot V (9), and the secondary pressure • Shockless relief valve circuit
acts on PBs port of C/V (2), and simultaneously acts on
low pressure sensor (SE-41).
2. The voltage output by the low pressure sensor is input
in the mechatro controller, and is signal-processed.
3. Then, the secondary pressure led into PBs port of C/V
(2) switches the swing spool.
8.8.2 SWING AUTO PARKING

BRAKE
Purpose:
Swing lock in neutral position and parking
Principle:
Release mechanical brake only when required to operate
swing and arm in.
Operation:
1. The swing parking system excites the swing parking
SOL (SV-1) usually if the key switch is turned on and
works by the action of the mechanical brake.
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 in actions acts
upon any of the low pressure sensors (SE-7, 41).
3. The swing parking solenoid (SV-1) is excited five
seconds after the pressure of the swing low pressure
sensors (SE-41) is reduced to zero. In the case of arm
in operation, the swing parking solenoid (SV-1) is
excited the moment the pressure of the arm in low
pressure sensor (SE-7) is reduced to zero. This causes
the mechanical brake to operate.
8-20
YN01Z00266P1 02
SWING CIRCUIT : Swing operation (LH)
8-21
8.9 ARM CIRCUIT 8.9.2 ARM-IN, LIGHT-LOAD applied is operated, the meter-in path of arm 2 spool is
VARIABLE NORMAL closed, resulting in single flow operation.
This section describes the following operations.
RECIRCULATION, INTERNAL Spool position at arm in,
• Arm in, light-load operating pilot circuit
CONFLUX MAIN CIRCUIT light load and combined operation
• Arm-in, light-load variable normal recirculation, internal (This position is not shown in hydraulic diagram)
conflux main circuit Operation: Neutral position Meter-in passage

(Close)
1. The P2 pump delivery oil flows in travel left section
8.9.1 ARM IN, LIGHT-LOAD through P2 port of C/V (2) and is branched off in by-
OPERATING PILOT CIRCUIT pass circuit and parallel circuit, but because arm 1
spool is switched, the delivery oil which goes through
Normal recirculation opsition
Purpose: parallel circuit opens load check valve LCa and is Arm 2 spool
Speed-up and Anticavitation when the arm is at light flowed into arm 1 spool.
loaded. 2. On the other hand, P1 pump delivery oil flows in P1
port of C/V (2), and the flows in travel straight section
Principle: and travel right tandem path. Then because arm 2
The oil returning from the arm cylinder rod (R) is spool was switched, the delivery oil opens load check
recirculated variably to the head (H) at arm 2 spool in C/V. valve LCAT2, goes through arm 2 spool, and
confluences with P2 pump delivery oil in the valve
Operation: section, and then is flowed into arm cylinder head (H)
1. When the arm in operation is performed, the secondary side through Aa port of C/V (2).
pilot proportional pressure gets out of port 7 of the left 3. The return oil from arm cylinder (R) side flows in Ba
pilot valve (9) and acts upon the low pressure sensor port of C/V (2) and passes through the Ba port
(SE-7).At the same time, the pressure is branched off because the arm lock valve CRa is open, and is flowed
in two flows, acts upon the Paa1 port and the PLc2 into arm 2 spool through arm 1 spool.
port, changes over the arm spool and the arm lock 4. Because arm 2 spool is switched to normal
valve CRa. releases. recirculation position, causing restriction of passage to
2. The output voltage by the low pressure sensor is input tank, the return oil from arm cylinder (R) side flows into
into mechatro controller, and is pilot signal-processed, arm cylinder (H) side.
and is output to P1, P2 pump proportional valve (PSV- • Because, at light load operation, the pressure in cylinder
P1), (PSV-P2) and arm 2 inverse proportional valve rod (R) side is higher than that in the head (H) side, it
(PSV-A). opens the check valve housed-in arm 2 spool and the oil
3. The secondary pressure from pilot proportional valve, is recirculated in the head (H) side, resulting in the speed
which is reduced by arm 2 inverse proportional valve up of arm-in operation at light load.
(PSV-A) switches arm 2 spool. 5. ARM-IN ANTI-CAVITATION CONTROL
Command current is output to arm 2 solenoid
proportional valve by signal processing of E/G speed
and arm-in pilot pressure, accordingly the arm 2 spool
is switched to neutral (cavitations prevention) position,
resulting in cavitations prevention.
Neutral position
(Anticavitation position)
Normal recirculation position
Recirculation cut position
From arm out

P/V
From arm 2 inverse
proportional valve
Position of arm 2 spool
Reference:
In light-load arm-in operation (normal recirculation, conflux),
when the attachment to which the circuit in P1 pump side is
8-22
YN01Z00266P1 02
ARM CIRCUIT : Arm in (light load) operation, arm recirculation, conflux & anti cavitation function
8-23
This section describes the following operations. 8.9.4 ARM IN, HEAVY LOAD
• Arm in, heavy load operating pilot circuit (recirculation OPERATING RECIRCULATION
cut) CUT MAIN CIRCUIT
• Arm in, heavy load operating recirculation cut main
circuit Purpose:
Power up for arm in operation
8.9.3 ARM IN, HEAVY LOAD
Principle:
OPERATING PILOT CIRCUIT
Cut the recirculation and reduce rod pressure.
Operation:
Operation:
1. Left pilot valve actuation due to arm-in operation is
equivalent to that at light load operation. 1. P2 pump delivery oil flows in the travel left section
through P2 port of C/V (2) and branched off in by-pass
2. In arm-in operation, when the heavy loading is applied
circuit and parallel circuit. Consequently the arm spool
to arm and the P2 pump pressure increases to the set
is switched and pushes and opens load check valve
pressure, the voltage output by P2 pump pressure
LCa through parallel circuit, and flows in the arm spool.
sensor (SE-23) is converted to signal (signal
processing) by mechatro controller, consequently the 2. On the other hand, P1 pump delivery oil flows in P1
current of arm 2 solenoid proportional valve is port of C/V (2), and flow in travel right tandem passage
controlled according to the load pressure and the arm through travel straight section. Then because arm 2
variable recirculation is cut. spool was switched, the delivery oil opens load check
When the recirculation is cut, internal confluence is valve LCAT2, and confluences with P2 pump delivery
held similarly to that in light load operation. oil in the valve section, and is flowed into arm cylinder
head (H) side through Aa port of C/V(2).
3. The return oil from arm cylinder (R) side flows in Ba
port of C/V(2) and is flowed to arm lock valve CRa, but
because the arm lock valve CRa is open, the return oil
goes through arm lock valve CRa and flows in arm 2
spool.
4. The return oil returns directly into tank circuit because
arm 2 spool is switched to recirculation cut position.
Neutral position Recirculation cut position
From arm out

P/V
From arm 2 inverse

proportional valve
8-24
YN01Z00266P1 02
ARM CIRCUIT : Arm in (heavy load) operation, arm conflux & recirculation cut function
8-25
This section describes the following operations. 8.9.7 NATURAL FALL PROTECTION
• Arm out pilot circuit WITH ARM LOCK VALVE
• Arm out 2 pumps conflux main circuit
Purpose:
• Natural fall protection with arm lock valve
To prevent the arm from falling naturally by the weight of the
arm and bucket.
8.9.5 ARM OUT PILOT CIRCUIT
Principle:
Operation:
Complete seat of the return circuit against the arm spool of
1. When the arm out operation is performed, the
the arm cylinder (R) side circuit.
secondary pilot proportional pressure gets out of port 8
of the left pilot valve (9), and acts upon the low Operation:
pressure sensor (SE-8). At the same time, the oil is
1. When the secondary pressure for arm operation
branched off in two flows and act upon the PBa1 and
disappears and the arm cylinder stops, the pressure on
PBa2 ports of C/V (2).
the rod (R) side passes through the selector of the lock
2. The operating proportional secondary pressure flowed valve from the Ba port of C/V, acts the back pressure
in Pba1 port of C/V (2) switches the arm 1 spool. on the lock valve CRa and seats the lock valve.
3. Then, the operating secondary pressure flowed in 2. Since the oil flow into the arm spool from the lock valve
PBa2 port of C/V (2) switches the arm 2 spool valve. is shut off completely, natural fall of the arm due to oil
leaks through the arm spool is prevented.
8.9.6 ARM OUT 2 PUMPS CONFLUX
MAIN CIRCUIT
Purpose:
Arm out operation speed up.
Principle:
The oil delivered by the P1 pump is confluxed with that
delivered by the P2 pump in C/V (2).
Operation:
1. P1 pump delivery oil opens load check valve (LCAT2)
by switching arm 2 spool and confluxes with P2 pump
delivery oil just short of the arm lock valve.
2. And, P2 pump delivery oil flows through arm 1 spool
and confluences with P1 delivery oil, opens lock valve
of arm lock valve CRa with free flow and is flowed into
arm cylinder rod (R) side through Ba port of C/V(2).
3. On the other hand, the return oil from arm cylinder (H)
side flows in Aa port, and returns into tank circuit
through arm 1 spool and arm 2 spool.
The return line which does not pass through boost
check valve is used for this return circuit to reduce the
pressure loss.
8-26
YN01Z00266P1 02
ARM CIRCUIT : Arm out operation, Conflux function
8-27
8.10 COMBINED CIRCUIT 8.10.2 BOOM UP / TRAVEL, MAIN

CIRCUIT
This section describes only the difference in combined
operation. Purpose:
• Boom up / travel, pilot circuit To insure straight travel movement during travel operation
• Boom up / travel, main circuit even if the attachment is operated.
Principle:
8.10.1 BOOM UP / TRAVEL, PILOT
CIRCUIT The travel action and the attachment action are actuated by
separate pumps.
Operation:
Operation:
• Different point of pilot circuit from independent operation
1. P1 pump delivery oil flows through P1 port of C/V(2)
1. The mechatro controller outputs command current to and branches off in P1 parallel circuit and travel
travel straight solenoid proportional valve after signal straight spool.
processing, and the solenoid valve outputs secondary P2 pump delivery oil flows through P2 port of C/V(2)
pressure and acts on PTb port of C/V (2). and branches off in P2 tandem circuit and travel
2. Then the pressure of PTb port switches the travel straight spool.
straight valve. 2. The delivery oil flowed into P1 parallel circuit of P1
pump opens check valve LCb1 and flows in boom
spool, which exerts on boom up operation.
The delivery oil flowed into travel straight spool of P1
pump opens check valve LCb2 because the travel
straight spool is shifted, and flows in boom conflux
spool and exerts on boom up operation with the
internal oil conflux.
(In travel straight operation, P1 pump delivery oil exerts
on swing operation of attachment.)
3. The delivery oil flowed into P2 tandem circuit of P2
pump flows in left travel spool to travel leftward.
The delivery oil flowed into travel straight spool of P2
pump flows in right travel spool because the travel
straight spool is shifted and exerts on the right travel
operation.
(In travel straight operation, P2 pump delivery oil exerts
on travel operation.)
4. However, a portion of the flow is led to the travel
straight spool notch restriction. The speed of
attachments like travel, boom, etc. is adjusted by the
circuit of restriction.
8-28
YN01Z00266P1 02
COMBINED CIRCUIT : Boom up & travel forward (RH & LH) 1st speed operation, travel straight function.
8-29
This section describes only the difference in combined 8.10.4 SWING / ARM IN, SWING
operation. PRIORITY MAIN CIRCUIT
• Swing / arm in light load, pilot circuit
Purpose:
• Swing / arm in, swing priority main circuit
Stable swing speed.
8.10.3 SWING / ARM IN LIGHT LOAD, Principle:
PILOT CIRCUIT
Raise the oil pressure flowing to arm cylinder, and give a
Operation: priority of the delivery of P2 pump to swing operation.
1. On operating swing (left) and arm in motions Operation:

simultaneously, mechatro controller outputs command
1. The swing main circuit operates with P2 pump flow. But
current to travel straight solenoid proportional valve
on P2 pump circuit side, the flow goes to the swing
(PSV-C) and arm 2 solenoid inverse proportional valve
circuit and arm circuit simultaneously because the
according to signal processing, and this proportional
swing circuit and arm circuit are parallel. The arm 2
valve outputs secondary pressure, which acts on PTb
spool is switched to forced recirculation position and
port and PAa2 port of C/V(2).
the opening of meter-out is not there, so the pressure
2. PTb port pressure switches the travel straight spool of return oil is raised, causing the rise of circuit
according to the secondary pilot pressure, and the pressure on the arm cylinder head (H) side.
PAa2 port pressure switches the arm 2 spool to the
2. At the same time meter-in of arm 2 spool closes and
forced recirculation position.
arm in conflux is therefore cancelled, and delivery oil
from P2 pump and P1 pump are combined in the
parallel circuit on P2 pump side because the travel
straight spool was switched.
The conflux oil of P1 and P2 delivery oil in high
pressure flows in swing side taking priority over all
others.
This operation is called "Swing Priority Circuit".
Position of forced recirculation
Neutral position Meter-in passage

(Close)
From From arm 2

arm out inverse
P/V proportional valve
Normal recirculation opsition
Arm 2 spool
8-30
YN01Z00266P1 02
COMBINED CIRCUIT : Swing left / arm in (light load) operation, swing priority function
8-31
8.11 PRESSURE DRAINING 8.11.2 PRESSURE DRAIN MAIN

CIRCUIT
• Pressure drain (releasing) pilot circuit
• Pressure drain main circuit
When the hydraulic pressure releasing is performed, make
8.11.1 PRESSURE DRAIN sure to place bucket on the ground.
(RELEASING) PILOT CIRCUIT
Purpose: Operation:
When the operating lever is shifted to neutral during engine
To release the pressure in main circuit for piping repair
running, "DRAINING HYD. PRESS." is displayed on the
works.
gauge cluster while the mode switch is changed to pressure
Principle: relieving mode. In this time the intermittent buzzer sounds
continuously. When right and left operating levers are
After the mode is switched to "Pressure Relief Mode" with operated 4 or 5 times to their full stroke, pressure is
switch on gauge cluster, mechatro controller outputs the relieved.
following commands. After draining pressure is completed, turn off the starter key
1. Minimum tilting command value to pump proportional and buzzer sound stops.
valve (PSV-P1, PSV-P2). If the pump pressure is determined to be more than 1 MPa
2. Output "Pressure relief control speed command value" (145 psi) by the output value of the high pressure sensor or
at ECU. (Electric system) the high pressure sensors (SE-22,23) are broken, "FAIL
3. Stand-by command value to P1, P2 unloading DRAIN HYD.PRESS" is displayed and the buzzer sounds
proportional valves continuously. In that case, also the buzzer is not stopped
unless the engine key is turned to OFF. Repeat the
How to switch to "Pressure release mode" pressure releasing procedure once again.
1. Select the service diagnosis mode. Operation:
(Hold down the "BUZZER STOP SWITCH" on gauge
cluster, turn the starter key switch on.) If the travel straight valve is turned to the pressure release
position, the oil delivered by each pump is unloaded to the
2. Select the service adjustment mode 1.
tank passage.
(Under the condition that "Screen No.1" of "Service
If the spools are switched by pilot operation, the remaining
diagnosis mode 1" is indicated, hold down the
pressure from the actuators may be relieved to the tank
"BUZZER STOP SWITCH", press the "MENU
circuit, i.e. the main circuit pressure may be released.
SWITCH" 3 times. When "SERVICE MENU" is
displayed, using the "UP" or "DOWN" arrow switch,
select "SERVICE ADJUST 1". Press the "RIGHT"
arrow switch, to select "SERVICE ADJUST 1-2".)
3. Using the "UP" or "DOWN" arrow switch, select
"PRESS DRAIN". Then press the "RIGHT" arrow
switch, and the cursor points to "OFF".
4. Press the "UP" arrow switch to display "ON", and press
"MENU" switch.
5. Screen of gauge cluster changes to ordinary display,
and "DRAINING HYD.PRESS." is appeared.
Operation:
1. Pump proportional valve reduces the pump flow rate to
the minimum.
2. Unloading proportional valves (PSV-D, PSV-B) output
secondary pressure and the secondary pressure flows
in PCb, PCa ports of C/V(2) and switches the P1, P2
unloading valves to OPEN position.
8-32
YN01Z00266P1 02
PRESSURE DRAIN (RELEASE) CIRCUIT : At pressure release mode
8-33
8-34
［9. ELECTRICAL SYSTEM］
9. ELECTRICAL SYSTEM
9.2 ELECTRICAL EQUIPMENT LIST ..............................................................................................9-4
9.3 ELECTRICAL DIAGRAM ......................................................................................................... 9–9
9.4 HARNESS............................................................................................................................. 9–17
9.4.1 HARNESS LIST .................................................................................................................. 9–17
9.4.2 INSTRUMENT PANEL ASSY............................................................................................... 9–18
9.4.3 CONTROLLER & RELAY BOX ASSY INSTALLATION ......................................................... 9–20
9.4.4 OPERATORS CONTROLS .................................................................................................. 9–22
9.4.5 SWITCH INSTALLATION (CAB WORKING LIGHT) .............................................................. 9–23
9.4.6 UPPER ELEC ASSY ........................................................................................................... 9–24
9.4.7 UPPER HARNESS ASSY.................................................................................................... 9–27
9.4.8 UPPER HARNESS ASSY (FLOOR PLATE).......................................................................... 9–44
9.4.9 WASHER TANK ASSY ........................................................................................................ 9–49
9.4.10 CAB HARNESS ASSY ...................................................................................................... 9–50
9.4.11 CAB HARNESS ASSY (BOOM CYLINDER LIGHT) ............................................................ 9–65
9.4.12 IT KIT HARNESS ASSY .................................................................................................... 9–69
9.4.13 BOOM HARNESS ASSY ................................................................................................... 9–73
9.4.14 BOOM HARNESS ASSY (BOOM CYLINDER LIGHT) ......................................................... 9–74
9.4.15 BOOM LIGHT INSTALLATION .......................................................................................... 9–75
9.4.16 BOOM CYLINDER LIGHT INSTALLATION......................................................................... 9–76
9.4.17 UPPER LIGHT INSTALLATION ......................................................................................... 9–77
9.4.18 CAB 1 LIGHT INSTALLATION ........................................................................................... 9–78
9-1
9-2

9
9-3
9.2 ELECTRICAL EQUIPMENT LIST

ELECTRICAL DIAGRAM: YN03Z00104P1 03
(C) CONTROLLER
ITEM NAME PART No.

C-1 MECHATRO CONTROLLER(MAIN) YN22E00488F1
C-2 CLUSTER GAUGE YN59S00033F1
C-4 AIR CONDITIONER AMP. LQ20M00088F1
C-5 RADIATOR COOLANT LEVEL CONTROLLER ENG. ACCESSORY PARTS
C-7 IT CONTROLLER YN22E00643F1
C-7 IT CONTROLLER YN22E00664F1
C-8 ENG. CONTROLLER ENG. ACCESSORY PARTS
C-9 IT CONTROLLER(CHINA) LQ22E00345F1
(D) DIODE
ITEM NAME PART No.

D-4 DIODE YN02D01001P1(4P)
FUSE & RELAY BOX

D-9 DIODE
ACCESSORY PARTS
D-12 DIODE ↑
D-13 DIODE ↑
D-14 DIODE ↑
D-20 DIODE ↑
D-21 DIODE ↑
D-22 DIODE ↑
D-23 DIODE ↑
D-24 DIODE ↑
D-25 DIODE YN02D01001P1(4P)
(E) ELECTRIC FITTINGS
ITEM NAME PART No.

E-1 FUSE & RELAY BOX YN24E00016F3
E-2 ALTERNATOR ENG. ACCESSORY PARTS
E-5 HORN HIGH LC53S00001D1
E-6 HORN LOW LC53S00001D2
E-7 TUNER AM & FM (CHINA) YN54S00030P4
E-8 SPEAKER LEFT LQ54S00003S002
E-9 SPEAKER RIGHT ↑
E-10 RECEIVER DRIER LQ54S00005P1

E-11 AIR COMPRESSOR CLUTCH YX91V00001F1
E-12 BATTERY (CKCM) YN72S00017F1
E-12 BATTERY (TKCM) YN72S00018F1

E-13 TRAVEL ALARM YN53S00004F1
9-4
ITEM NAME PART No.

E-15 FUSIBLE LINK YB73S00001P1
E-22 DC-DC CONVERTER YN77S00017P1
E-23 12V SOCKET YN81S01002P1
9
E-24 GPS ANTENNA (NAY-3930G) YN54S00052P1
E-27 ACCEL REDUNDANT VOLUME YN52S00106P1
E-35 GLOW ENG. ACCESSORY PARTS
E-36 GSM ANTENNA (CHINA) LQ54S00007P1
E-37 GPS ANTENNA (CHINA) PY54S00006P1

E-38 RESISTOR LC22E01001D1
E-46 REAR CAMERA YN55S00009F1
E-63 DC-DC CONVERTER (FOR CAMERA) YN77S00040P1
E-65 24V SOCKET LQ81S01001P1
E-101 CAN RESISTOR 1 PY26E01001P1
E-102 CAN RESISTOR 2 ↑
E-103 ENG. CONTROLLER CHECK CONNECTOR ENG. ACCESSORY PARTS

E-104 9P CONNECTOR ↑
E-126 3G/GSM ANTENNA (DB-BRO-DCS(BNC)) YN54S00048P1
E-127 GSM ANTENNA (DB-BRO) ↑
(L) LIGHT
ITEM NAME PART No.

L-1 BOOM WORKING LIGHT LEFT YW80S00001F1
L-1 BOOM WORKING LIGHT LEFT (CHINA) YN80S00039F1
L-2 FRAME WORKING LIGHT RIGHT YT80S00002F2
L-2 FRAME WORKING LIGHT RIGHT (CHINA) YN80S00040F2
L-3 SWING FLASHER LEFT & WORKING LIGHT UNIT YM80S00001F1
L-4 SWING FLASHER RIGHT & WORKING LIGHT UNIT YM80S00001F2
L-5 ROOM LIGHT YT80S00001P1
L-6 BOOM WORKING LIGHT RIGHT YW80S00001F1
L-6 BOOM WORKING LIGHT RIGHT (CHINA) YN80S00039F1
L-7 CAB WORKING LIGHT FRONT 1 YT80S00002F2
L-8 CAB WORKING LIGHT FRONT 2 ↑
L-9 BOOM CYLINDER WORK LIGHT ↑
L-20 ROTARY LIGHT 2456R457
(M) MOTOR
ITEM NAME PART No.

M-1 STARTER MOTOR ENG. ACCESSORY PARTS
M-3 WIPER MOTOR LQ53C00003S001
9-5
ITEM NAME PART No.

M-4 WASHER MOTOR YT54C00003F1
M-11 FUEL SUPPLY PUMP YF22P00009P1
(PSV) PROPORTIONAL SOLENOID VALVE
ITEM NAME PART No.

PSV-A ARM TWO-SPEED INVERSE PROPORTIONAL SOL. YN35V00049F1
PSV-B P2 UN-LOAD PROPORTIONAL SOL. YN35V00048F2
PSV-C TRAVEL PRIORITY PROPORTIONAL SOL. ↑
PSV-D P1 UN-LOAD PROPORTIONAL SOL. ↑
PSV-H ARM CUSHION PROPORTIONAL SOL. LS35V00004F1

PSV-P1 PUMP P1 PROPORTIONAL SOL. YN35V00054F1
PSV-P2 PUMP P2 PROPORTIONAL SOL. ↑
PSV-23 BOOM 2 PROPORTIONAL SOL. YN35V00048F2

PSV-24 BOOM 3 PROPORTIONAL SOL. ↑
(R) RELAY
ITEM NAME PART No.

R-1 BATTERY RELAY YN24S00008F1
R-2 STARTER RELAY ENG. ACCESSORY PARTS
R-3 GLOW RELAY ↑
R-4 SAFETY RELAY YN24S00010P1

R-5 HORN RELAY ↑
R-6 WORK LIGHT RELAY ↑
R-8 TRAVEL ALARM RELAY ↑
R-9 CAB WORKING LIGHT RELAY 1 ↑
R-11 CAB WORKING LIGHT RELAY 2 ↑
R-19 FLASHER RELAY YY24S00001P2

R-23 AUTO IDLE STOP RELAY 1 YN24S00010P1
R-24 AUTO IDLE STOP RELAY 2 ↑
R-25 ENG. EMERGENCY STOP RELAY ↑
R-26 LEVER LOCK RELAY ↑
R-28 ALTERNATOR RELAY ↑
R-29 WIPER MOTOR RELAY YN24S00012P2

R-30 WIPER MOTOR REVERSING RELAY ↑
R-31 PREVENT SPARK RELAY ↑
R-32 WINDOW WASHER MOTOR RELAY ↑
R-45 BOOM CYLINDER WORK LIGHT RELAY EN24S00008P1

R-94 NEUTRAL STOP RELAY YN24S00010P1
R-145 KEY ON MAINTENANCE RELAY ↑
9-6
(SE) SENSOR
ITEM NAME PART No.

SE-1 PRESS. SENSOR: BUCKET DIGGING LC52S00019P1 9
SE-2 PRESS. SENSOR: BUCKET DUMP ↑
SE-3 PRESS. SENSOR: BOOM RAISING ↑
SE-4 PRESS. SENSOR: BOOM LOWERING ↑
SE-7 PRESS. SENSOR: ARM IN ↑
SE-8 PRESS. SENSOR: ARM OUT ↑
SE-9 PRESS. SENSOR: TRAVEL RIGHT ↑
SE-10 PRESS. SENSOR: TRAVEL LEFT ↑
SE-11 PRESS. SENSOR: P2 OPT. ↑
SE-13 ENG. REVOLUTION SENSOR ENG. ACCESSORY PARTS

SE-15 FUEL SENSOR YN52S00094F1
SE-16 ACCEL POTENTIO. LQ52S00025P1
SE-19 ARM POTENTIO. YR52S00016P1
SE-20 PRESS. SENSOR: P1 OPT. LC52S00019P1
SE-21 HYD. FLUID TEMP. SENSOR YN52S00105P1
SE-22 PRESS. SENSOR: PUMP P1 YN52S00103P1
SE-23 PRESS. SENSOR: PUMP P2 ↑
SE-24 PRESS. SENSOR: BOOM HEAD YN52S00104P1

SE-25 PRESS. SENSOR: BOOM ROD ↑
SE-29 OPT. SELECTOR DETECT SENSOR LC52S00019P1

SE-40 PRESS. SENSOR: SWING RIGHT ↑
SE-41 PRESS. SENSOR: SWING LEFT ↑
SE-60 HYD. FLUID FILTER RESTRICTION SENSOR JE04002A203A

SE-74 FUEL DISCRIMINANT SENSOR YN52S00091P1
SE-99 SWING SPEED SENSOR LQ52S00032P1
SE-100 PRESS. SENSOR: BOOM HEAD (FOR HIGH-REACH) YN52S00104P1
SE-102 ENG. COOLANT THERMO SENSOR ENG. ACCESSORY PARTS
(SV) SOLENOID
ITEM NAME PART No.

SV-1 SWING PARKING BRAKE SOL. YN35V00051F1
SV-2 POWER BOOST SOL. YR35V00009S022
SV-3 TWO-SPEED SELECT SOL. ↑
SV-4 LEVER LOCK SOL. YN35V00061F1

SV-13 OPT. SELECTOR SOL. YN35V00050F1
SV-105 BOOM METER IN CUT SOL. YR35V00009S022
(SW) SWITCH
ITEM NAME PART No.

SW-1 KEY SW. YN50S00026F1
SW-4 SWING PARKING RELEASE SW. YN50S00040D9
9-7
ITEM NAME PART No.

SW-7 ENG. OIL PRESS SW. ENG. ACCESSORY PARTS
SW-8 AIR FILTER RESTRICTION SW. YR11P00008S005
SW-10 HORN SW. LEFT YN50E00017P1
SW-11 LEVER LOCK SW. YN50S00055F1
SW-12 OVER LOAD ALARM SELECT SW. YN50S00040D6
SW-13 TRAVEL ALARM SW. YN50S00040DF
SW-19 WIPER INTERLOCK SW. YT50S00004P1
SW-20 POWER BOOST SW. RIGHT YN50E00017P1
SW-21 POWER BOOST SW. LEFT ↑
SW-22 RELEASE SW. (KPSS) YX50S00004F1

SW-26 CAB WORK LIGHT SW. YN50S00040D4
SW-27 RADIATOR COOLANT LEVEL SW. ENG. ACCESSORY PARTS
SW-40 ROTARY LIGHT SW. YN50S00040D2
SW-55 BOOM, DECK WORKING LIGHT SW. YN50S00040D1
SW-56 FUEL SUPPLY AUTO STOP SW. YF52S00004P1
SW-113 FUEL RESTRICTION SW. ↑
SW-137 BATTERY DISCONNECT SW. LP50S00003P1
9-8
9.3 ELECTRICAL DIAGRAM
(1/8)
YN03Z00104P1 03
9–9
(2/8)
YN03Z00104P1 03
9–10
(3/8)
YN03Z00104P1 03
9–11
(4/8)
YN03Z00104P1 03
9–12
(5/8)
YN03Z00104P1 03
9–13
(6/8)
YN03Z00104P1 03
9–14
(7/8)
YN03Z00104P1 03
9–15
(8/8)
YN03Z00104P1 03
9–16
9.4 HARNESS
9.4.1 HARNESS LIST
9
DRAWING No. HARNESS
REMARKS
NAME ASSEMBLY No. CODE No. NAME PART No.
UPPER FRAME
INSTRUMENT PANEL ASSY YN17M00179F1
CONTROLLER & RELAY BOX ASSY CONTROLLER INSTALLATION YN22E00670F1
INSTALLATION
CONTROLLER INSTALLATION YN22E00667F1 MECHATRO CONTROLLER
CONTROLLER INSTALLATION YN22E00669F1
RELAY BOX ASSY YN24E00040F1
OPERATORS CONTROLS CONTROL BOX ASSY YN03M00504F1
GRIP ASSY YN03M02496F1
SWITCH INSTALLATION SWITCH INSTALLATION LQ50E00011F1 CAB WORKING LIGHT SWITCH
(CAB WORKING LIGHT)
UPPER ELEC ASSY LQ03E00016F1 13 CABLE LQ13E01334P1 BATTERY TO GROUND

UPPER HARNESS ASSY YN13E00252F1 1 HARNESS YN13E01884P5 UPPER
2 CABLE YN13E01885P2 STARTER
3 CABLE LQ13E01315P1 BATTERY TO RELAY
4 CABLE LQ13E01248P1 BATTERY TO BATTERY
7 CABLE LQ13E01337P1 ENGINE GROUND
9 CABLE LE13E01006P1 FLOOR GROUND
UPPER HARNESS ASSY (FLOOR PLATE) LC13E00181F1 1 HARNESS LC13E01562P5 FLOOR
2 CABLE LE13E01005P1 GROUND
CAB
WASHER TANK ASSY YN54C00013F1
CAB HARNESS ASSY LQ14E00024F1 1 HARNESS LQ14E01036P7
10 HARNESS LQ14E01037P1
CAB HARNESS ASSY (BOOM CYLINDER LIGHT) YN11E00136F1 1 HARNESS YN11E01282P2
2 HARNESS YN11E01283P1
IT KIT HARNESS ASSY IT KIT HARNESS ASSY LQ11E00076F1 3-1 CABLE YN11E01224P1
(CONNECTOR ASSY)
IT KIT HARNESS ASSY YN11E00138F1 3 HARNESS YN11E01292P1

(CONTROLLER)
BOOM
BOOM HARNESS ASSY YN15E00066F1 1 HARNESS YN15E01088P1 1 LIGHT
BOOM HARNESS ASSY (BOOM CYLINDER LIGHT) YN15E00067F1 1 HARNESS YN15E01018D1 1 LIGHT
LIGHT
BOOM LIGHT INSTALLATION YN80E00011F2
BOOM CYLINDER LIGHT INSTALLATION YN80E00081F1
UPPER LIGHT INSTALLATION LQ80E00014F1
CAB 1 LIGHT INSTALLATION LQ80E00035F1 1-2 HARNESS LQ80E01019P2 1 LIGHT
NOTE : Use the above part numbers for reference only, as they may be subject to improvement or modification.
9–17
9.4.2 INSTRUMENT PANEL ASSY

INSTRUMENT PANEL ASSY YN17M00179F1 (01)
ITEM PART NAME PART No. Q'TY REMARKS

1 INSTRUMENT PANEL ASSY YN17M00196F1 - (20)
1-9 CLUSTER GAUGE YN59S00039F1 1

1-11 KEY SWITCH YN50S00026P1 1
1-13 POTENTIOMETER LQ52S00025P1 1
1-25 SOCKET LQ81S01001P1 1
2 SWITCH INSTALLATION YN50E00077F1 - (02)
2-1 SWITCH YN50S00040D1 1
INSTRUMENT PANEL ASSY (1/2)
9–18
INSTRUMENT PANEL ASSY (2/2)
9–19
9.4.3 CONTROLLER & RELAY BOX

ASSY INSTALLATION
1. CONTROLLER INSTALLATION YN22E00670F1 (02)

1-1 CONTROLLER ENG. ACCESSORY PARTS 1 MECHATRO CONTROLLER (7.15 lbf.ft)
(7.15 lbf.ft)
1-2 CONTROLLER ENG. ACCESSORY PARTS 1

(3.69 lbf.ft)
2-1 CONTROLLER YN22E00668F1 1

3-2 ANGLE SENSOR LQ52S00032P1 1
3-3 SWITCH YN50S00040D7 1
3-4 POTENTIOMETER YN52S00106P1 1
3-8 SWITCH YX50S00004F1 1
3-17 RESISTER LC22E01001D1 1
4. RELAY BOX ASSY YN24E00040F1 (03)

(2.14 lbf.ft)
ITEM PART NAME PART No. Q'TY REMARKS (7.15 lbf.ft)
4-1 RELAY BOX ASSY YN24E00036F2 1

4-2 LABEL YN73E01042P2 1
(2.14 lbf.ft)
(7.15 lbf.ft)
CONTROLLER & RELAY BOX ASSY INSTALLATION (1/2)
9–20
CONTROLLER & RELAY BOX ASSY INSTALLATION (2/2)
9–21
9.4.4 OPERATORS CONTROLS

1. CONTROL BOX ASSY YN03M00504F1 (09)

1-5 SWITCH YN50S00058P1 1 RIMIT SWITCH
2. GRIP ASSY YN03M02496F1 (03)

2-1 GRIP ASSY YN03M02619F1 1 L/H HORN
2-2 2-1
2-1-3 SWITCH ASSY YN50E00017P1 1
2-2 GRIP ASSY YN03M02619F2 1 R/H POWER BOOST
2-2-3 SWITCH ASSY YN50E00017P1 1 A
2-2-3
2-1-3
2 P LACES
NUT
CAPSCREW CAPSCREW TIGHTENING TORQUE
TIGHTENING TORQUE TIGHTENING TORQUE 41.2 N.m (30.4 lbf.ft)
2.7 N.m (1.99 lbf.ft) 2.7 N.m (1.99 lbf.ft)
1-5
SECTION AA
L/H R/H
LOCK WASHER
CAPSCREW
FORWARD (MAKER RECOMMENDED VALUE)
TIGHTENING TORQUE
0.4 N.m (0.3 lbf.ft)
ISOMETRIC DRAWING
OPERATORS CONTROLS
9–22
9.4.5 SWITCH INSTALLATION (CAB

WORKING LIGHT)
SWITCH INSTALLATION
LQ50E00011F1
9
(CAB WORKING LIGHT) (01)

1 SWITCH YN50S00040D4 1
2 RELAY YN24S00010P1 1
SWITCH INST ALLATION RELAY INS TALLATION
9–23
9.4.6 UPPER ELEC ASSY

UPPER ELEC ASSY LQ03E00016F1 (01)

1 BATTERY RELAY YN24S00008F1 1
2 HORN LC53S00001D1 1 HIGH
3 HORN LC53S00001D2 1 LOW
13 CABLE LQ13E01334P1 1 BATTERY - GROUND
UPPER ELEC ASSY (1/2)
9–24
GROUND 9
UPPER ELEC ASSY (2/2)
9–25
BATTERY GROUND CABLE : LQ13E01334P1
410 (16.1”)
TAP ED IN TWO TURNS
15
60-8
AV60s qfB TERMINAL
CORRUGATED TUBE TO BE
INS TALLED.
CAP TERMINAL
YAZAKI 7134-2201(BLACK) YAZAKI 7306-2107-02
OR
TAP ED IN TWO TURNS
HERO ELECTRIC DVCP -B (BLACK)
9–26
9.4.7 UPPER HARNESS ASSY

UPPER HARNESS ASSY YN13E00252F1 (08)
SE-6 0:
FIX WHITE TAP ING
P OS ITION FIX WHITE TAP ING P OS ITION
ITEM PART NAME PART No. Q'TY REMARKS HYD.FLUID FILTER
RES TRICTION S ENS OR
CLIP CLIP CLIP
E-1 3:
9
1 HARNESS YN13E01884P5 1 UPPER L-2:
TO TRAVEL ALARM(OP T)
CONNECT CONNECT OR
FRAME WORKING SE-2 3:
2 CABLE YN13E01885P2 1 S TARTER OF UPP HARNESS WITH
BLUE TAP ING TO CAB HARNES S LIGHT RIGHT XVI P RES S S ENS OR:P UMP P 2
WITH BLUE TAP ING
XVIII PSV -P 2:
3 CABLE LQ13E01315P1 1 BATTERY to RELAY P UMP 2 P ROP ORTIONAL S OL.
FIX WHITE TAP ING P OS ITION PSV -P 1:
4 CABLE LQ13E01248P1 1 BATTERY to BATTERY CLIP P UMP 1 P ROP ORTIONAL S OL.
UPP HARNESS II XVII
7 CABLE LQ13E01337P1 1 ENGINE GROUND SE-2 2:
1
XI X P RES S S ENS OR:P UMP P 1
9 CABLE LE13E01006P1 1 FLOOR GROUND SE-1 3:
CLIP ENG.REVOLUTION
SEN S OR
XIX
E-6 :HORN LOW
V XII
16P E-5 :HORN HIGH
XXVIII
XIV XXII A
36P
A I
14P CONNECT CONNECT OR TO HARNES S OF
CONNECT
36P OF UPP HARNESS WITH XXVI XXIV ATTACHED ENG.
CONNECT 2P RED TAP ING TO CAB
PLAS TERMINAL MINUS TERMINAL 12P 36P 4P
CONNECT CONNECT OR OF HARNESS WITH RED TAP ING
UPP HARNESS WITH TO ATT HARNES S
2 S TARTER CABLE
NOTE 1 YELLOW TAP ING TO CAB HARNES S CLIP VII
3 BATTERY WITH YELLOW TAP ING FIX WHITE TAP ING P OS ITION
RELAY CABLE XX
VIEW III
NOTE 1 XXV XXIX
BATTERY 4 P-31 FLOOR HARNESS GROUND aa
CABLE OVER LOAD ALARM SELECT SW.
POWER BOOST SW. LEFT III
HORN SW . LEFT S W-27:
CAB WORKING LIGHT SW. XXXIII RADIATOR COOLANT
POWER BOOST SW. RIGHT LEVEL S W.
NOT INTERFERENCE WAS HER MOTOR
FOR CAP AND INS TALL XXI
BRACKET TO BE INS TALLED 12V SOCKET
CABLE.
BATTERY DIS CONNECT

SEMS-BOL T 9 SE-1 5: E-1 0: BATTERY RELAY BOX
SW CABLE GND FLOOR EAR TH CABLE FUEL S ENS OR
IX RECEIVER DRIER
DETAIL OF BATTERY NOTE 2 TO AIR FILTER
TIGHTEN AFTER RES TRICTION S W.
CHECKING NO PAINT
FIX A WHITE TAP ING

OF HARNESS TO
THE PIP BY A CLIP CLIP
CLIP
SE-2 4: HARNES S OF ATTACHED ENG. CLIP TO ATT HARNES S
P RES S . S ENS OR:BOOM HEAD TO ENGINE
CONNECT "S E-24" TAG
OF CONNECTOR
XXXIV
FIX WHITE TAP ING
POSITION
CLIP
TO FRAME WORKING S TARTER CABLE UPP HARNESS CLIP FIX WHITE TAP ING
LIGHT RIGHT FIX WHITE TAP ING P OS ITION P OS ITION
SE-2 5:
CLIP NOTE 5
FIX A HARNES S PART OF P RES S . S ENS OR:BOOM ROD
COULGATED TO P RES S CONNECT "S E-25" TAG
SENSOR BY A CLIP OF CONNECTOR
VIEW I VIEW XXXIV SECTION AA
UPPER HARNESS ASSY(1/6)
9–27
FIX A HARNES S TO THE HOS E

FIX A HARNES S PART OF COULGATED BY A CLIP BUNDLE S OL.S IDE
TO P RES S S ENS OR WITH CLIP CLIP
HARNES S BY A CLIP
SE-3: CLIP CLIP
PRESS SENSOR: FIX WHITE TAP ING P OS ITION
BOOM RAISING. VI CLIP
CONNECT "SE-3" TAG FIX A HARNES S PART OF COULGATED
OF CONNECT OR TO P RES S S ENS OR WITH CLIP
SE-4: CLIP
PRESS SENSOR: FORWARD
BOOM LOWERING. TO FUEL S ENS OR
CONNECT "SE-4" TAG FIX A HARNES S BY A CLIP
OF CONNECT OR TO P IP METAL FITTING
SE-8: CLIP
PRESS SENSOR:
ARM OUT.
CONNECT "SE-8" TAG VIII
OF CONNECT OR
VIEW VII
SE-41:
PRESS SENSOR:
SWING LEFT.
CONNECT "SE-41" TAG FIX WHITE TAP ING P OS ITION
OF CONNECT OR BUNDLE AND FAS TEN
CLIP A RES T S OL.S IDE HARNES S
FIX A HARNES S TO S V-2: TO THE CONNECTOR BY A CLIP
THE MOUS E P IECE P OWER BOOS T S OL. CLIP
OF HOS E BY A CLIP A1 A2 A3
CONNECT "S V-2" TAG
FOR WARD OF CONNECTOR TO
"A3" S OL.
S V-3:
VIEW V TWO-S P EED S ELECT S OL.
CONNECT "S V-3" TAG
VIEW VI OF CONNECTOR TO
"A2" S OL.
FIX WHITE TAP ING P OS ITION S V-105:
TO THE HOS E BOOM METER IN CUT S OL.
CLIP CONNECT "S V-105" TAG
UPP HARNESS OF CONNECTOR TO
"A1" S OL.
VIEW VIII
UPP HARNESS
FIX HARNESS TO
SE-15:FUEL SENSOR THE HOSE
CONNECT A HARNES S
CLIP
WITH IN A CAP.
FIX WHITE TAP ING P OS ITION
CLIP
FIX WHITE TAP ING P OS ITION CLIP
FORWARD
L-2:
FOR WARD FRAME WORKING
LIGHT RIGHT
FOR WARD
CLIP

CLIP
CLIP
CLIP
CLIP UPP HARNESS FIX WHITE TAP ING P OS ITION
FIX A CONNECTORS PART
TO FUEL S ENS OR CLIP THERE IS RES T HARNES S FOR
FIX WHITE TAP ING P OS ITION LIGHT S IDE HARNES S
CLIP IT BUNDLES AND FIXES HERE.
SET THE WHITE TAP ING
POSITI ON TO THE CLIP VIEW II
FOR HO SE AND FIX BY A CLIP
VIEW IX VIEW XXXIII
9–28

SEMS-BOL T
TO ENG.REVOLUTION E-1 3:
SEN S OR TRAVEL ALARM
FIX A CONNECTOR HAS TAG OF
"ALARM" ON THE BRACKET 9
CLIP
FIX WHITE TAP ING P OS ITION S WING FLAS HER RIGHT
XV CLIP
FIX WHITE TAP ING P OS ITION FIX WHITE TAP ING P OS ITION CLIP
CLIP CLIP
CLIP
TO ENGINE
FORWARD
SEMS-BOL T
CLIP PLATE
FIX WHITE CLIP FIX WHITE TAP ING P OS ITION
TAP ING P OS ITION FIX WHITE TAP ING P OS ITION CLIP
UPP HARNESS
FORWARD
CLIP
XIII FOR WARD
INSULATION
STICK THE INSULATION CLIP
AFTER COA TING
COMPLETELY CLEAN & TO TRAVEL ALARM AND
TO HYD.FLUID FILTER
REMOVE DUSTS,F ATS & S WING FLAS HER RIGHT
FOR WARD RESTRICTION SENSOR
OILS AND WATER FROM
THE STICKING F ACE, VIEW XIV
THEN STICK IT VIEW XV VIEW XVI
VIEW XIII
CLIP
VIEW XII FIX WHITE TAP ING P OS ITION

FIX A HARNES S TO
THE ROOT OF LUG BY A CLIP
CLIP
FIX A HARNES S TO
THE MOUS E P IECE
NOTE 6 OF HOS E BY A CLIP
FIX WHITE TAP ING P OS ITION S V-4:
FIX A HARNES S PART OF COULGATED CLIP
PSV -P1: CLIP NOTE 6 OP ERATING
PUMP P1 TO S OL. WITH A CLIP BUNDLE AND FIX LEVER LOCK S OL.
PROPOR TIONAL SOL. CLIP HARNESS B Y A CLIP PSV -D:
P 1 UNLOAD
FIX WHITE TAP ING P OS ITION P ROP ORTIONAL S OL.
CLIP S V-1:
S WING PARKING
CLIP BRAKE S OL.
PSV -C:
TRAVEL P RIORITY
P ROP ORTIONAL S OL.
PSV -B:
P 2 UNLOAD
PSV -24:
BOOM 3
CLIP PSV -23:
PSV -P2: FIX A HARNES S PART BOOM 2
PUMP P2 P ROP ORTIONAL S OL.
CLIP OF COULGATED TO P RES S
PROPOR TIONAL S OL. SEN S OR WITH A CLIP PSV -A:
SEMS-BOL T ARM TWO-S P EED INVERS E
TIGHTENING TORQUE SE-2 2: P ROP ORTIONAL S OL.
25.5N .m(18.8 lbf .ft) SE-21: P RES S S ENS OR:P UMP P 1
FIX WHITE TAP ING HYD. FLUID TEMP
POSITION TIGHTEN THE NUT ACCES S ORY OF
HYD.FLUID TEMP S ENS OR. CLIP
CLIP FORWARD
FIX A HARNES S BY A CLIP TORQUE OF M4 S CREW TO FIX A HARNES S PART
CLIP FORWARD
TO P IP METAL FITTING BE 0.49N .m(0. 36 lbf.ft) OR LES S , OF COULGA TED SE-23:
FIX A HARNES S TO PRESS SENSO R:P UMP P 2
NO SLIP IS P ERMITTED ON TO P RES S S ENS OR
THE LUG BY A CLIP
MOLDING PART. WITH A CLIP
VIEW XVII VIEW XVIII VIEW XIX
9–29
E-10:
NOTE 6 RECEI VER DRIER
CLIP ITEM 1 HARNESS HARNES S OF
CLIP ATTACHED ENG.
UNDER BRACKET
DIRECTION CLIP OF ATTACHED
OF MACHINE SEMS-BOL T CONNECT OR
HOSE ENG.HARNES S
US E THE CLIP OF
ATTACHED ENGINE
XXIII
S W-27: CLIP FIX A CONNECTOR
CLIP TO THE BRACKET
RADIATOR COOLANT
FIX HARNESS TOGETHER HOS E BY A CLIP
LEVEL SW.
FIX HARNESS TOGETHER HOS E 16P
12P 14P
FIX WHITE TAP ING P OS ITION BY HOS E S IDE CLIP BRACKET
CLIP FIX WHITE TAP ING
P OS ITION
FOR WARD CLIP FIX WHITE TAP ING P OS ITION
CLIP
FAS TEN UP P HARNES S
AND S TARTER CABLE
CLIP
SET THE WHITE TAP ING P OS ITION CLIP SEMS-BOL T
TO AIR FILTER FIX HARNES S TOGETHER HOS E SEMS-BOL T
RES TRICTION S W. TO THE CLIP FOR HOS E
AND FIX BY A CLIP
FIX HARNESS TOGETHER HOS E
BY HOS E S IDE CLIP
TO RECEIVER DRIER VIEW XXI
S TARTER CABLE
HOSE
UPP HARNESS E-10:
TO CONNECTOR UPP HARNESS
CLIP
RECEI VER DRIER
FIX HARNES S TO THE HOS E

CLIP
VIEW XXII
FORWARD
VIEW XXIII INSER T UP P HARNES S

AND STARTER CABLE
FOR SLIT OF INSULATION
VIEW XX DETAIL OF RADIATOR COOLANT LEVEL S W.INS T. FIX S O THAT THE TERMINAL OF
THE AIR FILTER MAY BECOME IT UP.
FIX WHITE TAP ING P OS ITION TO BATTERY RELAY BOX
CLIP
FIX WHITE TAP ING P OS ITION FORWARD HARNES S OF
CLIP ATTACHED ENG.
FOR WARD FIX A UP P HARNES S

CLIP
FIX A S TARTER CABLE

CLIP
SE-60: FORWARD
HYD. FLUID FILTER
RESTRICTION SENSOR S W-8:
AIR FILTER
CLIP
FIX A CONNECTOR TO THE BRACKET FAS TEN UP P HARNES S ,
RESTRICTION S W. AND STARTER CABLE BY A CLIP
CLIP FIX WHITE TAP ING P OS ITION
TO HYD.FLUID FILTER
CLIP BUNDLE AND FASTEN RESTRICTION SENSOR UPP HARNESS
A RES T S ENS OR S IDE CLIP
HARNESS TO THE FIX WHITE TAP ING P OS ITION
S TARTER CABLE
CONNECT OR BY A CLIP CLIP
FOR WARD FAS TEN UP P HARNES S
AND STARTER CABLE
BY A CLIP
VIEW XI VIEW X VIEW XXV VIEW XXIX
9–30
FIX A HARNES S TO THE HOLE OF

A ADJ US TMENT P LATE BY A CLIP
CLIP ENG. COOLANT THERMO S ENS OR
E-2 :
ALTERNATOR
TIGHTENING TORQUE 4.0N.m(2 .95 lbf.ft)
9
ALTERNATOR(B)

TIGHTENING TORQUE 3.8N.m(2 .80 lbf.ft)
SEMS-BOL T
CLIP
ENG.EAR TH CABLE
SEMS-BOL T
TIGHTENING TORQUE
S PACER 51.9N.m(3 8.3 lbf.ft)
S W-7: ALTERNATOR
ENG. OIL PRESS SW . TIGHTENING TORQUE 25.5N.m(18.8 lbf .ft)
SEMS-BOL T VIEW XXVII
BRACKET DETAIL OF ALTERNATOR
CLIP
FIX A HARNES BY A CLIP
TO THE BRACKET OF
ENG.ACCESSOR Y
XXVII
FOR WARD
UPP HARNESS
CLIP
SEMS-BOL T SEMS-BOL T
FIX WHITE TAP ING P OS ITION BRACKET
TIGHTENING TORQUE TIGHTENING TORQUE 25.5N.m(1 8.8 lbf.ft)
23.0N.m(1 7.0 lbf.ft)
VIEW XXVI GLOW NUT CLIP
CLIP SE-1 3: FIX WHITE TAP ING P OS ITION
ENG.REVOLUTION S ENS OR
FIX A CONNECTOR ON BRACKET FIX A HARNES S PART OF
FIX A WHITE TAP ING P OS ITION COULGATED TO P LATE WITH A CLIP
FORWARD
OF HARNES S TO
THE BRACKET WITH CLIP
TO GLOW
DETAIL OF ENGINE REVOLUTION SENSOR INST
WAS HER
COLLAR
S TARTER CABLE FIX WHITE TAP ING P OS ITION

TIGHTENING TORQUE 25.5N.m(1 8.8 lbf.ft)
UPP HARNESS CLIP
SEMS-BOL T
SEMS-BOL T
FORWARD
FORWARD
INS TALL THE RUBBER CAP
BRACKET ON UP P ER S IDE
NUT S TARTER CABLE TO GLOW

CLIP
SEMS-BOL T WAS HER
M-1: SEMS-BOL T
FAS TEN UP P HARNES S UPP HARNESS GND
AND STARTER CABLE
bb S TARTER MOTOR
S TARTER CABLE NOTE 2
FIX WHITE TAP ING P OS ITION NUT TIGHTEN AFTER
UPP HARNESS WAS HER CHECKING NO PAINT
TIGHTENING TORQUE
13.5N.m(1 0.0 lbf.ft)
DETAIL bb
TIGHTENING TORQUE 7
UPP HARNESS 4.5N.m(3 .32 lbf.ft)
S TARTER CABLE ENG.EAR TH CABLE
M-1:
S TARTER MOTOR CLIP VIEW XXIV
FAS TEN HARNES S FOR
S TARTER MOTOR AND
VIEW XXVIII HARNES S FOR GLOW
9–31
R-3: NOTES
CONNECT TO 2P CONNECTOR 1. TIGHTENING TORQUE OF BATTERY TERMINAL 6N.m(4 .43 lbf.ft)
GLOW RELAY F TERMINAL TIGHTENING TORQUE43N.m(2 .53 lbf.ft)
FOR HARNESS OF ATTACHED
USE NUT OF ATTACHED 2. TIGHTEN TO TORQUE AT EARTH: 10.7N.m(7 .89 lbf.ft)
GLOW RELAY S TERMINAL GLOW RELAY
3. TIGHTEN TO TORQUE
CONNECT WHITE TAP ING HARNES S
M8 : 23N.m(1 7.0 lbf.ft)
FAS TEN GLOW RELAY S TERMINAL
AND CONNECT OR HARNESS M10 : 46.5N.m(3 4.3 lbf.ft)
CLIP CONNECT RED TAP ING HARNES S . 4. ATTACHMENT OF WELDING CLIP WITHOUT DIRECTIONS IS MADE INTO THE FOLLOWING.
C TERMINAL TIGHTENING TORQUE3.8N.m(2 .80 lbf.ft)

CLIP
USE NUT OF ATTACHED
B TERMINAL S TARTER RELAY
R-2: R-2:
CONNECT TO S TARTER RELAY HARNESS
E-15 S TARTER RELAY(COIL)
BUNDLE THE HARNES S BY
FUSIBLE LINK CLIP
THE SIDE OF A RELAY
3P 5. FIX THE HARNES S WITH THE S LIT OF CORRUGATED TUBE ADJ US TED TO THE LOWER S IDE.
UPP HARNESS
FIX A CONNECTOR ON 6. ATTACHMENT OF CLIP IS MADE INTO THE FOLLOWING.
THE BRACKET
XXXI CLIP TO THE ROOT OF THE CLIP
S OL.S IDE CONNECTOR.
R-1:
BATTERY RELAY
CONNECT THIS TERMINAL WITH
S TARTER CABLE SOL.
TIGHTENING TORQUE7.3N.m(5 .38 lbf.ft)
CLIP CONNECT THIS TERMINAL CLIP TO THE ROOT OF THE

FAS TEN UP P HARNES S WITH BATTERY RELAY CABLE RADIATOR COOLANT LEVEL S W. CLIP
AND STARTER CABLE TIGHTENING TORQUE7.3N.m(5 .38 lbf.ft)
S TARTER CABLE

CLIP RADIATOR COOLANT LEVEL S W.
FAS TEN UP P HARNES S ,
FIX FUSE BOX S TARTER CABLE AND
BATTERY RELAY CABLE FIX A CONNECTOR ON
P-14 UPPER HARNESS GROUND P-16 UPPER HARNESS GROUND
WITH THE BRACKET THE BRACKET
SEMS-BOL T RADIATOR COOLANT LEVEL CONTROLLER OPT. SELECTOR SOL.
ADJUST THE LOCK OF P-15 UPPER HARNESS GROUND FRAME WORKING LIGHT RIGHT
THE FUSE BOX COVER POWER BOOST SOL.
TO THE UP P ER S IDE.
LEVER LOCK SOL.
BATTERY RELAY CABLE TWO-SPEED SELECT SOL.
S TARTER CABLE SWING PARKING BRAKE SOL.
UP P HARNES S
TRAVEL ALARM
UPP HARNESS
SWING FLASHER RIGHT & WORKING LIGHT UNIT
P-4 UPPER HARNESS GROUND SWING FLASHER LEFT & WORKING LIGHT UNIT
TO CAB HARNES S GLOW RELAY
P-9 UPPER HARNESS GROUND BATTERY RELAY
UPP HARNESS
BRACKET FUSE&RELAYBOX RADIATOR COOLANT LEVEL SW.
FIX A CONNECTOR ON DIODE
THE BRACKET HYD. FLUID FILTER RESTRICTION SW.
1P FIX WHITE AIR FILTER RESTRICTION SW.
TAP ING P OS ITION CLIP
BOOM METER IN CUT SOL.
2P
P-81 UPPER HARNESS GROUND
GND
FIX A LONG S IDE TO NOTE 2 AIR CONDITIONER UNIT
THE UP P ER ROW. SEMS-BOL T
P-20 UPPER HARNESS GROUND TIGHTEN AFTER
CHECKING NO P-10 UPPER HARNESS GROUND
ENG. CONTROLLER PAINT
DETAIL OF BATTERY RELAY PART FUEL SENSOR
P-23 UPPER HARNESS GROUND TWO TERMINALS MECHATRO CONTROLLER
ENG. CONTROLLER ARE FIXED BACK
TO BACK P-11 UPPER HARNESS GROUND
P-21 UPPER HARNESS GROUND MECHATRO CONTROLLER
ENG. CONTROLLER
ENG. HARNESS SHIELD
P-42 UPPER HARNESS GROUND
MECHATRO CONTROLLER
DETAIL aa
VIEW XXXI
9–32
YN13E01884P5
CORRUGA TE TUBE
CAP TO BE INS TALLED 7034-1280
WHITE TAP ING
WHITE TAP ING CORRUGA TE TUBE
SECTION AA
WHITE TAP ING
WHITE TAP ING
RED TAP ING
CLIP
HARNESS
CLIP
CLIP
WHITE TAP ING WHITE TAP ING
CLIP
WHITE TAP ING
TAP ING
WHITE TAP ING

BLUE TAP ING TAP ING TAP ING
WHITE TAP ING WHITE TAP ING WHITE TAP ING WHITE TAP ING
403A-403B-403C 401A-401B-401C
SPL ICE SPL ICE
WHITE TAP ING 402A-402B-402C
YELLOW TAP ING SPL ICE
A A
CLIP
CLIP WHITE TAP ING WHITE TAP ING WHITE TAP ING
CLIP
CAP
TO BE INS TALLED CAP
CLIP
(1/10) YN13E01884P5
9–33
WHITE TAP ING
WHITE TAP ING
TAP ING
WHITE TAP ING

WHITE TAP ING
SH1 SHIELD
UN-CONNECTED
WHITE TAP ING
WHITE TAP ING
WHITE TAP ING

WHITE TAP ING
TAP ING AFTER
BUNDLED
WHITE TAP ING WHITE TAP ING WHITE TAP ING WHITE TAP ING WHITE TAP ING
CLAMP
WHITE TAP ING
(2/10) YN13E01884P5
9–34
7034-1280
CAP TO BE INSTALLED
9
7034-1279
CAP TO BE INSTALLED
WHITE TAP ING
WHITE TAP ING

TAPING AFTER MAKE THE
DIRECTION OF THE BENT
ACCORDING TO THE SHOWING.
7034-1279 WHITE TAP ING

CAP TO BE INSTALLED
RED T APING
7034-1280
CAP TO BE INSTALLED
WHITE TAP ING
TAPING
WHITE TAP ING

58A-58B-58C
SPLICE
64A-64B-64C
SPLICE
157A-157B-157C
SPLICE
(3/10) YN13E01884P5
9–35
LEVER LOCK SOL. TRAVEL PRIORITY

PROPOR TIONAL SOL.
ALTERNATOR
TO ENG. CONT. HARNES S
TO CAB HARNES S
POWER BOOST SOL.

P1 UN-LOAD
PROPOR TIONAL SOL.
ENG. COOLANT THERMO
ENG. OIL PRESS SW . SENSOR
TO BOOM WORK LIGHT

P2 UN-LOAD
PROPOR TIONAL SOL.
ARM TWO-SPEED INVERSE
PROPOR TIONAL SOL.
(4/10) YN13E01884P5
9–36
PRESS SENSOR: HORN HIGH

TWO-SPEED SELECT SOL.
PUMP P1 PUMP P2
PRESS. SENSOR: ENG.REVOLUTION SENSOR
PROPOR TIONAL SOL.
BOOM LOWERING
SUPPL Y WITH
TO BE INS TALLED
YN13E01322P1 CAP . HORN HIGH
PRESS. SENSOR:
SWING P ARKING PUMP P2
BRAKE SOL. SEALING PLUG TO BE
INSER TED INTO ALL
PRESS. SENSOR:
ARM OUT
FUEL SENSOR
TRAVEL ALARM
HORN LOW
PUMP P1
PROPOR TIONAL SOL.
PRESS. SENSOR: RECEIVER DRIER
BOOM RAISING
(5/10) YN13E01884P5
9–37
DIODE
YAZAKI 7321-9822
SUPPLY WITH DIODE
ADAPT CONNECTOR 7123-7144
STARTER RELAY BATTERY RELAY ADAPT TERMINAL 7116-1181
HORN LOW GLOW
DIODE
SUPPLY WITH
INSTALLATION SUMITOMO 6440-0294(2 PIECES)
SUPPLY WITH SUMITOMO 6911-2024 BATTERY RELAY

SEALING PLUG TO BE
INSERTED INTO ALL RADIATOR COOLANT
LEVEL SW.
SUPPLY WITH
ARM CUSHION
PROPORTIONAL SOL.
SEALING PLUG TO BE
INSERTED INTO ALL
GLOW RELAY
BATTERY RELAY TO SWING FLASHER LEFT
(6/10) YN13E01884P5
9–38
SUPPL Y WITH
SUPPL Y WITH
BOOM 3
PRESS. SENSOR: PROPOR TIONAL SOL.
HYD. FLUID FILTER BOOM HEAD
RESTRICTION SENSOR
SEALING PLUG TO BE
INSER TED INTO ALL
SEALING PLUG TO BE
INSER TED INTO ALL
TO CAB HARNES S
TO BOOM/
TO S WING FLAS HER RIGHT SRM POTENTIO.
BOOM 2
PROPOR TIONAL SOL.
TO CAB HARNES S
TO CAB HARNES S
PRESS. SENSOR:
BOOM ROD
TO CAB HARNES S
PRESS. SENSOR:
SWING LEFT
TO CAB HARNES S
BOOM METER IN CUT SOL.
(7/10) YN13E01884P5
9–39
SUPPL Y WITH
FRAME GND OF UNDER

S TARTER MOTOR GLOW RELAY FLOOR
AIR FILTER
RESTRICTION SW .
TO CAB HARNES S SEALING PLUG TO BE

INSER TED INTO ALL
TO OP T. S ELECTOR FRAME GND OF UNDER FRAME GND OF UNDER

DETECT SENSOR FLOOR FLOOR
S TARTER RELAY
FRAME WORKING LIGHT

RIGHT
TO CAB HARNES S
GLOW RELAY FRAME GND OF UNDER

FRAME WORKING LIGHT FLOOR
RIGHT ALTERNATOR
AIR FILTER
RESTRICTION SW .
(8/10) YN13E01884P5
9–40
TO EARTH TO EARTH
FRAME GND OF UNDER CHASSIS GND
FLOOR
TO EARTH
FRAME GND OF UNDER HYD. FLUID TEMP. SENSOR

ALTERNATOR
FLOOR
TO EARTH
CHASSIS GND
TO EARTH
TO EARTH
(9/10) YN13E01884P5
9–41
(10/10) YN13E01884P5
9–42
STARTER CABLE : YN13E01885P2 ENGINE EARTH CABLE : LQ13E01337P1
BATTERY RELAY CABLE : LQ13E01315P1 FLOOR EARTH CABLE : LE13E01006P1
100
LA308 5B E E 5B E
1PAM
YAZAKI 7122-3010
BATTERY CABLE : LQ13E01248P1
9–43
9.4.8 UPPER HARNESS ASSY

(FLOOR PLATE)
UPPER HARNESS ASSY (FLOOR PLATE) LC13E00181F1 (07)

1 HARNESS LC13E01562P5 1 FLOOR
2 CABLE LE13E01005P1 1 GROUND
FIX WITH TILTED LEVER

LEVER LOCK SW .
AT THE FRONT
SIDE HARNESS
bb CLIP
S W-11:
aa LEVER ROCK S W.
S W-21:
P OWER BOOS T S W. LEFT
I (YELLOW TAP ING)
FIX A P OWER
LEVER ROCK SW . S W-10:
SIDE HARNESS TO HOS E HORN S W. LEFT (BLUE TAP ING)
CLIP
CLIP
BUNDLE TO HORN S W.LEFT S IDE HARNES S AND
LEVER ROCK S IDE HARNES S .
CLIP CLIP
FIX TO A HALL OF P LATE.
1 SET WHITE TAP ING P OS ITION
AND FIX TO A S LIT OF P LATE.
CLIP CLIP
SET WHITE TAP ING P OS ITION
CAB HARNESS
CONNECT TO
S W-12: PILOT HOSE CAB HARNESS
OVER ROAD ALARM S ELECT S W.
(OVER L TAG)
M-4:
WAS HER MOTOR DETAIL OF LEFT CONSOLE
III
S W-26:
CAB WORKING LIGHT S W. S W-26:
FIX POWER BOOST SW. TO (CAB LIGHT TAG) CAB WORKING LIGHT S W.
RIGHT OF FLOOR HARNESS (CAB LIGHT TAG)
VIEW III S W-12:
OVER ROAD ALARM S ELECT S W.
(OVER L TAG) FRONT
S W-12:
INSULATION
FIX WITH TILTED
LEVER OVER ROAD ALARM SELECT SW. (OVER L TAG)
AT THE FRONT FLOOR HARN ESS
CLIP
BUNDLE POWER BOOST SW.
FIX WHITE TAP ING P OTIS ION FRONT DETAIL OF bb
SIDE HARNESS AT THE BACK OF
FLOOR HARNESS FIX TO A HALL OF P LATE. TO THE MOUS E P ICE OF HOS E CLIP
BY A CLIP.
CLIP FIX WHITE TAP ING P OTIS ION.
II CLIP
S W-20:
POWER BOOST SW. RIGHT FIX TO THE P ILOT HOS E. PILOT HOSE
(YELLOW TAP ING)
CLIP FIX WHITE TAP ING P OTIS ION

CLIP
FIX WHITE TAP ING P OTIS ION
FIX TO A HALL OF P LATE
TRIM
CLIP
VIEW II DETAIL OF RIGHT CONSOLE VIEW I
UPPER HARNESS ASSY (FLOOR PLATE) (1/2)
9–44
FIX WHITE TAP ING P OTIS ION. CLIP M-4:

SE-20: WAS HER MOTOR
PRESS SENSOR:P1 OPT .
P-31 FLOOR HARNESS GROUND

OVER LOAD ALARM SELECT SW.
SE-10:
9
POWER BOOST SW. LEFT PRESS SENSOR:TRA VEL LEFT
HORN SW . LEFT TIGHTEN AFTER
CAB WORKING LIGHT SW. CHECKING NO P AINT.
TIGHTENING TORQUE10.7N.m(7.89 lbf .ft)
POWER BOOST SW. RIGHT
NUT
WAS HER MOTOR WAS HER
12V SOCKET LOCK WASHER
GND
NOTE 2
1. ATTACHMENT OF CLIP IS MADE INTO THE FOLLOWING.
TO S ENS OR
CLIP
PRESS SENSOR FIX HARNES S TOGETHER HOS E

BY HOS E S IDE CLIP
CONNECT WITH EARTH CABLE
OF UPP FRAME.
FIX A CORRUGATERD TUBE NOT SE-9:

CONTACT LOCK OF CONNECT OR. PRESS SENSOR:TRA VEL RIGHT
SE-1 1:
NOTE 1
FIX WHITE TAP ING P OTIS ION.
BUNDLE THE REMAINDER OF HARNESS
AND FIX IN THIS POSITION FIX TO A HOS E
CLIP FIX WHITE TAP ING P OTIS ION.
CLIP CLIP
FIX WHITE TAP ING P OTIS ION. TO THE FRONT S IDE OF CLIP FIX WHITE TAP ING P OTIS ION.
SE-2: FIX WHITE TAP ING P OTIS ION.
FLOOR P LATE.
PRESS SENSOR: CAB HARNESS
BUCKET DIGGING
FIX TO A HOS E
FIX WITH HOSE SIDE BY CLIP
VIEW FROM THE BACK SIDE OF FLOOR PLA TE.
SE-1:
FOR FIXATION IS POSSIBLE.
PRESS SENSOR:
CLIP BUCKET DIGGING
NOTE 1 SE-4 0:
FIX WHITE TAP ING P OTIS ION. P RES S S ENS OR: SE-7 :
SE-40: BUNDLE THE REMAINDER OF HARNESS P RES S S ENS OR:
S WING RIGHT
PRESS SENSOR: AND FIX IN THIS POSITION ARM IN NOTE 1
SWING RIGHT CLIP
CLIP SE-7 : SE-2 :
SE-1 :
P RES S S ENS OR: P RES S S ENS OR:
SE-7: SE-2 : NOTE 1 P RES S S ENS OR:
ARM IN BUCKET DUMP
TO THE BACK S IDE OF PRESS SENSOR: SE-4 0: P RES S S ENS OR: CLIP BUCKET DIGGING FRONT
FLOOR PLA TE. ARM IN P RES S S ENS OR: BUCKET DUMP
S WING RIGHT
SE-2: SE-1:
PRESS SENSOR: PRES S S ENS OR:
DETAIL OF aa : CASE OF SENSOR BLOCK SK330-10 BUCKET DIGGING BUCKET DIGGING
FRONT
SE-1:
FIX TO A HOS E PRESS SENSOR:
FIX WITH HOSE SIDE BY CLIP BUCKET DIGGING
FOR FIXATION IS POSSIBLE.
CLIP
SE-40: CLIP FIX TO A HOS E CLIP
CLIP PRESS SENSOR: NOTE 1
FIX TO A HOS E
SWING RIGHT FIX WHITE TAP ING P OTIS ION.
CLIP BUNDLE THE REMAINDER OF
SE-7: NOTE 1 HARNES S AND FIX IN THIS
PRESS SENSOR: FIX WHITE TAP ING P OTIS ION. P OS ITION
TO THE BACK S IDE OF BUNDLE THE REMAINDER OF HARNES S
ARM IN
FLOOR PLA TE. AND FIX IN THIS P OS ITION
DETAIL OF aa : CASE OF MUL TI SK330-10

DETAIL OF aa : CASE OF SENSOR BLOCK SK200, SK250-10 DETAIL OF aa : CASE OF MUL TI SK200, SK250-10
UPPER HARNESS ASSY (FLOOR PLATE) (2/2)
9–45
FLOOR HARNESS : LC13E01562P5
WHITE TAP ING
TAP ING
TAP ING
TAP ING WHITE TAP ING
WHITE TAP ING

TAP ING
WHITE TAP ING

TAP ING
WHITE TAP ING

YELLOW TAP ING
542A-542B-542C
SPLICE
WHITE TAP ING
HARNESS INSULATION
YELLOW TAP ING BLUE TAP ING
TAP ING
WHITE TAP ING
FLOOR HARNESS (1/3) : LC13E01562P5
9–46
PRESS. SENSOR: CAB WORKING LIGHT SW.

WAS HER MOTOR PRESS. SENSOR:
ARM IN PRESS. SE NSOR:
TRAVEL LEFT OVER LOAD ALARM
SWING RIG HT
SELECT SW.
SUPPL Y WITH AMP 1565123-1

LEVER LOCK SW .
TO CAB HARNES S
POWER BOOST SW. RIGHT
PRESS. SENSOR: TO CAB HARNES S
BUCKET DIGGING
SUPPL Y WITH S UMITOMO 6440-0128

TO FRAME EARTH
HORN SW . LEFT
PRESS. SENSOR:
TRAVEL RIGHT
SUPPL Y WITH AMP 1565123-1
PRESS. SENSOR:
BUCKET DUMP
PRESS. SENSOR:P1 OPT .
POWER BOOST SW. LEFT
9–47
FLOOR HARNESS(3/3) : LC13E01562P5 FLOOR EARTH CABLE : LE13E01005P1
100
1PAF
YAZAKI
9–48
9.4.9 WASHER TANK ASSY

WAS HER TANK AS S Y YN54C00013F1 (05)
CUT THE S URP LUS LENGTH
GROMMET
ITEM PART NAME PART No. Q'TY REMARKS THAT ADJ US TMENT.
9
1 WATER TANK AS S Y YT54C00003F1 1 CONNECT OR
(0.43")
(11)
5 8 8 (2
3 .5 ")
(5.91")
150
(3.74")
95
FOR WARD
TIGHTENING TORQUE
23N .m (17.0 lbf .ft) CAB CLIP FIXED THAT.
SEMS-BOL T CLIP CUT A LENGTH OF CAB HOS E,
THAT ADJ US TMENT.
335 (13.19") SECTION AA
675 (26.58")
VIEW I
1
BRACKET
SEMS-BOL T
TIGHTENING TORQUE I
9.7N .m (7.15 lbf .ft)
III
HARNESS FIXED THAT.
VIEW II MUST LAYOUT THE HOS E MUST NOT BE CRUSHING
ALONG THE HARNESS. OF THE HOSE.
CLIP
FOR WARD
TUBE
11 0 (4 .3
3 ")
1
(3 . 0 0
100 (3.94")
94
")
RUBBER
A
7”)
50
(1.9
CLIP
HARNESS FIXED THAT. 360
)
.7 9 ”
(1 4
20)
MUST NOT BE CRUSHING .1 7

")
(1 0 ~
9 ~0
OF THE HOSE.
(0 . 3
A II
WHITE TAP E P OS ITION
S TARTING S TICK P OS ITION OF FOR HARNESS.
RUBBER (END OF R)
CLIP
VIEW III HARNESS FIXED THAT AT THE
RUBBER INST ALLATION WHITE TAP E P OS ITION. TUBE LAYOUT UNDER FLOOR PLA TE
MUST NOT BE CRUSHING
OF THE HOSE.
9–49
9.4.10 CAB HARNESS ASSY

CAB HARNESS ASSY LQ14E00024F1 (11)

TO THE FRONT S IDE OF
1 HARNESS LQ14E01036P7 1 FLOOR PLA TE.
CONNECT ITEM 1 HARNESS TO UP P HARNES S
WITH YELLOW TAP ING BETWEEN
10 HARNESS LQ14E01037P1 1 TWO BRANCHES CONNECT ORS.
CONNECT ITEM 1 HARNESS TO

UPP HARNESS WITH YELLOW TAP ING
BETWEEN TWO BRANCHES CONNECT ORS.
CONNECT ITEM 1 HARNESS TO

UPP HARNESS WITH RED TAP ING
BETWEEN TWO BRANCHES CONNECT ORS.
UPP HARNESS
DETAIL aa
C-2: IV V
II FIX TO BEACKET
CLUSTER GAUGE CLIP
34 PIN CONNECT OR 31 PIN CONNECT OR

32 PIN CONNECT OR
35 PIN CONNECT OR 35 PIN CONNECT OR
VIEW V
VIII
cc
1
III
I aa 31 PIN CONNECT OR
34 PIN CONNECT OR 32 PIN
CONNECT OR
35 PIN CONNECT OR
35 PIN CONNECT OR CONNECT TO
WIPER RELA Y
M-3: VIEW IV VIEW III
WIPER MOT OR
CAB HARNESS ASSY (1/4)
9–50
C-1:
E-1 : E-7 : E-6 5: MECHATORO
FUS E&RELAY BOX TUNER 24V S OCKET CONTOROLLER
9
bb
CLIP
VI
FIX WHITE
TAP ING P OTIS ION.
RES IS ITOR S IDE HARNES S

FIX WHITE
TAP ING P OTIS ION.
CLIP E-3 8:
RES IS ITOR
CONNECTO TO RES IS ITOR

S IDE HARNES S
DETAIL bb
CLIP CLIP
FIX WHITE TAP ING P OTIS ION. CLIP FLOOR HARNESS FIX THE CLIP TO THE BRACKET. dd FIX THE CLIP TO THE BRACKET.
CONNECT TO FIX WHITE TAP ING P OTIS ION.
FLOOR HARNES S . FIX WHITE TAP ING P OTIS ION.
VIEW I
TIGHTENING TORQUE
CONNECT TO
TUNER S IDE HARNES S 4.4N.m(3 .25 lbf.ft)
TIGHTEN AFTER CHECKING NO PAINT.
TIGHTEN WITH TWO EYELET TERMINALS .
GND
P-2 CAB HARNESS GROUND
SEMS-BOL T SPLICE
ROTARY LIGHT
FLASHER RELA Y
A A DC-DC CONVER TER(12/24V SOCKET)
CAB WORKING LIGHT FRONT 1
CAB WORKING LIGHT
ENG. CONTROLLER CHECK CONNECT OR
RELEASE SW .(KPSS)
KEY SW. GROUND
WIPER MOT OR
CLUSTER GAUGE
P-13 CAB HARNESS GROUND
GND P-19 CAB HARNESS GROUND
CONNECTO TO RELEAS E S W. FUEL SUPPL Y P UMP SEMS-BOL T
CLIP (KPSS)SI DE HARNES S FROM UPPER HARNESS
CLIP P-80 CAB HARNESS GROUND TIGHTENING TORQUE
S W-22: IT CONTROLLER 4.4N.m(3 .25 lbf.ft)
FIX WHITE TAP ING P OTIS ION. RELEASE SW .(KPSS) TIGHTEN AFTER CHECKING
FUSE & RELAY BOX NO PAINT.
TUNER AM&FM TIGHTEN WITH TWO EYELET
VIEW VI TERMINALS .
FUEL DISCRIMINANT SENSOR
BOOM,DECK WORKING LIGHT SW.
DETAIL bb WIPER INTERLOCK SW .
NEUTRAL ST OP RELAY SECTION AA
9–51
FIX THE CONNECTOR TO HARNES S CONNECT DOUBLE S P LICE OF RED YELLOW WIRE
CONNECT 6P CONNECTOR OF CAB HARNES S TO RED YELLOW WIRE
BUNDLE A RES T CAB S IDE CLIP OF CAB HARNES S TO DC-DC OF CAB S IDE HARNES S .
OF S P EAKER HARNES S CONVERTER FOR CAMERA(OP T) CONNECT WITH CAB WORK LIGHT FRONT.
BY A CLIP CLIP
B SE-9 9:
BUNDLE AND FAS TEN
FIX TO THE HARNES S R-19: P RES S S ENS OR:
OF AIR CONDITIONER UNIT. FLAS HER RELAY S WING S P EED S ENS OR CLIP A RES T CAB S IDE OF
CLIP CAB WORK LIGHT
FRONT HARNES S
C-8: BY A CLIP
ENG
CONTOROLLER
B E-6 3:
FIX WHITE TAP ING P OTIS ION. DC-DC CONVERTER
(FOR CAMERA)
(OP T)
FIX TO THE HARNES S CONNECT
OF AIR CONDITIONER UNIT. WITH S P EAKER.
CLIP CLIP
FIX WHITE TAP ING
P OTIS ION.
FIX TO CAB S IDE

VII AIR CONDITIONER
RADIO CABLE
HARNES S
CLIP
DIVERGRS HARNES S
CLIP
TO FUS E&RELAY BOX.
C-5:
RADIATOR COOLANT
ee LEVEL CONTOROLLER
FIX WHITE
TAP ING P OTIS ION.
2 P OINTS
CLIP
PLATE
SEMS-BOL T
TIGHTENING TORQUE FIX WHITE
9.7N.m(7 .15 lbf.ft) CLIP TAP ING P OTIS ION.
FLOOR
HARNESS CLIP CONNECT WITH WIP ER CLIP
THREW CLIP TO S LIT OF BRACKET. INTALOCK S W. FIX THE CLIP
FIX HARNESS TO CENTER OF FIX HARNES S TOGETHER CAB S IDE
GROMMET TO THE BRACKET. WITH THE CAB S IDE RADIO RADIO CABLE
INSULATION BY THE LOCATED OF GROMMET.
CABLE BY A CLIP.
FIX WITH FLOOR HARNESS. CONNECT WITH
DETAIL cc CAB WORK LIGHT.
CONNECT DOUBLE S P LICE OF RED YELLOW WIRE
VIEW II
OF CAB HARNES S TO RED YELLOW WIRE
OF CAB S IDE HARNES S .
CONNECT DOUBLE S P LICE OF BLACK WIRE
OF CAB HARNES S TO BLACK WIRE OF CAB S IDE HARNES S .
CONNECT WITH FIX THE CLIP TO

ROOM LIGHT. THE BRACKET.
S W-1: S W-55:
SE-1 6: BOOM,DECK WORKING LIGHT S W.
KEY S WITCH ACCEL P OTENTIO
CONNECT CONNECTOR
CONNECT WITH NAME TAG OF E-2 7: S W-4: WITH "CN3-1" TAG.
"BOOM DECK". ACCEL REDUNDANT S WING PARKING RELEAS E S W.
CONNECT CONNECTOR
VOLUME CONNECT CONNECTOR WITH "CN3-2" TAG.
CONNECT TO THE WITH "CN1" TAG.
EARTH OF KEY S W. CONNECT CONNECTOR
CONNECT CONNECTOR WITH "CN2-3" TAG.
WITH "CN13" TAG.
CLIP
CONNECT WITH
CONNECT TO NAME TAG OF "PARKING".
ACCEL P OTENTIO.
10 CONNECT WITH NAME

CONNECT CONNECTOR
CONNECT CONNECTOR
TAG OF "FAIL S AFE". WITH "CN4-1" TAG.
WITH "CN12" TAG.
CONNECT CONNECTOR
CLIP CLIP CONNECT CONNECTOR WITH "CN4-2" TAG.
CONNECT TO 1P CONNECTER FIX WHITE TAP ING P OTIS ION. WITH "CN-5RF" TAG. CONNECT CONNECTOR
OF CAB HARNES S . FIX THE CLIP TO THE BRACKET. WITH "CN2-1" TAG.
SECTION BB VIEW VII
DETAIL OF THE SWITCH JOINT .
9–52
CAB HARNES S . CAB S IDE RADIO CABLE
9
CONNECT THE CONNECTOR(1P ) OF
CAB HARNES S TO ROOM LIGHT CABLE.
CAB ROOM LIGHT CABLE
FLOOR S IDE CONNECT THE FLOOR S IDE

RADIO CABLE RADIO CABLE TO CAB S IDE CABLE
VIEW VIII
J OINED TO LOCK S IDE FOR CHECK TO CONNECTER J OINED TO

P OWER S UP P LY CONNECTION. UNLOCK S IDE FOR NON-P OWER
S UP P LY CONNECTION.
GSM ORBCOMM
ASSEMBLY
CHECK TO CONNECTER J OINED CHECK THE ANTENNA OF

TO LOCK S IDE. ORBCOMM IS NOT ATTACHED.
TRY COMMUNICATION TES T. J OINED TO LOCK S IDE FOR P OWER

S UP P LY CONNECTION.
TRY CONNECTION TES T.
GSM ORBCOMM
TEST
CHECK TO CONNECTER J OINED TO UNLOCK S IDE FOR

J OINED TO LOCK S IDE. NON-P OWER S UP P LY CONNECTION.
GSM ORBCOMM
SHIPMENT
DETAIL ee
9–53
CAB HARNESS : LQ14E01036P7
WHITE TAP ING
TAP ING TAP ING
WHITE TAP ING
SPLICE WHITE TAP ING

TAP ING
19A-19B-19C
SPLICE
WHITE TAP ING UN-CONNECTED

SH8
TAP ING 5B-5C-5D

SPLICE
TAP ING
62A-62B-62C
SPLICE
582C-582D 6A-6B-6C-6D
HARNESS SPLICE SPLICE
TAP ING
TAPING
TAP ING
E38-991 TAP ING TAP ING WHITE
SPLICE TAP ING
SH8-E17 770C-770D
SPLICE SPLICE
TAP ING
SUPPL Y WITH
CAB HARNESS (1/10) : LQ14E01036P7
9–54
60B-60C-60D
SPLICE
9
TAP ING
52A-52B
SPLICE
62D-62E-62C
SPLICE
51A-51B B AVS S 0.5f

SPLICE UN-CONNECTED
WHITE TAP ING
UN-CONNECTED
TAP ING SH2
INSULATION
TAP ING
WHITE TAP ING BLUE TAP ING
UN-CONNECTED
SH11
SPLICE RED TAP ING
TAP ING
YELLOW TAP ING
WHITE TAP ING
9–55
SUPPL Y WITH S UMITOMO 6440-0128 SUPPL Y WITH S UMITOMO 6409-0075
ENG. CONTROLLER CHECK

CONNECT OR
ENG. CONTROLLER ENG. CONTROLLER ENG. CONTROLLER

TO ROOM LIGHT
RESIST OR
TO FUS E & RELAY BOX
ENG. CONTROLLER ENG. CONTROLLER
RELEASE SW .(KPSS)
9–56
TO WIP ER INTERLOCK S W. FLASHER RELA Y

9P CONNECTOR
MECHATRO CONTROLLER MECHATRO CONTROLLER

(TCO-63-1A) (MAIN) (TCO-63-1A) (MAIN) MECHATRO CONTROLLER
(TCO-63-1A) (MAIN)
24V SOCKET
SWING P ARKING RELEASE S W.
TO FUEL S UP P LY P UMP
TO UP P HARNES S
MECHATRO CONTROLLER MECHATRO CONTROLLER

(TCO-63-1A) (MAIN) (TCO-63-1A) (MAIN)
24V SOCKET
9–57

DT04-3P-P006
CAN RESIST OR
DEUTSCH CONNECT OR
TO FLOOR HARNES S KEY SW. AIR CONDITIONER UNIT

DC-DC CONVER TER
(FOR CAMERA)
CAN RESIST OR 2
DT04-3P-P006
CAN RESIST OR
DEUTSCH CONNECT OR ACCEL POTENTIO.
RADIATOR COOLANT TO REAR CAMERA CABLE
LEVEL CONTROLLER
BOOM,DECK WORKING
LIGHT SW.
TUNER AM&FM
CAN RESIST OR 1
ACCEL REDUNDANT VOLUME
9–58
SUPPL Y WITH 6910-0120

TO UP P HARNES S
TRAVEL ALARM S W. SWING SPEED SENSOR

CLUSTER GAUGE
TO S P EAKER
TO UP P HARNES S
TO IT HARNES S
TO UP P HARNES S
CLUSTER GAUGE
TO DC-DC CONVERTER
TO UP P HARNES S
TO UP P HARNES S
TO ROTARY LIGHT
TO FLOOR HARNES S WIPER MOT OR
9–59
TO KEY S W. EARTH
FUEL DISCRIMINANT
TO FUS E & RELAY BOX TO FUS E & RELAY BOX TO FUS E & RELAY BOX
TO UP P HARNES S
IT P OWER DIS CONNECT

TO CAB WORKING LIGHT

TO UP P HARNES S

IT P OWER DIS CONNECT

9–60
TO CAB WORKING TO CAB EARTH TO CAB EARTH

LIGHT FR ONT TO CAB WORKING LIGHT
TO CAB EARTH
TO CAB WORKING
TO CAB WORKING LIGHT FR ONT
LIGHT FR ONT
TO CAB EARTH

TO CAB WORKING
LIGHT FR ONT
9–61
9–62
9–63
KEY SWITCH EAR TH : LQ14E01037P1
9–64
9.4.11 CAB HARNESS ASSY (BOOM

CYLINDER LIGHT)
CAB HARNESS ASSY(BOOM CYLINDER LIGHT) YN11E00136F1 (02) 9
CONNECT WITH BOOM CYLINDER
1 HARNESS YN11E01282P2 1 LIGHT HARNES S
UPP HARNESS
2 HARNESS YN11E01283P1 1
3 RELAY EN24S00008P1 1 BOOM CYLINDER
LIGHT HARNES S
CLIP
FIX TO UP P HARNES S
2
SET THE WHITE TAP ING PART TO CLIP

THE WHITE TAP ING PART OF CAB HARNES S FIX TO UP P HARNES S
AND FIX TO CAB HARNES S BY A CLIP.
CLIP
E-45:
BOO M CYLINDER WORK LIGHT RELAY
CAB HARNESS
II
III
3
IV SEMS-BOL T
E-4 5:
BOOM CYLINDER
WORK LIGHT RELAY
TIGHTENING TORQUE
9.7N.m(7.15 lbf.ft)
CLIP CLIP
FIX TO CAB HARNES S SET THE WHITE TAP ING PART TO
THE WHITE TAP ING PART OF CAB HARNES S
AND FIX TO CAB HARNES S BY A CLIP.
VIEW II
VIEW I
9–65
SET THE WHITE TAP ING PART TO

THE WHITE TAP ING PART OF CAB HARNES S
FIX TO CAB HARNES S AND FIX TO CAB HARNES S BY A CLIP.
CLIP CLIP
FIX TO CAB HARNES S
CLIP
CONNECT WITH CAB WORK LIGHT SW.
SET THE WHITE TAP ING PART OF ITEM 1 HARNES S

ITEM 1 HARNESS TO CLIP P OTIS ION OF CAB HARNES S
AND FIX CAB HARNES S AND FLOOR HARNES S BY A CLIP
CLIP
CONNECT TO CONNECTOR TAG OF
"CAB LIGHT" WITH CONNECTOR OF
FLOOR HARNESS
FLOOR HARNESS
FLOOR HARNESS
ITEM 1 HARNESS UP S IDE
PILOT HOSE
CLIP
FOR RIG HT CONS OLE OF ITEM 1 HARNES S
THREAD UNDER THE FLOOR HARNES S FOR V ITEM 1 HARNES S
LEFT CO NS OLE.
A FIX TO CAB HARNES S

A
FIX TO THE P ILOT HOS E CLIP
FLOOR HARNESS FLOOR HARNESS

CLIP
FIX TO FLOOR HARNES S CONNECT TO CONNECTOR WITH TAG OF "BCYL" FOR
CLIP ITEM 1 HARNES S AND ITEM 2 HARNES S
FLOOR HARNESS SET THE WHITE TAP ING PART TO
THE WHITE TAP ING PART OF FLOOR HARNES S
AND FIX TO FLOOR HARNES S BY A CLIP
CAB HARNESS
CLIP
ITEM 1 HARNESS
ITEM 2 HARNES S
SET THE WHITE TAP ING PART TO
THE WHITE TAP ING PART OF FLOOR HARNES S
AND FIX TO FLOOR HARNES S BY A CLIP VIEW III
UPP HARNESS CLIP

VIEW IV
CONNECT CONN ECTOR WHTH
TAG OF "CN8" FOR ITEM 2 HARNES S
FLOOR HARNESS
CAB HARNESS
ITEM 1 HARNESS]
THROUGH TOO HOLE OF GROMMET.
VIEW V
SECTION AA
9–66
9
SUPPL Y
WITH
RESER VE CONNECT OR
BOOM CYLINDER WORK

LIGHT RELAY
TAP ING
CAB WORKING LIGHT SW.
TO BOOM CYLINDER WORK

LIGHT(UPP SIDE) HARNESS
WHITE TAP ING
TAP ING
WHITE TAP ING
WHITE TAP ING
TO FLOOR HARNES S
9–67
TO BOOM CYLINDER WORK

LIGHT(CAB SIDE) HARNESS
BOOM CYLINDER WORK LIGHT
WHITE TAP ING

BOOM CYLINDER WORK LIGHT
9–68
9.4.12 IT KIT HARNESS ASSY

1. IT KIT HARNESS ASSY (CONTROLLER ) YN11E00138F1 (01)

GPS ANTENNA
ORBCOMM ANTENNA 9
1-1 CONTROLLER YN22E00664F1 1
P OWER S OURCE CABLE
TO CONNECTED
1-3 HARNESS YN11E01292P1 1 2-3 2-3 CAB HARNES S .
CLIP
2. IT KIT HARNESS ASSY (CONNECTOR ASSY) LQ11E00076F1 (03) HARNES S IS CLAMP ED US ING
THE HOLES OF CONTROLLER.
2-3 CONNECT OR ASSY LQ11E01092F1 1 (02)
2-3-1 CABLE YN11E01224P1

2-3-5 ANTENNA YN54S00064P1
CLIP
TO ATTACH BUNDLED ORBCOMM AND
GP S ANTENNA WIRES .
TIGHTENING TORQUE
5.0 N.m(3.69 lbf .ft) ORBCOMM & GPS ANTENNA WIRE IS
SEMS-BOL T CLAMPED WITH CAB HARNESS. DETAIL bb
bb 1-1 CLIP
ANTENNA
aa ORBCOMM ANTENNA
DETAIL aa
THE ST ATE AT THE TIME OF
DELIVERY OF CAB
VIEW I
IT KIT HARNESS ASSY (1/3)
9–69
9–70
9–71
IT KIT HARNES S FOR S ATELLITE COMMUNICATION : YN11E01292P 1
9–72
9.4.13 BOOM HARNESS ASSY

BOOM HARNESS ASSY BOOM HARNESS : YN15E01088P1
YN15E00066F1 (02)
ITEM PART NAME PARTS No. Q'TY REMARKS 9

1 HARNESS YN15E01088P1 1 BOOM HARNESS
9–73
9.4.14 BOOM HARNESS ASSY

(BOOM CYLINDER LIGHT)
BOOM HARNESS ASSY BOOM HRNESS : YN15E01018D1
YN15E00067F1
(BOOM CYLINDER LIGHT) (02)
1600 (5’3”)
1 HARNESS YN15E01018D1 1 1 LIGHT CA 104 CB 104
CONNECT TO CONNECT TO UP P
LIGHT HARNES S
CB 104 CA 104
aa
CLIP
CLIP CONENECT WIHT BOOM CYLINDER

LIGHT HARNES S (UP P S IDE)
I
VIEW I
FIX A ITEM 1 HARNES S PART

OF COULGATED UNDER THE
BRACKET FOR LIGHT FIXATION
WITH A CLIP. CLIP
II
CONNECT TO LIGHT
DETAIL aa VIEW II
9–74
9.4.15 BOOM LIGHT INSTALLATION

BOOM LIGHT INSTALLATION YN80E00011F2 (06)
ITEM PART NAME PARTS No. Q'TY REMARKS 9

6 LIGHT YN80S00012F1 1
TO CENTER OF BUCKET
BRACKET
LOCK WASHER
REMOVE LOCK W ASHER ATTACHED TO LIGHT
CAPSCREW
LOCK WASHER
TIGHTENING TORQUE: 46.1N.m(34.0 lbf .ft)
SECTION AA
9–75
9.4.16 BOOM CYLINDER LIGHT

INSTALLATION
BOOM CYLINDER LIGHT INSTALLATION YN80E00081F1 (01)
ITEM PART NAME PARTS No. Q'TY REMARKS

1 LIGHT YT80S00002F2 1 1 LIGHT
TIGHTENING TORQUE
31.5N .m(23.2 lbf .ft)
APP LY LOCTITE #242.
CAPSCREW
A BAND LOCK WASHER
BAND
CAPSCREW
LOCK WASHER
TIGHTENING TORQUE
31.5N .m(23.2 lbf .ft)
APP LY LOCTITE #242.
1 TIGHTENING TORQUE(M12)
18.6N .m(13.7 lbf .ft)
BOOM CYL.L.H. SECTION AA
BOOM CYL.R.H.
9–76
9.4.17 UPPER LIGHT INSTALLATION

UPP LIGHT INSTALLATION LQ80E00014F1 (02)
ITEM PART NAME PART No. Q'TY REMARKS 9

1 LIGHT YT80S00002F2 1
A
1
NUT
(SUPPLIED WITH LIGHT )
GROMMET
BRACKET
VIEW I
SEMS-BOLT
LIGHT HARNESS TIGHTENING TORQUE
46.1N .m(34.0lbf .ft)
SECTION AA
NOTE
1. TIGHTENING TORQUE OF ITEM 1 TO BE 18.6 N.m (13.7lbf .ft)
9–77
9.4.18 CAB 1 LIGHT INSTALLATION
CAB 1 LIGHT INSTALLATION LQ80E00035F1 (01)

1 CAB LIGHT INSTALLATION LQ80E00033F1 - (02)
1-1 LIGHT YT80S00002F2 1

1-2 HARNESS LQ80E01019P2 1
CAB 1 LIGHT INSTALLATION : LQ80E00033F1
CAB 1 LIGHT INSTALLATION (1/3) : LQ80E00033F1
9–78
9–79
CAB 1 LIGHT HARNESS : LQ80E01019P2
170 (6.69”)
70 (2.76”)
9–80
［10. COMPONENTS SYSTEM］
10. COMPONENTS SYSTEM

10.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL.............................................................10-3
10.2 HYDRAULIC COMPONENTS ................................................................................................10-4
10
10.2.1 HYDRAULIC PUMP - REGULATOR....................................................................................10-4
10.2.2 CONTROL VALVE............................................................................................................ 10-17
10.2.3 OPERATION OF CONTROL VALVE .................................................................................. 10-37
10.2.4 PILOT VALVE (ATT) ......................................................................................................... 10-57
10.2.5 PILOT VALVE (TRAVEL) .................................................................................................. 10-61
10.2.6 SWING MOTOR UNIT ...................................................................................................... 10-64
10.2.7 OPERATION OF SWING MOTOR UNIT ............................................................................ 10-70
10.2.8 TRAVEL MOTOR UNIT..................................................................................................... 10-76
10.2.9 TRAVEL MOTOR UNIT OPERATION ................................................................................ 10-82
10.2.10 SWIVEL JOINT .............................................................................................................. 10-95
10.2.11 CONTROL VALVE (N&B)................................................................................................ 10-97
10.2.12 PILOT VALVE (N&B) .................................................................................................... 10-100
10.2.13 CYLINDER................................................................................................................... 10-104
10.2.14 CONSTRUCTION OF CYLINDER ................................................................................. 10-105
10.3 ELECTRICAL EQUIPMENT .............................................................................................. 10-109
10.3.1 ELECTRICAL EQUIPMENT LIST.................................................................................... 10-109
10.3.2 SPECIFICATIONS ELECTRICAL EQUIPMENT ............................................................... 10-113
10-1
10-2

10
10-3
10.2 HYDRAULIC COMPONENTS

10.2.1 HYDRAULIC PUMP - REGULATOR
10.2.1.1 SUMMARY
Outside view and Hydraulic port

Unit88 mm (ft-in)
2X4-M12
(Dr) Depth 22 (0.87")
a1 B1 a2
a4
a5 A1 A2
(Dr) Psv
VIEW
MAX. FLOW RATE MIN. FLOW RATE
ADJUSTING SCREW ADJUSTING SCREW
2 2-1 EYE BOLT (M10) 2-1
2
a4 a5
Psv
3 Psv
(Dr)
B3 B3
B1
A3
a1 a2
(Dr) a3 a3
P H1 P H2 P H2
A1 A2
Hydraulic ports
No. Parts Q'TY No. Ports name Size
1 Main pump assy 1 A1,A2 Delivery port SAE 6000psi 1"
2 Regulator assy 2 B1 Suction port SAE 2500psi 2 1/2 "
2-1 Solenoid proportional reducing valve 2 Dr Drain port PF3/4-20
3 Gear pump assy (for pilot) 1 Psv Servo assist port PF3/8-17
PH1,2 pressure sensor port PF3/8-17
a1,a2 gauge port PF1/4-15
a3 gauge port PF1/4-14
a4,a5 gauge port PF1/4-15
A3 Delivery port of gear pump PF1/2-19
B3 Suction port of gear pump PF3/4-20.5
10-4
Hydraulic circuit diagram
(FRONT) (REAR)
(KDRDE5K) (KR7G-0E1K-V) a 1 A1 P H1 P s v P H2 A2 a 2 (KR7G-0E1K-V) (KDRDE5K) Solenoid
Solenoid
proportional proportional
reducing reducing
valve (PSV -P1) valve (PSV -P2)
a4 a5
Regulator
10
Regulator
Gear pump for pilot
Main pump
Dr A3
B1 B3 a3
Hydraulic circuit diagram of pump
Specifications
Item Main pump Gear pump
Pump assy YN10V00070F1 —

Parts No.
Single pump YN10V00072F1 LQ10V00036F1
Pump model K7V125DTP1K9R-0E1K-V ZX10LARZ1-07G
Max. displacement
cm3 (cu·in) 110(6.71) X 2 10 (0.61)
capacity
Revolu- min-1
Rated 2000 ←
tion (Clockwaise seen from shaft end)
Rated 34.3 (4980)

Pres-
ATT boost MPa (psi) 5.0 (725)
sure 37.8 (5480)
pressure
Max.flow L/min (gal/min) 220 (58) X 2 20 (5.3)
Max.input horse power kW (ps) 114 (115) 3.1 (4.2)
Max.input torque N·m (lbf·ft) 544 (401) 14.7 (10.8)
Part No. YN10V01011F1

Model KR7G-0E1K-V
Regulator Control function Electric flow control,positive flow control
With solenoid proportional reducing valve

Others
(KDRDE5K-31/30C50-143)
Weight kg (lb) 141 (311)
10-5
10.2.1.2 HYDRAULIC PUMP
Main pump
953 806 537 789 732 532 532 548 531 214 808 901 954 792 702 534 717 981 983 151 152
211
490
251
C C
886
B B 04
127
111
A A
774
261 113
710 272
123 824 271 212 153 466 156 157 468 313 124 711 116 312 724 885 314 401 141
406 723 726
414
326
Tighte ning torque
Item Tighte ning torque
number Thread size
N.m (lbf.ft)
401 M20 430 (317)
406 M8 29 (21) (537) 953 806 419
414 M10 57 (42)
419 M16 240 (177) 544 724
466 PF 1/4 36 (27)
468 PF 3/4 170 (125) 723
545
490 M7X0.75 18 (13)
806 M16 130 (96)
808 M20 240 (177) 541
VIEW C SECTION B-B SECTION A-A
No. Parts Q'ty No. Parts Q'ty No. Parts Q'ty
111 Drive shaft (F) 1 314 Va lve pla te & L) 1 717 O-ring 2
113 Drive shaft (R) 1 326 Cover 1 723 O-ring 14
116 Gear #1 1 401 Socket bolt;M20X210 4 724 O-ring 10
123 Roller bearing 2 406 Socket bolt;M8X16 4 726 O-ring 4
124 Needle bearing 2 414 Socket bolt;M10X20 4 732 O-ring 2
127 Bearing spacer 4 419 Socket bolt;M16X35 4 774 Oil seal 1
141 Cylinder block 2 466 ROH plug PF1/4 2 789 Back-up ring P18 2
151 Piston 18 468 ROH plug PF3/4 4 792 Back-up ring G35 2
152 Shoe 18 490 Plug;M7X0.75 18 806 Nut ; M16 2
153 Set plate 2 531 Tilting pin 2 808 Nut ; M20 2
156 Spherlcal bush 2 532 Servo piston 2 824 Stop ring 2
157 Cylinder spring 18 534 Stopper (L) 2 885 Pin 4
211 Shoe plate 2 535 Stopper (S) 2 886 Pin 2
212 Swash plate 2 537 Servo cover 2 901 Eye bolt ; M10 2
214 Tilting bus h 2 541 Seat 4 953 Socket screw 2
251 Swash plate support 2 544 Stopper 1 4 954 Set screw ; M20 2
261 Seal cover (F) 1 545 Steel ball 4 981 Name plate 1
271 Pump casing (F) 1 548 Feed back pin 2 983 Pin 2
272 Pump casing (R) 1 702 O-ring 2 04 Gear pump 1
312 Va lve block B 1 710 O-ring 1
313 Va lve pla te & R) 1 711 O-ring 1
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
10-6
Gear pump (For pilot)
Suction port : PF 3/4 887

Tightening torque : 433
710 700 354 351 74N .m (54.6 lbf .ft)
Z
X
10
B3
434
X
311 A3
X
312
a3 850
732 355
Z
435 361 353 307 310 308 309 434 466
SECTION ZZ 725
Delivery port : PF1/2
Tightening torque : 53N .m (39.1 lbf .ft)
№ Name Q'ty № Name Q'ty
307 Poppet 1 433 Flange socket ; M8 X 35 2
308 Seat 1 434 Flange socket ; M8 X 50 2
309 Ring 1 435 Flange socket ; M8 X 20 4
310 Spring 1 466 VP Plug ; PF1/4 1
311 Ajusting screw 1 700 Ring 1
312 Lock nut ; M14 X 1.5 1 710 O-ring ; 1B G105 1
351 Gear case 1 725 O-ring ; 1B P11 1
353 Drive gesr 1 732 O-ring ; 1B P16 1
354 Driven gear 1 850 Locking ring 1

355 Filter 1 887 Pin ; dia. 5 X L9 2
361 Front case 1
10-7
10.2.1.3 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
REGULATOR
different axis. Thus the engine rotation is transmitted to
front shaft (111) that drives the two pumps and, at the
same time, drives the auxiliary pump (OPT) arranged on
another shaft.
116
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 111
block group that selects between oil suction and delivery
and the PTO group (OPT) that transmits the drive power
to the auxiliary pump.
Rotary group
The rotary group consists of shaft(111), cylinder block PTO GEAR CASE
(OPT)
(141), piston (151), shoe (152), plate (153), spherical
AUXILIARY PUMP
bushing (156), and cylinder spring (157). The shaft is (OPT)
supported by bearings (123) and (124) at its both ends.
The shoe, which is caulked to the piston, forms a
Construction of hydraulic pump
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 (313) by the action of cylinder spring (157).
3 1 3
1 2 4
3 1 2
1 1 1
1 1 6
1 2 4
3 1 4
1 4 1
1 5 7
1 5 6
1 5. 1 1 5 3
1 5 2
2 1 1
Rotary group
10-8
Swash plate group 532

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). 214
The swash plate is the cylindrical part that is formed on 211
531
the opposite side of the shoe sliding surface and is
212
supported by the swash plate support. The hydraulic
312
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 10
plate support via the spherical part of the tilting pin and 251
changes the tilting angle (α).
272
Swash plate group
Valve block group

The valve block group consists of valve block (312),
313
valve plates (313 or 314), and valve plate pin (885).
312
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
116
valve plate is connected with the external pipe by way of 111
the valve block. 314
141
885
Valve block group
PTO group (OPT.) 117

The PTO group is composed of 1st gear (116), 2nd gear
126
(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
118
an eye on a single piston, it makes a motion away from
the valve plate (oil suction process) in the first 180 deg. 125
and a motion toward the valve plate (oil delivery process)
in the remaining 180 deg. If the swash plate is not
inclined (zero tilting angle), the piston does not stroke i.e. 125
delivers no oil. 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
PTO group (OPT.)
is linked to the 3rd gear.
10-9
10.2.1.4 STRUCTURE OF REGULATOR

B
898 643 642 644 646 418 079 728 645
A
728
a
641
924
755 801
758 656
708 402
A
887
468 658
467 728 601 497

729
412
726 755
VIEW B
614 466
Tighte ning torque
414 874 Tighte ning torque

Item No. Thread size
N.m (lbf.ft)
402 M6 12 (9)
876 412,414 M8 29 (21)
415 M5 6.9 (5.1)
611 466 PF 1/4 36 (27)
467,641 PF 1/2 110 (81)
468 PF 1/8 17 (12.5)
SECTION A-A 497 M7X0.75 18 (13.3)
614 PF 3/8 74 (55)
658 M6 6.9 (5.1)
10-10
№ Name Q'ty № Name Q'ty
402 Socket bolt ; M6 X 16 3 646 Pilot spring 1
412 Socket bolt ; M8 X 40 5 656 Cover 1

414 Socket bolt ; M8 X 25 1 658 Restrictor ; M6X dia. 0.9 1
418 Socket bolt ; M5 X 12 2 708 O-ring 1
466 ROH plug ; PF1/4 2 726 O-ring 1
467 ROH plug ; PF1/2 1 728 O-ring 3
468 ROH plug ; PF1/8 1 729 O-ring 1 10

497 MH plug ; M7 X 0.75 9 755 O-ring 3
601 Regulator casing 1 758 Square-ring 10
611 Feedback lever 1 801 Nut ; M10 1

614 Adjust plug 1 874 Pivot Pin 1
641 Pilot plug 1 876 Pin 1
642 Pilot spool 1 887 Pin 1
643 Pilot sleeve 1 *924 Socket screw ; M10 X 20 1

644 Spring seat (Q) 1 79 Solenoid proportional reducing valve 1
645 Adjust stem (Q) 1
The item having the number marked with * is an adjusting screw. Do not touch the adjusting screw as much as
possible.
10-11
10.2.1.5 OPERATION OF REGULATOR
Control function
Control function :
• Positive flow control
Summary
Regulator KR7G-0E2K-V for the swash plate type axial piston pump K7V series consists of the following control
mechanisms.
• Control of current flow rate, Positive flow control
The pump swash plate angle (delivery flow rate) is controlled in accordance with a controlled command current
value of the proportional pressure reducing solenoid valve equipped with this regulator. This regulator is
operated by a positive control, which increases a delivery flow rate as command current value I increases. With
this mechanism, when a current is input in accordance with the working status, the pump delivers only a required
flow rate and do not use an extra power.
Operation
• Control of current flow rate
The delivery flow rate of the pump is controlled in
accordance with command current value I as shown
De live ry flow ra te Q
in the right figure.
• Operation to increase current flow rate
When command current value I increases, the second
pressure of the proportional pressure reducing
solenoid valve increases and spool (642) moves
through pilot piston (898) and stops at the position
where the hydraulic pressure to the right direction and
the power of pilot spring (646) balance each other. Command current I
If spool (642) moves, pilot sleeve/spool pressure
adjusting part (C1) opens and the pressure at the large-diameter part of servo piston (532) is released. Then,
servo piston (532) moves right due to delivery pressure P1 of the small-diameter part to increase the swash
plate angle.
Feedback lever (611) is linked with the servo piston and sleeve (643) and if the servo piston moves right, the
feedback lever rotates around the supporting point and the sleeve moves right. Opening part (C1) of the spool
and the sleeve starts to close gradually and at its fully-closed position, the servo piston stops and stabilizes.
• Operation to decrease current flow rate
If command current value I decreases, the secondary pressure of the proportional pressure reducing solenoid
valve decreases and spool (642) moves left.
After the spool moves, pilot sleeve/spool pressure adjusting part (C2) opens and delivery pressure P1 is led to
the large-diameter chamber of the servo piston. Delivery pressure P1 is always led to the small-diameter
chamber of the servo piston and the servo piston moves left due to the difference of the areas to decrease the
swash plate angle. If the servo piston moves left, the feedback lever rotates around the supporting point and the
sleeve moves left. It moves until the opening part of the spool and the sleeve closes and it stops at the closed
position.
10-12
643 642 646 Fulcrum 876 079 645
898 Pd1
P2
532
C1 C2 10
924
Pd1 Pcl
030
801
Pcl
656
954
953
Left Right 808
806 (Flew reducing) (Flew reducing)

KR7G-0E2K-V
(KDRDE5K) b A Psv
Explanation figure of regulator operation
10-13
10.2.1.6 Adjustment of maximum and minimum flows

The regulator may be adjusted in terms of maximum flow, minimum flow, horsepower (at emergency mode control)
control characteristics, flow control characteristics using the adjust screw.
Adjustment of maximum flow (main pump)

Adjust the maximum flow by loosening nut (808) and by
tightening set screw (954) (or loosening it). Tightening
set screw (954) decreases the delivery rate, as indicated
Delivery flow rate Q

in right Fig..
Only the maximum flow varies, but other control
characteristics remain unchanged.
Input current I (Pilot pressure Pi)
Adjusting the max. delivery flow
Adjust screw no. 954

No. of turns for tightening 1/4
Pilot pressure Pi (Input current I) No change
Max. increase in delivery flow

5.7 (1.5)
L/min (gal/min)
Adjustment of minimum flow (main pump)

Adjust the minimum flow by loosening nut (806) and by
tightening socket screw (953) (or loosening it).
Tightening socket screw increases the delivery rate, as
indicated in right Fig..

Other control characteristics remain unchanged in the
same way as maximum flow adjustment, care should be
used of the fact that overtightening may increase a
required power at the maximum delivery pressure (at
relieving action).
Adjusting the min. delivery flow

Pilot pressure Pi (Input current I) No change
Min. increase in delivery flow

4.1 (1.1)
L/min (gal/min)
10-14
Adjusting the flow control characteristics

Adjust them by loosening nut (801) and socket bolt (924)
(or loosening it). Socket bolt causes the control chart to
move to the right as shown in right Fig..

10
Adjusting the flow control characteristics

Increase pilot pressure Mpa (psi) 0.11 (16)
Decrease in delivery flow L/min (gal/min) 15.3 (4.0)
10.2.1.7 CAUSES OF FAULT RESULTING FROM REGULATOR

When trouble due to this regulator occurs, disassemble and inspect it referring to "Chapter YN33-II"
When the engine is overloaded,

Load every unit of pump, and check on pumps on the right and left sides for possible damages. When pumps on
both sides are failed, check on them for the following failures 1), 2). When pump on the one side is failed, start
checking from para. 3).
1. Check that the power shift command current I is normal
2. The power shift pressure is low.
• Check the dither of amp.
• Replace solenoid proportional reducing valve.
3. Pilot plug (641) and pilot piston (898) stick
• Disassemble and wash them
4. Pilot sleeve (643) and spool (642) stick
Maximum flow rate cannot be delivered

1. Check that the secondary pressure of the proportional pressure reducing solenoid valve is normal or not.
2. Pilot plug (641) and pilot piston (898) stick
3. Pilot sleeve (643) and spool (642) stick
When deep scratches are found on the parts, replace them.
10-15
10.2.1.8 CHARACTERISTIC CURVE
Pump characteristic curve
300
(79)
250
(66)
Q d (Up side)
699mA 220 L/min (58 ga l/min)
737mA
200 3.92
Flow ra te Q d [L/min (ga l/min)]
(53) (568)
3.43
(497)
150 2.94
S e conda ry pre s s ure P 2 [MP a (ps i)]

(40) (426)
2.76 MPa (400 ps i)
700 mA 2.45
P2 (355)
100 1.96
(26) (284)
1.47
(213)
0.92 MPa (133 ps i)
400mA
50 0.98
(13) (142)
15 L/min (4ga l/min) 0.49

400 mA (71)
0 0
200 300 400 500 600 700 800
Input electric current (mA)
10-16
10.2.2 CONTROL VALVE

10.2.2.1 SPECIFICATIONS OF CONTROL VALVE
OUTSIDE VIEW
P Tb
PBL
P2
CT2
10
CP 2
Pc
(P6 ) (P5 )
Dr2
P1
P Cb PAL
(P6 ) (P6 ) (P5 )
P Tb CT1 T2 T1
CT2
Travel Dr1 P1 P Cb PAL
P AL
Travel left
PCb P BL
straight CMR1 CMR2
PL unload CP 2 BL
MR AL
Ar
P Ca
Travel PAr PB1 Boom
PBr right PAr PB1
Br
CP L Ab
AbR conflux LCb2 P2 unload
PAb XAb Prb
Bb PBb Pra Boom 2 CAb
Pc PBb Pra
Dr2 CRbL
Boom CRb2 CRa CBb Boom 3
P Lc1
PAc Bucket PBs
Ac Bc BcR PBs Swing As Bs P Aa
LCc LCs
PBc P Cc P Cc P Aa 1
Arm 2 CBa PBa 1 P Lc2 CRa
PBa 2 Arm 1 Aa
PAa 2 PBa 2 PBa 1
Ta LCAP 2 LCAT2 MU Ba LCa
MU Ba R
PBa 2 PBa 1
Arm 2 PAa 2 PAa 1 Arm 1

CTa Aa R
AcR
Bucket PAc
PAs Swing
Dr2 BbR
Boom PAb
Boom 3
Pc Prb
Travel right PBr P2 unload

P Ca (T3)
Travel PBL Travel left

P Tb
straight
PAa 1
PAa 2
(P6 ) (P5 )
VIEW A
A
Outside view
10-17
PORTS
Tightening
Port size Ports Description
torque
PF3/4 150 to 180N·m MU

(111 to 133 lbf·ft) (T3)
(P5)
(P6)
PF3/8 69 to 78N·m PAa1 Arm 1 (in) pilot port

(51 to 58 lbf·ft) PBa1 Arm 1 (out) pilot port
PAb Boom (up) pilot port
PBb Boom (down) pilot port
PAc Bucket (digging) pilot port
PBc Bucket (dump) pilot port
PBL Travel left (reverse) pilot port
PBr Travel right (reverse) pilot port
PAs Swing (right) pilot port
PBs Swing (left) pilot port
PAa2 Arm 2 (in) pilot port
PBa2 Arm 2 (out) pilot port
PB1 Boom (up) conflux pilot port
DR1 Drain port
PF1/4 34 to 39N·m PLc1 Lock valve select pilot port

(25 to 29 lbf·ft) PLc2 Lock valve select pilot port
PAL Travel left (forward) pilot port
PAr Travel right (forward) pilot port
PL Attachment boost port
Dr2 Drain port
Pc Pilot port for logic control valve
Pra Boom 2 pilot port
Prb Boom 3 pilot port
PTb Travel straight pilot port
PCa Unload valve (P2 side) pilot port
PCb Unload valve (P1 side) pilot port
PCc Bucket (digging) stroke limiter pilot port
M12 83 to 110N·m P1 Pump port (P1 side)

(61 to 81 lbf·ft) P2 Pump port (P2 side)
T1 Tank port 1
T2 Tank port 2
Ta Tank port only for arm out
M10 49 to 65N·m Ar Right travel motor port (forward)

(36 to 48 lbf·ft) Br Right travel motor port (reverse)
AL Left travel motor port (forward)
BL Left travel motor port (reverse)
As Swing motor port (right)
Bs Swing motor port (left)
Ab Boom cylinder head side port (up)
Bb Boom cylinder rod side port (down)
Aa Arm cylinder head side port (in)
Ba Arm cylinder rod side port (out)
Ac Bucket cylinder head side port (digging)
Bc Bucket cylinder rod side port (dump)
The operation enclosed by ( ) is normally blocked.
10-18
SPECIFICATIONS
Item Specifications
Model KMX15YF/B44004
Maximum flow rate [L/min (gal/min)] 220 (58) X 2
Maximum set pressure [MPa (psi)] 37.8 (5480) (P port)/39.7 (5760) (A,B port)
Main relief valve set pressure [MPa (psi)] When power boost Std 34.3 (4970) [at 70 X 2 L/min (18.5 X 2 gal/min)]
pressure High 37.8 (5480) [at 60 X 2 L/min (15.9 X 2 gal/min)]
Overload relief valve set pressure

(Boom head, Bucket head, Arm rod) [MPa (psi)]
39.7 (5760) [at 30 L/min (8 gal/min)] 10
Overload relief valve set pressure
37.8 (5480) [at 30 L/min (8 gal/min)]
(Boom rod, Bucket rod, Arm head) [MPa (psi)]
10-19
10.2.2.2 CONTROL VALVE CONSTRUCTION
Control Valve
J
J
154 164 101
P2
T2
PAL P BL
J
P B1 P Ca
Pra Prb
P Bs PAs
PBa 1 PAa 1
162 162 162

SECTION A-A
154 164
P1 102
974
973
P Tb P Cb
974
973
P Br PAr
973
PAb P Bb
973 973
PAc
973 P Cc
P Bc
PAa 2 PBa 2
973 973
162 162 162
SECTION B-B
Section (1/6)
10-20
T2
H 273x1 0 H
P1 unload P Cb PAL Travel left
C 273x10 C
PAr P B1 977 10
Travel right Boom conflux
D D
978x2
Boom P Bb Pra
Boom 2
E
E
P Bs
Bucket Swing
F F
P Cc
PBa 2 PBa 1
Arm 2
Arm 1
G G
MU
K K
B A
PBa 2 PBa1
274x 4 274x4
Dr2
Pc
213 213
PAa 1
PAa 2
Section (2/6)
10-21
202 P 1 unload Travel left 202

333 PCb PAL 333
331 331
336 336
329 324
327 323
331 331
261 MR 261
309
601
PL 306
AL 163
511
512
521
522 CP2
CMR2 551
552 164
562
CMR1 162
BL
552
522 163
Dr1
512
307
261
331 PBL 264
327 205
329
336
331 SECTION C-C
333
202 PTb
Travel straight

202 201
333 PAr PB1 333
331 331
336 339
324 326
323 325
331 331
261 261
306
305
161
Ar
511 511
521 521
CP1 LCb2
551
551
164 164
163 Br
310
161
(T3)
164
264 154
PBr
261
205 331
327
SECTION D-D
329
336
PCa 331
P 2 unload 333
202
Section (3/6)
10-22
203 202
333 Boom Boom 2 333
331 331
336 P Bb Pra 336
319 322
321 320
603 331
AbR 261
L 331 L 212
163
211 M N N
M 261 161
266 159
159 PLc1 312
514 CAb
551
524
CRb1
521
164
10
556 CRb2 511
164
556
Dr2 164
529
Pc 513
CRe 164
208 551
520 521
Bb 516
162
163
CBb 313
551
301 164
264 521
162 511
PAb
161 261
602 BbR 331
SECTION E-E 320
205 322
336
Prb 331
Boom 3 333
202
164 551 Backet
209
216 P Cc Swing 201
333 333
PBs
331 331
336 P Bc
336
322 322
321 321
602 BcR
331 331
261
261
304
Bc
162 As
511 511
521 523
LCc
LCs
551
556
164
164
163 Ac
Bs
162
162
162
264 303
PAc
264
603 PAs
205 SECTION F-F 205
AcR
Section (4/6)
10-23
201
201 333
333 Arm 2 Arm 1 331
331 PBa2 PBa1 336
340 322
328 321
321
BaR 603
331
331
550 211
261 562
525 L L
CBa 261
519 159
MU
308
PLc2 514
162
162 524
CRa
162 556
511
164
521
551 LCAT2 511
164 521
515 LCa
521 551
LCAP2
551 164
164 302
162
162 Ta Aa
163
162
510
526 CTa 604
167 264
557 PAa1
P P
264 205
210 PAa2 AaR
SECTION G-G
T2
161
P1
T1
163
CT1
551
163
164
162
P2
CT2
551
164
SECTION H-H
Section (5/6)
10-24
207
606 606 563
160
278x 5 564
266
264 264
527 528 SECTION P-P

T2 T1
517
518
10
SECTION N-N SECTION L-L
SECTION J -J SECTION K-K
Section (6/6)
Tightening Tightening
torque No. Name Q'ty torque No. Name Q'ty
N·m (lbf·ft) N·m (lbf·ft)
101 Casing A 1 326 Spring 1
102 Casing B 1 327 Spring 3

220 to 250
154 Plug ; PF3/4 3 328 Spring 1
(162 to 184)
16 to 20
159 Plug ; M7X0.75 4 329 Spring 3
(12 to 15)
7.8 to 9.8
160 Plug ; R-1/16MEC 1 331 Spring seat 26
(5.8 to 7.2)
16 to 18
161 O-ring 5 (12 to 13) 333 Spacer bolt 13
Loctite #262
162 O-ring 21 336 Stopper 11
167 O-ring 1 510 Poppet 1
201 Cover 4 511 Poppet 9

Back pressure check valve
207 1 515 Poppet 1
cover
25 to 34
208 Logic control valve 1 516 Poppet 1
(18 to 25)

9.8 to 14
211 Lock valve selector sub 2 519 Poppet 1
(7.2 to 10.3)
10-25
9.8 to 14
212 Lock valve selector sub 1 520 Sub logic valve 1
(7.2 to 10.3)
213 Plate 2 521 Spring 10
216 Piston 1 522 Spring 2
261 O-ring 13 523 Spring 1
264 Square ring 9 524 Spring 2
266 Square ring 2 525 Spring 1

25 to 34
273 Socket bolt 40 526 Spring 1
(18 to 25)
98 to 120
(72 to 89)
25 to 34
(18 to 25)
301 Boom spool sub 1 529 Spring 1

130 to 150
302 Arm 1 spool 1 550 Plug 1
(96 to 111)
230 to 260
303 Swing spool 1 551 Plug 13
(170 to 192)
130 to 150
304 Bucket spool 1 552 Plug 2
(96 to 111)
230 to 260
305 Boom conflux spool 1 556 Plug 4
(170 to 192)
49 to 59
306 Travel spool 2 557 Plug 1
(36 to 44)
307 Travel straight spool 1 562 O-ring 3

13 to 17
308 Arm 2 spool sub 1 563 Plug 1
(9.6 to 12.5)
309 P1 unload spool 1 564 O-ring 1

69 to 78
310 P2 unload spool 1 601 Main relief valve 1
(51 to 58)
69 to 78
312 Boom 2 spool sub 1 602 Port relief valve 2
(51 to 58)
69 to 78
313 Boom 3 spool sub 1 603 Port relief valve 3
(51 to 58)
69 to 78
319 Spring 1 604 Port relief valve 1
(51 to 58)
69 to 78
320 Spring 2 606 Bypass cut valve 2
(51 to 58)
140 to 180
321 Spring 5 973 Socket bolt 8
(103 to 133)
140 to 180
(103 to 133)
323 Spring 2 977 Name plate 1
10-26
324 Spring 2 978 Pin 2
325 Spring 1
Main relief valve (Two step relief) (601)
10
Main relief valve (Two step relief)
69 to 78
103 Plug 1 562 Back up ring 1
(51 to 58)
104 Adjust plug 1 611 Poppet 1
121 C-ring 1 613 Stopper 1
122 Spacer 1 614 Piston 1
123 C-ring 1 621 Spring 1

28 to 31
124 Filter stopper 1 652 Adjust screw 1
(21 to 23)
125 Filter 1 661 O-ring 1
163 O-ring 1 663 O-ring 1
512 Plunger 1 664 O-ring 1
521 Spring 1 671 Lock nut 1

46 to 52
541 Seat 1 673 Lock nut 1
(34 to 38)
561 O-ring 1
10-27
Port relief valve (602,603,604)
Port relief valve
69 to 78
101 Body 1 541 Seat 1
(51 to 58)
69 to 78
102 Plug 1 561 O-ring 1
(51 to 58)
161 O-ring 1 562 Back up ring 1
162 O-ring 1 563 O-ring 1
123 C-ring 1 564 Back up ring 1
124 Filter stopper 1 611 Poppet 1
125 Filter 1 612 Spring seat 1
301 Piston 1 621 Spring 1
511 Plunger 1 651 Adjust screw 1
521 Spring 1 661 O-ring 1

28 to 31
522 Spring 1 671 Lock nut 1
(21 to 23)
10-28
Arm 2 spool (308)
351 319 308 317 340 361 371 350

371 361 340
Arm 2 spool
10
16 to 18 (12 to 13)
308 Spool 1 350 Plug 1
Loctite #638
16 to 18 (12 to 13)
317 Plunger 1 351 Plug 1
Loctite #638
319 Plunger 1 361 O-ring 2
340 Spring 2 371 Back up ring 2
Boom spool (301)
353 372 362 301
Boom spool
301 Spool 1 362 O-ring 1

16 to 18 (12 to 13)
Loctite #638
10-29
Boom 3 spool (313)
353 372 362 313
Boom 3 spool

24 to 26 (18 to 19)
Loctite #638
Boom 2 spool (312)
351 361
371 312
Boom 2 spool

24 to 26 (18 to 19)
Loctite #638
10-30
Lock valve selector (211)
101 10
164
171
201
321
PLc A B Dr
166 541 167 511 161
Lock valve selector
10 to 14
101 Casing 1 171 Socket bolt 3
(7.4 to 10.3)
49 to 59
161 O-ring 4 201 Plug 1
(36 to 44)
166 O-ring 1 511 Spool 1
167 O-ring 1 541 Sleeve 1
10-31
Lock valve selector (212)
101
164
171x3
201
321
166 541 167 511 161x4
Lock valve selector
10 to 14
101 Casing 1 171 Socket bolt 3
(7.4 to 10.3)
49 to 59
161 O-ring 4 201 Plug 1
(36 to 44)
166 O-ring 1 511 Spool 1
167 O-ring 1 541 Sleeve 1
10-32
Emergency manual lowering valve (For EUROPE/CHAINA)
102
106x4
103
10
104
101 105
Emergency manual lowering valve
6 to 8
101 Casing 1 104 Adjust screw 1
(4.4 to 5.9)
20 to 24
102 O-ring 1 (14.8 to 105 Lock nut 1
17.7)
103 C-ring 1 106 Square ring 4
Logic valve (208)

104
102 101
110
114
112 113 103
120x4
Logic valve
101 Casing 1 112 O-ring 1
103 Spring seat 1 114 O-ring 1

25 to 34
(18 to 25)
13 to 17
110 Plug 1
(10 to 13)
10-33
Logic valve poppet (520)

103
106
104
107
102
101
Logic valve poppet
24.5 to 29.5
101 Logic poppet 1 (18.1 to 104 Plug 1
21.8)
102 Poppet 1 106 Spring 1
103 Spring seat 1 107 Spring 1
10-34
Bypass cut valve (606)
202 301
10
T Dr
102 101 201
Bypass cut valve
69 to 78
101 Plug 1 202 O-ring 1
(51 to 58)
25 to 29
102 O-ring 1 301 Lock nut 1
(18 to 21)
25 to 29
201 Adjust screw 1
(18 to 21)
Boost check valve (517)
104
107
102
101
Boost check valve
20 to 29 (15 to 21)
101 Poppet 1 104 Plug 1
Loctite #262
102 Poppet 1 107 Spring 1
10-35
10.2.2.3 HYDRAULIC CIRCUIT DIAGRAM
Travel
straight
P 1 Unload Travel left
Travel right P2 unload
Boom conflux
Boom 3
Boom
Boom 2
Swing
Bucket
Arm 1
Arm 2
10-36
10.2.3 OPERATION OF CONTROL VALVE

10.2.3.1 At Neutral
The working fluid discharged from the hydraulic pump enters the port P1 of the control valve, and returns to the
working fluid tank through the P1 unloading valve (309), the low-pressure circuit (D), and the return port T1.
Besides, in case the P1 unloading valve (309) has been disabled resulting from electric control system failure, by
loosening the adjustment screw of the bypass cut valve (606) in the downstream of the center bypass (52) and
opening, the working fluid discharged from the P1 port of the hydraulic pump passes the travel straight spool (307),
the center bypass(52) leading to the travel right, boom, bucket, and arm 2, and the bypass cut valve (606) on the
P1 side, and returns to the working fluid tank from the return port T1 by flowing through the low-pressure circuit and
the boost check valve (517). 10
Similarly to that from the hydraulic pump P1, the working fluid discharged from the hydraulic pump P2 returns to the
working fluid tank through the P2 unloading valve (310), the low-pressure circuit (D), and the boost check valve
(517). In case the unloading valve has been disabled, by loosening the adjustment screw of the bypass cut valve
(606) in the downstream of the center bypass (52) and opening, the working fluid discharged from the P2 port of the
hydraulic pump passes the main passage, the center bypass leading to the travel left, swing, and arm 1, and the
bypass cut valve on the P2 side, and returns to the working fluid tank from the return port T1 by flowing through the
low-pressure circuit (D) and the boost check valve (517)
(D)
606
52
517
307
T1
P2
P1
309
606
55 310
(D)
Connected to low
pressure circuit of
P2 side casing
At neutral
10-37
10.2.3.2 Travel Operation
Travel Exclusive Operation

When travel operation (forward) is made, the working fluid discharged from the hydraulic pump P1 is supplied to the
travel right motor and that from the hydraulic pump P2 is supplied to the travel left motor. The pilot pressure enters
PAr and PAL, and the travel spools (306) on the left and right move right opposing the springs (323) and (324),
while the secondary pressure of the solenoid-operated proportional control valves [X1] and [X2] is applied to Ports
PCb and PCa to change over the unloading spools (309) and (310).
The working fluid discharged from the hydraulic pump P1 flows to the main passage through the travel straight
spool (307) and to Port Ar through the clearance between the periphery and the casing, and is supplied from here
to the A side of the travel right motor. The working fluid discharged from the hydraulic pump P2, similarly to that
from the hydraulic pump P1, flows to Port AL through the periphery of the travel left spool (306), and is supplied to
the A side of the travel left motor.
On the other hand, the return oil from the travel right B side and travel left B side flows from Ports Br and BL to the
low-pressure circuit (D) and boost check valve (517) passing the portion between the periphery of the travel right
and travel left spools (306) and the casing, and returns to the working fluid tank through the return port T1.
Travel reverse operation (when the pilot pressure is applied to Ports PBr and PBL of the control valve) can also be
made similarly to the travel forward operation.
Travel (left) motor
A B
AL BL
306 CP2
323
324
PAL PBL
Travel left backward (Pressurizing PBL)
10-38
Travel Straight Operation

When actuator other than travel operation and the travel operation are operated simultaneously in the said in travel
independent) "In travel independent operation" the pilot signal from the outside acts on port PTb and the travel
straight spool (307) moves upward.
With this operation, the hydraulic oil delivered by hydraulic pump P1 mainly flows from P2 to A and is used for each
actuator, and the hydraulic oil delivered by hydraulic pump P2 mainly flows from P2 to B and into main passage,
and is used for right and left travel operations as hydraulic oil realizing the actuator and travel simultaneous
operation. (Travel straight function)
At circuit (I) position, a part of hydraulic oil delivered by hydraulic oil P1 passes through circular notch on travel
straight spool (307) and enters from P1 to B enabling the hydraulic oil to be supplied from actuator side to travel
side. And at circuit (II) position, the circular notch on travel straight spool (307) closes and the pump line on the 10
travel sides is independent from pump line on actuator.
C M R 2 C M R 2
B P 2 B P 2
C M R 1 C M R 1
P 1 P 1
A A
3 0 7 3 0 7
3 2 7 3 2 7
3 2 9 3 2 9
P T b P T b
P 2 P 1 P 2 P 1
P T b P T b
D r D r D r D r
B A A
T o e a c h a c tu a to r B T o e a c h a c tu a to r
T o tr a v e l r ig h t T o tr a v e l r ig h t
C ir c u it ( I) C ir c u it ( II)
Movement of travel straight spool
10-39
10.2.3.3 Bucket Control
Bucket Excavating Operation

On starting bucket digging operation, the pilot pressure enters port PAc, bucket spool (304) moves leftward the
force of springs (321)(322), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on
port PCb and switches unloading spool (309).
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check
valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing through U-shaped
passage, and supplied to bucket cylinder head side (H) through port (Ac).
In the meantime, the return oil from bucket cylinder rod side (R) passes through between the perimeter of bucket
spool (304) and casing, flows through low pressure circuit (D) and boost check valve (517), and returns to the
hydraulic tank through tank port T1.
And when the flow rate of hydraulic oil delivered by hydraulic pump P1 with engine running in low idling is low, the
pilot signal from the outside enters port PCc and piston (216) moves rightward. With this actuation, the maximum
leftward stroke of bucket spool (304) is limited, consequently the area of passage between the perimeter of bucket
spool (304) and casing minimizes. Consequently the flow rate of return oil from bucket cylinder rod side (R) reduces
and bucket cylinder moving speed is limited preventing cavitation which may be occurred on bucket cylinder head
side (H). (Stroke limiter ON)
53
216
PAc
PCc PBc
321
322 (D) Bc LCc Ac
304 511
(R) (H)
Bucket excavating operation (Stroke limiter ON)
10-40
Bucket Dumping Operation

In the bucket dumping operation, the pilot pressure enters Port PBc, the bucket spool (304) moves right opposing
the springs (321) and (322), the secondary pressure of the solenoid-operated proportional control valve [X1] is
applied to Port PCb to change over the unloading spool (309).
The working fluid discharged from the hydraulic pump P1 flows to the parallel passage (53), pushes and opens the
load check valve LCc (511), passes the portion between the periphery of the bucket spool (304) and the casing
through the U-shaped passage, and is supplied to the bucket cylinder rod side (R) through the port (Bc).
On the other hand, the return oil from the bucket cylinder head side (H) passes the portion between the periphery of
the bucket spool (304) and the casing, flows to the low-pressure circuit (D’), and returns to the hydraulic tank
through the return port T1. The return oil does not pass the boost check valve (517).
53 (D')
10
216
The down stream of
the boost check valve.
PAc
PCc PBc
322
321
Bc Ac
LCc
304
511
(R) (H)
Bucket dumping operation
10-41
10.2.3.4 Boom Control
Boom Hoisting Operation

In the boom hoisting operation, the pilot pressure enters Port PAb, the boom spool (301) moves right opposing the
springs (319) and (321), and the secondary pressure of the solenoid-operated proportional control valve [X1] is
applied to Port PCb to change over the unloading spool (309).
Besides, the pilot pressure also enters PB1 to change over the boom confluence spool (305) opposing the springs
(325) and (326), and the secondary pressure of the solenoid-operated proportional control valve [X2] is applied to
Port PCa to change over the unloading spool (310).
logic poppet (520-101), passes the chamber BH passing the portion between the periphery of the boom spool (301)
and the casing through the U-shaped passage, pushes and opens the lock valve poppet CRb1 (514), and is
supplied to the boom cylinder head side (H) through the port (Ab).
On the other hand, the return oil from the boom cylinder rod side (R) passes the portion between the periphery of
the boom spool (301) and the casing through the port (Bb), flows to the low-pressure circuit (D) and the boost check
valve (517), and returns to the hydraulic tank through the return port T1.
(R) (R)
(H) (H)
520 514
Pc Dr2 321 319
Ab BH chamber
301 (D) 53
CRb1
Bb
PAb
PBb
Boom hoisting operation (Boom spool)
10-42
Boom hoisting confluence

The hydraulic oil delivered by the P2 hydraulic pump passes through the travel left spool and enters parallel
passage (56).
Then the hydraulic oil pushes and opens load check valves CP2 and LCb2, flows through between the perimeter of
boom conflux spool (305) and the casing, pushes and opens lock valve poppet CRb2 (513), enters port Ab through
the conflux passage inside the casing, and joins the hydraulic oil from the P1 hydraulic oil pump.
P B1
326 10
325
305
Conflux passage
To Ab port of P1 casing
511
LCb2
56
Boom hoisting confluence operation (Boom confluence spool)
10-43
Boom Lowering Operation

On starting boom down operation, the pilot pressure enters port PBb, boom spool (301) moves leftward against the
force of springs (319) and (321), the secondary pressure of solenoid proportional valve[X3] enters port Prb, and
boom 3 spool (313) moves leftward against the force of springs (320) and (322). Also the secondary pressure of
solenoid proportional valve [X1] acts on port PCb and switches unloading spool (309). Simultaneously, the spools
of lock valve selectors (211) and (212) are switched, and holding of poppets (514) and (513) is released because
the spring chambers of lock valve poppets CRb1 (514) and CRb2 (513) are connected to the drain circuit.
The hydraulic oil delivered by the P1 hydraulic pump flows into parallel passage (53), pushes and opens logic
poppets LCb (520-101) , flows through between the perimeter of boom spool (301) and the casing from the U-
shaped passage, and is supplied to boom cylinder rod side (R) through port (Bb).
On the other hand, the return oil from boom cylinder head side (H) enters the control valve through port (Ab). There
are lock valve poppet CRb1 (514) located on in front of the boom spool (301) and lock valve poppet CRb2 (513)
located on in front of boom 3 spool (313) and lock valve poppets (514) and (513) are pushed and opened because
holding of poppets (514) and (513) is released. Then the return oil enters the BH and BH’ chambers. The oil from
the BH chamber passes through the circular notch of boom spool (301) into the inside of boom spool (301), flows
through low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic oil tank through tank
port T1. Also, the oil from the BH’ chamber flows through the circular notch of boom 3 spool (313) into the inside of
boom 3 spool (313), flows through low pressure circuit (D) and boost check valve (517), and then returns to the
hydraulic oil tank through tank port T1.
Also, the secondary pressure of solenoid proportional valve [X4] enters port Pra and boom 2 spool (312) moves
leftward against the force of springs (320) and (322). The return oil through the BH’ chamber passes through the
circular notch of boom 2 spool (312) into the inside of boom 2 spool (312), and then is led to the U-shaped passage.
Then, the oil pushes and opens load check valves CRe (516) and is supplied to parallel passage (56) at the P2
side. This function is used when boom down combine operation is performed.
(R) (R)
(H) (H)
520 514
P c Dr2 321 319
Ab BH Cha mbe r
301 CRb1
Bb
PAb
PBb
BH Cha mbe r
Prb Pra
P Lc1
CBb CRe CRb2 CAb
56
322 320 313 516 513 511 312 320 322
Boom lowering operation
10-44
(R) (R)
(H) (H)
520 514
P c Dr2 321
Ab BH Cha mbe r 319
301 CRb1
Bb
10
PAb
PBb
BH Cha mbe r
Prb Pra
P Lc1
CBb CRe CRb2 CAb
56
320 320
322 313 516 513 511 312 322
Boom down operation
10-45
10.2.3.5 Arm operation
Arm Out Operation

On starting arm out operation, the pilot pressure enters ports PBa1, arm 1 spool (302) moves rightward against the
force of springs (321) and (322), and simultaneously the secondary pressure of solenoid proportional valve [X2]
acts on port PCa to switch unloading spool (310).
Also, the pilot pressure enters port PBa2, arm 2 spool (308) moves against the force of springs (321) and (328),
and simultaneously the secondary pressure of solenoid proportional valve [X1] acts on port PCb to switch
unloadingspool (309).
The hydraulic oil delivered by the P2 hydraulic pump flows into parallel passage (56), pushes and opens load check
valve LCa (511), and flows into the AR chamber through between the perimeter of arm 1 spool (302) and the casing
from the U-shaped passage. On the other hand, the hydraulic oil delivered by the P1 hydraulic pump flows through
center by-pass passage (52), pushes and opens load check valve LCAT2 (511), and enters the U-shaped passage.
The oil from parallel passage (53) also pushes and opens load check valve LCAP2 (515) with orifice, and flows into
the U-shaped passage. And then the hydraulic oil from the U-shaped passage flows through between the perimeter
of arm 2 spool (308) and the casing, enters the AR chamber through passage (RR) inside the casing, and joins the
hydraulic oil from the P2 hydraulic pump.
The conflux hydraulic oil opens lock valve poppet CRa (514) and is supplied to arm cylinder rod side (R) through
port (Ba).
On the other hand, the return oil from arm cylinder head side (H) passes through between the perimeter of arm 1
spool (302) and the casing, flows into low pressure special circuit (D”), and then returns to the hydraulic oil tank
through tank port Ta. The return oil of low pressure special circuit (D”) does not pass through boost check valve
(517).
(R) (H)
321 AR chamber
322 211 514 302
CRa LCa
Ba 56 Aa
P1
PBa1 PAa1
(D')
(D) LCAT2 LCAP2
ARM 1
P1
RR RH HH (D'') PAa2 PBa2
52 53 Dr Dr
ARM 2 CBa
To arm 1 spool
PBa2 PAa2 Aa (HEAD)
Ba
(ROD)
To bypass cut valve
MU CTa
LCAT2 LCAP2 Ta
328 321 308 (D) 511 515
In arm out operation
10-46
Arm Excavating Operation (At Light Load : Arm Regeneration Function)

In the arm excavating operation, the pilot pressure enters Ports PAa1 and PLc2, the arm 1 spool (302) moves left
opposing the springs (321) and (322), and the secondary pressure of the solenoid-operated proportional control
valve is applied to Port PCa to change over the unloading spool (310). At the same time, the spool of the lock valve
selector (211) is changed over, the spring chamber of the lock valve poppet CRa (514) is communicated with the
drain circuit, and retention of the poppet (514) is canceled.
Besides, the pilot pressure passes the pilot-operated proportional control valve [XR], enters Port PAa2 also, the
arm 2 spool (308) moves left opposing the springs (321) and (328), and the secondary pressure of the pilot-
operated proportional control valve [X1] is applied to Port PCb to change over the unloading spool (309). However,
at light load, the solenoid-operated proportional control valve [XR] is operated, and the arm 2 spool (308) is
positioned as shown in Circuit (I). 10
load check valve LCa (511), and flows between the periphery of the arm 1 spool (302) and the casing through the
U-shaped passage and to the port (Aa). On the other hand, the working fluid discharged from the hydraulic pump
P1 pushes and opens the load check valve LCAT2 (511) through the center bypass (52), and enters the U-shaped
passage, while it pushes and opens the load check valve with a restrictor LCAP2 (515) through the parallel
passage (53) also, and enters the U-shaped passage. It passes the portion between the periphery of the arm 2
spool (308) and the casing, and becomes confluent with the working fluid from the hydraulic pump P2 side. The
confluent working fluid is supplied to the arm cylinder head side (H) through the port (Aa).
On the other hand, the return oil from the arm cylinder rod side (R) enters the control valve from the port (Ba). The
lock valve poppet CRa (514) is located in the upstream of the arm 1 spool (302), and the return oil pushes and
opens the lock valve poppet CRa (514) to enter the AR chamber because the lock valve is in the canceled
condition.
The return oil from the AR chamber passes the portion between the periphery of the arm 1 spool (302) and the
casing and the casing internal passage (RH), and is led to the arm 2 spool (308) inside through the circular notch
(a) of the arm 2 spool (308). At light load, the pressure of the return oil is higher than that of the arm cylinder head
side (H) caused by the own weight of the arm and others, so the working fluid inside the arm 2 spool (308) flows to
the casing internal passage (HH) through the check valve (317) to be supplied again to the arm cylinder head side
(H). (Arm Regeneration Function)
Besides, part of the return oil led to the arm 2 spool (308) inside passes the check valve (319), the low-pressure
circuit (D), and the boost check valve (517), and returns to the hydraulic tank through the return port T1.
(R) (H)
321 AR chamber
322 211 514 302
CRa LCa
Ba 56 Aa
P1
PBa1 PAa1
(D')
(D) LCAT2 LCAP2
Arm 1 P1
RR RH HH PAa2 PBa2
(D) 52 53 Dr Dr
Arm 2 CBa
To arm 1 spool
PBa2 PAa2 Aa (HEAD)
Ba
(ROD)
MU CTa To bypass cut valve

Circuit (I)
Ta
(D) LCAT2 LCAP2
328 321 308 511 515
Arm excavating operation (At light load : Arm regeneration function)
10-47
Arm Ecavating Operation (At heavy load)

The arm regeneration function is effective for fast movement of the arm cylinder at light load, but causes power loss
at heavy load (in operation requiring power). Change over of activating the regeneration function or not depending
upon light load or heavy load is made for this control valve by the solenoid-operated proportional control valve [XR].
(Adjustable Regeneration Function)
The flow path of the working fluid at heavy load is the same as that at light load on the arm cylinder supply side, but
the flow path of the return oil is different. At heavy load, the solenoid-operated proportional control valve [XR] is
operated, and the arm 2 spool (308) is in the position shown in Circuit (II).
The return oil from the arm cylinder rod side (R) enters the control valve through the port (Ba). The lock valve
poppet CRa (514) is located in the upstream of the arm 1 spool (302), but the return oil pushes and opens the lock
valve poppet CRa (514) to enter the AR chamber because the lock valve is in the canceled condition. The return oil
of the AR chamber passes the arm 1 spool (302) and the casing internal passage (RR), and proceeds to the arm 2
spool (308). The arm 2 spool (308) is communicated with the low-pressure passage (D) in Circuit (II), so most of the
return oil passes the portion between the periphery of the arm 2 spool (308) and the casing, low-pressure passage
(D), and the boost check valve (517), and returns to the working fluid tank through the return port T1.
The return oil from the AR chamber passes the portion between the periphery of the arm 1 spool (302) and the
casing and the casing internal passage (RH), and is led to the arm 2 spool (308) inside through the circular notch
(a) portion of the arm 2 spool (308), but because the arm cylinder head side pressure is higher at heavy load, the
working fluid inside the arm 2 spool (308) does not flow to the casing internal passage (HH), but passes the check
valve (319) and the boost check valve (517) through the low-pressure circuit (D), and returns to the working fluid
tank through the return port T1.
(R) (H)
321 AR chamber
322 211 514 302
CRa LCa
Ba 56 Aa
P1
PBa1 PAa1
(D')
(D) LCAT2 LCAP2
Arm 1 P1
PAa2 PBa2
RR RH HH Dr Dr
(D) 52 53
Arm 2 CBa
To arm 1 spool
Aa (HEAD)
PBa2 PAa2 Ba
(ROD)
To bypass cut valve

MU CTa Circuit (II)
(D) LCAT2 LCAP2 Ta

328 321 308 319 511 515 317
Arm ecavating operation (At heavy load)
10-48
10.2.3.6 Swing Operation

On starting swing operation, the pilot pressure enters ports PAs or PBs, and swing spool (303) moves leftward or
rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid
proportional valve [X2] acts on port PCa and switches unloading spool (310).
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check
valve LCs (511) and flows through between the perimeter of swing spool (303) and casing through U-shaped
passage and is supplied to swing motor A side or B side through port (As) or (Bs). In the meantime, the return oil
from swing motor A side or B side passes through between the perimeter of swing spool (303) and casing through
port (Bs) or (As) and flows through low pressure circuit (D) and boost check valve (517), and then returns to the
hydraulic tank through tank port T1.
10
PBs
PAs
303
Bs As 321 322
LCs
(D) 56 511
B A
Swing motor
Swing operation
10-49
10.2.3.7 Lock Valve Operation

The control valve connected with the arm cylinder rod side (R) and the boom cylinder head side (H) has built-in lock
valves between each port and the arm spool or the boom spool, the boom3 spool, the boom2 spool and lowers
leakage amount due to the retention pressure of each cylinder.
Boom Spool Neutral Position (Arm Spool : Similar)

In the neutral position of the boom spool (301), the spool (211-511) and (212-511) of the lock valve selector is also
retained to the left as shown in the drawing. In this position, the passage Sa and the passage Sb are communicated
with each other through the periphery of the spool (211-511) and (212-511) inside the bush (211-541) and (212-
541). Therefore, retention pressure from the boom cylinder head side (H) is applied to the spring chamber (RH) of
the lock valve poppet (514) and (513) through the passage Sa, the bush (211-541) and (212-541), and the spool
(211-511) and (212-511), so the lock valve poppet (514) and (513) is pushed downward as shown in the drawing
keeping the seating condition, and restricts leakage amount to the minimum.
Return oil from 211-541 211-511
boom cylinder head
514
BH cha mbe r
CRb1 Sa
Sb
A A P Lc
(a ) S a Sb (b) Dr
RH S ECTION A-A
chambe r
P Bb
301
Dr
Lock valve operation (At boom spool neutral position)
10-50
Boom Lowering (Arm Excavating)

The pilot pressure PBb for boom lowering is applied to Port PLc also, and the spool (211-511) moves right as
shown in the drawing. In addition, the pilot pressure is applied to Port PLc1 also, and the spool (212-511) moves.
Along with the spool (211-511) and (212-511) movement, the restrictor hole (a) of the bush (211-541) and (212-541)
are closed first, so the passage Sa and the passage Sb are blocked, and the retention pressure from the boom
cylinder head side (H) is not applied to the spring chamber (RH) of the lock valve poppet (514) and (513) any
longer.
Then, along with the spool (211-511) and (212-511) movement, the bush (211-541) and (212-541) inside are
communicated with the drain passage Dr through the spring (211-321) and (212-321) chamber and Port Dr.
As a result, the spring chamber (RH) of the lock valve poppet (514) and (513) are communicated with the drain
passage Dr through the passage Sb and the restrictor hole (b) of the bush (211-541) and (212-541), and the force 10
for pushing the lock valve poppet (514) and (513) downward are canceled. Therefore, the lock valve poppet (514)
and (513) are pushed up and opened because the retention pressure of the boom cylinder head side (H) is applied
to the circular pressure receipt portion composed of the guide diameter of the lock valve poppet (514) and (513)
and the seat diameter.
The above operation is made in the boom lowering operation before the opening portion (metering out opening) for
returning the return oil from the boom cylinder head side of the boom spool (301) to the tank is opened, and does
not influence maneuverability of the boom lowering operation.
In case arm excavating operation is made, the pilot pressure is applied to Port PLc2 and the lock valve selector
(211) mounted on arm 1 cylinder rod port operates similarly.
Return oil from 211-541 211-511
boom cylinder head
BH cha mbe r
514
CRb1 Sa
Sb
A A
P Lc (a ) S a S b (b) Dr
RH cha mbe r
S ECTION A-A
P Bb
301
Dr
Boom lowering (Arm excavating)
10-51
10.2.3.8 Logic Control Valve Operation

The secondary pressure of the solenoid-operated proportional control valve [X4] is applied to Port Pc, the spool of
logic control valve (211-511) moves right as shown in the drawing opposing the springs (208-104). By the
movement of the spool, the path between (a) and (b) are blocked. So, the working fluid discharged from the
hydraulic pump P1 pushes and opens the poppet (520-102), and passes to the chamber (e) through the path (c)
and (b). The working fluid in chamber (e) is pressurized and and pushes the the logic poppet (520-101) to the
casing.Therefore, the logic poppet (520-101) shuts off the the working fluid from the parallel passage to the boom
spool. This function is called “Boom Meter In Supplying Cut” and used in lowering boom and operating other
attachment and so on.
208-102
Pc Dr2
208-104
(b)
520-102
520-101 (a)
(e)
(d)
(c)
Logic control valve operation
10-52
10.2.3.9 Bypass Cut Valve

The bypass cut valve is located in the utmost downstream of the P1 side center bypass (52) and the P2 side center
bypass (55), and the working fluid flow from each center bypass to the low-pressure passage (D) is controlled.
[Normally]
The adjusting screw (201) of the bypass cut valve (606) is tightened normally and apical tapered portion of the
adjusting screw (201) is pushed to the seating portion of casing. Then, the center bypass (52) and the low-pressure
passage (D) are blocked.
As a result, in the normal operation, the center bypass (52) are always blocked from the low-pressure passage (D),
the working fluid discharged from the hydraulic pump P1 at neutral does not pass the center bypass (52), but
returns to the working fluid tank through the P1 unloading spool (309). 10
201
(D)
52
Bypass cut valve (Normal operation)
10-53
[At Failure]
When the electric control system is failed, the P1 unloading spool (309) remains at the neutral position. Because
the working fluid discharged from the hydraulic pump P1 is blocked by the P1 unloading spool (309) and the center
bypass (52) is blocked from the low-pressure passage (D) by the bypass cut valve (606), the pressure of pump P1
rise to the main relief setting pressure. However, the working fluid passed through the center bypass (52) passes to
the low-pressure passage (D) through the bypass cut valve (606) by loosing the lock nut and the adjusting screw
(201) of the bypass cut valve (606).
Thus, when the electric control system has failed, the P1 unloading spool is positioned at neutral to block the
passage to the low-pressure passage (D), but the center bypass (52) instead is communicated with the low-
pressure passage (D) through the bypass cut valve (606) to prevent the pump pressure from rising abnormally by
loosing the adjusting screw (201) of the bypass cut valve (606).
201
(D)
52
Bypass cut valve (At failure)
10-54
10.2.3.10 Boost Check Valve and Bypass Check Valve
Boost Check Valve

The boost check valve is located between the low-pressure passage (D) and the tank port T1, and generates boost
pressure necessary for the low-pressure passage.
• In Normal Operation
The working fluid flowing from the low-pressure passage (D) moves the boost check valve (517) upward
opposing the spring (527), and returns to the working fluid tank through the return port T1. The pressure
generated by the spring (527) at this time is the boost pressure of the low-pressure passage.
However, the return oil in arm dumping operation does not pass the boost check valve (517) but returns to the
working fluid tank through the low-pressure passage (D”) for arm dumping and the tank port Ta. Besides, the 10
return oil in the bucket dumping operation does not pass the boost check valve (517) but returns to the working
fluid tank through the low-pressure passage (D’) and the tank port T1.
• In Make-Up Operation
In case make-up flow is supplied from the low-pressure passage (D) in operations like swinging stop, working
fluid is supplied from the working fluid tank to the low-pressure passage (D) when the working fluid quantity in
the low-pressure passage (D) is insufficient.
In case the working fluid quantity is insufficient, the pressure in the low-pressure passage (D) decreases.When
the low-pressure passage (D) pressure lowers below the return port T1 pressure, the built-in poppet (102) of the
boost check valve (517) receives the return port T1 pressure at the circular pressure receiving portion composed
of the guide diameter of the poppet (102) and the seat diameter of the poppet (102), and is opened upward, and
the working fluid in the working fluid tank flows into the low-pressure passage (D) to supply make-up flow.
5 2 7
5 2 8
( D ')
T 2 5 1 8
T 1
1 0 2
5 1 7 (D ) 5 2 7 5 2 8
T 2 5 1 8
In n o r m a l o p e r a tio n 1 0 2 T 1
5 1 7
(D )
In m a k e u p o p e r a tio n
Boost check valve operation
10-55
Bypass Check Valve

Even if the return port T1 pressure rises resulting from the sudden change of the return flow, the bypass check
valve is operated, and the return port T1 pressure is kept below the predetermined value, thus protecting the oil
cooler and the filter between the return port T1 and the working fluid tank.
When the return port T1 pressure rises up to the pressure raised by the spring (528), the bypass check valve (518)
is opened upward opposing the spring (528), and the working fluid of the return port T1 is directly returned to the
working fluid tank through the return port T2.
527
528
(D') T2
518
T1
102
517
(D)
Bypass check valve operation
10-56
10.2.4 PILOT VALVE (ATT)

10.2.4.1 OVERVIEW OF PILOT VALVE (ATT)
Outside view
5-PF3/8
Single operating angle Single operating angle T=49.0 (36.1)
(Port 2, 4) (Port 1, 3)
The adjust nut

(opposing flats : 22 mm (0.87") )
Fix adjust nut
PF1/4
10
(opposing flats : 22 mm (0.87") )
when the lever is installed by T=29.4 (21.7)
means of spanner or the like.
Then tighten the mating lock T=Tightening torque
nut to 41.2 N .m (30.4 lbf .ft). : N .m (lbf.ft)
VIEW A
Part No. LQ30V00043F1

Model PV48K21 10
Operating torque Refer to the curve below
Max. primary pressure 6.9 MPa (1000 psi)
Primary pressure 5.0 MPa (725 psi)
Rated flow 20 L/min (5.3gal/min)
We ight Approx. 1.9 kg (4.2 lbs)
A
POR T 1, 3 POR T 2, 4
(580)4.0 4.0(3.0) (580)4.0 4.0(3.0)
S e conda ry pre s s ure [MP a (ps i)]
S e conda ry pre s s ure [MP a (ps i)]
Ope ra tion torque [N.m (lbf.ft)]
Ope ra tion torque [N.m (lbf.ft)]

SECONDAR Y PRESSURE SECONDAR Y PRESSURE
(493)3.4 (493)3.4
(435)3.0 3.0(2.2) (435)3.0 3.0(2.2)
(377)2.6 (377)2.6
SINGLE OPERA TING TORQUE 2.03(1.50)
SINGLE OPERA TING TORQUE
(290)2.0 2.0(1.5) (290)2.0 2.0(1.5)
1.96(1.45) 1.75(1.27)
1.68(1.24)
(145)1.0 1.0(0.74) (145)1.0 1.0(0.74)

(87)0.6 0.83(0.61) (87)0.6 0.65(0.48)
0.87(126) 0.87(126)
0.68(99) 0.68(99)
0 0.8 6.4
0 0 0.8 8.8
0
0 2 4 6 7 0 2 4 6 8 9.4
PUSH ROD STROKE (mm) PUSH ROD STROKE (mm)
0 5 10 15 19 0 5 10 15 20 25
Operating angle (deg.) Operating angle (deg.)

P T
1 3 2 4
HYDRAULIC SYMBOL
10-57
10.2.4.2 STRUCTURE OF PILOT VALVE (ATT)
312
M14
Apply Loctite #262 68.6±4.9 N .m
Application part (hatched area) (50.6±3.61 lbf .ft)
302
501 301
Apply grease on
Apply grease rotating and sliding sections.
on top section 246-1 Be careful the
212 assembling direction
246-2 213 M14
151 47.1±2.9 N .m
(34.7±2.14 lbf .ft)
218
211
214
216-2 216-1
241-2 241-1
201-2
Secondary 201-1
pressure 217
adjusting shim
101 221
POR T 2,4 POR T 1,3
torque No. NAME Q'TY torque No. NAME Q'TY
N･･m (lbf･･ft) N･･m (lbf･･ft)
101 Case 1 218 Seat 4

201-1 Spool 2 241-1 Spring 2
201-2 Spool 2 241-2 Spring 2
211 Plug 4 246-1 Spring 2
212 Push rod 4 246-2 Spring 2

47.1
213 Seal 4 301 Joint : M14 1
(34.7)
214 O-ring : 1B P20 4 302 Circular plate 1

68.6
216-1 Spring seat 2 312 Adjust nut : M14 1
(50.6)
216-2 Spring seat 2 501 Cover 1
217 Washer 2 (Shim) 4
10-58
10.2.4.3 OPERATION OF PILOT VALVE (ATT)

Lever in neutral
The action of spring (241–2) (for secondary pressure
setting) that determines the output pressure of the pilot
valve does not act upon spool (201–2). Therefore, spool
(201–2) (for return) is pushed up by spring (221) [spring
seat (216–2)]. The output ports (2,4) connect with the T
port. The result is that the output pressure is equal to the
tank pressure.
216-2 216-1
241-1
10
241-2
221
221
201-1
201-2
POR T (2,4) POR T (1,3)
Lever in neutral
When the pilot lever is tilted

When the lever is tilted and the push rod (212) strokes,
the spool (201–2) [spring seat (216–2)] moves
downward 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 212
port 2 ,4 to produce a pressure.
216-2
201-2
POR T (2,4) POR T (1,3)
When the pilot lever is tilted
10-59
Lever held
When the pressure at ports (2,4) rises to a level
equivalent to the action of spring (241–2) that is set by
tilting the lever, 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 241-2
port open while ports (2,4) and the T port close. Thus the
secondary pressure is kept constant.
T P ORT
Operation in the area where the tilting angle of the
P P ORT
lever is large. (varies with the model)
If the lever is inclined beyond a certain angle on certain
models, the top end of the spool contacts the bottom of POR T (2,4) POR T (1,3)
the bore of the push rod. This keeps the output pressure
connected with the P port pressure. When the lever is held
Furthermore, on a model in which a spring seat and a
spring are built in the push rod, the bottom of the bore of the push rod contacts the spring if the lever 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.
10-60
10.2.5 PILOT VALVE (TRAVEL)

10.2.5.1 OVERVIEW OF PILOT VALVE (TRAVEL)
Outside view
10
Tightening torque
Port size N.m (lbf.ft) Port name Function
1 LH travel forward port
2 LH travel reverse port
PF3/8 30 (22) 3 RH travel forward port
4 RH travel reverse port
T Tank port
5 LH travel pressure sensor port
PF1/4 16.7 (12.3) 6 RH travel pressure sensor port
P Pilot primary pressure port
Specifications
P T
Item Specifications
Type 6TH6NRZ
Primary pressure 5.0MPa (725psi)
Secondary pressure 0.54~2.35MPa (78~341 psi)
Rated flow 25 L/min (6.6 gal/min)
Weight Approx. 8kg (18 lbs)
1 5 2 3 6 4
Hydraulic symbol
10-61
Performance characteristics
Secondary pressure
[MPa (psi)] Secondary pressure
2.35 + 0.15
(340 + 22)
0.54 + 0.1
(78 + 15) 0
1 30'~ 11 30'~ Pedal angle (degree)
(4.7 + 0.5) 2 30' 12 30'
6.4 + 0.64
7.7 + 0.77
(5.7 + 0.6)
12.7 + 1.27
(9.4 + 0.9)
Operating Operating torque
torque
[N.m (lbf.ft)] Control diagram
10-62
10.2.5.2 STRUCTURE AND OPERATION OF PILOT VALVE (TRAVEL)

The hydraulic remote control valve in TH6NR type is operated with directly-operated pressure-reducing valve.
The pilot control equipment TH6NR in double foot pedal type is made up of the actuating section which is equipped
with 2 foot supports (1), 4 pressure-reducing valves (11), 4 damper system (12) and body (6).
Every pressure-reducing valve is made up of control spool (2), control spring (3), return spring (4) and plunger (5).
The dumper system is made up of plunger (8), orifice (9) and return spring (10).
In stationary condition, the pedal is held in neutral position by return spring (10).
In operation, the foot pedal pushes the plunger (5) used for pressure-reducing valve and plunger (8) used for
dumper system.
The hydraulic oil fed into damper chamber is restricted in the orifice (9) by the pressure corresponding to the
operating speed. [Similarly, when the foot pedal returns to the neutral position with the return spring, the hydraulic 10
oil trapped in the damper chamber is forced out. Consequently the return speed is controlled by the flow rate of
hydraulic oil led through orifice (9).]
Simultaneously, the plunger (5) is pushed against return spring (4) and control spring (3). The control spring (3) first
moves the control spool (2) downwards, and then closes the passage between control port and the return pipe to
tank port (T). At the same time, the control port is connected to passage (7). When the control spool reaches to the
position the force of control spring (3) balances the pressure of control port (1 or 2), it starts retaining the condition.
The pressure of control port is proportional to the stroke of plunger (5) and the position of pedal (1) according to the
mutual relations between the control spool (2) and control spring (3).
The closed circuit pressure control makes proportional control of selector valve and high responsibility of hydraulic
pump and motor possible in relation with the characteristics of foot pedal (1) position and control spring (3).
5
3
8 10
3
11 12
4
10
9
9
7 6
2
control ports 1-3 P line control ports 2-4

T line
10-63
10.2.6 SWING MOTOR UNIT

10.2.6.1 SPECIFICATIONS OF SWING MOTOR UNIT
General view and hydraulic port
Tightening
Port
Symbol Port name torque
size N.m (lbf.ft)
A,B Main port PF3/4 167 (123)
DB Drain port PF3/8 74 (54.6) B
B PB
M DB
M Make-up port PF3/4 167 (123)
PR DB
PA,PB Pressure meaduring port PF1/4 36 (27.0)
A
PA
PR Parking break release port PF1/4 36 (27.0) A
Gear oil filler port
IP,L,AR serving also as level gauge PT3/4 98 (72.3)
and air breather port PB
PA
Lifting bolt 2-M12 IP, L, AR
Thread depth 24 (0.94")
Lifting capacity M
2160N (486 lbf)
A, B
PR
PR
DB
PA PB
Grease nipple
A B
Hydraulic diagram
10-64
Specifications
Swing motor unit part No. YN15V00078F1
Type M5X130CHB-10A-4RA/295

Displacement cm3 (in3)/rev 129.2 (7.88)
Working pressure Mpa (psi) 32.4 (4700)
Hydraulic motor Max. flow L/min (gal/min) 220 (58)
Braking torque N･m (lbf･ft) 655 (483)

10
Release pressure Mpa (psi) 2.5 to 5.0 (362 to 725)
Relief set pressure Mpa (psi) 29 (4205)
Weight kg (lbs) 47 (104)
Anti-reaction Type 2KAR6P72/240-712

valve block Weight kg (lbs) 2.5 (5.5)
Hydraulic motor assy weight kg (lbs) 52 (114)
Part No. YN32W00025F1

Speed reduction type Planetary 2-stage
Reduction ratio 15.378

Lubicate oil Gear oil SAE90 (API class GL-4 grade)
Reduction unit
Lubicate oil volume L (gal) Approx. 2.7L (0.7)
Grease Extreme pressure lithum base #2 grease
Grease volume kg (lbs) Approx. 0.7 (1.5)
Weight kg (lbs) 134 (295)
Total weight kg (lbs) Approx. 185 (408)
10-65
10.2.6.2 STRUCTURE OF SWING MOTOR UNIT
Swing motor
993
390 391
VIEW I
351
355
051
(051-1)
469
702
488
401 712
151
171 161 163 985 444 984 131
052
A A
I Arrangement of brake spring
162
451
303
985
472
707 712
702
980
706 743
100
111
742
121
400-1
123 994
052
400-2
122 400
124 443 491 101 114 301 SECTION A-A
10-66
torque No. Parts Q'ty torque No. Parts Q'ty
N･･m (lbf･･ft) N･･m (lbf･･ft)
177 69 Anti-reaction valve ;

51 Relief valve ; M33-P1.5 2 400 2
(131) (51) M22-P1.5
051-1 O-ring ; 1B G30 2 400-1 O-ring ; 1B P20 2
52 Anti-reaction valve sub 1 400-2 Backup ring 2

430
100 Casing for anti-reaction 1 401 Socket bolt ; M20X45 4
(317)
101 Drive shaft 1 443 Roller bearing 1

10
111 Cylinder 1 444 Roller bearing 1
114 Spring plate 1 451 Pin 2

334
121 Piston 9 469 ROMH plug ; M30-P1.5 2
(246)
122 Shoe 9 472 O-ring ; W1516, WG40 1
123 Set plate 1 488 O-ring ; 1B P28 2
124 Shoe plate 1 491 Oil seal 1
131 Valve plate 1 702 Brake piston 1

36
151 Plug ; PF1/4 2 706 O-ring ; W1516, WG38 1
(27)
161 O-ring ; 1B P11 2 707 O-ring ; W1516, WG41 1
162 O-ring ; 1B P12 2 712 Brake spring 18
163 O-ring ; 1B P6 2 742 Friction plate 3

29
171 Socket bolt ; M8X55 4 743 Separator plate 4
(21)
0.9
301 Casing 1 980 Plug ; PF1/4 1
(0.7)
1.7
303 Valve casing 1 984 Plug ; PF3/8 1
(1.3)
4.4
351 Plunger 2 985 Plug ; PF3/4 3
(3.2)
65
355 Spring 2 993 Plug ; PT1/2 1
(48)
98
390 Name plate 1 994 Plug ; PT3/4 1
(72)
391 Rivet 2
10-67
Swing reduction unit

Be careful about installation
direction of retaining ring.
Apply Three
Bond #1211. Apply Loctite #515.
Paint this machined surface. Apply Loctite #515.
Tightening torque
181 N .m (134 lbf .ft)
12 10 20 8 4 7 6 23 Apply Three Bond 1360K
OIL FILLING POR T P T3/4
A
2
LEVEL
POR T P T1/2
A
II
1 9 22 18 17 5 18 14 3 16 15 28 19
21 29 11
Be careful about
Insert 1mm(0.04") deep from installation direction
Lubricate grease.
the surface of Item 8 (spider). of retaining ring.
13 27 26 25
Wind seal tape around plug and
install it (tightening torque Wind seal tape around tube and install elbow to tube
10N .m (7 lbf .ft)) to item 26 elbow with tightening torque 30N .m (22 lbf .ft) and then make
until its surface becomes direction of elbow as shown in drawing by retightening.
the same surface of elbow end.
Wind the seal tape or
Install grease nipple apply the Locktite #577
as facing to motor side. 30 31 around the screw.
Tightening torque
10.8N .m (8.0 lbf .ft)
Leave installation angle as it is.
Punch here 2 portions to deform holes in order to
prevent spring pin (22) from coming out.
Be careful about installation direction

of pin and spring.
VIEW II
4 places
SECTION AA
10-68
torque N･･m No. Parts Q'ty torque N･･m No. Parts Q'ty
(lbf･･ft) (lbf･･ft)
1 Pinion shaft 1 16 Roller 102

2 #1 sun gear 1 17 Needle bearing 4
3 #1 pinion 3 18 Thrust washer 8
4 #2 sun gear 1 19 Retaining ring 1
5 #2 pinion 4 20 Retaining ring 1
6 Ring gear 1 21 Sleeve 1 10

7 Spider assy 1 22 Retaining ring 4
8 Spider 1 181 (134) 23 Capscrew ; M14X130 11

Tube
9 Shaft 4 25 1
L=130mm (5.12 inch)
10 Spherical bearing 1 26 Elbow 1
11 Spherical bearing 1 10 (7) 27 Plug 1
12 Oil seal 1 28 Retaining ring 3
13 Housing 1 29 Oil seal 1
14 Thrust washer 3 30 Grease nipple 1
15 Thrust washer 3 31 Plug 1
10-69
10.2.7 OPERATION OF SWING MOTOR UNIT

10.2.7.1 HYDRAULIC MOTOR
When the high pressure oil flows into the cylinder
through inlet port (a) of valve plate (131) as shown in the Cylinder block (111)
figure, the hydraulic power is applied to piston (121) and
force F occurs in the axial direction. This force is
F2
separated by shoe (122) and that vector is resolved into F1
a vertical force F1, and force F2, in the direction of the
right angle to the shaft. This force F2 is transmitted to F
cylinder block (111) via piston (121) and causes
generation of the angular moment around the drive shaft.
Driving shaft (101)
Nine pistons (121) are equally aligned inside cylinder
block (111) and a running torque is transmitted to the
drive shaft in order by the several pistons communicated
with the inlet port of high pressure oil.
If the directions of oil moving in and out are reversed, the
Valve plate
rotation of the drive shaft is also reversed. (131)
Theoretical output torque T can be obtained by the Shoe plate Shoe Piston
following equation. (124) (122) (121)
Low press. oil High press. oil
Outlet port Inlet port (a)
Pxq P; Effective pressure differential MPa

T=
2x q; Dis pla ce me nt pe r re volution cc/re v
Operation of hydraulic motor
10-70
10.2.7.2 VALVE CASING SECTION

Anti-Cavitation Check Valve Section
Since the system using this type of motor is not equipped
351
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
deficient oil, in order to prevent cavitation from occurring
due to oil deficiency.
M port
(Ma ke -up port)
10
DIRECTIONAL VALVE
Anti-Cavitation Check Valve Section
Operation of relief valve Chamber h

Orifice m Spring (321) Piston 1 (302)
1. Consider where the relief valve is pressurized.
The pressure at the P, R ports is equal to the tank
pressure at the beginning, as shown in Fig.
”Functional explanation of relief valve (1)”. P
The relief valve begins to operates when the
hydraulic pressure that is determined by the product R
Pressure Chamber g
of the pressure-receiving area A1 of plunger(301) receiving A3 A2 Orifice n A4
area A1 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 Functional explanation of relief valve (1)
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 below Fig. and the relief pressure :
• Condition shown in Fig. “Functional explanation of Chamber h
Orifice m Spring (321)
relief valve (2)”. Pin (303) Piston 1 (302)
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) P
increases and when it balances the load Fsp of spring
(321), the relief valve performs relieving action by the R
pressure P1. Plunger (301) Orifice n Chamber g
This relationship is expressed as :
P1XA1=FSP1+Pg1XA2
Functional explanation of relief valve (2)
where FSP1 : primary set load value of spring (321)
10-71
• Condition shown in Fig. “Functional explanation of Orifice m Spring (321) Chamber h

Pin (303) Piston 1 (302)
relief valve (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 P
(321), the piston 1 begins to move to the left.
On that occasion, since the machine turns to the left R
while discharging the oil of chamber h arranged Orifice n
between piston 1 and adjust plug (401) into chamber Plunger (301) Chamber g
g via orifice n provided in piston 1 (302), chamber h

serves as a dumping chamber. Functional explanation of relief valve (3)
The load of the spring increases slowly till piston 1
reaches the end of the adjust plug. The relief pressure P rises smoothly.
• The machine does not travel to the left further when Orifice m Spring (321) Pin (303) Piston 1 (302)
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.
R
Plunger (301) Orifice n Chamber g
Functional explanation of relief valve (4)
In the processes 1 to 3 above, the relief pressure

changes as shown in right Fig.
Condition
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.
“Functional explanation of relief valve (1)”
10-72
Operation of anti-reaction valve
10
Hydraulic circuit diagram for anti-reaction valve.
1. Neutral condition
Above Fig. illustrates the relationship between the
neutral condition of the anti-reaction valve and the
hydraulic circuits. L
Now, let us consider a braking condition in which
brake pressure generates on the AM port side.
k
322 313 321 311
Neutral condition
2. When brake pressure occurs

m n
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 led
P=PS
to the n chamber.
When the pressure P rises above a value (Ps) set L
by spring (321), plunger (311) compresses spring
(321) and shifts it to the left.
Seat (313) compresses weak spring (322) as 322 313 321 311
pushed by plunger (311) and moves to the left.
When brake pressure occurs
p t
P<PS
k
322 313 g r 321 311
When brake pressure occurs (Operation of anti-

reaction valve)
10-73
3. At anti-reaction action P Y
When inertia load stops moving (point Y below Fig.),
PS
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) PB
X
tries to move to the right by the action of spring Z
(322), but since chamber p provides damping action T
by orifice g, the return of the seat makes a time
delay with regard to the return of the plunger. Pressure change diagram of anti-reaction
Consequently, seat t opens. This makes a passage operation
connecting the AM port and BM ports or both ports
of the hydraulic motor by way of L→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 below Fig.. This prevents the hydraulic motor from swing
shock by the closing pressure of the AM port.
10.2.7.3 OPERATION OF BRAKE SECTION

The cylinder (111) is jointed by drive shaft (101) and a 712
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 702
(301) via separator plate (743) and brake piston (702) by 712 743
the action of brake spring (712), frictional force is created
between friction plate (742) and casing (301) and 702 742
between separator plate (743) and brake piston (702).
The frictional force bounds the drive shaft to brake the 111 301
motor.
In the meantime, when brake release pressure applied to 743 742 301 101
the oil chamber formed between brake piston (702) and
casing (301) overcomes the spring force, the brake is Operation of swing brake
released as brake piston (702) moves till friction plate
(742) is separated from casing (301).
10-74
10.2.7.4 SWING REDUCTION UNIT

The swing reduction unit is used to reduce the rotating Ring ge a r (Fixe d) P la ne ta ry s ha ft
speed which is transmitted by the hydraulic motor and to
convert it to the strong turning force (torque).
This swing speed reduction unit is equipped with
planetary speed reducing mechanism. S pide r
The planetary mechanism is made up of sun gear,
S un ge a r
planetary pinion, planetary shaft, spider and ring gear, as
shown in Fig. “Planetary mechanism”.
10
P la ne ta ry pinion
Planetary mechanism
For the operation of the 1st stage planetary, the hydraulic Swing motort
motor rotates #1 sun gear (2). Sun gear (2) is engaged
with planetary pinion (3) and rotates, but since ring gear 3 2
(7) is fixed, planetary pinion (3) revolves about sun gear 7
(2) with the planetary shaft and spider (28).
The role of spider is to hold the planetary pinion and 28
planetary shaft and transmits the power from the 5
planetary pinion to the spider through the planetary
shaft. 29
The #1 spider (28) is linked with #2 sun gear (5) by the
involute spline, and transmits the power to the 2nd stage 30
planetary mechanism. For the operation of the 2nd stage 6
planetary, the power is transmitted to sun gear 12
(5)→planetary pinion (6)→spider (29) similarly to the 1st
stage.
The #2 spider (29) 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 11 1
rotates.
Function of reduction unit
10-75
10.2.8 TRAVEL MOTOR UNIT

10.2.8.1 TRAVEL MOTOR UNIT SPECIFICATIONS
Outside view
SPROCKET
INSTALLING FACE
Pm1 P1
T
Pm2
A
Tin
P2
Pp
Ps
LUBRICATION PORT
LEVEL CHECK PORT

PORT SIZE Tightening torque PORT PORT NAME
N.m (lbf.ft) SYMBOL
P1 Motor drive port
PF1 255 (188)
P2 Motor drive port
PF1/2 108 (79.7) T Drain port
Ps 1st,2nd speed change over pilot port
Pm1 P1 side pressure detecting port DRAIN PORT
PF1/4 36.3 (26.7) Pm2 P2 side pressure detecting port VIEW A
Pp Parking brake release port
Tin Lubrication port in the inside of motor case
Specifications
Parts No. YN15V00051F5
Item
Type MAG-170VP-3800G-K10
Reduction ratio 1/43.246
Reduction unit Lube oil Gear oil SAE #90 GL4
Oil level L (gal) 5.0 (1.3)
Max. displacement cc/rev (cu･in/rev) 168.9/100.3 (10.3/6.12)
System. pressure MPa (psi) 34.3 (4980)

Hydraulic motor
2-speed changeover pressure MPa (psi) 4.9 (710)
Auto 1st-speed return pressure MPa (psi) 27.3 (3960)
Braking torque K N･m (lbf･ft) 25.0 (18440)

Parking brake
Release pressure MPa (psi) 1.5 (220)
Total weight kg (lbs) 263 (580)
10-76
10
10-77
10.2.8.2 TRAVEL MOTOR UNIT CONSTRUCTION

19 20 Z2 Z2
Z3 Z3
17 22 23 19,20 21 24 26 23 25 17
X1 X1
28
S ECTION Z6-Z6
(1P LACE)
29
11 13 12 7 6 5 4 3 67 30 8 9 10 S ECTION Z5-Z5
(3P LACES )
65 66
Z6
Z4 Z4
Z6
33 34 15 14 14 15 34 33
18
S ECTION Z4-Z4 S ECTION X1-X1
Travel motor unit construction (1/2)
10-78
18 18 18
Z5 Z5
Z5
Z5
Z5 Z5
S ECTION Z2-Z2 S ECTION Z3-Z3
41 44 43 42 37 45 38 40 39 48 61 73 72 75 76 74 85 86 96
10
52 87
60 90
51 91
69 92
62 88
89
93
32
31
50
68 94
95
59
56 97
98
64
83
60
84
57 63 58 55 54 1 36 46 70 47 49 53 71 99 77 78 79 80 81 82
Travel motor unit construction (2/2)
10-79
Tight- Tight-
width width
ening ening
across across
torque No. Name Q'TY torque No. Name Q'TY
flats flats
N･･m N･･m
mm mm
205
1 FLANGE 1 12 52 CAPSCREW; M14X35 10
(151)
OIL SEAL;
2 BASE PLATE 1 53 1
TCZ50X72X9
(SPOOL)
3 1 54 DISK PLATE 3
PLUNGER
4 CHECK VALVE 2 55 FRICTION PLATE 2
5 SPRING 2 56 BRAKE PISTON 1
137*
14 6 PLUG; M24,P=1.5 2 57 O-RING 1
(101)
7 O-RING; 1B P21 2 58 O-RING 1

8 SPRING SEAT 2 59 SPRING 6
9 SPRING 2 60 PIN 4
11 CAP 2 62 VALVE PLATE 1
12 O-RING; 1B G45 2 63 O-RING; 1B P10 4
108
10 13 CAPSCREW; M12X40 8 64 O-RING 1
(80)
14 O-RING; 1B P8 2 65 NAME PLATE 1

20.6
14 15 PLUG; PF1/8 2 66 RIVET 2
(15.2)
373 RELIFE VALVE ASSY;

27 17 2 67 PLUG; PT1 2
(275) PF1-5/16
9.8 PLUG; METAL PLUG
2.5 18 8 68 PLUG; PT1/2 1
(7.2) M5
SPOOL A; 2-SPEED
19 1 69 PLUG; PT1/4 1
CHANGE OVER
20 SPOOL C 1 70 FLOATING SEAL 2
21 SPRING 1 71 ANGULAR BEARING 2
118 HOUSING
10 22 PLUG; PF1/2 1 72 1
(87) (RING GRAE)
23 O-RING; 1B P18 2 73 SHIM 1

24 SPRING GUIDE 1 74 HOLDER C 1
118
10 25 PLUG; PF1/2 1 75 WASHER 8
(87)
539* Torques
26 WASHER 1 76 BOLT; M20X70 8
(398) T90
2.45
2.5 28 ORIFICE; M5X0.8 1 77 THRUST PLATE 4
(1.81)
2.45
2.5 29 ORIFICE; M5X0.8 3 78 INNER RACE 4
(1.81)
2.45
2.5 30 ORIFICE; M5X0.8 2 79 NEEDLE BEARING 4
(1.81)
10-80
Tight- Tight-
width width
ening ening
across across
torque No. Name Q'TY torque No. Name Q'TY
flats flats
N･･m N･･m
mm mm
36.8
6 31 PLUG; PF1/4 4 80 PLANETARY GEAR C 4
(27.1)
32 O-RING; 1B P11 4 81 THRUST PLATE 4

539* Torques
33 BALL 2 82 BOLT; M20X130 4
(398) T90
10
34 SPRING 2 83 SUN GEAR C 1
36 SHAFT 1 84 SNAP RING 1
37 CYLINDER BLOCK 1 85 HOLDER B 1
38 PISTON ASSY 9 86 THRUST PLATE 3
39 RETAINER PLATE 1 87 INNER RACE 3
40 RETAINER HOLDER 1 88 NEEDLE BEARING 3
41 SNAP RING 1 89 PLANETARY GEAR B 3
42 SPRING SEAT 1 90 THRUST PLATE 3
43 SPRING 1 91 THRUST PLATE 1
58.8 Torques
44 COLOR 1 92 SCREW; M10 3
(43.4) T50
45 PIN 3 93 DRIVE GEAR 1
PLATE
46 1 94 THRUST PLATE 1
(SWASH PLATE)
47 BALL 2 95 COVER 1
73.4
48 PISTON ASSY 2 8 96 BOLT; M10X16 16
(54.1)
157
49 BALL BEARING 1 12 97 PLUG; PF3/4 3
(116)
50 BALL BEARING 1 98 O-RING; 1B P24 3

51 PIN 1 99 PIN 4
* : Apply Loctite
10-81
10.2.9 TRAVEL MOTOR UNIT OPERATION

10.2.9.1 SUMMARY
(See the figure “Hydraulic circuit of piston motor”.)
This travel motor is made up of the following units, and those functions are described below.
Piston motor
REDUCTION UNIT
R/G
The piston motor is of swash plate type, and is used to
PARKING BRAKE
convert fluid energy of pressure oil from the hydraulic
PISTON MOTOR AUTO
motor to mechanical energy and outputs the power in Tin
2-SPEED
low speed and high torque. Ps CHANGE
OVER
CROSSOVER PISTON
Double counterbalance valve (Brake valve) RELIEF VALVE
The purpose of this valve is to control the motor speed Pmi Pm2
DOUBLE
according to the supply flow rate. Therefore the overrun COUNTER-
of motor due to the outer load is prevented. BALANCE
VALVE Pp P1 P2 T
Hydraulic circuit of piston motor
Crossover relief valve

The purpose of this valve is to decide the driving force
AUTO
and braking force of motor. Therefore, for this valve, the
2-SPEED
shockless function is employed to soften the shock CHANGE
generated when the motor starts or stops and to provide OVER
the preferable operability. And this function is integrated PISTON MOTOR PISTON
into the counter balance relief valve in compact size,
composing a brake circuit.
Auto 2-speed change over mechanism

This motor is equipped with auto 2-speed change over
mechanism, enabling it to select either the low speed
mode fixed position or the auto 2-speed position. In the
auto 2-speed position, the motor capacity corresponding
to the motor load pressure is selected to automatically
change the speed, high speed or low speed.
Parking brake PARKING BRAKE

For the piston motor, a parking brake function is REDUCTION UNIT
contained. When the motor stops, the mechanical brake
actuates and prevents the rotation of motor due to the
AUTO 2-SPEED
outer load. CHANGE OVER
SPOOL
Reduction unit
The simple epicycle 2-stage speed reduction mechanism
is employed as low speed mechanism, and the
mechanism is of the rotary casing type. This speed
reduction unit converts the power in high speed and low
speed torque output by the piston motor to the power in
low speed and high torque and outputs it through the
reduction unit casing. DOUBLE COUNTERBALANCE CROSSOVER
VALVE RELIEF VALVE
In addition, the floating seal is contained in it to prevent
the entry of mud, sand, water, etc.
Travel motor made up
10-82
10.2.9.2 PISTON MOTOR

The construction drawing of piston motor is shown in below Fig..
Nine pistons (29) are placed in the cylinder block (28), the end face of cylinder block is in contact with valve plate
(63) in the two ports B and C (shaped somewhat like crescent). The hydraulic pump oil delivered flows into the
piston through P1 or P2 port and flows out through P2 or P1 port while having the piston motor rotated.
And, the drain oil escaped through each sliding section and the space in the case returns in the hydraulic tank
through T port of base plate (2).
1. The high pressure oil through P1 port flows into B port (shaped somewhat like crescent) of valve plate, applies
pressure to piston (29) and moves swash plate (37) from top dead point to bottom dead point rotating itself.
2. The P2 port is moved to the low pressure side and piston (29) discharges the oil through C port (shaped
somewhat like crescent) of valve plate (53) into P2 port.
10
3. With the reciprocating motion of piston (29), shaft (27) linked with cylinder block (28) and each other rotates in
the opposite direction to arrow as shown in the figure.
4. When the piston motor rotates clockwise, P1 side turns to the low pressure side and P2 side turns to the high
pressure side.
This way, the piston motor converts the hydraulic fluid energy from the hydraulic pump to the mechanical energy,
and outputs the turning effort at low speed and high torque. And the torque and speed of the piston motor is
decided according to the pressure and flow rate. If the pressure and flow rate are raised, the torque and speed of
piston motor are also raised.
27
29
28
53
37 C
Construction of piston motor
10-83
10.2.9.3 DOUBLE COUNTERBALANCE VALVE
Functions
The function of double counter balance valve is described below.
• Overrun prevention function to control the speed of piston motor to the speed corresponding to the supply flow
rate when the piston motor speed is higher than the speed decided by the supply flow rate (hereinafter called
pumping action) due to the outer load.
• Braking function to gradually stop the piston motor revolution by forming the brake circuit by the use of crossover
relief valve and giving the braking force to the piston motor revolution.
• Shuttle valve function for high pressure selection to release the parking brake with the aid of self pressure.
Operation
1. Stop condition
(See Fig. “Construction of double counter balance valve (stop condition)”.)
When the control valve is at the neutral position (motor is stopped), M1 and M2 ports are locked by plunger (3)
and check valve (4) (hydraulic lock) and the motor stops rotating because the pressure does not flow through
P1 and P2 ports.
OIL PASSAGE B
OIL PASSAGE C2
OIL PASSAGE C1
ORIFICE D1
ORIFICE D3
DAMPER CHAMBER DAMPER CHAMBER

A1 A2
ORIFICE D2
ORIFICE D4
SPRING CHAMBER 1 SPRING CHAMBER 2
3
4
Construction of double counter balance valve (stop condition)
10-84
2. When motor starts rotating

(See Fig. “Double counter balance valve when motor is rotated”.)
When the oil delivered from the hydraulic pump is led into P1 port of the double counter balance valve, check
valve (4) moves leftward resisting to the spring (5) force and oil passage C1 opens, and the oil delivered flows
into the piston motor through M1 port and tries to rotate the piston motor.
On the other hand, the return oil from the piston motor flows into the double counter balance valve through M2
port, but the flow of the oil delivered is interrupted by check valve (4) consequently the delivery pressure of the
hydraulic pump is raised.
Therefore, the pressure in P1 port side is raised, the pressure oil flows through orifice (21), acts on the spring
chamber 1 and damper chamber A1 and moves plunger (3) rightward resisting the spring (8) force on the
opposite side with the force in proportion to the pressure. 10
Then, the return oil through M2 port flows through oil passage B on the notched section around plunger (3) into
P2 port, generates back pressure in M2 port, and flows into P2 port, and returns into the tank through the
control valve, and consequently the piston motor starts rotating.
3. Counter balance function
(See Fig. “Double counter balance valve when motor is rotated”.)
When the piston motor is rotating, if the outer load is applied on it to forcibly rotate further, the piston motor give
rise to the pumping action and causes a overrun. In this case, P1 port side is in suction side, and the pressure
falls. Concurrently the pressure of spring chamber 1 and damper chamber A1 also lowers. Therefore, plunger
(3) is moved leftward by the spring (8) force, oil passage B closes, and the flow of return oil also stops.
Immediately after stopping the flow of oil in oil passage B, the pressure in P1 port side is raised by the oil
delivered of the hydraulic pump and moves plunger (3) rightward.
This way, when the pumping action is caused by the outer load, plunger moves bit by bit, and maintains the
opening area of oil passage B in the appropriate condition. And the piston motor maintains the speed
corresponding to the supply flow rate from the hydraulic pump, and prevents vacuum phenomenon in the
hydraulic circuit to protect the piston motor from overrunning.
OIL PASSAGE B
OIL PASSAGE C2
OIL PASSAGE C1
ORIFICE D1 ORIFICE D3

A1 A2
ORIFICE D2
ORIFICE D4
SPRING CHAMBER 2
SPRING CHAMBER 1
8 21
21 4
5 4 3
Double counter balance valve when motor is rotated
10-85
4. Braking of piston motor

(See Fig. “Double counter balance valve and relief valve when piston motor is braked.”.)
The double counter balance valve composes the brake circuit with the crossover relief valve.
By returning the control valve to the neutral position, the pressure oil from the hydraulic pump is cut, and the
pressure of P1 and P2 becomes equal. And plunger (3) returns to the neutral position and the opening area of
oil passage B becomes smaller.
On the other hand, the piston motor tries to further rotate due to the inertia energy of the outer load (pumping
action of piston motor), and consequently the pressure of M2 port rises and acts on the piston motor to brake it
to stop the revolution.
Then, when the pressure in M2 port side reaches to the set pressure of relief valve (11), poppet (11-2) on M1
port side moves leftward resisting the spring (11-5) to escape the pressure oil in M1 port side. Consequently,
the shock pressure due to the inertia energy in M2 port side is controlled and concurrently the generation of
vacuum in M1 port side is prevented.
11-2
11
OIL PASSAGE B
11-5
OIL PASSAGE C2
OIL PASSAGE C1
ORIFICE D1
ORIFICE D3

A1 A2
ORIFICE D2
ORIFICE D4
SPRING CHAMBER 1 SPRING CHAMBER 2
Double counter balance valve and relief valve when piston motor is braked.
10-86
5. Shuttle valve function for high pressure selection

(See Fig. “High pressure selecting function (In case of selecting high pressure)”.)
The double counter balance valve contains the high pressure select shuttle valve function for the release of
parking brake self-pressure additionally.
When the pressure oil is supplied through P1 port, plunger (3) moves rightward to the position shown in below
Fig.. and oil passage D to cylinder chamber E of the parking brake opens, and the pressure oil is led into oil
passage G through orifice and flows into cylinder chamber E of the parking brake to release the parking brake.
In addition, when the piston motor stops, plunger (3) returns to the neutral position, oil passage D closes and
parking brake is actuated by the action that the brake pistons (47) are pushed back with spring (50).
3
10
OIL PASSAGE D
OIL PASSAGE D
OIL PASSAGE D
ORIFICE 50 47
OIL PASSAGE G CYLINDER CHAMBER E

OIL PASSAGE G
High pressure selecting function (In case of selecting high pressure)
10-87
10.2.9.4 CROSSOVER RELIEF VALVE

The construction of relief valve is shown in below Fig..
This relief valve is the differential area direct driven type.
Construction of relief valve
Operation and function of relief valve 11-2 11-5

After starting the control valve, and if the piston motor is
started or braked, the pressure on the front side of
poppet (11-2) rises to the set pressure or higher and
resists against spring (11-5) force, and poppet (11-2)
moves rightward and is separated from poppet seat (11-
3). And the high pressure oil in the front side of poppet
11-3
(11-2) is bypassed into the oil passage on the low
pressure side. This way, by bypassing the high pressure
oil into the low pressure side, the shock pressure due to Operation of relief valve
the inertia energy in the oil passage on the high pressure
side is controlled and concurrently the generation of vacuum in the low pressure oil passage is prevented.
Shockless function
11-5
(See Fig. “Shockless function and comparison of 11-2 AREA S2
pressure waves”.)
When the relief valve starts operating, shockless piston
(11-9) moves leftward. And the inside of spring chamber
D is held at the low pressure. Consequently the pressure
receiving area of poppet (11-2) becomes S1, and the
receiving are is only S1 to the Receiving area S1-S2
when the relief valve is set to the regular position. 11-3 AREA S1 11-9 SPRING
CHAMBER D
Therefore, the relief valve operating pressure is kept in
approx. 1/3 of the regular set pressure until the
movement of shockless piston (11-9) is completed, and
P RES S URE
P RES S URE
the shock pressure due to the inertia energy in the oil

passage on the high pressure side is absorbed.
After completion of the movement of shockless piston,
the pressure in the spring chamber D rises and the
pressure on the front and after sides of poppet (11-2)
becomes equal, and the relief valve operates at the CONVENTIONAL TYPE SHOCKLESS TYPE
regular set pressure.
As described above, the relief valve operates in two
stages to reduce the shock generated when starting or Shockless function and comparison of pressure
braking the piston motor, and provides a fine operability. waves
And the difference of pressure wave form between the
conventional type and shockless type is shown in below Fig..
10-88
10.2.9.5 AUTO 2-SPEED CHANGE OVER
2-Speed change over mechanism

Fig. “High speed (low capacity)” shows the function when the motor capacity is low (at high speed).
Swash plate (37) has three faces A to C. This swash plate (37) is installed on flange holder (1) with two steel balls
(38) in the condition where the tilt rotation is possible. And 2-speed control piston (39) is in contact with the face B
of swash plate (37).
And 2-speed control (select) valves (13,14) are installed on base plate(2).
1. When switching the motor capacity to low capacity
(See Fig. “High speed (low capacity)”.)
With turning the speed control switch to high speed, the pilot pressure oil acts on Ps port and moves 2-speed 10
control valves (13,14) rightward resisting to the spring (15) force until the valves come into contact with plug
(19). Therefore M1 and M2 ports of the motor are connected with oil passages A1 and A2 led to the 2-speed
control piston chamber F and the motor drive pressure is led into the 2-speed control piston chamber F. The 2-
speed control piston (39) is pushed up until the face A of swash plate (37) is in contact with flange holder (1)
and the tilt angle of swash plate becomes smaller, and consequently the piston motor turns to high speed.
PS (PILOT PRESSURE)
PILOT PRESSURE OIL PASSAGE A MOTOR LOAD PRESSURE CHAMBER

OIL CHAMBER 15
19
T1 T2
13,14
OIL PASSAGE B
A1
A2
PISTON
CHAMBER F
39
39 FACE B
2-SPEED FACE C M1 M2
CONTROL
PISTON THRUST (29)
PISTON
THRUST
SPRING
THRUST (34)
37
38 FACE A
1 38
High speed (low capacity)
10-89
2. When switching the motor capacity to large capacity (low speed mode)
(See Fig. “When fixed to low speed (large capacity)”.)
When switching the motor capacity to large capacity (low speed mode), (See below Fig..) With turning the
speed control switch to low speed, by returning the pilot pressure oil acting on Ps port into the tank, 2-speed
control valves (13,14) is moved rightward by the spring (15) force until it comes into contact with plug (16).
Therefore M1 and M2 ports of the motor close, and oil passages A1 and A2 led to the 2-speed control piston
chamber F is led into motor case drain oil passages T1 and T2. And pressure oil in the 2-speed control piston
chamber F is led into the motor case drain, and the face C is pushed by the thrust of piston (29) and spring (34)
until the face B of swash plate (37) comes in contact with flange holder (1), consequently the tilt angle of swash
plate (37) becomes larger and the piston motor speed switches to low speed.
PS (PILOT PRESSURE)

OIL CHAMBER 15
16
T1 T2
OIL PASSAGE B
A1
A2
PISTON
CHAMBER F
39
FACE B
39
FACE C M1 M2
PISTON THRUST (29)
SPRING
THRUST (34)
37
38 FACE A
1 38
When fixed to low speed (large capacity)
10-90
Auto 2-speed change over operation

This piston motor is available to select the position where the motor capacity is fixed to the low speed (large
capacity) and the position auto 2-speed position containing the motor capacity section function corresponding to
the load pressure of the motor.
1. Selection of low speed (large capacity) fixing position
The condition where the motor capacity is fixed to the low speed (large capacity) is shown in Fig. When fixed to
low speed (large capacity). Turn the speed control switch to low speed, and the pilot pressure acting on Ps port
returns into the tank and consequently the motor capacity control valve housed in the motor is fixed to the low
speed (large capacity) position.
2. Selection of auto 2-speed position
The condition of auto 2-speed position where the motor capacity is selected according to the load pressure is
10
shown in "High speed (low capacity) in Auto 2-speed", "Low speed (large capacity) in Auto 2-speed" Fig.. Turn
the speed control switch to high speed and the specified pressure acts on Ps port, and the pressure oil which is
acted on Ps port acts on the front face of the motor capacity control valve housed in the motor, and the auto 2-
speed position which switches the motor capacity according to the load pressure to the motor can be obtained.
3. High speed (low capacity) position (See Fig. "High speed (low capacity) in Auto 2-speed".)
High speed (low capacity) position (See Fig. "High speed (low capacity) in Auto 2-speed".) The motor high
speed condition at auto 2-speed position is shown in below Fig.. Apply the specified pilot pressure on Ps port,
and the pilot pressure oil flows through oil passage A and acts on the pilot hydraulic pressure chamber on the
front face of the motor capacity control valve and pushes the motor capacity control valve rightward. And load
pressure Pin to the motor flows through oil passage B, acts on the motor load pressure chamber, and pushes
the motor capacity control valve leftward. When Pin is lower than the motor capacity control pressure P which
is decided with a ratio of the pressure receiving areas of the pilot pressure and motor load pressure, the motor
capacity control valve is maintained in the condition shown in "High speed (low capacity) in Auto 2-speed" Fig.
and the motor is operated in high speed (low capacity) mode.
PS (PILOT PRESSURE)
OIL
PILOT PRESSURE PASSAGE A MOTOR LOAD PRESSURE CHAMBER
OIL CHAMBER
T1 OIL T2
PASSAGE
B
Pin
M2 M1
High speed (low capacity) in Auto 2-speed
10-91
4. Low speed (large capacity) position (See Fig. “Low speed (large capacity) in Auto 2-speed”.)
The motor low speed condition at auto 2-speed position is shown in Fig. “Low speed (large capacity) in Auto 2-
speed”. When load pressure Pin to the motor is raised higher than the auto 1st speed return pressure, the
motor capacity control valve moves rightward, and is switched to the motor low speed (large capacity) mode,
that is, the motor low speed operation.
PS (PILOT PRESSURE)

OIL CHAMBER
T1 OIL T2
PASSAGE
B
Pin
M2 M1
Low speed (large capacity) position
10-92
10.2.9.6 PARKING BRAKE

The construction of parking brake section is shown in Fig. “Parking brake release condition”. The parking brake is
made up of disk plate (54) linked with the cylinder block, friction plate (55) and brake piston (56) located between
disks and spring (59) which transmits the force to the brake piston.
Releasing parking brake
(See Fig. “Parking brake release condition”.)
When the pressure oil is fed through P1 port and the
piston motor starts driving, the pressure oil is led into the
CYLINDER
cylinder chamber E of the parking brake through oil BLOCK
passage D as described in Article “Operation”-5 "Shuttle
valve function for high pressure selection" of "6.3.3
10
OIL
Double counter balance valve", the oil pressure acts on PRESSURE 45
brake piston (47) and moves leftward resisting the spring
46
(50) force. Consequently, the force pushing disk plate MOTOR CASE
(45) dies out, and disk plate (54) becomes free and the
parking brake is released.
50 47 CYLINDER CHAMBER E
Parking brake release condition
Operation of parking brake

(See Fig. “Parking brake operation condition”.)
When returning the control valve to the neutral position,
cutting the pressure oil to be fed into P1 port and
CYLINDER
stopping the piston motor, the oil passage D is
BLOCK
connected to motor case drain passage F as described
in Article “Operation”-5 "Shuttle valve function for high
SPRING
pressure selection" of "6.3.3 Double counter balance FORCE 45
valve", the pressure oil in cylinder chamber E of the
46
parking brake is led into the motor case drain and the MOTOR CASE
pressure drops. Therefore, brake piston (47) is moved
rightward by the spring (50) force, and disk plate (45) is
clamped by brake piston (47) and the motor case with
the spring (50) force, consequently the piston motor 50 47 CYLINDER CHAMBER E
shaft is locked and the parking brake actuates.
Parking brake operation condition
10-93
10.2.9.7 REDUCTION UNIT

(See Fig. “Construction of reduction unit”.) SPROCKET MOUNTING
The reduction unit is constructed so that simple
planetary gear reduction units which are made up of FIXED ON THE 1 67 74 76 63
drive gear, sun gear, holder, planetary gear and ring gear FRAME OF
(tooth is cut inside of the housing.) are combined in two MACHINE
stage. PISTON MOTOR
SHAFT
79
When the pressure oil flows into the piston motor, the
piston motor shaft rotates at high speed, and the power
78
is input to the reduction unit section.
In the reduction unit section, this high speed is reduced 80
in two stages by the simple planetary gear reduction unit
84
and has housing (63) with ring gear rotated, and
consequently the output in low speed and high torque is 73
obtained.
Operation of 1st stage reduction section

The 1st stage reduction section is made up of drive gear 65 63 71 69 70
(84), planetary gear B (80), ring gear (63), holder (76),
needle bearing (79) and inner race (78).
Planetary gear B (80) is engaged with drive gear (84). Construction of reduction unit
When drive gear (84) rotates clockwise, planetary gear B
(80) rotates counterclockwise. On the other hand, it is also engaged with the ring gear, it kicks the tooth of the ring
gear and attempts to revolve around drive gear (84).
This orbital motion in clockwise is transmitted to holder B (76) and holder B (76) starts rotating clockwise because
planetary gear (80) is fixed on holder B (76) through the aid of needle bearing (79) in rotation free condition.
And holder B (70) is engaged with the 2nd stage sun gear C (74) with spline, and the rotation of this holder B (76) is
transmitted to the 2nd stage sun gear C (74).
Operation of 2nd stage reduction section

The 2nd stage reduction unit is made up of sun gear C (74), planetary gear C (71), ring gear (63), holder C (65),
needle bearing (70) and inner race (69).
Planetary gear is engaged with sun gear C (74). When sun gear C (74) rotates clockwise, planetary gear C (71)
rotates counterclockwise.
Planetary gear C (71) is fixed on holder C (65) through the aid of needle bearing (70) in rotation free condition, and
holder C (65) is connected to flange (1) with bolts (67) (73) and the flange is not allowed to rotate because it is fixed
on the frame of machine.
Therefore, planetary gear C (80) is not allowed to revolve differently to the 1st stage reduction section, but is
allowed to rotate counterclockwise due to the installation position. And planetary gear C (71) is engaged with the
ring gear and this axial motion in counterclockwise of planetary gear C (71) is transmitted to the ring gear and
rotates the ring gear counterclockwise.
With the operation as described above, the housing cut on the inner bore of ring gear (63) receives the power of
planetary gear B and C (80) (71) and rotates, and the power is transmitted to the driven section of the machine
linked with housing (63) with ring gear.
10-94
10.2.10 SWIVEL JOINT

10.2.10.1 GENERAL VIEW OF SWIVEL JOINT
D
F E A
C
10
D
VIEW Y
C
VIEW Z
General view of swivel joint
10.2.10.2 SPECIFICATIONS OF SWIVEL JOINT

Item Specification
Assy parts No. YN55V00059F1
Working pressure 34.3 MPa (4973 psi)

High pressure ports
Max. impact pressure 51.5 MPa (7468 psi)
A, B, C, D
Rated flow 280 L/min (80.0 gal/min)
Low pressure ports Working pressure 0.49 MPa (71.1 psi)

E Rated flow 50 L/min (13.2 gal/min)
Low pressure ports Working pressure 5 MPa (725 psi)

F Rated flow 30 L/min (7.93 gal/min)
Revolution speed 15 min-1 (15 rpm)
A, B, C, D (Body) PF1
A, B, C, D (Stem) PF1
Ports size
E PF1/2
F PF1/4
Length: L 371 mm (14.6 inch)
Weight 23.7 kg (52.3 lbs)
10-95
10.2.10.3 CONSTRUCTION OF SWIVEL JOINT
Apply Three Bond

#1805 to stem
8
6
VIEW Y
5
5 places
7 3 places
Tighte ning torque
3 30.4 N .m (22.4 lbf .ft)
10 Apply Loctite #242
4
11 2 places
Tighte ning torque
30.4 N .m (22.4 lbf .ft)
Apply Loctite #242
Construction of swivel joint
No. Name Q'TY No. Name Q'TY
1 Body 1 7 O-ring (G95 1A) 1
2 Stem 1 8 O-ring (G80 1B) 2
3 Thrust plate 1 9 Plug 1
4 Cover 1 10 Capscrew (M8X30) 3
5 Seal 5 11 Capscrew (M8X20) 2

6 Seal 1
10.2.10.4 FUNCTION
The swivel joint consists mainly of body (1) and stem (2) that rotate mutually, thrust plate (3) preventing both
components from falling off, cover (4) closing one side of body (1), seal (5) that partitions off the circuits and seal
assy (6) and O-ring (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. 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.
10-96
10.2.11 CONTROL VALVE (N&B)

10.2.11.1 GENERAL OF CONTROL VALVE (N&B)
General view
(-) side (+) side
(-)
Type of conne ctor: e quiva le nt to AMP ECONOS EAL J s e rie s conne ctors
MARK II(+) cap hausing
(+)
Cap housing 174354-2 or equivalent 10
ELECTRICAL CIRCUIT Te rmina l 173706-1 or e quiva le nt
t1 P t2
LCo
BoR AoR
PAo P Bo
T
Dr
Ps
PBo
Bo Ao PL
HYDRAULIC CIRCUIT
Emergency manual screw

Max. tightening torque
2.0 N .m (5.8 lbf .ft) and below
Slit width 1.0mm (0.04inch)X
depth 1.3mm (0.05inch)
Tighte ning torque

6.9~7.9 N .m (5.1~5.8 lbf .ft) Bo
Ao
Width across flats 12
LCo
Item Specification
Assy parts No. LQ30V00046F1
Standard flow 300L/min (79.3gal/min)
Max,pressure (P,Ao,Bo ports) 38MPa (5510psi)
Allowable Tport pressure (At P⇔A) Degrees or less 0.8MPa (116psi)
Rated voltage DC 24V
Mass 32kg (70.6 lbs)
10-97
10.2.11.2 CONSTRUCTION OF CONTROL VALVE (N&B)

D 702x2
701x2
901
B B
P Bo LCo
Bo
Ao
BoR
C C
D 271x2
601 206 206 206

T
PAo
AoR
703x4
271x2
201 321 161 302 SECTION BB
207
162
PL Ps Dr 163
PBo PAo
t1 P t2
602 512 522 551 561 SECTION DD

Bo LCo Ao
602
BoR
AoR
PBo PAo
202
334
204 262 101 301 261 337 333 324 323 337
SECTION CC
10-98
TIGHTENING TORQUE LIST
Tightening torque
Item Size Note
N･･m (lbf･･ft)
206 M7X0.75 16 to 20 (12 to 15)
207 ROM-3/8 69 to 78 (51 to 58)
271 M8X25 25 to 34 (18 to 25)
334 - 16 to 18 (12 to 13) Loctite #262
551 - 310 to 350 (229 to 258)

10
602 - 69 to 78 (51 to 58)
701 M10X25 48 to 65 (35 to 48)
702 M5X12 5.8 to 7.9 (4.3 to 5.8)
703 M12X170 98 to 120 (72 to 89)
101 Casing 1 323 Spring 1
163 O-ring 1 334 Spacer bolt 2
201 Spring cover 1 337 Spring seat 1
202 Spring cover 1 512 Poppet 1
204 Spool cover 1 522 Spring 1
206 Plug 3 551 Plug 1
207 Plug 1 561 O-ring 1
261 O-ring 1 601 Solenoid operated directional control valve 1
262 Square ring 1 602 Relief hole plug assy 2

271 Hex S.H.O screw 4 701 Hex S.H.O screw 2
301 Option spool 1 702 Hex S.H.O screw 2
302 Selector spool 1 703 Hex S.H.O screw 4
321 Spring 1 901 Eye bolt 1
10-99
10.2.12 PILOT VALVE (N&B)

10.2.12.1 GENERAL OF PILOT VALVE (N&B)
2-M10x1.5 VIEW B
Thread depth15
Item Specification

Type 16030-00000
Effort to operate Refer to the curve below
Primary pressure 5MPa (725psi)
Secondary pressure 0.54 to 2.35MPa (78 to 341psi)
Mass 3kg (11 lbs)
Secondary pressure Effort to operate

[MPa ] [ps i] [N.m] [lbf.ft]
2.94 (426) 11.76 (8.67)
2.45 (355) 9.8 (7.2)

S e conda ry pre s s ure
2.35 ( 341)
Effort to ope ra te
1.96 (284) 7.84 (5.78)
1.47 (213) 5.88 (4.34)

4.61 (3.40)
0.98 (142) 3.92 (2.89)

0.54 (78)
0.49 (71) 1.96 (1.45)

1.11 (0.82)
0 0 2 4 6 8 10 12 [de g]
Operating angle
Hydraulic circuit Control diagram
10-100
10
10-101
10.2.12.2 CONSTRUCTION OF PILOT VALVE (N&B)

15 21 13 14
19
27
26 6
7 24
31
1
2
29 5
20
8 9
11
32 12
22
16 18
28
26
3
25
TIGHTENING TORQUE LIST
Tightening
Item Size torque Note
N･･m (lbf･･ft)
3 - 14.7 (10.8) Loctite #262
18 - 24.5 (18.1)
19 M12 39.2 (28.9)
20 M4 4.9 (3.61) Loctite #262
21 M8 14.7 (10.8)
- M10 70.6 (52.1) M10 screw tightening
- M10 70.6 (52.1) M10 mounting bolt
- PF1/4 29.4 (21.7) PF1/4 nipple tightening
10-102
1 Shim 2 16 Body 2
2 Shim 2 18 Plug 1
3 Seat 1 19 Capscrew 1
5 Sleeve 2 20 Bolt 2
6 Cover 1 21 Setscrew 2
7 Piston 2 22 Washer 2
8 Spring 1 24 Pin 2
Spring
10
9 2 25 Ball 1
11 Shim 2 26 Ball 3
12 Shim 1 27 O-ring 2
13 Cam 1 28 O-ring 1
14 Boot 1 29 O-ring 2
15 Pin 1 31 Piston assy 2
10-103
10.2.13 CYLINDER
10.2.13.1 SPECIFICATIONS OF CYLINDER
General View
B A
n gth ngth
ed le ed le
nd act
exte r etr
l l y ll y
Fu Fu
Part No. and Manufacturing No.

Stamp position
General view of cylinder
Specifications
Center distance of pins
Cylinder bore / Stroke Dry
Part No. of Full extend B / Full Cushion
Use Rod Dia. Unit: mm weight
cylinder assy retract A mm (inch)
Unit: mm (ft-in) (ft-in) [kg (lbs)]
Unit: mm (ft-in)
With cushion
Dia. 120 / Dia. 85 1,355 3,199 / 1,844 166
Boom YN01V00151F2 on rod side
(4.72”/3.34”) (4’5”) (10’6”/6’11”) (370)
R-50 (1.97”)
With cushion
135 dia./ 95 dia. 1,558 3,637 / 2,079 on both sides 255
Arm YN01V00175F4
(5.32"/3.74") (5’1”) (11’11”/6’10”) H-40 (1.57”), (562)
R-60 (2.36”)
Rod side
Dia. 120 / Dia. 80 1,080 2,675 / 1,595 143
Bucket YN01V00153F2 on rod side
(4.72”/3.15”) (3’7”) (8’9”/5’3”) (315)
R-50 (1.97”)
10-104
10.2.14 CONSTRUCTION OF CYLINDER

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).
10.2.14.1 CONSTRUCTION OF BOOM CYLINDER 10

T= Tighte ning torque ; N.m (lbf.ft)
4-M10x1.5
[Effective thread depth: 18mm (0.71 inch) ]
4-M12x1.75
[Effective thread depth: 21mm (0.83 inch) ]
(-0.02")
(4.13")-0.5
105 0
22 23 23 22
PS1/8
PT1/4
T=56.9 (42.0) [M12x1.75]

[Skate 2 places after tightening.]
With hole T=5460 (4029)

(1 place) [M65x3, width across flats 95]
T=267 (197) [12-M16x2]
10 20
9 8 7 6 3 4 5 12 11 2 1 13 14 16 17 24 19 15 21
[Location of the slit is

shown in the drawing.]
[At installation,
pay attention to
orientation of slit.]
Construction of boom cylinder
10-105
P/No: YN01V00151F2
No. NAME Q'ty No. NAME Q'ty No. NAME Q'ty
1 Cylinder tube 1 9 Wiper ring 1 17 Buckup ring 2
2 Piston rod 1 10 O-ring 1 19 Slide ring 2
3 Rod cover 1 11 Buckup ring 1 20 Set screw; M12 1
4 Bushing 1 12 Socket bolt; M16X75 12 21 Steel ball 1
5 Snap ring 1 13 Ring 1 22 Pin bushing 4
6 Buffer ring 1 14 Cushion seal 1 23 Dust seal 4
7 U-ring 1 15 Piston 1 24 Slide ring 2
8 Buckup ring 1 16 Seal ring assy 1
10.2.14.2 CONSTRUCTION OF ARM CYLINDER

T=56.9 (42) [M14×2] T= Tighte ning torque ; N.m (lbf.ft)
T=367 (271) [12 + M18×2.5] [Skate 2 places after tightening.] UNIT ; mm (inch)
T=7890 (5820) [M75x3, width across flats 1 10]
With hole
(1 place) 7 10
9 8 6 4 5 3 12 11 20
16 17 18 19 15 21 25 2322 24
29 31 13 14
[At installation, pay attention

to orientation of slit.] [Effective thread depth:
21 mm (0.83 inch)]
[Location of the slit is shown in the drawing.]
(-0.02")
(4.72")-0.5
120 0
30
30 27 27
Construction of arm cylinder
P/No: YN01V00175F4
3 Rod cover 1 12 Socket bolt 12 21 Steel ball 1

4 Bushing 1 13 Cushion bearing 1 22 Cushion bearing 1
5 Snap ring 1 14 Cushion seal 1 23 Cushion seal 1
6 Buffer ring 1 15 Piston 1 24 Stopper 2
7 Ring 1 16 ring assy 1 25 Snap ring 1
8 Buckup ring 1 17 Buckup ring 2 27 Dust seal 4
9 Wiper ring 1 18 Slide ring 2 29 Piston rod 1
10 O-ring 1 19 Slide ring 2 30 Bushing 2
11 Buckup ring 1 20 Setscrew; M12 1 31 Tube assy 1
10-106
10.2.14.3 CONSTRUCTION OF BUCKET CYLINDER

T= Tighte ning torque ; N.m (lbf.ft)
UNIT ; mm (inch)
4-M12×1.75
[Effective thread depth: 21mm (0.83 inch)]
(-0.02")
(-0.02")
(4.13") -0.5
(4.13")-0.5
105 0
105 0
10
25 22 22 25
PS1/8
PS1/8
T=56.9 (42) [M12×1.75]

[Skate 2 places after tightening.]
With hole T=6200 (4573) [M62x3, width across flats 95]

(1 place)
T=267 (197) [12 + M16×2]
10 19
9 8 7 6 3 4 5 12 11 24 23 13 15 16 17 18 14 20
[At installation, pay attention to orientation of slit.]
Construction of bucket cylinder
P/No: YN01V00153F2
3 Rod cover 1 11 Buckup ring 1 19 Set screw; M12 1
4 Bushing 1 12 Socket bolt; M16X75 12 20 Steel ball 1
5 Snap ring 1 13 Cushion bearing 1 22 Dust seal 4
6 Buffer ring 1 14 Piston 1 23 Cylinder tube 1
7 U-ring 1 15 Seal ring 1 24 Piston rod 1
8 Buckup ring 1 16 Buckup ring 2 25 Pin bushing 2
9 Wiper ring 1 17 Slide ring 2
10 O-ring 1 18 Slide ring 2
10-107
10.2.14.4 OPERATION OF CYLINDER

If pressurized oil is fed alternatively to the oil inlet and Cushion bearing (13) Chamber "A" Passege "B"
outlet provided in the cylinder, force acts on the piston Tank
which in turn causes the piston rod (2) to extend and Piston (15)
retract. Rod (2)
Operation of cylinder with cushion Rod side

Head side
Rod cover (3)

Cushion stroke
Cushion mechanism on the rod side
1. Cushion on rod side Tank

Clearance "D"
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 Mouth Gap C
through passage "B" at a fixed flow rate in a
intermediate stroke state (Right Fig.) of pressing
head side. Next, in a state of just before stroke end
(Right Fig.), cushion ring (13) plunges into passage
"B". At this time, an oil in chamber "A" passes
clearance "D" and mouth gap "C", an oil flow volume Cushioning action on the rod side
returning to tank suddenly drops and the piston part
movement slows down.
2. Cushion on head side Camber "A"
This construction is similar to the one of cushion on
Cushion seal (23)
rod side. In a state of intermediate stroke pressing
Passage "B" Tank Cushion bearing (22)
rod side, an oil in chamber "A" returns to tank by
passing through passage "B" at a fixed flow rate.
Next, in a state of just before stroke end, cushion
bearing (22) plunges into passage "B".So the
returning oil volume drops suddenly and the piston
movement slows down.
Clearance "D"
Mouth gap C
Cushion seal (23)
Cushion mechanism on the head side
10-108
10.3 ELECTRICAL EQUIPMENT

10.3.1 ELECTRICAL EQUIPMENT LIST
(C) Controller
Code NAME PART NO.

C-1 Mechatro controller (TCO-63-1A) (Hard) YN22E00488F1
C-2 Gauge cluster YN59S00039F1
C-4 Air conditioner controller (integrated into panel) LQ20M01375P1

10
C-5 Engine coolant level controller VH834701230
C-8 Engine controller VH89661E0010
(D) DIODE
Code NAME PART NO.

D-4 Diode YN02D01001P1 (4P)
D-9 Diode Accessory of fuse & relay box
D - 12 Diode ↑
D - 13 Diode ↑
D - 14 Diode ↑
D - 20 Diode ↑
D - 21 Diode ↑
D - 22 Diode ↑
D - 23 Diode ↑
D - 24 Diode ↑
D - 25 Diode YN02D01001P1 (4P)
(E) Electric Equipment
No. NAME PART NO.

E-1 Fuse & relay box YN24E00036F2
E-2 Alternator ENG. ACCESSORY PARTS
E-5 Horn (high) LC53S00001D1
E-6 Horn (low) LC53S00001D2
E-8 Speaker left LQ54S00003S002
E-9 Speaker right ↑
E - 10 Receiver dryer LQ54S00005P1
E - 11 Air conditioner compressor YX91V00001F1
E - 12 Battery YN72S00018F1
E - 15 Fusible link YB73S00001P1
E - 27 Accel redundant volume YN52S00106P1
E - 35 Glow ENG. ACCESSORY PARTS
E - 38 Resistor LC22E01001D1
E - 65 24V power socket LQ81S01001P1
E - 101 CAN resistor 1 PY26E01001P1
10-109
No. NAME PART NO.

E - 102 CAN resistor 2 ↑
E - 103 Engine controller check connector ENG. ACCESSORY PARTS

E - 104 9P connector ↑
(L) LIGHT
Code NAME PART NO.

L-1 Boom working light left YN80S00012F1
L-2 Deck working light right YT80S00002F2
L-5 Room light LQ02C00031S020
L-7 Cab working light front 1 YT80S00002F2
L-8 Cab working light front 2 ↑
L-9 Boom cylinder working light ↑
L - 15 Cab working light front 3 ↑
L - 16 Cab working light front 4 ↑
(M) Motor
Code NAME PART NO.

M-1 Starter motor ENG. ACCESSORY PARTS
M-3 Wiper motor LQ53C00003S001
M-4 Washer motor YT54C00003F1
(PSV) PROPORTIONAL SOLENOID VALVE
No. NAME PART NO.

PSV-A Arm two-speed inverse proportional sol. YN35V00049F1
PSV-B P2 unload proportional sol. YN35V00048F2
PSV-C Travel straight proportional sol. (LQ35V00008F1) ↑

Proportional solenoid valve
PSV-D P1 unload proportional sol. assy ↑
PSV - 23 Boom 3 proportional valve ↑
PSV - 24 Boom 2 proportional valve ↑
PSV - P1 P1 pump proportional valve (YN10V00070F1) YN35V00054F1
PSV - P2 P2 pump proportional valve Pump ↑
(R) Relay
Code NAME PART NO.

R-1 Battery relay YN24S00008F1
R-2 Starter relay VHS283001271
R-3 Glow relay VH286201420
R-4 Safety relay YN24S00010P1
R-5 Horn relay ↑
R-6 Working light relay ↑
10-110
Code NAME PART NO.

R-9 Cab working light relay 1 ↑
R - 11 Cab working light relay 2 ↑
R - 23 Auto idle stop relay 1 YN24S00010P1
R - 24 Auto idle stop relay 2 ↑
R - 25 Engine emergency stop relay ↑
R - 26 Lever lock relay ↑
R - 28 Alternator relay ↑
10
R - 29 Wiper motor normal rotation relay YN24S00012P2
R - 30 Wiper motor reverse rotation relay ↑
R - 31 Wiper motor arc prevention relay ↑
R - 32 Washer motor relay ↑
R - 45 Boom cylinder working light relay EN24S00008P1
R - 94 Neutral stop relay YN24S00010P1
R - 145 Key ON holding relay ↑
(SE) Sensor
No. NAME PART NO.

SE - 1 Pressure sensor : Bucket digging LC52S00019P1
SE - 2 Pressure sensor : Bucket dump ↑
SE - 3 Pressure sensor : Boom up ↑
SE - 4 Pressure sensor : Boom down ↑
SE - 7 Pressure sensor : Arm in ↑
SE - 8 Pressure sensor : Arm out ↑
SE - 9 Pressure sensor : Travel right ↑
SE - 10 Pressure sensor : Travel left ↑
SV - 11 (Pressure sensor : P2 side OPT.) ↑
SE - 13 Engine speed sensor VH89284E0020

SE - 15 Fuel sensor YN52S00094F1
SE - 16 Acceleration potentiometer LQ52S00025P1
SE - 20 (Pressure sensor : P1 side OPT.) (low pressure) LC52S00019P1
SE - 21 Hydraulic oil temperature sensor ENG. ACCESSORY PARTS
SE - 22 Pressure sensor : P1 pump (high pressure) YN52S00103P1
SE - 23 Pressure sensor : P2 pump (high pressure) ↑
SE - 40 Press. sensor : Swing right LC52S00019P1
SE - 41 Press. sensor : Swing left ↑
SE - 60 Hyd. oil filter clogging sensor YN52S00107P1
SE - 99 Swing speed sensor LQ52S00032P1
SE - 102 Engine coolant temperature sensor (for ECU) ENG. ACCESSORY PARTS
10-111
(SV) Solenoid
No. NAME PART NO.

SV - 1 Swing parking sol. (LQ35V00008F1) YN35V00051F1
SV - 4 Lever lock sol. Solenoid valve assy YN35V00061F1
SV - 2 Attachment boost pressure sol. LQ35V00007F1
(LQ35V00007F1)
SV - 3 2-speed travel sol. ↑
Solenoid valve assy
SV - 105 Boom meter in cut sol. ↑
(SW) SWITCH
Code NAME PART NO.

SW - 1 Key switch YN50S00026F1
SW - 4 Swing parking release switch YN50S00040D7
SW - 7 Engine oil pressure switch ENG. ACCESSORY PARTS

SW - 8 Air filter restriction switch YN11P00032S006
SW - 10 Horn switch (left) YN50E00017P1
SW - 11 Lever lock switch YN50S00058P1
SW - 19 Wiper interlock switch LQ50C00001S012
SW - 20 Attachment power boost switch (right) YN50E00017P1

SW - 22 KPSS release switch YX50S00004F1
SW-26 Cab working light switch YN50S00040D4
SW - 27 Radiator coolant level switch VH834601510
SW - 55 Boom and deck working light switch YN50S00040D1
10-112
10.3.2 SPECIFICATIONS ELECTRICAL EQUIPMENT

10.3.2.1 (C) CONTROLLER
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
C-1
Maker Sinko Electric Co., Ltd.
Controller
YN22E00488F1
Rated voltage DC24V 10
We ight 4.2 kg (9.3 lbs)
Mechatro controller
LQ16C10001–
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
C-2
Controller Maker Nippon seiki Co., Ltd.
Rated voltage DC24V
YN59S00039F1
Cluster gauge
YN15T17101–
YQ15–T3101–
C-4
Controller Maker SANDEN Co., Ltd.
Rated voltage DC24V
LQ20M00088F1
Rated imput power 215W
Air conditioner amplifier
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-113
10.3.2.2 (D) DIODE

Code No.
Parts Name
Use
Applicable Machine
D - 4, 25
Diode Maker's part No. 7321-9822
Repetitive peak voltage 400V
YN02D01001P1 (4P)
Mean output current 3A
Glow, Switch etc. Surge current 200A
YN15T17101–
YQ15–T3101–
10-114
10.3.2.3 (E) ELECTRIC EQUIPMENT

Code No.
Parts Name
Use
Applicable Machine
E-1
Fuse capacity and circuit
Fuse & relay box
YN24E00036F2
Fuse & relay 10
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
Front side of machine
E - 5, 6 Bottom L : Low sound

Type H : High sound
Horn
Rated voltage DC24V ST AMP
LC53S0001D1(high)
LC53S0001D2(low)
Operating voltage range DC20~30V
Sound level 113+5dB(A)/2m
Warning sound 420+20Hz high sound
Basic frequency
350+20Hz low sound
LQ16C10001-
Insulation resistance More than 3M /DC500V
LQ16H10001-
LL16C10001-
LL16H10001- 8.5
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
E - 8, 9
Model
Speaker
Rated input
LQ54S00003S002
Impedance
Radio Frequency
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-115
Code No.
Parts Name
Use
Applicable Machine
E - 10
Receiver dryer Maker SANDEN Co., Ltd.
Model 51440-A1300
LQ54S00005P1
IN SIDE
Air-conditioner
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001- OUT SIDE
YN15C10001-
PRESSURE SW .
YN15H10001-
APPLICABLE HOUSING MAKER’S P ART No.
YQ15C10001-
SUMITOMO WIRING SYSTEMS L TD. No. 6189-0094
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
E - 11
Maker's part No. 7360-6000
Air compressor
Rated voltage DC24V
YX91V00001F1
Max. revolution 4000rpm
Air-conditioner V belt Type B
YN12-56001- Refregerant R-134a
YQ12-08001- Oil SP-20:135cc(8.24cu .in)
LQ13-07001-
Cover (Clutch)
LL13-06001-
YF06-02501-
YU06-03001-
YF07-03001-
YU07-04001-
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-116
Code No.
Parts Name
Use
Applicable Machine
E - 12
Battery Type N120
Volta ge 12V
YN72S00018P1
Capacity (5HR) 96Ah
Power Weight (Incl. fluid) Approx. 33.0kg (72.8 lbs)
YN15T17101– 502 (19.76") 10
YQ15–T3101–
180 (7.09")
257 MAX (10.1")

500 (19.69") 179 (7.05")
E - 15
Fusible link Type Slow blow fuse
Allowable current 100A
YB73S00001P1
Fuse
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-117
Code No.
Parts Name
Use
Applicable Machine
E - 27
Accel redundant volume Rated voltage DC 5V
Parts Volume TOCOS RV24YN
YN52S00106P1
Engine redundant device
Furukawa Denko equivalent
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
HOUSING : 172131-5
Fix resistor with the harness tape TERMINAL : 170340-1
after fixing the PVC tube.
NUT
VIEW I
SPRING W ASHER
PLAIN WASHER
E - 38
Resistor Maker Nihon Te ikouki.Co.Ltd.
Rated voltage 40W
LC22E01001D1
Insulation resistance DC500V /
Resistor 20M or more
LQ16C10001- Dielectric strength AC1500V .1Minute
LQ16H10001-
LL16C10001- CONNECTOR YAZAKI
LL16H10001- HOUSING
YN15C10001- TERMINAL
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-118
Code No.
Parts Name
Use
Applicable Machine
E - 65
Type 433092-0002
24V power socket
LQ81S01001P1 Maximum current 5A
Socket Insulation resistance 1M or more / DC 500V megger
YN15T17101– Thermal fuse Fusing temperature180 to 210 degrees C 10
YQ15–T3101– ″ +″ te rmina l
Ground te rmina l
E - 101, 102
Resistance
Maker DEUTSCH JAP AN LIMIITED
Maker's part No. DT04-3P-P006
PY26E01001P1
CAN resistor 1,2
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-119
10.3.2.4 (L) LIGHT

Code No.
Parts Name
Use
Applicable Machine
L-1
Light (Halogen) Va lve 24V,70W
YN80S00012F1
Boom working light left
YN15T17101–
CA104
YQ15–T3101–
M14 1.5
L - 2, 7, 8, 9, 15, 16
Type BL84-200
Light (Halogen)
Bulb DC 24V,70W
YT80S00002F2 Effe ctive a re a of le ns 69.2cm 2
Boom cylinder working
light
Deck working light (RH)
Cab working light front 1,
front 2,
front 3, front 4
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
L-5
Volta ge 24V
Light
Type RL-8700 Body
Lens
LQ02C00031S020
Room light Room light BATT
LQ16C10001- OFF ON
LQ16H10001- DR S W
ON
LL16C10001- 24V (Door)
LL16H10001- 10W (Connector) OFF
YN15C10001- DR
YN15H10001- Bulb
Circuit
YQ15C10001-
YQ15H10001-
YQ15–20001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-120
10.3.2.5 (M) MOTOR

Code No.
Parts Name
Use
Applicable Machine
M-3
Motor Type 191-1 1H0-D
LQ53C00003S001
Wiper motor 10
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
M-4
Motor (Tank)
Injection flow 1.2L (0.32 gal) / min or more
YT54C00003F1 Capacity 1.5L(0.4 gal)
Washer motor Time ra te d Max. continuous 60 sec.
LQ16C10001- Injection nozzle 1 X 2 pcs.
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
PUMP
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-121
10.3.2.6 (PSV) PROPORTIONAL VALVE

Code No.
Parts Name
Use
Applicable Machine
PSV - A, B, C, D, 23, 24
YN35V00048F2
Proportional solenoid YN35V00049F1 YN35V00051F1 YN35V00061F1
valve assy YN35V00048F2
Hydraulic symbol
See A2, A4-A8

YN35V00048F2
YN35V00049F1
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
PSV-A PSV-23 PSV-24 PSV-B PSV-C SV-1 PSV-D SV-4
Tra ve l s tra igt
Le ve r lock
Arm 2nd s pe e d
Boom2
Boom3
P 2 unloa d
S wing pa rking
PSV - P1, P2 P 1 unloa d

AMP MARK II
RETAINING RING
Type KDRDE-5K HOUS ING: 174354-2
Proportional solenoid SPO OL SPR ING TERMINAL:173706-1
Max. feed press ORIFICE
13.7MPa(1987psi)
YN35V00054F1
Rated feed press 5.0MPa(725psi) HEX10
7.4N.m(5.46lbf.ft)
P1, P2 pump Allowable back press 1MPa(145psi)
proportional sol.
Control pressure range 0~2.7MPa(392psi)
LQ16C10001- Rated voltage DC 24V
LQ16H10001-
LL16C10001-
LL16H10001- S OLENOID
SEAL NUT
S LEEVE O-RING O-RING O-RING
YN15C10001- 1BP 20
O-RING
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-122
10.3.2.7 (R) RELAY

Code No.
Parts Name
Use
Applicable Machine
R-1
At start 24V2000A(0.1 sec) VIEW A
Te rmina l A
Relay Ra te d volta ge / curre nt
At charge 28V120A(Continuous)
YN24S00008F1 Exciting current 0.4A or less / 24V Lock section
Battery relay Contact pressure 37.2N {8.4lb} or more Te rmina l A 10

Closed circuit voltage 16V or less VIEW I
LQ13-07001- Te rmina l B
Open circuit voltage 7V or less HOUSING AMP GND terminal
LL13-06001- 174359-2
YF06-02501- Ins ula tion re s is ta nce 3M or more/500V megger RETAINER AMP

1-174360-7
TERMINAL AMP
YU06-03001- 171661-1
WIRE PROOF PLUG AMP
YF07-03001- 172888-2
YU07-04001- Te rmina l L
LQ16C10001- VIEW Z
Circuit diagram Flowing direction of
LQ16H10001- main current
o 9 X 30L F HOUSING YAZAKI
Te rmina l A Te rmina l A Te rmina l B 7123-4210-30
Heart shrinkage tube
LL16C10001- AVS 1.25G
F TERMINAL YAZAKI
AVS 1.25B 7116-3251*
LL16H10001- z GND wire
WIRE PROOF PLUG
AVS 1.25L
YN15C10001- I Terminal B
Terminal L 7157-3580-60
YN15H10001- F HOUSING YAZAKI Te rmina l B

7123-4220-30
YQ15C10001- F TERMINAL YAZAKI
7116-3251
YQ15H10001- REAR HOLDER YAZAKI
YQ15–20001- 7157-6801-30
WIRE PROOF PLUG
LL16–10001- 7157-3580-60
YN15T17101– Bracket groud
YQ15–T3101– o 7.0 X 150L
Corrugete tube (Black)
Fusible link assy B o 7.0 X 150L
Corrugete tube (Black)
Fusible link assy A
R - 4, 5, 6, 9, 11, 23-26,
28, 94 Maker TYCO ELECTRONIC AMP Co,.Ltd.
Relay Type V23074-A2002-A403

Part name Micro relay A
YN24S00010P1
Safety relay Contact assignment 1C
Horn relay
Work light relay * Relay box accesory
Auto idle stop
Relay 1, 2
E/G emergency stop
relay Pin assignment
Lever lock relay
Alternator relay etc.
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-123
Code No.
Parts Name
Use
Applicable Machine
R - 29, 30, 31, 32

Maker TYCO ELECTRONIC AMP Co,.Ltd.
Relay
Type V23134-A0053-C643
YN24S00012P2 Part name Relay
Wiper motor normal Rated voltage DV 24V
rotation relay Contact assignment 1C
Wiper motor reverse
revolution relay
* Relay box accesory
Wiper motor ark
Prevention relay
Washer motor relay
YF06-02501- Pin assignment

YU06-03001-
YF07-03001-
YU07-04001-
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
R - 45, 145
Relay
EN24S00008P1
Boom cylinder working
light relay (+ SIDE) (- SIDE)
Key ON holding relay
CIRCUIT DIAGRAM
YN15T17101–
Specification
YQ15–T3101–
Rated voltage: DC24
Insulation resistance: 1M or more by DC500V
insulation resistance tester
10-124
10.3.2.8 (SE) SENSOR

Code No.
Parts Name
Use
Applicable Machine
SE - 1-4, 7-11, 20, 40, 41

Pressure range 0~3MPa (0~435 psi)
Pressure sensor (Low
pressure) Rated voltage 5+0.5V DC
Insulation resistance
LC52S00019P1
100M or more /DC50V megger
10
Bucket dig and dump AMP MQS TYPE CONNECTOR
3P (B TYPE)
Boom up and down OPPOSITE CONNECTOR (FEMALE)
HOUSING : 2-967642-1
Swing TERMINAL No. CONNECTION TERMINAL : 965906-5
Arm in and out HEX 19 (GOLD PLATED)
1 COM HARNESS SEAL : 967067-1
Travel RH and LH and 2 OUTPUT(+)
other 3 POWER(+)
LL16C10001- O-RING PF1/4
1B P11 Tighte ning torque 32.0N.m(23.6 lbf.ft)
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YN15T17101–
YQ15–T3101–
SE - 15
Float operation
Fuel sensor
Float Resistance
YN52S00094F1 +0.1
FULL 10 -0.6
Fuel level 3/4 (19)
LQ16C10001- 1/2 32+5
LQ16H10001- 1/4 (49.5)
LL16C10001-
EMPTY 85 +10
0
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
Float
VIEW A
10-125
Code No.
Parts Name
Use
Applicable Machine
SE - 16
Tota l re s is ta nce
Accel potentio CONNECT OR (AMP)
Effe ctive e le ctrica l a ngle CAP HOUSING : 174359-2
LQ52S00025P1 TAB : 171661-1
RUBBER PLUG : 172888-2
Accel dial DOUBLE LOCK PLATE : 1-174360-1
LQ16C10001- PROTECT TUBE

LQ16H10001-
LL16C10001- A
LL16H10001- BLACK
YN15C10001- YELLOW RED
YN15H10001-
VIEW A
YQ15C10001-
ATTACHMENT SURFACE
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
SE - 21
Sensor
LS52S00046P1 17mm M16×1.5(II) Specifications
Hydraulic oil temperature (0.67 inch) 1. Working voltage : DC5.0V
sensor 2. Resistance standard
YN15T17101– Temperature(°C)(°F) 0(32) 50(122) (70)(158) 105(221)
YQ15–T3101–
Resistance( ) 1150 98.2 (45.6) 15.25
R 0 0 2 in
Allowance( ) ±126.5 +7.8 - ±0.76

(0 .
.5 m c h
M4×0.7 -5.9
m )
SE - 22, 23
Pressure range 0~50MPa(7250psi)
Pressure sensor (High
pressure) Ma x.a llowa ble pre s s . 120MPa(17400psi)
Operating source voltage 5+0.5V DC
YN52S00103P1
Insulation resistance 100M or more/DC50V megger
P1 PUMP (Between casing and terminal)
P2 PUMP
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-126
Code No.
Parts Name
Use
Applicable Machine
SE - 24, 25, 28, 100

Type KM16-F06 27mm
Pressure sensor (High
pressure) (1.06inch)
Specifications
YN52S00104P1 Pressure.range : 0~50MPa (10~7250psi)
Max.allowable press. : 120MPa (17400psi)
Boom head Brake down press : 10
Boom rod 200MPa (29000psi) or more
Extra press. Source voltage : 5.0VDC
Boom head Max source voltage : 6.0VDC
(for high-reach) Output : 1/10Vs~9/10Vs
YQ15–20001- Insulation resistance : 100M or more
LL16–10001- (Case~terminal 50V DC)
YN15T17101– Consumption current : less than 10mA DC
YQ15–T3101– Volta ge which is fit for us e : 150V AC (1min)
PF TIGHTENING TORQUE
73.5N .m(54.2ft-in)
SE - 60
Sensor Fluid Mineral hydraulic oil(ISO VG32,46,68)
Pro of pre s s ure 7.0MPa (1015psi)
YN52S00107P1
Range of oil temp -30 ~ 120 (-22~248 F)
Hyd. oil filter clogging
Port size JIS B2351 G1/2
sensor
Setting pressure 0.1±15 MPa (15±15 psi)
LQ16C10001-
Electric rating DC30V
LQ16H10001-
LL16C10001- Contact rating 100mA (Resistance load)
LL16H10001-
YN15C10001-
YN15H10001-
(1.06inch)
YQ15C10001-
27mm
YQ15H10001- G1/2
YQ15–20001-
LL16–10001-
YN15T17101– High pressure
YQ15–T3101–
Point of contact circuit at 0MPa

Low pressure
COM NC
NC(RED)
COM(BLACK) Point of contact circuit at 0.1MPa
COM NC
10-127
Code No.
Parts Name
Use
Applicable Machine
SE - 99
Swing speed sensor Type TAG 209
LQ52S00032P1
Sensor
LQ16C10001-
LQ16H10001-
LL16C10001-
LL16H10001- HOUSING 7122-2830(Y AZAKI)
YN15C10001- CONTACT 7114-2630(Y AZAKI)
Electrical wire for automobiles AVS 0.5s q
YN15H10001-
A
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
A
YN15T17101–
YQ15–T3101–
Te rmina l function
No Te rmina l Wire color Function

1 Vcc RED Power
2 GND BLACK Grounding
A-A 3 Vout WHITE Gyro sensor output
10-128
10.3.2.9 (SV) SOLENOID

Code No.
Parts Name
Use
Applicable Machine
SV - 1, 4
Rated pressure 5.0MPa(725psi)
Solenoid valve
(8sectional) Solenoid operated directional control valve Rated voltage:DC24V
P1,P2,T ,A1,A8Port PF3/8
Selector valve assy
Electromagnetic proportional valve
Dither current 100Hz,200mA
9Coil resistance 17.5Ω (at20
P-P
(68 F))
A2~A7Port
AMPmarkII
PF1/4 10
Hydraulic symbol
AMP mark II
See A1-A3
Conne ctor s pe cifica tion HOUSING Part No 174354-2 equivalent
TERMINAL PartNo 173706-1 equivqlent
YN35V00051F1
YN35V00061F1
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
SV - 2, 3, 105
Rated pressure 5.0MPa(725psi)
Solenoid valve
(3sectional) Solenoid operated directional control valve Rated voltage:DC24V
Selector valve assy
Hydraulic symbol
See A1-A3
(LQ35V00007F1)
16068–10100
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001- A3 A2 A1
YQ15–20001- SOL3 SOL2 SOL1
LL16–10001-
YN15T17101– T1 T2
YQ15–T3101–
PAC P
Circuit diagram A3 A2 A1 T
T
P
PAC
10-129
10.3.2.10 (SW) SWITCH

Code No.
Parts Name
Use
Applicable Machine
SW - 1
OFF AC
Switch C
Connection
ON
YN52S00026F1 Terminal
Position
Starter switch
S TA
Auto return
LQ16C10001-
RT
LQ16H10001- VIEW A
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001-
Te rmina l
YQ15C10001- arrangement
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
SW - 4
Switch Rated voltage DC 24V
Type Single-pole,single-throw type(alternate)
YN50S00040D7
Insulation resistance 1M or more/DC500Vmegger
Swing parking release
switch
LQ16C10001-
Connection
LQ16H10001-
LL16C10001- Term ina l
Positi on
LL16H10001-
YN15C10001-
YN15H10001-
YQ15C10001-
YQ15H10001-
YN15T17101–
YQ15–T3101–
SW - 8
Switch
2450R163S1 RED BLACK
Air filter restriction switch JIS-D5403-104(CA)
YN15T17101–
YQ15–T3101–
JIS-D5403-104(CB)
PT1/8
10-130
Code No.
Parts Name
Use
Applicable Machine
SW - 10, 20
Type Incorporated in grip S W-10 : Incorporated in left grip
Switch Le ft a nd right s witch a s s e mblie s
Switch assembly YN50E00017P1
YN03M02619F2 a re s a me
Rated voltage, current 125V 3A AC
(right grip)
YN03M02619F1 Insulation resistance 100M or more / DC 500V megger
(left grip) 10
Horn, ATT power boost
YN15T17101–
YQ15–T3101– SUMITOMO WIRING SYSTEMS L TD. Housing : 6090-1031 (2P male)
SUMITOMO WIRING SYSTEMS L TD. Te rmina l : 8230-4282
Lead wire (ROBOT OP DP 3)
SW - 11
Switch Type Panasonic coporation:ABV19440F
YN50S00058P1
Lever lock switch
LQ16C10001-
LQ16H10001-
BLACK
LL16C10001-
LL16H10001-
YN15C10001-
YN15H10001- WHITE RED
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-131
Code No.
Parts Name
Use
Applicable Machine
SW - 22 SUMITOMO
HOUSING : 6098-0258
Switch
TERMINAL : 8230-4282
YX50S00004F1
Release switch (KPSS)
YQ15–20001-
LL16–10001- VIEW I
YN15T17101– ON 1 SIDE
( NORMAL)
YQ15–T3101–
ON 2 SIDE
(KPSS RELEASE)
UNIT SHAPE OF SWITCH
Specifications
CHARACTERISTICS OF CIRCUIT NUMBER OF
1.Rating : AC 125V 10A AC 250V 7A
CONTACY POSITION CIRCUIT DIAGRAM TERMINALS
DC30V 10A
2.Initinal contact resistance
CENTER
: 20m or less at DC2~4V 1A
3.Insulation resistance
ONqq NONE ONrr
:The valve between insulated terminals
18
and between terminal frames to be 100 M
or more at DC500V megger .
4.Dielectric strength
:Insulations between insulated terminals and
between terminal frame must be endured against
AC2000V for one minutes.
SW - 26
Single pole single throw
YN50S00040D4 Type (alternate)
More than 1M /
Cab working light switch Insulation resistance DC500V megger UP
YQ15–20001-
LL16–10001- Te rmina l conne ctor
Connector
YN15T17101– Position
YQ15–T3101–
SW - 27
Purpose Coolant level detection
Switch
Working te mpe ra ture -40 ~130 (-40~266 F)
S8346-01510 Type of conne ctor
Engine cooling coolant Hino P/No. : S82580-7170
Sumitomo P/No. : 6188-01 10
level switch Electrode side
(To controlle r)
YQ15–20001-
LL16–10001-
YN15T17101– Housing side CONNECT OR
YQ15–T3101– (To ground)
Mating connector
Hino P/No. : S82580-7180
Sumitomo P/No. : 6189-0189
10-132
Code No.
Parts Name
Use
Applicable Machine
SW - 55
Single pole single throw
YN50S00040D1 Type (alternate)
More than 1M /
Boom work light switch Insulation resistance DC500V megger UP
LL16C10001- 10
LL16H10001- Te rmina l conne ctor
Connector
YN15C10001- Position
YN15H10001-
YQ15C10001-
YQ15H10001-
YQ15–20001-
LL16–10001-
YN15T17101–
YQ15–T3101–
10-133
10-134
［11. AIR-CONDITIONER SYSTEM］
11. AIR-CONDITIONER SYSTEM

11.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL ............................................................. 11-3
11.2 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER) .................................... 11-4
11.2.1 AIR CYCLE........................................................................................................................ 11-4
11.2.2 AUTO AIR CONDITIONER SYSTEM OUTLINE ................................................................... 11-5
11.3 AIR CONDITIONER COMPONENT AND CONSTRUCTION .................................................... 11-6
11.3.1 AIR CONDITIONER COMPONENT PARTS ......................................................................... 11-6
11.3.2 AIR CONDITIONER CONSTRUCTION ................................................................................ 11-7 11
11.4 AIR CONDITIONER PIPING ................................................................................................ 11-10
11.4.1 AIR-CONDITIONER ......................................................................................................... 11-10
11.4.2 AIR DRYER ASSY............................................................................................................ 11-18
11.5 AIR CONDITIONER FUNCTION .......................................................................................... 11-19
11.5.1 MECHANISM OF COOLING CIRCUIT............................................................................... 11-19
11.5.2 COOLING CIRCUIT.......................................................................................................... 11-21
11.5.3 AIR CONDITIONER COMPONENT PARTS ....................................................................... 11-22
11.6 AIR CONDITIONER DISASSEMBLY AND ASSEMBLY ......................................................... 11-26
11.6.1 PRECAUTIONS TO BE EXERCISED IN OPERATION........................................................ 11-26
11.6.2 DISASSEMBLY AND ASSEMBLY OF UNIT ....................................................................... 11-27
11.7 CHARGING REFRIGERANT ............................................................................................... 11-34
11.7.1 PRECAUTIONS TO BE EXERCISED IN OPERATION........................................................ 11-34
11.7.2 OPERATING PROCEDURE .............................................................................................. 11-36
11.7.3 CHARGING PROCEDURE ............................................................................................... 11-37
11.8 AIR CONDITIONER ELECTRIC CIRCUIT............................................................................. 11-42
11.8.1 AIR CONDITIONER WIRING DIAGRAM AND CONNECTORS ........................................... 11-42
11.8.2 STRUCTURE AND OPERATION OF EACH PARTS ........................................................... 11-44
11.9 AIR CONDITIONER TROUBLESHOOTING.......................................................................... 11-47
11.10 PANEL DISPLAY FOR SELF DIAGNOSIS.......................................................................... 11-53
11-1
11-2

11
11-3
11.2 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR

CONDITIONER)
Air-conditioner is the unit which places evaporator and heater core parallel, and unifies a blower fan and an inside /
outside air switching unit. And this unit changes hot air to cool air.
11.2.1 AIR CYCLE

Heater
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is
performed with hot air (heating) at the heater core of air-con unit, and then the heated air blows off from grille
through duct.
Cooler
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is
performed with cold air (dehumidifying and cooling) at the evaporator of air-con unit, and then the cooled air blows
off from grille through duct.
Heater system
The heater recycles (circulates) the cooling water in the engine, and the hot water delivered by the engine flows in
the heater core of air-con unit and then heat exchange is performed.
The intake air is heated and the heated air blows off from the grille provided on the inside of cab.
The blow off air temperature is controlled by the temperature control switch on the control panel, and the operation
is controlled by air mixing damper on the air-con unit.
11-4
11.2.2 AUTO AIR CONDITIONER SYSTEM OUTLINE

AIR CONDITIONER CONTROL PANEL
25. 0 COMPRESSOR
SOLAR RADIATION SENSOR COMPRESSOR DRIVE SOURCE
REFRIGERANT
AIR MIXED DAMPER SIGNAL PRESSURE SWITCH
AIR-CON BLOWER REVOLUTION SIGNAL
AIR OUTLET SWITCHING SIGNAL CONTROLLER

11
INNER AIR SENSOR
EVAPORATION SENSOR
INNER AIR AND OUTER AIR
SWITCHING SIGNAL
OUTER AIR INTAKE

MOTOR
VENT ACTUATOR
INNER AIR
MOTOR
ACTUATOR
AIR CONDITIONER UNIT FACE
FOOT MOTOR BLOWER

ACTUATOR CONTROLLER
11-5
11.3 AIR CONDITIONER COMPONENT AND

CONSTRUCTION
11.3.1 AIR CONDITIONER COMPONENT PARTS
41-1
41-2
42-2
41-1-1-15
41-1-1
42-1
41-3
41-1-3
41-1-2
42-4
42-4-2
42-3 42-4-1
42-4-7
42-4-8
42-4-6
42-4-3
Air conditioner group
Air Conditioner Assy: YN20M00170F1(05)
No. Name Q'ty No. Name Q'ty
41 Air-conditioner assy 1 42-2 Pully assy 1
41-1 Air-conditioner assy 1 42-3 Condenser 1
41-1-1 Air-conditioner 1 42-4 Air dryer assy 1
41-1-1-15 Filter 1 42-4-1 D hose: 19 mm dia. (0.75”) 1
41-1-2 Hose 1 42-4-2 S hose: 24.5 mm dia. (0.96”) 1
41-1-3 Clamp 1 42-4-3 L hose: 15 mm dia. (0.59”) 1
41-2 Panel 1 42-4-6 L hose: 15 mm dia. (0.59”) 1
41-3 Filter 1 42-4-7 Receiver dryer 1
42 Air-conditioner assy 1 42-4-8 Bracket 1
42-1 Compressor 1
11-6
11.3.2 AIR CONDITIONER CONSTRUCTION

Air conditioner unit
9
16
33 48 23 22 26 35 11
49
50 25 47 20 36
31
34 32 10
20 47
35
30 24
47 29 27 36
1 28 29
14
35
47 11
15 47 39
51
47
38 4
45
47 37
44
40
17
51
42
7 41
6
3 5
47
8 2 12
47 43
20 13
47
18
21 46
19
Air conditioner unit
11-7
Air conditioner unit: LQ20M00088F1(01)
1 HEATER CORE 1 27 JOINT FOOT 1

2 CASE INTAKE 1 28 JOINT DEF 1
3 LINER FILTER 2 29 ROD COMMON 2
4 PAKING INTAKE 1 30 LEVER MODE MAL 1
5 MAL LEVER INTAKE 1 31 LEVER AIR MIX MAIN 1
6 LEVER INTAKE 1 32 LEVER AIR MIX SUB 1
7 DAMPER INTAKE 1 33 LINK MODE 1
8 INCAR SENSOR 1 34 MAIN ROD 1
9 DUCT JOINT 1 35 DAMPER MODE ASSY A 3
10 CORE HEATER R 1 36 DAMPER MODE ASSY B 2
11 CORE HEATER L 1 37 DAMPER AIR MIX ASSY 1
12 CASE DRAIN 1 38 RELAY 24-4PE 2
13 CLIP HARNESS 1 39 FAN DRIVER 1
14 LINK COVER 1 40 EVAPORATER ASSY 1
15 FILTER RECIRCULATION 1 41 TXV (EXPANSION VALVE) 1
16 PAKING DUCT OUTLET A 2 42 EVA SENSOR 1
17 PAKING DUCT OUTLET B 1 43 CAPSCREW M5 X 40 2
18 COOLING HOSE 1 44 HARNESS HOLDER 1
19 BLOWER MOTOR 1 45 THERMISTOR HOLDER 1
20 MOTOR ACTUATOR 3 46 +BA5 X 14(T1) 3
21 HARNESS ASSY 1 47 +BA4×16(T1) 36

22 LEVER VENT 1 48 BUSH D3 PIN 4
23 LEVER FACE 1 49 ROD HOLDER 2
24 LEVER FOOT 1 50 +BA4 X 16 (RW) 1
25 LEVER DEF 1 51 Insulation 2
26 JOINT VENT 1
11-8
Receiver dryer
REFRIGERANT 2
INLET
REFRIGERANT
OUTLET
2-M6
1
3
4
5
11
6
Receiver dryer
No. Name Q'ty
1 PRESSURE SWITCH 1
2 SIGHT GLASS 1
3 DESICCANT 1
4 SUCTION PIPE 1
5 FILTER 1
6 RECEIVER TANK 1
11-9
11.4 AIR CONDITIONER PIPING

11.4.1 AIR-CONDITIONER
AC UNIT
A
6 PLACES 24
TIGHTENING TORQUE
16.7~18.6N ~ m
(12.3~13.7 lbf .ft)
LENGTH OF
INSER T HOS E
28
(1.18”)
(1.18”)
14 VIEW XIV
13 VIEW FROM
THE TOP FLOOR
PLATE
A
A CLIP FOR
DRAIN HOS E
(42-4-6)
H S-H OS E
(0.59”)
(0.79”)
FOR WARD LENGTH OF

INS ERT HOS E
A
DRAIN HOS E
CLIP INS TALLATION S IZE
FOR HVAC CONECTION BOL T A

TIGHTENING TORQUE 8~12N~ m
(5.90~8.85 lbf .ft) a FIX BY US ING THE HOLE
30 IN UP P FRAME.
30 I L-HOS E
32 (42-4-3)
VIEW II HOSE LAYOUT UNDER FLOO R P LATE
11-10
DIMENS ION TO
INS TALL RECEIVER
(3.15”)
F
39
36 TIGHTENING. TORQUE 11N~ m

SEC TION BB (8.11 lbf ft)
DETAILS IN INS TALLATION
PART OF CONDENS ER
4 P LACES
VIEW I
VIEW XIII
BOLT FOR L-HOS E CONNECTION
K TIGHTENING TORQUE 7.8~11.8N~ m
30
D-HOSE G (5.90~8.70 lbf .ft) P ROVIDE CLEARANCE BETWEEN
25 THE RADIATOR HOS E AND D-HOS E.
TIGHTENING TORQUE
30 (1 .1 8”)
TIGHTENING TORQUE
23N~ m
(17.0 lbf .ft) 30
CLAMP THREE HOS ES
(S-H OS E · D-HOS E ·
HEATER HOS E).
11
/ ~ N 25 9
(17.0 lbf .ft)
(6.42”)
10
k
j 30
F
VIEW V
L L-HOS E (42-4-6)
N FOR RECEIVER INST BKT
CONNECT THE COMP RES S OR 31
HARNES S WITH THE ENGINE
M RECEIVER HARNES S .
25 CLAMP THE CONNECTOR OF

30 TIGHTENING TORQUE 23N~ m (17.0 lbf .ft)
FOR WARD
30 ENGINE-S IDE HARNES S TO
THE ENGINE HARNES S .
32 I L-HOSE (42-4-3) VIEW VIII
A/C HOSE IS CLAMPED
USING THE HIGH NUT OF 30 A/C HOSE IS CLAMP ED US ING 26
RADIATOR FLAME.
32 THE HOLE OF RADIA TOR FLAME. TIGHTENING TORQUE
46.5N~ m
(34.3 lbf .ft)
31
CLAMP US ING THE CLEARANCE
BETWEEN THE COMP RES S OR
AND THE CONTACT PART OF
BRACKET.
P REVENT THE HARNES S FROM VIEW VI
ABUTTING ON THE CORNER OF
BKT FOR THE INTERCOOLER HOS E.
G D-HOSE
IT IS AN IMP OS ITION IN ITEM 43 S O THAT
(14.8~18.4 lbf .ft)
43 THE CHAMFERED PART BECOMES FRONT
OF THE MACHINE.
TIGHTENING
TORQUE
23N~ m 25
(17.0 lbf .ft) TIGHTENING TORQUE 4.9N~ m
44 2 P LACES (3.61 lbf .ft)
2 P LACES
L ATTACHING ANGLE OF ITEM M (RECEIVER)

(42-4-6)
L-HOSE
(8.85~11.1 lbf .ft)
VIEW XII
11-11
BOLT FOR D-HOS E CONNECTION

J TIGHTENING TORQUE d / ~ N
(14.8~18.4 lbf .ft)
J
BOLT FOR S -HOS E CONNECTION
TIGHTENING TORQUE d / ~ N
(14.8~18.4 lbf .ft)
b c d e
TORQUE / ~ N
35 TIGHTENING
(17.0 lbf .ft)
38 4 P LACES
i
30 h
27
45 g
CLAMP USING THE HIGH
NUT OF UPP FRAME.
30
CLAMP USING
TIGHTENING TORQUE THE CLIP OF fCENTER OF
THE R-CLIP
/ ~ N UPP FRAME.
(34.3 lbf .ft) 30
32
30
CLAMP THREE HOS ES 27 TIGHTENING 30 46
SECTION AA (S-HOS E·D-HOS E·
HEATER HOS E).
45 TORQUE / ~ N
(34.3 lbf .ft)
PUT IT ON THE UPP FRAME

AFTER THE HOSE DISTRIBUTION.
40
30
(3.35”)
VIEW VII
(1.18”)
25 TIGHTENING TORQUE
.
23N~ m
12
(17.0 lbf ft)
29 INS TALLATION P ROCEDURE
FOR COMP RES S OR BKT:
TIGHTEN ITEM 25 AND THEN
27 TIGHTENING TORQUE LENGTH OF ITEM 26.
46.5N~~ m
LENGTH OF
INSER T HOS E
33 (34.3 TIGHTENING
lbf .ft) TORQUE 37 INSER T HOS E
23N~~ m
(17.0 lbf .ft)
38
22
29 D
(1.18”)
(1 .1 8”)
28
LENGTH OF INS ERT HOS E
15 11 8
ADJ US TMENT OF BELT
TENS ION (AT INITIAL BELT)
TENSION PULLEY ”) IT ADJ US TS S O THAT R MAY
98
(0 .
LOCKING NUT BE P US HED BY THE LOAD
TIGHTENING OF 28N(6.29 lbf) AND IT
TORQUE E MAY BEND 7 to 8mm(0.28 to 0.31”).
46.5N~~ m
(34.3 lbf .ft) (2 .5 (0 .6 28
6 ”) 1 ”)
23
APPLY THREEBOND
1110B ON THREADS .
TIGHTENING TORQUE
69.1N~ m
(51.0 lbf .ft)
CLAMP USING THE HIGH
NUT OF GUARD.
VIEW IV
11-12
32 (42-4-2) (42-4-3)
14 L-HOSE I 14
H S-HOSE (42-4-2)
S-HOSE H
13
13
(42-4-3)
L-HOSE I 14
I L-HOSE 30
30 (42-4-3) 30
SECTION DD
SECTION CC 30 S-HOSE H 13
14 (42-4-3) 14 (42-4-2)
(42-4-3)
L-HOSE 30 L-HOSE I
I S-HOSE H 13 SECTION FF
(42-4-2) 13 (42-4-2)
S-HOSE H
13
45 47
(42-4-1)
SECTION EE SECTION GG D-HOSE G
30
H S-HOSE
13 13
30 32 46
(42-4-2) 11
30
(42-4-1) D-HOSE G
D-HOSE G H S-HOSE (42-4-1) H
(42-4-2) S-HOSE
(42-4-2)
SECTION JJ SECTION KK
SECTION HH
(42-4-2)
S-HOSE H 30
30
(42-4-1) 30
G G D-HOSE
D-HOSE 13
32 32 (42-4-1)
G D-HOSE L-HOSE I
(42-4-1) (42-4-3)
I L-HOSE
(42-4-3)
SECTION LL
I L-HOSE
SECTION MM G (42-4-3)
D-HOSE
30
(42-4-1)
SECTION NN No. Na me Q'ty
SECTION PP
A Air-conditione r a s s y 1
30 (42-4-1) B P a ne l 1
D-HOSE
(42-4-2) G C Filte r 1
13
H D Air-compre s s or 1
S-HOSE
E P ully a s s y 1
FUEL F Conde ns e r 1
HOSE
D
COMPRESSOR L G Hos e a s s y 1
FUEL L-HOSE F
HOSE (42-4-6) CONDENSER H Hos e a s s y 1
I Hos e a s s y 1
I
L-HOSE J Ca ps cre w 2
(42-4-3) K Ca ps cre w 2
A L Hos e a s s y 1
A/C UNIT
H M Re ce ive r drye r 1
S-HOSE
SECTION QQ (42-4-2) A/C CIRCUIT DIAGRAM N Bra cke t 1
11-13
FOR WARD
CLIP A
CONNECT WITH
VIEW X ITEM B HARNESS. CONNECTOR FOR P OWER
S UP P LY OF A/C UNIT IS
B CONNECTED WITH
MAIN HARNES S .
A CLIP
FOR WARD
VIEW III
LAYOUT OF A/C HARNES S C ATTACH TO OUTS IDE AIR DUCT.
US E AND CLAMP
USE AND CLAMP THE L THE HOLE OF THE
CHARACTER CL IP OF 31 RELAY BOX
THE RELAY BOX BRACKET.
BRACKET. 31
CAB HARNES S AND FIXATION IN

30 A CAB HARNES S DIVERGENCE DEPARTMENT
VIEW IX
FROM THE END OF HOS E
NOTES
1. APPLY OIL (S P 20) FOR R134a TO ALL CAP S OF A/C HOS E (0.59~0.67”) DON’T LEAN THE CLAMP
DON’T RUNNING
2. QUANTITY OF R134a 850g±50g (1.87 0.111lbs
¢ 1.87±0.1 lbs)£
AGROUND TO BEADING
3. UNSPECIFIED INST ALLATION POSITION AND INSTALLATION
OF HOSE CLIP TO BE AS FOLLOWS .
HEATER-HOS E
11-14
S-HOSE : (42-4-2)
(10’7”)
(5’1”)
(29.1”)
(3’9”)
(18.5”)
(35.0”)
(17.7”)
(12.2”)
(1.30”) (5.12”) (4.33”) (1.30”)
(0.94”)
(1.18”)
31 18 31
(2.80”) (0.39”) (10’2”) (0.39”)
D-HOSE : (42-4-1)
(8’10”)
(33.5”) 11
(20.1”)
(36.6”) (13.8”)
(26.0”)
(1.26”) (6.30”) (1.26”)
(0.75”)
(0.94”)
31 31
19
(1.02”) (0.39”) (8’6”) (0.39”)
L-HOSE : (42-4-3)
(8’11”)
(5’1”)
(3’8”)
(34.3”)
(18.1”) (35.0”)
(1.18”) (5.51”) (23.2”) (1.18”)

(0.59”)
(0.94”)
31
19 31
(2.76”) (0.39”)
(8’6”) (0.39”)
L-HOSE : (42-4-6)
(13.4”)
(1.18”) (1.18”)
31 20 31
(1.18”) (0.39”) (9.84”) (0.39”)
11-15
HEATER HOSE : (13)

(10’6”)
(5’5”)
(4’1”) (27.6”)
(37.4”) (16.9”)
(24.0”)
13 (12.6”) (10.6”)
(0.83”)
(1.06”)
31 31
16
(7.87”) (0.39”) (9’8”) (0.39”)
(1.97”)
HEATER HOSE : (14)

(7’7”)
(4’3”) (21.9”)
(38.6”)
(24.0”) (11.4”)
14 (12.6”)
(0.83”)
(1.06”)
31 31
17
(0.39”) (6’7”) (0.39”)
(9.84”) (1.97”)
HEATER HOSE : (15)

(17.7”)
15
(0.94”)
(1.18”)
31 21
31 (0.39”)
(3.94”) (0.39”) (11.8”)
(1.97”)
11-16
Air Conditioner: YN20M00170F1(05)
8 V-belt 1 28 Clip 4
9 Bracket 1 29 Clip 2
13 Hose: L=3200 (10’6”) 1 33 Clip 1
14 Hose: L=2300 (7’7”) 1 35 Capscrew: M8×100 4
15 Hose: L=450 (17.7”) 1 36 Capscrew: M8×30 4
16 Tube for heater: L=2950 (9’8”) 1 37 Capscrew: M8×25 2
17 Tube for heater: L=2000 (6’7”) 1 38 Washer 6
18 Tube for S hose: L=3100 (10’2”) 1 39 Washer 4 11

19 Tube for D, L hose: L=2600 (8’6”) 2 40 Insulation 1
20 Tube for L hose: L=250 (9.84”) 1 41 Air-conditioner assy 1
21 Tube for heater: L=300 (11.8”) 1 42 Air-conditioner assy 1

22 Tube 1 43 Bracket 1
23 Connector 1 44 Sems bolt: M6×20 2
24 Sems bolt: M10×25 6 45 Clip 2
25 Sems bolt: M8×25 10 46 Clip 1

26 Sems bolt: M10×40 2 47 Sems bolt 1
27 Sems bolt: M10×20 2
11-17
11.4.2 AIR DRYER ASSY

4
7
3
A/C CIRCUIT DIAGRAM
Air Dryer Assy: YN96V00050F1(01)
1 D hose: 19 mm dia. (0.75”) 1 6 L hose: 15 mm dia. (0.59”) 1
2 S hose: 24.5 mm dia. (0.96”) 1 7 Receiver 1
3 L hose: 15 mm dia. (0.59”) 1 8 Bracket 1
4 Capscrew: M8×25 2
5 Capscrew: M6×25 2
11-18
11.5 AIR CONDITIONER FUNCTION

11.5.1 MECHANISM OF COOLING CIRCUIT
Mechanism of Cooling
In the cooling process, the refrigerant that flows through the cooling circuit changes its phases from liquid to gas
and vice versa while which process heat is transferred from the low temperature part (compartment) to the high
temperature part (outside of the vehicle).
1. Kind of Refrigerant
Many kinds of refrigerants that change in that way are available, but the following requirements are needed for
use in such applications :
• Latent heat of vaporization (heat of vaporization) is large.
• It is easy to liquefy (condense). (It dose not require very high pressure for condensation.)
• It is easy to gasify (evaporate). (It evaporates sufficiently at not too low pressure, i.e. cools down an object.)
• It has small specific heat. (Since the refrigerant itself is cooled by the expansion valve, the loss resulting from it
must be held down to a minimum.)
11
• It has a high critical temperature and a low solidification point.
• It is stable chemically and does not corrode and permeate into the circuit parts.
• It is free from toxicity, objectionable odor, flammability and explosiveness and excels in thermal conductivity and
electric insulation.
• It has small specific volume.
• 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 designated refrigerant for the cooling unit.
The following table shows the principal characteristics of the R134a refrigerant that is used in this machine.
Item HFC-134a(R134a)
Chemical formula CH2FCF3

Molecular weight 102.03
Boiling point -26.19 ℃ (-15.14 ℉)
Critical temperature 101.14 ℃ (214.05 ℉)
Critical pressure 4.065 MPa *1 (41.45 kgf/cm2*1)
Critical density 511 kg/m3 (31.9 lb/ft3)
Density of saturated liquid

1206 kg/m3 (75.3 lb/ft3)
[25℃(177.0℉)]
Specific volume of saturated

vapor 0.0310 m3/kg (0.496 ft3/lb)
[25℃(177.0℉)]
Latent heat of vaporization

197.5 KJ/kg {47.19kcal/kg}
[0℃(32℉)]
Flammability Nonflammable
Ozone destruction coefficient 0
*1 : 1MPa (mega pascal) equals 10.1972 kgf/cm2 (145psi)
11-19
Characteristics of Refrigerant
In general, the fluid (general term of gas and liquid) has the following qualities:
1. As a gas under certain pressure is cooled down, it
PRESSURE
begins to condensate at a certain temperature to MPa(psi)
take a liquid state. The temperature at which R134a
4(580)
condensation begins is unique to each substance
(fluid) at a given pressure. The temperature 3(435)
determined by a given pressure is called saturation LIQUID
temperature. 2(290)
1(145) GAS
0.5(75)
TEMPERATURE
[ ( )]
0 0 15 18 35 50 100
(32) (59)(64) (95) (122) (212.0)
Pressure-temperature characteristics of R134a
2. Inversely to 1) above, the pressure at which a gas condenses is determined by a given temperature. This
pressure is called saturation pressure. The graph in the figure “Pressure-temperature characteristics of R134a”
shows 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 the figure “Pressure-temperature characteristics of R134a” 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 operator’s station. In order to cool the inside of the
operator’s station down to 25C degrees (77F degrees), the refrigerant must transform (evaporate) from a liquid
to a gaseous state at a temperature lower than that. It can be seen from the figure “Pressure-temperature
characteristics of R134a” 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 the air 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 35C degrees (95F degrees). Therefore the
refrigerant is capable of condensing at the pressure of 1 MPa (145psi) or more, as seen from the figure
“Pressure-temperature characteristics of R134a”.
11-20
11.5.2 COOLING CIRCUIT

The right figure. illustrates the cooling circuit of the car
air-conditioner.
In this circuit diagram, the portion that cools the air of the INSIDE OF COMPARTMENT(CAB)
operator’s station is the evaporator. The cooling circuit
cools an object by heat absorption from the surrounding
area, known as evaporation heat, occurring when
refrigerant evaporates. Since the part at which EVAPORATOR EXPANSION
vaporization of the refrigerant takes place is the VALVE
BLOWER
evaporator, air to be cooled is constantly delivered to the
circumference of the evaporator by the blower fan. In the
meantime, liquid refrigerant (wet vapor refrigerant with INSIDE OF ENGINE
S D ROOM
low dryness) is fed into the evaporator, when "cooling"
COMPRESSOR COOLING FAN
effect is attained.
For instance, in order to cool the air to 15C degrees (59F
degrees), the refrigerant can not absorb evaporation
heat from the air unless it evaporates at a temperature RECEIVER
lower than 15C degrees (59F degrees). For that
DRYER 11
purpose, it can be seen from the figure “Structure of CONDENSER
cooling circuit” that the pressure of the refrigerant in the
evaporator must be less than 0.51 MPa (74psi).
Furthermore, the cooling effect deteriorates unless the Structure of cooling circuit
feed rate of the refrigerant is controlled so that all of the
refrigerant supplied to the evaporator vaporizes and turns into dry vapor.
Consequently, the cooling circuit is constructed that the pressure in the evaporator is decreased to allow the
evaporator to cool an object (air in this case) sufficiently and an adequate amount of refrigerant can be fed to the
evaporator.
The feed rate of the refrigerant is controlled by the expansion valve, and 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.
11-21
11.5.3 AIR CONDITIONER COMPONENT PARTS

1. Evaporator
The evaporator is an important heat exchanger that
EVAPORATOR
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 O-RING
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 EXPANSION VALVE
water drops freeze. Therefore, how to discharge
water is an important point.
The amount of refrigerant supplied to the evaporator SOCKET BOLT M5X40(2 PCS.)
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 constituent factor 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.
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.
The figure “Block type expansion valve” shows how
the block type expansion valve is constructed. The
temperature sensing part is provided in the shaft of DIAPHRAGM
the expansion valve to directly detect the refrigerant
temperature at the outlet of the evaporator.
The diaphragm contains R134a in saturated state.
REFRIGERANT
The pressure in the diaphragm changes according OUTLET
EVAPORATOR
to the temperature detected by the sensor. The SIDE
change in the pressure causes the force acting upon
the diaphragm to vary accordingly. SHAFT
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). REFRIGERANT
INLET
On that occasion, part of the refrigerant evaporates
by the own heat of the refrigerant and cooled off.
The result is that low-pressure low-temperature BALL
VALVE
damp refrigerant vapor is fed to the evaporator.The SPRING
opening of the valve is determined by the balance
between the pressure (low) of the evaporator side,
the action of the adjust spring and the pressing force Block type expansion valve
of the diaphragm (the temperature of the refrigerant
at the outlet of the evaporator to be sensed by the temperature sensor).
11-22
The feed rate is controlled automatically so that under the pressure in the evaporator, the refrigerant is properly
overheated (3 to 8C 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. Expansion valve outside view
Compressor
The compressor performs the following three functions in the cooling circuit: 11
1. Suction action
The suction action, as combined with the throttling D HOSE
action, works to decrease the refrigerant pressure in
the evaporator. This permits the refrigerant to
vaporize at low temperature in order to perform
S HOSE
cooling effect.
Compressor
2. Pumping action
The pumping action serves to cause all the refrigerant to circulate in the cooling circuit. This enables
continuous cooling.
3. Compressive action
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. Because of this, for instance, cooling down
the refrigerant by the use of external air of 35C degrees (77F degrees) to liquefy the refrigerant become
possible. 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. Moreover, since the
compressive action takes place only for a short period, the refrigerant hardly exchanges heat with external air.
That is to say, it takes a form of close to adiabatic compression, so that the refrigerant discharged by the
compressor is high-temperature high-pressure vapor and is delivered to the condenser.
11-23
Condenser
This is a heat exchanger that cools the vaporized
refrigerant at high temperature and high pressure by the
use of external 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 external 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.
Condenser
11-24
Receiver dryer
1. Receiver Tank
REFRIGERANT SIGHT GLASS
On the air-conditioner, the revolution of the INLET
compressor varies greatly which causes the proper
flow of refrigerant in the cooling circuit to vary. It is REFRIGERANT
OUTLET
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
PRESSURE SWITCH
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 11
the amount of water mixed in the refrigerant should
be held below a concentration of 30 ppm. The air-
conditioner uses a molecular sieve as desiccant DESICCANT
suited for the circuit, in order to absorb water
content that intrudes into the circuit when the dryer SUCTION
is installed or when refrigerant is charged. PIPE
3. Sight Glass
This is a inspection window with which the
refrigerant level in the circuit is determined, the only FILTER
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 RECEIVER
off the power supply to the compressor when high TANK
pressure increases abnormally high [more than 3.14
MPa (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 0.2 MPa (28psi).
Receiver dryer
11-25
11.6 AIR CONDITIONER DISASSEMBLY AND ASSEMBLY

11.6.1 PRECAUTIONS TO BE EXERCISED IN OPERATION
1. Special Refrigerator Oil PIPE JOINTS Unit : N .m (lbf.ft)
This air-conditioner uses special refrigerator oil
SP20 for use with new refrigerant R134a. Oils other PIPE F ASTENING P ART TIGHTENING TORQUE
than SP20 may not be used. Since SP20 tends to
D hose and compressor (M8 bolt) 19.6~24.5 (14~18)
absorb moisture and may corrode paint and resin,
the following points must be noted: D hose and condenser 19.6~24.5 (14~18)
1) Do not keep open all pipe connections on a new L hos e a nd conde ns e r 11.8~14.7 (8.7~11)
compressor and the component parts of the
installed refrigeration circuit (Remove valves and L hose and receiver dryer (M6 bolt) 7.8~1 1.8 (5.8~8.7)
caps at the pipe openings of the compressor, just L hos e a nd a ir-conditione r unit 11.8~14.7 (8.7~11)
before connecting pipes. If you have removed a
pipe joint for repair, put a cap to both ports S hose and air-conditioner unit 29.4~34.3 (22~25)
immediately.)
Expansion valve 1.96~2.45 (1.4~1.8)
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. SCREWS AND BOLTS Unit : N .m (lbf.ft)
3. Tightening Torque SCREW SIZE TIGHTENING TORQUE

1) Pipe Joints N4,T4 machine screw , M4 0.78~1.18 (0.58~0.87)
(See the table “PIPE JOINTS”)
When connecting pipe joints, coat the O-ring with N5,T5 machine screw , M5 1.96~2.45 (1.4~1.8)
special oil (SP20) and fasten to the tightening
M6 (mounting pa rt of L hos e joint) 7.85~1 1.8 (5.8~8.7)
torque indicated in the table, using a double
spanner. M6 (except mounting part of L hose joint) 9.8~1 1.8 (7.2~8.7)
2) Screws and Bolts M8 (mounting part of S,D hose joints) 19.6~24.5 (14~18)
(See the table “SCREWS AND BOLTS”)
Fasten screws and bolts to the tightening torque M8 (mounting part of A/C unit) 9.8~1 1.8 (7.2~8.7)
indicated in the table. M8 (other than those mentioned above ) 1.18~15.7 (8.7~12)
4. Amount of Oil for Compressor
M10 39.2~53.9 (29~40)
(See the table “AMOUNT OF OIL FOR
COMPRESSOR”)
The compressor SD7H (HD type) is filled with 135cc
(8.2cu-in) 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 AMOUNT OF OIL FOR COMPRESSOR
will be deteriorated. Once the air-conditioner is
REPLACED P ARTS AMOUNT TO BE FILLED IN
operated, part of the oil is dispersed in the
refrigeration circuit. Therefore, when replacing the EVAP ORATOR 40 cc (2.4 cu .in)
parts in the right table “AMOUNT OF OIL FOR
CONDENSER 40 cc (2.4 cu .in)
COMPRESSOR”, adjust the oil level to that of table.
5. Before performing operation, stop the engine and Drain out the volume of oil left in
turn off all power supplies to the equipment related the compressor to be replaced
COMPRESSOR
to the air-conditioner. from the new compressor .
6. After the operation is over, confirm that all faults
have been repaired completely, by operating the air- RECEIVER DR YER 20 cc (1.2 cu .in)
conditioner.
HOSES 20 cc (1.2 cu .in)
11-26
11.6.2 DISASSEMBLY AND ASSEMBLY OF UNIT

1. Disassembly and assembly of blower motor
1) Disassembly
• Disconnect cooler hose from A/C unit.
• Loosen 3 tapping screws.
• Pull out the blower motor to the direction (the rear
Cooler hose
side of the cab) shown in the figure.
• Disconnect cooler hose from blower motor.
Ta pping s cre w A/C unit

Blower motor
2) Assembly
11
• Assemble the A/C unit in the reverse order of disassembly.
2. Disassembly and assembly of internal/external actuator
1) Disassembly HVAC Unit
• Remove the connector. Groove of
damper lever
Lever pin
• Remove actuator as shown. Actuator
Ta pping s cre w
Conne ctor
2) Assembly
• Assemble the actuator in the reverse order of disassembly.
Insert lever pin of actuator into groove of damper lever.
3. Disassembly and assembly of relay

1) Disassembly
• Loosen tapping screws. HVAC Unit
• Remove relay as shown. Ta pping s cre w

Relay
11-27
2) Assembly
• Assemble the relay in the reverse order of disassembly.
When performing the above-mentioned relay installation, put the cable of the inner air sensor in the position in the
following figure.
Put cable of inner

Inner sensor sensor in this pos ition.
A
Inner sen s or A
SECTION AA
4. Disassembly and assembly of inner air sensor

1) Disassembly
Inne r a ir filte r
• Pressing lock of connector 1, remove the
connecter from inner air sensor. HVAC Unit
• Pressing lock of sensor, remove inner air sensor as
shown. Lock of sensor
• Lift inner air filter upwards and remove it.
• Pressing lock of connector 2 inwards, remove the
Inner air sensor
connecter.
Con ne ctor 1
Connector 2
2) Assembly
• Assemble the inner air sensor in the reverse order of disassembly.
11-28
When performing the above-mentioned relay installation, put the cable of the inner air sensor in the position in the
following figure.
Put cable of inner

Inner sensor sensor in this pos ition.
A
Inner sen s or A
SECTION AA
11
5. Disassembly and assembly of fan driver
1) Disassembly
• Disconnect connector from fan driver. Connector
HVAC Unit
• Remove fan driver as shown.
Tapping screw Fan driver
2) Assembly
• Assemble the fan driver in the reverse order of disassembly.
6. Disassembly and assembly of link cover
1) Disassembly
• Remove link cover as shown.
Link cover
HVAC Unit
Tapping screw
2) Assembly
• Assemble the link cover in the reverse order of disassembly.
11-29
7. Disassembly and assembly of mode actuator and air mix actuator

1) Disassembly R o d
R o d la tc h
• Remove link cover.
See the paragraph of “Disassembly and assembly
of link cover”
• Remove the connector of the actuator.
• Turn rod latch of mode actuator in the direction of
arrow as shown. And release link rod.
• Twist link bar of air mix actuator in the direction of
arrow as shown. And remove the link rod from A ir m ix a c tu a to r
damper lever.
• Loosen 3 tapping screws fixing each actuator.
• Remove each actuator as shown.
L in k b a r
M o d e a c tu a to r
Air mix actuator
Mode actuator
HVAC Unit Tapping screw
2) Assembly
• Assemble the actuators in the reverse order of disassembly.
8. Disassembly and assembly of heater core
1) Disassembly
• Remove link cover. HVAC Unit
See the paragraph of “Disassembly and assembly Connector
of link cover”
• Disconnect connector from air mix actuator.
Air mix actuator
• Remove heater core as shown.
Heater core
11-30
2) Assembly
• Assemble the heater core in the reverse order of disassembly.
Do not exert excessive load on piping.
9. Disassembly and assembly of evaporator

1) Disassembly
Ta pping s cre w
• Turn HVAC unit upside down.
• Loosen 5 tapping screws. HVAC Unit
• Disconnect connector of evaporator sensor.
• Pull out evaporator as shown. Ta pping s cre w
11
HVAC Unit
Connection area of
evaporator sensor connector
2) Assembly
• Assemble the inner air sensor in the reverse order of disassembly.
To avoid damage, pull out evaporator sensor cord from groove of HVAC unit carefully.
11-31
10. Disassembly and assembly of expansion valve

1) Disassembly
• Loosen 2 socket bolts.
2 7 th
• Remove expansion valve as shown. ro ws
9 th r o f fin Evaporator
o ws
o f fin
Thermistor holder
73mm
(2.87 inch)
Stay
Harness holder
Evaporator sensor
O-ring 1/2
O-ring 5/8
Expansion valve
Socket bolt
20mm
(0.79 inch)
Enlarged illustration of sensor
and thermistor holder
Do not exert excessive load on piping.
2) Assembly
• Assemble the expansion valve in the reverse order of disassembly.
• Prior to assembly, apply PAG oil to O-ring.
Breakage of O-ring causes gas leak.
11. Disassembly and assembly of evaporator sensor

1) Disassembly
• Remove harness holder and thermistor holder from evaporator.
To avoid trouble, do not pull cord forcibly.
2) Assembly
• Assemble the evaporator sensor in the reverse order of disassembly.
• Install the harness holder and thermistor holder as shown.
11-32
• Install the tip of sensor and thermistor holder as shown.
When the sensor cord is loose-fitted, the cord is caught by door.
11
11-33
11.7 CHARGING REFRIGERANT

11.7.1 PRECAUTIONS TO BE EXERCISED IN OPERATION
Assign a person in charge of handling refrigerant.
Refrigerant charge operation involves dangers as it handles high pressure gas. Assign a person familiar with how
work is done for handling refrigerant.
HANDLING OF REFRIGERANT
• Wear protective goggles.

(You may lose your sight if the refrigerant gets in your eyes.)
• The refrigerant in liquid state is at very low temperature [approx. -26C degrees (-15F degrees)]. Therefore,
handle it with care.
(You may get a frostbite if the refrigerant is sprayed over your skin.)
Storage and Transportation

1. Keep the service can (hereinafter called can) less than 40C degrees (104F degrees). 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 explode as the result.
It is for this reason why the can temperature must be kept below 40C degrees (104F degrees).
2. For storage, choose dark cold place not exposed to direct sunlight.
3. If the can is placed near a fire, it is exposed to radiation heat and gets hot. This causes the inside pressure to
rise and may cause the can to blow out. Do not 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. Do not bring the can into the compartment.
5. Note that if the can has scratches, dents and distortion, the strength of the can will deteriorate.
• Do not drop or knock on the can.
• When transporting, loading or unloading cans and packages containing cans, do not throw or drop them.
6. Keep can out of reach of children.
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 40C degrees (104F degrees) or
below. If the can is put in hot water or heated by a direct fire, the pressure of the can may rise sharply,
thereby the can explodes.
2. When charging refrigerant while running the engine, to avoid explosion, do not open the high pressure valve
(HI) of the gauge manifold.
If the high pressure valve is open, it is very dangerous because a high pressure gas flows in the reverse
direction, causing the service can and the charging hose to explode.
Others
• Reuse of service cans is prohibited by the regulation, so never reuse them.
• Do not allow foreign materials 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 prevent water and dust from entering the refrigerant cycle.
11-34
• Be careful about overcharge of gas.

• Fasten pipes to the specified torque.
11
11-35
11.7.2 OPERATING PROCEDURE

Refrigerant charge into the air-conditioner consists mainly of "vacuum making operation", and "gas
charge 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 charging 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 filling 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.
Operation Chart
Va cuum ma king ope ra tion Gas charging operation
More tha n Le a ve it a s it is ,
30 min. for five minute s .
Be gin va cuum S top va cuum Che ck Cha rge Che ck for Cha rge
ma king ma king air-tightness re frige ra nt ga s le a k re frige ra nt
Lowe r tha n
-750mmHg Ga uge indica te s
a bnorma lity
Cha rge re frige ra nt ga s to a ga uge
Che ck a nd corre ct joints pre s s ure of 0.098 MP a (14.2 ps i)
Tools
No. Parts Q’ty Sketch Service No. Parts Q’ty Sketch Service
Low pressure
4 Quick joint 1 23.5mm
(0.93 inch) side
Gauge
1 1
manifold
For service
5 T joint 1
can valve
Red :
high pressure
side
Blue :
Charging Service can For service
2 3 low pressure 6 2
hose valve can
side
Yellow :
vacuum pump
side
Vacuum
For vacuum
3 Quick joint 1 7 pump 1
27.5mm pump
(1.08 inch) adapter
11-36
11.7.3 CHARGING PROCEDURE

VACUUM MAKING OPERATION
1. Connecting gauge manifold
HIGH
1) Close the high pressure valve (HI) and the low LOW PRESSURE PRESSURE GAUGE
pressure valve (LO) of the gauge manifold. GAUGE GAUGE MANIFOLD
2) Connect the charging hoses (red and blue) with (CLOSED)LOW HIGH PRESSURE
PRESSURE VALVE VALVE(CLOSED)
the service valves of the compressor. RED
Red hose : BLUE
High pressure side (HI) of the gauge manifold
HIGH
→high pressure side (DIS) of compressor PRESSURE YELLOW
Blue hose : SIDE
Low pressure side (LO) of gauge manifold DIS
LOW
→low pressure side (SUC) of compressor PRESSURE
3) Connect the center valve of the gauge manifold SIDE
SUC
with the charging hose of the vacuum pump.
COMPRESSOR VACUUM PUMP(STOP) 11
BLUE
RED
CHARGING
HOSE
(GAS VALVE)
• 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.
• Some kinds of gauge manifolds are not equipped with an open/close valve in the center.
2. Vacuum making
LOW PRESSURE VALVE(OPEN) (CLOSE)
1) Open the high pressure valve (HI) and the low HIGH PRESSURE VALVE(OPEN) More than (CLOSE)
pressure valve (LO) of the gauge manifold. 30 min
2) Turn on the switch of the vacuum pump and
make vacuum for more than 30 minutes.
GAUGE MANIFOLD
3) When vacuum making for a specified duration is
over (degree of vacuum : less than - 750 mmHg),
close the high pressure valve and the low
pressure valve of the gauge manifold.
4) Then turn off the vacuum pump. DIS
SUC
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 0.
11-37
If the gauge indication goes toward 0, there is somewhere that is leaking. Retighten pipe joints, make vacuum again
and make sure of no leakage.
GAS CHARGING OPERATION

1. Charging from high pressure side
1) After making vacuum repeatedly, change the
charging hose (yellow) of the gauge manifold AIR PURGE
from the vacuum pump to the service can. CLOSE
SCREW DRIVER OPEN SERVICE

YELLOW CAN VALVE
BLUE RED
Gas charging operation
2) Air purge
Open the service can valve. (However, close the
high and low pressure valves of the gauge
manifold.) LOW PRESSURE HIGH PRESSURE VALVE
Then push the gas valve of the side service port VALVE(CLOSE) (OPEN) (CLOSE)
on the low pressure side of the gauge manifold, RED FILL IN 1~1.5 CANS
using a screw driver, in order to let out the air in BLUE OF REFRIGERANT
the charging hose by the pressure of the
DIS
refrigerant. YELLOW
(The operation ends when a hissing sound is SERVICE CAN
VALVE
heard.) (OPEN) (CLOSE)
CHARGE
SUC
Gas charging operation (High pressure side)
3) Open the high pressure valve of the gauge manifold and charge in refrigerant. [Charge in gaseous
refrigerant to a gauge pressure of 0.098 MPa (14.2 psi).]
After charging, close the high pressure valve of the gauge manifold and the service and valve.
CHARGING WORK OF REFRIGERANT

Do not run the compressor during this work,
(Otherwise the refrigerant flow in reverse direction which causes the service can and the hoses to explode. This is
very dangerous.)
2. Checking for gas leak

Check for gas leak in the cycle, using a gas leak detector (electric type). Retighten and correct leaking points.
Use the leak tester for R134a. (Do not use one for flon gas service as it provides poor sensitivity.)
11-38
3. Charging from low pressure side
CHARGING WORK OF REFRIGERANT
• Do not open the high pressure valve of the gauge manifold.

• Do not turn over the service can. (The compressor valve may be damaged because the refrigerant is sucked in a
liquid state.)
1) Make sure that the high-pressure and low-

pressure valves of the gauge manifold and the
service can valve are closed.
LOW PRESSURE HIGH PRESSURE
VALVE VALVE(CLOSE)
OPEN CLOSE
WHEN AIR RED (CLOSE SECURELY)
BUBBLES IN THE
SIGHT GLASS
DISAPPEAR
YELLOW
DIS
BLUE 11
SERVICE CAN
VALVE(OPEN)
SUC
COMPRESSOR SERVICE CAN

OPERATION (DO NOT TURN OVER)
Gas charging operation (Low pressure side)
2) Start the engine and run the revolution from 1400 to 1600rpm and close 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 from 1.37 to 1.57 MPa (199 to 228psi).
5) Open the low pressure valve of the gauge SIGHT GLASS
manifold and the service can valve and fill in
refrigerant till air bubbles of the sight glass of the
receiver disappear.
[Total amount of gas to be charged: 800 to 900g
(1.76 to 1.98 lbs)]
RECEIVER DRYER
Receiver dryer
6) When refrigerant charge is completed, close the low pressure valve of the gauge manifold and the service
can valve.
11-39
4. Criterion for checking the amount of refrigerant filled in
JUDGMENT OF REFRIGERANT LEVEL THROUGH THE SIGHT GLASS OF RECEIVER DRYER
After A/C is turned on, only a little

PROPER LEVEL bubbles are seen and thereafter light
milky white is seen.
After A/C is turned on,

OVERCHARGE no air bubbles are seen.
After A/C is turned on, continuous

UNDERCHARGE
air bubbles are seen.
HANDLING OF REFRIGERANT
• If the air-conditioner is run with poor refrigerant R134a, it has adverse effect on the compressor.
• 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 as follows.
1) Press the "L" shape metal fitting of the charging hose (blue) on the low pressure side against the service
valve of the compressor to avoid leakage of the refrigerant. 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 0.98 MPa (142 psi)].
3) Disconnect the charge hose (red) on the high pressure side the same way as on the low pressure side.
11-40
11
11-41
11.8 AIR CONDITIONER ELECTRIC CIRCUIT

11.8.1 AIR CONDITIONER WIRING DIAGRAM AND CONNECTORS
NOTE) 1. THe double chain lines indicate the wiring

on the excavator side.
2. The connector colors indicate the cord colors seen
from the connecting part.
3. Unless otherwise specified, wire diameters are 0.5.
4. Use the fuses that are specified capacity in this diagram.
LIGHT
PINK WHITE BLACK RED YELLOW GREEN BLUE BROWN GREEN ORANGE
Electric diagram (1/2)
11-42
11
Electric diagram (2/2)
11-43
11.8.2 STRUCTURE AND OPERATION OF EACH PARTS

Control panel
The control unit is integrated into control panel, and
processes the signal input by each sensor, etc. and the
signal input by each switch through control panel with
the function of the built-in micro computer, and
comprehensively controls each actuator (Air inlet / outlet
mode select, air mix), blower motor and compressor on
the output side. Control panel
And the self-diagnosis performance is provided to
facilitate the trouble shooting.
Fan driver
TERMINAL NO.
CONTINUITY
The power transistor shifts the blower motor into variable 1 2 3
speed with base current from the control unit. CONTINUED
<Check for fan driver> TESTER NOT CONTINUED
Check over the continuities between terminals of fan
CONTINUED(DIODE PARALLEL
driver. AND FORWARD DIRECTION FLOW)
2 3
Blower controller
Relay
Four-electrode relay is used for the blower OFF relay
and compressor relay.
1. Blower OFF relay
The blower OFF relay turns on after receiving the
signal from the control amplifier.
When the blower OFF relay turns on, the source
voltage is supplied to the blower motor and the
blower motor starts running.
2. Compressor relay
The relay ON-OFF is switched by the control
amplifier and electronic thermostat control.
3. Relay specification and inspection
1) Coil resistance: 320Ω
2) Specified voltage: DC20V to 30 V
3) Be careful about the coil polarity of relay.
4) Inspection: Inspect the continuity between terminals 3 and 4 as follows.
20 to 30 V applied between terminals 1-2: Continued
20 to 30 V not applied between terminals 1-2: Not continued
11-44
Motor actuator
Air mix actuator is located in at the center of air-con unit,
and opens and closes air mix damper through the link
motion.
The air mix actuator incorporates potentiometer which is
switched by linked shaft with actuator.
When the target air mix door position is determined Control panel Motor actuator
through the temperature control switch, the control unit
M
reads the level of potentiometer of the actuator. And it
determines the rotating direction of motor in either
normal rotation or reverse rotation. And the motor
rotates, the contact point is moved, and when the
contact point is detached or the output signal of control
unit turns OFF, the motor stops. Both motor actuators
Mode actuator (12V)

< C o n n e c to r a rra n g e m e n t >
Mode actuator is located in outlet of air conditioner unit.
And it opens or closes mode door through link. 11
The mode actuator incorporates potentiometer which is < M o to r in p u t >
switched in accordance with shaft of actuator. T e r m in a ls
When a target air mix door position is determined R o ta tio n a l
d ir e c tio n
through the temperature control switch, the control unit

reads the level of potentiometer of the actuator. And it
determines a forward or reverse rotation of motor. The
P o te n tio r e s is ta n c e c h a r a c te r is tic
contact point moves in accordance with the movement of - B e tw e e n e le c tr o d e s 1 2 0 d e g r e e s C T o ta l
the motor and when output signals of the control unit r e s is ta n c e 4 .7 k ilo - o h m s
stop, the motor stops.
W h e n 5 v o lt is a p p lie d to c ir c u it
b e tw e e n (6 ) a n d (4 )
b e tw e e n (5 ) a n d (4 )
(+ a t (6 ) a n d - a t (4 ))
O u tp u t v o lta g e
C ir c u it b o a r d c h a r a c te r is tic
11-45
The actuator for air inlet / outlet (12V)

The actuator for inlet and outlet air mode select is installed on the blower intake unit, and opens and
closes inlet or outlet air damper through the link motion.
The actuator for inlet and outlet air mode select incorporates position detection switch which is switched with the
movement of shaft of the actuator.
When the inlet or outlet damper position is set by the inlet and outlet switch on the control panel, the control unit
reads the signal of the position detection switch in the actuator and determines the rotation direction of motor in
either normal rotation or reverse rotation. And the motor rotates, the position detection switch also rotates and
makes it stop at the set position of the inlet or outlet air damper.
Evaporator sensor - air inlet sensor
This sensor is used to control the evaporator outlet
temperature with the compressor ON-OFF to protect the
evaporator from freezing, and this evaporator sensor
functions as a sensor of this control.
• Evaporator sensor and air inlet sensor specifications
Terminal resistance:
at 0 degree C: 7.2 kΩ
Evaporator sensor - air inlet sensor
at 25 degree C: 2.2 kΩ
Dual pressure switch
SPECIFICATION OF DUAL PRESSURE SWITCH
The dual pressure switch is installed on the upper part of 0.02 MPa 0.59 MPa
(2.9 psi) (86psi)
the receiver dryer.
It turns off the compressor when the pressure is ON
abnormally high at the high pressure side and when the
OFF
refrigerant is not charged at the low pressure side to 0.20 MPa 3.14 MPa
(29 psi) (455 psi)
protect each cycle.
(LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)
Dual pressure switch
Relief valve (part of compressor)

3.50 to 4.10 MP a
This discharges the refrigerant in the system to prevent (508 to 595 psi)
Close (in normal condition)
rupture of the parts in the system when the above-
mentioned dual pressure switch does not work properly Open (under abnormally
high pressure) 2.89 MP a
even if the pressure inside the system becomes
(419 psi) or more
abnormally high due to abnormally high temperature
caused by a fire of the air conditioning system environment.
Relief valve (assembly part of compressor)
11-46
11.9 AIR CONDITIONER TROUBLESHOOTING

Air temperature does not fall.
If AUTO switch or A/C switch is pressed,

"HL.E" is indicated on the set temp. display of the panel.
NO YES
* is any of the numbers 0 to 9.
"HL. " is shown on the set temp.
* . Connector for air mix M/A is
display of the panel. disconnected or in poor contact.
. Air mix M/Ais failed.
NO YES . Main harness has poor continuity .
A s now ma rk ( ) on A s now ma rk ( )
the panel is flashing. on panel is flashing. Check and correct or replace parts.
NO YES
11
. Inner air sensor or harness is disconnected or shorted. . Both inner air sensor and
. Inner air sensor connector is disconnected or in poor contact. evaporator sensor are
disconnected or shorted.
See paragraph of monitor mode. . Controller failed.
See paragraph of monitor mode.

Check and correct or replace parts.
A
NO YES
Outlet temp. falls if temp. is set . Evaporator sensor connector

at LO and the outlet mode is changed is disconnected or in poor contact.
to vent mode. . Evaporator sensor is disconnected
simultaneously or shorted.
NO YES
Air mix damper is Cool air is flowing

in LO (COOLMAX). into inner air sensor Check and correct or replace parts.
NO YES
NO YES
M/A stops halfway . Inspect and correct
ON/OFF and power circuit
of compressor clutch. Controller is faulty Check duct or
or inner air sensor eliminate cause for
is faulty. cool air intrusion.
Refer to troubleshooting
for refrigeration cycle.
Check and replace.
NO YES
M/A or controller is . Check, correct or replace

out of order . M/A lever link.
. After cleaning lever link,
apply grease.
Replace.
11-47
Air outlet temperature does not rise.
HL.E is shown on the set temp. display of the panel.

NO YES
* is any of the numbers 0 to 9.
"HL. " is shown on the set temp.
* . Connector for air mix M/A is
display of the panel. disconnected or in poor contact.
. Air mix M/Ais failed.
NO YES . Main harness has poor continuity .
. Inner air sensor or harness is disconnected or shorted.

. Inner air sensor connector is disconnected or in poor contact. Check and correct or replace parts.
Outlet temp. rises at FOOT

mode if temp. is set at HI
NO YES
Air mix damper is Wa rm a ir is flowing into

in HI (HOT MAX). inner air sensor .
NO YES
NO YES
M/A action stops, Check warm water piping.
halfway.
Controller or Check duct or
inner air sensor eliminate causes
is out of order . for warm air entry .
NO YES
Check and replace.
M/A or controller is . Check, correct or

out of order . replace M/A lever link.
. Clean lever link and apply grease.
Replace.
11-48
Blower motor does not run.
At air flow HI, battery voltage acts on

Note 1) both terminals (+) and ( -) of blower motor .
NO YES
Battery voltage is applied on between Replace blower motor .

red/white wire of blower motor
(+) power supply and ground wire.
NO YES
Check blower motor OFF relay . Volta ge a cts on ye llow wire

Note 2) If connecting white/green wire and white/red and ground wire of blower amplifier .
wire of blower motor OFF relay directly ,
blower motor runs.
NO YES
NO YES 11
Is there continuity between yellow
Check, repair , Replace controller . wire and black wire?
or replace harness.
NO YES
Battery voltage is applied on between
white/green wire of blower motor relay
and ground wire. Eliminate cause Check and
of failure and then repair harness.
NO YES replace blower amplifier .
Check, repair , or Blower motor turns if brown wire of blower

replace harness. motor relay is connected with ground.
NO YES
Replace relay . Check and repair wire harness

or replace controller .
Note 1)
In the connector connected condition, measure the voltage.
Note 2)
When connecting the wires directly , turn of f the air conditioner , starter switch,
and light switches for safety .
11-49
Blower motor speed does not change.
CASE (1)
Note) is any of the
"HL. " is shown on the set temp. display of the panel.
* *
numbers 0 to 9.
NO YES
Replace blower . Inner air sensor or harness is disconnected or shorted.

amplifier or controller . . Inner air sensor connector is disconnected or in poor contact.
Magnet clutch does not engage.
S now ma rk ( ) lights on,

whe n AUTO s witch or
A/C s witch is pre s s e d.
No Ye s
Snow mark ( ) flickers and E is Voltage acts on clutch.

shown on panel display.
No Ye s
To A Volta ge is a pplie d on be twe e n Clutch is faulty.

pre s s ure s witch ha rne s s . Replace compressor.
No Ye s
Voltage is applied on between red/white wire of P re s s ure s witch fa ilure or re frige ra nt

machine side harness connector and ground (black) wire. high a nd low pre s s ure s a re a bnorma l.
No Ye s
Re fe r to trouble s hooting
for re frige ra tion cycle .
Che ck clutch Check air conditioner
fus e s . harness for possible failure.
No Ye s
Replace harness. Re pla ce controlle r.
11-50
Recirculation and fresh air do not change.
Recirculation/fresh air mode display

on operation panel is flickering.
No Ye s
Foreign matters are adhered to Connector of recirculation/fresh air

M/A lever or M/A lever is broken. M/A is disconnected or in poor
No Ye s contact condition.
Or M/A or main harness is faulty.
Replace M/A. Remove foreign matters

or replace part. Inspect or replace.
11
Modes do not change.
Mode display (Mark of body)

on control panel is flickering.
No Ye s
M/A rod does not come off. Connector of recirculation/fresh

air M/A is disconnected or in
No Ye s
poor contact condition.
Or M/A or main harness is faulty.
Repair. Each damper lever does not come off.
No Ye s Che ck a nd re pla ce .
Repair. Whe n rod is re move d a nd ca m is ope ra te d

by ha nd, it is he a vy.
No Ye s
Replace M/A or controller. . Cam or damper shaft does not

work due to foreign matter or is broken
. Malfunction occurs due to
contaminated grease.
. Re move fore ign ma tte r or re pla ce pa rts .

. Cle a n ca m a nd a pply ne w gre a s e .
11-51
Trouble of refrigeration circuit.
Both high and low pressures are low.

Low pressure is low.
NO YES
Air bubbles are seen in sight glass.
Air bubbles are seen in High pressure
NO YES sight glass. is low.
Cooling does not work Oil comes out from
if refrigeration circuit is piping and parts.
operated at high speed. Compre s s or cylinde r Compressor cylinder
NO YES doe s not ge t hot. gets extremely hot.
NO YES
Expansion valve Expansion valve Natural Gas leaks
is clogged. is frozen or leak from from pipe
intruded by water. hose. joints and Expansion valve is Compressor does
parts. maladjusted. not discharge well.
Replace After performing (too much open)
expansion valve. air purge by Charge gas. Retighten
vacuum, refill or replace
refrigerant and parts. Replace Replace compressor
replace receiver. expansion valve.
High pressure
is low.
Air bubbles are seen in sight glass.

NO YES
High pressure gets Condenser is
decreased slowly. contaminated or clogged.
High pressure YES NO

circuit before
receiver is Air bubble s a re ha rd to
clogged up. go out e ve n if wa te r
is poure d on conde ns e r.
Remove Clean
clogging or condenser. Air is mixed.
replace parts. Perform air purge
by vacuum and
refill refrigerant.
11-52
11.10 PANEL DISPLAY FOR SELF DIAGNOSIS

Display for detection of motor actuator disconnection and motor actuator lock
When a failure occurs in the input circuit of the motor actuator drive line, it can be checked by the monitor display.
Failure part of motor actuator Display of failures
Air mixture “HL.E” is displayed on temperature indication segment.
Air outlet mode Human-shaped display is flashing
Recirculation and
Recirculation and fresh air display is flashing
fresh air selection
Display for detection of evaporator sensor or inner air sensor disconnection

When a failure occurs in the input circuit of the evaporator sensor or inner air sensor, it can be checked by the panel
11
display.
Failure part of
Display of failures
sensor
18 degrees C: LO.E
·“E” is indicated on first decimal
Evaporator sensor 25 degrees C: 25.E
place of temperature indication
32 degrees C: HO.E
·“HL” is indicated on temperature

indication
Inner air The figure from “0 to 9” is HL.0 to HL.9
indicated on first decimal place of
temperature indication
Detection of each sensor error by monitor mode function (for obtaining failure control status from the
control panel)
• When the air conditioner is in operating condition, press the internal and external air selector switch and main
power switch for one second or more simultaneously. And the display of monitor mode begins. To return the
display to previous display, perform the same operation.
• Normal condition, disconnection and short circuit of inner air sensor, evaporator sensor and solar sensor are
indicated in segment of display.
11-53
7 segments indication Example :

only for monitor Display location of 7 segment
Sensor 7 segments indication only for monitor 3-digits segment list
indication Second digit of segment
Inner Ü Ý Þ ß à á â ã ä å í î ï ð ñ ò
air sensor 0
0
Evaporator Intake air sensor disconnection indication “0CH ”
sensor 1 Ü
1
Evaporator sensor disconnection indication “0CH ”
Each kind
of data 2 to F Ý
Example : Þ
Error contents of indication Position of digit indication ß
Third digit of s e gme nt

Sensor Short circuit Disconnection Second digit : F
indication indication à
Inner Ü Ü
á
air sensor " $ $ â Each sensor is normal
Evaporator Ý Ý
ã
sensor " $ $
ä
å
Third digit : F
í
Example: î
At normal condition ï
ð
ñ
Inner air sensor short circuit indication “F6H0”
ò
Evaporator sensor short circuit indication “F6H1”
11-54
［12. DISASSEMBLING AND ASSEMBLING］
12. DISASSEMBLING AND

ASSEMBLING
12.2 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY .....................................12-4
12.2.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY ..................................................12-4
12.2.2 INDICATION OF TIGHTENING TORQUE ............................................................................12-4
12
12-1
12-2

12
12-3
12.2 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY &

ASSEMBLY
12.2.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY
This chapter is consist of 3-Section as follows.
ATTACHMENTS
1. Removing and Installing
2. Disassembling and Assembling
1) Cylinder
UPPER STRUCTURE
1) Hydraulic Pump
2) Control Valve
3) Pilot Valve (ATT)
4) Pilot Valve (Travel)
5) Slewing Motor
6) Swivel Joint
TRAVEL SYSTEM
1) Travel Motor
12.2.2 INDICATION OF TIGHTENING TORQUE

Tightening torque is indicated as follows,
for example; T=98N･m(72 lbf･ft)
Tolerance is to 10% unless otherwise specified.
• Refer to Chapter "TOOLS" for standard tightening torque.
12-4
［13. ATTACHMENTS］
13. ATTACHMENTS
13.2 PREFACE ............................................................................................................................13-4
13.3 REMOVING AND INSTALLING ATTACHMENT ......................................................................13-5
13.3.1 ATTACHMENT ASSEMBLY AND NAME .............................................................................13-5
13.3.2 BUCKET............................................................................................................................13-6
13.3.3 ARM..................................................................................................................................13-9
13.3.4 BOOM ............................................................................................................................. 13-13
13.4 DISASSEMBLING AND ASSEMBLING ............................................................................... 13-18
13.4.1 CYLINDER ...................................................................................................................... 13-18
13
13-1
13-2

13
13-3
13.2 PREFACE
• This Manual describes all the procedures from removing to attaching, arranging them by item.
• This Manual consists of mainly 2 sections of "REMOVING AND INSTALLING ATTACHMENT" and
"DISASSEMBLING AND ASSEMBLING".
• The removing and installing can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
• The removing and installing procedure does not completely cover all possible situations because of differences
of field condition and defective section.
• Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.
13-4
13.3 REMOVING AND INSTALLING ATTACHMENT

13.3.1 ATTACHMENT ASSEMBLY AND NAME
(D) (C)
(A)
1
4
(F)
(E)
(J) 2
5
(G)
3
8 6
7 (K) (B)
(I)
(H)
Front attachment and position
No. NAME No. NAME

(A) BOOM FOOT PIN 1 BOOM
(B) BOOM CYLINDER HEAD PIN 2 BOOM CYLINDER
(C) BOOM CYLINDER ROD PIN ARM

3
13
(D) ARM CYLINDER HEAD PIN 4 ARM CYLINDER
(E) ARM CYLINDER ROD PIN 5 BUCKET
(F) BOOM TOP PIN 6 BUCKET LINK
(G) BUCKET CYLINDER HEAD PIN 7 IDLER LINK
(H) BUCKET CYLINDER ROD PIN 8 BUCKET CYLINDER
(I) IDLER LINK PIN
(J) BUCKET DRIVE PIN
(K) BUCKET ATTACHING PIN
13-5
13.3.2 BUCKET
13.3.2.1 REMOVING BUCKET
1. Put the machine in position to remove bucket.
Position to remove bucket
2. Removing pin (2)

Expand slit of ring (1) with screwdriver, and remove BOSS SECTION
it. Push out the pin (2) with flat-blade screwdriver. DRIVER
1 2
SECTION OF BOSS
Removing pin (2)
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). K
Removing bucket attaching pin
13-6
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, J
and pull out pin (J).
Store the removed pin (J) in original position again.
Removing bucket drive pin
13.3.2.2 ATTACHING BUCKET

• Attaching bucket drive pin (J)
Attach bucket drive pin (J) first, then continue in the
reverse procedure of removing.
J
13
Attaching bucket
ABOUT BUCKET INSTALLATION
• When aligning the pin holes, do not put your finger in the pin holes, but align them visually.
• Check the seals for damaged and replace as necessary.
• When inserting the pin, coat the shaft with grease.
13-7
13.3.2.3 PROCEDURE FOR ADJUSTING CLEARANCE

Adjustment of clearance between bucket and arm
1. Shift O-ring (3) toward the bucket boss, using a Apply rust preventive oil +1.0 +0.039"
326 -0.5 (12.84 -0.020" )
spatula. (a→b) New bucket
2. When adjusting clearance (B), bring the non- B

12 : WASHER 3 : O-RING
adjusting side of the bucket in contact with the arm. 11 : CAPSCREW b a
3. Measure clearance (B) and check that it is within 1.0
mm (0.04 in).
4. Adjust clearance (B) where it is more than 1.0 mm
(0.04 in).
7 : BUSHING
5. An average of 5 shims (9) of 1mm (0.04in) thickness
are set in the plate (8) fixed by the three capscrews 8 : PLATE
(11). The clearance can be decreased by 1mm
Install pin (10) until the top
(0.04in) if one shim is removed. 9 : SHIM 10 : PIN of pin is even surface
Tools: Socket: 24mm with bushing.
Tightening torque: 279N·m (206 lbf·ft)

Adjusting clearance between bucket and arm
6. After adjustment, tighten the capscrews evenly.
• The gap exceeding the specified dimension
causes early wear.
7. Operate the bucket and confirm that the total sum of both clearance is within 1.0 mm (0.04 in).
8. Replace O-ring (3) on its original position.
• When shifting O-ring (3) by means of a spatula, use care so as not to damage O-ring (3).
• Remove shims (9), push out bushing (7) rightwards by means of three capscrews (11) and adjust clearance (B)
so it settles within the standard value evenly all round.
13-8
13.3.3 ARM
13.3.3.1 REMOVING ARM
1. Put the machine in position to remove arm.
Extend the arm cylinder, retract the bucket cylinder
and bring the arm down on the ground.
Position to remove arm
2. Disconnecting piping of bucket cylinder

Release pressure of hydraulic tank, place oil pan to
prepare for oil leaking, and disconnect pipes.
OIL PAN
Disconnecting piping of bucket cylinder
Plug both end of disconnected pipes.

Plug: See "Plug for ORS joints" in Chapter "TOOLS".
Plug: See "Plug for half clamp" in Chapter "TOOLS". 13
• When the removal of bucket cylinder is not required, skip to procedure 6.
13-9
3. Removing bucket cylinder rod pin (H) G A

A
Loosen nut (9), remove capscrew M20X145 (7), and D
H
push out pin (H).
D
Install resin shim

to cylinder side. Tota l cle a ra nce of both s ide
SHIM SHIM to be 0.6~1.0mm (0.02~0.04in)
after adjusting by shims.
9
SHIM bb
DETAIL bb
H 7
DUST SEAL
cc Apply Molybdenum
SHIM added grease
SHIM Install resin shim DUST SEAL
in the inner surface.
to bucket link side.
SECTION DD
DETAIL cc
Detail of bucket cylinder rod pin (H)
4. Removing cylinder head pin (G)

aa
Loosen nut M16 (3), remove capscrew M16X140 Tota l cle a ra nce of both s ide to be
0.6~2.0mm (0.02~0.08in)
(2), and push out pin (G). SHIM after adjusting by shims.
Install resin shim
to cylinder side.
SHIM
2 SHIM
G
Apply
Molybdenum
added grease
in the inner surface. 3
SECTION AA DETAIL aa
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: 143 kg (315 lbs)
Slinging bucket cylinder
13-10
6. Removing arm cylinder rod pin (E)

E
1) Put a wooden block between the arm cylinder B
BLOCK
and the boom.
2) Loosen nut M16 (3), remove capscrew M16X150

(2), and push out arm cylinder rod pin (E). B
3) Retract arm cylinder rod, and return pin (E) to the

original position (hole).
A
A F
Apply Molybdenum added grease

aa 2
E
SHIM
SHIM SHIM
Tota l cle a ra nce of
3 Install resin shim
both side to be to cylinder side.
0.6~2.0mm (0.02~0.08in)
SECTION BB DETAIL aa
Detail of arm cylinder rod pin (E)
7. Removing boom top pin (F)

Install resin shim
1) Loosen capscrew M16X30 (3), and pull out boom
to arm side. 13
SHIM
top pin (F). Tighte ning torque
2 3 279N .m (206 lbf .ft)
Tools: Spanner: 24mm Apply loctite #242 to bolt.
2) Insert pin (F) into the original hole. SHIM

DETAIL aa
Apply Molybdenum
added grease
aa
SHIM
Tota l cle a ra nce of both s ide
to be 0.5mm (0.02in) or less
F
SECTION AA
Detail of boom top pin (F)
13-11
8. Slinging arm assy

Sling arm with nylon sling and remove it.
Arm weight: 806kg (1,777 lbs)
Slinging arm assy
13.3.3.2 ATTACHING ARM

Instal the arm in the reverse order of removing, paying attention to the following:
• When aligning the pin holes, do not put your finger in the pin holes, but align them visually.
(0.02")
CLEARANCE
• Check the seals for damage and replace as necessary.

• When inserting the pin, coat the shaft with grease.
• Pin lock nut handling procedure
Tools: Spanner: 24mm, 30mm
• When installing the arm and the cylinder, inspect the clearance in the thrust direction of the pins and decide the
thickness of shims by referring to the Maintenance Standard.
When installing the shims, install the plastic shims first and then fill the clearance with the iron shims.
Regarding the installation positions of the plastic shims and the iron shims, see the figure explaining each pin at
arm removal.
• Tightening torque
Tightening torque
Classification Size
N·m (lbf·ft)
147 (108)
M16
Metric threads 279 (206)
M20 181 (134)
1/8" 16.7 (12.3)

PF, PT threads
1/4 36.3 (26.8)
13-12
13.3.4 BOOM
PREPARATION
When removing and attaching the boom in the position shown in the figure "Position to remove boom", to remove
and install boom foot pin (A), removing and attaching of the cab and the guard on the upper structure are required.
13.3.4.1 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
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
A
STAND 13
Lifting up boom cylinder temporarily
3. Press the boom cylinder rod pin (C)

SHIM
Loosen nut (6) and remove 2 capscrews (5)
M16×150 and 2 bosses (3) and push in pin (C).
Tota l cle a ra nce of both s ide
to be 0.6~2.0mm (0.02~0.08in) SHIM
4. Preparing for disconnecting cylinder pipes after adjusting by shims. Install resin shim
Retract the above mentioned cylinder rod, and place SHIM to cylinder side.
one side of cylinder on stand. DETAIL bb
See the figure "Lifting up boom cylinder 5 C
temporarily". 5
3
6 3
SHIM
6
bb Apply Three bond SHIM
#1901 in the inner surface.
SECTION AA
Detail of boom cylinder rod pin (C)
13-13
5. Disconnecting the arm cylinder and bucket cylinder

pipings
1) Release pressure from arm and bucket circuit

and bleed air in hydraulic tank, and then A1
disconnect pipe at (A1), (A2), (A3), (A4) and hose A4
(B1), (B2), (B3), (B10). A3
Tools: Spanner: 36mm, 41mm A2
2) After disconnection of pipe, plug every pipe.

Plug: See "Plug for ORS joints" in Chapter
"TOOLS".
6. Lifting up boom assy temporarily O-RING
Lift up boom cylinder with nylon sling so that boom B1
B3
foot pin (A) is not loaded. O-RING BUCKET (H)
Weight of single boom: 1,800kg (3,970 lbs) B2 BUCKET (R)
B10
ARM (H)
ARM (R)
Boom piping disconnection
A A
Boom assy temporary lift up procedure
7. Removing boom foot pin (A) Tota l cle a ra nce of both s ide s to be
0.5mm (0.02in) after adjusting by shims.
1) Remove capscrew (4) M20×40 and plate (3). SHIM
2) Draw out pin (A). 2

A
8. Hoisting boom assy
Hoist and remove boom assy.
Weight of single boom: 1,800kg (3,970 lbs)
4
Apply Loctite
#242 3
Apply Molybdenum added grease
SECTION A-A
Details of boom foot pin (A) section
13-14
D
D
Boom assy hoisting procedure
9. Completion of removal of front attachments

When the removing and attaching of cylinder are not required, the work is finished.
10. Removing and installing arm cylinder
1) Lift up arm cylinder (2) with nylon sling so that the

head of cylinder is not loaded. 2
2) Disconnect hose (F1) and (F2) at position A. After

disconnection of hose, plug both ends of hose. F2
SHIM
Plug:
See "Plug for ORS joints" and "Plug for half
SHIM
clamp" in Chapter "TOOLS".
Install resin
Tools: Spanner: 36mm shim to cylinder side.
Tools: Allen wrench: 12mm DETAIL aa 2 F1
D A
3) Removing arm cylinder head pin (D)
Loosen nut M16 (3), remove capscrew M16X150
3 13
(2) and pull out pin (D). Apply
aa
Tools: Spanner: 24mm Molybdenum
added grease
4) Removing arm cylinder (2). in the inner
surface.
Weight of arm cylinder: 255kg (560 lbs)
SHIM
Tota l cle a ra nce of
both side to be
0.6~1.0mm
(0.02~0.04in)
after adjusting by shims. SECTION DD
Removing and installing arm cylinder
13-15
11. Removing and installing boom cylinder
1) Release pressure from boom circuit and bleed air

in hydraulic tank.
2) Sling boom cylinder (2) using nylon sling

temporally not to act the weight of cylinder upon
2
the cylinder head.
3) Disconnect each two hoses (C2) and (C3). And 2

plug their both ends.
B
Plug: See "Plug for ORS joints" in Chapter
"TOOLS".
Tools: Spanner: 32mm, 36mm, 37mm, 41mm C3
C2
C3
Removing and installing boom cylinder
4) Removing boom cylinder foot pin (B) Tota l cle a ra nce of both s ide to be
(See the figures "Removing and installing boom 0.6~1.0mm (0.02~0.04in)
cylinder head pin (B)" and "Installing boom foot SHIM
pin (A)".) 5 SHIM
Remove nut (6) and capscrew (5) M16×150 and
B
pull out pin (B). SHIM
6 aa
Tools: Spanner: 24mm Install resin
shim to
5) Sling boom cylinder (2) and remove it. Apply Molybdenum cylinder side.
Weight of boom cylinder: 166kg (366 lbs) added grease
in the inner surface. DETAIL aa
5
6) Remove another boom cylinder the same way. Apply Molybdenum added
grease in the inner surface. B
6
SECTION AA
Removing and installing boom cylinder head pin

(B)
13-16
13.3.4.2 ATTACHING BOOM

• Attaching boom foot pin (A)
First of all, insert boom foot pin (A) and install the
boom assy.
Attach it in the reverse procedure of removing,
paying attention to the following points.
• When aligning the pin holes, do not put your A
finger in the pin holes, but align them visually.
• Check that the dust seals is not damaged and
replace as necessary.
• When inserting the pin, coat the shaft with
grease.
• See Paragraph "ATTACHING ARM" for the A
installation procedures of the pin retaining nut. B
• When installing boom and cylinder, check the
clearance of mounting section in thrust direction, A
and decide the thickness of shim according to the
maintenance standard.
Install resin shim first, and insert iron shim into Installing boom foot pin (A)
remaining gap.
Regarding the position of shim, refer to details of boom foot pin (A) section.
13
13-17
13.4 DISASSEMBLING AND ASSEMBLING

13.4.1 CYLINDER
13.4.1.1 PREPARATION BEFORE DISASSEMBLY
Before assembly, secure a dustfree workshop and necessary equipment and facilities.
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 to 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.
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 making level and liner movement under load for retracting and extending the piston rod and the tube.
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 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 damage of seals.
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.
8. Others
Oil extracting hoses, wooden blocks, clean cloths and sawdust in which oil soaked are also necessary.
13-18
NECESSARY TOOLS
The tools and jigs to be used depend on the cylinder to work with. Prepare necessary tools referring to the table
below as a rough guideline.
List of Tools and Jigs
Tool/Jig Remarks Tool/Jig Remarks

Hammer 1. Steel hammer Spatula Metallic one with smooth corners.
2. Wooden or plastic hammer
Screwdriver A few types of large and small sizes Gimlet A sharp-point tool may be used in place of a
gimlet.
Chisel Flat chisel Special jig 1. For removing and press-fitting bushing. (A),
(D), (C)
2. For press-fitting wiper ring. (D)
3. For inserting and reforming seal ring.

(E), (F), (G), (H)
(See Paragraph "SPECIAL JIG" for details.)
Vise One having an operation wide enough Rust remover

to hold cylinder head O.D. and tube
mounting pins (clevis)
Wrench 1. Eye wrench or hydraulic pump Measuring 1. Slide caliper

instruments
2. Allen wrench 2. Micrometer
3. Extension pipe for wrenches 3. Cylinder gauge (See the figure "Cylinder
gauge".)
4. V-block
• For the details of special tools and jigs, refer to the back pages of this manual.
EXTERNAL CLEANING 13
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. Cylinder gauge
• The following describes the construction of boom
cylinder. When disassembling and servicing the cylinder, confirm the construction of cylinder referring to Parts
Manual.
13-19
DISCHARGING OIL
Place a wooden-block on the work bench and place the WOODEN BLOCK
cylinder on it to prevent it from rotating. Charge air into
ports A and B alternately to actuate the piston rod till the
PORT B
hydraulic oil in the cylinder is drained out. At this time,
V BLOCK
connect a suitable hose to each port so that the hydraulic
oil may not gush out. PORT A
AIR
OIL PAN
Preparation
13-20
13.4.1.2 CONSTRUCTION OF GENERAL CYLINDER

25 24 12 24 25
PS1/8
PT1/4
SLIT 15
ONE HOLE
DETAILA DETAIL B
DETAIL C
Piston with piston nut type
9 8 7 6 4 5 3 11 10 2 1 13 14 15 17 16 18 19 *20 *21 22 23
C
A
13
Construction of general cylinder
No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY
1 Cylinder tube 1 10 O-ring 1 19 Slide ring 2
2 Piston rod 1 11 Back-up ring 1 20 Shim *1

3 Rod cover 1 12 Socket bolt 12 21 Piston nut *1
4 Bushing 1 13 Cushion bearing 1 22 Setscrew; M12 1
5 Snap ring 1 14 Cushion seal 1 23 Steel ball 1
6 Buffer ring 1 15 Piston 1 24 Pin bushing 2
7 U-ring 1 16 Seal ring 1 25 Wiper ring 4
8 Back-up ring 1 17 Back-up ring 2
9 Wiper ring 1 18 Slide ring 2
In case of piston with piston nut type, the parts with * are not used.
13-21
13.4.1.3 DISASSEMBLY
• 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.
• The figures in parentheses after part names correspond to those in Fig. "Construction of general cylinder"
• The following explanation and quantities are for a general use cylinder which has separated piston and piston
nut. In case that piston and piston nut are combined, the construction differs from separated type, refer to the
sentence in parenthesis.
REMOVING ROD COVER 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 200 mm (7.87in).

Because the piston rod is heavy, finish extending it m
0m
2 0 .8 7 ")
with air pressure after the above-mentioned oil (7
draining operation.
3. Loosen and remove socket bolts (12) of the rod cover in sequence.
Cover the extended piston rod (2) with cloths to prevent it from being accidentally damaged during operation.
4. Strike the corner of the rod cover flange by means of ALLEN WRENCH 12
a plastic mallet till rod cover (3) comes off.
Turn counterclockwise
3
Cover here with cloths
2
• At this time, the weight of piston rod (2) is loaded on KNOCK THIS EDGE
rod cover (3). Therefore, lift the top end of the piston WITH A PLASTIC MALLET.
LIFT HERE.
rod with a hoist to the extent that only the rod weight
may be held.
3
2
Drawing out piston rod assy (2)
13-22
5. Draw out the piston rod assy from cylinder tube (1). LIFT HERE. 1
PULL STRAIGHT
SIDEWAYS
HORIZONTALLY
OIL PAN
Method of drawing out the piston rod assy
Since the piston rod assy is heavy in this case, lift the tip of the piston rod (2) with a hoist 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 which may score the
surface, but use a strong cloth belt or a rope.
6. Place the removed piston rod on a horizontal

wooden V-block.
• Cover a V-block with cloths. PISTON ROD ASSY
WOODEN V-BLOCK
(PLACE CLOTHS)
Method of placing the piston rod
7. Remove slide ring (18) and (19) from piston (15).

15
Remove slide ring by
widening the slit toward 13
the arrow
19
18
Remove slide ring (18) and (19)
13-23
REMOVING PISTON ASSY

1. Fix piston rod (2) by holding its clevis section in a 3 WOODEN BLOCK
vise. Fix the piston rod (2) securely as piston nut 2
(21) or [piston (15)] is tightened to a high torque. 15
21
WOODEN V-BLOCK
(PLACE CLOTHS)
How to loosen piston nut (21)
• Note that the tightening torque differs with the type, the working pressure and the mounting method of the piston
(15), though the rod diameter is the same.
• It is also necessary to place a suitable supporting block near the piston (15). In case a V-block is used, put cloths
or something over the rod to prevent it from damage.
2. Scrape off the caulked part of setscrew (22) of

22 DRILL
piston nut (21) or [piston (15)] by means of a hand
drill and loosen setscrew (22) and remove steel ball
(23).
21
23
Removing setscrew (22) and ball (23)
3. Loosen and remove piston nut (21) or [piston (15)].
TURN COUNTER
CLOCKWISE.
15
EYE WRENCH
21
How to loosen piston nut (21)
13-24
• Since piston nut (21) and piston (15) is tightened by a strong torque, use an eye wrench of proper size for the
outside diameter of piston nut (21) and "piston (15) hexagonal part" and use a power wrench using a hydraulic
jack or hydraulic cylinder.
• In case that piston and piston nut are combined, apply the eye wrench to hexagonal part of piston and loosen the
piston directly.
4. After removing shim (20), remove piston (15) by

tapping it with a plastic mallet, supporting weight of
piston (15).
4 15
Removing piston (15)
In case that piston and piston nut are combined, the shim (20) is not used.
5. After removing cushion bearing (13) and cushion

LIFT WITH A HOIST. STRIKE WITH
seal (14), separate rod cover (3) from piston rod (2).
A PLASTIC MALLET.
If it is too hard to slide it, knock the flanged part of
rod cover (3) with a plastic mallet. But when drawing PULL STRAIGHT.
it out, lift rod cover (3) by hoist and pull it straight
horizontally. NOTE: 13
DO NOT
DAMAGE
PISTON ROD
SURFACE.
3 4 6 8,7 9 2
Removing rod cover (3)
Take care so rod bushing (4) and the lip of packings (6,7,8,9) may not be damaged by thread of the piston rod (2).
13-25
DISASSEMBLING PISTON ASSY

1. Remove seal ring (16) and back-up ring (17).
HAMMER
SCREWDRIVER (OR CHISEL)
BACK-UP RING SEAL

17 RING
16
USE CARE NOT

15 TO DAMAGE O-RING
THE GROOVE.
Removing seal ring (16) and back-up ring (17)
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.
DISASSEMBLING ROD COVER ASSY

1. Remove O-ring (10) and back-up ring (11). Remove SPATULA
back-up ring (11) and O-ring (10) by pulling and
stretching them with an spatula like earpick. 10
11
Removing the outer circumferential seal of rod

cover (3)
2. Remove buffer ring (6), U-ring (7) and back-up ring GIMLET
(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. 8
3 7
Removing the inner circumferential seal of rod

cover (3)
13-26
Take care in this operation not to damage the grooves.
3. Remove wiper ring (9). When taking out wiper ring HAMMER SCREW- 3
(9), fix rod cover (3) in a vise. DRIVER
WOOD PIECE
WOOD PIECE
VISE
Removing wiper ring (9)
4. Remove snap ring (5) and bushing (4).

Take out snap ring (5) first and then bushing (4). PRESS HERE
CHUCK ASSY TOOL A
Bushing (4) is press-fitted into rod cover (3) strongly,
so push it out by a press with the jig as shown in the
figure.
(See Paragraph "SPECIAL JIG HANDLING BUSHING 4
PROCEDURE" for details of removal.)
BLOCK TOOL C
13
Removing rod bushing
REMOVING PIN BUSHING

1. Apply driver to wiper ring (25) of cylinder tube (1) PUSH WITH A PRESS.
and piston rod (2), and strike it by hammer lightly. JIG J
24 BASE
Drawing out pin bushing (24)
2. Push out pin bushing (24) press fitted in cylinder tube (1) and piston rod (2) with press.
13-27
13.4.1.4 CLEANING
1. After disassembly the cylinder, wash all parts with commercial detergent.
Never use benzene (gasoline, thinner, etc.) because it may be damage the rubber, etc.
2. Do not use the used oil seal, O-ring, back-up ring, etc. even if they are not damaged after inspection.
3. After cleaning, dry all parts by compressed air, and put them on the working bench taking care not to damage
them.
13-28
13.4.1.5 ASSEMBLING PIN BUSHING

Start assembling the following sub assy
• Cylinder tube assy
• Piston assy
• Rod cover assy
ASSEMBLING PIN BUSHING

1. Press fit pin bushing (24) in cylinder tube (1) and PUSH WITH A PRESS
piston rod (2) respectively with press. 2
24
OIL HOLE LOCATION
Press fitting of pin bushing (24)
2. Press fit wiper ring (25) in the upper and lower sides of cylinder tube (1) and piston rod (2) respectively with
press.
• Before press fitting, apply grease on wiper ring and boss hole.
• Before press fitting the pin bushing, align the position of oil hole.
13
ASSEMBLING OF PISTON ASSY
1. The fitting of seal ring (16) requires special tool as PRESS HERE METAL (G)
shown in right Fig. Seal ring (16) is pushed in by
PRESS JIG (E)
press, etc. with pushing in tool as shown in the
figure. (The O-ring of seal ring (16) and back-up ring
(17) on one side should be installed beforehand.) SLIDE JIG (F)
15
16 O-RING
17
How to fit seal ring (16)
Heat them, and they may be soften. But never heat them over 100C degrees (212.0F degrees) or more.
13-29
2. Fit back-up ring (17) on the other side. After fitting it, PRESS HERE
correct seal ring (16) immediately by correctional jig 16 17
(H) as shown in the figure "Correcting seal ring (16)"
to prevent it from remaining in an expanded CORRECTIONAL
condition. JIG (H)
Correcting seal ring (16)
• For piston, stop it once tentatively (for 3 to 5 seconds), and then push it in fully.
• After fitting, wind tape around seal ring (16) 2 or 3 times, and remove it immediately before piston (15) is inserted
in cylinder tube (1).
• Fit slide rings (18) (19) at the same time when piston (15) is inserted in cylinder tube (1).
ASSEMBLING ROD COVER ASSY

1. Press fit bushing (4) in rod cover (3) with bushing PRESS HERE. (STRAIGHT DOWN)
press-fitting jig (A). Then, fit snap ring (5) in the PRESS FITTING JIG (A)
4
groove. Apply hydraulic oil on internal surface of rod
cover (3).
GROOVE FOR
FIXING SNAP RING (5)
Press bushing till bushing

comes in contact with
3
this face.
The snap ring (5) can not be fitted when the bushing (4) is not press-fitted fully to the stop end.
2. Apply grease to wiper ring (9), and fit wiper ring (9), PRESS HERE. (STRAIGHT DOWN)
directing the lip side toward the groove of retainer
tool (D). And set retainer tool (D) on rod cover (3) RETAINER TOOL (D)
and press fit wiper ring (9) with press.
U-RING GROOVE
Press fitting of bushing (4)
13-30
3. Fit buffer ring (6), back-up ring (8) and U-ring (7) in PUSH BAR (WOOD OR PLASTIC)
their grooves in that order. Before setting packings, 10
coat them with hydraulic oil (or vaseline if not
11
available). If you forget the coating, the packings Tube side
may be scored. 3
When attaching seals, deform them in a heart shape
as illustrated.
7
8
9
How to fit U-ring (7)
INSERT U-RING INTO GROOVE FROM THIS SIDE.
13
Inserting a seal into the inner circumference of rod

cover
• 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 U-ring 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.
• Buffer ring (6) should be fitted taking care of the fitting direction. The reverse fitting may cause deformation,
damage, etc. of the piston due to high pressure generated between the buffer ring and U-ring.
• If U-ring (7) is set upside down, the lip may be damaged. Check the correct orientation of U-ring (7) shown in the
figure "How to fit U-ring (7)"
• Attach back-up ring (11) on the open air side of O-ring (10).
13-31
INSERTING ROD COVER ASSY TO PISTON ROD

Inserting rod cover (3) to piston rod assy by the following procedure.
1. Fix piston rod assy on working bench.
INSERT GUIDE JIG (I) 3
PUSH
Inserting rod cover (3)
2. Install rod cover (3) on piston rod (2) by using inserting guide jig (I) as shown in the figure "Inserting rod cover
(3)" paying attention for the lip sections of the wiper ring and the U-ring not to be caught on the stepped
section.
• For the rod the outer diameter of piston installing section is small, insert spacer on the faucet section of rod first,
and attach inserting guide jig.
• Apply hydraulic oil on the inserting guide jig and outer surface of piston rod lightly to make the insertion smooth.
ASSEMBLING PISTON ASSY ONTO PISTON ROD

1. Cushion on extension side PISTON
Install cushion on the extraction side, cushion 13
bearing (13) and cushion seal (14) by the following 14
procedure.
1) Put cushion seal (14) on it, directing the slit
machined side toward the piston side.
2) Fit cushion bearing (13) directing the flattening
side as shown in the figure "Cushion mechanism
on extension side". FLAT SECTION
Direct slit toward

piston side
Cushion mechanism on extension side
2. When cushion is installed on the retraction side, fit Direct slit toward
cushion bearing (13) and cushion seal (14) by the thread side
following procedure. THREADED PART
1) Fit cushion bearing before fitting piston nut. The

nut attached obstructs the fitting of cushion
PISTON ROD
bearing.
2) Put cushion seal on it, directing the slit machined
side toward the piston side.
3) Fit cushion bearing directing the flattening side as
shown in the figure "Cushion mechanism on SNAP RING
CUSHION SEAL CUSHION STOPPER
retraction side". (Slit 1 place) BEARING (Divide into 2 portions)
4) Put stopper in the groove. Push cushion bearing
to stopper fully, and drive snap ring. Use plastic
Cushion mechanism on retraction side
13-32
mallet in order not to damage the rod, cushion bearing.
• Cushion seal and cushion bearing should be fitted taking care of the fitting direction.
If they are fitted in reverse directions, the cushion does not effective.
• After installing cushion, be sure that the cushion bearing moves up and down, and right and left.
3. Insert shim (20), and tighten piston nut (21) or 21

[piston (15)] till it gets tight. Always tighten the piston
nut (21) or [piston (15)] of each piston to specified
torque. See "TIGHTENING TORQUE" described
later for the tightening torque. EYE WRENCH
Tightening piston nut (21)
• In case that piston and piston nut are combined, the shim (20) is not used. Apply the eye wrench to hexagonal
part of piston and loosen the piston directly.
• Always correct the threads in piston nut (21) or [piston (15)] before fixing piston nut, using a tapping.
• Insufficient tightening torque causes an inner leak and a damage of thread. And over tightening torque causes a
bulge of cushion bearing and a deformation of piston contacted surface.
• Clean and decrease (with solvent) the parts of piston assembly, and dry it, then tighten this piston assembly.
13
4. Put steel ball (23) into hole and tighten setscrew ANTI-LOOSENING
(22). 22 CAULKING 20
2
After tightening the setscrew to a specified torque,
caulk the two places of the thread of the piston nut
side to secure the setscrew. See "TIGHTENING
TORQUE" described later for the tightening torque.
V-BLOCK
21
Attaching setscrew (22)
13-33
5. Attach two slide rings (18) and (19). 22 18 19

2
Take off vinyl tape wound around the perimeter of
piston (15), apply high-quality grease (or vaseline)
to slide rings (18) and (19) and attach the slide rings
in a manner that they may be coiled around the
groove. Set the slide rings as the orientation
difference between them is about 90 degrees so
that the slits may not point to the same direction.
21 V-BLOCK
Attaching slide ring (18), (19)
OVERALL ASSEMBLY
1. Place a V-block on a work bench (A wooden V-
1
block is preferable.). Place the cylinder tube assy
(1) on it and fix the assy by passing a wooden bar LIFT
through the clevis pin hole to lock the assy.
STRAIGHT
PREVENT TURNING
WITH WOODEN BAR.
Inserting piston rod assy
2. Insert the piston rod assy into the cylinder tube assy, while lifting and moving the piston rod assy with a hoist. 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 of the piston rod assy with the center of the cylinder tube assy and put it in straight
forward.
When inserting, make sure that slide rings (18), (19) on the perimeter of the piston is not out of the groove.
3. Tighten socket bolt (12).
12
Match the bolt holes of the rod cover flange to the
threaded holes in the cylinder assy, and screw in PLACE CLOTH
socket bolts (12) one by one. Tighten the bolts to a
specified torque, taking care so the bolts may not be
tightened unevenly. See "TIGHTENING TORQUE"
described later for the tightening torque.
ALLEN WRENCH
TURN CLOCKWISE
Tightening socket bolts (12)
Take care so as not to damage the rod surface by accidentally slip a wrench. Covering the rod surface with cloth is
recommended to prevent damage to it.
13-34
13.4.1.6 INSPECTION AFTER ASSEMBLY
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 sure that
it operates without failure. DIRECTIONAL VALVE
PUMP
H R
HYDRAULIC CYLINDER
External leak test
• Do not raise the hydraulic pressure above the maximum pressure of 37.8MPa (5480psi) for the cylinder of the
machine.
• Grease coated on the O-rings and the seals of the rod cover may come out. Wipe it off and retest the cylinder in
such a case.
LEAK TEST
1. Apply a test pressure to the retracting and extending
sides of the cylinder for 3 minutes independently to MEASURE THE
check the rod part, the welded part and others for INTERNAL LEAK. 13
external leakage and permanent deformation.
Furthermore, regarding an internal leak test,
perform it by connecting the cylinder with a test unit
as shown in the figure "Internal leak test".
2. After completing the test, apply a plug to each port
and store the cylinder. (See the figure "Cylinder FROM DIRECTIONAL VALVE
storing method".)
Internal leak test
• For storage, place the cylinder on wooden V-blocks CYLINDER ASSY

and bring the cylinder to the most retracted condition.
PLUG PLUG
Cylinder storing method
13-35
13.4.1.7 MAINTENANCE STANDARDS

Visually inspect all parts after cleaning to see that excessive wear, crack and other damage that are detrimental to
use are not present.
Inspection Item
Parts Name Inspecting Portion Inspection Item Remedy
Neck of rod pin Presence of crack Replace
Weld on rod hub Presence of crack Replace
Stepped part to which

Presence of crack Replace
piston is attached
Threads Presence of seizure Recondition or replace
Bend Measure degree of bend Refer to Table "Example of

Piston rod (See Fig. "Measuring method") measurement"
Plated surface Plating is not worn off to base
Replace or replate
metal
Rust is not present on plating. Replace or replate
Scratches are not present. Recondition, replate or replace.
Rod Wear of O. D. Recondition, replate or replace.
Bushing at mounting part Wear of I. D Replace
Weld on bottom Presence of crack Replace
Weld on head Presence of crack Replace
Cylinder tube Weld on hub Presence of crack Replace
Tube interior Presence of damage Replace if oil leak is seen.
Bushing at mounting part Wear on inner surface Replace
Bushing See Paragraph "LIMIT OF

Wear on inner surface
Rod cover SERVICEABILITY".
Flaw on inner surface Replace if score is deeper than coating.
REPAIR METHOD
Check all seals and parts to see that they do not show excessive damage and wear. For correction of scores 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 indention with an oilstone. If
the score or the indention is excessive, replace or replate the damaged part.
• Always regrind after replating. The thickness of the plating must be maximum 0.1 mm (0.004 in).
• In case plating is removed to the base metal during reconditioning with an oilstone, do not fail to replate the
surface.
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 damage 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).
13-36
2. Bend of piston rod

The allowable bend of the rod is maximum 1mm / 1m (0.04"/3'3"). For measurement, support both ends of the
parallel section of the piston rod with V-blocks, set a dial indicator in the center between the two V-block turn
the piston rod, and read the difference between the maximum and minimum deflection on the dial indicator.
• Table shows an example of measurement.
Example of measurement
Deflection of the dial

Distance between
indicator in the middle
V-blocks Remedy
of the rod
m (ft-in)
mm (in)
1 (3'3") 1 (0.04") Replace Measuring Method
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.
TIGHTENING TORQUE
Unit : N･m (lbf･ft)
B A C A B C
Cylinder Piston nut or
Socket bolt Setscrew
[Piston]
Boom 5460 (4030) 267 (200) 56.9 (42)
Arm 7890 (5820) 367 (270) 56.9 (42)
Bucket 6200 (4570) 267 (200) 56.9 (42)

13
VOLUME OF OIL LEAK

The oil leak rates as mentioned in "Leak test" in Paragraph "INSPECTION AFTER ASSEMBLY "are shown in the
following table.
Cylinder Volume of Internal Oil Leak
Boom 1.0 cc (0.06 cu-in) or below / 3 min
Arm 1.0 cc (0.06 cu-in) or below / 3 min
Bucket 1.0 cc (0.06 cu-in) or below / 3 min
13-37
13.4.1.8 TROUBLESHOOTING
Trouble Failed Parts Cause Remedy
Oil leak through sliding Back-up ring Foreign matter is trapped in the Remove foreign matter.
surface of piston rod. Oil ring bore of back-up ring.
is formed on piston rod, and
Lips on outer and inner diameter Replace back-up ring.
the ring grows up to oil drops,
surfaces of back-up ring are
and they drip.
scored.
Other back-up ring are failed. Replace back-up ring.
OIL LEAKS FROM HERE U-ring Foreign matter is trapped in the Remove foreign matter.
bore of U-ring.
Score is present on the bore of Replace U-ring.

U-ring.
Other U-rings are failed. Replace U-ring.
Buffer ring Foreign matter is trapped in the Remove foreign matter.

bore of buffer ring.
Score is present on the bore of Replace buffer ring.

buffer ring.
Other buffer rings are failed. Replace buffer ring.
Wiper ring Foreign matter is trapped in the Remove foreign matter.

bore of wiper ring.
Lip on the bore of wiper ring is Replace wiper ring.

scored.
Another wiper ring is failed. Replace wiper ring.
Piston rod Score is present on the sliding Smooth out the sliding surface with an
surface of piston rod. 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 leak
will not stop by that treatment, replace piston
rod.
Hard chromium plating has Replate.
peeled off.
Oil leaks from the O-ring O-ring is damaged. Replace O-ring.

circumference of rod cover.
Backup ring Back-up ring is damaged. Replace back-up ring.
Cylinder tube Swelling of cylinder tube. Replace cylinder tube.

OIL LEAKS FROM HERE
Oil leaks from welds. Cylinder tube Welds of cylinder are broken. Replace cylinder tube.
WELDS
Cylinder falls by it-self. Piston seal Foreign matter is trapped in the Remove foreign matter.
[When the rod is loaded with sliding surface of seal ring.
a static load equal to the
Score is present on the sliding Replace seal ring.
maximum working pressure
surface of seal ring.
multiplied by the area of the
cylinder bore, the maximum Slide ring Sliding surface of slide rings is Replace slide ring.
movement of the piston is scored.
more than 0.5mm (0.02") in
Piston rod Piston rod and piston are Replace piston rod.
ten minutes.]
elongated. (Loose nut)
13-38
13.4.1.9 SPECIAL JIG
SPECIAL JIG LIST (POSSIBLE TO SUPPLY)

When assembling, the following jigs are required.
Application Shape
A D
For removing and press fitting bushing

EDGE OF C
CHUCK
D
For press fitting wiper ring
E H
F
For correcting seal ring
INS ERTING J IG CORRECTING J IG
I
For inserting rod cover 13
For above jigs, contact our dealer.

(See "Special Jig No. List" in the following paragraph for the cylinder manufacturer's part numbers.)
13-39
SPECIAL JIG No. LIST

• For jigs for rod cover, select jig corresponding to respective rod diameter.
• For jigs for piston, select jig corresponding to the cylinder bore.
Application rod diameter mm (inch) Kit No. of maker

65 (2.56") 3006J-56001
70 (2.76") 3007J-06001
75 (2.95") 3007J-56001
80 (3.15") 3008J-06001
85 (3.35") 3008J-56001
Jig for rod cover
90 (3.54") 3009J-06001
removing & installing
95 (3.74") 3009J-56001
100 (3.94") 3010J-06001
105 (4.13") 3010J-56001
110 (4.33") 3011J-06001
115 (4.53") 3011J-56001
120 (4.72") 3012J-06001
Application cylinder bore mm (inch) Kit No. of maker
95 (3.74") 3009J-51001
100 (3.94") 3010J-01001
105 (4.13") 3010J-51001
110 (4.33") 3011J-01001
115 (4.53") 3011J-51001
120 (4.72") 3012J-01001
Jig for seal ring
125 (4.92") 3012J-51001
inserting & correcting
130 (5.12") 3013J-01001
135 (5.31") 3013J-51001
140 (5.51") 3014J-01001
145 (5.71") 3014J-51001
150 (5.91") 3015J-01001
160 (6.3") 3016J-01001
170 (6.69") 3017J-01001
13-40
OTHER SPECIAL JIGS (PREPARED BY SERVICE SHOP)

1. Bushing removing jig (Symbol J)
80(3.15") MATERIAL : Mild steel

50(1.97") 15 15(0.59")
(0.59")
12-S
5(0.20 ") Unit : mm (inch)
C2(0.08 ") R2(0.08 ") R0.2 (0.008 ")
10 12-S d D Cylinder Used
-0.008"
-0.4 -0.016"
-0.158"
-0.020"
-1 -0.040"
-0.118"
25-S 80 (3.15) 94 (3.70) Bucket
D -0.2
D -0.5
D -3-4
85 (3.35) 94 (3.70) Arm

85 (3.35) 99 (3.90) Boom
2. Wrench for piston nut or [piston]
Unit : mm (inch)
B Cylinder Used
110 (4.33) Arm

95 (3.74) Boom
B
95 (3.74) Bucket
13
13-41
SPECIAL JIG HANDLING PROCEDURE
HOW TO REMOVE BUSHING FROM ROD COVER

1. Attaching chuck assy tool
Insert tool in rod cover slowly until the edge top end
of chuck assy reaches to the end of bushing (4).
• Special attention must be paid so that the inner E D G E
surface of rod cover is not damaged by the edge of
tool.
• Attach top on the position 5mm (0.2 in) from the
bushing end face so that the edge does not protrude
from the end face.
4 5 (0.197")
(CHUCK)
13-42
2. Tightening chuck assy tool temporarily

1) Fit allen wrench to the head of adjuster bolt on L E V E R
the top end of tool, and insert lever in the round
hole on the rear end of tool.
2) Fix it with allen wrench and lever to the position
where the tool does not drop even if the rod cover
is raised, inclining it forward and rearward.
• Move rod cover onto the working bench holding tool
attached.
• Be careful not to drop it on foots, etc.
A L L E N W R E N C H
A
13
3. Attaching tools for retainer
Put retainer on the press bench directing the wiper
ring fitting section of rod cover upward, then put D
retainer tool (D) on the rod cover.
FLANGE
• Fit retainer tool as shown in the right figure directing
large diameter section (flange section) upward.
• Clean the surface of press bench, and take care for
the tool bottom face not to be damaged by foreign
matter like dust, chip, etc.
13-43
4. Cutting into of the edge of chuck PRESS HERE

Press the upper section of retainer tool gradually so
that the edge of chuck tool (A) cuts into the bushing
surface.
Set the pressing force to 2 to 3 tons (4410 to 6615
lbs).
After completion of pressing, tighten adjuster bolt
again by hand.
• Press it with retainer tool (D).
CHUCKING JIG A
5. Setting of tools for block (C)

Prepare block (C), and put rod cover (3) on it aligning them.
Select corresponding block (C) in shape, dimensions, etc. from the table shown below.
D
15 (0.59") 15 (0.59")
d 10
10
Unit : mm (inch)
Class
d D h
(Nominal size)
ø55 (2.17) 62 (2.44) 88 (3.46) 80 (3.15)
ø60 (2.36) 67 (2.64) 96 (3.78) 80 (3.15)
ø65 (2.56) 72 (2.83) 96 (3.78) 80 (3.15)
ø70 (2.76) 77 (3.03) 100 (3.94) 80 (3.15)
ø75 (2.95) 82 (3.23) 110 (4.33) 80 (3.15)
ø80 (3.15) 87 (3.43) 112 (4.41) 80 (3.15)
ø85 (3.35) 92 (3.62) 124 (4.88) 90 (3.54)

C
ø90 (3.54) 97 (3.82) 135 (5.31) 90 (3.54)
ø95 (3.74) 102 (4.02) 145 (5.71) 90 (3.54)
ø100 (3.94) 107 (4.21) 145 (5.71) 90 (3.54)
ø105 (4.13) 112 (4.41) 150 (5.91) 90 (3.54)
ø110 (4.33) 117 (4.61) 165 (6.50) 90 (3.54)
ø115 (4.53) 122 (4.80) 170 (6.69) 90 (3.54)
ø130 (5.12) 137 (5.39) 190 (7.48) 90 (3.54)
13-44
6. Removing of bushing
1) Move block (C) and rod cover (3) with tool under
the press.
2) Press the upper part of retainer tool (D) slowly
until bushing (4) is take out from rod cover (3)
D
(until there is a sound that the chuck tool (A)
drops on the work bench)
The force of 3 tons (6615 lbs or less) is
necessary to press it out.
The stroke of press ram is about 32 to 52 mm
(1.26 in to 2.04 in).
(But it varies according to the difference of
dimension of cylinder head.)
• Press it with retainer tool (D)
When the block and rod cover assy are not
aligned, interrupt the work and align the block
and rod cover assy.
7. Removing of rod cover

1) Remove block (C) with rod cover (3) near side,
remove retainer tool (D) from rod cover (3), and
then move rod cover (3) to other place.
2) Take out the chuck tool (A) with bushing from
block (C).
13
ABOUT ROD COVER REMOVING WORK

Do not work under the press because it is very dangerous.
13-45
8. Removing of bushing
1) Place chuck tool (A) with bushing (4) sideways,
and loosen adjuster bolt with allen wrench and
lever.
A D J U S T E R B O L T
2) Place the chuck tool (A) vertically and turn the

adjuster by hand until the wedge is raised about 4
5mm (0.2 in).
3) Remove the wedge from the edge of chuck

• Clean the surface of work bench, and be careful for the tool not to be damaged by foreign matters like dust,
chips, etc.
9. Tightening of adjuster bolt
Tighten the chuck tool (A) the bushing (4) is
removed to the extent that there is no gap between A D J U S T B O L T
the chuck and the wedge upper face, turning the
adjuster bolt by hand.
• This special tool differs according to the W E D G E
corresponding piston rod diameter.
• The chuck edge is an important portion. Take care of
handling and storage.
C H U C K
13-46
Rod cover bushing press-fitting procedure

1. Temporary setting of head bushing
Put rod cover (3) on the press-working bench 4
directing the tube connection upward.
Set bushing (4) on the inner surface of rod cover (3)
temporarily.
• Make sure that the inner and outer surfaces of
bushing (4) are free from foreign matter.
2. Setting chuck assy tool (A)

Insert the chuck assy tool (A) in temporary-set
bushing (4) directing the flange downward, and set it
on rod cover (3).
A
• Be sure that the adjuster bolt is tightened to the extent
that there is no gap between adjuster of chuck assy
(A) and wedge.
13
3
ADJUSTER BOLT
WEDGE
13-47
3. Attaching retainer tool

Put retainer tool (D) on the wedge stepped section
of chuck assy tool (A) slowly directing the flange
upward.
• Align chuck assy (A) and the wedge.
S T E P O F W E D G E
4. Preparation for press-fitting PRESS RAM

Move the rod cover on which chuck tool (A) and
retainer tools are attached under the press.
• Adjust it so that the press ram is centered to the tool.
RETAINER(D)
CHUCK(A)
BUSHING(4)
BUSHING PRESS-
FITTING PART
13-48
5. Press-fitting of bushing
Push the head of retainer (D) with press, and press
fit bushing (4) to the specified position of rod cover
(3) slowly.
• The pressing force should be held 5 tons (11025 lbs)
or less, keeping the required force for the press-fitting. STEP OF WEDGE
• Raise the pressure gradually adjusting the force by
means of pressure adjusting valve of press unit.
• Be sure that the end face of bushing is located on the
interior of the groove for snap ring. When it is located
on near place, press fit and adjust the location again.
LIFTING THREAD
RETAINER JIG (D)
ADJUSTER BOLT
WEDGE
13
CHUCK TOOL ASSY (A)
CHUCK
BLOCK TOOL (C)
Bushing removing and press fitting jig (For reference only)
13-49
13-50
［14. UPPER SLEWING STRUCTURE］
14. UPPER SLEWING STRUCTURE

14.2 FOREWORD ........................................................................................................................14-4
14.3 REMOVING AND INSTALLING ASSEMBLY ..........................................................................14-5
14.3.1 REMOVING AND INSTALLING OPERATOR'S SEAT...........................................................14-5
14.3.2 CAB ..................................................................................................................................14-6
14.3.3 REMOVING AND INSTALLING BATTERY ........................................................................ 14-10
14.3.4 GUARD ........................................................................................................................... 14-12
14.3.5 REMOVING AND INSTALLING UNDER COVER ............................................................... 14-19
14.3.6 REMOVING AND INSTALLING FUEL TANK ..................................................................... 14-20
14.3.7 HYDRAULIC OIL TANK.................................................................................................... 14-22
14.3.8 HYDRAULIC PUMP ......................................................................................................... 14-27
14.3.9 AIR CLEANER................................................................................................................. 14-33
14.3.10 MUFFLER...................................................................................................................... 14-35
14.3.11 REMOVING AND INSTALLING COUNTERWEIGHT ........................................................ 14-38
14.3.12 RADIATOR AND OIL COOLER....................................................................................... 14-40
14.3.13 ENGINE......................................................................................................................... 14-49
14.3.14 REMOVING AND INSTALLING CONSOLE COVER......................................................... 14-54
14.3.15 REMOVING AND INSTALLING CONTROL VALVE .......................................................... 14-55
14.3.16 REMOVING AND INSTALLING PILOT VALVE (ATT) ....................................................... 14-59
14.3.17 REMOVING AND INSTALLING PILOT VALVE (TRAVEL)................................................. 14-61
14.3.18 REMOVING AND INSTALLING SWING MOTOR UNIT..................................................... 14-63
14.3.19 REMOVING AND INSTALLING SWIVEL JOINT............................................................... 14-66
14.3.20 REMOVING AND INSTALLING UPPER FRAME.............................................................. 14-70
14.4 DISASSEMBLING AND ASSEMBLING COMPONENT......................................................... 14-72 14
14.4.1 HYDRAULIC PUMP AND REGULATOR ............................................................................ 14-72
14.4.2 CONTROL VALVE............................................................................................................ 14-99
14.4.3 PILOT VALVE (ATT) ....................................................................................................... 14-133
14.4.4 PILOT VALVE (FOR TRAVEL) ........................................................................................ 14-145
14.4.5 SWING MOTOR UNIT .................................................................................................... 14-160
14.4.6 SWIVEL JOINT .............................................................................................................. 14-198
14-1
14-2

14
14-3
14.2 FOREWORD
1. This manual describes all the procedures from removing to attaching, arranging them by item.
2. This chapter consists of the first half, "REMOVING AND INSTALLING ASSEMBLY", and the second half,
"DISASSEMBLING AND ASSEMBLING COMPONENT".
3. The removing and installing can be performed in the order specified in TABLE OF CONTENTS, but in view of
actual repairing or time saving, some processes can be omitted.
4. The removing and installing procedures of assembly parts do not completely cover all possible situations
because of differences of field condition and defective section, and limitation of editing. We hope for your
understanding about this.
5. Recognize well that a service man must decide a work procedure before proceeding to repair.
When removing, installing, disassembling, or assembling procedure is required, choose an item that is needed,
familiarize yourself with the contents of the work and itemize the work procedure, before starting work.
14-4
14.3 REMOVING AND INSTALLING ASSEMBLY

14.3.1 REMOVING AND INSTALLING OPERATOR'S SEAT
14.3.1.1 REMOVING OPERATOR'S SEAT
Preparation
• Remove head rest (A1-1) of operator's seat (A1) for easy handling.
• Move the whole control stand to its foremost position.
• Move the whole control stand to its foremost position.
• Incline the reclining seat as forward as possible.
Rail displacement
Upper rail.....Fixed at the lower surface of the seat (forward direction: 80 mm (3.15 inch) and rear direction: 80 mm
(3.15 inch))
Lower rail.....Fixed at the seat stand (forward direction: 60 mm (2.36 inch) and rear direction: 60 mm (2.36 inch))
Adjustment amount of seat height: (upper: 23 mm (0.91 inch) and lower: 37 mm (1.46 inch))
1. With the conditions described in the preceding

paragraph, remove two capscrews (B2) M8 x 20 at A1-1
the rear side of the upper rail and then move the
control stand to the rearmost position and remove
two capscrews (B2) M8 x 20 at the front side.
2. Remove the operator's seat assembly.
A1
Approx. 20 kg (44 lbs)
B2
14
Removing and installing seat
14.3.1.2 INSTALLING OPERATOR'S SEAT

At installation, use the reverse order of removal with the tightening torques in the tightening torque table.
Tightening torque
Name
N·m (lbf·ft)
Cap screw (B2) 23 (17)
14-5
14.3.2 CAB
14.3.2.1 REMOVING CAB
1. Remove the floor mat. A48
2. Removing cover assembly (A36)
1) Remove caps (A42) and four sems bolts (A23)

M6 x 20. FOR WARD
Tools: Phillips screwdriver
2) Remove cover assembly (B36).

3. Removing cover assemblies (A34) and (A35) VIEWèè
Remove four clips (A46) and then remove cover
assemblies (A34) and (A35). A48 A46
Tools: Flat-head screwdriver A34 A37
A35
4. Removing ducts (A37) and (A39)
A42 A46
1) Remove four sems bolts (A22) M6 x 20. A22
A46
Tools: Phillips screwdriver A22
A23 A39
2) Remove ducts (A37) and (A39).
A5 A42
5. Removing harness connector è A23 A46
(See Chapter "ELECTRIC SYSTEM".) A50 A22
A23
Remove the antenna cable for the tuner located at
the left rear side of the cab. A36
A23
A23
1) Remove four sems bolts (A48) M6 x 20.
A23 A8
Tools: Torx driver
A1 A23
2) Remove cover assembly (A5).
FOR WARD
1) Remove two sems bolts (A23) M6 x 20.

Tools: Phillips screwdriver Removing and installing cover assembly and ducts

8. Remove plastic tube (B5) for the window washer
located at the right front of the cab. B5
FOR WARD
Removing and installing plastic tube for window

washer
14-6
9. Removing gauge cluster (A3) A3

2) Remove gauge cluster (A3).

(See the figure "Removing and installing cover A21
assembly and ducts".)
1) Remove two sems bolts (A23) M6 x 20.
FOR WARD
Removing and installing gauge cluster
11. Removing mechatro controller and relay box

assembly (C2)
C1
1) Remove three sems bolts (C7) M6 x 25. C2
2) Remove one sems bolt (C7) M6 x 25 and one

sems bolt (C12) M6 x 40. FORWARD
3) With the harnesses connected, remove mechatro

controller (C1) and relay box assembly (C2), and
place them at the front side temporarily. C7 C12 C7
12. Removing engine controller (D1) and controller (D2)
1) Remove five sems bolts (D5) and (D6) M6 x 16. Removing mechatro controller and relay box
assembly (C2)
Tools: Socket: 10 mm
2) Remove engine controller (D1), and controller D1 D5

(D2).
D2 D6
14
FOR WARD
Removing engine controller (D1) and controller

(D2)
14-7
13. Removing cab mounting bolts
1) Remove four capscrews (E1) M12 x 35.
2) Loosen nut (C6) M20 and remove washer (C3).
3) Loosen pin (C9) to remove it.

E1
4) Remove four nuts (F3) M16.
E1
E1
E1
F3
F3
Removing and installing cab mounting bolts
14. Slinging cab
1) Remove two plastic plugs on the front upper

surface of the cab. Then sling the cab with wires
with a hook as shown in the figure "Slinging cab".
2) Then lift up the cab slowly avoiding interference

with the surroundings.
Wire with hook: Length 1.5 m (4ft-11in) x 12 mm
(0.47 inch) diameter x 4 pcs.
Cab weight: Approx. 401 kg (884 lbs)
Slinging cab
14-8
14.3.2.2 INSTALLING CAB

Tool Tightening torque

Name
(mm) N·m (lbf·ft)
Nut M16 (F3) 20 191 (141)
Capscrew (E1) 19 80 (66)
Sems bolt M6 (A22) Phillips screwdriver 4.0 (3.0)
Sems bolt M6 (A23) Phillips screwdriver 5.0 (3.7)
Sems bolt M6 (A48) Torx driver 5.0 (3.7)
Sems bolt M8 (A21) Socket 23.0 (17)
Sems bolt M6 (C7) and (C12) Phillips screwdriver 9.7 (7.2)
Sems bolt M6 (D5) Socket 9.7 (7.2)
Sems bolt M6 (D6) Socket 5.0 (3.7)
14
14-9
14.3.3 REMOVING AND INSTALLING BATTERY

14.3.3.1 REMOVING BATTERY
Follow the procedures for removing and installing the battery cable.
Disconnect the battery cable at the ground side first but when connecting the battery cable, connect it to the ground
side last. If these procedures are not followed, it may cause a short circuit resulting in spark.
1. Opening left panel assembly (C2).
1) Release the lock with the engine key.
2) Open left panel assembly (C2).
3) Fix it with the stay.

2. Removing battery cover (B1)
Remove nut (B6) M10 and then battery cover (B1).
Tools: Wrench: 17 mm
C2
3. Removing battery cable A5

1) Remove cable (A3) (between the earth and the
battery negative terminal). A4
2) Remove cable (A4) (between the battery positive

and negative terminals).
3) Remove cable (A5) (between the battery positive

terminal and the battery relay).
Tools: Wrench: 13 mm A3
4. Removing battery (C1)
1) Remove four capscrews (B3) M10 x 235.

2) Remove plate (B2).
3) Remove battery (C1).
B1 B2
B6 B3
C1
Removing and installing battery
14-10
14.3.3.2 INSTALLING BATTERY

1. Installation should be done in the reverse order of removal.
Hold down plate (B2) against battery (C1), and insert and tighten capscrew (B3) to fix it.
Tools: Socket: 17mm
Tightening torque: 10.8 N·m (7.97 lbf·ft)
2. Installing cable
1) Install cable (A3) last. Check carefully that the grounding face of the machine body is free from painting and
rust, etc.
14
14-11
14.3.4 GUARD
14.3.4.1 REMOVING GUARDS
1. Release all the locks with the starter key.
B2 E1
2. Removing bonnet assembly (B1) and cover C5 D2 C1
assembly (B3)
D1
1) Release the lock of bonnet (B1) and open bonnet
(B1).
2) Loosen two nuts (B11) M12 and remove bonnet

(B1).
Tools: Socket: 19mm B3
Weight: 22 kg (49 lbs) C2 B1
3) Loosen five sems bolts (B14) M12 x 25 and
remove cover assembly (B3). Position of guard assemblies
Tools: Socket: 19mm
B D D
B1
B3
I
B3
E E
B
B14
B11 VIEW II
SECTION BB
B11 9 B14
SECTION EE
B14
II B3
SECTION DD
B14 VIEW I
Removing and installing bonnet assembly (B1) and cover assembly (B3)
14-12
3. Removing panel assemblies (C1) and (C2)

B
1) Open panel assembly (C1) by releasing the lock.
B
2) Loosen two nuts (C13) M12 and remove panel C1
assembly (C1). B
C13
B SECTION AA
3) Loosen two nuts (C13) M12 and remove panel
assembly (C2).
Tools: Socket: 19mm A
Weight:
A
Panel assembly (C1): 13 kg (29 lbs)
Panel assembly (C2): 13 kg (29 lbs) A
FOR WARD A
4) Loosen two nuts (C13) M12 and remove panel C2
assembly (C3).
C3
C13
SECTION BB
Removing and installing panel assemblies (C1)

and (C2)
4. Removing guards (D1) and (D2)

D2
D1 D15
1) Loosen six sems bolts (D17) M12 x 25 and
remove guard (D2).
(A)Normal position of the stay
(B)The stay is attached to the second holder
D15
remove guard (D1).
Tools: Socket: 19mm
Weight: Guard (D1): 7 kg (15 lbs)
: Guard (D2): 11 kg (24 lbs)
FOR WARD
D2
B5 B1 14
A
B
Removing and installing guards (D1) and (D2)
14-13
To open and fix the bonnet, hook up stay (B5) at the A position of cover (D2) and even if cover (D2) is removed, by
hooking up stay (B5) to the second holder (B position), bonnet (B1) can be kept open.
The second holder (B position) is located at the front of the counterweight. Use this as required such as when
maintaining the area around the muffler.
5. Removing guard assembly (C5)
1) Loosen six sems bolts (C12) M12 x 25 and

C12
remove guard assembly (C5).
Tools: Socket: 19mm
Weight: Guard assembly (C5): 11 kg (24 lbs)
C12
C5
FOR WARD
Removing and installing guard assembly (C5)
14-14
6. Removing brackets (C4), (C6), (C7), and (C8)
1) Loosen two sems bolts (C12) M12 x 25 and

remove bracket (C4).

C7
A
B
A B
Tools: Socket: 19mm
4) Loosen two sems bolts (C12) M12 x 25 and C8

C6
FOR WARD
aa
C4
FOR WARD
C12 C6
SECTION BB
FOR WARD
C8
C12
C12 C7
SECTION AA
14
C12
C4
DETAIL aa
Removing and installing brackets (C4), (C6), (C7),

and (C8)
14-15
7. Removing cover assemblies (D3), (D4), and (D5) D15

1) Loosen two sems bolts (D15) M12 x 25 and
remove cover assembly (D4).
2) Loosen seven sems bolts (D15) M12 x 25 and


Tools: Socket: 19mm
D15
D15
FOR WARD
D3 D4 D5
Removing and installing cover assemblies (D3),

(D4), and (D5)
8. Removing covers (D13) and (D14), bracket A

assembly (D12), pillars (D7) and (D8), and bracket
D15
(D6)
D7
remove cover (D13). A
D15
2) Loosen four sems bolts (D15) M12 x 25 and
remove cover (D14). D15 D6
D16
remove bracket assembly (D12).
D8
remove bracket (D6).
D12 D16
remove pillar (D7). D15
D14
remove pillar (D8).
Tools: Socket: 19mm D15
D15
D15 D15
D13
SECTION AA
Removing and installing covers (D13) and (D14),

bracket assembly (D12), pillars (D7) and (D8), and
bracket (D6)
14-16
9. Removing beams (D17) and (D11), and pillars (D9) D11

and (D10) D15
1) Loosen five sems bolts (D15) M12 x 25 and D15

remove beam (D11). D15
D17
remove beam (D17).
Tools: Socket: 19mm

remove pillar (D9).
D15 D16
remove pillar (D10).
D9
D16 D10
Removing and installing beams (D17) and (D11),

and pillars (D9) and (D10)
10. Removing beams (A5) and (A6), pillars (A1) and

A12
(A2), guard assembly (A3), and cover (A4)
A12
A11 A12
1) Loosen four sems bolts (A12) M12 x 25 and
remove beam (A5). A6
2) Loosen three sems bolts (A12) M12 x 25 and
remove beam (A6).
3) Loosen two sems bolts (A11) M12 x 30 and A1

remove pillar (A1).
I A4
4) Loosen five sems bolts (A12) M12 x 25 and II
remove pillar (A2).
5) Loosen three sems bolts (A11) M12 x 30 and A3

A5 A12 A12
remove guard assembly (A3). A11 A2
Tools: Socket: 19mm
Weight: Pillar (A2): 11kg (24 lbs)
A12
6) Loosen three sems bolts (A12) M12 x 25 and
remove cover (A4).
14
A12
A12
VIEWéé
VIEWèè
Removing and installing beams (A5) and (A6),

pillars (A1) and (A2), guard assembly (A3), and
cover (A4)
14-17
11. Removing cover assemblies (F1) and (F2)

F3
1) Loosen two sems bolts (F3) M12 x 25 and
remove cover assembly (F2).
2) Open cover (F1-2), loosen four sems bolts (F3) F2

M12 x 25 and remove cover assembly (F1).
F1-2
Tools: Socket: 19mm
Weight: Cover assembly (F1): 27 kg (60 lbs)
F1
FOR WARD F3
F3
Removing and installing cover assemblies (F1) and

(F2)
12. Removing handrail (E1)

E7
1) Loosen one capscrew (E5) M10 x 55 and two
capscrews (E7) M16 x 65, and remove clamp
(E3).
2) Loosen one capscrew (E5) M10 x 55 and one

capscrew (E6) M12 x 60, and remove handrail
(E1) together with clamp (E4).
Tools: Socket: 17 mm, 19 mm, 24 mm E3
E5
13. Removing other brackets
Remove the other brackets as required.
E1 E5 E4 E6
Removing and installing handrail (E1)
14.3.4.2 INSTALLING GUARDS

• At installation, use the reverse order of removal with the tightening torques in the tightening torque table.
Tightening torque Unit: N·m (lbf·ft)
Size Cap screw Sems bolt Nut
M10 46.5 (34) - -
M12 80 (59) 80 (59) 80 (59)
M16 191 (141) - -
14-18
14.3.5 REMOVING AND INSTALLING UNDER COVER

8
6
4
8
3 9
9
2
11
9
1 5
9
9
11
9 FOR WARD
Removing and installing under cover
14.3.5.1 REMOVING UNDER COVER

1. Remove all attached sems bolts (8) M12 x 20, (9) M12 x 35, and (11) M12 x 30.
2. Remove under covers (1,2,3,4,5,6, and 7).
14.3.5.2 INSTALLING UNDER COVER

• Install under covers (1,2,3,4,5,6, and 7).
14
14-19
14.3.6 REMOVING AND INSTALLING FUEL TANK

14.3.6.1 REMOVING FUEL TANK
Preparation
• Remove the guards and the components which need to be removed to remove the fuel tank. (See Paragraphs
"REMOVING AND INSTALLING GUARDS", "REMOVING AND INSTALLING AIR CLEANER", and "REMOVING
AND INSTALLING RADIATOR AND OIL COOLER".)
1. Draining fuel
1) Unlock cap (B2) with the key and open it.
2) Loosen cock (A9) under the tank.
3) Drain the fuel.

Tank capacity: 321L (85 gal) 16
2. Remove the connector of fuel level sensor (A6). 10
3. Removing fuel hoses
6
1) Loosen clip (16) and pull out hoses (6) and (10).
16
2) Attach plugs with the proper size for the hose
bores.
Removing and installing fuel hoses (6) and (10)
4. Remove four cap screws (A1) M20 x 50.

B2
5. Sling fuel tank assembly (B1) to remove it.
Weight: 149kg (329 lbs)
6. Remove shim (A3).
B1
A6
A3,A4,A5
A7,A8
A9
A1
Removing and installing fuel tank
Record the positions of the shims.
14-20
14.3.6.2 INSTALLING FUEL TANK
If the clearance (gap) between the tank mounting base and the frame is 1 mm (0.04 inch) or more, adjust the
clearance with shim (A3) and then tighten the bolts.
• At installation, use the reverse order of removal with the tightening torques in the tightening torque table.
Tank mounting bolt (A1) M20 x 50
Tools: Socket: 24 mm, apply Loctite #262
Tightening torque
Tightening torque
Item Name
N·m (lbf·ft)
A1 Cap screw 370 (273)
A7 Machine screw 1.96 (1.45)
A9 Stop valve 34 (25)
14
14-21
14.3.7 HYDRAULIC OIL TANK

14.3.7.1 REMOVING HYDRAULIC OIL TANK
• In addition to panel assembly (C1) and guard (D1),
remove the guards which need to be removed to D1
remove the hydraulic oil tank. (See Paragraph
"GUARD".)
C1
Removing guards
1. Releasing tank internal pressure

CAP
Press the cap on the air breather to release the
internal pressure. Push
Air breather
Element No.
YN57V00010S002
Releasing tank internal pressure
Continue to press the valve until the hissing sound stops.
14-22
2. Removing tank cover (B3) B9
1) Remove six sems bolts (B9) M10 x 25. B9 B2

B3
2) Remove cover (B3).
(C)
3) Remove suction strainer (B4).
3. Removing tank cover (B2) (B) B7
1) Remove six sems bolts (B9) M10 x 25.
Tools: Socket: 17 mm B4
(A)
2) Remove cover (B2).
3) Remove filter element (B7).

4. Disassembling filter element
Disassemble removed filter element (B7).
Disassembled parts: (A), (B), and (C) Hyd.tank
Air breather
5. Draining hydraulic oil
Put a pump for draining hydraulic oil into the tank
and then drain the hydraulic oil.
Tank capacity: Approx. 248 L (66 gal)
Removing and installing covers (B2) and (B3)
6. Removing suction hose (A3)

Remove two clips (A14) at the tank side and pull out
hose (A3).
Tools: Flat-head screwdriver
FOR WARD
14
A14
A13 A3
Removing and installing suction hose
14-23
7. Removing return hose for main piping

B1
1) Remove sems bolt (B17) M12 x 35 and then
return hose (B1).
2) Remove sems bolt (B17) M12 x 35 and then B17

return hose (B2). C/V T2-
Tools: Wrench: 19 mm B17 TANK
B2
8. Removing pump drain hose (B7)
9. Removing drain hose (B6) for swing motor S/M DB- PUMP Dr-
TANK TANK
Tools: Wrench: 27 mm B6 B7
Removing and installing return hose for main

piping
10. Removing return hose for pilot valve
1) Remove pilot hose (C7).

2) Remove pilot hose (C8).

Tools: Wrench: 22 mm C/V Dr2
-TANK
3) Remove pilot hose (C10). C2
Tools: Wrench: 22 mm C/V Dr1
-TANK
4) Remove pilot hose (C2). C7
C8
S/V (8ROWS) T1 C10
-TANK PT T
-TANK
Removing and installing return hose for pilot valve
14-24
11. Removing drain hose (B4) for sensor

B4
Removing and installing drain hose for sensor
12. Removing mounting bolts of hydraulic oil tank

Remove four capscrews (D1) M20 x 45.
Tools: Socket: 30mm
13. Removing hydraulic oil tank
By using the plate for lifting on the tank, sling the
tank and remove it.
Tank weight: Approx. 168 kg (370 lbs)
14. Removing shims (D3), (D4), and (D5)
D3, D4, D5
D2
14
D1
Removing and installing hydraulic oil tank
Record the positions of the shims.
14-25
14.3.7.2 INSTALLING HYDRAULIC OIL TANK

Installation should be done in the reverse order of removal.
Preparation
• Clean the hydraulic oil tank.
• Clean the suction hose.
• Clean the tank mounting base in the upper frame.
1. Install four mounting cap screws (D1) M20 x 45.
(See the figure "Removing and installing hydraulic oil tank".)
If the clearance (gap) between the tank mounting base and the frame is 1 mm (0.04 inch) or more, adjust the
clearance with shims (D3), (D4), and (D5) and then tighten the bolts.
2. Connecting suction hose (A3) O-ring

(See the figure "Removing and installing suction
hose".)
1) Apply Permatex on the hose connecting part at

the hose side and insert the hose.
(C)
2) Install clip (A14).
Tightening torque: 5.39N·m (3.98 lbf·ft)
(B)
3. Assembling return element
Assemble the filter element by using element kit (B-
100). (See the figures "Removing and installing B4 Suction strainer
LQ50V00004F1
covers (B2) and (B3)" and "Return element &
suction strainer".) (A)
4. Install return element (B7).

(See the figure "Removing and installing covers (B2)
Element kit
and (B3)".) (B-100)
YN52V01025R100
5. Install suction strainer (B4).
6. Install tank covers (B2) and (B3), and then sems
bolt (B9) M10 x 25. Return element & suction strainer
M10 tightening torque: 46.5N·m (34 lbf·ft)
Replace the O-ring at the back side of the tank cover with a new one.
Element (A) is one element.
14-26
14.3.8 HYDRAULIC PUMP

14.3.8.1 REMOVING HYDRAULIC PUMP
• Remove the guards which need to be removed to remove the hydraulic pump.
1. Release the internal pressure of the hydraulic oil
B9
tank. (See Paragraph "HYDRAULIC OIL TANK".)
2. Remove six sems bolts (B9) M10 x 25.
B3
3. Remove cover (B3).
Tools: Socket: 17 mm Suction
stopper
4. Take out the suction strainer.
Suction strainer
5. Install the suction stopper.
See Chapter "TOOLS" for the suction stopper.
Hydraulic oil tank
Installing suction stopper
6. Loosen sems bolts (A10) M12 x 40 mounting half

clamps (A5) of hoses (A1) and (A2) and remove two
hoses (A1) and (A2) at the delivery side.
Tools: Wrench: 19 mm A10 A3
7. Removing suction hose (2) for pilot pump (See the A5
A2
figure "Removing and installing other hoses")
8. Removing suction hose (A3) and drain hose (B7) A5
1) Remove four capscrews (B2) M12 x 30. B7 A5

A10 14
2) Remove elbow (B1) of suction hose (A3) from the
pump. A1
3) Remove drain hoses (B7) and (Dr). A5

2
B2
B1
Removing and installing delivery and suction

hoses
14-27
9. Removing other hoses
1) Remove the hoses connected to the following

ports.
2) Attach a tag to each hose for identification.
3) Plug the hoses and the ports of the pump.
Removing and installing other hoses
Hose Tool
Port Remarks
No. (mm)
*Psv 1 22 Pilot primary pressure
Psv 9 22 Pilot pump delivery
Remove the item with the * mark as required.
10. Removing connectors PSV -P1:

Fix corrugated part of harness to
Remove all of the connectors of the pressure P1 pump proportional
solenoid valve with cable tie.
solenoid valve
sensors and the proportional valves. CLIP
PSV -P2:
P2 pump
CLIP proportional
SEMS BOL T solenoid valve
Tighte ning torque SE-21:
25.5N .m (18.8 lbf .ft) Hydraulic oil
CLIP
Fix white taping part. Fix harness to temperature sensor
pipe fitting with Tighte n a cce s s ory nut
CLIP cable tie. of hydraulic oil
Fix harness to lifting temperature sensor .
eye with cable tie. Tighte ning torque of M4 s cre w is
0.49N m (0.36 lbf .ft) or less and
.
no spinning is allowed at mold part.
CLIP Fix white taping part.

Fix harness to Fix harness to mouth fitting
bottom of lifting CLIP
of hose with cable tie.
eye with cable tie. CLIP
Fix white taping part.
CLIP
Fix corrugated part of

harness to pressure
sensor with cable tie.
CLIP
SE-22:
Pressure sensor:
P1 pump
CLIP
Fix corrugated part of harness SE-23:
to pressure sensor with cable tie. Pressure sensor: P2 pump
Removing and installing connectors
14-28
11. Removing pump body 1

1) Sling the hydraulic pump and with the condition
that slight tension is applied on the ropes, loosen 3
eight capscrews (4) M10 x 35.
Tools: Socket: 17 mm 0
2) While adjusting the tension applied to the wire

ropes, take out the power take off assembly
slowly from the flywheel housing. 4
At this time, it is taken out with the condition that
insert MAs (2-3) remain in the flywheel side of the 2
engine. 2-4 2-1
2-3 2-3
3) Take out element (5-1) from the end of the spline 2-7 2-5 2-5 2-5
shaft. 2-4 2-6 2-4
2-5 A
4) Remove four capscrews (2-5) M18 x 55 mounting 2-3
2-7
insert MRs (2-4) and then remove insert MRs (2- 2-4
4). 2-5 2-3
2-5 2-3 2-5
Tools: Allen wrench: 14mm 2-4
2-2
A
5) Removing hub (2-2)
Loosen two set screws (2-6) M16 x 22 to allow
the hub to come off from the spline shaft of the
pump. Removing and installing hydraulic pump
6) Remove four capscrews (2-5) M18 x 55 mounting insert MAs (2-3) from the engine side flywheel and
remove insert MAs (2-3), as required. Furthermore, remove spring pins (2-7) from insert MAs (2-3). Tools:
Allen wrench: 14mm
7) Removing bracket (1)

Remove four capscrews (3) M20 x 55 and then separate bracket (1) and pump (0).
14
14-29
14.3.8.2 INSTALLING HYDRAULIC PUMP

1. Installing bracket (1)
Install bracket (1) with capscrew (3) and tighten temporarily.
Apply Loctite #262
2. Installing hub (2-2)
Insert hub (2-2) into the spline of the pump and install it with two set screws (2-6) at the position of 0 mm from
the spline end surface (See the figure "Installing hydraulic pump" for Detail aa).
Tightening torque: 110 N·m (81 lbf·ft)
3. Installing insert MRs (2-4)
Install four insert MRs (2-4) to hub (2-2) with four capscrews (2-5).
4. Installing element (2-1)
Insert element (2-1) into hub (2-2) and insert MR (2-4).
5. Installing insert MAs (2-3)
Insert four spring pins (2-7) into four insert MAs (2-3) and install them to the engine side flywheel with four
capscrews (2-5).
(Regarding the above-mentioned procedures 1 to 5, see the figure "Removing and installing hydraulic pump".)
Do not use Loctite for capscrew (2-5).

(The accessory bolt is coated with micro capsule.)
14-30
6. Installing pump (See the figure "Removing and 5-5

installing hydraulic pump".)
3
Horizontally sling the pump with bracket (1) and
dock coupling (2) so that insert MA (2-3) is put in the
groove of element (2-1). 2-7
7. Coat eight capscrews (4) M10 x 35 with Loctite #262

and install them in place.
(*with the drain port facing downward)
2-6
8. Install delivery hoses (A1) and (A2) with half clamps I
(A5) and sems bolts (A10) M12 x 40. aa 1
(See the figure "Removing and installing delivery
and suction hoses".) 4 4
5-5
9. Install elbow (B1) with four capscrews (B2) M12 x
30. (See the figure "Removing and installing delivery
and suction hoses".)
Tools: Allen wrench: 10 mm 0mm
0 (inch)
Tightening torque: 60 N·m (44 lbf·ft) CAUTION
Dimension between
4
10. Install suction hose (A3) with each two clips (A13) hub end surface and
spline end surface
d 1
and (A14). (See the figure "Removing and installing Coupling hub
can be assembled VIEW I
delivery and suction hoses".) DETAIL aa reversely .
Installing hydraulic pump
11. Install hose (3) with two clips (11). (See the figure
"Removing and installing other hoses")
12. Install the hydraulic pipes by referring to Chapter "HYDRAULIC SYSTEM".
13. Installing each hose (See the figure "Removing and installing other hoses")
Tightening
Tightening Hose Tool
torque
position No. (mm)
N·m (lbf·ft)
14
Cap nut Psv 1.3 22 49 (36)
Cap nut Dr B7 36 118 (87)
14. Install the connectors of the pressure sensors and the proportional valves.
15. Remove the suction stopper.
16. Install the suction strainer.
When replacing the pump, be sure to supply the hydraulic oil of 1 L (0.26 gal) or more form drain port (Dr).
14-31
17. Bleeding air from pump Dr

Loosen drain port Dr to bleed the air.
18. Check the level of the hydraulic oil.
19. Start the engine and check oil leakage and
abnormal noise.
20. Install the drain pipe to the lower portion of the
engine muffler.
21. Installing guards
(See the figure "Removing guards".)
Pump air bleed port (Dr)

Name
(mm) N·m (lbf·ft)
Sems bolt M12 19 80 (59)
14-32
14.3.9 AIR CLEANER

14.3.9.1 REMOVING AIR CLEANER
Preparation
• Remove the guards which need to be removed to remove the air cleaner.
FOR WARD
FOR WARD 6 2
6
I 3
11
1
III
5
aa 1
II
HOSE INSERTION CLIP
ALLOWANCE INSTALLATION
INSTALL POSITION HOSE INSERTION 9
THE CLIP ALLOWANCE TIGHTENING
TORQUE
IN THE 6 46.5N .m
4 0 7 ”)
ORIENTATION 40 4 (34.3 lbf.ft)

(1 .
CLIP
5
SHOWN IN 5 INSTALLATION 7
(1 .
(0 .
57
THE FIGURE.
20
5 30 (1.18”) POSIT ION

”)
”)
TIGHTENING TORQUE DETAIL aa

(0 .
17 (0.67”) 39.2N .m(28.9 lbf.ft)

20
”)
APPLY LOCTITE #262.

9 8 4 PLACES
TIGHTENING
6 TORQUE TUBE INSERTION
INSTALL 46.5N .m HOSE INSERTION ALLOWANCE A
THE CLIP (34.3 lbf .ft)
CLIP ALLOWANCE
(1.57”)
IN THE INSTALLATION
40
ORIENTATION POSITION 25 (1.0”)

17 (0.67”)
SHOWN IN
(0.91”)
THE FIGURE. 5
23
VIEW I CLEANER,
INSTALL
AIR ACCESSORIES
THE CLIP TIGHTENING TORQUE CLIP
IN THE 3.9N .m(2.88 lbf .ft)
VIEW II INSTALLATION
ORIENTATION 7
INSTALL THE CLIP POSITION
SHOWN IN TO BE INSERTED IN
THE FIGURE. IN THE O RIENTATION VIEW III
SHO WN IN THE FIGURE. THE INSULATION.
14
Removing and installing air cleaner
1. Pull out the bullet terminal of the indicator wiring.

2. Pull out the wiring connector of the airflow sensor.
3. Removing precleaner assembly (11)
1) Loosen clamp (A).
2) Draw out precleaner assembly (11).

4. Puling out hose (3)
1) Loosen two clips (6) at the both sides of hose (3).
2) Pull out hose (3).

5. Removing air cleaner assembly (1)
14-33
1) Remove four sems bolts (8) M10 x 25.

Tools: Socket: 17mm
2) Remove air cleaner assembly (1) from bracket (4).
14.3.9.2 INSTALLING AIR CLEANER

Installation should be done in the reverse order of removal, paying attention to the following.
• See the figure "Removing and installing air cleaner" and insert the air hose to the length of insertion allowance
securely.
Tightening Torque
Tightening torque
Item Name
N·m (lbf·ft)
A Clamp 4.0 (2.95)
7,8,16 Clip 5.9 (4.35)
39.2 (28.9)
9 Sems bolt
(Apply Loctite #262.)
B Indicator 3.9 (2.88)
Replacing element and deteriorated parts

• Outer element (1)
• Cover (2)
• Inner element (3)
• O-ring (4)
4 1
14-34
14.3.10 MUFFLER
14.3.10.1 REMOVING MUFFLER
Preparation
• Remove the guards which need to be removed to remove the muffler.
9 9
3
6 9
10
9
8 5
A 11
A
2
14
Removing and installing muffler
14-35
1. Removing clamp assembly (3)
1) Remove two capscrews (7) M10 × 35, and then clamp assembly (3).
2. Removing muffler (1)
1) Loosen eight nuts (9) and remove two U bolts (4).
2) Remove muffler (1).

Weight: Approx. 14 kg (31 lbs)
3. Removing other parts
Loosen three sems bolts (5) and two capscrews (6), and remove bracket (2), as required.
Tools: Socket: 19mm
14-36
14.3.10.2 INSTALLING MUFFLER

Installation should be done in the reverse order of removal, paying attention to the following item.
1. Attach bracket (2) to the engine, and then three
TIGHTENING PROCEDURE FOR THE U BOLT
sems bolts (5) and two capscrews (6).
1. COMPLETELY TIGHTEN ITEM A NUT. (4 PLACES).
AT THIS TIME, CHECK THAT EACH C DIMENSION OF U BOLT IS EQUAL.
2. Attach muffler (1) to bracket (2), and then two U 2. TIGHTEN ITEM A NUT WITH THE SPECIFIED TORQUE.
bolts. CHECK AGAIN EACH C DIMENSION ON CLEARANCE
THE LEFT AND RIGHT SIDES.
(See the figures for the installation procedure of the 3. TIGHTEN ITEM B NUT WITH
U bolts.) THE SPECIFIED TORQUE (4 PLACES ).
CHECK THAT THE U BOLT IS NOT
TILTED.
3. Attach clamp assembly (3) to muffler (1). (DETERMINE THE C DIMENSION
(See the figures for the installation procedure of the AFTER CHECKING B
PRODUCT VARIATION.)
clamp.)
C
MOUNTING P ROCEDURE
FOR THE CLAMP ASSEMBLY
UPP ER
9 SIDE
(UPPER
SIDE)
(LOWER
9 SIDE) LOWER
SIDE
AFTER MOUNTING THE THE MOUNTING SURFACE OF
ATTACHED GASKET, COMPLETELY CLAMP SHOULD NOT
TIGHTEN THE BOLT. OVERLAP THE SLIT.
TO BE 10 +0 FROM
MUFFLER SLIT.
AFTER FIXING THE MUFFLER
(0.39 + 0 )
THE END OF
0.20
WITH THE U BOLT, MOUNT
5
THE SEAL CLAMP.
SEE THE MOUNTING PROCEDURE
FOR THE CLAMP ASSEMBLY.
3
7
MUFFLER
MOUNT THE WASHERS SIDE
ON THE NUT SIDE.
TIGHTENING TORQUE
68. 6|| 98N .m
(50.6|| 72 lbf.ft) ENGINE
COMPLETELY SIDE
TIGHTEN THEM.
Tightening Torque
Tightening torque
14
Item Name
N·m (lbf·ft)
108 (80)
5 Sems bolt
108 (80)
6 Capscrew
7 Capscrew 68.6 to 98 (50.6 to 72)
9 Nut (upper side) 10.8 (8.0)
9 Nut (lower side) 8.8 (6.49)
Parts Liable to Degrade
Name PART NO.

Muffler (1) YN12P00072P1
14-37
14.3.11 REMOVING AND INSTALLING COUNTERWEIGHT
Lifting counterweight
14.3.11.1 REMOVING COUNTERWEIGHT

1. Temporarily lifting counterweight
Attach a wire rope to plate (C1-1) and temporarily lift C1-1
the counterweight to the degree that the wire rope is
not slacked.
Counterweight weight: Approx. 4,300 kg (9480 lbs)
Wire of 24 mm (0.94 inch) diameter or more: 1.5 m
(4ft-11in) x 2 pcs.
2. Removing counterweight
1) Remove four cap screws (A1) M33 x 350. A3, A4, A5, A6
Tools: Socket: 50 mm 10 (0.39”)
Adjus t cle a ra nce be twe e n Adjus t cle a ra nce with
counte rwe ight a nd de ck from 1 to 2 s hims .
to 10mm (0.39 inch).
2) Remove shims (A3), (A4), (A5), and (A6).
A1, A2
(Selection)
3) Remove counterweight (C1).
Adjus t cle a ra nce be twe e n

10 (0.39”) counte rwe ight a nd de ck
to 10mm (0.39 inch).
Removing and installing counterweight
14-38
14.3.11.2 INSTALLING COUNTERWEIGHT

1. Reattach shims (A3), (A4), (A5), and (A6) in place.
2. Lifting and putting counterweight in place
Make sure that all four mounting bolts can be screwed in by hand.
3. Apply Loctite #262 to cap screw (A1) and tighten it with washer (A2).
Tightening torque: 2,250N·m (4960 lbf·ft)
14
14-39
14.3.12 RADIATOR AND OIL COOLER

14.3.12.1 REMOVING RADIATOR AND OIL COOLER
• After bleeding the air of the internal pressure in the hydraulic oil tank, install the suction stopper. (See
Paragraphs "HYDRAULIC OIL TANK" and "HYDRAULIC PUMP".)
• Remove the guards which need to be removed to remove the radiator and the oil cooler.
• Remove the battery. (See Paragraph "BATTERY".)
• Remove the other parts which need to be removed to remove the radiator and the oil cooler.
• Remove the under cover under the radiator.
1. Draining water of radiator
Place a plastic container of 18 L (5 gal) under the aa
drain cock hose and then drain the coolant.
(Radiator water capacity: Approx. 5.5 L (1.5 gal))
2. Removing hose of radiator sub tank (1)
Remove clip (29) at the radiator cap side and pull
out hose (8).
1
29 FOR WARD
DETAIL aa
Removing and installing hose of sub tank (1)
Do not loosen or remove the connecting parts of the hoses related to the air conditioner. It will cause leakage of
coolant.
14-40
3. Moving air conditioner condenser, oil cooler, and

receiver tank

Tools: Socket: 13 mm 25
2) Move the air conditioner condenser together with 25
the receiver tank.
4. Disconnect the connector of coolant level switch
(B12). (See the figure "Removing and installing
radiator stays".)
FOR WARD
Moving condenser and receiver tank
5. Removing radiator stays (A1) and (A2)
1) Remove four sems bolts (A3) M12 x 30. A3

2) Remove stays (A1) and (A2). A2

A3
6. Removing water hoses (2) and (3) A3
A1
1) Loosen hose band (22) of water hose (2).
Tools: Flat-head screwdriver A3
2) Remove hose (2).
3) Loosen hose band (22) of water hose (3) and

remove sems bolt (20) M10 x 25.
Tools: Flat-head screwdriver A4
4) Remove hose (3). Removing and installing radiator stays
14
14-41
7. Removing hoses (4), (5), and (9) for intercooler

15
FOR WARD
16
1) Loosen eight nuts (16) M8 and remove two U
bolts (15). 2316
24 4 24
2) Loosen hose bands (23) and (24) of hose (4) and

remove hose (4).
3) Loosen hose band (24) of hose (5) and remove

sems bolt (21) M10 x 25 and then hose (5).
21
4) Loosen hose band (24) of hose (9) and remove 3

32
hose (9). 5
Tools: Flat-head screwdriver 23 24
4 9
24
20 6
FOR WARD
Removing and installing hoses for radiator and

intercooler
8. Removing guards (13) and (14) (See the figure

13
"Removing and installing hose of sub tank (1)".) 14
18
2) Remove guards (13) and (14). 18

FOR WARD
Removing guards (13) and (14)
14-42
9. Separating hydraulic oil hoses (1) and (2) O/C OUT -

TANK
Place a container for hydraulic oil under the 1
connecting part of the hose and remove four sems
bolts (8) M12 x 35 and then separate hoses (1) and OUT
(2).
FOR WARD
10. Removing radiator assembly (See the figure
"Removing and installing radiator stays".)
8
Tools: Socket: 19mm
2) Move the radiator outward so as not to contact

T1
with the engine fan when the radiator is being
lifted.
3) Plug the pipe opening with clean waste clothes,

etc.
4) Put a sling to the lifting eyes of the radiator IN

assembly and remove the radiator assembly by a
crane.
8
2
C/V T1-
O/C IN
Separating hydraulic oil hoses (1) and (2)
14
14-43
14.3.12.2 INSTALLING RADIATOR AND OIL COOLER

Installation should be done in the reverse order of removal. And, reinstall the clip for each hose in place.
II
FOR WARD
IV aa
FORWARD
III
bb
5 HOS E INSER TION

3 ALLOWANCE
45 (1.77”)
HOS E INSER TION

(1.57”)
ALLOWANCE
40
3
(1 . 5
HOS E INSER TION INSTALL THE CLIP 38
”)
IN THE ORIENT ATION
ALLOWANCE SHOWN IN THE FIGURE.
(0.63”)
CLIP 22 24
16
24 23 INSTALLATION INSTALL THE CLIP

INSTALL THE CLIP INSTALL THE CLIP POSITION IN THE ORIENT ATION
IN THE ORIENT ATION IN THE ORIENT ATION SHOWN IN THE FIGURE.
SHOWN IN THE FIGURE. SHOWN IN THE FIGURE.
VIEW I 40
(1.57”) 5
HOS E INSER TION
ALLOWANCE
TIGHTENING TORQUE 10
39.2N .m(28.9 l bf.ft) 3
APPLY LOCTITE #262. 5 INSTALL THE CLIP VIEW II
3 SO THAT THE RUBBER
21 31 CABLE COVER IS NOT
CAUGHT.
TIGHTENING TORQUE
. .
21 39.2N m(28.9 lbf ft)
APPLY LOCTITE #262.
32
INSTALL THE CLIP SO THAT
THE RUBBER CABLE COVER
IS NOT CAUGHT.
DETAIL bb
Hose insertion standard (1/2)
14-44
HOS E INSER TION

ALLOWANCE 40
(1 .5 7 ”) HOS E INSER TION
22 ALLOWANCE 9
(1 .7 7 ”)
INSTALL THE CLIP IN
45
THE ORIENT ATION (1 40 6
SHOWN IN THE FIGURE. . 57 INSTALL THE
”) CLIP IN THE
TO BE INSTALLED
HOS E INSER TION 23
SO THAT THE WHITE
PAINT COMES ON
22 ORIENTATION
SHOWN IN ALLOWANCE INSTALL THE CLIP
THE TOP OF THE FIGURE. IN THE ORIENTATION
(1 .7 7 ”)
ENGINE SIDE. 2
1 5 (0
45
TO BE INSTALLED SO THAT SHOWN IN THE FIGURE.
THE WHITE P AINT COMES
.5
ON THE TOP OF ENGINE SIDE.
9 ”)
23
(1.57”)
INSTALL THE CLIP IN 4

40
(1.77”)
THE ORIE NTATION
HOS E INSER TION VIEW III
45
SHOWN IN THE FIGURE.
ALLOWANCE HOS E INSER TION
(0.63”)
ALLOWANCE TIGHTENING
16
TORQUE
CLIP TIGHTENING 10. 8N.m
TORQUE .
INSTALLATION
POSITION 2.2N.m 16 (8.0 lbf ft) 15
23 INSTALL THE CLIP IN (1.62 lbf.ft)
THE ORIENT ATION 16
VIEW IV SHOWN IN THE FIGURE. 17
TO I/C 12 9 11
19 TIGHTENING
TORQUE
19.6N .m
(14.5 lbf.ft)
APPLY LOCTITE
#262.
FROM
THE ENGINE
TURBO
15
TIGHTENING 20 17
TORQUE 17
39.2N .m TIGHTENING 19
TIGHTENING
(28.9 l bf.ft) TORQUE
TORQUE
2.2N.m
16 16 TIGHTENING
TORQUE
APPLY 19.6N .m
LOCTITE #262. (1.62 lbf.ft) 2.2N.m (1.62 lbf.ft)
(14.5 l bf.ft) 16
APPLY LOCTITE TIGHTENING 16 TIGHTENING
#262. TORQUE TORQUE
10. 8N.m 10. 8N.m (8.0 lbf.ft)
(8.0 lbf.ft) ' ( 7 $ , / D D
Hose insertion standard (2/2)
1. Installing radiator assembly

Put a sling to the lifting eyes of the radiator assembly and place the radiator assembly in place temporarily.
Then install the hydraulic hose, the radiator hose, and the intercooler hose. Regarding the insertion standard
for each hose, see the figure "Hose insertion standard".
2. Radiator mounting bolt
Apply Loctite #262 to the four sems bolts (A4) M12 x 30 and tighten them.
Tools: Socket: 19mm
14
3. Adjust the whole circumference of the clearance between the fan and the radiator shroud according to the
figure "Adjustment position of front and rear of radiator".
4. Clean the fitting surface for the insulation completely and then attach the insulation.
14-45
5. Refilling hydraulic oil and LLC (Long Life Coolant) ADJUST THE CLEARANCE BETWEEN
THE FAN AND THE RADIATOR
After finishing the other installation works, refill 9
SHROUD IS TO 9±5 mm (0.35±0.20").
(0.35”)
hydraulic oil and coolant.
Amount of coolant in engine body: 9 L (2 gal)
Amount of radiator coolant: 5.5 L (1.5 gal)
Amount of hydraulic oil in oil cooler: 2.4 L (0.6 gal) I
ADJUST THE WHOLE Fa

CIRCUMFERENCE OF n
d ia
THE CLEARANCE m
BETWEEN THE FAN et
er
(
AND THE RADIATOR (2 φ 6 5
SHROUD TO 20±5 mm 5. 0
6” )
(0.79"±0.20"). )
VIEW I
Adjustment position of front and rear of radiator
14-46
14.3.12.3 REMOVING AND INSTALLING RADIATOR, INTERCOOLER CORE, AND OIL COOLER
Preparation
• Remove one under cover under the radiator.
• Wait until the engine coolant temperature goes down 4
Forward
to a temperature that will not cause burns, then
remove the radiator cap, open the drain cock at the
lower rear side, drain the coolant, and receive it with a
container. 13
Tighte ning torque
* When only the intercooler is to be pulled out, the 23.5 ±2.0N .m
(17.3 ±1.5 lbf .ft)
above work is unnecessary. 10
9
1. Removal
1) Disconnect the wiring connector of radiator

coolant level switch (B12).
2) Remove three sems bolts (13) M8 x 20 mounting

plate assembly (4) and then remove plate
assembly (4).
3) Remove two bolt assemblies (9) M10 x 50 fixing

the upper part of the radiator core.
B12
4) Check that the coolant is completely drained and

then loosen and remove upper and lower hose
bands (22) of the radiator only at the radiator
side. (See the figure "Removing and installing
hoses for radiator and intercooler".)
5) Sling the radiator core by using the lifting eyes on

the upper part of the radiator core and remove it. Oil
Intercooler Radiator
Weight: Approx. 9.6 kg (21.2 lbs) cooler
Check that rubber bushing (5) at the lower
mounting part of the radiator core does not come
out.
6) Remove two capscrews (9) M10 x 50 fixing the

upper part of the intercooler core.
7) Loosen and remove upper and lower hose bands

(23) of the intercooler only at the intercooler side. 14
(See the figure "Removing and installing hoses
for radiator and intercooler".) Drain cock
5
8) Sling the intercooler by using the lifting eyes on
the upper part of the intercooler and remove it.
Weight: Approx. 6.0 kg (13.2 lbs)
Check that the rubber bushing at the lower
Details of mounting part
mounting part does not come out, same as the at bottom of ra dia tor core
radiator core.
9) Separating hose for hydraulic oil cooler Removing and installing radiator and intercooler
core
Separate hoses (1) and (2) at the upper and
lower sections of the cooler and drain the
hydraulic oil. (See the figure "Separating hydraulic oil hoses (1) and (2)".)
10) Sling the cooler by using the flange on the upper part of the cooler and lift the cooler temporarily.
11) Remove four capscrews (10) M8 x 30.
12) Lift the cooler.
14-47
Weight: Approx. 6.0 kg (13.2 lbs)
There is no specified removal order among the radiator core, the intercooler core, and the oil cooler, so that remove
those components as required.
2. Installation
14-48
14.3.13 ENGINE
14.3.13.1 REMOVING ENGINE
Preparation
• Remove the battery ground cable (See Paragraph "BATTERY").
• Remove the bonnet and the guards (See Paragraph "GUARD") and remove the under cover (See Paragraph
"UNDER COVER").
• Remove the air cleaner hose (See Paragraph "AIR CLEANER").
• Remove the counterweight (See Paragraph "COUNTERWEIGHT").
• Remove the radiator hoses and the intercooler hoses (See Paragraph "RADIATOR AND OIL COOLER").
• Remove the fuel hose and the heater hose, and remove the air conditioner hose as required
• Remove the pump, the muffler, and the radiator as required.
• Remove the harnesses and the connectors. (See Chapter "ELECTRIC SYSTEM".)
– Engine ground cable
– Starter cable of starter B terminal
– Connectors of ECU harness and engine accessory harness
– Upper harness
P5-Alternator B terminal
CN-136F-Engine speed sensor
CN-141F and CN142F-Pump proportional valve
CN-139F and CN-140F-P1 and P2 pump pressure sensors
CN-212F-Glow
P3-C terminal of starter motor
Prepare a cradle which can support the weight of the engine and keep the removed engine at a stable condition.
(See Chapter "TOOLS".)
14
14-49
THERMOST AT
OIL FILTER
ELEMENT
ALTERNATOR
FUEL FILTER
S TARTER ELEMENT
Appearance of engine
14-50
RADIATOR S IDE
III BUNDLE THE
bb FOR WARD HARNESSES
50 WITH CLIP.
INSTALL THE FAN AS
THE PROJECTION TURNED 32
aa TO RADIATOR S IDE.
DETAIL hh
51
PROJECTION 6 PLACES
hh
32
I
34 ee 33
cc FIX ITEM 24, 25,
AND 26 HOS ES .
dd
44, 47
6 44, 47
20
43, 46 19
33 4 P LACES
33
II
17 20
VIEW I 19
15
39
28 VIEW II 19
37
OUT
25 47
2, 3 45
DETAIL ee DETAIL cc
3, 29
IN
24 HOS E INS ERTION ALLOWANCE
42 CLIP INS TALLATION P OS ITION
14
1 40
(0.91”)
(0.12”)
8
23
48 5 27
DETAIL aa 32
7
26 5
4
2 P LACES
VIEW V
38 21
14
IV
35 13 AFFIX THE LABEL
IN THE ORIENTATION
VIEW VI
P UMP S IDE
S HOWN IN THE FIGURE.
23
32
31
21 22
48 P OS ITION S LIT OUTS IDE
22 5
49
4 P OS ITION
41 FAN S IDE S LIT OUTS IDE
DETAIL bb DETAIL dd VIEW IV

VIEW III
Removing and installing engine (1/2)
14-51
FOR WARD
ff
DETAIL OF MTG.
BREATHER 7 ENGINE MOUNT (FR)
HOSE
(2.8”)
(70)
VIEW FROM F AN SIDE.

gg
FROM THE
UNDER COVER
44, 47
V DETAIL OF MTG.
8 36 ENGINE MOUNT (RE)
20 VIEW FROM FLY-WHEEL S IDE.
9, 10 19
4 P LACES
A
4 P LACES
43, 46 A 6
44, 47
18
20
19
VI 19 11
47 12
45
DETAIL gg
39 16
19 PIN (ITEM6) IS Hydraulic hose
STRICKEN TO
Thread Tighte ning torque
THE PIN HOSE OF 6 diameter N.m(lbf.ft)
F/W HOUSING.
AND INSER T P INS PF1 137 ±15 (101±1 1)
IN ENGINE SIDE. PF1/4 29 ±4.9 (21±3.6)
47
M12 26.5 ±2.6 (19.5±1.9)
45
DETAIL ff Tighte ning torque
SECTION AA for engine remote
oil filter piping
Removing and installing engine (2/2)
1. Separating hose of engine oil filter

Place a container for drain oil under the connecting part of filter (1) and remove hoses (24), (25), and (26) at *
mark positions.
Tools: Wrench: 19 mm and 41 mm
2. Attach the plugs to the filter side connectors and the hoses.
3. Removing frame mounting bolts
1) Remove three nuts (45) M18

2) Remove four capscrews (44) M18 x 140.
3) Remove four plates (20)
14-52
4) Remove four rubber mounts (19) each at the upper side.

4. Slinging engine body
Prepare a cradle which can support the weight of the engine and keep the removed engine at a stable condition.
(See Chapter "TOOLS".)
1) Put a wire with hook to the lifting eyes at the front and rear of the engine.
Wire: 6 mm (0.24 inch) diameter x 1 m (3feet-3inch), 2pcs.
5. Place the engine on the engine cradle in a stable condition.
14.3.13.2 INSTALLING ENGINE

Tightening torque
Tightening
Item Name torque Remarks
N·m (lbf·ft)
4 Bolt 26.5 (19.5)
10 Nut 28.5 (21.0)
12 Bolt 28.5 (21.0)
35 Sems bolt 46.1 (34.0)
36 Sems bolt 46.1 (34.0) Apply Loctite #262.
39 Sems bolt 115 (85) Apply Loctite #262.
40 Capscrew 46.1 (34.0) Apply Loctite #262.
41 Capscrew 46.1 (34.0)
43 Capscrew 172 (127) Apply Loctite #262.

14
45 Nut 26.5 (19.5)
51 Sems bolt 28.5 (21.0)
Tightening torque for engine remote oil filter piping
Tightening torque
N·m (lbf·ft)
Thread
O-ring fitting Hydraulic hose
diameter
PF1 205 (151) 137 (101)
PF1/4 - 29 (21)
M12 - 26.5 (19.5)
14-53
14.3.14 REMOVING AND INSTALLING CONSOLE COVER

14.3.14.1 REMOVING RIGHT CONSOLE COVER
1. Lift and remove the boot by pushing the "A" part of
the boot with a flat-head screwdriver.
4
2. Remove two sems bolts (1-18) M6 x 16 and one
sems bolt (1-20) M6 x 20.
A
3. Remove console cover (1-6), disconnect the
harness connector of the switch, and then remove
two sems bolts (1-18) M6 x 16 and then control
cover (1-7).
• The boot does not need to be removed Installing and removing boot
completely and the lever does not need to be
removed.
14.3.14.2 REMOVING LEFT CONSOLE COVER

1. Remove the boot same as the right console cover. Tighte ning torque
1-18 5.0N .m (3.69 lbf .ft)
(See the figure "Removing and installing boot".)
2. Remove one sems bolt (1-18) M6 x 16 and one
sems bolt (1-20) M6 x 20 individually.
1-18
Tools: Phillips screwdriver Tighte ning torque
5.0N .m (3.69 lbf .ft)
3. Remove console cover (1-8).
1-18
4. Remove three sems bolts (1-18) M6 x 16 and then Tighte ning torque
lower console cover (1-9). 5.0N .m (3.69 lbf .ft)
Before attaching floor mat

1-18
Tighte ning torque
5.0N .m (3.69 lbf .ft)
Tighte ning torque 1-6
5.0N .m (3.69 lbf .ft) 1-7
1-9
1-18
1-8 1-18
Tighte ning torque
5.0N .m (3.69 lbf .ft)
1-20
Tighte ning torque
5.0N .m (3.69 lbf .ft)
1-10
1-20
Tighte ning torque
5.0N .m (3.69 lbf .ft)
Removing and installing console cover
14.3.14.3 INSTALLING CONSOLE COVER

At installation, use the reverse order of removal with the tightening torque in the tightening torque table below.
Tightening torque
Item Name
N·m (lbf·ft)
1-18
Sems bolt M6 5.0 (3.69)
1-20
14-54
14.3.15 REMOVING AND INSTALLING CONTROL VALVE

Preparation
• Remove the guards which need to be removed to remove the control valve.
• Install the suction stopper to the hydraulic oil tank.
• Remove the hoses of piping connected to the ports shown in the figure "Port name of control valve (1/2)" and
"Port name of control valve (2/2)".
Write a port name on each hose and remove it.
14
14-55
Function Port name Upper side (base machine) port Port name Function
Left side Right side

P2 bypass cut+ + P1 bypass cut
BaR
MU Supply line
Arm 1 (arm out) pilot PBa1
Swing (left) pilot PBs PBa2 Arm 2 (arm out) pilot
Bucket (bucket in)
PCc stroke limiter pilot
Boom 2 pilot Pra
Tra ve l le ft (re a rwa rd) pilot PBL PBb Boom (down) pilot
Tra ve l le ft (forwa rd) pilot PAL PAr Tra ve l right (forwa rd) pilot
Return to tank T2 MR Main relief valve

PCb Unload valve (P1 side)
pilot
Rear side (base machine) port
P 1 P1 pump
P 2 P2 pump
Right side (base machine) port
Arm 2 (arm out) pilot PBa2 Upper side Lower side
Bucket (bucket out) pilot PBc
Bucket (bucket in) stroke PCc Ta Arm out dedicated tank

limiter pilot
Ac Bucket cylinder head side (bucket in)
Bucket cylinder rod side (bucket out) Bc
Emergency manual valve drain XAb Bb Boom cylinder rod side (boom down)
Boom cylinder head side (boom up) Ab Br Right travel motor (rearward)
Right travel motor (forward) Ar
Power boost PL
Port name of control valve (1/2)
14-56
Function Port name Left side (base machine) port Port name Function
Lower side Upper side

Arm cylinder head side (arm in) Aa Ba Arm cylinder rod side (arm out)
PLc2 Lock valve selector pilot

Swing motor (left) Bs
Ac Swing right
Left travel motor (rearward) BL
PLc1 Lock valve selector pilot
AL Left travel motor (forward)
T1 Return to tank
Lower side (base machine) port

Tra ve l le ft (re a rwa rd) pilot PBL PTb Tra ve l s tra ight pilot
Unload valve (P2 side) pilot PCa PBr Tra ve l right (re a rwa rd) pilot
Boom 3 pilot Prb PAb Boom (boom up) pilot
Swing (right) pilot PAs PAc Bucket (bucket in) pilot
Arm 1 (arm in) pilot PAa 1 PAa 2 Arm 2 (arm in) pilot
Aa R
Port name of control valve (2/2)
14.3.15.1 REMOVING CONTROL VALVE

• Remove three cap screws (4) M16 x 45, sling
control valve (1), and remove it.
14
1
Removing and installing STD main control valve
14-57
14.3.15.2 INSTALLING CONTROL VALVE

1. Install the control valve with three cap screws (4) M16 x 45.
Tightening torque for joint and hose
Tightening torque
Size Port name
N·m (lbf·ft)
PLc1, PLc2, Pra, Prb, PAL, PCa, PCc,

PF1/4 34 to 39 (25 to 29)
PAr, PCb, PL, Dr2, Pc, PTb, XAb
PAa1, PBa1, PAs, PBs, PBL, PB1, PAa2, PBa2,
PF3/8 69 to 78 (51 to 58)
PAc, PBc, PAb, PBb, PBr, Dr1
PF3/4 150 to 180 (111 to 133) MU, (T3), (P5), (P6)
Ar, Br, AL, BL, As, Bs, Ab, Bb,

M10 49 to 65 (36 to 48)
Aa, Ba, Ac, Bc
M12 83 to 110 (61 to 81) P1, P2, T1, T2, Ta
2. Check oil leakage and operation.
14-58
14.3.16 REMOVING AND INSTALLING PILOT VALVE (ATT)

14.3.16.1 REMOVING PILOT VALVE (ATT)
The preparations for removal of the left and right pilot valves are the same and the following procedures are for the
left side.
Preparation
• Lower the attachment to the ground, stop the engine, and release the pressure in the hydraulic oil tank.
• Remove left console covers (1-8) and (1-9) according to Paragraph "REMOVING AND INSTALLING CONSOLE
COVER".
• Attach tags to the hoses to make the assembly work secure and easier.
1. Disconnect the connector for the horn harness.
2. Remove each hose in order from the nearest hose to the farthest hose.
Tools: Wrench: 19 mm and 22 mm
3. Move boot (3) upward and loosen nut (6). (See the
figure "Removing and installing boot and lever".)
3
4. Turn lever (1-2) and remove the lever parts as a set.
(See the figure "Removing and installing boot and
6
lever".) 1-2
Removing and installing boot and lever
5. Remove four cap screws (A2) M6 x 25. (See the A2

figure "Pilot valve connector".)
6. Remove the pilot valve.
7. Plug the hoses. Pilot valve
Plug: PF 1/4, and PF 3/8
Tighte ning torque
49N .m (36 lbf .ft) Tighte ning torque
29.4N .m (21.7 lbf .ft)
PF3/8 Width across
Va lve s ide
flats 22mm
PF1/4
Width across
14
flats 19mm
"F" stamp
PF3/8
PF1/4
P port conne ctor
Hose side (with filter)
1 to 4 and 5 to 6 T port conne ctor
Pilot valve connector
14-59
14.3.16.2 INSTALLING PILOT VALVE (ATT)

At installation, use the reverse order of removal with the following tightening torque.
Tools: Allen wrench: 5 mm Torque=11.8N·m (8.70 lbf·ft) Machine front
Cap screw (A2)
T x Arm (R) t Boom (R)
T (gray) r
(green) Bucket (R)
(blue)
v
Swing (R)
(red)
u
Swing (L)
q
(gray) Bucket (H)
(red) P
w Arm (H) P
(blue ) s Boom (H)
Left side (gre e n) Right side
Port position of pilot valve (seeing from above)
As the pilot valve is made of aluminum, use caution with the tightening torque.
14-60
14.3.17 REMOVING AND INSTALLING PILOT VALVE (TRAVEL)

14.3.17.1 REMOVING PILOT VALVE (TRAVEL)
Preparation
• Release the internal pressure of the hydraulic oil tank
(Refer to Paragraph "REMOVING AND INSTALLING
HYDRAULIC OIL TANK").
• Release under cover (1) (Refer to Paragraph
"REMOVING AND INSTALLING UNDER COVER"). A1
A9
A2 A8
A5
A8
A6
B1
A9
Removing and installing floor mat, pedal, and lever
14
14-61
1. Remove floor mat (B1). T: Tighte ning torque N.m (lbf.ft) A13 A10
2. Separate the wires for two pressure sensors SE-9 A1
(A10) and SE-10 (A10) and then remove two SE-9
pressure sensors (A10) form the pilot valve. 6
Tools: Wrench: 19 mm T=30 (22)
A10 5 T
T=30 (22)
3. Put tags to hoses (A1), (A2), (A3), (A4), and (A5)
P A1
and separate the hoses and the connectors.
3 A5
SE-10 PT
(T port, P port, and 1 to 4 ports) A2 PT T
C/V P
T=30 (22) 4
PAr
4. Plug each hose. 1 A3
Plug PF1/4
2
C/V BLOCK
B5
5. Remove four sems bolts (A9) M8 x 25 and then PAL
A4
remove left and right pedals (A5) and (A6). BLOCK
Width across flats 19mm B6
PF1/4 PF1/4
6. Remove four sems bolts (A8) M10 x 25 and then
remove left and right levers (A1) and (A2).
Tools: Socket: 17 mm Va lve s ide Hose side
7. Remove four sems bolts (A13) M10 x 30. Va lve s ide T port conne ctor
Tools: Wrench: 17 mm PF3/8
8. Pull up the pilot valve and remove it. Width across flats 19mm
Va lve s ide Hos e s ide
PF1/4
9. Attach plugs PF 1/4.
P F3/8 P F1/4
Hose side
P port conne ctor
1 to 4 port connector (with filter)
Removing and installing pilot valve
14.3.17.2 INSTALLING PILOT VALVE (TRAVEL)

At installation, use the reverse order of removal with the tightening torques in the tightening torque table below.

Name
(mm) N·m (lbf·ft)
Sems bolt (A13) Wrench 17 37 (27)
Sems bolt (A8) Wrench 17 35 (26)
Sems bolt (A9) Socket 13 23.5 (17.3)
Pressure sensor Wrench 19 30 (22)
14-62
14.3.18 REMOVING AND INSTALLING SWING MOTOR UNIT

14.3.18.1 REMOVING SWING MOTOR UNIT
Preparation
• Park the machine on a level and firm ground and place the attachment on the ground.
• Remove the guards which need to be removed to remove the swing motor unit. (See Paragraph "REMOVING
AND INSTALLING GUARDS".)
• Operate the switch on the gauge cluster and change the machine to the pressure release mode and operate the
control lever to release the pressure inside the circuit. (See Section "PRESSURE DRAINING" in Chapter
"HYDRAULIC SYSTEM".)
• Release the internal pressure of the hydraulic oil tank and put a tag on which a port name is written to each
hose.
1. Removing hoses 4
1) Remove hose (3) from the connector of make-up S/J HYD. TANK
port M. E
Tools: Spanner: 36mm 5

2) Remove two hoses (4) and (5) from the tee of
drain port DB. 3
Tools: Wrench: 27 mm DB M
3) Remove hose (B15) from the elbow of port PR

(for swing parking brake). (See the figure
"Removing and installing piping of swing motor
unit".) A1
Tools: Wrench: 19 mm A
B
4) Remove two hoses (A1) and (A2) from the
connector of ports A and B.
Tools: Wrench: 32 mm PR
Attach plugs PF 3/4, PF1/2, PF 1/4, and 1-14 B15

A2
UNS to the port openings with the hoses
removed.
5) Remove the swing reduction unit lubrication

hose.
Tools: Wrench: 19 mm Removing and installing piping of swing motor
unit 14
14-63
2. Removing swing motor unit 4 4

Remove thirteen capscrews (5) M20 x 55.
Tools: Socket: 30mm 5
1) Remove two plastic caps (4) M12 on the upper

surface of the swing motor and install lifting eyes.
2) Put a sling to the lifting eyes and remove the

swing motor unit.
Swing motor unit weight: Approx. 186 kg (410
lbs) (including reduction unit)
Removing and installing swing motor unit
14.3.18.2 INSTALLING SWING MOTOR UNIT

Check the swing motor unit orientation of installation and then install it by the reverse order of removal.
1. Clean the mounting surfaces of the swing motor unit and the upper frame.
Tools: Spatula and cleaning solvent
2. Apply Loctite #515 to the all-round mounting surface of swing motor unit (A).
3. Tighten thirteen cap screws (5) M20 x 55.
Tightening torque: 539N·m (398 lbf·ft) FOR WARD 2 4
Apply Loctite #262
4. Before installing the drain piping, fill the casing with 5
the hydraulic oil from the motor drain port.
5. Wind a seal tape around the thread part of filler tube
(2) and then install it.
Installing swing motor unit
14-64
14.3.18.3 INSPECTION BEFORE OPERATION

1. Check the level of gear oil #90 (GL-4 grade in API Service Classification) in the swing reduction unit before
starting operation.
Total amount of oil: Approx. 2.7 L (0.7 gal)
2. Before starting operation, operate the motor for several minutes at low speed while the engine is running at low
idle and check the motor for oil leakage and abnormal sound.
14
14-65
14.3.19 REMOVING AND INSTALLING SWIVEL JOINT

14.3.19.1 REMOVING SWIVEL JOINT
• Remove the boom piping hoses.
A B
C D
(Tra ve l motor) (Tra ve l motor)
P2(Lower)Rearward P1(Lower)Rearward
(Left side) A,B,C,D-PF1 (Right side)
P1(Upper)Forward P2(Upper)Forward
E-PF1/2
F-PF1/4
A2
Swivel joint
D A4
B
A7
F
A1 B2
F
C
E A16
A
B2
A16 A7
A3
Removing and installing lower piping
1. Removing tubes and hoses of undercarriage
1) Remove two hoses (A16). (E port: PF1/2)

Tools: Wrench: 27 mm and Tightening torque: 78.5N·m (57.9 lbf·ft)
2) Remove tubes (A1) and (A2). (C and D ports: PF1)

Tools: Wrench: 41 mm and Tightening torque: 275N·m (203 lbf·ft)
3) Remove tubes (A3) and (A4). (A and B ports: PF1)

Tools: Wrench: 41 mm and Tightening torque: 275N·m (203 lbf·ft)
4) Remove two hoses (A7). (F port: PF1/4)

Tools: Wrench: 19 mm and Tightening torque: 29.4N·m (21.7 lbf·ft)
14-66
2. Removing hoses of upper part of swivel joint

A6
1) Remove drain hose (5). (E port: PF1/2)
5
2) Remove hoses (A3) and (A5).
(A and C ports: 1-7/16-12UN-1)
3) Remove hoses (A4) and (A6). D

(B and D ports: 1-7/16-12UN-1)
B
4) Remove hose (B5).
C
(Two speed switching port: PF1/4)
Tools: Wrench: 19 mm A
Tightening torque: 29N·m (21 lbf·ft) A3
F
A5
B25
B5
Removing and installing hoses of upper part of

swivel joint
3. Removing whirl-stop of swivel joint

11 10 Tighte ning torque
1) Loosen nut (11) M24. 157N .m (116 lbf .ft)
2) Remove one cap screw (10) M24 x 130.

mm )
1 3 in c h
4. Removing joint for piping 51
(0 . Clearance at installation
(See the figure "Removing and installing lower
piping" and "Removing and installing hoses of upper
part of swivel joint".) 14
Removing and installing whirl-stop nut and cap
1) Remove two connectors (B2). (F port) screw
2) Remove connector for travel 2 speed switching (B25).

(F port: PF1/4)
14-67
5. Removing seal (B4)

Tighte ning torque B3
1) Remove six sems bolts (B4) M10 x 25. 2.0N .m (1.48 lbf .ft)
Tools: Socket: 17 mm Tighte ning torque B4
14.7N .m (10.8 lbf .ft)
2) Remove clip (B3). Apply Loctite #572 or
Tools: Flat-head screwdriver #577 for waterproofing
3) Remove seal (B1).

B2
B1
Removing and installing seal (B1)
6. Removing mounting sems bolts

Install the lifting eye and lift the swivel join
temporarily and remove three sems bolts (C2) M12
x 25.
See No.9 plug in Section "SPECIAL TOOLS" in Lifting eye
Chapter "TOOLS".
7. Remove the swivel joint.
Sems bolt
Weight: Approx. 24 kg (53 lbs) M12×25
Loctite #262
Lower frame T=108N .m (80 lbf .ft)
C2
C1
Swivel joint
Removing and installing mounting sems bolts
14-68
14.3.19.2 INSTALLING SWIVEL JOINT

1. Installation should be done in the reverse order of removal.
Tightening torque for piping
Tightening torque
Thread N·m (lbf·ft)
Tool
diameter
mm O-ring type Hydraulic
PF
connector hose
1/4 19 36 (27) 29 (21)
3/8 22 74 (55) 49 (36)
1/2 27 108 (80) 78 (58)
3/4 36 162 (119) 118 (87)
1 41 255 (188) 137 (101)
1-7/16-12UN 46 - 206 (152)
2. Check the swivel joint for oil leakage and hydraulic oil level.
3. Check the swivel joint for operation.
14
14-69
14.3.20 REMOVING AND INSTALLING UPPER FRAME

14.3.20.1 REMOVING UPPER FRAME
Preparation
• Remove the attachment/equipment
(See Chapter "ATTACHMENT").
• Remove the cab (See Paragraph "REMOVING AND INSTALLING CAB").
• Remove the guards (See Paragraph "REMOVING AND INSTALLING GUARDS").
• Remove the counterweight
(See Paragraph "REMOVING AND INSTALLING COUNTERWEIGHT").
• Remove the swivel joint
(See Paragraph "REMOVING AND INSTALLING SWIVEL JOINT").
1. Sling the upper frame temporarily.
Match mark
2. Attaching match mark to swing bearing
Make match marks on the upper frame and the
swing bearing.
Match marks on swing bearing and upper frame
3. Removing upper frame mounting bolts

Remove thirty-two cap screws (7) M20 x 100
mounting the upper frame on the swing bearing and
one reamer bolt (8) M20 x 105.
4. Slinging upper frame
Remove the upper frame by slinging it and place it
on a cradle which can support that weight.
Weight: Approx. 5 tons (11,030 lbs)
Removing and installing upper frame mounting

bolt
14-70
14.3.20.2 INSTALLING UPPER FRAME

1. Cleaning mating surfaces
Clean the mating surfaces of the upper frame and the swing bearing.
2. Apply Loctite #515 to the inside of the cap screws at the mating surface.
3. Slinging upper frame
Align the match marks and install the upper frame by tightening one reamer bolt (8) M20 x 105 temporarily.
4. Installing swing bearing Apply Loctite #515.
Apply Loctite #515 to race surface
1) Install thirty-two cap screws (7) M20 x 100. inside cap screw in whole circumference
Tools: Socket: 30 mm, apply Loctite #262 of hatched area.
2) Tighten one reamer bolt (8) finally.

*Mark 1 place
7 8
Apply Loctite #262. Apply Loctite #262.
Tightening torque Tightening torque
392N .m (289 lbf .ft) 392N .m (289 lbf .ft)
Detail of bearing mounting section
Two kinds of bearing mounting bolt
Outer S zone position of swing bearing
14
Reamer bolt position (*) and apply Loctite on

hatched area
Make sure the position of the reamer bolt by the figure "Reamer bolt position (*) and apply Loctite on hatched area".
14-71
14.4 DISASSEMBLING AND ASSEMBLING COMPONENT

14.4.1 HYDRAULIC PUMP AND REGULATOR
14.4.1.1 HYDRAULIC PUMP
14.4.1.1.1 STRUCTURAL EXPLODED VIEW OF HYDRAULIC PUMP
Main pump
534
792
702
983 532
981 548
886 214
530
490
732
789
535
537 808
806 954
251
953 901
490
726
419 468
272
824 723 545 031

04 466
127 544
541
123 885
717 885
014 490
314 116
113 401
141
312
157
156 124
153
011 326
414
151
152
211
030 711
531
212
406
261
774
710
111
123
723 724 127
824
490
141
313
724 271
013
Structural exploded view of main pump
14-72
The marks (W), (X), (Y), and (Z) in Fig. "Structural exploded view of regulator" show the position where regulator is
installed.
No. Name Q'ty No. Name Q'ty No. Name Q'ty
111 Drive shaft (F) 1 414 Socket bolt; M10 X 20 4 *806 Nut; M16 2
113 Drive shaft (R) 1 419 Socket bolt; M16 X 35 4 *808 Nut; M20 2
116 Gear #1 1 466 ROH plug PF1/4 2 824 Stop ring 2
123 Roller bearing 2 468 ROH plug PF3/4 4 885 Pin 4
124 Needle bearing 2 490 Plug; M7 X 0.75 18 886 Pin 2
127 Bearing spacer 2 531 Tilting pin 2 901 Eye bolt; M10 2
141 Cylinder block 2 532 Servo piston 2 *953 Socket screw 2
151 Piston 18 534 Stopper (L) 2 *954 Set screw; M20 2
152 Shoe 18 535 Stopper (S) 2 981 Name plate 1
153 Set plate 2 537 Servo cover 2 983 Pin 2
156 Spherlcal bushing 2 541 Seat 4 985 Name plate 1
157 Cylinder spring 18 544 Stopper 1 4 987 Pin 2
211 Shoe plate 2 545 Steel ball 4
212 Swash plate 2 548 Feed back pin 2
214 Tilting bushing 2 702 O-ring 2
251 Swash plate support 2 710 O-ring 1
261 Seal cover (F) 1 711 O-ring 1
271 Pump casing (F) 1 717 O-ring 2
272 Pump casing (R) 1 723 O-ring 14
312 Valve block B 1 724 O-ring 10
313 Valve plate(R) 1 726 O-ring 4
314 Valve plate(L) 1 732 O-ring 2 14

326 Cover 1 774 Oil seal 1
401 Socket bolt; M20 X 210 4 789 Back-up ring P18 2
406 Socket bolt; M8 X 16 4 792 Back-up ring G35 2

The item having the number marked with * is an adjusting screw. Do not touch the adjusting screw as much as possible.
Tightening torque of bolt, plug, nut, and servo piston
Tighte ning torque Tighte ning torque

No. Thread size No. Thread size
401 M20 430 (317) 468 PF 3/4 170 (125)
406 M8 29 (21) 490 M7 X 0.75 18 (13)
414 M10 57 (42) 806 M16 130 (95)
419 M16 240 (177) 808 M20 240 (177)
466 PF 1/4 36 (27)
14-73
14.4.1.1.2 DISASSEMBLING AND ASSEMBLING MAIN PUMP
TOOL
The tools necessary to disassemble/reassemble K7V
pump are shown in the following list.. B
The size of bolts and plugs depend on the pump type.
○: Necessary
Tool name and size Tool Part name
Pump model
ROH plug
Hexagon socket Hexagon socket
Names B K7V125 VP plug
head cap screw head set screw
(Parallel thread)
2 ― ― M4
2.5 ― ― M5
3 ― ― M6
4 M5 ― M8
5 M6 ― M10
6 ○ M8 PF1/4 M12, M14
Allen wrench 8 ○ M10 PF3/8 M16, M18

10 ○ M12 PF1/2 M20
14 ○ M16, M18 PF3/4 ―
17 ○ M20, M22 PF1 ―
19 M24, M27 ― ―
21 ― ― ―
22 M30 ― ―
Adjustable angle wrench ― ○ Medium size 1set
Screwdriver ― ○ Flat-blade screwdriver(medium size) 2pieces
Hammer ― ○ Plastic hammer 1piece
Plier ― ○ TSR-160 for stop ring(retaining ring/internal snap ring)
Torque wrench ― ○ Capable of tightening with the specified torques
Disassembling Procedures
1. Selection of a place for disassembling
• Select a clean place.
• Spread a rubber sheet or cloth on the workbench to prevent parts from being damaged.
2. Cleaning
Remove dust, and rust, etc., from the pump surfaces with cleaning oil or so on.
14-74
3. Draining oil
Remove drain port plugs (468) and let the oil out
from pump casings (271) and (272).
Tools: Spanner: 36 mm
• Drain the oil from each plug opening of the front and
rear pumps.
4. Removing regulator
Remove socket bolts (414) (See Figures "Structural exploded view of main pump" and "Structural exploded
view of regulator") and remove the regulator.
• Refer to Paragraph "REGULATOR" for dissembling the regulator.
5. Removing PTO unit and PTO cover (326)
Place the pump horizontally on a workbench with its
regulator-fitting surface down, and remove the PTO
unit by removing flange socket (435).
• Before bringing the regulator-fitting surface down,
spread a rubber sheet on the workbench to avoid
damaging the fitting surface.
• Check the PTO unit maintenance manual for
disassembling or assembling the PTO unit.
In case the pump is not equipped with the PTO unit,

remove cover (326).
14
Removing PTO unit and PTO cover (326)
14-75
6. Removing gear pump (04)

Remove flange sockets (435) and then gear pump
(04).
Removing gear pump (04)
7. Removing socket bolts (401)

Loosen socket bolts (401) fixing pump casings (F)
(271) and (R) (272), and valve block (312).
• Remove the gear pump first before performing this
work.
Removing socket bolts (401)
8. Separating pump casings (F) (271) and (R) (272)

and valve block (312)
Separate pump casings (F) (271) and (R) (272) and
valve block (312).
• When separating the pump casings and the valve
block, also take out 1st gear (116).
Separating pump casings (F) (271) and (R) (272)

and valve block(312)
14-76
9. Pulling out cylinder assembly

Pull out cylinder (141) straight over shaft (111) and
(113) from pump casing (F)(271) and (R)(272)
together with piston sub assembly (011),set plate
(153), spherical bushing (156), and cylinder springs
(157).
• Take care not to damage the sliding surfaces of the
cylinder blocks, spherical bushings, shoes, swash
plates and drive shafts, and the rolling surfaces of the
needle bearings at the drive shafts.
Pulling out cylinder assembly
10. Removing seal cover (F) (261)

Remove socket bolts (406) and then seal cover (F)
(261).
• Put a flat-head screwdriver into the notch groove of
seal cover (F) to remove the cover easily.
• The oil seal is fitted on seal cover (F) and take care
not to damage it while removing the cover.
Removing seal cover (F) (261)
11. Removing drive shaft (111) and (113)

Remove drive shaft (111) and (113) from pump
casing (271) and (272) by tapping the rear end
section of the shaft slightly.
14
Removing drive shaft (111) and (113)
14-77
12. Removing shoe plate (211) and swash plate(212)

Separate the swash plate (212) and shoe plate
(211) from swash plate support (251), and take them
out from pump casing (271) and (272) by tilting them
as shown in the figures.
Removing shoe plate (211) and swash plate(212)
13. Pulling out swash plate support (251)

Remove swash plate support (251) from pump
casing (271) and (272).
• In the case it is difficult to remove, tap the opposite
side of the swash plate support (251) with a plastic
hammer to remove it easily.
Pulling out swash plate support (251)
14-78
14. Removing valve plates (313), (314)

Remove valve plates (313) and (314) from valve
block (312).
• They may be removed unintentionally in Work 8.
Removing valve plates (313), (314)
15. Removing other parts

If necessary, remove the servo covers (537), stoppers (L) (534) and (S) (535), and servo piston sub
assemblies (530) from pump casings (271) and (272).
• Do not remove the needle bearings as far as possible, except the case that the bearings are considered to be
out of their service life.
• Do not loosen hexagon nuts of the valve block and the servo cover. If loosened, the flow setting will be changed.
Assembling Procedures
1. Precautions of assembling
Perform assembling procedures in the reverse order of disassembling procedures by taking care of the
following items.
• Be sure to repair the parts damaged during disassembling, and repair replacement parts in advance.
• Clean each part fully with cleaning oil and dry it with compressed air.
• Be sure to apply clean hydraulic oil to the sliding portions and the bearings, etc. before assembling them.
• Always replace the sealing parts, such as the O-ring and the oil seal, in general.
• Prepare a torque wrench for mounting socket bolts or plugs at each part and tighten them with the specified
torques shown in "Tightening torque for hydraulic pump".
• In case of a tandem pump is used, take care not to mix up parts of the front pump with those of the rear pump.
2. Installing swash plate supports (251)
Install swash plate support (251) to positioning pin
(886) of the casing (271) and (272). 14
• If the servo piston, stopper (L), stopper(S), and servo
cover are removed, fit them to pump casing in
advance for reassembling.
Installing swash plate supports (251)
14-79
3. Installing swash plates (212)

Attach shoe plate (211) to swash plate (212) and
insert tilting pin (531) to tilting bushing (214) of servo
piston(532). As shown in the following figure, attach
them to swash plate support (251)correctly, leaning
swash plate and shoe plate.
• Confirm that the swash plate can be moved smoothly
with fingers of both hands.
• Apply grease to sliding sections of swash plate and
swash plate support, to assemble the drive shaft
easily.
• Take care not to damage the sliding surface of the
shoe plate.
Installing swash plates (212)
4. Installing drive shaft (111), (113)

Fit drive shaft (111), (113) with needle bearing(123),
bearing spacer (127), and stop ring(824) installed to
pump casing (271), (272).
Installing drive shaft (111), (113)
14-80
5. Installing seal cover (F) (261)

Assemble seal cover (F) (261) to pump casing (271)
and fix it with socket bolts(406).
• Apply grease lightly to the oil seal in seal cover (F).
• Assemble the oil seal, taking full care not to damage
it.
Installing seal cover (F) (261)
6. Inserting piston cylinder sub assembly

Assemble the piston cylinder sub assembly [cylinder
(141), piston sub assembly (151), (152), set plate
(153), spherical bushing (156) and cylinder spring
(157)] and align it with spline phases of the spherical
bushing and the cylinder. Then, insert piston
cylinder sub assembly into the pump casing.
Inserting piston cylinder sub assembly
7. Installing valve plate (313), (314)

Fit valve plate (313) and (314) to valve block (312)
aligning pin (885).
• Take care not to mistake suction/delivery directions of
valve plate.
14
Installing valve plate (313), (314)
14-81
8. Installing valve block (312) to pump casings (271)

and (272)
Place pump horizontally on the workbench with its
regulator-fitting surface down, and attach valve
block (312) to pump casings (271) and (272).
• Before bringing the regulator-fitting surface down,
spread a rubber sheet on the workbench to avoid
damaging that surface.
• Take care not to mistake the orientation of the valve
block. (Install it to the pump casings so that the
regulator is placed on the upper side and the suction
flange is placed at the right side, when seeing from
the front side.)
• When installing the pump casings to the valve block, Installing valve block (312) to pump casings (271)
install the 1st gear simultaneously. and (272)
9. Installing valve block (312)

Fix pump casings (271) and (272) to valve block
(312) with socket bolts (401).
Installing valve block (312)
10. Installing gear pump (04), valve block (312), and

pump casings (271), (272)
Install gear pump (04) by tightening flange socket
(435). Fix pump casings (271) and (272) to valve
block (312) with socket bolts (401).
Installing gear pump (04), valve block (312), and

pump casings (271), (272)
14-82
11. Installing PTO unit

Attach the PTO unit by tightening flange sockets
(435) to valve block (312).
• Be careful about the orientation of installation of the
PTO unit.
Installing PTO unit
12. Installing cover (326)

In case the pump is not provided with the PTO unit,
attach cover (326) with socket bolts (414).
Installing cover (326)
13. Installing regulator

Attach the feedback lever of the regulator into the
feedback pin of tilting pin install the regulator, and
tighten socket bolts (412) and (414).
(See the figure of "STRUCTURAL EXPLODED
VIEW OF REGULATOR")
Socket bolts (412) and (413): For regulator
14
• Take care not to mistake the front regulator for the
rear regulator, or vice versa.
Installing regulator
14. Installing drain port plug(466), (468)

Fit drain port plugs (466), (468). This is the end of assembling procedure.
Tools: Allen wrench: 19mm, 36mm
Tightening torque: 36N·m (27 lbf·ft) (466)
Tightening torque: 170N·m (125 lbf·ft) (468)
14-83
14.4.1.1.3 MAINTENANCE STANDARD OF HYDRAULIC PUMP
Replacement Criteria of Worn Parts

Replace or readjust parts when they exceed any of the following criteria.
However, when those parts are damaged significantly in appearance, be sure to replace them.
Recommended
Standard
replacement
Part name and inspection dimension Countermeasures
value
mm (inch)
mm (inch)
Clearance between piston and cylinder 0.029 0.057

(D-d) Replace piston or cylinder.
bore (0.0011) (0.0022)
Play between piston and shoe-caulking 0 to 0.1 0.3 Replace assembly of piston &
(δ)
section (0 to 0.0039) (0.0118) shoe.
5.0 4.8 Replace assembly of piston &
Thickness of shoe (t)
(0.197) (0.189) shoe.
41.8 41.0
Free height of cylinder spring (L) Replace cylinder spring.
(1.65) (1.61)
Combined height of set plate and 25.0 24.0 Replace set plate or spherical
(H-h)
spherical bushing. (0.98) (0.94) bush.
d D
(L)
Cle a ra nce be twe e n pis ton $ Free height of

cylinde r bore (D-d) cylinder spring (L)
H
h
t
P la y be twe e n pis ton $ shoe caul king pa rt ( ) Combi ned hei ght of set pl ate $
Thickne s s of s hoe (t) Spheri cal bushi ng (H-h)
Correction Criteria Cylinder, Valve Plate and Swash plate(Shoe plate)

Surface roughness for valve plate Surface roughness necessary to be corrected 3-Z
(sliding face)
swash plate (shoe plate area) Standard surface roughness
0.4Z or lower (Lapping)
& cylinder (sliding face) (Corrected value)
14-84
14.4.1.1.4 Tightening torque for hydraulic pump
Tightening B
Part name Size torque dimension Tool
N·m (lbf·ft) mm (inch)
M5 6.9 (5.09) 4 (0.16)

M6 12 (9) 5 (0.20)
M8 29 (21) 6 (0.24)
M10 57 (42) 8 (0.31)
Socket bolot M12 98 (72) 10 (0.39)
M14 160 (118) 12 (0.47)
M16 240 (177) 14 (0.55) Allen
M18 330 (243) 14 (0.55) wrench
M20 430 (317) 17 (0.67)
PF1/4 29 (21) 6 (0.24)

PF3/8 74 (55) 8 (0.31)
ROH plug
PF1/2 98 (72) 10 (0.39)
PF3/4 150 (111) 12 (0.47)
14
14-85
14.4.1.1.5 TROUBLESHOOTING
How to check failure

The pump is often fitted with the regulator, accessory valves and attached pumps, and so it is very difficult to find a
cause of failure. Inspect the following inspection items to find failure.
1. Inspecting Filter and Drain Oil
Checkthe filter elements for a significant amount of impurities. Since the shoes and cylinders produce worn
metal particles, a small amount of particles can be found. However, if a significant amount of metal particles
are found in the filters, it is considered that the shoes may be damaged. Similarly, check the drain oil from the
pump casing.
2. Existence of Abnormal Noise or Vibrations
Check the pump body for abnormal noise or vibrations. Check noise for constant frequency, such as hunting of
the regulator or the relief valve of the accessory valve. If it is judged as abnormal noise or vibrations, it could be
caused by cavitation or damage inside the pump.
3. When Using Two Pumps
When the circuit is equipped with two pumps or motors or a double pump, exchange the piping of one pump
with that of the other one. With the results of this exchange, the problem will turn out to be caused by the circuit
downstream the pump or the pump.
4. Pressure Measurement at Various Points
If a failure occurs in control, do not overhaul the pump recklessly, but measure pressures at various points to
investigate the abnormal part.
Troubleshooting
1. Overload of engine
Cause Countermeasure Caution

The speed or pressure is higher than Set them as specified.
-
their specified values.
The torque setting of the regulator is Adjust the regulator. See the instruction manual of the
higher than specified value. regulator.
Seizure or damage of a part inside the Replace the damaged part. Check the filter and drain oil for abnormal
pump. worn metal particles.
Wrong fitting of the regulator piping. Correct the regulator piping. -
2. Extreme Decrease of Pump Oil Level or Delivery Pressure Does Not Increase.

Failure of the regulator. Repair the regulator. See the instruction manual of the
regulator.
Seizure or damage of a part inside the Replace the damaged parts. Check the filters and drain oil.
pump.
Failure of the attached pump. Replace the damaged parts. Remove the attached pump and check
the shaft coupling.
Failure of the accessory valve. Replace the accessory valves. See the instruction manual of the
(Especially, check the poppets, seats accessory valves.
and springs.)
Wrong fitting of the regulator piping. Correct the regulator piping. -
14-86
3. Abnormal Noise and Abnormal Vibrations

Cavitation Prevention from cavitation. Low boost press.
Check working oil for emulsion.
Failure of the attached pump
Air leakage at the suction pipe.
Increased suction resistance.

Damage in the caulking section of the Replace the piston, shoe, shoe plate,
-
shoe. etc.
Cracking of the cylinder. Replace the cylinder. -
Wrong installation of the pump. Correct installation. -
Hunting of the regulator. Repair the regulator. See the instruction manual of the
regulator.
Hunting of the relief valve of the Repair the accessory valve.

-
accessory valve.
Damage of the gear. Replace the gear. -
14
14-87
14.4.1.2 REGULATOR
14.4.1.2.1 STRUCTURAL EXPLODED VIEW OF REGULATOR
(874)
876
611
642
643
898
728
418
641
079
412 467
466
412 728
755 801
412 924
402
497
466 656
755 728
497 645
646
644
726
601
658 414 614
729
468 874
497
887
497
758
755
758
708
Structural exploded view of regulator
14-88
The marks (W), (X), (Y), and (Z) in the figure above show the pump casing mounting position. (See Fig. "Structural
exploded view of main pump".)
No. Name Q'ty No. Name Q'ty No. Name Q'ty
402 Socket bolt; M6 X 16 3 641 Pilot plug 1 729 O-ring 1
412 Socket bolt; M8 X 40 5 642 Pilot spool 1 755 O-ring 3
414 Socket bolt; M8 X 25 1 643 Pilot sleeve 1 758 Square-ring 10
418 Socket bolt; M5 X 12 2 644 Spring seat (Q) 1 801 Nut; M10 1
466 ROH plug; PF1/4 2 645 Adjusting stem (Q) 1 874 Pivot Pin 1
467 ROH plug; PF1/2 1 646 Pilot spring 1 876 Pin 1
468 ROH plug; PF1/8 1 656 Cover 1 887 Pin 1

Restrictor; M6 X 0.9
497 MH plug; M7 X 0.75 9 658 1 898 Pilot piston 1
diameter
601 Regulator casing 1 708 O-ring 1 *924 Socket screw 1
611 Feedback lever 1 726 O-ring 1
614 Adjusting plug 1 728 O-ring 3

The item having the number marked with * is an adjusting screw. Do not touch the adjusting screw as much as possible.
Tightening torque of bolt, plug, and nut
NOMINAL
Tightening torque
No. DESIGNATION OF
N·m (lbf·ft)
SCREW THREAD
402 M6 12 (9)
412, 414 M8 29 (21)
418 M5 6.9 (5.1)
466 PF1/4 36 (27)
468 PF1/8 17 (12.5)
497 M7X0.75 18 (13.3) 14

614 PF3/8 74 (55)
467, 641 PF1/2 110 (81)
658 M6 6.9 (5.1)
14-89
14.4.1.2.2 DISASSEMBLING AND ASSEMBLING REGULATOR
Tools
Tool and dimension Part name
Required tool
(Marked with ○) Socket bolt ROH plug Hex head socket
Name B
(Flange bolt) (PF screw) set screw
2 - - M4
2.5 - - M5
3 ○ - - M6
4 ○ M5 - M8
5 ○ M6 ROH-1/8 M10
6 ○ M8 ROH-1/4 M12, M14
Allen wrench
8 M10 ROH-3/8 M16, M18
10 ○ M12 ROH-1/2 M20
12 M14 - -
14 M16, M18 ROH-3/4 -
17 M20, M22 ROH-1 -
19 M24, M27 - -
22 ○ - VP-3/8 -
24 M16 - -
27 ○ M18 VP-1/2 -
Eye wrench 30 M20 - -
Socket wrench
36 - VP-3/4 -
Double (single) end
wrench 41 - VP-1 -
46 M30 - -
50 - VP-1 1/4 -
55 - VP-1 1/2 -
Adjustable wrench - ○ Middle-sized, 1 pc.
Torque wrench - ○ Wrench that is possible to tighten with specified torque
Socket bolt - ○ For pulling out adjusting stem, M4, L=approx. 50 mm
Preparations for disassembling

• Since the regulator consists of small, precise, and well-finished parts, disassembling and assembling are rather
complicated. For this reason, before disassembling the regulator, read this manual thoroughly to the endand
then disassemble the regulator following the specified order.
• Before disassembling the regulator, mark the front regulator and the rear regulator to identify them.
• When disassembling and assembling the regulator, prepare a vise to hold the regulator stable because the
regulator contains three parts tightened with high torque.
• The numbers in parentheses after part names represent the item number in Fig. "Structural exploded view of
regulator".
Disassembling procedure
1. Selection of a place for disassembling
2. Cleaning
Remove dust, and rust, etc. from surfaces of the regulator with clean oil.
14-90
3. Removing regulators
Remove socket bolts (412) and (414), and remove the regulator from the pump.
• When disassembling the pump body, check the maintenance manual for K7V series axialpiston pump.
• Take care not to lose O-rings while removing the regulator.
4. Removing proportional pressure reducing solenoid valve (079)
Remove hexagon socket head cap screws (418) and remove the proportional pressure reducing solenoid
valve (079).
• When removing the proportional pressure reducing solenoid valve, do not damage the connector of it.
5. Loosen pilot plug (641).
• Do not remove the pilot plug (641). If it is removed,
the pilot spring (646) and the sprig seat (Q) (644) will
fall from the casing.
• Be careful about falling down of the workpiece while
loosening pilot plug (641) because it was tightened
with a high torque.
• Do not damage the regulator mating surface while
using a vise.
6. Removing cover (656) (See Fig. "Structural

exploded view of regulator")
Remove socket bolt (402) and remove cover (656).
• Cover (656) is provided with hex head socket set
screw (924), hexagon nut (801). Do not loosen the
screw and nut. If they are loosened,pressure-flow
setting will be changed.
Removing cover (656)

14
7. Removing pilot spring (646) and spring seat (Q)
(644)
Remove adjusting stem (Q) (645) at position (D) in
Fig. "Structural exploded view of regulator", and
take out pilot spring (646), and spring seat (Q) (644)
from the regulator.
• Adjusting stem (Q) (645) can easily be drawn out with
M4 screw.
• Take care not to lose the pilot spring (646) and the
spring seat (Q) (644) which may fall from the casing
when adjusting stem (Q) (645) is removed.
Removing pilot spring (646) and spring seat (Q)

(644)
14-91
8. Removing pilot plug (641) (See position (A) in Fig.

"Structural exploded view of regulator")
Remove pilot plug (641) and then pilot piston (898).
• Take care not to lose pilot piston (898) after removing
it.
Removing pilot plug (641)
9. Removing pilot spool (642)

Take out pilot spool (642).
Removing pilot spool (642)
10. Removing adjusting plug (614) and feedback lever

(611)
Remove adjusting plug (614) and then take out
feedback lever (611).
loosening adjusting plug (614) because it was
tightened with a high torque.
• Do not remove pin (876) press-fitted in feedback lever
(611).
Removing adjusting plug (614) and feedback lever

(611)
14-92
11. Taking out pilot sleeve (643)

Take out pilot sleeve (643).
Taking out pilot sleeve (643)
12. Removing ROH plugs (466), (467), (468)

Remove ROH plugs (466), (467), and (468). ROH plugs (466)
loosening ROH plug (466) because it was tightened
with a high torque.
Removing ROH plugs (466), (467), (468)
13. Removing restrictor (658)

Remove restrictor (658).
This completes disassembling of this regulator.
• Be careful not to lose the restrictor.
14
Removing restrictor (658)
Since component parts are small, take care not to lose them.
14-93
ASSEMBLING PROCEDURES
Perform assembling procedures in the reverse order of disassembling procedures by taking care of the following
items.
• Be sure to repair the parts damaged during disassembling, and repair replacement parts in advance.
• If foreign materials enter the regulator, it will cause malfunction. Clean each part fully with cleaning oil, dry it with
air blow, and then perform work at a clean place.
• Prepare a torque wrench for mounting bolts or plugs at each part and tighten them with the specified torques
shown in " Tightening torque of bolt, plug, and nut ".
• Be sure to apply clean hydraulic oil to the sliding portions before assembling them.
• Always replace the sealing parts such as the O-ring etc., in general.
1. Selection of a place for assembling
2. Installing restrictor (658)
Fully wash out casing (601) and restrictor (658).
Remove oil from the restrictor (658) completely.
Then, apply a drop of *adhesive to only the thread
part of the restrictor (658), and tighten it into the
casing.
Tightening torque: 6.9N·m (5.1 lbf·ft) (466)
• Do not operate this pump for approximately three
hours after installing the restrictor (658). (The
hydraulic oil will wash out the adhesive before it is
hardened and it may cause the restrictor to lose its
effect.)
• If adhesive is adhered to other parts, wipe off the
adhesive at once.
*adhesive
Product name: Loctite#241
Maker: Henkel Japan Ltd.
Installing restrictor (658)
14-94
3. Install ROH plugs (466), (467), and (468).

Install ROH plugs (466), (467), and (468). ROH plugs (466)
Tools: Allen wrench: 5mm, 6mm, 10mm
Tightening torque: 17N·m (13 lbf·ft),36N·m (27
lbf·ft),110N·m (81 lbf·ft)
tightening ROH plug (466) because the tightening
torque is high.
Install ROH plugs (466), (467), and (468)
4. Installing pilot sleeve (643)

Fit pilot sleeve (643) into casing (601).
• Be careful not to insert pilot sleeve (643) with a wrong
orientation.
• Confirm that the pilot sleeve (643) slides smoothly in
the casing without sticking.
Pin hole of sleeve (643)
Installing pilot sleeve (643)
5. Installing feedback lever (611)

Hook pin (876) press-fitted in feedback lever (611)
into the pin hole of pilot sleeve (643). Then put the
hole portion at the support point of feedback lever
(611) onto pivot pin (874) press-fitted inside casing
(601).
• If pilot spool (642) is in pilot sleeve (643) at this time, 14
feedback lever (611) cannot be installed.
Installing feedback lever (611)
14-95
6. Installing adjusting plug (614)

Install adjusting plug (614) to casing (601).
tightening adjusting plug (614) because the tightening
torque is high.
• After installing the adjusting plug (614), confirm that
pilot sleeve (643) and feedback lever (611) slide
smoothly inside casing (601) without excessive gaps
among parts.
Installing adjusting plug (614)
7. Installing pilot spool (642)

Fit the pilot spool (642) into pilot sleeve (643).
• Be careful not to insert pilot spool (642) with a wrong
orientation.
Installing pilot spool (642)
14-96
8. Installing pilot piston (898) and pilot plug (641)

After inserting pilot piston (898) into pilot plug (641), Pilot piston (898)
(spherical surface is faced upward)
install pilot plug (641) to casing (601).
• Be careful not to insert pilot piston (898) with a wrong
orientation.
• At this stage, pilot plug (641) does not need to be
tightened with the specified torque.
Installing pilot piston (898) and pilot plug (641)
9. Installing spring seat (Q) (644) and pilot spring (646)

Put spring seat (Q) (644) and pilot spring (646) into
the casing.
• Spring seat (Q) (644) may fall off. Apply grease to the
spring seat (Q) (644) and the pilot spring (646) to
prevent the spring seat (Q) (644) from falling off.
14
Installing spring seat (Q) (644) and pilot spring
(646)
14-97
10. Installing adjusting stem (Q) (645), hex head socket

set screw (924), and hexagon nut (801)
Install adjusting stem (Q) (645) to casing (601) and
install cover (656) with hex head socket set screw
(924) and hexagon nut (801) installed to casing
(601).
Installing adjusting stem (Q) (645), hex head

socket set screw (924), and hexagon nut (801)
11. Installing pilot plug (641)

Tighten pilot plug (641) with the specified torque.
Tools: Socket: 27mm
tightening pilot plug (641) because the tightening
torque is high.
• Do not damage the regulator mating surface while
using a vise.
Installing pilot plug (641)
12. Installing proportional pressure reducing solenoid valve (079)

Install proportional pressure reducing solenoid valve (079) to casing (601).
This completes the regulator assembling work.
14-98
14.4.2 CONTROL VALVE

14.4.2.1 SECTIONAL ASSEMBLY DRAWING
J
J
154 164 101
P2
T2
PAL P BL
J
P B1 P Ca
Pra Prb
P Bs PAs
PBa 1 PAa 1
162 162 162

SECTION A-A
154 164
P1 102
974
973
P Tb P Cb
974
973
P Br PAr
14
973
PAb P Bb
973 973
PAc
973 P Cc
P Bc
PAa 2 PBa 2
973 973
162 162 162
SECTION B-B
Section (1/6)
14-99
T2
H 273x1 0 H
P1 unload P Cb PAL Travel left
C 273x10 C
PAr P B1 977
D D
978x2
Boom P Bb Pra
Boom 2
E
E
P Bs
Bucket Swing
F F
P Cc
PBa 2 PBa 1
Arm 2
Arm 1
G G
MU
K K
B A
PBa 2 PBa1
274x 4 274x4
Dr2
Pc
213 213
PAa 1
PAa 2
Section (2/6)
14-100
P 1 unload Travel left

202 202
333 PCb PAL 333
331 331
336 336
329 324
327 323
331 331
261 MR 261
309
601
PL 306
AL 163
511
512
521
522 CP2
CMR2 551
552 164
562
CMR1 162
BL
552
522 163
Dr1
512
307
261
331 PBL 264
327 205
329
336
331 SECTION C-C
333
202 PTb
Travel straight

202 201
333 PAr PB1 333
331 331
336 339
324 326
323 325
331 331
261 261
306
305
161
Ar
511
521
511
521 14
CP1 LCb2
551
551
164 164
163 Br
310
161
(T3)
164
264 154
PBr
261
205 331
327
SECTION D-D 329
336
PCa 331
P 2 unload 333
202
Section (3/6)
14-101
203 202
333 Boom Boom 2 333
331 331
336 P Bb Pra 336
319 322
321 320
603 331
279x3 AbR 261
211
L 331 L 212
163
215 M N N
M 261 161
266 159
159 PLc1 312
514 CAb
551
524 521
CRb1 164
556 CRb2 511
164
556
Dr2 164
529
Pc 513
CRe 164
208 551
520 521
Bb 516
162
163
CBb 313
551
301 164
264 521
162 511
PAb
161 261
602 BbR 331
SECTION E-E 320
205 322
336
Prb 331
Boom 3 333
202
164 551 Backet
209
216 P Cc Swing 201
333 333
PBs
331 P Bc 331
336 336
322 322
321 321
602 BcR
331 331
261
261
304
Bc
162 As
511 511
521 523
LCc
LCs
551
556
164
164
163 Ac
Bs
162
162
162
264 303
PAc
264
603 PAs
205 SECTION F-F 205
AcR
Section (4/6)
14-102
201
201 333
333 Arm 2 Arm 1 331
331 PBa2 PBa1 336
340 322
328 321
321
BaR 603
331
331
550 211
261 562
525 L L
CBa 261
519 159
MU
308
PLc2 514
162
162 524
CRa
162 556
511
164
521
551 LCAT2 511
164 521
515 LCa
521 551
LCAP2
551 164
164 302
162
162 Ta Aa
163
162
510
526 CTa 604
167 264
557 PAa1
P P
264 205
210 PAa2 AaR
SECTION G-G
T2
161
511
P1
T1
14
521
163
CT1
551
163
164
162
P2
CT2
551
164
SECTION H-H 511 521
Section (5/6)
14-103
207 606 606

160 563
278x 5 266 XAb
564
264 264
527 528
SECTION P-P
T2 T1
517
518
SECTION M-M
SECTION K-K
SECTION J -J
SECTION N-N SECTION L-L
Section (6/6)
torque Item Part Name Q'ty torque Item Part Name Q'ty
101 CASING A 1 325 SPRING 1

102 CASING B 1 326 SPRING 1
220 to 250
154 PLUG G-3/4 3 327 SPRING 3
(162 to 184)
16 to 20
159 PLUG M7*0.75 4 328 SPRING 1
(12 to 15)
7.8 to 9.8
160 PLUG R-1/16 MECH 1 329 SPRING 3
(5.8 to 7.2)
161 O-RING 5 331 SPRING SEAT 26

16 to 18 (12 to 13)
162 O-RING 21 333 SPACER BOLT 13
LOCTITE #262
163 O-RING 9 336 STOPPER 11
201 COVER 4 510 POPPET 1
BOOST CHECK VALVE
207 1 514 POPPET 2
COVER
25 to 34
208 LOGIC CONTROL VALVE 1 515 POPPET 1
(18 to 25)

9.8 to 14 LOCK VALVE SELECTOR
211 2 518 POPPET 1
(7.2 to 10.3) SUB-ASSEMBLY
14-104
9.8 to 14 LOCK VALVE SELECTOR

212 1 519 POPPET 1
(7.2 to 10.3) SUB-ASSEMBLY
LOGIC POPPET SUB-
213 PLATE 2 520 1
ASSEMBLY
BOOM LOWERING VALVE
215 1 521 SPRING 12
FOR EMERGENCY
216 PISTON 1 522 SPRING 2
261 O-RING 13 523 SPRING 1
264 SQUARE-RING 9 524 SPRING 2
266 SQUARE-RING 2 525 SPRING 1
25 to 34
273 SOCKET BOLT 40 526 SPRING 1
(18 to 25)
98 to 120
(72 to 89)
25 to 34
(18 to 25)
9.8 to 14
(7.2 to 10.3)
BOOM SPOOL SUB- 130 to 150

301 1 550 PLUG 1
ASSEMBLY (96 to 111)
230 to 260
302 ARM 1 SPOOL 1 551 PLUG 13
(170 to 192)
130 to 150
303 SWING SPOOL 1 552 PLUG 2
(96 to 111)
230 to 260
304 BUCKET SPOOL 1 556 PLUG 4
(170 to 192)
49 to 59
305 BOOM CONFLUX SPOOL 1 557 PLUG 1
(36 to 44)
306 TRAVEL SPOOL 2 562 O-RING 3

TRAVEL STRAIGHT 13 to 17
307
SPOOL
1
(9.6 to 12.5)
563 PLUG 1
14
ARM 2 SPOOL SUB-
308 1 564 O-RING 1
ASSEMBLY
69 to 78
309 P1 UNLOADING SPOOL 1 601 MAIN RELIEF VALVE 1
(51 to 58)
69 to 78
310 P2 UNLOADING SPOOL 1 602 PORT RELIEF VALVE 2
(51 to 58)
BOOM 2 SPOOL SUB- 69 to 78

312 1 603 PORT RELIEF VALVE 3
ASSEMBLY (51 to 58)
BOOM 3 SPOOL SUB- 69 to 78

313 1 604 PORT RELIEF VALVE 1
ASSEMBLY (51 to 58)
69 to 78
319 SPRING 1 606 BYPASS CUT VALVE 2
(51 to 58)
140 to 180
320 SPRING 2 973 SOCKET BOLT 8
(103 to 133)
140 to 180
321 SPRING 5 974 SOCKET BOLT 2
(103 to 133)
14-105
322 SPRING 5 977 NAME PLATE 1

323 SPRING 2 978 PIN 2
324 SPRING 2
14.4.2.2 DISASSEMBLING AND ASSEMBLING CONTROL VALVE
General Precautions
• The hydraulic components are all precision-machined, so a particularly clean place needs to be selected for
disassembling and assembling.
• Thoroughly be careful in handling the control valve also to prevent dust, dirt and sand from entering inside.
• In removing the control valve from the machine, apply a cap to each of the ports, confirm thorough application of
the caps prior to disassembling, and then cleanse the assembly outside. Besides, use an appropriate work
bench for working by spreading a clean sheet of paper or a rubber mat on it.
• In carrying and moving the control valve, politely handle it by supporting it at the body portion, but never the
lever, exposed spool, or end cover portions.
• Besides, conducting various tests (such as the relief valve characteristics, leakage test, overload valve setting,
and flow rate resistance, etc.) is desired after disassembling and assembling, but a hydraulic test device is
needed for these. Therefore, do not disassemble components unable to be tested or adjusted even though
disassembling is technically possible. In addition, prepare clean washing oil, hydraulic oil, and grease, etc. in
advance.
Tools
Prior to disassembling of the control valve, prepare the following tools.
Item Name Q'ty Remarks

a Vise bench 1
b Box wrench 1 for each size 24mm, 27mm, 32mm
c Allen wrench 1 for each size 5mm, 6mm, 10mm, 12mm, 14mm, 22mm
d Wrench 1 24 mm, 32 mm
e Loctite #262 1
f Scraper 1
g Tweezers 1
h Adjustable wrench 1
14-106
14.4.2.3 DISASSEMBLING CONTROL VALVE

The numbers inside the parentheses ( ) following the
part names in the description below show item numbers
in Fig. "SECTION (1/6)" to "SECTION (6/6)".
1. Put the control valve on the work bench so that the
boost check valve is directed upward.
Preparation for disassembling
Perform disassembling in a clean place, and avoid damaging flange faces and plate faces.
2. Disassembling P1 unload spool

1) Loosen socket bolt (273), and remove spring
cover (202) and O-ring (261) of the P1 unload
spool.
Removing P1 unload spring cover (202)

14
2) Remove P1 unload spool (309), spring seat
(331), springs (327) and (329), stopper (336),
and bolt (333) in an assembled condition out of
casing B (102).
Removing P1 unload spool sub-assembly (309)
14-107
When removing the spool assembly, be careful not to damage casing B (102).
3) Fix the P1 unload spool assembly to a vise

applying a protection plate (aluminum plate and
the like) in between them, remove bolt (333), and
then disassemble spring seat (331), springs
(327) and (329), and stopper (336) from P1
unload spool (309).
Disassembling P1 unload spool assembly (309)
3. Disassembling travel spools (travel left and right spools)

1) Loosen socket bolt (273), and remove travel
spring cover (201) and O-ring (261)of the travel
spool.
Removing travel left spring cover (201)
2) Remove travel spool (306), spring seat (331),

springs (323) and (324), stopper (336), and bolt
(333) in an assembled condition out of casing A
(101) or casing B (102).
Removing travel left spool assembly (306)
14-108
When removing the spool assembly, be careful not to damage casing A (101) or casing B (102).
3) Fix the travel spool assembly to the vise applying

a protection plate (aluminum plate and the like) in
between them, remove bolt (333), and then
disassemble spring seat (331), springs (323) and
(324), and stopper (336) from travel spool (306).
Removing travel right spring cover (202)
Removing travel right spool assembly (306)
4. Disassembling boom conflux spool

1) Loosen socket bolts (273), and remove boom 14
conflux spring cover (201) and O-ring (261) of the
boom conflux spool.
Removing boom conflux spring cover (201)
2) Remove boom conflux spool (305), spring seat (331), springs (325) and (326), stopper (339), and bolt (333)
in an assembled condition out of casing A (101).
14-109
When removing the spool assembly, be careful not to damage casing A (101).
3) Fix the boom conflux spool assembly to the vise

(325) and (326), and stopper (339) from boom
conflux spool (305).
Removing boom conflux spool assembly (305)
5. Disassembling boom 2 spool

1) Loosen socket bolts (273), and remove spring
cover (202) and O-ring (261) of the boom 2 spool.
Removing boom 2 spring cover (202)
2) Remove boom 2 spool (312), spring seat (331),

(333) in an assembled condition out of casing B
(102).
Removing boom 2spool assembly (312)
14-110
3) Fix the boom 2 spool assembly to the vise applying a protection plate (aluminum plate and the like) in
between them, remove bolt (333), and then disassemble spring seat (331), springs (320) and (322), and
stopper (336) from boom 2 spool (312). Do not disassemble boom 2 spool (312) any further.
6. Disassembling boom spool
cover (203) and O-rings (261) and (266) of the
boom spool.
Removing boom spring cover (203)
2) Remove boom spool (301), spring seat (331), springs (319) and (321), stopper (336), and bolt (333) in an
assembled condition out of casing B (102).
3) Fix the boom spool assembly to the vise applying

(321), and stopper (336) from boom spool (301).
Do not disassemble boom spool (301) any 14
further.
Removing boom spool assembly (301)
14-111
7. Disassembling swing spool

cover (201) and O-ring (261) of the swing spool.
Removing swing spring cover (201)
2) Remove swing spool (303), spring seat (331), springs (321) and (322), stopper (336), and bolt (333) in an
assembled condition out of casing A (101).
3) Fix the swing spool assembly to the vise applying

(322), and stopper (336) from swing spool (303).
Removing swing spool assembly(303)
8. Disassembling bucket spool

cover (209) and O-ring (261) of the bucket spool.
Removing bucket spring cover (209)
14-112
2) Remove bucket spool (304), spring seat (331),

(333) in an assembled condition out of casing B
(102).
Removing bucket spool assembly (304)
3) Fix bucket spool assembly to the vise applying a

protection plate (aluminum plate and the like) in
(322), and stopper (336) from bucket spool (304).
Disassembling bucket spring cover (209)
4) In case disassembling of spring cover (209) of the bucket spool is necessary, loosen plug (551) with the
condition that the cover is installed to casing B (102). After removing spring cover (209) from casing B (102),
removes plug (551), and take out piston (216).
14
9. Disassembling arm 1 spool
cover (201) and O-ring (261) of the arm 1 spool.
Removing arm 1 spring cover (201)
14-113
2) Remove arm 1 spool (302), spring seat (331), springs (321) and (322), stopper (336), and bolt (333) in an
assembled condition out of casing A (101).
3) Fix arm 1 spool assembly to the vise applying a

protection plate (aluminum plate and the like) in
(322), and stopper (336) from arm 1 spool (302).
Removing arm 1 spool assembly (302)
10. Disassembling arm 2 spool

cover (201) and O-ring (261) of the arm 2 spool.
Removing arm 2 spring cover (201)
2) Remove arm 2 spool (308), spring seat (331), springs (321) and (328), stopper (340), and bolt (333) in an
assembled condition out of casing B (102).
14-114
3) Fix the arm 2 spool assembly to the vise applying

(328), and stopper (340) from arm 2 spool (308).
Do not disassemble arm 2 spool (308) any
further.
Removing arm 2 spool assembly (308)
11. Disassembling travel straight spool

cover (202) and O-ring (261) of the travel straight
spool.
Removing travel straight spring cover (202)
2) Remove travel straight spool (307), spring seat (331), springs (327) and (329), stopper (336), and bolt (333)
in an assembled condition out of casing B (102).
When removing the spool assembly, be careful not to damage casing B (102). 14
3) Fix the travel straight spool assembly to the vise
(327) and (329), and stopper (336) from travel
straight spool (307).
Removing travel straight spool assembly (307)
14-115
12. Disassembling P2 unload spool

cover (202) and O-ring (261) of the P2 unload
spool.
Removing P2 unload spring cover (202)
2) Remove P2 unload spool (310), spring seat (331), springs (327) and (329), stopper (336), and bolt (333) in
an assembled condition out of casing A (101).
3) Fix P2 unload spool assembly to the vise

(327) and (329), and stopper (336) from P2
unload spool (310).
Removing P2 unload spool assembly (310)
13. Disassembling boom 3 spool

cover (202) and O-ring (261) of the boom 3 spool.
Removing boom 3 spring cover (202)
14-116
2) Remove boom 3 spool (313), spring seat (331),

(333) in an assembled condition out of casing A
(101).
Removing boom 3 spool assembly (313)
3) Fix the boom 3 spool assembly to the vise applying a protection plate (aluminum plate and the like) in
between them, remove bolt (333), and then disassemble spring seat (331), springs (320) and (322), and
stopper (336) from boom 3 spool (313).
14. Removing spool covers
1) Travel, boom, bucket, swing, and arm 1
Loosen socket bolts (273), and remove spool
covers (205) and O-rings (264).
14
Removing spool covers (205) and (210)
2) Arm 2
Loosen socket bolts (273), and remove spool cover (210) and O-ring (264).
Do not disassemble spool cover (210) any further.
14-117
15. Removing relief valve
Removing main relief valve (601)
1) Remove main relief valve (601), port relief valves

(602), (603) and (604) from the casing.
Removing port relief valves (602), (603) and (604)
• Port relief valves (602), (603) and (604) have the same external shape with different pressure settings, so put
identification tags to them for avoiding mistake at reassembling.
• Do not disassemble the relief valve themselves.
16. Removing bypass cut valve

1) Remove bypass cut valve (606) from the casing.
Removing bypass cut valve (606)
14-118
17. Removing logic control valve and logic valve poppet

Loosen socket bolts (208-120), and remove logic
control valve (208) from the casing and then remove
spring seats (520-103), springs (520-106), and logic
poppets (520-101) from the casing. Do not
disassemble logic control valve (208) and logic
poppets (520-101) any further.
Removing logic control valve (208)
Removing logic poppet (520 and 101)
18. Removing boost check valve and bypass check valve

1) Loosen socket bolts (278), and remove boost
check valve cover (207) and O-ring (264) from
the casing.
14
Removing boost check valve cover (207)
14-119
2) Remove springs (527) and (528), boost check

valve poppet sub-assembly (517), and bypass
check valve poppet (518) from the casing. Do not
disassemble boost check valve poppet sub-
assembly (517) any further.
Removing boost check valve poppet sub-assembly

(517) and bypass check valve poppet (518)
19. Removing manual emergency lowering valve and

lock valve selector sub-assembly
Loosen the socket bolts (279), and remove lock
valve selector sub-assembly (211) and the manual
emergency lowering valve (215) from the casing. Do
not disassemble lock valve selector sub-assembly
(211) andthe manual emergency lowering valve
(215) any further.
Removing manual emergency lowering valve (215)

and lock valve selector sub-assembly (211)
20. Removing lock valve selector sub-assembly

Loosen socket bolts (211-171) and (212-171), and
remove lock valve selector sub-assemblies (211)
and (212) from the casing. Do not disassemble the
lock valve selector sub-assemblies (211) and (212)
any further.
Then, place the control valve so that the spool cover

surface faces downward.
Removing lock valve selector sub-assemblies

(211) and (212)
When placing the control valve, be careful not to damage the spool cover surface.
21. Removing Plates
14-120
1) Loosen socket bolts (274), and remove plate

(213).
Removing plate (213)
2) After removing the plate, remove all of O-rings (162) remaining in the casing.
22. Removing check valve
1) Load check valve and conflux check valve
Remove plugs (551), and then poppets (511) and
springs (521).
Removing each plug
2) Anti-cavitation check valve (CAb), (CBb)

Remove plug (551), and then poppet (511) and spring (521).
3) Swing portion load check valve (LCs)
4) Arm 2 portion check valve (LCAP2)
14
• Be careful not to mistake the plugs and springs of (3) for those of (1) when reassembling them because they are
different from those of above-mentioned (1).
• Be careful not to mistake the poppet of (4) for that of (1) when reassembling them because it is different from
above-mentioned (1).
14-121
5) Boom 2 portion load check valve (CRe)

Remove plug (551), and then poppet (516) and
spring (521).
Removing each poppet
6) Anti-cavitation check valve (CBa)

7) Anti-cavitation check valve (CTa)
8) Lock valve portions (CRb1) and (CRa)
• Be careful not to mistake the poppet of (5) for that of (1) when reassembling them because it is different from that
of above-mentioned (1).
• Be careful not to mistake the parts of (6), (7), and (8) for those of (1) when reassembling them because all of
them are different kinds from those of above-mentioned (1).
9) Lock valve portion (CRb2)

10) Main relief valve portions (CMR1) and (CMR2)
• Be careful not to mistake the poppet and spring of (9) for those of (8) when reassembling them because they are
different from those of above-mentioned (8).
• Be careful not to mistake the parts of (10) for the above-mentioned parts when reassembling them because the
all parts of (10) are different kinds from the above-mentioned parts.
The plugs not described in the disassembling procedure above are those for plugging unnecessary holes and
casting holes, so do not disassemble them unless it is required specifically.
23. Disassembling casing
Do not disassemble the casing any further.
24. Inspection after disassembling
Thoroughly cleanse all the disassembled parts with clean mineral oil, dry them with compressed air, and put
the parts on a clean sheet of paper or cloth for inspection.
Control valve
• Inspect all the surfaces of the parts for burrs, scratches, carved damage, or other defects.
• Check that the faces of the O-ring grooves of the casing and the covers are smooth without dusts, dents, and
rust.
14-122
• In case dents or scratches are found on the check valve seat surface of the casing, remove them by lapping.
Be careful not to leave lapping agent inside the casing.
• Check the periphery of the sliding portion of the spool for scratches and dents and if small ones are found,
remove them using an oil stone or cloth applied lapping agent.
• Check the sliding and fitting parts for easy movement by hand and all the grooves and passages for foreign
materials.
• In case springs are broken or deformed, replace them with new ones.
• In case the relief valve does not work properly, replace it with a new one.
• Replace all the O-rings with new ones.
Relief valve
• Check that the main plunger and the seat face of the seat tip have uniform contact faces with no defects.
• Check the main plunger and the seat for easy and smooth movement by hand.
• Check the main plunger orifice for clogging by foreign materials. (Main relief valve)
• In case minor scratches are found in the inspections above, remove them by lapping.
• In case a failure part or relief valve malfunction is found, replace them with a new one.
• Replace the O-rings with new ones. (Sealing portions with the casing)
14
14-123
14.4.2.4 ASSEMBLING CONTROL VALVE

• Assembling procedures are only explained in the description texts below, so refer to Paragraph
"DISASSEMBLING CONTROL VALVE" for drawings.
• The numbers inside the parentheses ( ) following the part names in the description below show item numbers
in Fig. "SECTION (1/6)" to "SECTION (6/6)".
• Precautions on assembling O-rings
– Pay attention to avoid the O-rings from having failure caused by being formed into a shape or damage caused
by handled abruptly.
– Lubricate the O-rings sufficiently by applying grease or hydraulic oil to them.
– Do not extend the O-rings to the extent of permanent deformation.
– In assembling the O-rings, be careful not to let them roll to install them. Furthermore, twisted O-rings cannot
be returned to the normal condition naturally after being installed, and tend to cause oil leakage.
– Tighten the mounting bolts of each part using a torque wrench with the tightening torque shown in the table of
the sectional assembly drawing of the control valve.
1. Assembling check valve
1) Load check valve and conflux check valve
Assemble poppet (511) and spring (521), attach O-ring (164) to plug (551), and then tighten it with the
specified tightening torque. (7 places)
2) Anti-cavitation check valve (CAb) (CBb)
Assemble poppet (511) and spring (521), attach O-ring (164) to plug (551) and then tighten it with the
specified tightening torque. (1 place)
3) Swing portion load check valve (LCs)
4) Arm 2 portion load check valve (LCAP2)
5) Boom 2 portion load check valve (CRe)
6) Anti-cavitation check valve (CBa)
7) Anti- cavitation check valve (CTa)
8) Lock valve portions (CRb1) and (CRa)
9) Lock valve portion (CRb2)
10) Main relief valve portions (CMR1) and (CMR2)
specified tightening torque. (2 places)
The parts of (1) — (10) have similar shapes, so be careful not to assemble wrong parts and not to assemble parts in
wrong places.
2. Assembling plate
14-124
1) Attach O-rings (162) in the casing.

2) Attach plates (213), and tighten socket bolts (274) to the specified tightening torque.
• Then, place the control valve so that the plate mounting surface faces downward.
3. Assembling boost check valve and bypass check valve
1) Assemble boost check valve poppet sub-assembly (517), bypass check valve poppet (518), and springs
(527) and (528).
2) Attach O-rings (264) and (266) to boost check valve cover (207), assemble them to casing A (101), and
tighten socket bolt (278) to the specified tightening torque.
4. Assembling lock valve selector sub-assembly
Install lock valve selector sub-assemblies (211) and (212) to the casing, and tighten socket bolts (211-171) and
(212-171) to the specified torque.
5. Assembling manual emergency lowering valve and lock valve selector sub-assembly
Put lock valve selector sub-assembly (211) on manual emergency lowering valve (215) and install them to the
casing, and tighten socket bolts (279) to the specified torque.
6. Assembling logic valve poppet and logic control valve
1) Assemble logic valve poppet (520) to the casing.
2) Assemble logic control valve (208) to the casing holding the spring seat of logic valve poppet (520-103) and
tighten socket bolts (208-120) to the specified torque.
In assembling logic control valve (208) to the casing, be careful not to let spring (520-106) and spring seat (520-
103) of the logic valve poppet to fall off.
7. Assembling bypass cut valve

1) Loosen adjusting screw (606-201) and lock nut (606-301) of the bypass cut valve sufficiently.
2) Install bypass cut valve (606) to the casing and tighten it to the specified tightening torque.
3) Tighten adjusting screw (606-201) and lock nut (606-301) to the specified tightening torque.
8. Assembling relief valve
Tighten main relief valve (601) and port relief valves (602), (603) and (604) to the specified tightening torque at
each place.
14
Port relief valves (602), (603) and (604) have the same external appearance, so be careful not to choose a wrong
part by seeing the identification tags attached at the time of disassembling.
9. Assembling boom 3 spool

1) Fix the central portion of boom 3 spool (313) to the vise applying a protection plate (aluminum plate and the
like) in between them, attach spring seat (331), springs (320) and (322), and stopper (336), and tighten bolt
(333) to the specified tightening torque.
• In tightening bolt (333), apply Loctite #262 to it.
• Be careful not to fasten the vise excessively to the extent boom 3 spool (313) is deformed.
2) Assemble the boom 3 spool assembly described in (1) into casing A (101).
Assemble the boom 3 spool assembly into the casing A (101) carefully and slowly and never push it in forcefully.
14-125
3) Install spring cover (202) with O-ring (261) installed to the spring side of the boom 3 spool assembly, and
tighten socket bolt (273) to the specified torque.
10. Assembling P2 unload spool
1) Fix the central portion of P2 unload spool (310) to the vise applying a protection plate (aluminum plate and
the like) in between them, attach spring seat (331), springs (327) and (329), and stopper (336), and tighten
bolt (333) to the specified torque.

• Be careful not to fasten the vise excessively to the extent P2 unload spool (310) is deformed.
2) Assemble P2 unload spool assembly described in 1) into casing A (101).
Assemble the P2 unload spool assembly into casing A (101) carefully and slowly and never push it in forcefully.
3) Attach spring cover (202) with O-ring (261) installed to the spring side of the P2 unload spool assembly, and
11. Assembling travel straight spool
1) Fix the central portion of travel straight spool (307) to the vise applying a protection plate (aluminum plate
and the like) in between them, attach spring seat (331), springs (327) and (329), and stopper (336), and
tighten bolt (333) to the specified torque.

• Be careful not to fasten the vise excessively to the extent travel straight spool (307) is deformed.
2) Assemble the travel straight spool assembly described in 1) into casing B (102).
Assemble the travel straight spool assembly into casing B (102) carefully and slowly and never push it in forcefully.
3) Attach spring cover (202) with O-ring (261) installed it to the spring side of the travel straight spool
assembly, and tighten socket bolt (273) to the specified torque.
12. Assembling arm 2 spool
1) Fix the central portion of arm 2 spool (308) to the vise applying a protection plate (aluminum plate and the
(333) to the specified torque.

• Be careful not to fasten the vise excessively to the extent arm 2 spool (308) is deformed.
2) Assemble the arm 2 spool assembly described in 1) into casing B (102).
14-126
Assemble the arm 2 spool assembly into casing B (102) carefully and slowly and never push it in forcefully.
3) Attach spring cover (201) with O-ring (261) installed to the spring side of the arm 2 spool assembly, and
13. Assembling arm 1 spool
1) Fix the central portion of arm 1 spool (302) to the vise applying a protection plate (aluminum plate and the

• Be careful not to fasten the vise excessively to the extent arm 1 spool (302) is deformed.
2) Assemble the arm 1 spool assembly described in 1) into casing A (101).
Assemble the arm 1 spool assembly into casing A (101) carefully and slowly and never push it in forcefully.
3) Attach spring cover (201) with O-ring (261) installed to the spring side of the arm 1 spool assembly, and
14. Assembling bucket spool
1) Fix the central portion of bucket spool (304) to the vise applying a protection plate (aluminum plate and the

• Be careful not to fasten the vise excessively to the extent bucket spool (304) is deformed.
14
2) Assemble the bucket spool assembly described in 1) into casing B (102).
Assemble the bucket spool assembly into casing B (102) carefully and slowly and never push it in forcefully.
3) Attach spring cover (209) with O-ring (261) installed to the spring side of the bucket spool assembly, and
4) Assemble piston (216) into spring cover (209), attach O-ring (164) to plug (551), and then tighten it with the
specified tightening torque.
15. Assembling swing spool
1) Fix the central portion of swing spool (303) to the vise applying a protection plate (aluminum plate and the
14-127

• Be careful not to fasten the vise excessively to the extent swing spool (303) is deformed.
2) Assemble the swing spool assembly described in 1) into casing A (101).
Assemble the swing spool assembly into casing A (101) carefully and slowly and never push it in forcefully.
3) Attach spring cover (201) with O-ring (261) installed to the spring side of the swing spool assembly, and
16. Assembling boom spool
1) Fix the central portion of boom spool (301) to the vise applying a protection plate (aluminum plate and the

• Be careful not to fasten the vise excessively to the extent boom spool (301) is deformed.
2) Assemble the boom spool assembly described in 1) into casing B (102).
Assemble the boom spool assembly into casing B (102) carefully and slowly and never push it in forcefully.
3) Attach spring cover (203) with O-rings (261) and (266) installed to the spring side of the boom spool
assembly, and tighten socket bolt (273) to the specified torque.
17. Assembling boom 2 spool
1) Fix the central portion of boom 2 spool (312) to the vise applying a protection plate (aluminum plate and the

• Be careful not to fasten the vise excessively to the extent boom 2 spool (312) is deformed.
2) Assemble the boom 2 spool assembly described in 1) into casing A (101).
Assemble the boom 2 spool assembly into casing A (101) carefully and slowly and never push it in forcefully.
3) Attach spring cover (202) with O-ring (261) installed to the spring side of the boom 2 spool assembly, and
18. Assembling boom conflux spool
14-128
1) Fix the central portion of boom conflux spool (305) to the vise applying a protection plate (aluminum plate
and the like) in between them, attach spring seat (331), springs (325) and (326), and stopper (339), and
tighten bolt (333) to the specified torque.

• Be careful not to fasten the vise excessively to the extent boom conflux spool (305) is deformed.
2) Assemble the boom conflux spool assembly described in 1) into casing A (101).
Assemble the boom conflux spool assembly into casing A (101) carefully and slowly and never push it in forcefully.
3) Attach spring cover (201) with O-ring (261) installed to the spring side of the boom conflux spool assembly,
and tighten socket bolt (273) to the specified torque.
19. Assembling travel spools (travel left and right spools)
1) Fix the central portion of travel spool (306) to the vise applying a protection plate (aluminum plate and the

• Be careful not to fasten the vise excessively to the extent travel spool (306) is deformed.
2) Assemble the travel spool assembly described in 1) into casing A (101) or casing B (102).
Assemble the travelspool assembly into casing A (101) or casing B (102) carefully and slowly and never push it in
forcefully.
3) Attach spring cover (202) with O-ring (261) installed to the spring side of the travel spool assembly, and
14
20. Assembling P1 unload spool
1) Fix the central portion of P1 unload spool (309) to the vise applying a protection plate (aluminum plate and
the like) in between them, attach spring seat (331), springs (327) and (329), and stopper (336), and tighten
bolt (333) to the specified torque.

• Be careful not to fasten the vise excessively to the extent P1 unload spool (309) is deformed.
2) Assemble the P1 unload spool assembly described in 1) into casing A (101).
Assemble the P1 unload spool assembly into casing A (101) carefully and slowly and never push it in forcefully.
14-129
3) Attach spring cover (202) with O-ring (261) installed to the spring side of the P1 unload spool assembly, and
21. Assembling spool covers
1) Travel, boom, bucket, swing, and arm 1
Attach O-ring (264) to spool cover (205), and tighten socket bolt (273) to the specified torque.
2) Arm 2
Attach O-ring (264) to spool cover (210), and tighten socket bolt (273) to the specified torque.
14.4.2.5 MAINTENANCE STANDARD OF CONTROL VALVE
Part Inspection
Part Name Inspection Item Criterion and Measures
Casing Existence of scratches, rust, or corrosion In case damage occurs at portions below,
correct them or replace casing.
• Sliding portion of casing hole and spool, in
particular, land where holding pressure is
applied
• Sealing portions contacting with O-rings
• Sealing portions and seats of main and port
relief valves
• Seats and sliding portions of poppets
• Sealing portions of plugs
• Other damages likely to cause malfunctions
Spool Existence of scratches, galling, rust, or In case scratches are felt by your nails at
corrosion peripheral sliding portion (in particular, portions
contacting seals), replace spool.
Insert spool into casing hole, and rotate it to In case spool movement is not smooth, correct
confirm smooth stroke. or replace it.
Poppet In case spring has damage, replace it.

Damage of poppet and spring In case poppet seat and sliding portions have
damage, correct or replace them.
Insert poppet into casing, and operate it. Poppet is normal if it moves lightly and
smoothly without sticking.
Spring and related parts Rust, corrosion, deformation, and breakage of Replace severely damaged parts
spring, spring seat, stopper, spacer bolt, and
cover
Main relief valve External rust and breakage Replace if required
Port relief valve
Valve seat contact face Replace if damage is found
Bypass cut valve
O-ring Replace in principle
(Sealing portion contacting with casing)
Troubleshooting
• In case an abnormal phenomenon has been found, check if it is a failure of the control valve itself or a matter of
the pump body or the circuit. To check this, measurement of the pilot pressure, pump delivery pressure, and load
pressure, etc. is necessary. In case disassembled inspection is made even partially, follow the disassembling
and assembling procedures described above.
• Dust is very harmful to the hydraulic components, so be very careful about dust prevention. In case even a part
of the component is disassembled, perform it by taking dust prevention measures.
• Handle movable parts carefully. If they are damaged even slightly, correct the damage with an oil stone or
something.
• Work carefully not to damage the gasket surfaces of the O-rings. These damages are sure to cause oil leakage.
14-130
Control Valve
Phenomenon Possible Cause Remedy
Travel or swing Malfunction of main relief valve Pressure measurement of main relief valve
operations cannot be • Foreign materials between main poppet and • Disassembling, cleansing, and replacement
made. seat of assembly if damage is severe
Slow operation
• Foreign materials between poppet and seat • Same as above
(insufficient power) or
slow response • Sticking of main poppet • Replacement of assembly
• Breakage or permanent set in fatigue of • Replacement of assembly
spring
• Clogging of main poppet orifice • Replacement of assembly
• Loosening of adjusting screw • Readjustment and tightening of lock nut to
specified torque
Bypass cut valve seat failure Tightening of adjusting screw of bypass cut
(When electric control system is normal) valve
Simultaneous operation Malfunction of travel straight spool Measurement of pilot secondary pressure
of travel and other • Sticking of spool • Correction of sticking portion by oil stone or
attachments causes replacement of spool
travel deviation
• Breakage or permanent set in fatigue of • Replacement of spring
spring
• Excessive clearance between casing and • Replacement of spool
spool
Malfunction of main relief valve Replacement of main relief valve
Cylinder falls significantly Excessive clearance between casing and Replacement of spool
by its own weight with spool
spool in neutral position
Incomplete return of spool to neutral Measurement of pilot secondary pressure
• Foreign materials or sticking between • Disassembling, cleansing, correction by oil
casing and spool stone, or replacement of spool
• Breakage or permanent set in fatigue of • Replacement of spool
spring
• Clogging of pilot circuit • Removing of foreign materials
Malfunction of port relief valve Pressure measurement of port relief valve

(See "Inspection after disassembling") (See "Inspection after disassembling")
• Foreign materials between seats of casing • Removing of foreign materials and check of 14
and valve scratches at seat
Malfunction of lock valve selector (arm and Replacement of lock valve selector
boom)
• Foreign materials between casing and • Disassembling and cleansing
poppet
• Sticking of poppet • Correction of sticking by oil stone or
replacement of spool
spring
• Sticking of selector spool • Replacement of lock valve selector
assembly
14-131
Attachment/equipment Malfunction of load check valve

falls even when operating • Foreign materials between poppet and • Disassembling and cleansing, and if
cylinder for moving up casing correction of seat damage of casing is
operation impossible, replacement of control valve
• Sticking of poppet • Correction of sticking by oil stone or
replacement of poppet
spring
Bucket, boom, and arm, Malfunction of main spool Measurement of pilot secondary pressure
and swing operations are • Excessive clearance between casing and • Replacement of spool
impossible spool
Slow operation
• Foreign materials between casing and spool • Disassembling and cleansing
(insufficient power) or
slow response • Sticking of spool • Correction of sticking by oil stone or
return spring
• Clogging of pilot circuit • Removing of foreign materials
Malfunction of main relief valve Pressure measurement of main relief valve

Malfunction of port relief valve Pressure measurement of port relief valve

Boom conflux operation is Malfunction of conflux spool Measurement of pilot secondary pressure
impossible. • Excessive clearance between casing and • Replacement of spool
spool
• Sticking of spool • Correction of sticking by oil stone or
return spring
• Sticking of conflux check valve poppet • Correction of sticking by oil stone or
replacement of poppet
Relief Valve
Pressure does not rise at Relief valve remains open due to sticking of Checking for catching foreign materials
all main plunger or pilot poppet, or foreign Main plunger and seat must slide smoothly
materials at valve seat Replacement of assembly if failure is found
Unstable pressure Damaged seat of pilot poppet of relief valve Replacement of assembly
Incorrect pressure setting Wear due to dust Replacement of assembly
Loosened lock nut and adjusting screw Pressure adjustment
Oil leakage Check of smooth sliding between main plunger

and seat
Damage of seat Replacement of assembly if required
Wear of O-ring
Sticking of main plunger and seat due to dust Checking for scratches or foreign materials
Replacement of assembly if failure is found
14-132
14.4.3 PILOT VALVE (ATT)

14.4.3.1 SECTIONAL ASSEMBLY DRAWING OF PILOT VALVE (ATT)
312
M14
Apply Loctite #262 68.6±4.9 N .m
Application part (hatched area) (50.6±3.61 lbf .ft)
302
501 301
Apply grease on
Apply grease rotating and sliding sections.
on top section 246-1 Be careful the
212 assembling direction
246-2 213 M14
151 47.1±2.9 N .m
(34.7±2.14 lbf .ft)
218
211
214
216-2 216-1
241-2 241-1
201-2
Secondary 201-1
pressure 217
adjusting shim
101 221
POR T 2,4 POR T 1,3
Sectional view of pilot valve
torque torque
No NAME Q'TY No NAME Q'TY
N･･m N･･m
(lbf･･ft) (lbf･･ft) 14
101 Casing 1 218 Seat 4
201-1 Spool 2 241-1 Spring 2
201-2 Spool 2 241-2 Spring 2
211 Plug 4 246-1 Spring 2
212 Push rod 4 246-2 Spring 2

47.1
213 Seal 4 301 Joint: M14 1
(34.7)
214 O-ring: 1B P20 4 302 Circular plate 1

68.6
216-1 Spring seat 2 312 Adjust nut: M14 1
(50.6)
216-2 Spring seat 2 501 Cover 1
217 Washer 2 (Shim) 4
14-133
14.4.3.2 DISASSEMBLING PILOT VALVE (ATT)

1. Plug each port of pilot valve, and clean it with kerosine.
P port: PF1/4
1 to 4 and T port: PF3/8
2. Fix the pilot valve to a vise and remove cover (501).
501
Removing cover (501)
3. Remove adjusting nut (312) applying spanners to

adjusting nut (312) and circular plate (302).
Tools: Spanner: 22 mm, 32 mm 312
302
Removing adjusting nut (312)
4. Remove circular plate (302)

Tools: Spanner: 32 mm 302
Removing circular plate (302)
14-134
Circular plate is removed
5. Turn joint (301) in counterclockwise with Jig A to

remove.
Jig (A): See Paragraph "JIG FOR PILOT VALVE
(ATT)".
Installing Jig A
JI G A
301
14
Removing joint (301)
When the force of return springs (221) is strong, never loosen joint (301). If loosened, it might result in jumping out
of plate (151), plug (211) and push rod (212).
Remove joint (301) pressing plate (151) downward with two fingers.
14-135
6. Removing plate (151)

• When the force of return springs (221) are strong,
press plate to let it come up slowly. 151
Removing plate (151)
• When the force of return springs (221) are weak, plug

(211) is left in casing (101) due to sliding resistance of
O-ring (214).
Tools: Pull plug (211) out with a driver.
211
Removing plug (211)
To prevent personal injury, plug (211) must be removed slowly and evenly until the return spring (221) force is
completely released.
7. Remove push rod (212), plug (211), pressure

reducing valve assy (spool), return springs (221)
from casing (101). 212
211
221
101
Removing push rod, plug, pressure reducing valve

and spring
14-136
Record combination of port holes on casing and the pulled out parts. The stroke differs according to direction.
8. Push springs (241-1), (241-2) in the range of 7 mm

(0.28 inch) that the movement of spring seats (216- 216-1
1), (216-2) and shift the seats (216) in a side or 216-2
direction, and remove spools (201-1), (201-2)
through the larger hole of seat.
201-1
or 201-2
Removing spool (201)
Never push down spring seat (216-1) in 7 mm (0.28 inch) or more. (For port 1,3)
Never push down spring seat (216-2) in 9.4 mm (0.37 inch) or more. (For port 2,4)
9. Remove spool (201-1), (201-2), spring seats (216-

1), (216-2), spring (241-1), (241-2) and washer 241-1 216-1
(217). or 241-2 or 216-2
217
201-1
or 201-2
14
Disassembling pressure reducing valve
10. Remove spring (246-1), (246-2), spring seat (218),

from push rod (212). 246-1
246-2 214
218
212
211
Disassembling push rod
14-137
11. Pull out push rod (212) from plug (211).
212
Removing push rod (212)
12. Remove O-ring (214) from plug (211).

13. Remove inside seal (213) from plug (211) with small
driver.
213
Removing seal (213)
14.4.3.3 WASHING OF PILOT VALVE (ATT) PARTS

1. Clean parts with wash oil roughly.
2. Clean parts with wash oil completely.
3. Dry parts by swabbing clean rag.
4. Apply rust preventives on parts.
14-138
14.4.3.4 ASSEMBLING PILOT VALVE (ATT)

1. Fit washer 2 (217), springs (241-1), (241-2), spring
seats (216-1), (216-2) to spool (201-1), (201-2). 201-1 241-1 216-1
or or or 216-2
201-2 241-2
217
Assembling pressure reducing valve
2. Push spring seat (216-1) within 7mm (0.28 inch) and

insert the head of spool (201-1) through the larger 216-1
hole of the spring seat to assemble it. or 216-2
(See Fig. "Removing spool (201)")
In case of spring seat (216-2), push it within 9.4 mm
(0.37 inch) to assemble spool (201-2).
201-1
or 201-2
Installing spools (201-1), (201-2)
Never push down spring seat (216-1) in 7 mm (0.28 inch) or more. (For port 1,3)
Never push down spring seat (216-2) in 9.4 mm (0.37 inch) or more. (For port 2,4)
3. Place spring (221) into ports 1,3 of casing (101),

14
and then install pressure reducing valve assy in it. PRESSURE REDUCING
VALVE ASSY
Place springs (221) into ports 2,4 of casing (101),
and install it.
221
101
Installing pressure reducing valve assy
14-139
4. Fit O-ring (214) and seal (213) into plug (211).

PLUG (211)
• Apply hydraulic oil on surface of push rod. SEAL (213)
‚n -RING (214)
PUSH ROD
(212) Apply hydraulic oil
For the assembling

direction of seal (213).
211
214 213
Installing O-ring (214) and seal (213)
5. Insert push rod (212) in plug (211) and install spring

(246-1) and spring seat (218) to push rod (212) on
port 1,3 side.
Insert push rod (212) in plug (211) and install spring
(246-2) and spring seat (218) to push rod (212) on
port 2, 4 side.
246-1
212 211 246-2 218
Assembling push rod, spring (246-1), (246-2) and

seat (218)
14-140
6. Fit plug (211) assy to casing (101).

1) When the force of spring (211) is weak, it stops at
the position where it is pushed in by the sliding
resistance of O-ring (214).
101 211
Installing plug assy
2) When the force of spring (221) is strong, attach

plate (151) and press 4 push rods by hand at the 301
same time, and tighten joint (301) temporarily.
151
Installing plug assy and plate (151)
• Install spool (201) straight and evenly into the hole of casing (101).
• Take care so that plug (211) and plate (151) do not jump out of casing (101).
7. Install joint (301) on casing (101) with jig A securely.
Jig (A): See Paragraph "JIG FOR PILOT VALVE
(ATT)".
Tightening torque : 47.1N·m (34.7 lbf·ft) 14
101
JI G A
Installing joint (301)
14-141
8. Install circular plate (302) to joint (301)
312
302
Installing circular plate (302)
9. Screw adjusting nut (312) in until it touches circular plate (302), and tighten it applying spanner to stop circular
plate returning.
• Apply Loctite #277 to threads of joint.
Tightening torque: 68.6N·m (51 lbf·ft)
– Screw it in until it comes in contact with 4 push rods (212) equally.

– The exceeding of screw in may cause malfunction of machine.
10. Apply heat-resisting grease to joint (301) rotating

section and the top of push rod (212).
GREASE
301
212
Applying grease to joint section and push rod
11. Cover it with boots.

12. Spray rust preventives through each port and attach plug respectively.
14-142
14.4.3.5 MAINTENANCE STANDARD OF PILOT VALVE (ATT)

Check item Standard Remarks
When leakage quantity reaches to 1000 cc/min.
(61 cu·in/min) or more where handle is set in
neutral position, or to 2000 cc/min. (122 cu·in/ Conditions
Leakage min) or more in operation, replace spool with new Primary pressure 2.94 MPa (426 psi)
one. Hydraulic oil viscosity 23 cSt
If leaked, even if the spool is replaced, replace
pilot valve assy with new one.
When the wear of sliding section is 10 μm

Spool (0.0004 inch) more than the that of non sliding This condition may be the same as the above.
section, replace it with new one.
Push rod When the wear of top is 1 mm (0.04 inch) or more, replace it with new one.
When looseness of 2 mm (0.08 inch) or more on

Looseness of control circular plate (302) on control section and joint In case of the looseness due to the loosening on
section section (301) due to wear is pro-duced, replace tightening section, adjust it.
them with new ones.
In case abnormal noise, hunting, or decrease of
the primary pressure occurs during operation
and it cannot be returned to a normal condition
Stability of operation -
even though measures in
"TROUBLESHOOTING OF PILOT VALVE (ATT)"
are taken, replace the pilot valve assembly.
• O-ring, etc. should be replaced with new one at every disassembling.

• If socket bolt (125) was loosened, seal washer (121) should be replaced.
14.4.3.6 TROUBLESHOOTING OF PILOT VALVE (ATT)

It is very difficult to find defective section. The following table explains the several estimated causes. For repair,
refer to the estimated causes and corrective actions.
The following table explains general phenomenon, estimated causes and corrective actions. However, most
machine problems are not caused by the failure of only one part, but involve relations with other parts. Therefore
corrective action other than those described in this table is often required.
The following table does not cover causes and corrective actions for all the troubles. So it may be necessary to 14
perform further investigation of troubles and causes.
Phenomenon Possible Cause Corrective action

Primary pressure is insufficient. Secure primary pressure.
Secondary pressure springs (241) are broken or fatigued. Replace with new ones.
Secondary pressure Clearance between spool (201) and cas-ing (101) is Replace spool (201).
does not rise. abnormally large.
Handle has a looseness. Disassembly and reassembly or

replace handle section.
Sliding parts are caught. Repair the unsmoothed section.
Secondary pressure is Tank line pressure varies. Bring pressure directly to oil tank.
unstable.
Air has mixed into pipeline. Bleed air by operating it several
times.
Secondary pressure is Tank line pressure is high. Bring pressure directly to oil tank.
high. Sliding parts are caught. Correct.
14-143
14.4.3.7 JIG FOR PILOT VALVE (ATT)
Jig for removing and installing joint (301)
(1.14”)
(1)
Material ; SCM415 (N)
(1.04”) Carburizing and Quenching
(0.93”) (2) BUSHING
Material ; S45C (0.51”)
SECTION AA
(0.75”)
(2.72”)
(2.13”)
(1.97”)
(1.81”)
(0.98”)
A A
(0.67”)
(0.91”)
(1.06”)
(1.22”)
Installing condition on joint
(0.63”) * (1) and (2) are tight fitted

”) 1
(0 .5
Sectional drawing of jig

(0.02”)
(0.26”)
(0.61”)
(0
.
23
(0 .
”)
18 (0.02”)
”)
(0.49”)
(0.37”)
(0.02”)
Material ; SCM415 (N)
(0.46”) Carburizing and Quenching
Q'ty ; 2
Detail of bushing
14-144
14.4.4 PILOT VALVE (FOR TRAVEL)

14.4.4.1 CONSTRUCTION OF PILOT VALVE (TRAVEL)
T=Tighte ning torque
N .m (lbf.ft) 12-o
12-o
7-h
12-o
12-y
5 12-y
12-x 12-x
13
6 8
f
d
Loctite 262 10
g
T=3 (2.2)
g
14
q 11
T=5 r 15
(3.7)
u
t T=4 (3)
7-i T=30 (22)
15
7-k T=1.2 (0.9)
7-h u
15 t T=4 (3)
7-j t 14
u
r
q
17 21 T=5 (3.7)
Loctite 262 21
21
z
r 21
w' T=3-5 (2.2-3.7)
Exploded view of pilot valve

14
14-145
No. Parts Q'ty No. Parts Q'ty
5 Rubber boots 2 12-x Seal ø14 X 20 X 3 6

6 Foot pedal (Switch plate) (2) 12-y Wiper ring 6
6-d Switch plate 2 13 Damper spring 4
6-f Regulation screw M8 X 28 4 14 Check valve kit (2)
6-g Set screw M5 X 8 4 14-q Plug M8 2
7 Retaining plate kit (1) 14-r Ball M6, 35 2
7-h Plate 1 15 Orifice (4)
7-i Capscrew M10 X 20 2 15-u Plug M6 4

7-j Shaft 2 15-t Orifice M6 4
7-k Set screw M4 X 10 2 17 Shuttle valve kit (2)
8 Flange kit 4 17-w' Shuttle valve & orifice 2
10 Control spool 4 17-r Ball M6, 35 2
11 Return spring 4 17-z Orifice M5 2
12 Damper flange kit (4) 21 Plug 4
12-o Damper plunger ø14 4
14-146
14.4.4.2 DISASSEMBLING AND ASSEBMLING PILOT VALVE (TRAVEL)
Boot replacement
The pilot control unit does not need to be removed from the machine to perform this operation.
1. Remove both faulty boots.

(using a flat screw driver if necessary) S w itc h p la te
R e ta in in g p la te
Boot replacement
2. Replace both boots with a new one.

Reassembly:
1) First fit the lower part of the rubber boot on the retaining plate between the 2 switch plates
2) Then put the lower part in the external groove of the retaining plate
3) Finish by fitting the upper part of the rubber boot on the switch plate. 14
14-147
14.4.4.3 Switch plate removal

1. Preparation for removal
1) The pilot control unit from the machine. 2
2) Both rubber boots (See the paragraph "Boot
replacement")
1 L o c k in g s c r e w
3 A x is h o le
S w itc h p la te
a x is
4 5
Switch plate removal
2. Remove the screw locking the axis using a 2mm socket wrench. (See No. 1 of Fig. "Switch plate removal")
Reassembly:
1) Apply a droplet of Loctite #262 on the locking screw thread.
2) Tightening torque: 1.2N·m (0.9 lbf·ft)
3. Fit a M3 screw on the switch plate axis in order to remove it
(Using pliers if necessary). (See No. 2 of Fig. " Switch plate removal")
Reassembly:
Position the axis so that the hole is aligned with the locking screw as shown on the picture (See No. 3 of Fig. "
Switch plate removal")
4. Mark out the position of the switch plate before removing it.
5. Repeat the operation for the second switch plate.
6. Reassemble parts in reverse order.
14-148
14.4.4.4 Switch plate adjustment
If the switch plate is replaced, it is necessary to adjust the regulation screws.
1. Unscrew the 2 locking screws using a 2,5mm socket

wrench (See Fig. "Switch plate adjustment")
Reassembly:
1) Apply a droplet of Loctite #262 on the locking
screw thread.
2) Tightening torque: 3N·m (2.2 lbf·ft)
S c r e w s lo c k in g
th e r e g u la tio n
s c re w s
Switch plate adjustment
2. Set the switch plate horizontally.

3. Screw on simultaneously both regulation screws using a flat screw driver (5,5 X 150) until feeling some
resistance.
Do not misadjust the two damping screws. (See Fig. "Switch plate (seeing from backside)")
4. Tighten the locking screws to hold the regulation

screws in position.
14
Regulation Damping screws
screws to already adjusted
adjust and glued
SWITCH PLATE
The figure is shown
from the backside.
Switch plate (seeing from backside)
5. Repeat the operation for the second switch plate making sure both switch plates are parallel.
14-149
14.4.4.5 Retaining plate removal

1) The pilot control unit from the machine.
replacement")
3) Both switch plates (See Paragraph "Switch plate
removal")
Retaining plate removal
2. Unscrew simultaneously both screws holding the retaining plate using a 8mm socket wrench.
(See Fig. "Retaining plate removal")
Reassembly:
1) Apply a droplet of Loctite #262 on the screw thread.
2) Tightening torque: 30N·m (22 lbf·ft)
3. Lift the retaining plate to remove it. (See Fig.
"Condition with retaining plate removed")
Reassembly :
Use the retaining plate to insert the 4 guides into the
body simultaneously and perpendicularly. (See Fig.
"Condition with retaining plate removed")
Condition with retaining plate removed

5. Drain the pilot control unit (See the after-mentioned Paragraph "DRAIN OF HYDRAULIC PILOT CONTROL
UNIT").
14-150
14.4.4.6 Damping plunger seals replacement

2) Both rubber boots. (See the paragraph "Boot
replacement")
removal")
4) The retaining plate (See Paragraph "RETAINING
WIPER RING
PLATE REMOVAL".)
1 2 DAMPER PLUNGER
2. Remove the wiper ring of the damping plunger.

(See No. 1 of Fig. "Damping plunger seals R E T A IN IN G P L A T E
replacement")
Reassembly:
Replace with a new wiper ring. W IP E R R IN G
S E A L
D A M P IN G P L U N G E R
T H 6 N R B O D Y
D A M P IN G S P R IN G
Damping plunger seals replacement
3. Remove the damping plunger.

(See No. 2 of Fig. "Damping plunger seals replacement")
Always place the damping plunger prior to the wiper ring, and make sure the wiper ring is correctly positionned.
4. Using a needle, remove the seal placed inside the R e m o v e s e a l S E A L

body (See No. 3 and 4 of Fig. "Damping plunger u s in g n e e d le
seals replacement")
Reassembly :
14
Replace with a new seal and grease it.
3 4 B O D Y
14-151
1) Squeeze the seal between your fingers to obtain

a 8-shape. (See No. 5 of Fig. "Damping plunger
seals replacement")
5 6
7 8
Damping plunger seals replacement
2) Insert the seal within the groove with your fingers (lip in bottom position). (See No. 6 and 7 of Fig. "Damping
plunger seals replacement")
3) Push the seal against the side using the round head of a small socket wrench. (See No. 8 of Fig. "Damping
plunger seals replacement")
5. Repeat the operation for the other 3 assemblies.
6. Extract the damping springs from the body (using flat nose pliers).
7. Inspect the damping springs. If defects are detected, replace the 4 springs.
During the reassembly, make sure the seal is correctly positionned, and pay attention not to damage nor twist it.
14-152
14.4.4.7 Guide/plunger and regulation unit replacement

replacement")
removal")
D A M P E R
4) The retaining plate (See Paragraph "RETAINING P L U N G E R
PLATE REMOVAL".)
B O D Y
Guide/plunger assembly replacement
2. Guide/plunger replacement
Insert the end of a thin screwdriver between the guide and the body, carefully lift the guide to remove it from the
body.
3. Remove the guide / plunger assembly.
14
4. Repeat the operation for the other 3 sub-assemblies.
5. Visually check that the guides / plungers are in good condition. If defects are present, replace the 4 sub-
assemblies.
Hold the guides with the other hand during the extraction operation to limit the effect of the return spring.
14-153
6. Regulation unit replacement

1) Extract the regulation units from the body.
2) Inspect the regulation units. If defects are
detected on the parts, replace the 4 units.
Regulation unit replacement
7. Return spring replacement

1) Extract the return springs from the body.
2) Inspect the return springs. If defects are
detected, replace the 4 springs.
Return spring replacement
14-154
14.4.4.8 Throttle kit replacement

1) The pilot control unit from the machine
replacement")
removal")
4) The retaining plate (See Paragraph "RETAINING
PLATE REMOVAL".)
5) The damping plungers and springs (See
Paragraph "DAMPING PLUNGER SEALS
REPLACEMENT")
SCREW
THROTTLE
Throttle kit replacement
2. Unscrew the screw using a 3mm socket wrench. (See Fig. "Throttle kit replacement")
Reassembly:
1) Apply a droplet of Loctite #262 on the screw thread.
2) Screw on until it sets just above the body. (See Fig. "Throttle kit replacement")
3. Unscrew the throttle using a 3mm socket wrench.
Reassembly:
4. Repeat the operation for the other 3 assemblies.
5. Replace with new screws and new throttles.
14
14-155
14.4.4.9 Shuttle valve kit removal
The pilot control unit does not need to be disassembled to perform this operation.
1. Remove the pilot control unit from the machine
Shuttle valve kit removal
2. Unscrew the shuttle valve using a 4mm socket wrench. (See Fig. "Shuttle valve kit removal")
Reassembly:
1) Thoroughly clean the body to remove any trace of loctite.
2) Apply a droplet of Loctite #242 on the shuttle valve thread.
Wait for 8 hours before using the machine to let the Loctite #242 dry completely.
14-156
3. Put the body up-side-down to remove the shuttle

valve and the ball.
Shuttle valve kit
4. Unscrew the throttle using a 2,5mm socket wrench.

Reassembly:
Hand tighten.
5. Repeat the operation for the other subassemblies.
6. Inspect the shuttle valves, balls and throttles. If
defects are detected, replace all the assemblies. B A L L T H R O T T L E
S H U T T L E V A L V E
Inspection of shuttle valve, ball, and throttle
14
14-157
14.4.4.10 Check valve kit removal
The pilot control unit does not need to be disassembled to perform this operation.
1. Remove the pilot control unit from the machine

2. Unscrew the check valve plug using a 4mm socket
wrench. (See Fig. "Check valve kit removal")
Reassembly:
Drain the pilot control unit (See Paragraph "DRAIN
OF HYDRAULIC PILOT CONTROL UNIT")
Tightening torque: 5N·m (3.7 lbf·ft)
Check valve kit removal
3. Put the body up-side-down to remove the ball.

4. Repeat the operation for the second check valve kit.
5. Inspect the check valve plugs, O-rings and balls. If
defects are detected, replace all the assemblies.
(See Fig. "Inspection of check valve, O-ring, and
ball")
C H E C K V A L V E
P L U G
B A L L
Inspection of check valve, O-ring, and ball
14-158
14.4.4.11 DRAIN OF HYDRAULIC PILOT CONTROL UNIT

1. When removing the retaining plate, the throttle kit or
the shuttle valve kit, it is necessary to drain the pilot
unit.
Check valve plug removal
2. Reassemble the pilot unit control completely.

3. Install the pilot unit control in the machine.
4. Slightly unscrew the check valve plug using a 4mm socket wrench. (See Fig. "Check valve plug removal")
5. Switch on the machine.
6. Operate gently the pedal until the bubbles disappear.
7. Tighten the check valve plug.
Tightening torque: 5N·m (3.7 lbf·ft)
8. Repeat the operation for the other check valve plug.
14
14-159
14.4.5 SWING MOTOR UNIT

14.4.5.1 ASSEMBLY DRAWING OF SWING MOTOR UNIT
Swing motor
993
390 391
VIEW I
351
355
051
(051-1)
469
702
488
401 712
151
171 161 163 985 444 984 131
052
A A
I Arrangement of brake spring
162
451
303
985
472
707 712
702
980
706 743
100
111
742
121
400-1
123 994
052
400-2
122 400
124 443 491 101 114 301 SECTION A-A
14-160
torque torque
N·m N·m
(lbf·ft) (lbf·ft)
177 69 Anti-reaction valve ; M22-

51 Relief valve ; M33-P1.5 2 400 2
(131) (51) P1.5
051-1 O-ring ; 1B G30 2 400-1 O-ring ; 1B P20 2
52 Anti-reaction valve sub 1 400-2 Backup ring 2

430
100 Casing for anti-reaction 1 401 Socket bolt ; M20 X 45 4
(317)
101 Drive shaft 1 443 Roller bearing 1
111 Cylinder 1 444 Roller bearing 1
114 Spring plate 1 451 Pin 2

334
121 Piston 9 469 ROMH plug ; M30-P1.5 2
(246)
122 Shoe 9 472 O-ring ; W1516,WG40 1
123 Set plate 1 488 O-ring ; 1B P28 2
124 Shoe plate 1 491 Oil seal 1
131 Valve plate 1 702 Brake piston 1

36
151 Plug ; PF1/4 2 706 O-ring ; W1516,WG38 1
(27)
161 O-ring ; 1B P11 2 707 O-ring ; W1516,WG41 1
162 O-ring ; 1B P12 2 712 Brake spring 18
163 O-ring ; 1B P6 2 742 Friction plate 3

29
171 Socket bolt ; M8 X 55 4 743 Separator plate 4
(21)
0.9
301 Casing 1 980 Plug ; PF1/4 1
(0.7)
1.7
303 Valve casing 1 984 Plug ; PF3/8 1
(1.3)
4.4
351 Plunger 2
(3.2)
985 Plug ; PF3/4 3
14
65
355 Spring 2 993 Plug ; PT1/2 1
(48)
98
390 Name plate 1 994 Plug ; PT3/4 1
(72)
391 Rivet 2
14-161
Swing reduction unit

Be careful about installation
direction of retaining ring.
Apply Three
Bond #1211. Apply Loctite #515.
Paint this machined surface. Apply Loctite #515.
Tightening torque
181 N .m (134 lbf .ft)
12 10 20 8 4 7 6 23 Apply Three Bond 1360K
OIL FILLING POR T P T3/4
A
2
LEVEL
POR T P T1/2
A
II
1 9 22 18 17 5 18 14 3 16 15 28 19
21 29 11
Be careful about
Insert 1mm(0.04") deep from installation direction
Lubricate grease.
the surface of Item 8 (spider). of retaining ring.
13 27 26 25
Wind seal tape around plug and
install it (tightening torque Wind seal tape around tube and install elbow to tube
10N .m (7 lbf .ft)) to item 26 elbow with tightening torque 30N .m (22 lbf .ft) and then make
until its surface becomes direction of elbow as shown in drawing by retightening.
the same surface of elbow end.
Wind the seal tape or
Install grease nipple apply the Locktite #577
as facing to motor side. 30 31 around the screw.
Tightening torque
10.8N .m (8.0 lbf .ft)
Leave installation angle as it is.
Punch here 2 portions to deform holes in order to
prevent spring pin (22) from coming out.
Be careful about installation direction

of pin and spring.
VIEW II
4 places
SECTION AA
14-162
torque torque
N·m N·m
(lbf·ft) (lbf·ft)
1 Pinion shaft 1 16 Roller 102

2 #1 sun gear 1 17 Needle bearing 4
3 #1 pinion 3 18 Thrust washer 8
4 #2 sun gear 1 19 Retaining ring 1
5 #2 pinion 4 20 Retaining ring 1
6 Ring gear 1 21 Sleeve 1
7 Spider assy 1 22 Spring pin 4
8 Spider 1 181 (134) 23 Capscrew ; M14 X 130 11
9 Shaft 4 25 Tube L=130mm (5.12 inch) 1
10 Spherical bearing 1 26 Elbow 1
11 Spherical bearing 1 10 (7) 27 Plug 1
12 Oil seal 1 28 Retaining ring 3
13 Housing 1 29 Oil seal 1
14 Thrust washer 3 30 Grease nipple 1
15 Thrust washer 3 31 Plug 1
14.4.5.2 DISASSEMBLING AND ASSEMBLING SWING MOTOR
14.4.5.2.1 TIGHTENING TORQUE FOR SWING MOTOR BOLTS

The tightening torque for the bolts used in the motor is shown in the table below. When assembling the parts, be
sure to tighten them by referring to the table below.
Table of tightening torque
Tightening torque
Thread size Name Item No. of applicable part
N·m (lbf·ft)
M8 Socket bolt 29 (21) 171
M20 Socket bolt 431 (318) 401 14

M22 X P1.5 Anti-reaction valve 69 (51) 400
M33 X P1.5 Relief valve 177 (131) 51
M30 X P1.5 ROMH plug 539 (398) 469
PF1/4 ROH plug 36 (27) 151
When parts are different from the above-mentioned parts with item No., see the sectional assembly drawing.
14-163
14.4.5.2.2 TOOLS FOR DISASSEMBLING AND ASSEMBLING SWING MOTOR

The tools required for disassembling and assembling are shown in the table below. Each type of tools is intended
for specific bolts and plugs so they are different in each type of tools. Check bolts and plugs before preparing tools.
Wrenches
Item No. of
Name Size Size Tool
applicable part
Socket bolt M8 6 171 Allen wrench

Socket bolt M20 17 401 Allen wrench
Hexagonal spanner, and
Anti-reaction valve M22 X P1.5 24 400
socket wrench
Hexagonal spanner, and
Relief valve M33 X P1.5 41 51
socket wrench
ROMH plug M30 X P1.5 14 469 Allen wrench
ROH plug PF1/4 6 151 Allen wrench
When plugs and bolts are different from the above-mentioned plugs and bolts, see the sectional assembly drawing.
Tool Size
Screw driver Middle-sized flat-head screwdriver, 2pcs.
Steel rod Approx. 10 X 8 X 200 mm (0.39 X 0.31 X 7.87 lbf·ft), 1pc.
Plastic hammer, 1pc.

Hammer
Iron ammer, 1pc.
Range of torque adjustment
·4.9 to 9.8N·m (3.6 to 7.2 lbf·ft)
Torque wrench ·9.8 to 44N·m (7.2 to 33 lbf·ft)
·39 to 177N·m (29 to 131 lbf·ft)
·118 to 470N·m (87 to 347 lbf·ft)
Slide hammer bearing puller
14-164
14
(0.55”)
85 (3.35”)
75 (2.95”)
30 (1.18”)
15
(0.59”)
35 (1.38”)
2 .5 )
R1 49”
0 .
(
M16
Through
100 (3.94”)
30 (1.18”)
(0.55”)
44 (1.73”)
14
8 (0.31”)
M16
(0.16”)
BRAKE PISTON
4
DRAWING TOOL
o8
(0.31”) BRAKE PISTON
CASING
Dedicated jig for brake piston removal
14
Tools
14-165
14.4.5.2.3 DISASSEMBLING SWING MOTOR
General precautions
• The hydraulic components are precise components and have small internal clearances between the parts, so
that perform disassembling and assembling works at a place where the amount of dust is small and clean. Use
each kind of tools and wash oil that are clean and be very careful about handling them.
• After removing the swing motor from the machine body, take sufficient care not to allow dust and water to enter
the inside, so clean the area around the ports carefully and plug them. In case of installing the swing motor to the
machine body, do not remove plugs until starting a piping work.
• Before starting work, consider the construction drawing and prepare required parts according to your objective
and a range of the work. Disassembled seals and O-rings are impossible to reuse.
Furthermore, some parts cannot be available as a single part, so that it needs to be replaced as a part of sub
assembly. Refer to the parts catalog and prepare the replacement part or sub assembly beforehand.
• The pistons and the cylinder block are already assembled in a new machine, so that if the pistons are to be
reused, make match marks when removing the pistons from the cylinder block.
Disassembling procedures
In case of disassembling the swing motor, disassemble it following the order below. The numbers inside the
parentheses ( ) following the part names show item numbers in the construction drawing of "Swing motor".
1. Wind a wire rope around the motor periphery, lift it by a crane, and wash it with kerosene. After washing it, dry it
with compressed air.
Mask each port by a tape, etc. to prevent foreign materials from entering inside the motor, and then wash adhered
soil and dust.
2. Drain the oil inside casing (301) from the drain port.
3. Place drive shaft (101) with the shaft end facing
downward on a workbench that is proper for easy
disassembling, and fix it to the workbench. At this
time, make match marks on the mating portions of
casing (301) and valve casing (303).
Fix swing motor to

appropriate workbench
for inversion
Select a clean place. Spread a rubber sheet or cloth on the workbench to prevent parts from being damaged.
14-166
4. Loosen socket bolts (171) and remove casing of

anti-reaction valve (100) from valve casing (303).
If necessary, remove anti-reaction valves (400) from casing of anti-reaction valve (100).
5. Loosen relief valves (051) and remove it from valve

casing (303).
Be sure to replace the O-rings of the relief valves because they are damaged when loosening the relief valves.
6. Remove ROMH plugs (469) from valve casing (303)

and then remove springs (355) and plungers (351).
14
Be careful not to damage the seats of the plungers.
14-167
7. Loosen socket bolts (401) and remove valve casing

(303) from casing (301). (By the force of brake
spring (712), the valve casing is lifted from the
casing after the bolts are removed.) Then, remove
valve plate (131) from valve casing (303).
Be careful not to allow the valve plate to fall off from the valve casing. (The valve plate may be attached to the
cylinder side.) When prying the mating surfaces with a screw driver, be careful not to damage the mating surfaces.
8. Remove brake springs (712) from brake piston

(702).
9. Pull out brake piston (702) from casing (301) by

using the jig.
Hook the tip end of the jig to the groove of the brake piston and pull it up straight.
14-168
10. Then change the position of the motor to horizontal

and pull out cylinder (111) from drive shaft (101).
Furthermore, pull out piston (121), set plate (123),
spring plate (114), and shoe plate (124).
Be careful not to damage the sliding surfaces of the cylinder and the shoes. In case the shoe plate does not come
off, remove it in procedure 12.
11. Pull out friction plate (742) and separator plate (743)
from casing (301).
14
14-169
12. Pull out drive shaft (101) and shoe plate (124).
When pulling out the drive shaft, the spline will damage the oil seal, so that wind a vinyl tape, etc. around the spline
of the drive shaft.
13. Perform the following work if necessary.

1) Remove the inner race of roller bearing (443)
from drive shaft (101) by using a press. P RES S
Drive s ha ft
P la ce inne r ra ce
on pre s s s ta nd.
You can tap the inner race of the roller bearing by the hammer through the steel rod, but tap it evenly taking care
not to damage the bearing.
Do not reuse the removed bearing.
14-170
2) Tap the outer race of roller bearing (443) slightly from the housing side of oil seal (491) by the hammer
though the steel rod and then remove it from casing (301).
3) Remove roller bearing (444) from valve casing
(303) by using the slide hammer bearing puller.
Do not reuse the removed bearing.
That is all of the disassembling work. Inspect each part carefully for possible failure.
14
14-171
14.4.5.2.4 ASSEMBLING SWING MOTOR
General precautions
Assembling is performed in the reverse order of the disassembling. Perform it taking care of the following items.
• Be sure to repair parts damaged during the disassembling work and prepare replacement parts beforehand.
• Wash each part by cleaning solvent sufficiently and dry it with compressed air.
• Be sure to apply clean hydraulic oil to the sliding portions and the bearings before assembling them.
• Always replace the sealing parts such as the O-ring and the oil seal, etc. in general.
• Tighten the mounting bolts and the plugs of each part using the torque wrench with the tightening torque shown
in the table.
Assembling procedures
Assembling procedures are described as follows. The numbers inside the parentheses ( ) following the part
names show item numbers in the construction drawing of "Swing motor".
1. Place casing (301) on a proper workbench with valve casing (303) side facing upward.
2. (This procedure is required only if the roller bearing is removed.)
Shrink-fit the inner race of roller bearing (443) onto drive shaft (101).
OUTP UT S IDE
Be careful about the orientation of the roller bearing flange.
3. Insert oil seal (491) into casing (301) by using the

jig.
Be careful about the orientation of the oil seal. (See the sectional assembly drawing.)
Apply a thin coat of grease to the lip of the oil seal. Tap the jig evenly, taking care not to damage the periphery
portion.
14-172
4. Tap the outer race of roller bearing (443) by the

hammer through the steel rod and assemble it into
casing (301).
5. Attach drive shaft (101) to casing (301).
Be careful not to damage the lip of the oil seal when inserting the drive shaft. Protect the oil seal by winding a vinyl
tape, etc. around the spline portion of the drive shaft.
6. Then place casing (301) horizontally and insert shoe

plate (124).
14
Install the shoe plate with its larger chamfer side facing the casing side. Apply a thin coat of grease to the mating
surfaces to prevent the shoe plate from falling off.
14-173
7. Put set plate (123) on spring plate (114) and install

piston sub assemblies (121) and (122).
8. Assemble piston sub assemblies (121) and (122)

installed in set plate (123) into cylinder (111) and
then insert them aligning the spline of drive shaft
(101).
14-174
9. Change casing (301) position so that the oil seal

(491) side faces downward and then assemble
separator plates (743) and friction plates (742)
alternately in this order into casing (301). Assemble
four separator plates and three friction plates.
10. Attach O-rings (706) and (707) in casing (301).
14
Apply a thin coat of grease to the O-rings.
14-175
11. Assemble brake piston (702) into casing (301).
12. Assemble brake springs (712) into brake piston

(702).
13. (This procedure is required only if roller bearing

(444) is removed.) Tap the outer race of roller
bearing (444) by the hammer through the steel rod
to insert it into valve casing (303).
Tap the periphery of the outer race evenly until the outer race stops moving completely at the stepped portion of the
valve casing.
14-176
14. Assemble valve plate (131) into valve casing (303)

and then attach O-ring (472).
Apply a thin coat of grease to the mating surface of the valve plate. (falling off protection)
15. Install valve casing (303) to casing (301) by

tightening socket bolts (401).
14
• Be careful about the orientation of the valve casing at installation. (See "ASSEMBLY DRAWING OF SWING
MOTOR UNIT")
• Be careful not to allow the valve plate to come off.
• Be careful not to allow the brake springs to fall down.
• Tighten the socket bolts evenly.
14-177
16. Insert plungers (351) and springs (355) into valve

casing (303), and install ROMH plugs (469) with O-
rings (488) attached to valve casing (303) and
tighten them.
Check the plungers for smooth movement.
17. Install relief valve (051) to valve casing (303).
18. Install casing of anti-reaction valve (100) to valve

casing (303) by tightening socket bolts (171).
In case anti-reaction valves (400) are removed from casing of anti-reaction valve (100) at the time of
disassembling, install anti-reaction valves (400).
That is all of the assembling work.
14-178
14.4.5.3 DISASSEMBLING AND ASSEMBLING SWING REDUCTION UNIT
14.4.5.3.1 JIGS AND TOOLS

Jigs
Code Tool name Remarks

Material: 412 (16”)
SS400 270 (11”)
230 (9.1”)
a Stand
Material:
190 (7.5”) 22 (0.87”)

SS400 o 156 (6.1”)
Spherical bearing (12)

b 13-o 16
removing jig (I) (0.63”)
(Pos ition
spa ce e qua lly)
P.C.D 140
(5.5”) VIEW X
X
Material: 159 (6.3”) 10

SS400 (0.39”)
c
100 (4”)
removing jig (II)
Material: t=4.5 (0.18”)

SS400
d 8 5 5 ”)
removing jig (I) .3
(3
Material: 150 (5.9”)

(0.35”)
SS400
Oil seal (15)
9
e 125 (4.9”)
installing jig
Material: 105 t=10 14

SS400 (4.1”) (0.39”) or more
160 (6.3”) or more

f
press-fit jig
Material:
(0.35”)
132 (5.2”)
SS400
9
Oil seal (13) 95 (3.7”)

g
installing jig
Material:
(2.4”)
(2.0”)
60
50
SS400
Spherical bearing (12) 91
h
press-fit jig (3.6”)
158
(6.2”)
14-179
Tools
Code Tool Name Remarks

i Snap ring plier For shaft
j Torque wrench 200N·m (148 lbf·ft) class
k Plastic hammer (Wooden mallet)
m Press 30ton (66,150 lbs) class

n Flat-head screw driver
p General tools Allen wrench, Steel bar
q Screw locking agent Three Bond #1360K

Sealant Loctite #515
14.4.5.3.2 DISASSEMBLING SWING REDUCTION UNIT

The numbers inside the parentheses ( ) following the part names in the description of disassembling and
assembling show the item numbers in the figure "Swing reduction unit".
Inspection and preparation

1. Before disassembly, clean the outside of the reduction unit thoroughly and check each part for damage.
2. Drain the gear oil inside the reduction unit.
3. Disconnect the drain tube.
4. Stamping match marks
Place the reduction unit assembly on a stable
workbench as shown in Fig. "Removing swing motor
assembly" and stamp match marks on each
connecting portion of the housings before 23
disassembling them. It will help you to perform
assembly. Match mark
Removing swing motor assembly
Separating swing motor from reduction unit

1. Removing swing motor assembly
Remove all socket bolts (23) (M14). Install the lifting eyes (M12) on the holes for lifting eye on the upper
surface of the swing motor and then lift the swing motor by a crane.
If it is hard to remove the swing motor assembly from the reduction nit, lift it by inserting flat-head screwdriver
(h) in the pull groove of the flange.
Disassembling reduction unit

1. Remove #1 sun gear (2).
14-180
2. Removing #1 spider assembly (7) 3

7
Remove spider assembly (7) [consisting of thrust 2
washer (15), #1 pinion (3), needle bearing (17), and
retaining ring (28)] by lifting up the assembly with
the parts installed from the spline.
6
13
#1 sun gear and #1 spider assembly
3. Removing ring gear (6)

Attach lifting eyes (M12) to the top surface of ring
gear (6) and lift the ring gear lightly by a wire sling. #2 spider assembly
Lightly tap the outer circumference of the ring gear
with plastic hammer (k) and insert a flat-head
screwdriver (n) between the mating surfaces of ring 6
gear (6) and housing (13) to remove ring gear (6). n
13
Removing ring gear (6)
4. Removing #2 sun gear and #2 spider assembly

#2 spider assembly
Draw out #2 sun gear (4) and remove the #2 spider
4
assembly.
Regarding the disassembly of the #2 assembly,
refer to the after-mentioned "Disassembling #2
spider assembly".
14
Removing #2 spider assembly
14-181
• Do not disassemble the reduction unit further (refer to

the figure) unless failure is found.
Under this condition, check the parts for possible
failure according to the inspection procedures shown
in "INSPECTION ON SWING REDUCTION UNIT".
Also, replacing the pinion shaft and housing assembly
together is recommended as much as possible. But if
replacing a part of them is unavoidable, follow the
procedure shown below.
• If no failure is found by the check at this step, the
following disassembly is unnecessary.
5. Remove retaining ring (20) from pinion shaft (1).

6. Pulling out pinion shaft
PRESS
Pull out pinion shaft (1), sleeve (21), oil seal (29)
and spherical bearing (lower) (11) by using a press 20
while housing (13) is supported as shown in the
10
figure.
• Spherical bearing (upper) (10) and oil seal (12) are 12
left in the housing.
13
11
29
21
J IG (a )
Pulling out pinion shaft
14-182
7. Removing spherical bearing (lower) (11) PRESS

Pull out oil seal (29), sleeve (21) and spherical
bearing (lower) (11) by using jigs (b) (c) and a press
while the pinion shaft assembly is supported as JIG (b)
shown in the figure.
Press force: 30 ton (66,150 lbs)
• Do not reuse the removed oil seal and the bearing.
JIG (c)
21
29
11
Removing spherical bearing (lower)
8. Removing spherical bearing (upper)

Set housing (13) as shown in the right figure, insert HAMMER (k)
jig (d) between bearing (10) and oil seal (12) and FLAT-HEAD
remove bearing (10) by tapping the jig from the SCREWDRIVER (n)
upper side. STEEL BAR
13
12
10 14
JIG (d)
Removing spherical bearing (upper) (10) and oil

seal (12)
9. Remove oil seal (12) from housing (13).

• Do not reuse the removed oil seal and the bearing.
14-183
Disassembling spider assembly

1. Disassembling #1 spider assembly
28
1) Remove retaining ring (28) with plier (i). 15
16
2) Remove thrust washers (14) and (15), pinions
(3), and needle bearings (16). 3
7
14
Disassembling #1 spider assembly
• The shaft attached to spider assembly (7) is caulked. When replacing it, replace as the set of spider assembly.
• Pinions (3) cannot be replaced singly. Replace them it in a set of three.
2. Disassembling #2 spider assembly

1) Draw out spring pin (22).
18
2) Draw out shaft (9) from spider (8) and remove
thrust washer (18), pinion (5) and needle bearing 5
(17). 17
18
22
9
8
Disassembling #2 spider assembly
Pinions (5) cannot be replaced singly. Replace them it in a set of four.
14.4.5.3.3 ASSEMBLING SWING REDUCTION UNIT
Inspection and preparation

1. Wash each part by wash oil sufficiently and dry it with compressed air.
2. Check each part for possible failure.
Assembling pinion shaft assembly

1. Attaching oil seal
Attach oil seal (29) to sleeve (21) by using jig (e). JIG (e)
29
21
Attaching oil seal (29)
14-184
2. Inserting sleeve
Insert sleeve (21) and oils seal (29) assembly in
pinion shaft (1).
29
21
Inserting sleeve in pinion shaft
3. Applying gear oil

Apply a thin coat of gear oil to the perimeter of the axis of pinion shaft (1) to prevent seizure.
4. Fitting spherical bearing (lower)
PRESS
Seal a sufficient amount of grease in spherical
bearing (lower) (11) and press-fit it in pinion shaft (1)
by using jig (f).
Press force: 4 to 5 tons (8,820 to 11,030 lbs)
• Since the bearing has a partition at the center section,
seal grease in it from the both sides. JIG (f)
11
14
Fitting spherical bearing (lower)
14-185
5. Apply grease to the pinion shaft assembly as it

forms a high accumulation.
Grease: Lithium added extreme-pressure grease
(SHELL Albania EP2 or equivalent) GREASE
Applying grease
Installing pinion shaft assembly

1. Place housing (13) on a level workbench.
2. Attach a lifting eye to the screw (M10) hole at the
end of the pinion shaft assembly, and
perpendicularly lift up the pinion shaft assembly and
install it in the housing.
• Orient the outer race of the spherical bearing to a
complete horizontal position and then insert it in by
tapping it lightly.
If the outer race is tilted, it is hard to insert it in even
13
though it is tapped lightly. In this case, do not try to
insert it in forcefully, but pull it out and orient the outer
race to a horizontal position again and then insert it in
again.
3. Change the position of the housing assembly so that
the pinion faces downward.
Installing pinion shaft assembly
4. Fit oil seal (12) in housing (13) by using jig (g). JIG (g)
• Apply Three Bond #1211 to the periphery of the oil
seal.
• Fill one third (1/3) of the space of the groove-shaped
section on the oil seal lip with grease.
• Insert it horizontally taking care not to damage the oil 12
seal lip.
13
14-186
5. Press-fit spherical bearing (upper) (10) into pinion JIG (h)

PRESS
shaft (1) and housing (13) at the same time by using
jig (h).
10
13
Press-fitting spherical bearing
6. Attach retaining ring (20).
20
Attaching retaining ring
Assembling spider assembly

14
1. Assembling #1 spider assembly
28
1) Apply grease to the bore surface of pinion (3). 15
Put pinion (3) on thrust washer (14) and (15) and 16
assemble needle bearing (16) into the bore 3
7
surface.
14
Assembling #1 spider assembly
14-187
2) Fit thrust washer (14) and (15) and pinion (3) as

in the figure below and install retaining ring (28)
by using plier (i).
15
14
7
28 3
Attaching retaining ring
Attach the retaining ring with the sharp edge facing the motor side (upper side in the position of the figure
"Attaching retaining ring".
2. Assembling #2 spider assembly P unch he re 2 portions to de form hole s in orde r to

pre ve nt s pring pin (22) from coming out.
1) Apply grease to the bore surface of pinion (5).
Put pinion (5) on thrust washer (18) and Be careful about installation
direction of pin and spring.
assemble needle bearings (17) into the bore
surfaces.
5|| 7mm 5|| 7mm

(0.20 | 0.28 inch) (0.20 | 0.28 inch)
VIEW II
18
8 5
17
18
22
9
Assembling #2 spider assembly
14-188
2) Fit thrust washer (18) and pinion (5) as in the figure, insert shaft (9) into spider (8), and then insert spring
pin (22).
Insert shaft (9) into spider (8) so that the holes for spring pin (22) are aligned with each other.
Installing #2 spider assembly

#2 spider assembly
Insert #2 spider assembly into the spline axis of pinion
shaft (1).
Installing #2 sun gear (2)

2
Install #2 sun gear (2) with the spline facing upward.
Installing #2 sun gear (2)
Installing ring gear (6)

Apply a thin coat of sealant (Loctite #515) to the mating
surfaces of housing (13) and ring gear (6) and assemble #2 spider assembly
them, aligning the gear teeth according to the match 6
marks. 14
Align match marks.
13
Installing ring gear (6)
14-189

1. Engage the #1 spider assembly with ring gear (6) to 2 #1 spider assembly
install it.
6
2. Engage #1 sun gear (2) with #1 pinion (3) to install
it. 3
Install drain tube (25) and plug (27).

Filling lubricant 13
Fill approx. 2.7 L (0.71 gal) of gear oil #90 (API Service
Classification GL-4 grade) in the swing reduction unit.
Installing swing motor assembly
1. Attach lifting eyes (M12) in the tapped holes for
lifting eye on the swing motor and put a wire sling to
them.
2. Apply sealant (Loctite #515) to the mating surfaces M14 130
of ring gear (6), insert the spline of the swing motor, 23
aligning the match marks.
3. Apply screw locking agent (Three Bond #1360K) to
socket bolts (23) and tighten them.
Tools: Allen wrench: 12 mm Match mark
Installing swing motor assembly
14-190
14.4.5.4 MAINTENANCE STANDARD OF SWING MOTOR UNIT
14.4.5.4.1 SWING MOTOR
Replacement standard for parts

In case parts are worn exceeding the following standards, replace or readjust them.
However, if external appearance of the parts is damaged significantly, replace them regardless of the standards.
Recommended
Standard
Value for
Item Dimension Remedy
Replacement
mm (inch)
mm (inch)
Clearance between piston and cylinder

bore (D-d)
D
d
0.027 0.052
Replace piston or cylinder.
(0.00160) (0.00205)
Gap between piston and caulked part of

shoe (σ)
0.3
0 Replace piston and shoe assy.
(0.0112)
Thickness of shoe (t)
5.5 5.3
Replace piston and shoe assy.
(0.217) (0.209)
t
14
Thickness of friction plate (t)
2.0 1.8
Replace.
(0.0787) (0.0709)
Standard for correcting sliding surface

If the sliding surface roughness of the parts exceeds the following standard, correct or replace the parts.
Standard for correcting sliding surface
Name of parts Standard surface roughness Surface roughness requiring correction
Shoe 0.8-Z (Ra=0.2) (lapping) 3-Z (Ra=0.8)
Shoe plate 0.4-Z (Ra=0.1) (lapping) 3-Z (Ra=0.8)
14-191
Name of parts Standard surface roughness Surface roughness requiring correction
Cylinder 1.6-Z (Ra=0.4) (lapping) 12.5-Z (Ra=3.2)
Valve plate 0.8-Z (Ra=0.2) (lapping) 6.3-Z (Ra=1.6)
• Lap each sliding surface to the level that the surface roughness is equal or lower than the standard of surface
roughness.
• If the sliding ball surfaces of the spring plate and the cylinder are rough, replace these parts together.
14.4.5.4.2 INSPECTION ON SWING REDUCTION UNIT
Inspection at disassembly
1. Spacers and thrust washers
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 tooth surfaces do not show pitting and seizure.
2) Inspect the bottom of the teeth that it does not show cracks by dye penetrant test.
3. Bearings
Turn the bearings and check that they do not generate abnormal sound, catching and other faults.
Do not reuse the removed spherical bearings.
4. Oil seals
Do not reuse the removed oil seals. Be sure to replace the O-rings with new ones at assembly.
Inspection after assembly

1. Operation
Turn #1 sun gear (2) by hand to check possible failure.
2. Inspection for oil leakage and oil
Check the swing reduction unit for oil leakage.
Check the level gauge for oil level and contamination.
If the oil level is low, supply gear oil #90 (API Service Classification GL-4 grade).
14-192
Maintenance standard
A D
G
H Lubrica nt le ve l C
B
14
14-193
Unit: mm (inch)
Code Item Standard value Service limit Remedy

-0.021
45 dia. (-0.0008)
A Condition of #1 planetary shaft Replace as spider assembly
(1.55) -0.032
(-0.0013)
No fraking is
29.0 0 allowed
B Condition of #2 planetary shaft dia. -0.009 Replace four shafts as set
(1.14) (-0.00035)
No pitting exceeding 1.6 mm (0.06 inch)

Condition of tooth surface dia., abnormal wear, or seizure is
allowed Replace
C Gear (Replace second stage
planetary pinion as set of four
Condition of tooth flank No cracks are allowed
pinions and that of first stage
as set of three pinions.)
+0.1
2.0 (+0.0039)
D Thickness of thrust washer 1.8 (0.071) Replace
(0.08) –0.1
(-0.0039)
0
2.0
E Thickness of thrust washer –0.2 1.7 (0.067) Replace
(0.08) (-0.0079)
Wear of shaft 0
95 dia.
F (Diameter of section contacting -0.089 94.9 dia. (3.736) Replace
(3.740) (-0.0035)
with oil seal)
Apply Three Bond #1360K to

G Tightening torque of socket bolt M14-181 N·m (134 lbf·ft) bolt and tighten it to specified
torque
Gear oil # 90
H Lubricant (API Service 2.7 L (0.71 gal) Refill or replace
Classification GL-4 grade)
14.4.5.5 TROUBLESHOOTING OF SWING MOTOR UNIT
14.4.5.5.1 SWING MOTOR
Hydraulic motor does not rotate.

Trouble Cause Remedy
Pressure does Safety valve in circuit is not correctly. Set valve to correct value.
not increase.
Relief valve does not function well.
1. Sticking of plunger 1. Repair or replace stuck section.
2. Clogging of plunger throttle 2. Disassemble and clean plunger
Seat of plunger does not function well. Check seat section and replace it if damaged.
Pressure rises. Overload Remove load.

Seizure of moving parts Check and repair piston, shoe, cylinder, and valve
plate, etc.
Brake is not applied with release pressure. Check and repair circuit.
Brake piston sticks. Disassemble and check it.
Spool sticks. Disassemble and check it.
Friction plate is seized. Disassemble and check it. Replace seized one.
14-194
Motor rotates reversely.

Motor rotates Motor is assembled to rotate reversely. Check Fig. "ASSEMBLY DRAWING OF SWING
reversely. MOTOR UNIT" and reassemble it correctly.
Inlet and outlet of piping is reversed. Correct piping.
Speed does not reach set value.

Speed does Oil flow rate is insufficient. Check pump delivery rate and circuit to motor.
not reach set
Oil temp. is high and oil leaks abnormally. Reduce oil temp.
value.
Sliding parts are worn or damaged. Replace damaged parts.
Brake torque is insufficient.

Brake torque is Friction plate is worn. Disassemble and check it. Replace it, if it is worn
insufficient. more than criterion.
Brake piston sticks. Disassemble and check it.
Brake release pressure cannot be released. Check and repair circuit.
Brake release spool sticks. Disassemble and check it.
Spline of friction plate is damaged. Disassemble and check it. Replace it if damaged.
Hydraulic motor slips too much.

Investigate the drain flow rate of the hydraulic motor. If it is about 400 cc/min (24 cu·in/min) or lower, the motor is
considered to be normal.
When external Relief valve does not function well. Replace it.
driving torque
Same as item "Hydraulic motor does not rotate.". Same as item "Hydraulic motor does not rotate.".
is applied to
motor, it slips Seat of plunger does not function well. Replace it.
too much.
Oil leakage 14
Oil leaks from oil seal.
Oil leaks from Lip catches foreign materials and is damaged. Replace oil seal.
oil seal.
Shaft is scratched or worn. Shift lip and shaft contact position or replace them.
Lip of oil seal is turned up due to abnormally If drain piping is clogged, repair it.
increased internal pressure of casing.
Shaft is rusted. Disassemble and repair it.
14-195
Oil leaks through mating surfaces.
Oil leaks O-ring is unintentionally omitted. Install it correctly and carry out reassembling.
through mating
O-ring is scratched. Replace it.
surfaces.
Seal surface is scratched. Disassemble and repair it.
Bolts are loose or damaged. Tighten them with specified torque or replace them.
14-196
14.4.5.5.2 SWING REDUCTION UNIT

1) Reduction unit does not rotate.

Hydraulic motor inlet pressure has risen. Overloaded Reduce load of motor.
Reduction unit is broken. Replace reduction unit.
Parking brake of hydraulic motor Inspect release pressure

is not released. and brake.
Check release command

Hydraulic motor inlet pressure has not risen. pressure.
Rotating sound is heard from

hydraulic motor. Motor shaft is broken. Replace hydraulic motor.
Reduction unit is broken. Replace reduction unit.
Rotating sound is not heard from

hydraulic motor. Pump and valve are out of order. Check and correct failure.
2) Oil leakage
Disassemble and apply
Oil leaks through mating surfaces. Liquid packing is not applied. liquid packing.
Mating surfaces move because of Disassemble it and apply

insufficient tightness of bolts, use of screw locking agent and
then reassemble it as
screw locking agent other than specified.
specified one, or looseness.
Mating surfaces are damaged. Replace faulty parts.

14
Disassemble reduction
Oil leaks from shaft. Oil seal is damaged. unit and replace oil seal.
3) Temperature is high.
Check oil level and fill oil
Temperature of reduction unit casing is high. No gear oil or oil level is low. up to specified level.
Amount of grease is insufficient. Fill up grease.
Gear and bearing are damaged. Replace reduction unit.
14-197
14.4.6 SWIVEL JOINT

14.4.6.1 CONSTRUCTION OF SWIVEL JOINT
Apply Three Bond

#1805 to stem
8
6
VIEW Y
5
5 places
7 3 places
Tighte ning torque
3 30.4 N .m (22.4 lbf .ft)
10 Apply Loctite #242
4
11 2 places
Tighte ning torque
30.4 N .m (22.4 lbf .ft)
Apply Loctite #242
1 Body 1 7 O-ring (G95 1A) 1
2 Stem 1 8 O-ring (P80 1B) 2
3 Thrust plate 1 9 Plug 1
4 Cover 1 10 Cap screw (M8 X 30) 3
5 Seal 5 11 Cap screw (M8 X 20) 2

6 Seal 1
14-198
14.4.6.2 DISASSEMBLING AND ASSEMBLING OF SWIVEL JOINT
Tools
Item Part name Used for Remarks
Steel hammer
a Hammer
Wooden or plastic mallet
b Rubber mat Disassembly and 750 mm (30 inch) square or more

assembly Allen wrench
c Wrench Double end wrench and single end wrench
Extension bar for wrench

d Torque wrench Assembly 98N·m (72 lbf·ft)
Grind tip of nail to shape

as screwdriver
e Pin Disassembly
Make this from hack-saw blade
Spatula
Disassembly and Approx. 120 mm (4.72 inch)
f
assembly
Remove edge completely

Vinyl ta pe
and round it to smooth surface.
Disassembly and
g Vise Vise with movable range of 150 mm (6 inch) or more
assembly
h Loctite - #242
i Lubricant - Hydraulic oil or vasaline
j Wash oil - -
Facility
1. Hoist or crane
Prepare lifting devices that are capable of lifting the swivel joint in an assembly condition.
2. Workbench
14
A workbench with the size of approx. 1.2 m X 1.5 m (4ft X 5ft) is required.
3. Others
Waste clothes, wooden blocks, and containers for drain oil are required.
Cleaning outer surface

Clean the swivel joint to be free from dirt and dust, using steam and wash oil.
• Be sure to keep all the ports plugged while cleaning.
DISASSEMBLING SWIVEL JOINT

The part item numbers in this procedure show the item numbers in the construction drawing of "CONSTRUCTION
OF SWIVEL JOINT".
1. Removing cover
1) Make match marks on cover (4) and body (1). It will help you to perform assembly.
14-199
2) Place a V-block on a workbench, place the swivel 2

1
joint on it sideways, and fix the swivel joint. Then
4
loosen socket bolts (10) by using the extension
10
bar and the wrench.
As a method to fix the swivel joint, you can also
fix stem (2) by the vice.
ALLEN WRENCH
V-BLOCK EXTENTION BAR
Removing cover (4)
3) Remove cover (4) from body (1) and draw out O-

ring (7) from cover (4).
7
Removing O-ring (7)
2. Removing thrust plate

1
Loosen socket bolts (11) fixing thrust plate (3), in the 3
same manner of the above-mentioned "Removing 11
cover".
EXTENTION BAR
When removing thrust plate (3) by fixing body (1), support stem (2) to prevent it from falling off.
14-200
3. Removing stem WOODEN BLOCK

Secure with hands. 1 BODY
Place body (1) on the V-block and apply a wooden FOR PROTECTION
2 STEM
block to stem (2) and then strike it by the hammer
until 1/2 of it comes out of the body.
After 1/2 of the stem comes out, it can be pulled out
by hand easily.
Stem weight: Approx. 11.4 kg (25.1 lbs)
WORK BENCH V-BLOCK
Removing stem (2)
4. Removing sealing parts

S PATULA (f)
1) Remove O-rings (8) from the seal grooves by
using the spatula.
8
Removing O-ring (8)
Be careful not to damage body (1) by the tip of the spatula. Also, do not hit the spatula.
2) Pull out the slipper rings by stabbing pin (e) into

seals (5) and (6). The right figure shows one pin, S L IP P E R R IN G
but if you use two of this pin, the slipper rings can
be removed more surely. 14
The backup rings are made of rubber, so remove
B A C K U P R IN G
them in the same procedure as that of O-ring (8).
D E T A IL (6 )
O -R IN G
G R O O V E
S E A L (6 ) P IN (e ) S E A L G R O O V E
A S S Y
O IL G R O O V E
S E A L (5 ) S E A L G R O O V E
Removing seal assemblies (5) and (6)
ASSEMBLING SWIVEL JOINT

Before assembly, wash each part (except O-rings and seals) and lay them out in the assembly order.
14-201
Enclose grease in the seal grooves of seal (6) and O-rings (8).
1. Installing sealing parts
1) Apply a thin coat of petroleum jelly (or hydraulic
oil) to O-rings (8) and then attach them in the O-
ring grooves.
After attaching them, check the O-rings for twist.
2) Attach the slipper ring of seal assembly (6) by
deforming it little bit as shown in the right figure
after inserting the backup ring. Then, after all
sealing parts are inserted, securely put them into
the seal grooves by using the spatula.
3) Assemble seal (5) by the same procedure above.
Inserting slipper ring of seal assembly (6)
Remove petroleum jelly, hydraulic oil and grease from the seal groove completely before installing seal (5).
Seal (5) does not have a backup ring.
2. Assembling stem
Apply a thin coat of grease or petroleum jelly to the
Press in by applying your weight by your hands
periphery of stem (2) or the inside of body (1) and
then insert stem (2) slowly into body (1).
1
6
Work bench
Inserting stem (2)
• Insert stem (2) slowly because if it is pressed in too fast, the seal could be damaged.
• The clearance between body (1) and stem (2) is approx. 0.1 mm (0.0039 inch) so that push in the stem straight
along with the axial center.
14-202
3. Assembling thrust plate

1) While holding stem (2) and body (1), align the
11 3 2
holes of thrust plate (3) and stem (2) with each
other.
2) Next, after removing any oil from the thread of
socket bolt (11), apply Loctite #242 to it, and then
install and tighten it to stem (2).
Tightening socket bolt (11)
4. Assembling cover
1) After installing O-ring (7) to cover (4), align the
1
match marks of cover (4) and body (1) with each MATCH MARK
other.
2) Apply Loctite #242 to socket bolts (10), and then 10
install and tighten them. That is all of the
assembling work. 4
ALLEN WRENCH
EXTENTION BAR
Tightening socket bolts (10)
14.4.6.3 MAINTENANCE STANDARD OF SWIVEL JOINT

Inspection procedures and remedies
Interval Check Item Checking Procedure Remedy
Protection seal
Replace O-ring if any oil leakage is
14
2,000hr for oil leakage Check oil leakage outside
found.
outside
Replace all sealing parts.
4,000hr Seal assembly
In principle, All sealing parts - (slipper ring, and backup ring)
disassemble and Seal
check swivel joint O-ring
regardless of
occurrence of oil Check abnormal wear, scoring, or
Repair or replace according to service
leakage All sliding parts corrosion caused by foreign materials or
limit.
seizure.
When
Check seizure, foreign materials, Repair or replace according to service
disassembly is
All parts abnormal wear, and deformation or limit. All O-rings and seals should be
performed due to
damage of seals. replaced.
failure
14-203
Service limit of parts
Part Maintenance Standard Remedy
Sliding surface Plating layer is worn out or peeled due to seizure or

Replace
with sealing part foreign materials.
Sliding surfaces Abnormal wear or scratch of 0.1 mm (0.004 inch) ore

Replace
between body more in depth due to seizure or foreign materials.
and stem other Scratch of 0.1 mm (0.004 inch) or less in depth. Repair it with oilstone to
than sealing part smooth surface.
Body and stem
Wear of 0.5 mm (0.02 inch) or more or abnormal wear. Replace
Wear of 0.5 mm (0.02 inch) or less. Repair it to smooth

Sliding surface
surface.
with thrust plate
Damage of wear limit {0.5 mm (0.02 inch)} or less due Repair it to smooth
to seizure or foreign materials and that is repairable. surface.
Wear of 0.5 mm (0.02 inch) or more or abnormal wear. Replace
Wear of 0.5 mm (0.02 inch) or less. Repair it to smooth

Sliding surface
Cover surface.
with thrust plate
Damage of wear limit {0.5 mm (0.02 inch)} or less due Repair it to smooth
to seizure or foreign materials and that is repairable. surface.
Protruded excessively from seal groove.
Protrusion
Replace
(with backup ring)
Backup ring
Width of slipper ring is smaller by 1.5 mm (0.06 inch) or

more than that of seal groove or smaller than that of
backup ring.
Slipper ring
Replace
(with backup ring)
1.5 mm(0.06 inch)
(Ma x.)
Backup ring
Wear of 0.5 mm (0.02 inch) or more
0.5m m(0.02 inch) Replace

(Ma x.)
(with backup ring)
14-204
Inspection after assembly

After completion of assembly, inspect the swivel joint for oil leakage and pressure resistance, etc., using a device
as shown in the right figure.
High pressure port (A, B, C, and D port)

Install a selector valve and pressure gauge to the stem
1
side port and the body side port respectively. Then,
gradually increase the pressure while watching the
pressure gauge (for high pressure) installed to the body
side and regulating high pressure relief valve (7). When 9
Connected to
the pressure has reached 1.5 times the working body side
pressure, close stop valve (3) and lock in the hydraulic
oil in the swivel joint. 2
Keep stop valve (6) at the side of the low pressure relief
valve closed at this time.
Connected to stem side
Perform inspection by applying pressure for three
3
minutes and at this time, each part should not have any
looseness, deformation, and breakage. 8
Judge whether oil leakage occurs or not by the first 1
minute. A pressure drop during this period should be
within 10% of the trapped pressure.
7
This inspection should be carried out for every circuit.
Low pressure port (E port and F port)

Similarly as the high pressure port, install the selector
valve and the pressure gauge on each port of the stem
side and the body side.
Open stop valve (6) at the side of low pressure relief 6 5
Hydraulic source
valve (5), gradually increase the pressure while watching
the pressure gauge (for low pressure) connected to the
body side and regulating low pressure relief valve (5), Hydraulic circuit for inspection device
and check for outside leakage by color check at a
pressure of 0.49 MPa (71 psi).
Item Part name Remarks

Gauges for high and
1 Pressure gauge low pressures are
required.
14
2 Swivel joint
3 Stop valve
Low pressure relief Set pressure: 0.49 MPa

5
valve (71 psi)
6 Stop valve
Set pressure:
High pressure relief
7 (Working pressure X
valve
1.5)
8 Selector valve
9 Pipe, etc.
14-205
TROUBLESHOOTING
External leakage of hydraulic oil Defective O-ring & seal Replace all sealing parts.
Internal leakage of hydraulic oil Defective slipper ring Replace all sealing parts.
Excessive wear of sliding surface Replace assembly.
Seizure of swivel stem Seizure of stem and body Perform grinding and honing.
Replace assembly, if stem and body
are too loose and causing oil
leakage.
Inappropriate whirl-stop bracket Correct tightness of whirl-stop bolt.

Secure 2 to 3 mm (0.08 to 0.12 inch)
allowance to whirl-stop bracket.
Looseness of swivel stem and cover Insufficient tightening of socket bolt Retighten bolt with specified torque.
14-206
［15. TRAVEL SYSTEM］
15. TRAVEL SYSTEM

15.2 FOREWORD ........................................................................................................................15-4
15.3 REMOVING AND INSTALLING ASSEMBLY ..........................................................................15-5
15.3.1 NAME OF COMPONENTS IN TRAVEL SYSTEM.................................................................15-5
15.3.2 REMOVING AND INSTALLING CRAWLER .........................................................................15-6
15.3.3 MAINTENANCE STANDARD OF CRAWLER AND TOOLS AND JIGS................................ 15-10
15.3.4 REMOVING AND INSTALLING UPPER ROLLER.............................................................. 15-13
15.3.5 DISASSEMBLING AND ASSEMBLING UPPER ROLLER.................................................. 15-15
15.3.6 MAINTENANCE STANDARD OF UPPER ROLLER AND TOOLS AND JIGS ...................... 15-20
15.3.7 REMOVING AND INSTALLING LOWER ROLLER AND UPPER ROLLER .......................... 15-22
15.3.8 DISASSEMBLING AND ASSEMBLING LOWER ROLLER AND UPPER ROLLER .............. 15-24
15.3.9 MAINTENANCE STANDARD AND JIGS AND TOOLS OF LOWER ROLLER AND UPPER
ROLLER ...................................................................................................... 15-29
15.3.10 REMOVING AND INSTALLING FRONT IDLER ASSEMBLY............................................. 15-31
15.3.11 DISASSEMBLING AND ASSEMBLING IDLER ASSEMBLY ............................................. 15-33
15.3.12 ASSEMBLING AND DISASSEMBLING IDLER ADJUSTER ASSEMBLY .......................... 15-36
15.3.13 MAINTENANCE STANDARD OF FRONT IDLER AND TOOLS AND JIGS ........................ 15-41
15.3.14 REMOVING AND INSTALLING SPROCKET ................................................................... 15-44
15.3.15 MAINTENANCE STANDARD OF SPROCKET AND TOOLS............................................. 15-45
15.3.16 REMOVING AND INSTALLING TRAVEL MOTOR........................................................... 15-47
15.3.17 REMOVING AND INSTALLING SWING BEARING .......................................................... 15-50
15.3.18 DISASSEMBLING AND ASSEMBLING SWING BEARING .............................................. 15-52
15.4 REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT................................................ 15-54
15.4.1 CONSTRUCTION OF TRAVEL MOTOR ............................................................................ 15-54
15.4.2 DISASSEMBLING TRAVEL MOTOR................................................................................. 15-60
15.4.3 ASSEMBLING TRAVEL MOTOR ...................................................................................... 15-74
15.4.4 TRAVEL MOTOR MAINTENANCE STANDARD ................................................................ 15-93
15.4.5 TRAVEL MOTOR TROUBLE SHOOTING.......................................................................... 15-98
15
15-1
15-2

15
15-3
15.2 FOREWORD
1. This Manual describes all the procedures from removing to attaching, arranging them by item.
2. This Manual consists of the first half, "REMOVING AND INSTALLING ASSEMBLY", and the second half,
"REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT".
3. The removing and attaching can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
4. The removing and attaching procedure does not completely cover all possible situations because of
differences of field condition and defective section.
5. Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.
15-4
15.3 REMOVING AND INSTALLING ASSEMBLY

15.3.1 NAME OF COMPONENTS IN TRAVEL SYSTEM
10
6 9
8
7 3
2
5
4
Designation and location of undercarriage
No. Name No. Name

1 Crawler 6 Front idler
2 Lower frame 7 Grease nipple of track spring adjuster
3 Upper roller 8 Sprocket
4 Track guide 9 Travel motor
5 Lower roller 10 Swing bearning
15
15-5
15.3.2 REMOVING AND INSTALLING CRAWLER

15.3.2.1 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 (Refer to the figure "Removing/
fixing position of master pin").
2) Loosen the grease nipple and slacken crawler.

Crawler removing position
• When loosening the grease nipple of the adjuster, do not loosen it more than one turn.
• Where grease does not come out well, move 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) Apply jig on master pin and strike it out with a

mallet.
(Refer to the figure "Press fitting of master pin".)
R e m o v in g / fix in g
p o s itio n o f m a s te r p in
Removing/fixing position of master pin
When using a big hammer, wear protective goggles and a long-sleeved uniform so you do not injure yourself by
flying objects.
15-6
4) Removing crawler R e m o v in g
Put attachment on ground so that weight is not m a s te r p in
loaded to the lower frame, and remove track link
assy rotating sprocket.
Removing crawler
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.
15
15-7
15.3.2.2 INSTALLING CRAWLER

Installing is done in the reverse order of removing.
1. Checking crawler installation direction.
Place the track links on the ground so they
converge, facing the front idler, as shown in the
Front
figure on the right. idler side
Installing direction of crawler
2. Installing crawler
• Preparation for installation
Treat paint flaking protection with care not to
damage lower flame.
1) Winding crawler
Insert a crowbar into the master pin hole, lift the
lower frame 1 to 2cm (0.39 to 0.79 inch) above
the ground level by holding it by hand so the
machine body weight is not exerted on the shoe.
Retract the sprocket to help push the back
winding of the crawler.
3. Preparation for press fitting master pin
Winding crawler
1) Put square wood under the shoe plate.
(Refer to the figure "Removing/fixing position of master pin").
2) Aligning master pin holes

Aligning master pin holes through fine adjustment turning sprocket.
• 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.
• Coat the master pin with molybdenum disulfide grease, before pressing it in.
4. Press fitting of master pin

Apply the press-fitting jig on master pin, and strike it
with a mallet to press fit.
Press fitting jig

on master pin
Press fitting of master pin
15-8
5. Adjusting crawler tension

After installing, adjust tension of crawler.
Dimension of iron crawler in a max. slackened
condition
Standard dimension A: 320 to 350 mm (12.6 to 13.8
inch)
Adjusting crawler tension
15
15-9
15.3.3 MAINTENANCE STANDARD OF CRAWLER AND TOOLS AND JIGS

STRUCTURE
1-6
1-1
1-8
1-4
1-3 2
1-8
1-7
3
1-1
4
1-7 1-5
1-2 1-2
Track link assy and shoe plate
LC SPECIFICATION
Shoe assy YN60D00159F1

No. NAME Q'TY
1 Link assy YN62D00038F2 1
1-1 Track link R 49
1-2 Track link L 49
1-3 Bushing 48
1-4 Pin 48
1-5 Master bushing 1
1-6 Master pin 1

1-7 Collar 2
1-8 Seal 96
2 Shoe 600 mm (23.6 inch) 49
3 Bolt 2420Z1292 196
4 Nut YN60D01006P1 196
15-10
F E
D D G
B
Unit : mm (inch)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Link pitch 190 ±0.13 (7.4803 ± 0.0051) 194 (7.64) 198 (7.80)
Replace the
+0.1 (+0.0039) link assy if the
B O.D. of bushing 59.41 dia. (2.3390) 56 dia. (2.20) 55 dia. (2.17)
0 service limit is
exceeded
C Height of link 110 ±0.25 (4.3307 ± 0.0098) 104 (4.09) 104 (4.02)
Basic
Interference Tolerance Fit Fit
dimension
D between bushing
and link 59.41 dia. +0.1 (+0.0039) Interference Interference
Shaft
(2.3390) 0 0.05 (0.0020) 0 Replace
Interference
38.19 dia. +0.2 (+0.0079) Interference Interference
E between track pin Shaft
(1.5035) -0.1 (-0.0039) 0.05 (0.0020) 0
and link
Interference
37.8 dia. Interference Interference
F between master Shaft ±0.04 (±0.0016) Replace Link
(1.4882) 0.05 (0.0020) 0
pin and link
Clearance 8 (0.32) 10 (0.39)

G 1.5 (0.06) (both side) Replace
between links (both side) (both side)
Tightening torque
H 853 N·m (629 lbf·ft) Retightening
of shoe bolt
15
TOOLS AND JIGS
TIGHTENING TOOLS
Unit : mm
NAME WIDTH ACROSS FLATS
Socket 30
15-11
JIGS
Name Shape
Master pin press-fitting jig

for iron crawler
15-12
15.3.4 REMOVING AND INSTALLING UPPER ROLLER

STRUCTURE
UPPER ROLLER ASSY No. YN64D00053F1
ITEM NAME Q'TY REMARKS
1 ROLLER ASSY 4 YN64D01144F1
2 CAPSCREW 4 M20X120
(SEMS SCREW)
3 NUT 4
4 WASHER 8
15.3.4.1 REMOVING UPPER ROLLER
Preparation
Remove the crawler (by the above-mentioned procedures).
• Removing upper roller (1)
1) Remove nuts on support tightening section, and

also remove capscrew (2) M20X120. 3
Removing upper roller
15
15-13
15.3.4.2 INSTALLING UPPER ROLLER

Installation is done in the reverse order of removing.
Inspection
Before reassembling, check it that it rotates smoothly by hand and for leak.
1. Install cap screws (2) by installing the nuts on the
position shown in VIEW I and II. MACHINE FRONT MACHINE FRONT
S TAMP
2. Insert the roller until the collar comes in contact with 2 3
the support. 4 4 4 4
3. Fit it directing the stamp on the shaft end upward. 3 2
S TAMP
4. Apply Loctite #262 on capscrew M20X120, and
tighten it to the specified torque. VIEWéé (LEFT SIDE) VIEWèè (RIGHT SIDE)
1
è è
é é
Installing upper roller
15-14
15.3.5 DISASSEMBLING AND ASSEMBLING UPPER ROLLER

STRUCTURE
2 3 8 1 6 7 9 4 5 10
Construction of upper roller
ROLLER ASSY PART No. LQ64D01061F1

No. NAME Q'TY No. NAME Q'TY
1 Roller 1 6 Bushing 1
2 Shaft 1 7 Bushing 1
3 Collar 1 8 Floating seal 1

4 Plate 1 9 Bolt 2
5 Cover 1 10 Plug 1
15.3.5.1 DISASSEMBLING UPPER ROLLER

1. Draining oil 10
Remove plug (10) and drain out oil. 5
Tools: Allen wrench: 6 mm 1
9 4
2. Removing cover (5)
Mount the end face of the inside of upper roller (1)
on cradle jig (f) and remove cover (5), using the
screw hole of the plug.
3. Removing plate (4)
Loosen 2 socket bolts (9) and draw out plate (4).
f
15
Mounting upper roller on cradle jig (f)
15-15
4. Removing shaft (2)

Put the push-out jig (h) against the end face of shaft
(2) and push shaft (2) with collar (3) for floating seal
(8), using a press or hammer. h
Pushing out shaft
5. Removing floating seal (8)

Take out floating seal (8) from upper roller (1). 8
Taking out floating seal

Remove floating seal (8) from collar (3)
disassembled together with shaft (2).
Removing floating seal
Collar (3) is press-fitted into shaft (2). Therefore do not disassemble it.
15-16
7. Removing bushings (6) and (7)

Since the bushing is thin, machine it on a lathe or g
scrape it off, taking care so as not to damage the 7
bore of roller (1).
If the bushing is not worn much, mount upper roller 6
(1) on cradle jig (f), insert push-out jig (g) into the 1
end face of bushing (6) and push out bushings (6) f
and (7) with a press.
Pushing out bushing
15
15-17
15.3.5.2 ASSEMBLING UPPER ROLLER

Assembly of the upper roller is done in the reverse order of disassembly.
1. Place upper roller (1) on the top end face of cradle
P us h with pre s s
jig (f), with its floating seal setting side facing down.
2. Confirm that the outer surface of bushings (6) and i
(7) are not scuffed and coat the outer circumference
of the inserting side of the bushing, with 7
molybdenum disulfide grease. 6
3. Insert jig (i) into bushing (7) and press-fit it in, using 1
the bore of the bushing and the bore of the roller as
guides. f
4. Place upper roller (1) upside down, insert jig (i) into
bushing (6), and press-fit it in using the bore of the
bushing and the bore of the roller as guides.
Pushing in bushing
If you fail in this operation by press-fitting 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.
5. Installing floating seals (8)

Two floating seals (8) make a pair. Attach one
floating seal to collar (3) press-fitted in shaft (2), and 8
another to the inside of upper roller (1).
• Prior to placing floating seal (8) in, apply engine
oil lightly to the sealing surface. 8
3 1
Installing floating seals
6. Inserting shaft (2)

Insert shaft (2) into upper roller (1).
2
Inserting shaft
15-18
7. Installing plate (4) 10

Mount upper roller (1) on cradle jig (f) and attach 5
plate (4) to the end face of the shaft with bolt (9). 1
9 4
8. Installing cover (5)
Attach cover (5) to upper roller (1). Use a press in
this operation because the fitting part needs to be
press-fitted.
Installing plate (4) and cover (5)
9. Refilling oil
Refill 62 to 68cc (3.78 to 4.15 cu·in) of engine oil
API grade CD #30 through the plug hole of cover 10
(5). 5
1
10. Installing plug (10) 4
Wind seal tape around plug (10) and screw it into
9
the plug hole of cover (5).
Tightening torque: 21.6 to 24.5N·m (15.9 to 18.1
lbf·ft)
• After assembling the lower roller, confirm that oil f
is not leaking from the lower roller unit and that
the roller rotates smoothly by hand.
Refilling oil
15
15-19
15.3.6 MAINTENANCE STANDARD OF UPPER ROLLER AND TOOLS AND

JIGS
A
E
F
D D
B
G
Unit : mm (inch)
REPAIRABLE SERVICE
LEVEL LIMIT
A Dia. 140 dia.(5.51) - -
B Width 160 (6.30) - -

Replacement
C Tread dia. 120 dia.(4.72) 107 dia.(4.21) 105 dia.(4.13)
D Tread width 38 (1.50) - -
Basic
Clearance Tolerance Fit Fit
dimension
E between shaft and
bushing 45 dia. +0.086 (+0.0034) Clearance Clearance
Shaft Replace
(1.772) -0.066 (–0.0026) 0.7 (0.028) 1.0 (0.039)
bushing
Interference
49 dia. +0.210 (+0.0083) Interference Clearance
F between roller and Hole
(1.929) -0.186 (-0.0073) 0 0.01 (0.0004)
bushing
Tightening torque
G 115 N·m (85 lbf·ft)
of socket bolt
Oil Engine oil API grade CD #30, 62 to 68cc (3.78 to 4.15cu·in) Refilling
Roller rotation Roller rotates smoothly by hand. Reassembly
TIGHTENING TOOLS
Unit : mm
Socket 30
Allen wrench 6, 10
15-20
JIGS
Unit : mm (inch)
No. NAME SHAPE
120 (4.72)
90 (3.54)
160 (6.30)
f Cradle jig
52.5(2.07)
g
(0 .7 0 9 )
Shaft push-out jig
18
48(1.89)
h Shaft push-out jig

(1 .1 8 )
6 0 (2 . 3 6 )
+0 . 1
+0 . 1
0
0
4 4 .6
4 8 .5
Bushing press-fitting
i
1 . 7 5 6 +00 .0 0 4
1 . 9 0 9 +00 .0 0 4
jig (1.26)32
(1.46)37 50(1.97)
87(3.43)
15
15-21
15.3.7 REMOVING AND INSTALLING LOWER ROLLER AND UPPER

ROLLER
STRUCTURE
B5 Apply Loctite #262

T=455N .m (336 lbf .ft)
2 1 B2
Apply Loctite #262
T=455N .m (336 lbf .ft)
Lower roller assembly and track guide
ROLLER LC LQ64D00066F1
Assembly NLC LQ64D00025F1
No. NAME Q'TY REMARKS
LQ64D00063F1
1 Lower Roller 16
(LC)
YN64D00058F1
1 Lower Roller 16
(NLC)
2 Capscrew 64 M18×80(P=1.5)
15-22
15.3.7.1 REMOVING LOWER ROLLER AND UPPER ROLLER
Preparation for removal and installation

• Loosen the tension of the crawler, lift up the lower
frame by the front attachment and stop the engine
with that condition.
• Place safety blocks (wood) at the front and back of
the lower frame.
S A F E T Y B L O C K
(W O O D B L O C K )
Preparation for removal and installation
1. Removing track guide

Remove capscrews (B5) and remove track guide
(B2).
Tools: Socket: 27mm
Track guide weight: About 25kg (55 lbs)
B2,B5 B2,B5 B2,B5

(HD) (STD) (HD)
Removing and installing track guide
HD YN01F00048F1
Lower Roller
STD YN01F00047F1
No. NAME Q'TY
B2 TRACK GUIDE : YN63D00006P2 2 4
B5 CAPSCREW : M18X40(P=1.5) 8 16
2. Removing lower roller

Remove capscrews (2) and remove lower roller (1).
Tools: Socket: 27 mm, Lower roller weight: Approx. 37 kg (82 lbs)
15.3.7.2 INSTALLING LOWER ROLLER AND UPPER ROLLER

1. Installing lower roller
Coat mounting capscrews (2) with Loctite #262 and
tighten all 4 capscrews temporarily. Then tighten
them to a specified torque.
Tools: Socket: 27mm Tightening torque: 455N·m
(336 lbf·ft)
2. Installing track guide
15
Coat capscrews (B5) with Loctite #262 and tighten
all 4 capscrews temporarily. Then tighten them to a
specified torque.
Tools: Socket: 27mm Tightening torque: 455N·m
(336 lbf·ft)
Installing lower roller
3. Adjusting tension of crawler
Tighten grease nipple and fill it with grease.
Tools: Socket: 19mm Tightening torque: 59N·m (44 lbf·ft)
15-23
15.3.8 DISASSEMBLING AND ASSEMBLING LOWER ROLLER AND UPPER

ROLLER
STRUCTURE
6 9 1 2 4 53 7
Construction of lower roller
LC YN64D00058F1
Lower Roller
NLC LQ64D00063F1
1 ROLLER 1
2 SHAFT 1
3 COLLAR 1
4 BUSHING 2
5 FLOATING SEAL 2
6 PIN 2
7 O-RING 2 1A G60
8 PLUG 1 PT1/4
9 COLLAR 1
15.3.8.1 DISASSEMBLING LOWER ROLLER AND UPPER ROLLER

1. Draining oil
Remove plug (8) and drain out oil.
2. Removing pin (6)
Put both ends of the lower roller assembly on V-
L
shaped block (K), apply push-out bar (L) on the
upper end face of pin (6), and push pin (6) out
striking with a mallet. 3
Pushing out collar fixing pin (6)
15-24
3. Removing collar (3), and O-ring (7)

Removing collar (3), and O-ring (7) Put lower roller
on cradle jig (M) so that shaft (2) is perpendicularly JIG P
located, apply push-out jig (P) on the upper shaft 7
end, and push shaft (2) until O-ring (7) separates 3
from collar (3) with a press or mallet, and take out
upper collar (3) and O-ring (7). 1
4. Removing shaft (2) 2

In addition, push out and remove shaft (2) together
with lower collar (9) and O-ring (7).
JIG M
Removing shaft (2), collar (3), and O-ring (7)
The shaft (2) pushing-out operation may cause the remaining lube oil to flow out. Prepare an oil container
beforehand.
5. Removing collar (9), and O-ring (7)

Remove O-ring (7) from shaft (2) drawn out in the previous paragraph.
Remove floating seal (5) from collar (9).
5
Removing floating seal (5)

5
Remove floating seal (5) from roller (1).
1
15
15-25
8. Removing bushing (4)

Since thickness of bushing (4) is thin [thickness is
2.0 mm (0.08 inch)], remove it through lathe or strip N
it with care not to damage the bore of roller (1). If the
bushing is not worn much, place roller (1) on cradle 1
jig (M) and apply the end of push-out jig (n) on the
end face of bushing (4), and striking it out with a
mallet. 4
JIG M
Pushing-out bushing (4)
Strike the inside surface of the roller lightly with a mallet so as not to damage the surface. Put push-out jig (N)
securely over the circumference of bushing (4) and push-out it perpendicularly little by little.
15-26
15.3.8.2 ASSEMBLING LOWER ROLLER AND UPPER ROLLER

1. Installing O-ring (7) to one side 7 2
Install O-ring (7) to groove on shaft.
• Grease O-ring.
• Replace O-ring with new one without fail at
reassembling.
Installing O-ring (7) to one side
2. Press fitting of bushing (4)

Align the center of the bore of roller (1) and bushing JIG Q
(4) bushing press-fitting jig (Q) is being inserted in
bushing (4) and press-fit it vertically with the press-
4
fitting load of 5ton (11,030 lbs) or more.
• Apply molybdenum disulfide grease on press-
fitting section of bushing, and press-fit it in
ordinary temperature.
• Bushings which fail to be press-fitted due to one-
side pressing should be replaced with new ones.
Press fitting of bushing (4)
3. Press-fitting collar (9)

While aligning the pin hole of collar (9) attached with P RES S
floating seal (5) to the pin hole of shaft (2) at the side
to which O-ring (7) is installed, press-fit and install PIN HOLE
collar (9) with the load of 17 ton (37,490 lbs) or more 9
by a press 5
• Be careful not to damage O-ring (7) while press- PIN HOLE

fitting collar (9) to shaft (2). 2 7
Press-fitting collar (9)
4. Inserting pin (6)

Press-fit pin (6) to the pin hole after the pin holes of
shaft (2) and collar (9) aligned with each other. 5
6
5. Attaching floating seal (5) to roller
Attach floating seals (5) to the both ends of roller (1).
• Check that the seal surface is free from flaws and 2
rust, etc. before reusing the floating seal. 15
9
7
Inserting pin (6)
15-27
6. Inserting roller (1)

Insert roller (1) from the side where collar (3), O-ring
(7) is not press-fitted to shaft (2).
1
5
2
9
7
Inserting roller (1)
7. Installing O-ring (7)

Install O-ring (7) to groove on shaft. P RES S
• Replace O-ring with new one at reassembling.

PIN HOLE
• Grease O-ring.
3
8. Press-fitting collar (3)
Press-fit collar (3) for the other side to shaft (2). PIN HOLE
7
• Press-fit collar (3) so that the pin holes of collar
(3) and shaft (2) become the same.
9. Inserting pin (6)
Press-fit pin (6) to the pin hole after the holes of the 2
shaft (2) end and collar (3) aligned with each other.
10. Refilling oil
Remove plug (8) and refill 150 to 170cc (9.2 to
10.4cu·in) of engine oil API grade CD #30.
11. Checking it for leakage
Before tightening plug (8), check it for leakage in the
condition of air pressure of 0.2MPa (29psi).
Installing O-ring (7), and collar (3)
12. Installing plug (8)

Apply anaerobic sealant for plug on plug (8), and
8
tighten it in the plug hole on the collar (3) end face.
Tightening torque: 21.6 to 24.5N·m (15.9 to 18.1
lbf·ft)
Installing filler plug (8)
After assembling the lower roller, confirm that oil is not leaking from the lower roller unit and that the roller rotates
smoothly by hand.
15-28
15.3.9 MAINTENANCE STANDARD AND JIGS AND TOOLS OF LOWER

ROLLER AND UPPER ROLLER
C C
H
D
E
A
Lower roller
Unit : mm (inch)
REPAIRABLE SERVICE
LEVEL LIMIT
A O.D. of flange 185 dia.(7.28) - -
Build up repair or
B Tread dia. 150 dia.(5.91) 134 dia.(5.28) 128 dia.(5.04)
replacement.
C Flange width 33.5 (1.32) 18 (0.71) 16.5 (0.65)
Basic
Tolerance Fit Fit
dimension
Clearance between
D shaft and bushing -0.060
(Wrapped bushing) 65 dia. (-0.0024) Clearance Clearance
Shaft
(2.56) -0.090 0.7 (0.28) 1.0 (0.39) Replacement of
(-0.0035) bushing
+0.030
Interference between 69 dia. (+0.0012) Interference Clearance
E Hole
roller and bushing (2.71) -0.020 0 0.01 (0.0004)
(-0.0008)
F Oil Engine oil API grade CD #30, 150 to 170cc (9.2 to 10.4cu·in) Refilling
Plug (8) : LC Execute air leak test at 0.245MPa (35.5psi) before tightening the plug.
H
Plug (8) : NLC Execute air leak test at 0.2Mpa(29psi) before tightening the plug.
Roller rotation Rotates smoothly by hand Reassembly
TIGHTENING TOOLS 15
Unit : mm
Socket 19 and 27
Allen wrench 6
15-29
JIGS
Unit : mm (inch)
No. NAME SHAPE
K V-block
100(3.94)
Pin (5)
(0 .5 5 1 )
L
14
push-out rod
1 6 (0 .6 3 0 )
200(7.87)
Bushing
N
push-out rod
290(11.4)
1 6 0 (6 . 3 0 )
M Cradle jig
(4 .9 2 )
125
270(10.6)
Shaft
P
(2 .5 2 )
push-out jig
64
(1 . 1 8 )
30
86(3.39)
9 4 . 5 (3 . 7 2 )
6 4 . 5 (2 . 5 4 )
Bushing
Q
press-fitting jig
+0.1
64.6 0
(2.543 +0.004
0 )
15-30
15.3.10 REMOVING AND INSTALLING FRONT IDLER ASSEMBLY

STRUCTURE
FRONT IDLER ASSEMBLY YN52D00104F1
1 IDLER ASSY 2 YN52D00099F1
2 IDLER ADJUSTER 2
YN54D00033F1
ASSY
3 CAPSCREW 4 M16X45
4 GREASE NIPPLE 2
APPLY LOCTITE #262

ON THREAD.
1 TIGHTENING TORQUE:
279N .m(210 lbf .ft)
3 2
Front idler assembly
15.3.10.1 REMOVING FRONT IDLER ASSEMBLY

• Preparation for removal and installation
Remove the crawler (by the above-mentiond procedures).
• Removing front idler assembly
Sling the idler assembly, and push it forward with a
pry bar.
Weight of one side of front idler assembly: 203 kg
(448 lbs)
BAR
15
Removing and installing front idler assembly
WHEN REMOVING FRONT IDLER

Keep away from the front side of front idler.
15-31
15.3.10.2 INSTALLING FRONT IDLER ASSEMBLY

• Installation is done in the reverse order of removal.
15.3.10.3 WHEN IDLER ASSEMBLY NEEDS TO BE SEPARATED

• Loosen capscrew (3), and separate idler assembly 1
(1) from idler adjuster assembly (2).
Weight of idler assembly : 108 kg (238 lbs)
Weight of idler adjuster assembly : 95 kg (209 lbs) 2
• The separated idler assembly (1) should be
placed on wood blocks
3
4
Separating idler assembly (1)
15-32
15.3.11 DISASSEMBLING AND ASSEMBLING IDLER ASSEMBLY

STRUCTURE
1
2
3
7
8
6
5
4
Idler assembly
IDLER ASSEMBLY YN52D00099F1

1 IDLER 1 YN52D01006P1
2 BUSHING 2
3 COLLAR 2 YN52D01054P1
4 FLOATING SEAL 2
5 PIN 2
6 SHAFT 1
7 O-RING 2 1A G70
8 PLUG 2 PT1/8
15.3.11.1 DISASSEMBLING IDLER ASSEMBLY

1. Draining oil
Remove plug (8) on the side of collar (3) to drain the oil.
2. Removing pin (5) 5
Apply pin push-out jig (R) to the top of pin (5), and R
push it out by striking jig (R) lightly by a hammer.
15
Removing pin (5)
15-33
3. Removing collar (3) PUSH WITH PRESS

Put idler (1) on cradle jig (U), apply shaft push-out
S
jig (S) on shaft (6), and push-out shaft (6) attached 6
with collar (3), to remove collar (3). 3
1
U
3
Removing collar (3)
4. Removing collar (3) from shaft (6)

PUSH WITH PRESS
If removal of collar (3) on the opposite side is
required, turn over the front idler and perform the S
same procedure as described in the previous step 3. 6
3
Removing collar (3)
5. Removing bushing (2)

1 T 2
Mount idler (1) on the cradle jig and tap bushing (2)
lightly by a hammer, while placing the bushing push-
out 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), and collar
(3). If you re-use floating seals (4), confirm that there
is no flaws and rust on the contact surfaces and
store the floating seals in pairs by placing a card U
board between the sealing faces.
7. Removing O-ring (7)
Remove O-ring (7) from shaft (6). Removing bushing
15-34
15.3.11.2 ASSEMBLING IDLER ASSEMBLY

1. Press-fitting in bushing (2) PUSH WITH
2 PRESS V
Align the center of the bore of idler (1) and bushing
(2) while bushing press-fitting jig (V) is being 1
inserted in bushing (2) and press-fit bushing (2)
vertically with a press.
2. Installing O-ring (7)
Attach O-ring (7) to one side of the O-ring groove on
shaft (6).
• Grease O-ring
Press-fitting bushing (2)
3. Installing collar (3)

Press-fitting
Press-fit the O-ring (7) installed side of shaft (6) into
collar (3), and drive pin (5). 6
4. Installing floating seal (4)
Attach the half of floating seal (4) on each side of
collar (3) and idler (1) described in the previous 3
step. 5
Installing collar (3), and shaft (6)
5. Inserting idler (1)

6
Insert the floating seal (4) attached side of idler (1) 4
into shaft (6).
6. Installing floating seal (4) 1
Attach floating seal (4) on the other side of idler (1).
Inserting idler (1) and installing floating seal (4)
7. Installing collar (3)

Attach the half of floating seal (4) on the other collar 8 3
(3), press-fit it in shaft (6), and drive pin (5) in with a 5
hummer.
8. Refilling oil and inspection 1
Refill 200cc (12.2cu·in) of engine oil API grade CD
#30 through the plug hole of collar (3), then wind a 15
seal tape around plug (8) and plug the hole with it.
• After installing the idler assembly to the idler
adjuster assembly, make certain that no oil leaks
from the floating seal and plug (8) and idler (1) Installing collar (3) and refilling oil
rotates smoothly.
15-35
15.3.12 ASSEMBLING AND DISASSEMBLING IDLER ADJUSTER ASSEMBLY

STRUCTURE
2 4 3 7 1 5 98 6 10
IDLER ADJUSTER ASSY
IDLER ADJUSTER ASSY YN54D00033F1

1 Grease cylinder 1
2 Bracket 1
3 Nut 1
4 Spring pin 1 8 dia.X80
5 Spring 1
6 Piston 1
7 Collar 1
8 O-ring 1 1B G80
9 U-packing 1
10 Pin 2
15.3.12.1 DISASSEMBLING IDLER ADJUSTER
Preparation
• Spring set special jig
Before disassembling and assembling the idler
M30
adjuster assembly, prepare track spring set jig (V). HOLDING-DOWN NUT
(See "TRACK SPRING SET JIG" in Chapter
"TOOLS") RETAINER PLATE
Hydraulic jack capacity : 20 ton (44,100 lbs) or more
S TAND
HYDRAULIC JACK
BASE
Track spring set jig (V)
Large power is needed to set the spring. Prepare a special jig before disassembly and assembly.
15-36
1. 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.
2. Drawing out piston (6)
(See Fig. "Idler adjuster assembly".)
Draw out piston (6) from grease cylinder (1) of the idler adjuster assembly.
3. Removing U-packing (9), and O-ring (8)
(See Fig. "Idler adjuster assembly".)
Take out U-packing (9) and O-ring (8) from grease cylinder (1).
4. Slinging idler adjuster assembly
Set the idler adjuster assembly with the above-
2
mentioned parts removed on the stand of the jig,
with its bracket (2) side facing up.
S TAND
Slinging idler adjuster
5. Fixing idler adjuster assembly

Attach retainer plate to bracket (2), tighten holding-
3
down nuts alternately, and secure the idler adjuster
assembly.
HOLDING-DOWN NUT
RETAINER PLATE
4
Fixing idler adjuster assembly
6. Compression of spring (5) 5

Remove spring pin (4), compress spring (5) by lifting
it with the jack so that nut (3) can be turned freely,
and remove nut (3).
Tools: Socket: 80mm 15
Compression of spring (5)
15-37
7. 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). RETAINER PLATE
The free length of the spring: 526.5mm (20.7inch)
Removing retainer plate, and bracket (2)
8. Removing spring (5), and grease cylinder (1)

Install lifting eye nut (W) to screw M52XP3 on
grease cylinder (1) top end, put the wire to it, and W
1
remove the set of grease cylinder (1) and spring (5)
from the jig, using a crane.
Remove spring (5), collar (7), and grease cylinder
5
(1), in order.
Removing spring (5), and grease cylinder (1)
15-38
15.3.12.2 ASSEMBLING IDLER ADJUSTER ASSEMBLY

Assembly is done in the reverse order of disassembly.
1. Installing spring (5), and grease cylinder (1)
Insert grease cylinder (1), and collar (7) into spring W
(5) and attach lifting eye nut (W) to screw M52XP3 1
at the tip of the grease cylinder. Lift the grease
cylinder by a crane and erect it in the center of the
5
stand of the jig upright.
Installing spring (5) and grease cylinder (1) to jig
2. Fixing idler adjuster assembly

Install bracket (2) on the top of spring (5). Center the HOLDING-
DOWN NUT
rod part of grease cylinder (1) and the holes in
bracket (2). Attach the retainer plate and four RETAINER
holding-down nuts. Fasten the nuts evenly all round PLATE
and fix the idler adjuster assembly to the jig body.
At this time, install the spring so that the starting 2
point of the spring at the bracket (2) side becomes 4
35 degrees (See the figure in "MAINTENANCE 3
STANDARD OF IDLER ADJUSTER ASSEMBLY").
7
3. Compressing spring (5) and tightening nut (3) 1
Raise (extend) the hydraulic jack to compress spring
5
(5) to a set length and screw in nut (3) to the
screwed part at the tip of grease cylinder (1).
Set length of the spring: 432.2 mm (17.0 inch)
4. Installing spring pin (4) Compression of spring (5), and attaching nut (3)
Tighten nut (3) till the holes for locking spring pins and spring pin (4)
(4) are aligned. Then install spring pin (4).
5. Removing idler adjuster assembly
Remove idler adjuster assembly from the jig.
15
Removing idler adjuster assembly
15-39
6. Installing U-packing (9), and O-ring (8) 9 8 6

1
Install U-packing (9) and O-ring (8) to grease
cylinder (1).
• Grease U-packing (9) and O-ring (8).
7. Filling grease cylinder (1) with grease
Fill up grease cylinder (1) with grease, remove
grease nipple (6) from piston (6), and push in the
piston by hand to allow the inside air to bleed.
GREASE NIPPLE
• Direct the grease nipple hole downward and push
in the piston to make air bleeding easier.
8. Installing grease nipple Filling grease cylinder (1) with grease
Install grease nipple to piston (6).
Tightening torque: 59 N·m (43.5 lbf·ft)
15-40
15.3.13 MAINTENANCE STANDARD OF FRONT IDLER AND TOOLS AND

JIGS
MAINTENANCE STANDARD OF IDLER ASSEMBLY
160mm (6.3 inch)
C
D
E
A
Idler assembly
Unit : mm (inch)
REPAIRABLE SERVICE
LEVEL LIMIT
A Dia. of idler projection 535 dia. (21.1) - -
B Tread dia. 497 dia. (19.6) 490 dia. (19.3) 487 dia. (19.2) Replacement
C Flange width 84±0.5 (3.307±0.020) 78(3.07) 76(2.99)
Basic
Tolerance Fit Fit
dimension
Clearance between -0.03
D
shaft and bushing 75 dia. (-0.0012) Clearance Clearance
Shaft Replacement of
(2.9528) -0.06 1.5 (0.059) 2.0 (0.079)
bushing
(-0.0024)
+0.035
Interference between 83 dia. Interference Clearance
E Hole (+0.0014)
idler and bushing (3.2677) 0 0.01 (0.0004)
0
F Oil Engine oil API CD class # 30, 200 cc (12.2cu·in) Refilling
Idler rotation Rotates smoothly by hand Reassembly
15
15-41
MAINTENANCE STANDARD OF IDLER ADJUSTER ASSEMBLY

X
C E
X aa
A, B
INSTALLA HELICAL S P LING, WHOS E S TARTING P OINT
D AT ITEM 2 BRACKET S IDE TO BE 35 DEGREES
EES
5 DEGR
3
ASSEMBLE AFTER APPLYING GREASE

TO S LIDE S IDE OF U-PACKING AND O-RING.
DETAIL aa
SECTION XX
No. ITEM STANDARD VALUE

A Installed length of spring 432.2mm (17.0 inch)
B Free length of spring About 526.5mm (20.7 inch)
C Stroke 52mm (2.05 inch)
D Set length 716mm (28.2 inch)
E Outside view of piston No scoring and rusting
Tightening torque of grease

F 59 N·m (43 lbf·ft)
nipple
TIGHTENING TOOLS : IDLER ASSEMBLY
Unit : mm
Socket 24
Allen wrench 5
JIGS : IDLER ASSEMBLY
Unit : mm (inch)
No. NAME SHAPE

(0 .5 9 1 )
(1 . 1 8 )
15
30
R Pin pull-out jig

(0.591)
105(4.13) 15
15-42
Unit : mm (inch)
No. NAME SHAPE
340 (13.4)
(2 . 9 1 )
S Shaft push-out jig
74
(0 .6 3 0 )
16
300(11.8)
T Bushing push-out rod
U Cradle jig
(0 .7 8 7 )
105(4.13)
20
9 0 (3 . 5 4 )
Bushing press-fitting
7 0 (2 . 7 6 )
V
jig
+0. 1
74.6 0
(2.937 +0.
0
004
)
103(4.06)
W Collar press-fitting jig

(1 .1 8 )
30
15
15-43
15.3.14 REMOVING AND INSTALLING SPROCKET

15.3.14.1 REMOVING SPROCKET
• Preparation
Remove the crawler referring to the figure in
"REMOVING AND INSTALLING CRAWLER", lift up
the crawler frame by placing the attachment against
the ground, and put it on wood blocks to lift and
stabilize it.
Preparation for removal
• Removing sprocket
Loosen 30 sprocket mounting capscrews (5)
M16X55, and remove sprocket (4).
Weight of sprocket: 50 kg (110 lbs)
Tools: Socket: 24mm
Removing sprocket
15.3.14.2 INSTALLING SPROCKET

• Check before installation
Check the mating portion of the travel reduction unit and the sprocket, eliminate burrs and contamination
thoroughly and install the sprocket.
1. Tightening sprocket mounting capscrews
temporarily
Coat the screw part of the sprocket mounting
capscrews with Loctite #262 and tighten them
temporarily.
2. Tightening sprocket mounting capscrews
completely
Remove the wood blocks under the track frame,
bring the machine down on the ground and tighten
the capscrews.
Tightening sprocket mounting capscrews

temporarily
15-44
15.3.15 MAINTENANCE STANDARD OF SPROCKET AND TOOLS

MAINTENANCE STANDARD (YN51D01023P1)
NUMBER OF TEETH 21
SPECIFICATIONS
PITCH DIA. 644.602mm (25.333 inch)
UNIT: mm (inch)
B
190 (7.480")
C
Sprocket
Unit: mm (inch)
STANDARD VALUE
REPAIRABLE SERVICE
No. NAME Basic REMEDY
Tolerance LEVEL LIMIT
dimension
658 dia. Build up repair or
A O.D. of sprocket ±2 (±0.079) 650 dia.(25.6) 648 dia.(25.5)
(25.90) replacement.
Width of sprocket
B 66 (2.520) ±2 (±0.079) 60 (2.36) 58 (2.28) Replacement
teeth
I.D. of sprocket +2 (+0.079) Build up repair or
C 585 dia.(23.1) 577 dia.(22.7) 575 dia.(22.6)
bottom –1 (–0.039) replacement.
TIGHTENING TOOLS
Unit : mm
Socket 24
15
15-45
SPROCKET GEAR TEETH GAUGE

UNIT: mm (inch)
190 (7.480")
Gear teeth gauge (Full scale)
15-46
15.3.16 REMOVING AND INSTALLING TRAVEL MOTOR

STRUCTURE
2
APPLY LOCTITE #262
OR EQUIVALENT
TIGHTENING TORQUE:
279 N .m(206 lbf .ft)
Installing travel motor
INSTALLING TRAVEL MOTOR YN53D00016F5

3 CAPSCREW 54 M16X55
TRAVEL MOTOR
5 2 YN53D00017F4
ASSEMBLY
15.3.16.1 REMOVING TRAVEL MOTIR

• Preparation
Remove the crawler, lift up the crawler frame using the attachment, and put it on wood blocks to lift and stabilize
the sprocket.
• Preparation of oil pan
Remove sems bolt (6) M12X25 and also remove
cover (1).
15
6
1
Removing and installing cover (1)
15-47
2. Removing hydraulic pipes

Release the pressure from the travel circuit, and
bleed the air in the hydraulic oil tank, then remove
all pipes connecting to the travel motor. Then plug
up all pipes and joint sections to protect them from
entry of dust.
Tools: Spanner: 19 mm, 27 mm, 41 mm
Hydraulic pipe plug (See Chapter of "TOOLS")
Plug for flare hose (See Chapter of "TOOLS")
Removing and installing hydraulic pipe
3. Removing sprocket
Remove 30 (one side) capscrews (5) M16X55.
Removing and installing sprocket
4. Loosening travel motor mounting bolts (2) REMOVE PIPES (CUT OIL COMMUNICATION)
Apply match marks on the travel motor and the
crawler frame, and remove 27 (one side) capscrews
(2) M16X55.
Removing and installing travel motor mounting

bolts
15-48
5. Slinging travel motor assembly

Sling the travel motor with a nylon sling applied on
the side close to the sprocket installing section and
remove the motor.
Weight of motor: Approx. 263 kg (580 lbs)
Slinging travel motor
15.3.16.2 INSTALLING TRAVEL MOTOR

Installation of the travel motor pipes is performed in the reverse order of removal.
• Cleaning
Check that contact surface of the travel motor and crawler frame is free from burr and stain.
• Fill the casing with hydraulic oil through the motor drain port before installing the drain pipe. When starting
operation, run the engine at low idle speed and operate the motor for a few minutes at low speed to check it for
oil leakage and abnormal sound.
• Tightening torque
Tighten capscrews and hydraulic pipes to the torque specified in "Tightening Torque".
Tightening torque
TIGHTENING
TOOLS
NAME SIZE NO. TORQUE REMARKS
HEX
N·m (lbf·ft)
SEMS BOLT M12 19 6 83.4 (61.5) APPLY

LOCTITE
CAPSCREW M16 24 2,5 279 (206) #262
FLARELESS 10X1.5 dia. 19 - 49(36)
NUT FOR 18X2.5 dia. 32 - 147(108)
PIPES, AND 28 dia. 41 - 275(203)
SLEEVE
HOSE CAP PF1/4 19 - 29.4(21.7)
PF1/2 27 - 78.5(57.9)
CONNEC- PF1/4 19 - 36.3(26.5)

TOR PF1/2 27 - 108(80)
PF1 41 - 255(188)
15
15-49
15.3.17 REMOVING AND INSTALLING SWING BEARING

STRUCTURE
FRONT
A A
3 INNER S ZONE POSITION

OF SWING BEARING
GREASE FILLING POSITION
2 SECTION AA
APPLY LOCTITE #262

OR EQUIVALENT
T=564N .m (416 lbf .ft)
Swing bearing assembly
Swing bearing assembly YN40F00043F2

2 Capscrew 36 M20×P1.5×65
1 Swing bearing 1 YN40F00042F2
MAINTENANCE STANDARD OF SWING BEARING

Regarding the maintenance standard for wear of the swing bearing, see Paragraph "MEASURING
PERFORMANCES OF SWING BEARNIG" in Chapter "MAINTENANCE STANDARD AND TEST PROCEDURE"
15.3.17.1 REMOVING SWING BEARING

1. Matchmarks SWING BEARING
Remove upper structure, apply matchmarks on
inner race of swing bearing and lower frame. OUTER RACE
2. Remove 36 inner race mounting capscrews (2)

INNER RACE
M20X65.
Tools: Socket: 30 mm MATCHMARKS
Matchmarks
15-50
3. Removing grease SWING BEARING

Remove grease in grease bath.
EYE BOLT
4. Removing swing bearing
Attach eyebolt on swing bearing and sling it.
Weight of swing bearing: 242 kg (534 lbs)
GREASE BATH
Removing and installing swing bearing
15.3.17.2 INSTALLING SWING BEARING

• Cleaning
Clean the swing bearing completely so that installing surfaces of the swing bearing and the lower frame are free
from dust and oil.
1. Installation
Install the swing bearing on the lower frame aligning
the matchmarks and positioning the stamped S
mark on inner race as shown in the right figure.
2. Temporary tightening of inner race
Coat the threads of the capscrews (2) with Loctite
#262 and tighten all the capscrews (2) evenly and FRONT
temporarily.
Tools: Socket: 30 mm A A
INNER S ZONE POSITION

OF SWING BEARING
Location of S mark on swing bearing
3. Complete tightening of inner race mounting 1

capscrews
Tighten capscrews (2) alternatively and evenly at
GREASE FILLING POSITION
180 degree intervals in forward, backward, left, and
right directions, and finally tighten them to the
specified torque.
Tools: Socket: 30 mm 2 SECTION AA
APPLY LOCTITE #262
Tightening torque: 564 N·m (416 lbf·ft) OR EQUIVALENT
T=564N .m (416 lbf .ft)
4. Filling grease
Fill the grease bath with 9.5kg (20.9 lbs) of the 15
lithium added extreme-pressure grease "NIPPON Removing and installing capscrew
Grease NIGLUBE EP-2K" or equivalent.
15-51
15.3.18 DISASSEMBLING AND ASSEMBLING SWING BEARING

STRUCTURE
6
1 8
9
7
4, 3
5
2
Sectional view of swing bearing
ROLLER ASSY PART

YN40F00042F2
No.
Q'T- Q'T-
No. NAME No. NAME
Y Y
1 OUTER RACE 1 6 SEAL 1
2 INNER RACE 1 7 TAPER PIN 1
3 BALL 120 8 PLUG 1
4 RETAINER 120 9 GREASE NIPPLE(PT1/8) 1
5 SEAL 1
15.3.18.1 DISASSEMBLING SWING BERING

1. Remove seal (5) attached in the groove in the outer
circumference of lower inner race (2) and seal (6)
EYE BOLT
attached in the groove in the inner circumference of 6 2
7
upper outer race (1) and place them level on a wood
block or something. 1
WOOD BLOCK
2. Draw out taper pin (7), using a hammer and a push-
out rod.
3. Draw out plug (8) by screwing in a bolt into the 8
thread hole of the plug and using a puller. 5
Disassembling swing bearing
4. While rotating outer race (1) little by little, take out 1

ball (3) and retainer (4) through the plug hole, in
order.
2
4
3
Removing balls (3) and retainers (4)
15-52
15.3.18.2 ASSEMBLING SWING BEARING

1. Thoroughly remove the grease from the grooves for seal (6) located on the inner circumference of outer race
(1) and for seal (5) located on the outer circumference of inner race (2).
And apply the adhesive (Cyano Bond PX-3000 or equivalent) to the the groove for seal (5) and attach the seal
(5) into the groove all the way around.
Also, connect the both ends of seal (5) with the adhesive (Cyano Bond PO-X or equivalent).
Then place inner race (2) on wood blocks flatly.
2. Lower outer race (1) slowly to the position where upper surface of inner race (2) and the groove under the seal
of outer race (1) is mated, then put an adjusting washer under outer race (1) and support it so that inner and
outer raceway surfaces of ball (3) align with each other.
3. Insert ball (3) and retainer (4), on which the grease
(extreme pressure heavy duty) is applied, through
plug (8) hole on outer race (1), alternately.
1
PUSH-OUT ROD 6
2
3
5
WOOD BLOCK
Installing balls (3)
EYE BOLT
HOOK ROD
WOOD BLOCK
Installing retainer (4)
To insert ball (3) and retainer (4), use a push rod or hook rod etc., to protect persons from injury from inserting
fingers into the plug hole.
15
4. Install plug (8) to outer race (1) while checking the orientation and position of the taper pin hole.
5. Apply the adhesive (Cyano Bond PX-3000 or equivalent) to the groove for seal (6) and attach the seal to the
groove of outer race (1) all the way around. And connect both ends of seal (6) with the adhesive (Cyano Bond
PO-X or equivalent).
6. After completion of assembly, caulk the hole portion of taper pin (7) by punching.
7. Check that grease nipple (9) is in proper condition, and fill it with the grease (extreme pressure heavy duty).
Then, check the swing bearing for smooth rotation and the seal lip portion for flaws.
• Shell Albania EP#2; 160 cc (9.8 cu·in)
15-53
15.4 REMOVAL AND INSTALLATION OF TRAVEL MOTOR

UNIT
15.4.1 CONSTRUCTION OF TRAVEL MOTOR
15.4.1.1 CROSS-SECTIONAL VIEW OF TRAVEL MOTOR ASSEMBLY
19 20 Z2 Z2
Z3 Z3
17 22 23 19,20 21 24 26 23 25 17
X1 X1
28
S ECTION Z6-Z6
(1P LACE)
29
11 13 12 7 6 5 4 3 67 30 8 9 10 S ECTION Z5-Z5
(3P LACES )
65 66
Z6
Z4 Z4
Z6
33 34 15 14 14 15 34 33
18
S ECTION Z4-Z4 S ECTION X1-X1
Structure of travel motor(1/2)
15-54
18 18 18
Z5 Z5
Z5
Z5
Z5 Z5
S ECTION Z2-Z2 S ECTION Z3-Z3
41 44 43 42 37 45 38 40 39 48 61 73 72 75 76 74 85 86 96
52 87
60 90
51 91
69 92
62 88
89
93
32
31
50
68 94
95
59
56 97
98
64
83
60
84
57 63 58 55 54 1 36 46 70 47 49 53 71 99 77 78 79 80 81 82
Structure of travel motor(2/2)

15
15-55
Tightening width Tightening width

torque across torque across
N·m flats N·m flats
(lbf·ft) mm (lbf·ft) mm
205 CAPSCREW;
1 FLANGE 1 12 52 10
(151) M14X35
OIL SEAL;
2 BASE PLATE 1 53 1
TCZ50X72X9
(SPOOL)
3 1 54 DISK PLATE 3
PLUNGER
4 CHECK VALVE 2 55 FRICTION PLATE 2
5 SPRING 2 56 BRAKE PISTON 1
137*
14 6 PLUG; M24,P=1.5 2 57 O-RING 1
(101)
7 O-RING 1B P21 2 58 O-RING 1

9 SPRING 2 60 PIN 4
11 CAP 2 62 VALVE PLATE 1
12 O-RING 1B G45 2 63 O-RING 1B P10 4
108 CAPSCREW;
10 13 8 64 O-RING 1
(80) M12X40
14 O-RING 1B P8 2 65 NAME PLATE 1
20.6
14 15 PLUG; PF1/8 2 66 RIVET 2
(15.2)
373 RELIFE VALVE

27 17 2 67 PLUG; PT1 2
(275) ASSY; PF1-5/16
9.8 PLUG;
2.5 18 8 68 PLUG; PT1/2 1
(7.2) METALPLUG M5
SPOOL A :
19 2-SPEED 1 69 PLUG; PT1/4 1
CHANGE OVER
20 SPOOL C 1 70 FLOATING SEAL 2
ANGULAR
21 SPRING 1 71 2
BEARING
118 HOUSING
10 22 PLUG; PF1/2 1 72 1
(87) (RING GEAR)
23 O-RING 1B P18 2 73 SHIM 1

24 SPRING GUIDE 1 74 HOLDER C 1
118
10 25 PLUG; PF1/2 1 75 WASHER 8
(87)
539* Torques
26 WASHER 1 76 BOLT; M20X70 8
(398) T90
2.45
2.5 28 ORIFICE; M5X5 1 77 THRUST PLATE 4
(1.81)
2.45
2.5 29 ORIFICE; M5X5 3 78 INNER RACE 4
(1.81)
2.45 NEEDLE
2.5 30 ORIFICE; M5X5 2 79 4
(1.81) BEARING
15-56
Tightening width Tightening width

torque across torque across
N·m flats N·m flats
(lbf·ft) mm (lbf·ft) mm
36.8 PLANETARY
6 31 PLUG; PF1/4 4 80 4
(27.1) GEAR C
32 O-RING 1B P11 4 81 THRUST PLATE 4
539* Torques
33 BALL 2 82 BOLT; M20X130 4
(398) T90
34 SPRING 2 83 SUN GEAR C 1
36 SHAFT 1 84 SNAP RING 1
CYLINDER
37 1 85 HOLDER B 1
BLOCK
38 PISTON ASSY 9 86 THRUST PLATE 3
39 RETAINER PLATE 1 87 INNER RACE 3
RETAINER NEEDLE
40 1 88 3
HOLDER BEARING
PLANETARY
41 SNAP RING 1 89 3
GEAR B
42 SPRING SEAT 1 90 THRUST PLATE 3
43 SPRING 1 91 THRUST PLATE 1
58.8 Torques
44 COLOR 1 92 SCREW; M10 3
(43.4) T50
45 PIN 3 93 THRUST PLATE 1
PLATE
46 1 94 DRIVE GEAR 1
(SWASH PLATE)
47 BALL 2 95 COVER 1
73.4
48 PISTON ASSY 2 8 96 BOLT; M10X16 16
(54.1)
157
49 BALL BEARING 1 12 97 PLUG; PF3/4 3
(116)
50 BALL BEARING 1 98 O-RING 1B P24 3

51 PIN 1 99 PIN 4
* : Apply Loctite
15
15-57
15.4.1.2 TOOLS
Standard tools
Application Application
Tools name Type･･size Tools name Type･･size
Item (No.) Item (No.)
Nominal 60 18, 28, 29, 30 Opposing flats 2.5 28, 29, 30
Nominal 230 15 Opposing flats 6 31

Allen wrench
Preset torque Nominal 900 92, 96 Opposing flats 10 13, 22
wrench Nominal 1800 6,13,22,25,97 Opposing flats 12 52, 97
Nominal 2800 52 Opposing flats 14 6,15

Spanner
Nominal 5600 76, 82 Opposing flats 27 17
Opposing flats 2.5 18, 28, 29, 30 Radio pench 17
Opposing flats 6 31 Snap ring pliers S-2 Type 41
Hex bit for Opposing flats 8 96 Minus driver 6X100 2, 62, 68, 70
socket wrench Opposing flats 10 13, 22 Plastic hammer Nominal #3
Opposing flats 12 52, 97 For M20
Eye bolt
Opposing flats 14 6,15 For M12 2
Torques Size T50 92 Chain string(wire)

T type bit Size T90 76, 82
Socket for Opposing flats 10 25

socket wrench Opposing flats 27 17
Materials
Materials name Description Materials name Description
For the repair of

Sealing tape Lapping plate
moving surface
For the repair of

Adhesive Loctite 76,82,14 Lapping medium
moving surface
Gear oil GL-4#90 or equivalent 1, 47, 48 Copper plate
2, 3, 19, 37, 38, Tube brush For cleaning 2, 37

Hydraulic oil ISO VG46 or equivalent 39, 40, 46, 47,
62 Bamboo brush For cleaning
7, 12, 14, 23, 32, Oil pan Container for oil

Grease Lithium base 43, 56, 57, 58,
62, 64, 98 Plastic container Grease container
Kerosene No.2 or equivalent Rag
Liquid packing Three bond 72, 95
15-58
Special tools
Special tools name Description Special tools name Description
Pulley puller 49, 50 Shim thickness adjusting jig 73

Bearing fixing jig 49 Rod 3
Bearing fixing jig 50 Thrust plate selecting jig 96
Floating seal fixing jig 70 Oil seal fixing jig 53
Rod 71 Brake piston positioning jig 56

Angular bearing fixing jig 71 Snap ring removing/fixing jig 41
Measuring instrument
Measuring Application
Description
instrument name Item (No.)
Dial gauge JIS B7503 73, 96
Micro meter JIS B7502 73, 96
15
15-59
15.4.2 DISASSEMBLING TRAVEL MOTOR

1. Removing cap (11)
Fix the motor on a stable work bench, loosen eight
socket bolts (13) and remove cap (11) with O ring
(12).
14,15,33,34
Next, remove spring seat (10), spring (9) and spring
seat (8).
Next, remove plug (15), O-ring (14), spring (34), and
8 17
ball (33).
9
Tools: Spanner: 14 mm 12
11
13
Removing the cap assy
Cap (11) is pressed out by spring(9). Therefore, do the work, taking care of the following.
• Loosen socket bolts (13) evenly all round.
• Loosen socket bolts (13), holding down cap (11).
2. Removing double counterbalance plunger (3)

Push the end of plunger (3) lightly so part of plunger
(3) comes out of base plate (2). Then, hold the end
of plunger (3) by hand and draw out plunger (3) from
base plate (2), while turning it by hand.
Removing double counterbalance valve spool(3)
Plunger (3) and base plate (2) have a very tight fit. Therefore, do the work, paying attention to the following.
• In case plunger (3) gets stuck halfway and does not come out, do not try to force it out. If it is pulled out by force,
the bore surface of base plate (2) and the outer surface of plunger (3) are scored.
In case the plunger gets stuck halfway, do as follows:
Put plunger (3) back into base plate (2) by lightly tapping the end face of it with a plastic mallet. Then make sure
that the plunger (3) moves smoothly and draw out the plunger (3) once again, turning it by hand.
• Do not disassemble plunger (3) unless it is necessary; the outer surface of it may be scored at disassembly.
15-60
3. Removing relief valve assy (17)

17-3
Loosen plug (17-6) and remove relief valve assy
(17). In that case, poppet seat (17-3) remains in
base plate (2).
17-6 2
17-16
17-15
17
Removing relief valve (17)
Relief valve assy (17) is set at certain pressure. The set pressure of it determines the starting power and the
braking power of the motor.
For this reason, do not do the following.
• Do not loosen nut (17-16) and tamper with set screw (17-15). If the set screw is turned, the set pressure of the
relief valve changes, making the motor unable to attain required performances.
• Do not disassemble the relief valve assy. Otherwise, the set pressure changes and the motor is unable to attain
required performances.
4. Removing poppet seat (17-3)

Separate poppet seat (17-3) from base plate (2),
using the poppet seat removing jig.
17-3
Removing poppet seat (17-3)
Do not perform disassembly if it is not required.

15
15-61
5. Removing auto 2-speed select spool (19)

Loosen plugs (22),(25) and take off plugs (22),(25)
and spring (21). Next, push out part of spool(19)
from base plate (2) by pushing the end of spool (19).
25
Then draw spool (19) out of base plate (2), while
21
holding the end of spool (19) by hand and turning it.
2
19
22
Removing auto 2-speed select spool(19)
Spool (19) and base plate (2) are combined to a very small fit. For this reason, execute the work, paying attention to
the following.
• Do not disassemble spool (19) unless necessary.
• In case the spool gets stuck halfway, do not force it out. If the spool is forced out, the bore surface of base plate
(2) and the outer surface of spool (19) are scored.
If it gets stuck, do as below.
Put spool (19) into base plate (2) once again by lightly tapping the end face of spool (19) with a plastic mallet.
Then, make certain that spool (19) moves smoothly and draw it out, turning spool (19) by hand.
6. Do not remove orifice plug (18) unless necessary.

Orifices (28),(29),(30) are caulked so they do not get loose.
Do not disassemble them. (See the figure "Structure of travel motor".)
7. Removing base plate (2)
Loosen capscrew (52) and remove base plate (2).
52
2
59
Removing base plate (2) (1)
15-62
60
Removing base plate (2) (2)
When removing base plate (2), do the work, taking care of the following.
• Base plate (2) is pushed up by the action of spring (59). Therefore, loosen the cap screws evenly all round.
• A positioning knock pin (60) is placed between base plate (2) and the main body. When removing base plate (2),
do it upright toward the motor shaft center so knock pin (60) is not wrenched. In case it is wrenched, bring knock
pin (60) back in place by lightly tapping base plate (2) with a plastic mallet and remove the knock pin.
• When removing base plate (2), valve plate (62) comes with base plate (2). Since the moving surface of valve
plate (62) tends to be scored, use care so valve plate (62) does not fall.
8. Removing valve plate (62) 62

Separate valve plate (62) from base plate (2), using
a flat-blade screwdriver.
Removing valve plate (62)
15
When removing valve plate (62), take care of the following.
• The moving surface of valve plate (62) tends to be scored. If the surface is scored, desired performances are not
available; use care so as not to score it.
15-63
9. Removing O-ring, knock pin (60) and spring (59).

Take off O-ring (63),(64), and knock pin (60). Then 59
take off spring (59).
60
63
64
Taking off O-ring (63), (64), knock pin (60), and

spring (59)
10. Removing brake piston (56)

1) Attach a jet air nozzle to the oil path for the
parking brake of flange (1), make brake piston
(56) afloat by blowing jet air into the parking
brake cylinder chamber and remove the brake
piston.
56
Removing brake piston (56)
2) After removing brake piston (56), remove disk

plate (54) and friction plate (55). Then separate
O-rings (57),(58) from brake piston (56).
56
57
58
54
55
54
55
54
Removing disk plate (54), friction plate (55), and O-

ring (57),(58)
15-64
When removing brake piston (56), take care of the following.

• When blowing in jet air from the parking brake oil path of flange (1), take measures so jet air does not leak.
• If the jet air pressure is high when blowing in jet air from the parking brake oil path of flange (1), you may be
injured as brake piston (56) pops out. For this reason, keep the air pressure less than 0.29MPa (42.1psi) and do
the work, holding down brake piston (56) so brake piston (56) does not jump off.
11. Removing cylinder block (37)

Take out cylinder block (37) from flange (1).
37
Removing cylinder block (37)
When drawing out cylinder block (37), use care of the following :
• Hold cylinder block (37) by both hands and take it out slowly, while turning it both ways lightly.
• Exercise care so as not to score the moving surface of cylinder block (37) in contact with valve plate (62). If the
surface is scored, desired performances will not be attained.
• Exercise care so as not to score the moving surface of the shoe of piston assy (38). Desired performances will
not be attained if the surface is scored.
12. Disassembling cylinder block (37)

1) Give a matching mark to piston assy (38) and
cylinder block (37) so they can be reassembled in
the same positions. Then separate piston assy
(38) and retainer plate (39) from cylinder block
(37).
37 15
38
39
Removing piston assy (38)
15-65
2) Give a matching mark to piston assy (38) and

retainer plate (39) so they can be reassembled in
the same position. Then remove piston assy (38)
from retainer plate (39).
39
38
Removing retainer plate (39)
3) Separate retainer holder (40) from cylinder block

(37). Then take off pin (45) from cylinder block
(37).
45
37
40
Removing retainer holder (40) and pin (45)
4) Fix cylinder block (37) on a manual press bench

so the moving surface faces upwards. Take off
41
snap ring (41), push collar (44) with the jig, bend
spring (43) and take off snap ring (41), using
snap ring pliers.
JIG
37
Removing snap ring (41)
When removing snap ring (41), take care as below, so as not to injure yourself.
• If snap ring (41) is tight to remove with snap ring pliers, you may injure yourself when the snap ring comes off
from the pliers. Always use the removing jig to remove the snap ring and make certain that the claw of the pliers
is set in the hole of the snap ring.
15-66
5) Separate collar (44), spring (43) and spring seat

(42) from cylinder block (37). 44
43
42
37
Removing collar (44), spring (43) and spring seat

(42)
13. Removing swash plate (46)

Separate swash plate (46) from flange (1).
46
Removing swash plate (46)
Use care of the following when removing swash plate (46).

• Take care so as not to score the sliding surface of swash plate (46). Desired performances will not be attainted if
the surface is scored.
• Swash plate (46) comes off with piston assy (48) and steel ball (47) in some cases. On that occasion, use care
so piston assy (48) and steel ball(47) do not fall.
14. Removing travel 2-speed select piston assy (48)

and steel ball (47) 61
Separate piston assy (48) from flange(1). Then take
off spring (61).
Separate steel balls (47) from flange (1).
15
48
47
Removing piston assy (48) and steel balls (47)
15-67
Since steel balls (47) are hard to come off, do it as below :

• Degrease steel balls (47) fixed in flange (1), using kerosene or thinner.
• Separate steel balls (47) from flange (1), using a magnet.
15. Removing shaft (36)

Separate shaft (36) and ball bearing (49) from
flange (1).
36
49
Removing shaft (36) and ball bearing (49)
When removing shaft (36), use care of the following :

• Use care so the spline of shaft (36) is not damaged.
Exercise care so the sliding part of oil seal (53) in shaft (36) is not scored. If it is scored, oil leakage occurs.
16. Draining lube oil from the reduction gear

Next, before disassembling the reduction unit, put a
screw in two tapped holes of flange (1) that are in
diagonal positions and lift the reduction unit by 1
crane. Remove two plugs (97) and drain lube oil
from the reduction unit.
97 97
Draining oil from reduction unit
Prepare an oil container before doing the work.

• Do not lift the reduction unit too high, but do the work at as low level as possible. (height of your knees)
15-68

Loosen bolts (96) and remove them.
Then remove cover (95).
96
72
95
Removing cover (95)
Remove the cover (95) as below

• Liquid packing is applied between cover (95) and housing (72). For this reason, the cover is hard to come off.
Loosen bolts (96) and tap the top and side faces of the removed cover (95) with a plastic mallet.
• Put a flat-blade screwdriver between cover (95) and housing (72) and take off cover (95).
18. Removing thrust plate (94)

Separate thrust plate (94) from the top face of thrust
plate (91)
91
94
Removing thrust plate (94)
19. Removing drive gear (93)

Remove drive gear (93)
15
93
Removing drive gear (93)
15-69
20. Removing the 1st stage holder assy

Remove the 1st stage holder assy that consists of
holder B (85), planetary gear B (89), needle bearing
(88), inner race (87), thrust plate (86), thrust plate
(90), thrust plate (91) and screw (92).
1 s t s ta g e h o ld e r a s s y
Removing the 1st stage holder assy
Use care of the following when removing the 1st stage holder assy :
• Take care so you do not pinch your fingers at removing.
21. Removing the 1st stage holder assy

Fix the 1st stage holder assy in a vise and heat
screw (92) with a hair dryer and loosen it.
Separate screw (92), thrust plate (91), thrust plate
(90), planetary gear B (89), needle bearing (88),
inner race (87) and thrust plate (86), from the holder 92
B, in that order. 85
87
88
89
90
91
Disassembling the 1st stage holder assy
When loosening screw (92), exercise care of the following :

• Screw (92) is coated with Locktite and hard to get slack.
If you loosen it by force, it is scored and can not be reused.
Heat the screw with a hair dryer before loosening it.
15-70
22. Removing sun gear C (83)

Remove sun gear C (83)
83
Removing sun gear (83)
23. Removing planetary gear C (80)

1
Fix flange (1), loosen bolt (82) and remove it. Next,
separate thrust plate (81), planetary gear C (80),
needle bearing (79), inner race (78) and thrust plate
(77), in that order.
78
80 77
81
82
Removing planetary gear (80)
Exercise care of the following when loosening bolt (82) :

• Bolt (82) is coated with adhesive Locktite to prevent it from loosening. Fix flange (1) securely for that reason.
• When loosening bolt (82), use a tool with a sufficiently long extension such as iron pipe. If you do not use it and
try to loosen by force, you may injure your waist or other parts.
24. Removing holder C (74)

Fix flange (1) and loosen and remove bolt (76).
Holder C (74) is fixed to flange (1) with pin (99).
Attach the removing jig from the motor side and
74
separate holder C (74) by the use of a press. 15
76
99
Removing holder (74)
15-71
When loosening bolt (76), use care of the following :

• Coat bolt (76) with screw locking agent to prevent it from loosening. For that purpose, fix flange (1) securely.
• To loosen bolt (76), use a tool with a sufficiently long extension such as an iron pipe. If you loosen it by force, you
may injure your waist or yourself in some cases.
25. Separating flange (1) from housing (72) JIG

Attach a jig to the end face on the outer flange of
1
housing and separate flange (1) from housing (72)
by pressing flange (1) by press.
99
72
72
Separating flange (1) from housing (72)

Remove floating seal (70) by pushing up the outer
circumference of floating seal (70) with a flat-blade
screwdriver.
70
15-72
27. Storage of parts

This completes disassembly. Clean the disassembled parts thoroughly, coat them with a thick film of rust
preventive oil, put them in plastic bags and store them in a cool, dark, dry place.
If the parts are stored in a hot humid place, they may be rusted even if rust preventive oil is applied.
Keep the parts so no dust adheres to them.
15
15-73
15.4.3 ASSEMBLING TRAVEL MOTOR

Reduction unit
1. Assembling floating seal (70) into flange (1)
Confirm the below items concerning floating seal
(70). Then assemble floating seal (70) to flange (1),
using the floating seal fixing jig.
1
70
Floa ting s e a l fixing jig
Assembling floating seal (70)
Make certain that there is no dust on the surface of flange (1) in contact with floating seal (70).
• Thoroughly degrease the surface where floating seal (70) of flange (1) is located.
• Make sure that no dust is there on the O-ring of floating seal (70).
• Thoroughly degrease the surface of the O-ring in floating seal (70).
2. Assembling angular bearing (71) to housing (72)

Press angular bearing (71) into housing (72), using
a pressing jig and a press.
71
72
71
Angular bearing fixing jig
Pressing in angular bearing (71)
15-74
3. Assembling floating seal (70) into housing (72)

Make sure of the following as to floating seal (70).
Then assemble floating seal (70) into housing (72),
using the floating seal fixing jig.
Floa ting s e a l
fixing jig
70
72
Fixing floating seal (70)
Make certain that there is no dust and foreign matter on the surface on which floating seal (70) in housing (72) is
located.
• Thoroughly degrease the surface where floating seal (70) in housing (72) is located.
• Make sure that there is no dust and foreign matter on the O-ring of floating seal (70).
• Thoroughly degrease the surface of the O-ring in floating seal (70).
4. Assembling housing (72) into flange (1)

Make sure of the below items and assemble
housing (72) into flange (1), using a crane, so
floating seal (70) of flange (1) matches floating seal
(70) of housing (72).
72
Assembling housing (72) into flange (1)
Make certain that there is no foreign matter on the moving surface of the seal ring located in floating seal (70).
• Apply lubricating oil for the reduction unit or hydraulic oil to all sliding surface of seal ring located in floating seal 15
(70).
• When assembling housing (72) into flange (1), make sure that the shaft centers are aligned with each other.
5. Selecting the thickness of shim (73)

Choose the thickness of pre-load adjusting shims according to the following procedure :
15-75
1) Press the end face of the inner race of angular

74
bearing (71) at a load of 3,000kgf (6,600 lbf),
using the shim thickness adjusting jig.
h
Press load : 3,000kgf (6,600 lbf)
J IG
H
71
Selecting shim thicknesses (73)
2) In that case, measure the step H between the end face of the inner race of angular bearing (71) and the end
face of flange (1).
3) Measure the step h at holder (74).
4) Select and combine the repair kit [T=0.05mm (0.002inch), 0.1mm (0.004inch), 0.3mm (0.012inch), 0.5mm
(0.020inch), 1.0mm (0.039inch)] of shims (73) so as to attain shim thickness that matches (H-h).
Do not reuse shims (73) that were once used.

• Do this work without fail. If pre-load adjustment is not done well, the reduction unit may be broken during
operation.
• Clean the measuring surface thoroughly.
6. Assembling holder C (74)

74
Fix flange (1) and erect pins (99) (four places)
upright on flange (1).
Bring the shims selected under (5) in contact with 73
holder C (74), using grease, match the pin holes in
holder C (74) to the pins and press it in by press.
99
Fit washer (75) to holder C (74), coat bolts (76) with
Locktite and tighten the bolts to a specified torque.
Tightening torque: 539N·m (398 lbf·ft) 1
15-76
73
74
99
75
76
75
Be wa re of the a s s e mbling
dire ction of wa s he r (75).
Look a t the dire ction on
the figure on the right.
Installing holder (74)
Confirm that pins (99) are not inclined.

• Washer (75) is equipped with a spike to prevent it from getting slack. Fit the spike to the seat of holder C (74).
• Thoroughly clean the threads of bolt (76), degrease it and coat it with adhesive Locktite.
• Thoroughly clean and degrease the inside of the screw threads of flange (1).
7. Assembling planetary gear C (80) 72

Assemble thrust plate (77) to planetary gear C (80). 74
Next, fit needle bearing (79) to planetary gear C (80)
Finally, attach inner race (78). Then install planetary 77
78
gear C (80) by engaging the bore diameter of inner 80 79
race (78) with trunnions (four) of holder C (74).
80 77 79 78
Place the draft on
the holder (74) side.
74 Assembling direction of
15
thrust plate (77)
Assembling planetary gear (80)
15-77
Assemble thrust plate (77) to planetary gear C (80) so the draft of the thrust plate (77) is located on holder C (74)
side.
• When the planetary gears C (80) are installed finally to the holder C (74), mesh the inner gear of housing (72)
with gear of planetary gear C (80).
• Use care of the assembling direction of planetary gear C (80).
8. Assembling thrust plate (81)

Install planetary gear C (80) so the chamfer side in
the bolt hole of thrust plate (81) comes below the
neck of bolt (82).
After placing it, coat the screw threads of bolt (82)
with Locktite, attach bolt (82) and tighten it to a
specified torque.
Tightening torque: 539N·m (398 lbf·ft) 82 81
82
P la ce s o C2 cha mfe r s ide

come s on the s e a t s ide .
81
Assembling thrust plate (81)
Use care of the attaching direction of thrust plate (81). If the neck of the bolt is damaged, it breaks down.
• Clean the screw threads of bolt (82) thoroughly, degrease it and coat it with Locktite.
• Clean the screw threads in the tapped hole of holder C (74) thoroughly and degrease it thoroughly.
15-78
9. Assembling sun gear C (83)

Make sure that snap ring (84) is fitted to sun gear C
(83). Then attach sun gear C (83) to four planetary
gears C (80). 80
84 83
Assembling sun gear C (83)
Engage the teeth of planetary gear C (80) with those of sun gear C (83) and assemble them together.
10. Assembling holder B (85)

Engage the inner gear teeth of holder B (85) with the
teeth of sun gear C (83) and assemble holder B (85)
into sun gear C (83).
83
85
Attaching holder B (85)
15
15-79
11. Assembling planetary gear B (89)

Assemble thrust plate (86) to planetary gear B (89).
Next, attach needle bearing (88) to planetary gear B
(89).
Finally, attach inner race (87), engage the bore with
the trunnions (3 places) of holder B (85), and
86
assemble planetary gear B (89) into holder B (85).
89
85
87
88
P la ce the dra ft on 89 86 88 87
the holde r (85) s ide .
85
Assembling direction of thrust plate(86)
Assembling planetary gear B (89)
Attach thrust plate (86) to planetary gear B (89) so the draft side (by press) of thrust plate (86) is located on the
holder B side (85).
• Finally, when assembling planetary gear B (89) to holder B (85), engage the inner gear teeth of housing (72) with
the teeth of planetary gear B (89)
• Be careful of the assembling direction of planetary gear B (89).
12. Assembling drive gear (93)

Attach thrust plate (90) to planetary gear B (89) and
then attach thrust plate (91). 89
Coat the threads of screw (92) with Loctite and 90
91
tighten it to a specified torque.
Tools: Allen wrench: 8mm,
Tightening torque : 58.8N·m (43.4 lbf·ft) 93
Assemble drive gear (93) to three planetary gears B
(89) by directing the spline of drive gear (93) toward
the motor assembling side. Then engage the teeth
of planetary gear B (89) with the teeth of drive gear 92 78 79 80 81
(93).
Place the draft on
74 the holder (80) side.
As s e mbling dire ction of thrus t pla te (81)
Assembling drive gear (93)
15-80
Be careful about the assembling direction of thrust plate (90).

• Thoroughly clean and degrease the tapped hole in holder B (85) and the threads of screw (92).
13. Attaching thrust plate (94)

72
Measure the step between the end face of housing
(72) and thrust plate (94), using the thrust plate 91
selecting jig, choose and attach thrust plate (94)
according to the table below :
94
72
Measure the step T.
91
94
Assembling thrust plate (94)
Unit : mm (inch)
Step Shim
Thrust plate code
dimension (T) thickness (t)
1.20 to 0.67
20941 - 62306 2.3 (0.09)
(0.0472 to 0.0264)
0.66 to 0.04
20941 - 62307 2.8 (0.11)
(0.0260 to 0.0016)
0.03 to -0.16
20941 - 62308 3.0 (0.12)
(0.00122 to -0.0063)
-0.174 to -0.41
20941 - 62309 3.2 (0.13)
(-0.00685 to -0.0161)
-0.42 to -0.80
B0841 - 23017 3.6 (0.14)
(-0.0165 to -0.0315)
15
Align the hole in the center of thrust plate (94) with the convex part of drive gear (93) and assemble them together.
15-81
14. Attaching cover (95)

72
Remove foreign matter completely from the
matching surface between the end face of housing
(72) and cover (95). 95
Next, thoroughly degrease the matching surface 96
between the end face of housing (72) and cover
(95).
Further, apply liquid packing to the corner of the
spigot joint on the matching surface side of housing
(72) of cover (95). Match the tapped holes in
housing (72) with the bolt holes in cover (95) and
place cover (95) in housing (72).
Finally, attach bolts (96) and tighten them to
specified torque.
Tightening torque : 73.4N·m (54.1 lbf·ft)
Attaching cover (95)
15. Fitting plugs (97)

Take off O-ring (98) from plug (97), replace it with a
95
new one and place it in plug (97).
Then, attach plugs (97) to the oil inlet/outlet and the
level ports (3 in all) of cover (95), and tighten them
to specified torque. 98
Tightening torque :157N·m (116 lbf·ft)
Fixing plugs (97)
This completes the assy of the reduction unit.

Next comes the assemble of the motor. Assemble it, referring to "Assembling the Motor".
Motor
1. Fitting oil seal (53)
Make sure that flange (1) is equipped with oil seal
(53). If not, press oil seal (53) into flange (1), using
the oil seal fixing jig.
Oil s e a l
fixing jig
53
Fixing oil seal (53)
15-82
Before attaching oil seal (53), apply grease to the bore surface of flange (1) and outer diameter surface of oil seal
(53).
• Coat the lip of the bore of oil seal (53) with grease and put it in.
• Push the oil seal upright. If it is tilted, the outer diameter of oil seal (53) will be scored.
• Be careful so as not to score the lip of the bore of oil seal (53) when fixing it. If the lip is scored, oil leakage may
occur and break the inside of the reduction gear while the motor is running.
2. Assembling piston assy (48)

Place spring (61) in the hole where piston assy (48) 48
of flange (1) is located. 61
Then, mount piston assy (48) to flange (1).
Assembling piston assy (48)
Place spring (61) in the center of the hole.

• Install piston assy (48) with its cylindrical part facing downward.
• Before assembling piston assy (48), apply hydraulic oil to the bore of flange (1) and the outer surface of the
cylindrical part of piston assy (48).
• After assembling piston assy (48), confirm that it moves smoothly.
3. Fitting steel balls (47)

Fit steel balls (47) in the holes in the spherical
surface of flange (1).
47 15
Fixing steel balls (47)
15-83
Before fixing steel balls (47), apply hydraulic oil to the bore surface in the spherical part of flange (1) and steel balls
(47).
4. Installing shaft (36)

36
Press ball bearing (49) into shaft (36), using the
bearing fixing jig.
49
Then mount shaft (36) into the center of flange (1). Be a ring
fixing jig
Installing shaft (36)
Assemble ball bearing (49) upright.

• After mounting shaft (36), confirm that shaft (36) rotates smoothly.
5. Installing swash plate (46)

Attach flange (1) so the inclined surface of swash
plate (46) faces up. 46
Installing swash plate (46)
15-84
Assemble swash plate (46) by matching the holes in the rear spherical surface of the swash plate (46) to steel balls
(47).
• After coating steel balls (47) with hydraulic oil and assemble swash plate (46).
• After assembling swash plate (46), make sure that the swash plate moves smoothly.
6. Assembling cylinder block(37)

1) Place cylinder block (37) on a hand press bench
44
so the sliding surface of valve plate (62) faces up.
Assemble cylinder block (37) so the slope of
spring seat (42) faces downward. Then mount 43
spring (43) and collar (44) on spring seat (42), in
that order.
42
37
Assembling cylinder block (37)
2) Press in the top face of collar (44), using a jig,

41
and fix snap ring (41).
J IG
Fixing snap ring (41)
15
If snap ring (41) is tight, the snap ring pliers come off from the snap ring and you are injured by it, in some cases.
When fixing the snap ring, always use a jig and make sure that the claw of the snap ring pliers is engaged in the
hole of the snap ring
• If it is difficult to narrow the snap ring, use snap ring pliers one size larger.
• To press in collar (44), align the center of the cylinder block with that of the press.
15-85
3) Place cylinder block (37) on a work bench so the

sliding surface of cylinder block (37) in contact
45
with valve plate (62) faces downward.
Place three pins (45) into the slanted holes in
cylinder block (37).
37
Fixing pins (45)
Before placing cylinder block (37) on a work bench, make certain that there is nothing on the work bench.
• Use care so as not to score the sliding surface of valve plate (62) in cylinder block (37). If the surface is scored,
the motor performances are deteriorated which leads to a failure of the motor in an early stage.
• Before fixing pins (45), coat the pin holes with grease.
4) Install retainer holder (40) to cylinder block (37).
37
40
Attaching retainer holder (40)
5) Attach piston assy (38) (9pcs.) to retainer plate

(39) so the tapered face of retainer plate (39)
faces downward.
39
38
Assembling retainer plate (39)
15-86
6) Install piston assy (38) to cylinder block (37).
37
38
Assembling piston assy (38)
Coat the piston holes (9pcs.) in cylinder block (37) with hydraulic oil, before installing piston assy (38)
• Coat the spherical surface of retainer holder (40) with hydraulic oil, before assembling it.
7. Assembling cylinder block (37)

Engage the inner tooth splines of retainer holder
(40) and cylinder block (37) with the outer tooth
spline of shaft (36) so the sliding surface of cylinder
block (37) in contact with valve plate (62) faces
upwards. Then assemble cylinder block (37) into 37
flange (1).
Assembling cylinder block (37)
At assy, use care so piston assy (38), retainer plate (39) and retainer holder (40) do not come off from cylinder block
(37).
• Before assy, coat the surface of swash plate (46) and the sliding surface of piston assy (38) with hydraulic oil.
15
15-87
8. Attaching disk plate (54)

Engage the inner teeth of disk plate (54) with the
outer teeth of cylinder block (37) and mount them to
flange (1).
Assemble the convex portion of the outer
circumference of friction plate (55) with the 54
concavity of flange (1) and install them to flange (1). 55
54
In this way attach disk plate (54) and friction plate 55
54
(55) to the flange, in that order.
Assembling disk plate (54)
Disk plate (54) is a wet type disk.

Before assembly, immerse the disk plate (54) in hydraulic oil so disk plate (54) sucks in sufficient hydraulic oil.
9. Installing brake piston (56)

Attach O-rings (57),(58) to brake piston (56).
Next, mount brake piston (56) to flange (1) so the
larger diameter side of the brake piston faces
upward.
56
57
58
Positioning jig
56
Installing brake piston (56)
Coat O-rings (57),(58) with sufficient grease, before fixing them.

• Align the knock pin hole in flange (1) in contact with base plate (2) with the knock pin hole in brake piston (56),
using the positioning jig. Then install brake piston (56).
• Before fitting brake piston (56), coat the outer surface of the brake piston and the bore of flange (1) with grease.
• Assemble brake piston (56) by pressing it so it does not tilt. If the brake piston is assembled inclined, it develops
trouble and tears off O-rings in some cases.
15-88
10. Fitting springs (59)

Fit springs (59) into eight holes in brake piston (56).
59
Fixing spring (59)
11. Attaching valve plate (62)

62
Place base plate (2) on a work bench and press
bearing (50) in the center of base plate (2), using the Be a ring
bearing fixing jig. fixing jig
Confirm that knock pin (60) is fixed in base plate (2)
and attach valve plate (62) to base plate (2). 50
Attaching valve plate (62)
Place valve plate (62) with the copper alloy side facing upward.
• Coat the matching face between base plate (2) and valve plate (62) with grease to prevent the valve plate from
falling off.
• Use care so as not to score the copper alloy surface of valve plate (62).
12. Attaching base plate (2)

60 2
Fit O-rings (64) and O-rings (63) (4 places) to the
top face of flange (1).
Fit knock pin (60) to base plate (2).
Attach base plate (2) to flange (1) so the surface of
valve plate (62) in contact with base plate (2) faces
downward. Then tighten them with capscrew (52). 52
15
Tightening torque : 205 N·m (151 lbf·ft) 63
64
Attaching base plate (2)
15-89
Coat O-ring (64) with grease.

• Do not coat O-ring (63) with grease.
• Fix knock pin (60) with its taper part upward.
• Coat the surface of valve plate (62) and the cylinder block (37) with hydraulic oil and install them to base plate
(2).
• Since the surface of the base plate (2) in contact with base plate (2) faces downward, take care so the valve
plate does not fall.
• When installing base plate (2) to flange (1), make sure of the location of O-ring (63) and the location of the oil
passage hole in base plate (2).
• Before assmble, make sure of the knock pin (60) fixed in base plate (2), the hole in the base plate (2) into which
spring (59) enters, the knock pin hole on the flange side (1), and the position of spring (59).
• Tighten capscrew (52) evenly all round on the circumference.
13. Assembling travel 2-speed select spool (19)

Attach spring (21) to spool (19). Then attach them to
base plate (2). After placing spool (19), make certain
that O-ring (23) is set in plug (22), fit plug (22) to 25
base plate (2) and tighten it to a specified torque. 23
21
Next, make sure that O-ring (23) is fitted to plug
(25), install spring guide (24) and washer (26), place
plug (25) to base plate (2), and tighten it to a 2
specified torque.
Tightening torque : 118N·m (87 lbf·ft)
23
22
Assembling travel 2-speed select spool (19)
Assemble spool A (19) into base plate (2) so that the pipe port surface of base plate (2) comes toward yourself and
that the side of spool A (19) on which spring (21) is placed comes on the right. If the spool is assembled inversely,
spool change may get out of order and other trouble may occur in some cases.
• Coat the outer surface of spool (19) with hydraulic oil, before assembling it.
• After spool (19) is placed, make certain that it moves smoothly.
15-90
14. Assembling relief valve (17)

Make sure that poppet seat (17-3) is placed at the
tip of relief valve (17). Then assemble relief valve
(17) to base plate (2) and tighten them to a specified
torque.
17-17,18 2
17-3
17-7
17
Assembling relief valve (17)
Replace O-ring (17-7) with a new one, before assembly.

• Make sure that O-ring (17-7) and backup ring (17-18) are fitted to poppet seat (17-3).
• Coat O-ring (17-17) and backup ring (17-18) with grease, before assy.
15. Assembling counterbalance valve plunger (3)

Assemble plunger (3) to base plate (2).
Installing spool (3)
15
Assemble the plunger (3) to the base plate, while turning the plunger.
• Install plunger (3) straight.
• In case plunger (3) gets stuck, do not force it in, but tap it lightly with a plastic mallet.
• Coat the outer surface of plunger (3) with hydraulic oil before assmble.
15-91
16. Attaching cap (11)

Install spring seat (8) and spring (9) to plunger (3) in
this order.
Install ball (33), spring (34), and plug (15) with O-
ring (14) in this order to the hole at the side of cap
33,34,14,15
(11) of base plate (2).
Make sure that O-ring (12) is installed to cap (11)
and then install spring seat (10), spring (9), and
8 2 17
spring seat (8) to base plate (2) and install cap (11)
to base plate (2). 9
Finally, tighten capscrew (13) to the specified 10
torque.
Tools: Allen wrench: 10mm 11,12
13
Fitting cap (11)
Coat O-ring (12) with grease.

• Cap (11) is pushed up by the action of spring (9). When tightening up socket bolts (13), hold them down by hand.
• Tighten four socket bolts (13) evenly all round. If cap (11) is tightened up tilted, O-ring (12) is damaged, resulting
in oil leakage.
This completes assy of the hydraulic motor.
15-92
15.4.4 TRAVEL MOTOR MAINTENANCE STANDARD

Motor parts
Parts Check point Tolerance Remedy
Piston assy (38) Sliding surface of shoe The roughness is 0.8a or the Lap the moving surface of shoe
surface is roughened or the (#1000).
scratch is deeper than 0.02mm If the scratch does not
(0.0008inch). disappear, replace cylinder
block assy.
O.D. of piston The roughness is 1.2a or the Replace cylinder block assy.
surface is roughened or the
scratch is deeper than 0.02mm
(0.0008inch).
O.D. of piston and bore Clearance :

diameter of cylinder block 0.060mm (0.00236inch)
Gap on shoe ball Gap 0.4mm (0.016inch)
Cylinder block (37) Sliding surface of The roughness is 0.8a or the Lap the sliding surface (#1000).
valve plate surface is roughened or the If the scratch does not
scratch is deeper than 0.02mm disappear, replace cylinder
(0.0008inch). block assy.
Bore diameter The roughness is 1.6a or the Replace cylinder block assy.
(0.0008inch).
Bore diameter and the O.D. Clearance :

of piston assy 0.060mm (0.00236inch)
Spline at the joint of The pin that measures the Replace cylinder block assy.
shaft (36) between dia. 38.749mm
(1.52732inch) measures 3.333
dia.mm (0.13122inch) (V1=2.80)
or is broken.
Valve plate (62) Sliding surface A scratch deeper than 0.02mm Lap the moving surface.
(0.0008inch) is there on the 0.8a (#1000) If the scratch does not
roughness moving surface or a disappear, replace the valve
seizure is seen on the surface. plate.
The moving surface shows
abnormal wear.
Retainer plate (39) Sliding surface The sliding surface of 0.8a Replace retainer plate and
Retainer holder (40) roughness shows a scratch retainer holder.
deeper than 0.02mm
(0.0008inch) or shows a seizure.
Swash plate (46) Sliding surface The sliding surface of 0.8a Lap the sliding surface. (#1000)
roughness shows abnormal If the scratch does not
wear or a scratch deeper than disappear, replace the valve
0.02mm (0.0008inch). plate. 15
Spherical hole in which a The spherical surface of 1.6a Replace swash plate.
steel ball is placed roughness shows a scratch
deeper than 0.02mm
(0.0008inch) or is roughened.
Spherical hole in which a Ball depth :

steel ball is placed 14.5mm (0.571inch)
15-93
Shaft (36) O.D. of oil seal sliding surface The sliding surface shows a Replace shaft.
scratch deeper than 0.02mm
(0.0008inch) or is roughened,
except the oil seal lip moving
marks on the 1.6a roughness.
Spline at the joint of cylinder The pin that measures the over-
block (37) pin dia. 47.380mm
dia.mm (0.11811inch) or is
broken.
Spline at the joint of drive The pin that measures the
gear between dia. 30.498mm
broken.
Brake piston (56) Appearance and dimension Height : Replace brake piston.
38.2mm (1.504inch)
Sliding surface Roughness: 2.5a
Appearance The surface shows a scratch

deeper than 0.02mm
Disk plate (54) Appearance and dimension Thickness : Replace disk plate.
3.2mm (0.126inch)
Appearance The moving surface has a deep

scratch or the abrasive material
is peeled off.
Ball bearing (49) Rolling surface Flaking or impressed marks are Replace ball bearing.
Ball bearing (50) seen.
Function Rotation is abnormal.
(abnormal sound and uneven
rotation)
Piston assy (48) Sliding surface of shoe The roughness is 1.6a or the Lap the sliding surface of shoe.
surface is roughened or the (#1000)
scratch is deeper than 0.02mm In case the scratch does not
(0.0008inch). disappear, replace the flange
holder kit.
O.D. of piston The roughness is 1.2a or the Replace flange holder kit.
(0.0008inch).
O.D. of piston and bore Clearance:

diameter of flange holder (1) 0.040mm (0.00157inch)
Gap on shoe ball Gap : 1.0mm (0.039inch)
Plunger (3) O.D. of plunger The roughness is 0.8a or the Replace base plate kit.
surface shows a scratch deeper
than 0.02mm (0.0008inch) or is
roughened.
O.D. and the bore dia. of Clearance:

base plate 0.060mm (0.00236inch)
15-94
Base plate (2) Hole in which plunger (3) is The surface has a roughness Replace base plate kit.
placed more than 0.8a or shows a
scratch deeper than 0.02mm
Bore dia. of base plate and Clearance :

O.D. of plunger 0.060mm (0.00236inch)
Hole in which spool A (19) is The surface has a roughness

placed more than 0.8a or a scratch
deeper than 0.02mm
Bore dia. of base plate and Clearance :

O.D. of spool A (19) 0.060mm (0.00236inch)
Moving surface and seat of The surface has a scratch

free piston in relief valve assy deeper than 0.02mm
(17) (0.0008inch) or is roughened.
Spool A (19) O.D. of spool The surface has a roughness Replace base plate kit.
more than 0.8a or a scratch
deeper than 0.02mm
O.D. of spool and bore dia. of Clearance :

base plate 0.060mm (0.00236inch)
Free piston (17-9) Sliding surface and seat The surface has a scratch Replace relief valve assy.
surface of base plate deeper than 0.02mm
Housing (17-1) Moving surface (O.D.) of free The surface has a scratch
piston deeper than 0.02mm
Spring (43) Appearance and dimension Free length :

61.0mm (2.40inch)
Appearance It is deformed or the coil surface

is damaged.

39.0mm (1.54inch)

is damaged.

41.5mm (1.63inch)

is damaged.

48.5mm (1.91inch) 15
is damaged.

28.3mm (1.11inch)

is damaged.
O-rings and oil seals At disassy Replace O-rings and oil seals.
15-95
Reduction unit parts

Planetary gear A (89) Tooth thickness Bridged dimension of 6 teeth : Replace planetary gear.
66.649mm (2.62397inch)
Tooth face Pitching or fracture is seen on

10% or more of the tooth face.
Bore diameter Flaking is seen on the bore Replace planetary gear, needle
surface. bearing and inner race.
Needle bearing (88) Rolling surface of roller Flaking is seen on the surface.
Inner race (87) Outer diameter surface Flaking is seen on the surface.
Drive gear (93) Tooth thickness Bridged dimension of 3 teeth: Replace drive gear.
29.908mm (1.17748inch)

10% or more of the tooth face.
Spline The pin that measures the over- When drive gear is replaced,
pin dia. 38.989mm check shaft at the same time.
broken.
Holder B (85) Tooth thickness of inner gear The pin that measures the Replace holder.
between dia. 66.742mm
broken.
Sun gear C (83) Tooth thickness Bridged dimension of 4 teeth: Replace sun gear
41.371mm (1.62637inch)

more than 10% of the tooth face.
Planetary gear C (80) Tooth thickness Bridged dimension of 6 teeth: Replace planetary gear.
65.662mm (2.58511inch)

Bore diameter Flaking is seen on the bore Replace planetary gear, needle
surface. bearing and inner race.
Needle bearing (79) Rolling surface of roller Flaking is seen on the surface.
Inner race (78) Outer diameter surface Flaking is seen on the surface.
Housing (72) Tooth thickness The pin that measures the Replace housing.
between dia. 330.449mm
dia.mm (0.27559inch).

Shim (73) At disassembly Replace shims.
Flange (1) Bore dia. of the hole in 2- Clearance : Replace flange kit.
speed piston and the O.D. of 0.040 mm (0.00157inch)
piston assy
Bore dia. of the hole in 2- The surface has a roughness

speed piston more than 1.2a or is roughened
or has a scratch deeper than
0.02mm (0.0008inch).
15-96
Thrust plate (94) Thickness The plate thickness is either Replace thrust plate.
3.3mm (0.130inch), 2.5mm
(0.098inch), 2.9mm (0.114inch),
2.0mm (0.079inch), 2.7mm
(0.106inch) or the moving
surface has a deep scratch.
Angular bearing (71) Rolling surface of ball Flaking is seen. Replace angular bearing
Function Bearing makes an abnormal

sound as it turns. It does not turn
smoothly.
Floating seal (70) Sliding surface A deep scratch that develops oil Replace floating seal.
leaks is on the surface.
O-ring The surface has developed Do not disassemble any further
cracks. as oil leakage may occur if the
sliding marks on the seal ring
do not match the surface at
disassembly.
O-rings At disassembly Replace O-rings.
15
15-97
15.4.5 TRAVEL MOTOR TROUBLE SHOOTING

Piston motor
Trouble Probable cause Remedy
Motor does not turn. Devices other than piston motor and Check that pressure is at the inlet of the
reduction gear have trouble. motor. Then check for the cause, inspect
and repair.
The motor itself has a problem; the Disassemble, clean, eliminate foreign
operating part is stuck with dirt. matter and reassemble. In case parts are
scored by foreign matter, replace parts.
Motor inlet pressure is low. Increase the set pressure by operating the
main relief valve of the circuit.
The moving surface of piston motor is Disassemble and replace such parts that
abnormally worn and oil pressure is are worn abnormally.
escaping. Eliminate scratches and burrs from the
surface, clean parts and reassemble.
The main parts of piston motor are broken. Disassemble and replace those parts that
In that case, piston motor makes an are broken.
abnormal sound. After cleaning, reassemble parts.
Relief valve is operating as piston motor is Check the loaded condition and adjust the
loaded too much. load to a level that matches the set pressure
of relief valve.
Rotating speed of motor is low. Because of some trouble of hydraulic Check that a required flow is supplied to the
pump, pressure regulating valve, flow inlet of piston motor.
control valve and the like, the piston motor Then check for the cause of the trouble,
does not receive a required flow. This is the inspect and repair.
cause of low revolution.
Since the moving surface of piston motor is Disassemble, check the worn condition of
worn, hydraulic pressure escapes from the the moving surface of piston motor, and
high to low sides. (Volumetric efficiency is repair or replace according the maintenance
low.) manual.
This is why the revolution is deficient.
Motor revolution varies much Since the moving surface of piston motor is Disassemble and check the worn condition
and motor makes a big sound. worn, high pressure oil runs out of the drain of the moving surface.
port. Then repair or replace according to the
This causes the revolution to decrease maintenance procedure.
extremely and changes the revolution.
When machine goes downhill, double Disassemble and check the worn condition
counterbalance valve develops hunting of double counterbalance valve.
and causes the motor revolution to vary. Then repair or replace according to the
maintenance procedure.
Operating sound is large. Poor alignment causes the driven part to Align the centers correctly.
interfere with other part and make a sound.
Piston motor bearing is worn or broken, or Disassemble and replace broken parts such
spring is broken. as bearing and spring.
This causes the motor to make a sound. Clean parts and reassemble.
15-98
Oil leak Bolts in matching surface get slack. Retighten fastening bolts to a specified
This developed oil leakage. torque.
Oil is leaking as oil seal, O-ring and Disassemble and replace seals.
packing are broken. Confirm the temperature of hydraulic oil. In
case the operating oil temperature has risen
above 80C degrees (176F degrees),
examine the cooler and hold down the
hydraulic oil temperature below 80C
degrees (176F degrees).
Since the sliding surface of piston motor is Disassemble and check the worn condition
worn, the drain rate increased. of sliding surface.
This caused the oil seal to break and Repair or replace according to the shop
developed an oil leak. manual. Review oil seals.
Clean parts and reassemble.
Drain pressure rose as drain pipe was Disassemble and replace oil seals.
stuck with foreign matter or drain pipe is too Clean drain pipe and eliminate foreign
small or long. This caused oil seal to break matter. Review piping system so as to
and developed an oil leak. decrease the line resistance.
Abnormal sound and revolution Hydraulic oil level in hydraulic tank fell, Confirm the hydraulic oil level in hydraulic
and pressure fluctuations occur entrapped air and developed aeration. oil tank and resupply hydraulic oil according
due to cavitation. to the instructions of the machine proper.
Motor is installed improperly or the location Confirm the motor orientation and if it is
of hydraulic oil tank is improper. wrong, correct it to the correct orientation.
Therefore, hydraulic oil is discharged from Check that the oil level in the hydraulic oil
motor piping and motor circuits while the tank is above the motor level and if not,
hydraulic device is not running. change it higher than the motor level.
The motor developed aeration immediately Before running, place a self supply circuit so
after motor was driven. hydraulic oil is filled up in motor circuit and
piping.
When motor makes pumping action, motor Disassemble and repair or replace double
inlet pressure becomes negative due to counterbalance valve according to the shop
malfunctioning double counterbalance manual.
valve. This causes the motor to develop
cavitation.
Motor stopped while running Engine stalled because of too much load. Review load condition and change it to a
suitable level.
Motor stalled as the sliding surface of Check the spec (flow and motor revolution
piston motor was seized. in particular). if the motor revolution
exceeds a limit value, decrease the flow.
Replace motor as insides of motor are
broken beyond reuse.
15
15-99
Parking brake
If motor is rested under external Parking brake torque is low as disk is worn. Disassemble and replace parking brake
load, motor rotates. disk. Clean parts and reassemble.
Disk face deteriorated due to poor contact. Disassemble and replace disk.
This decreased the parking brake torque. Correct the surface in contact with the disk
and reassemble.
Spring is distorted or broken. Disassemble and replace spring.
This decreased the parking brake torque. Clean parts and reassemble.
Since external load is too large, power of Review the external load and change it to a
the parking brake is deficient. suitable level.
Motor does not produce Since O-ring is broken and pressure Disassemble and replace O-ring.
required drive force. escapes, the parking brake is not released. Clean parts and reassemble.
Motor generates abnormal heat.
Orifice in parking brake release oil passage Disassemble and remove foreign matter
is stuck with foreign matter. Therefore, from orifice. Then clean parts and
pressure does not reach parking brake reassemble. Flush the inside of pipes.
cylinder chamber. Thus parking brake is
not released.
Since drain pipe is stuck with foreign Clean drain pipe.
matter, drain pipe is small or long, drain Also, review piping system to decrease the
pressure rises. line resistance.
This prevents parking brake from being
released.
15-100
Relief valve
Motor does not turn or revolution Foreign matter is included between poppet Disassemble and remove foreign matter.
is low. seat and poppet of relief valve. Clean parts and reassemble.
This developed poor seating, and high
pressure oil is leaking toward the low
pressure side.
Spring of relief valve is broken and the high Replace relief valve.
pressure oil is leaking toward the low Disassemble motor, clean parts and
pressure side. reassemble.
Since the spring of relief valve is distorted, Replace relief valve.

set pressure falls. Thus the relief valve
operates at low pressure.
Foreign matter is included between free Remove relief valve and eliminate foreign
piston of relief valve and seat in contact matter.
with base plate.
This causes the set pressure to fall.
Foreign matter gets stuck in orifice located Remove relief valve and eliminate foreign
in poppet of relief valve. This causes set matter.
pressure to fall. Remove relief valve and
eliminate foreign matter.
Motor does not stop or motor Since foreign matter is included between Disassemble and eliminate foreign matter.
stops late. poppet seat and poppet of relief valve, poor Clean parts and reassemble.
seating occurs.
Relief valve does not close.
Spring of relief valve is broken, and relief Replace relief valve.
valve does not close. Disassemble motor, clean parts and
reassemble.
Since spring of relief valve is fatigued, set Replace relief valve.
pressure falls and the braking power drops.
Since foreign matter is included between Remove relief valve and eliminate foreign
free piston of relief valve and seat in matter.
contact with base plate, set pressure falls
and the braking force decreases.
Since foreign matter is included in orifice Remove relief valve and eliminate foreign
located in poppet of relief valve, set matter.
pressure falls and the braking power falls.
Shocks are large at stop. Since foreign matter is included in the Replace relief valve.
moving surface of poppet, poppet does not
operate.
Free piston does not operate as it is stuck Remove relief valve and remove foreign
with foreign matter. matter. Then reassemble.
Set pressure of relief valve is too high. Replace relief valve.

15
15-101
Counterbalance valve
If motor makes pumping action Plunger does not operate smoothly as Disassemble and remove the
as external load acts on it, motor foreign matter is included in plunger. contamination.
revolution changes. Then clean the plunger and reassemble it.
Wrong orifice size is used in pilot oil Replace with a correct orifice.
passage.
No orifice is fixed in pilot oil passage. Fix orifice in a correct position.
If motor makes pumping action Foreign matter is included in plunger. Disassemble and eliminate foreign matter.
as external load acts on motor , Plunger movement is bad and motor does Check the extent of damage according to
motor develops cavitation and not display counterbalance functions. the shop manual and reassemble if it is still
makes an abnormal sound. serviceable.
In case plunger is not serviceable, replace
base plate kit.
Since spring of plunger is broken, Disassemble and remove foreign matter.

counterbalance action does not work. Then replace spring and reassemble.
Since spring is not placed in plunger, Assemble a regular spring.

counterbalance valve does not work.
Since spring is not placed in check valve, Disassemble, eliminate foreign matter and
counterbalance function does not work. replace spring.
Since spring is not placed in check valve, Assemble a regular spring.

counterbalance function does not work.
Since orifice in pilot oil passage is clogged Disassemble, clean foreign matter and
with foreign matter, counterbalance reassemble.
function does not work.
15-102
Auto 2-speed select function

High-speed rotation can not be Pilot pressure is not at Ps port. Check that pilot pressure is at Ps port,
selected check for the cause, inspect and repair.
Foreign matter is included between spool Disassemble, remove foreign matter, and
and base plate, and spool does not change check the extent of scratch according to the
over. maintenance manual.
If spool is reusable, reassemble.
If it can not be reused, replace base plate
kit.
2-speed control piston develops abnormal Disassemble and replace flange holder kit.
wear and pressure is leaking into casing.
2-speed control piston is not fixed. Assemble 2-speed piston in a regular

position.
Orifice in 2-speed oil passage is clogged Disassemble, eliminate foreign matter and
with foreign matter. Therefore, pressure reassemble.
does not reach 2-speed control piston.
Motor changes over to high 2-speed control piston is worn abnormally, Disassemble and replace flange holder kit.
speed, but changes to low and pressure is leaking into casing.
speed as the temperature of
hydraulic oil rises.
Motor does not select low Pressure at Ps port does not go down even Check that pressure at Ps port is below
speed. if speed control switch is set at low speed. 0.5MPa (72.5psi) and review piping system.
Spring in 2-speed control valve is broken. Disassemble, remove foreign matter and
replace spring.
Spring is not placed in 2-speed control Assemble spring in a correct position.

valve.
Since foreign matter is included between Disassemble, clean foreign matter, and
spool and base plate, spool does not come check the extent of scratch according to the
back. maintenance manual.
If spool is reusable, reassemble.
If not, replace base plate kit.
Motor does not change over to Orifice in 2-speed passage is clogged with Disassemble, remove foreign matter and
low speed. foreign matter, and pressure does not go reassemble.
out of 2-speed control piston chamber.
Spring in 2-speed control valve is fatigued. Disassemble and replace spring.

As the result, change pressure is low.
Motor changes to low speed, but Pilot piping is clogged with foreign matter Clean the inside of piping and remove
changes to high speed while and oil leaks from 2-speed control valve. foreign matter.
running. As the result, pilot pressure rises to a Also review the piping system.
changeover level.
15
15-103
Reduction unit
Reduction unit does not rotate. Devices other than piston motor and Check that pressure is there at the motor
reduction unit have trouble. inlet, check for the cause, inspect and
repair.
Motor except reduction unit failed. Refer to the troubleshooting procedure in

the above steps (1) to (5).
Load exceeding motor output torque is Check load condition and get rid of load
acting on it. acting upon motor.
Reduction unit does not turn as angular Replace reduction unit.

bearing is broken. Check that excessive external load is not
acting upon it.
In case external load is too much, eliminate
it.
Reduction unit does not turn as gear in it is Replace reduction unit.
broken.
Reduction unit does not turn as bearing in it
is broken.
Reduction unit does not turn as spline in it
is broken.
Reduction unit makes a sound Gear in reduction unit is broken. Replace reduction unit.
while running.
Bearing in reduction unit is broken.
Parts are interfering with each other Disassemble and confirm the broken
because the sliding surface in reduction condition. If something broken is
unit is broken. discovered, replace reduction unit.
If no part is broken, replace worn parts,
clean them and reassemble.
Reduction unit is generating Lube oil in reduction unit is deficient. Confirm that there is no oil leakage.
abnormal heat. Disassemble and make sure of the
damaged condition in reduction unit.
If something is found broken, replace
reduction unit.
Fill lube oil to a specified level.
Too much lube oil is filled in reduction unit. Adjust lube oil volume to a specified level.
Bearing in reduction unit is broken. Replace reduction unit.
Abnormal thrust load is acting in reduction Disassemble and confirm the damaged
unit because of wrong selection of thrust condition of the inside.
plate. If something broken is confirmed, replace
reduction unit.
If not, replace thrust place with one of
proper thickness.
15-104
Oil leakage occurs. Reduction unit cover is slack and oil is Remove cover, reapply liquid packing and
leaking. tighten cover to a specified torque. Then fill
in lube oil to a specified level.
Oil is leaking from leaked plugs in oil inlet, Retighten plugs to specified torque. After
outlet, and check ports of reduction unit tightening, fill in lube oil to a specified level.
cover.
Oil is leaking as O-rings in oil inlet, outlet Replace O-rings in plugs. After
and check ports of reduction unit cover are replacement, fasten plugs to a specified
aged. torque and fill in lube oil to a specified level.
Oil leaks as housing is cracked. Replace reduction unit.
Oil is leaking as foreign matter is included Disassemble reduction unit, remove foreign
in the sliding surface of floating seal. matter from floating seal and reassemble.
Oil is leaking as the sliding surface of Disassemble reduction unit and replace
floating seal is corroded. floating seal.
Oil is leaking as O-ring on floating seal is

aged or scored.
Oil is leaking as seal collar of floating seal

is fractured.
15
15-105
15-106
［16. TROUBLE SHOOTING(BY ERROR CODES)］
16. TROUBLE SHOOTING(BY ERROR

CODES)
16.2 PREFACE ............................................................................................................................16-4
16.3 JUDGMENT OF ACTUAL THING AT SITE .............................................................................16-5
16.4 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING .................................................16-6
16.5 THE BLOWN FUSE OF MECHATROCONTROLLER ..............................................................16-7
16.6 TROUBLESHOOTING BY ERROR CODE..............................................................................16-8
16
16-1
16-2

16
16-3
16.2 PREFACE
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.
Attending the field to verify actual thing.
16-4
16.3 JUDGMENT OF ACTUAL THING AT SITE

GET TO THE SITE AS QUICKLY AS POSSIBLE
Verify model name, number, situation of trouble andfield, and notify person of arrival time.
VERIFY BACKGROUND OF TROUBLE OCCURRED

• Model name and serial number
• Kind of attachment
Check that the combination of attachment is proper or
that the operating method is not unreasonable.
• Operating time by hour-meter
• Situation of trouble
Check that the trouble occurred first time or occurred
again.
• History of trouble occurred and additional works.
Recurrence of past trouble, or problems on the
additional works.
Verifying background of trouble occurred
HOW TO DIAGNOSE TROUBLE

• Verify the defective part
• Make the condition of trouble again
• Classify the trouble and make sure the procedures of
troubleshooting
(See “CLASSIFICATION OF FAILURE AND
TROUBLESHOOTING“.)
• Where the defective parts can not be verified, surmise
causes systematically.
• Verify reasons for surmise
• Report the methods, procedure, and period for
repairing to a user.
Confirm symptoms of trouble
PRECAUTIONS FOR REPAIRING

• Explain the cause of trouble to the user.
For example, oil leak through piston is caused by
flawson the piston rod. And the method of using the
machines should be explained so that thesame kind
of trouble does not reoccur.
• 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 Failure diagnosis by troubleshooting
hydraulic unit, etc. and return them. And also use care
not to flaw and damage those surfaces.
16
16-5
16.4 CLASSIFICATION OF FAILURE AND

TROUBLESHOOTING
Classify failures into the following 3 types and carry out the troubleshooting.
No. Classes of failure Troubleshooting
When error code of self diagnosis is displayed on gauge Carry out troubleshooting according to the error code.
A
cluster.
When no failure is detected currently but error code after When it is hard to recreate the failure situation, cancel the
self diagnosis is remained in trouble history. data in the history and reproduce the failed situation or
B
suppose the cause according to the troubleshooting by
error code, and then repair it.
When error code of self diagnosis is not displayed or is Carry out troubleshooting according to instructions in
C
not remained in history. "TROUBLESHOOTING (BY TROUBLE)".
16-6
16.5 THE BLOWN FUSE OF MECHATROCONTROLLER

If the fuse of mechatro controller has blown, the following display appears on the gauge cluster.
The blown fuse of mechatro controller

• Blown fuse 5A of mechatro controller:
"DATA COMMUNICATION ERROR" is displayed on the gauge cluster in the condition where the controller
program is not executed.
• Blown fuse 20A of mechatro controller:
The controller functions normally but the power supply applied when the controllerdrives the solenoid, etc. stops.
Many error codes are displayed on the gauge cluster.
D013, D023, D033, D063,
E013, E023, F021
16
16-7
16.6 TROUBLESHOOTING BY ERROR CODE

When error code was displayed on the gauge cluster with the aid of self-diagnosis display function, carry out the
troubleshooting referring to applicable page in the contents of error codes.
ERROR CODE LIST

Error Code Trouble
A015 Engine adjustment (A adjustment) is not adjusted yet or is failed.
A025 Pump proportional valve adjustment (B adjustment) is not adjusted yet or is failed.
A035 Unload valve adjustment (C adjustment) is not adjusted yet or is failed.
A215 Written data of ROM adjustment data is incorrect.
A225 Writing of ROM adjustment data is incorrect.
A235 Written data of ROM hour meter data is incorrect.

A245 Writing of ROM hour meter data is incorrect.
A255 Writing of proportional valve adjustment data is incorrect.
B012 Incorrect output of boom up pressure sensor
B013 Disconnection of boom up pressure sensor
B014 Power short circuit of boom up pressure sensor
B022 Incorrect output of boom down pressure sensor
B023 Disconnection of boom down pressure sensor
B024 Power short circuit of boom down pressure sensor
B032 Incorrect output of arm-out pressure sensor
B033 Disconnection of arm-out pressure sensor
B034 Power short circuit of arm-out pressure sensor
B042 Incorrect output of arm-in pressure sensor
B043 Disconnection of arm-in pressure sensor
B044 Power short circuit of arm-in pressure sensor
B052 Incorrect output of bucket digging pressure sensor
B053 Disconnection of bucket digging pressure sensor
B054 Power short circuit of bucket digging pressure sensor
B062 Incorrect output of bucket dump pressure sensor
B063 Disconnection of bucket dump pressure sensor
B064 Power short circuit of bucket dump pressure sensor
B072 Incorrect output of swing right pressure sensor
B073 Disconnection of swing right pressure sensor
B074 Power short circuit of swing right pressure sensor
B082 Incorrect output of swing left pressure sensor
B083 Disconnection of swing left pressure sensor
B084 Power short circuit of swing left pressure sensor
B092 Incorrect output of travel right pressure sensor
B093 Disconnection of travel right pressure sensor
B094 Power short circuit of travel right pressure sensor
B102 Incorrect output of travel left pressure sensor
16-8
Error Code Trouble

B103 Disconnection of travel left pressure sensor
B104 Power short circuit of travel left pressure sensor
B113 Disconnection of option selector position detect pressure sensor
B114 Power short circuit of option selector position detect pressure sensor
B162 Incorrect output of P1 side option pressure sensor
B163 Disconnection of P1 side option pressure sensor
B164 Power short circuit of P1 side option pressure sensor
B172 Incorrect output of P2 side option pressure sensor
B173 Disconnection of P2 side option pressure sensor
B174 Power short circuit of P2 side option pressure sensor
C012 Incorrect output of P1 pump pressure sensor
C013 Disconnection of P1 pump pressure sensor
C014 Power short circuit of P1 pump pressure sensor
C022 Incorrect output of P2 pump pressure sensor
C023 Disconnection of P2 pump pressure sensor
C024 Power short circuit of P2 pump pressure sensor
C033 Disconnection of boom head pressure sensor
C034 Power short circuit of boom head pressure sensor
C043 Disconnection of boom rod pressure sensor
C044 Power short circuit of boom rod pressure sensor
D012 Failure of output transistor ON of P1 unload proportional valve
D013 Disconnection of P1 unload proportional valve
D022 Failure of output transistor ON of P2 unload proportional valve
D023 Disconnection of P2 unload proportional valve
D032 Failure of output transistor ON of travel straight proportional valve
D033 Disconnection of travel straight proportional valve
D062 Failure of output transistor ON of arm-in spool 2 proportional valve
D063 Disconnection of arm-in spool 2 proportional valve
D172 Failure of output transistor ON of boom 2 proportional valve
D173 Disconnection of boom 2 proportional valve
D182 Failure of output transistor ON of boom 3 proportional valve
D183 Disconnection of boom 3 proportional valve
E012 Failure of output transistor ON of P1 pump proportional valve
E013 Disconnection of P1pump proportional valve
E022 Failure of output transistor ON of P2 pump proportional valve
E023 Disconnection of P2 pump proportional valve
E032 Failure of output transistor ON of option relief 1 proportional valve 16

E033 Disconnection of option relief 1 proportional valve
E042 Failure of output transistor ON of option relief 2 proportional valve
E043 Disconnection of option relief 2 proportional valve
16-9
Error Code Trouble

F011 Failure of output transistor OFF and GND short circuit of power boost SOL valve
F013 Failure of output transistor ON and disconnection of power boost SOL valve
F021 Failure of output transistor OFF and GND short circuit of swing parking SOL valve
F023 Failure of output transistor ON and disconnection of swing parking SOL valve
F031 Failure of output transistor OFF and GND short circuit of travel 1-2 speed SOL valve
F033 Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve
F041 Failure of output transistor OFF and GND short circuit of option selector SOL valve
F043 Failure of output transistor ON and disconnection of option selector SOL valve
F071 Failure of output transistor OFF and GND short circuit of boom M/I cut SOL valve
F073 Failure of output transistor ON and disconnection of boom M/I cut SOL valve
G032 Overrun of Mechatro-controller direct input speed sensor
G033 Disconnection of Mechatro controller direct input speed sensor
G042 Overrun of received data from Mechatro-controller direct input speed sensor and engine controller
G043 Disconnection of received data from Mechatro-controller direct input speed sensor and engine controller
H013 Disconnection of acceleration potentiometer
H014 Power short circuit of acceleration potentiometer
H023 Disconnection of boom angle potentiometer
H024 Power short circuit of boom angle potentiometer
H033 Disconnection of arm angle potentiometer
H034 Power short circuit of arm angle potentiometer
H091 GND short circuit of fuel sensor

H093 Disconnection of fuel sensor
H111 GND short circuit of temperature sensor for hydraulic oil clogging
H113 Disconnection of temperature sensor for hydraulic oil clogging
H123 Disconnection of swing speed sensor
H124 Power short circuit of swing speed sensor
I111 Reception error of CAN1 communication (passive error)
I113 Reception error of CAN1 communication (time-out)
I121 Transmission error of CAN1 communication (busoff)
I211 Reception error of CAN2 communication (busoff)
I213 Reception error of CAN2 communication (time-out)
I221 Transmission error of CAN2 communication (busoff)
K014 Adhesion of battery relay contact
R014 Failure of arc prevention relay of wiper motor
R024 Failure of normal rotation relay of wiper motor
R034 Failure of reverse rotation relay of wiper motor
R044 Failure of washer motor relay
R054 Failure of bucket limitation relay
R134 Failure of swing flasher right relay
R144 Failure of swing flasher left relay
16-10
Error Code Trouble

R154 Failure of travel alarm relay
R164 Failure of auto idle stop relay 2
R174 Failure of engine emergency stop relay
R184 Failure of lever lock relay
R214 Failure of safety relay
16
16-11
Error Code A015

Trouble Engine adjustment (A adjustment) is not adjusted yet or is failed.
Judging Engine adjustment is not adjusted yet. Or the value cannot be set in the adjustment range during
condition adjustment.
Symptom Deviated from the command engine speed, but no problem in normal operations.
Control in the Operated at the default engine speed.

event of failure
Return in normal The engine adjustment is completed normally.
condition
Screen 2 G-3 ENGINE SPEED SETTING
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
Checking object Checking contents and remedy
1 • Performing adjustment Perform engine adjustment (A adjustment).

When "ERROR ENGINE" is displayed during adjustment, see "MEASURES WHEN
MECHATRO CONTROL ADJUSTMENT IS IMPOSSIBLE".
2 • Mechatro controller Check that the error is corrected after replacement of the controller.
Error Code A025

Trouble Pump proportional valve adjustment (B adjustment) is not adjusted yet or is failed.
Judging The pump proportional valve adjustment is not adjusted yet.

condition Or the value cannot be set in the adjustment range during adjustment.
Symptom Deviated from the pump output, but no problem in normal operations.
Control in the Works with the default data.

event of failure
Return in normal The pump proportional valve adjustment is completed normally.
condition
Screen 6 C-1 P1 PUMP
No.
Service
diagnosis
No.
checking screen
Screen
No.
1 • Performing adjustment Perform pump adjustment (B adjustment).

When "ERROR PUMP" is displayed during adjustment, see "MEASURES WHEN
16-12
Error Code A035

Trouble Unload valve adjustment (C adjustment) is not adjusted yet or is failed.
Judging The adjustment of unload valve is missed.

condition Or the adjusting value can not be set in the adjusting range.
Symptom Deviated from the unload valve output, but no problem in normal operations.
Control in the Works with the default data.

event of failure
Return in normal The adjustment of unload valve is completed normally.
condition
Screen 7 D-1 P1 UN-LOAD (BP-CUT)
No.
Service
diagnosis
No.
checking screen
Screen
No.
1 • Performing adjustment Perform unload valve adjustment (C adjustment).

When "ERROR PUMP" is displayed during adjustment, see "MEASURES WHEN
Error Code A215

Trouble Written data of ROM adjustment data is incorrect.
Judging Check adjustment data, and judge the content of memory is correct or not. (Trouble history only)
condition
Symptom Becomes not normal output, but no problem in normal operation.
Control in the Controlled by the correct memory data.

event of failure
Return in normal Does not return. Replacement of the controller is required.
condition
Screen
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 Mechatro controller Check that the error is corrected after replacement of the controller.
2
3
16
16-13
Error Code A225

Trouble Writing of ROM adjustment data is incorrect.
Judging Check adjustment data, and judge the data is correct or not.
condition
Symptom No effect
Control in the Controlled by the default value.

event of failure
condition
Screen
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
2
3
Error Code A235

Trouble Written data of ROM hour meter data is incorrect.
Judging Check backup, and judge the content of memory is correct or not. (Trouble history only)
condition
Symptom No effect
Control in the Controlled by the correct memory data.

event of failure
condition
Screen
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
2
3
16-14
Error Code A245

Trouble Writing of ROM hour meter data is incorrect.
Judging Check adjustment data, and judge the content of memory is correct or not.
condition
Symptom The hour meter reading can become 0.
Control in the The machine works normally.

event of failure
condition
Screen
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
2
3
Error Code A255

Trouble Writing of proportional valve adjustment data is incorrect.
Judging Check adjustment data, and judge the content of memory is correct or not.
condition
Symptom Becomes not normal output, but no problem in normal operation.
Control in the Controlled by the default value.

event of failure
condition
Screen
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
2
3
16
16-15
Error Code B012

Trouble Incorrect output of boom up pressure sensor
Judging During the period after the starter switch ON until start of the engine, the input voltage from the boom up
condition pressure sensor is from 1.4V or more to less than 4.7V.
Symptom The boom up operability becomes poor.
Control in the Normal control

event of failure
Return in normal Not returned automatically under normal condition. Switch the power OFF once and turn on it again.
condition
Screen 5 B-1 BOOM RAISE
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Boom up pressure sensor When B012 is cancelled and another error occurs by turning the starter switch on
SE-3 after replacing the connector with that of another sensor, check the sensor unit for
possible failure and replace it if necessary.
2 • Wiring between boom up When B012 is displayed by turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure according
CN-126F to the wiring checking procedures and repair it if necessary.
CN-101F
Error Code B013

Trouble Disconnection of boom up pressure sensor
Judging The input voltage from boom up pressure sensor is less than 0.1V.
condition
Symptom Speed of all operations slows down.
Control in the The output of P1 and P2 pump proportional valves becomes a constant current.
event of failure
Return in normal It returns automatically in normal condition.
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-101F
16-16
Error Code B014

Trouble Power short circuit of boom up pressure sensor
Judging The input voltage from boom up pressure sensor is 4.7V or more.
condition
event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-101F
Error Code B022

Trouble Incorrect output of boom down pressure sensor
Judging During the period after the starter switch ON until start of the engine, the input voltage from the boom
condition down pressure sensor is from 1.4V or more to less than 4.7V.
Symptom The boom down operability becomes poor.

event of failure
condition
Screen 5 B-2 BOOM LOWER
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Boom down pressure sensor When B022 is cancelled and another error occurs by turning the starter switch on
2 • Wiring between boom down When B022 is displayed by turning the starter switch on after replacing the
CN-127F to the wiring checking procedures and repair it if necessary. 16
CN-101F
16-17
Error Code B023

Trouble Disconnection of boom down pressure sensor
Judging The input voltage from boom down pressure sensor is less than 0.1V.
condition
event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
pressure sensor and controller connector with that of another sensor, check the wiring for possible failure
CN-127F according to the wiring checking procedures and repair it if necessary.
CN-101F
Error Code B024

Trouble Power short circuit of boom down pressure sensor
Judging The input voltage from boom down pressure sensor is 4.7V or more.
condition
event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-101F
16-18
Error Code B032

Trouble Incorrect output of arm-out pressure sensor
Judging During the period after the starter switch ON until start of the engine, the input voltage from the arm-out
Symptom The arm-out operability becomes poor.

event of failure
condition
Screen 5 B-3 ARM OUT
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Arm out pressure sensor When B032 is cancelled and another error occurs by turning the starter switch on
2 • Wiring between arm-out When B032 is displayed by turning the starter switch on after replacing the
CN-101F
Error Code B033

Trouble Disconnection of arm-out pressure sensor
Judging The input voltage from arm-out pressure sensor is less than 0.1V.
condition
event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Arm out pressure sensor When B033 is cancelled and another error occurs by turning the starter switch on
2 • Wiring between arm-out When B033 is displayed by turning the starter switch on after replacing the
CN-101F
16-19
Error Code B034

Trouble Power short circuit of arm-out pressure sensor
Judging The input voltage from arm-out pressure sensor is 4.7V or more.
condition
event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Arm out pressure sensor When B034 is cancelled and another error occurs by turning starter switch on after
SE-8 replacing the connector with that of another sensor, check sensor unit for possible
failure. If failure found, replace it.
2 • Wiring between arm-out When B034 is displayed after turning the starter switch on after replacing the
pressure sensor and controller connector with that of another sensor, check wiring for possible failure according to
CN-131F the wiring checking procedure and repair it if necessary.
CN-101F
Error Code B042

Trouble Incorrect output of arm-in pressure sensor
Judging During the period after the starter switch ON until start of the engine, the input voltage from the arm-in
Symptom The arm-in operability becomes poor.

event of failure
condition
Screen 5 B-4 ARM IN
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Arm in pressure sensor When B042 is cancelled and another error occurs by turning the starter switch on
2 • Wiring between arm-in When B042 is displayed by turning the starter switch on after replacing the
CN-101F
16-20
Error Code B043

Trouble Disconnection of arm-in pressure sensor
Judging The input voltage from arm-in pressure sensor is less than 0.1V.
condition
Symptom Cavitation occurs during independent arm-in operation. Speed of all operations slows down.
The output of P1 and P2 pump proportional valves becomes a constant current.

Control in the The output of P1 and P2 unload proportional valves becomes 750 mA (only during independent
event of failure operation)
The output of arm-in spool 2 proportional valve becomes 200 mA.

condition
Screen 5 B-4 ARM IN
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-101F
16
16-21
Error Code B044

Trouble Power short circuit of arm-in pressure sensor
Judging The input voltage from arm-in pressure sensor is 4.7V or more.
condition
Symptom Cavitation occurs during independent arm-in operation. Speed of all operations slows down.
The output of P1 and P2 pump proportional valves becomes a constant current.

Control in the The output of P1 and P2 unload proportional valves becomes 750 mA (only during independent
event of failure operation)
The output of arm-in spool 2 proportional valve becomes 200 mA.

condition
Screen 5 B-4 ARM IN
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-101F
16-22
Error Code B052

Trouble Incorrect output of bucket digging pressure sensor
Judging During the period after the starter switch ON until start of the engine, the input voltage from the bucket
condition digging pressure sensor is from 1.4V or more to less than 4.7V.
Symptom The bucket digging operability becomes poor.

event of failure
condition
Screen 5 B-5 BUCKET DIG
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Bucket digging pressure When B052 is cancelled and another error occurs by turning the starter switch on
sensor after replacing the connector with that of another sensor, check the sensor unit for
SE-1 possible failure and replace it if necessary.
2 • Wiring between bucket When B052 is displayed by turning the starter switch on after replacing the
digging pressure sensor and connector with that of another sensor, check the wiring for possible failure according
controller to the wiring checking procedures and repair it if necessary.
CN-124F
CN-101F
Error Code B053

Trouble Disconnection of bucket digging pressure sensor
Judging The input voltage from bucket digging pressure sensor is less than 0.1V.
condition
event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
digging pressure sensor and connector with that of another sensor, check the wiring for possible failure according 16
CN-124F
CN-101F
16-23
Error Code B054

Trouble Power short circuit of bucket digging pressure sensor
Judging The input voltage from bucket digging pressure sensor is 4.7V or more.
condition
event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
digging pressure sensor and connector with that of another sensor, check the wiring for possible failure according
CN-124F
CN-101F
Error Code B062

Trouble Incorrect output of bucket dump pressure sensor
Judging During the period after the starter switch ON until start of the engine, the input voltage from the bucket
condition dump pressure sensor is from 1.4V or more to less than 4.7V.
Symptom The bucket dump operability becomes poor.

event of failure
condition
Screen 5 B-6 BUCKET DUMP
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Bucket dump pressure sensor When B062 is cancelled and another error occurs by turning the starter switch on
2 • Wiring between bucket dump When B062 is displayed by turning the starter switch on after replacing the
CN-101F
16-24
Error Code B063

Trouble Disconnection of bucket dump pressure sensor
Judging The input voltage from bucket dump pressure sensor is less than 0.1V.
condition
event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-101F
Error Code B064

Trouble Power short circuit of bucket dump pressure sensor
Judging The input voltage from bucket dump pressure sensor is 4.7V or more.
condition
event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-101F
16-25
Error Code B072

Trouble Incorrect output of swing right pressure sensor
Judging During the period after the starter switch ON until start of the engine, the input voltage from the swing
condition right pressure sensor is from 1.4 V or more to less than 4.7 V.
Symptom The swing operability becomes poor.

event of failure
condition
Screen 5 B-7 SWING
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Swing right pressure sensor When B072 is cancelled and another error occurs by turning the starter switch on
2 • Wiring between swing right When B072 is displayed by turning the starter switch on after replacing the
CN-105F
Error Code B073

Trouble Disconnection of swing right pressure sensor
Judging The input voltage from swing right pressure sensor is less than 0.1 V.
condition
Control in the The swing parking solenoid is demagnetized (release condition).

event of failure
condition
Screen 5 B-7 SWING
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-105F
16-26
Error Code B074

Trouble Power short circuit of swing right pressure sensor
Judging The input voltage from swing right pressure sensor is 4.7 V or more.
condition

event of failure
condition
Screen 5 B-7 SWING
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-105F
Error Code B082

Trouble Incorrect output of swing left pressure sensor
Judging During the period after the starter switch ON until start of the engine, the input voltage from the swing left
condition pressure sensor is from 1.4 V or more to less than 4.7 V.

event of failure
condition
Screen 5 B-7 SWING
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Swing left pressure sensor When B082 is cancelled and another error occurs by turning the starter switch on
2 • Wiring between swing left When B082 is displayed by turning the starter switch on after replacing the
CN-102F
16-27
Error Code B083

Trouble Disconnection of swing left pressure sensor
Judging The input voltage from swing left pressure sensor is less than 0.1 V.
condition

event of failure
condition
Screen 5 B-7 SWING
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-102F
Error Code B084

Trouble Power short circuit of swing left pressure sensor
Judging The input voltage from swing left pressure sensor is 4.7 V or more.
condition

event of failure
condition
Screen 5 B-7 SWING
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-102F
16-28
Error Code B092

Trouble Incorrect output of travel right pressure sensor
Judging During the period after the starter switch ON until start of the engine, the input voltage from the swing
condition right pressure sensor is from 1.4V or more to less than 4.7V.
Symptom The travel right operability becomes poor.

event of failure
condition
Screen 5 B-9 TRAVEL (R)
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Travel right pressure sensor When B092 is cancelled and another error occurs by turning the starter switch on
2 • Wiring between travel right When B092 is displayed by turning the starter switch on after replacing the
CN-101F
Error Code B093

Trouble Disconnection of travel right pressure sensor
Judging The input voltage from travel right pressure sensor is less than 0.1V.
condition
event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-101F
16-29
Error Code B094

Trouble Power short circuit of travel right pressure sensor
Judging The input voltage from travel right pressure sensor is 4.7V or more.
condition
event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-101F
Error Code B102

Trouble Incorrect output of travel left pressure sensor
Judging During the period after the starter switch ON until start of the engine, the input voltage from the travel left
Symptom The travel left operability becomes poor.

event of failure
condition
Screen 5 B-10 TRAVEL (L)
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Travel left pressure sensor When B102 is cancelled and another error occurs by turning starter switch on after
SE-10 replacing the connector with that of another sensor, check sensor unit for possible
failure. If failure found, replace it.
2 • Wiring between travel left When B102 is displayed by turning the starter switch on after replacing the
CN-101F
16-30
Error Code B103

Trouble Disconnection of travel left pressure sensor
Judging The input voltage from travel left pressure sensor is less than 0.1V.
condition
event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Travel left pressure sensor When B103 is cancelled and another error occurs by turning the starter switch on
CN-101F
Error Code B104

Trouble Power short circuit of travel left pressure sensor
Judging The input voltage from travel left pressure sensor is 4.7V or more.
condition
event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Travel left pressure sensor When B104 is cancelled and another error occurs by turning the starter switch on
CN-101F
16-31
Error Code B113

Trouble Disconnection of option selector position detect pressure sensor
Judging The input voltage from option selector position detect pressure sensor is less than 0.1V.
condition
Symptom The switched position of the selector valve cannot be detected.

event of failure
condition
Screen 13 B-11
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Option selector position detect When B113 is cancelled and another error occurs by turning the starter switch on
pressure sensor after replacing the connector with that of another sensor, check the sensor unit for
2 • Option selector position detect When B113 is displayed by turning the starter switch on after replacing the
pressure sensor connector with that of another sensor, check the wiring for possible failure according
CN-103F
Error Code B114

Trouble Power short circuit of option selector position detect pressure sensor
Judging The input voltage from option selector position detect pressure sensor is 4.7V or more.
condition
Symptom The switched position of the selector valve cannot be detected.

event of failure
condition
Screen 13 B-11
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Option selector position detect When B114 is cancelled and another error occurs by turning the starter switch on
pressure sensor after replacing the connector with that of another sensor, check the sensor unit for
2 • Option selector position detect When B114 is displayed by turning the starter switch on after replacing the
pressure sensor connector with that of another sensor, check the wiring for possible failure according
CN-103F
16-32
Error Code B162

Trouble Incorrect output of P1 side option pressure sensor
Judging During the period after the starter switch ON until start of the engine, the input voltage from the P1side
condition option pressure sensor is from 1.4V or more to less than 4.7V.
Symptom The P1 side option operability becomes poor.

event of failure
condition
Screen 5 B-16 P1 OPT.
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • P1 side option pressure When B162 is cancelled and another error occurs by turning the starter switch on
2 • Wiring between P1 side option When B162 is displayed by turning the starter switch on after replacing the
CN-102F
Error Code B163

Trouble Disconnection of P1 side option pressure sensor
Judging The input voltage from P1 side option pressure sensor is less than 0.1V.
condition
event of failure But normal control is done when the left control pedal selection is ON.

condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
connector with that of another sensor, check the wiring for possible failure according
pressure sensor and controller
CN-102F
16-33
Error Code B164

Trouble Power short circuit of P1 side option pressure sensor
Judging The input voltage from P1 side option pressure sensor is 4.7V or more.
condition

condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-102F
Error Code B172

Trouble Incorrect output of P2 side option pressure sensor
Judging During the period after the starter switch ON until start of the engine, the input voltage from the P2 side
condition option pressure sensor is from 1.4V or more to less than 4.7V.
Symptom The P2 side option operability becomes poor.

event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-102F
16-34
Error Code B173

Trouble Disconnection of P2 side option pressure sensor
Judging The input voltage from P2 side option pressure sensor is less than 0.1V.
condition
event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-303F to the wiring checking procedures and repair it if necessary
CN-102F
Error Code B174

Trouble Power short circuit of P2 side option pressure sensor
Judging The input voltage from P2 side option pressure sensor is 4.7V or more.
condition

condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-102F
16-35
Error Code C012

Trouble Incorrect output of P1 pump pressure sensor
Judging During the period after the starter switch ON until start of the engine, the input voltage from the P1 pump
Symptom Speed of all operations slows down. Engine speed goes down significantly.

event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • P1 pump pressure sensor When C012 is cancelled and another error occurs by turning the starter switch on
2 • Wiring between P1 pump When C012 is displayed by turning the starter switch on after replacing the
CN-103F
Error Code C013

Trouble Disconnection of P1 pump pressure sensor
Judging The input voltage from P1 pump pressure sensor is less than 0.1V.
condition
Control in the P1 pump pressure is controlled as 25 MPa (3625 psi).

event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-103F
16-36
Error Code C014

Trouble Power short circuit of P1 pump pressure sensor
Judging The input voltage from P1 pump pressure sensor is 4.7V or more.
condition

event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
SE-22 after replacing the connector with that of another sensor, check sensor unit for
possible failure. If failure found, replace it.
CN-103F
Error Code C022

Trouble Incorrect output of P2 pump pressure sensor
Judging During the period after the starter switch ON until start of the engine, the input voltage from the P2 pump

event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-103F
16-37
Error Code C023

Trouble Disconnection of P2 pump pressure sensor
Judging The input voltage from P2 pump pressure sensor is less than 0.1V.
condition

event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-103F
Error Code C024

Trouble Power short circuit of P2 pump pressure sensor
Judging The input voltage from P2 pump pressure sensor is 4.7V or more.
condition

event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-103F
16-38
Error Code C033

Trouble Disconnection of boom head pressure sensor
Judging The input voltage from boom head pressure sensor is less than 0.1V.
condition
Symptom Not affect machine movement.

event of failure
condition
Screen 13 C-3 BOOM-HEAD
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Boom head pressure sensor When C033 is cancelled and another error occurs after replacing the connector with
SE-24 that of another sensor, check the sensor unit for possible failure and replace it if
necessary.
2 • Wiring between boom head When C033 is displayed after replacing the connector with that of another sensor,
pressure sensor and controller check the wiring for possible failure according to the wiring checking procedures
CN-706F and repair it if necessary.
CN-105F
Error Code C034

Trouble Power short circuit of boom head pressure sensor
Judging The input voltage from boom head pressure sensor is 4.7V or more.
condition

event of failure
condition
Screen 13 C-3 BOOM-HEAD
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Boom head pressure sensor When C034 is cancelled and another error occurs by turning the starter switch on
2 • Wiring between boom head When C034 is displayed after replacing the connector with that of another sensor,
CN-706F and repair it if necessary. 16
CN-105F
16-39
Error Code C043

Trouble Disconnection of boom rod pressure sensor
Judging The input voltage from boom rod pressure sensor is less than 0.1V.
condition

event of failure
condition
Screen 13 C-4 BOOM-ROD
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Boom rod pressure sensor When C043 is cancelled and another error occurs after replacing the connector with
necessary.
2 • Wiring between boom rod When C043 is displayed after replacing the connector with that of another sensor,
CN-103F
Error Code C044

Trouble Power short circuit of boom rod pressure sensor
Judging The input voltage from boom rod pressure sensor is 4.7V or more.
condition

event of failure
condition
Screen 13 C-4 BOOM-ROD
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Boom rod pressure sensor When C044 is cancelled and another error occurs after replacing the connector with
necessary.
2 • Wiring between boom rod When C044 is displayed after replacing the connector with that of another sensor,
CN-103F
16-40
Error Code D012

Trouble Failure of output transistor ON of P1 unload proportional valve
Judging The feed-back value from the proportional valve is 1000mA or more.
condition
Symptom Arm out/option conflux operation is impossible. Travel right operation is impossible.

event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • P1 unload proportional sol. When D012 is cancelled and another error occurs after replacing the connector with
PSV-D that of another proportional valve, check the proportional valve unit for possible
failure and replace it if necessary.
2 • Wiring between P1 unload When D012 is displayed after replacing the connector with that of another
proportional valve and proportional valve, check the wiring for possible failure according to the wiring
controller checking procedures and repair it if necessary.
CN-120F
CN-104F
Error Code D013

Trouble Disconnection of P1 unload proportional valve
Judging The feed-back value from proportional valve is less than 100mA. (If output is less than 150mA, judging is
condition not done.)
Symptom The fine operability becomes poor.

event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • P1 unload proportional sol. When D013 is cancelled and another error occurs after replacing the connector with
PSV-D that of another proportional valve, check the proportional valve unit for possible
proportional valve and proportional valve, check the wiring for possible failure according to the wiring 16
CN-120F
CN-104F
16-41
Error Code D022

Trouble Failure of output transistor ON of P2 unload proportional valve
condition
Symptom Independent operations of boom up, bucket digging, and bucket dump become slow. Travel left operation
is impossible.

event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • P2 unload proportional valve When D022 is cancelled and another error occurs after replacing the connector with
PSV-B that of another proportional valve, check the proportional valve unit for possible
controller checking procedures and repair it if necessary
CN-118F
CN-104F
16-42
Error Code D023

Trouble Disconnection of P2 unload proportional valve
Symptom The fine operability becomes poor.

event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • P2 unload proportional valve When D023 is cancelled and another error occurs after replacing the connector with
PSV-B that of another proportional valve, check the proportional valve unit for possible
CN-118F
CN-104F
Error Code D032

Trouble Failure of output transistor ON of travel straight proportional valve
condition
Symptom Travel deviation occurs by combined operation of traveling and attachment.

event of failure
condition
Screen 7 D-3 S-TRAVEL
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Travel straight proportional When D032 is cancelled and another error occurs after replacing the connector with
valve that of another proportional valve, check the proportional valve unit for possible
PSV-C failure and replace it if necessary.
2 • Wiring between Travel straight When D032 is displayed after replacing the connector with that of another
CN-119F
CN-103F
16-43
Error Code D033

Trouble Disconnection of travel straight proportional valve
Symptom Travel deviation occurs by combined operation of traveling and attachment. Speed of all operations slows
down.
event of failure
condition
Screen 7 D-3 S-TRAVEL
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Travel straight proportional When D033 is cancelled and another error occurs after replacing the connector with
PSV-C failure and replace it if necessary.
2 • Wiring between Travel straight When D033 is displayed after replacing the connector with that of another
CN-119F
CN-103F
16-44
Error Code D062

Trouble Failure of output transistor ON of arm-in spool 2 proportional valve
Judging The feed-back value from proportional valve is 1000mA or more.

condition
Symptom Operability of combined operation including arm-in becomes poor.

event of failure
condition
Screen 7 D-6 ARM IN2-SPEED
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Arm-in spool 2 proportional When D062 is cancelled and another error occurs after replacing the connector with
PSV-A failure and replace it if necessary.
2 • Wiring between Arm-in spool When D062 is displayed after replacing the connector with that of another
2 proportional valve and proportional valve, check the wiring for possible failure according to the wiring
CN-121F
CN-104F
16
16-45
Error Code D063

Trouble Disconnection of arm-in spool 2 proportional valve
Judging The feed-back value from proportional valve is 100mA or less. (If output is 150mA or less, judging is not
condition done.)
Symptom Cavitation occurs during independent arm-in operation. Operability of combined operation including arm-
in becomes poor.

event of failure
condition
Screen 7 D-6 ARM IN2-SPEED
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Arm-in spool 2 proportional When D063 is cancelled and another error occurs after replacing the connector with
PSV-A failure and replace it if necessary.
2 • Wiring between Arm-in spool When D063 is displayed after replacing the connector with that of another
2 proportional valve and proportional valve, check the wiring for possible failure according to the wiring
CN-121F
CN-104F
16-46
Error Code D172

Trouble Failure of output transistor ON of boom 2 proportional valve
condition

event of failure
condition
Screen
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Boom 2 proportional valve When D172 is cancelled and another error occurs after replacing the connector with
PSV-23 that of another proportional valve, check the proportional valve unit for possible
2 • Wiring between boom 2 When D172 is displayed after replacing the connector with that of another
CN-799F
CN-105F
Error Code D173

Trouble Disconnection of boom 2 proportional valve
condition done.)

event of failure
condition
Screen
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-799F
CN-105F
16-47
Error Code D182

Trouble Failure of output transistor ON of boom 3 proportional valve
condition

event of failure
condition
Screen
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-823F
CN-105F
16-48
Error Code D183

Trouble Disconnection of boom 3 proportional valve
condition done.)

event of failure
condition
Screen
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-823F
CN-105F
16
16-49
Error Code E012

Trouble Failure of output transistor ON of P1 pump proportional valve

condition
Symptom The fine operability of the attachment becomes poor.

event of failure
condition
Screen 6 E-1 P1 PUMP
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • KPSS release switch Check that the KPSS release switch is set at the "release" side or not.
SW-22
2 • P1 pump proportional valve When E012 is cancelled and another error occurs after replacing the connector with
PSV-P1 that of another proportional valve, check the proportional valve unit for possible
3 • Wiring between P1 pump When E012 is displayed after replacing the connector with that of another
proportional valve, KPSS proportional valve, check the wiring for possible failure according to the wiring
release switch, and controller checking procedures and repair it if necessary.
CN-141F
CN-56F
CN-103F
16-50
Error Code E013

Trouble Disconnection of P1pump proportional valve
Judging The feed-back value from proportional valve is less than 100mA. (If output is 150mA or less, judging is

event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
SW-22
CN-141F
CN-56F
CN-103F
16
16-51
Error Code E022

Trouble Failure of output transistor ON of P2 pump proportional valve

condition
Symptom The fine operability of the attachment becomes poor.

event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
SW-22
CN-142F
CN-56F
CN-103F
16-52
Error Code E023

Trouble Disconnection of P2 pump proportional valve

event of failure
condition
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
SW-22
release switch, and controller checking procedures and repair it if necessary
CN-142F
CN-56F
CN-103F
16
16-53
Error Code F011

Trouble Failure of output transistor OFF and GND short circuit of power boost SOL valve
Judging The feed-back signal is grounding level while exciting command is output.
condition
Symptom Not switch to power boost operation.

event of failure
Return in normal The feed-back signal is 24V level while exciting command is output.
condition
Screen 3 F-1 POWER BOOST
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • ATT boost solenoid valve When F011 is cancelled and another error occurs after replacing the connector with
SV-2 that of another solenoid valve, check the solenoid valve unit for possible failure and
replace it if necessary.
2 • Wiring between ATT boost When F011 is displayed after replacing the connector with that of another solenoid
solenoid valve and controller valve, check the wiring for possible failure according to the wiring checking
CN-117F procedures and repair it if necessary.
CN-102F
16-54
Error Code F013

Trouble Failure of output transistor ON and disconnection of power boost SOL valve
Judging The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Not switch to power boost operation. Or not switch from power boost operation.

event of failure
Return in normal The feed-back signal is grounding level while exciting command is not output.
condition
Screen 3 F-1 POWER BOOST
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • ATT boost solenoid valve When F013 is cancelled and another error occurs after replacing the connector with
2 • Wiring between ATT boost When F013 is displayed after replacing the connector with that of another solenoid
CN-102F
16
16-55
Error Code F021

Trouble Failure of output transistor OFF and GND short circuit of swing parking SOL valve
condition
Symptom Swing parking brake does not change. (The brake does not work.)

event of failure
condition
Screen 3 F-2 SWING-BRAKE
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Swing parking solenoid valve When F021 is cancelled and another error occurs after replacing the connector with
2 • Swing PB release switch Set swing PB release switch to the release side and check that connector (CN-63F)
SW-4 is switched.
If failure is found, replace it.
3 • Wiring between swing parking When F021 is displayed after replacing the connector with that of another solenoid
solenoid valve, swing PB valve, check the wiring for possible failure according to the wiring checking
release switch, and controller procedures and repair it if necessary.
CN-123F
CN-63F
CN-104F
CN-102F
16-56
Error Code F023

Trouble Failure of output transistor ON and disconnection of swing parking SOL valve
condition
Symptom Swing parking brake does not change. (Stays in braking condition or the brake does not work.)

event of failure
condition
Screen 3 F-2 SWING-BRAKE
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Swing parking solenoid valve When F023 is cancelled and another error occurs after replacing the connector with
2 • Swing PB release switch Set swing PB release switch to the release side and check that connector (CN-63F)
SW-4 is switched.
If failure is found, replace it.
3 • Wiring between swing parking When F023 is displayed after replacing the connector with that of another solenoid
solenoid valve, swing PB valve, check the wiring for possible failure according to the wiring checking
release switch, and controller procedures and repair it if necessary.
CN-123F
CN-63F
CN-104F
CN-102F
16
16-57
Error Code F031

Trouble Failure of output transistor OFF and GND short circuit of travel 1-2 speed SOL valve
condition
Symptom The speed does not switch to the travel 2 speed.

event of failure
condition
Screen 3 F-3 1/2-TRAVEL
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Travel 1, 2speed solenoid When F031 is cancelled and another error occurs after replacing the connector with
valve that of another solenoid valve, check the solenoid valve unit for possible failure and
SV-3 replace it if necessary.
2 • Wiring between travel 1, When F031 is displayed after replacing the connector with that of another solenoid
2speed solenoid valve and valve, check the wiring for possible failure according to the wiring checking
controller procedures and repair it if necessary.
CN-122F
CN-102F
16-58
Error Code F033

Trouble Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve
condition
Symptom The speed does not switch to the travel 2nd speed. Or it does not switch to the travel 1st speed from the
travel 2nd speed.

event of failure
condition
Screen 3 F-3 1/2-TRAVEL
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Travel 1, 2speed solenoid When F033 is cancelled and another error occurs after replacing the connector with
valve that of another solenoid valve, check the solenoid valve unit for possible failure and
SV-3 replace it if necessary.
2 • Wiring between travel 1, When F033 is displayed after replacing the connector with that of another solenoid
2speed solenoid valve and valve, check the wiring for possible failure according to the wiring checking
CN-122F
CN-102F
16
16-59
Error Code F041

Trouble Failure of output transistor OFF and GND short circuit of option selector SOL valve
condition
Symptom The option selector solenoid valve does not change.

event of failure
condition
Screen 9 F-4 OPT SELECT
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Option selector solenoid valve When F041 is cancelled and another error occurs after replacing the connector with
replace it if necessary
2 • Wiring between option When F041 is displayed after replacing the connector with that of another solenoid
selector solenoid valve and valve, check the wiring for possible failure according to the wiring checking
CN-1031F
CN-102F
16-60
Error Code F043

Trouble Failure of output transistor ON and disconnection of option selector SOL valve
condition
Symptom The option selector solenoid valve does not change. Or stays in the changed condition.

event of failure
condition
Screen 9 F-4 OPT SELECT
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Option selector solenoid valve When F043 is cancelled and another error occurs after replacing the connector with
2 • Wiring between option When F043 is displayed after replacing the connector with that of another solenoid
selector solenoid valve and valve, check the wiring for possible failure according to the wiring checking
CN-1031F
CN-102F
Error Code F071

Trouble Failure of output transistor OFF and GND short circuit of boom cut SOL valve
condition

event of failure
condition
Screen
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Boom cut solenoid valve When F071 is cancelled and another error occurs after replacing the connector with
2 • Wiring between boom When F071 is displayed after replacing the connector with that of another solenoid
procedures and repair it if necessary.
16
CN-800F
CN-104F
16-61
Error Code F073

Trouble Failure of output transistor ON and disconnection of boom cut SOL valve
condition

event of failure
condition
Screen
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Boom cut solenoid valve When F073 is cancelled and another error occurs after replacing the connector with
2 • Wiring between boom When F073 is displayed after replacing the connector with that of another solenoid
CN-104F
Error Code G032

Trouble Overrun of Mechatro-controller direct input speed sensor
Judging Engine rpm input is 3000rpm or more. (Only trouble history)

condition
Symptom Operates without problem.
Control in the Receives rpm from the engine controller to perform control.
event of failure
condition
Screen 2 G-3 MEAS 1 (for mechatro controller)
No.
Service
Screen 2 G-3 MEAS 2 (receives from engine controller)
diagnosis
No.
checking screen
Screen
No.
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6 to 2.0 kΩ
2 • Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure and
sensor and controller repair it if necessary.
CN-136F Especially check wiring for false disconnection and noise included.
CN-103F
(The controller is broken only when power voltage is applied to the signal GND
side.)
16-62
Error Code G033

Trouble Disconnection of Mechatro controller direct input speed sensor
Judging The voltage of the alternator is 12 V or more and the speed sensor indicates the extreme low speed or
condition less.
Control in the Receives rpm from the engine controller to perform control.
event of failure
condition
No.
Service
diagnosis
No.
checking screen
Screen
No.
CN-136F
CN-103F
side.)
16
16-63
Error Code G042

Trouble Overrun of received data from Mechatro-controller direct input speed sensor and engine controller
Judging Engine rpm input is 3000rpm or more. (Only trouble history)

condition

event of failure
condition
No.
Service
diagnosis
No.
checking screen
Screen
No.
CN-136F Especially check wiring for false disconnection and noise included.
CN-103F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure and
speed sensor, pressure repair it if necessary.
sensor and controller Especially check wiring for false disconnection and noise included.
side.)
5 • Engine controller Check that the error is corrected after replacement of the controller.
16-64
Error Code G043

Trouble Overrun of received data from Mechatro-controller direct input speed sensor and engine controller
Disconnection of received data from Mechatro-controller direct input speed sensor and engine controller
Judging The voltage of the alternator is 12 V or more and the received data from the speed sensor and the engine
condition controller is the extreme low speed or less.
Symptom Abrupt load application may cause the engine speed to go down significantly.
Control in the Engine speed input becomes 0 rpm. And ESS horse power reduction command becomes 0.
event of failure
condition
No.
Service
diagnosis
No.
checking screen
Screen
No.
CN-136F
CN-103F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure and
speed sensor, pressure repair it if necessary.
sensor and controller
• (The controller is broken only when power voltage is applied to the signal GND
side.)
5 Engine controller Check that the error is corrected after replacement of the controller.
•
16
16-65
Error Code H013

Trouble Disconnection of acceleration potentiometer
Judging The input voltage from accel potentiometer is less than 0.1V.
condition
Symptom LOW idling is fixed.
Control in the LOW idling is fixed.

event of failure
condition
Screen 2 H-1 ACCEL VOLT.
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Acceleration potentiometer Measure the resistance between terminals of the acceleration potentiometer.
Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between acceleration Check wiring for possible failure according to the wiring checking procedure and
potentiometer and controller repair it if necessary.
CN-402F
CN-102F
16-66
Error Code H014

Trouble Power short circuit of acceleration potentiometer
Judging The input voltage from acceleration potentiometer is 4.7V or more.

condition
Symptom LOW idling is fixed.
Control in the LOW idling is fixed.

event of failure
condition
Screen 2 H-1 ACCEL VOLT.
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Acceleration potentiometer Measure the resistance between terminals of the acceleration potentiometer.
Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between acceleration Check wiring for possible failure according to the wiring checking procedure and
potentiometer and controller repair it if necessary.
CN-402F
CN-102F
Error Code H091

Trouble GND short circuit of fuel sensor
Judging The input voltage from fuel sensor is less than 0.1V.
condition
Symptom Warning for low fuel level is indicated.
Control in the The fuel level is regarded as 0 %.

event of failure
condition
Screen 8 H-9 FUEL LEVEL
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Fuel sensor Move fuel sensor and measure the resistance between terminals of fuel sensor.
SE-15 EMPTY 95 Ω to FULL 5 Ω
2 • Wiring between fuel sensor Check wiring for possible failure according to the wiring checking procedure and
and controller repair it if necessary.
CN-152F
CN-103F 16
16-67
Error Code H093

Trouble Disconnection of fuel sensor
Judging The input voltage from fuel sensor is 4.7V or more.
condition
Symptom Warning for low fuel level is indicated.
Control in the The fuel level is regarded as 0 %.

event of failure
condition
Screen 8 H-9 FUEL LEVEL
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel sensor.
SE-15 EMPTY 95 Ω to FULL 5 Ω
2 • Wiring between fuel sensor Check wiring for possible failure according to the wiring checking procedure and
and controller repair it if necessary.
CN-152F
CN-103F
Error Code H111

Trouble GND short circuit of temperature sensor for hydraulic oil clogging
Judging The input voltage from the sensor is less than 0.1V.
condition
Control in the Hydraulic oil temperature is regarded as 0C degrees.

event of failure
condition
Screen 8 H-10 HYD. OIL TEMP
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Hydraulic oil temperature Measure the resistance between terminals of the hydraulic oil temperature sensor
sensor by changing the temperature of the sensor.
SE-21 0 degrees C (32 degrees F): 1150 Ω to 50 degrees C (122 degrees F): 98.2 Ω
2 • Wiring between hydraulic oil Check wiring for possible failure according to the wiring checking procedure and
temperature sensor and repair it if necessary.
controller
CN-59F
CN-103F
16-68
Error Code H113

Trouble Disconnection of temperature sensor for hydraulic oil clogging
Judging The input voltage from the sensor is 4.7V or more.

condition
Control in the Hydraulic oil temperature is regarded as 0 degrees C (32 degrees F).
event of failure
condition
Screen 8 H-10 HYD. OIL TEMP
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Hydraulic oil temperature Measure the resistance between terminals of the hydraulic oil temperature sensor
sensor by changing the temperature of the sensor.
SE-21 0 degrees C (32 degrees F): 1150 Ω to 50 degrees C (122 degrees F): 98.2 Ω
2 • Wiring between hydraulic oil Check wiring for possible failure according to the wiring checking procedure and
temperature sensor and repair it if necessary.
controller
CN-59F
CN-103F
Error Code H123

Trouble Disconnection of swing speed sensor
Judging The input voltage from swing speed sensor is less than 0.1V.
condition

event of failure
condition
Screen
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Wiring between swing speed Check wiring for possible failure according to the wiring checking procedure and
CN-798F
CN-105F
2 • Swing speed sensor Check that the error is corrected after replacement of the sensor. 16
SE-99
16-69
Error Code H124

Trouble Power short circuit of swing speed sensor
Judging The input voltage from swing speed sensor is 4.7V or more.
condition

event of failure
condition
Screen
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Wiring between swing speed Check wiring for possible failure according to the wiring checking procedure and
CN-798F
CN-105F
2 • Swing speed sensor Check that the error is corrected after replacement of the sensor.
SE-99
Error Code I111

Trouble Reception error of CAN1 communication (passive error)
Judging Data from the engine controller cannot be received correctly. (Only trouble history)
condition
Symptom Affects operation very little.
Control in the Keeps the last receiving condition.

event of failure
condition
Screen 22 RECEIVE COUNT.
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Wiring between ECU and Check wiring for possible failure according to the wiring checking procedure and
controller repair it if necessary.
CN-1F (There is a possibility of false disconnection.)
CN-3F
CN-5F
CN-104F
16-70
Error Code I113

Trouble Reception error of CAN1 communication (time-out)
Judging Data from the engine controller cannot be received correctly.

condition
Control in the Operates as the coolant temperature is 20 degrees C (68 degrees F). Output of the P1 and P2 pump
event of failure proportional valves becomes 350 mA.

condition
Screen 2 G-5 WATER TEMP
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-3F
CN-5F
CN-104F
Error Code I121

Trouble Transmission error of CAN1 communication (busoff)
Judging Transmission data of the mechatro controller cannot be transmitted correctly.

condition
Symptom Affects operation very little.

event of failure
Return in normal Normal control
condition
Screen 22 TRANS. COUNT.
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-3F
CN-5F
CN-104F
16
16-71
Error Code I211

Trouble Reception error of CAN2 communication (busoff)
Judging Data from the gauge cluster cannot be received correctly. (Only trouble history)
condition
Symptom Switches of gauge cluster can not be used.

event of failure
condition
Screen
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Wiring from gauge cluster and Check wiring for possible failure according to the wiring checking procedure and
CN-102F
CN-33F
Error Code I213

Trouble Reception error of CAN2 communication (time-out)
Judging Data from the gauge cluster cannot be received correctly.

condition
Symptom Switches of gauge cluster can not be used.

event of failure
condition
Screen
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-102F
CN-33F
16-72
Error Code I221

Trouble Transmission error of CAN2 communication (busoff)
Judging Transmission data of the mechatro controller cannot be transmitted correctly.

condition
Symptom Gauge cluster can not be used.

event of failure
condition
Screen
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
CN-102F
CN-33F
16
16-73
Error Code K014

Trouble Adhesion of battery relay contact
Judging The power 24V is continuously supplied to controller for 40 seconds or more while the key switch ON
condition signal turned OFF
Symptom The power on the battery relay secondary side does not turn OFF even if the key switch is turned OFF.
Control in the Normal control with key switch OFF

event of failure
Return in normal Turn key switch ON.
condition Or when the power supply 24V to mechatro controller is stopped.
Screen 4 K-1 AIS RELAY 2

No.
Service
Screen 4 K-3 KEY SWITCH OFF
diagnosis
No.
checking screen
Screen
No.
1 • Battery relay Turn key switch off and disconnect the connector (CN-256F) on the battery relay
R-1 coil. If 24V power lives on battery relay secondary side, check on battery relay for
CN-256F failure and replace it if failed.
2 • Auto idle stop relay 2 Turn off the key switch, and remove the connector (CN-256F) on the battery relay
R-24 coil side. If power of battery relay on secondary side falls, remove either auto idle
stop relay 2 or alternator relay.
• Alternator relay
The failure may be occurred in case where the power falls after the relay was
R-28
removed, and therefore check on the relay unit and replace it with new one if failed.
3 • Wiring between auto idle stop When R024 is left displayed with the relay removed, check that 24V is produced on
relay/alternator relay and relay (-) line according to the wiring checking procedure and repair it.
controller
CN2-1,CN-102F, and CN-
104F When no failure is found after checking on wiring and K014 is left displayed, replace
fuse/relay box.
• Fuse & relay box
E-1
16-74
Error Code R014

Trouble Failure of arc prevention relay of wiper motor
Judging The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the power
condition source.
Symptom Wiper does not move.
Control in the Relay output is stopped.

event of failure
Return in normal When the power is OFF
condition
Screen 19 PREVENT ARC
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Wiper motor arc prevention When error is cancelled after removing wiper motor arc prevention relay, check
relay relay unit for failure, replace it with new one if falied.
R-31 When resistance between relay terminals (1) and (2) shown in the right figure is 0
Ω, relay is failed.
2 • Wiring between wiper motor When R014 is left displayed with the relay removed, check that 24V is produced on
arc prevention relay and relay (-) line according to the wiring checking procedure and repair it.
controller
CN-101F,CN2-1
When no failure is found after checking on wiring and R014 is left displayed, replace
fuse/relay box.
E-1
16
16-75
Error Code R024

Trouble Failure of normal rotation relay of wiper motor
Judging The mechatro controller output line to wiper motor normal rotation relay is short-circuited with the power
condition source.
Symptom Wiper does not move.

event of failure
condition
Screen 19 CW MOTOR RLY
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Wiper motor normal rotation When error is cancelled after removing wiper motor normal rotation relay, check
relay relay unit for failure, replace it with new one if failed.
normal rotation relay and relay (-) line according to the wiring checking procedure and repair it.
controler
CN-101F,CN2-1 When no failure is found after checking on wiring and R024 is left displayed, replace
fuse/relay box.
E-1
16-76
Error Code R034

Trouble Failure of reverse rotation relay of wiper motor
Judging The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the power
condition source.
Symptom Wiper does not move after forward rotation.

event of failure
condition
Screen 19 CCW MOTOR RLY
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Wiper motor reverse rotation When error is cancelled after removing wiper motor reverse rotation relay, check
relay relay unit for failure, replace it with new one if failed.
forward rotation relay and relay (-) line according to the wiring checking procedure and repair it.
controller
CN-101F,CN2-1 When no failure is found after checking on wiring and R034 is left displayed, replace
fuse/relay box.
E-1
16
16-77
Error Code R044

Trouble Failure of washer motor relay
Judging The mechatro controller output line to washer motor relay is short-circuited with the power source.
condition
Symptom Washer motor does not move.

event of failure
condition
Screen 19 WASHER MOTOR RELAY
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • WASHER MOTOR RELAY When error is cancelled after removing washer motor relay, check relay unit for
R-32 failure, replace it with new one if failed.
When resistance between relay terminals (1) and (2) shown in the right figure is 0
2 • Wiring between washer motor When R044 is left displayed with the relay removed, check that 24V is produced on
relay and controllerWASHER relay (-) line according to the wiring checking procedure and repair it.
MOTOR RELAY
CN-105F, CN2-1 When no failure is found after checking on wiring and R044 is left displayed, replace
fuse/relay box.
E-1
16-78
Error Code R134

Trouble Failure of swing flasher right relay
Judging The mechatro controller output line to the swing flasher relay is short-circuited with the power source.
condition
Symptom Swing flasher right relay does not work.

event of failure
condition
Screen 16 D013
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Swing flasher relay When the error is cancelled after removing the swing flasher relay, check the relay
R-19 unit for failure, replace it with a new one if failed.
When the resistance between relay terminals H and D shown in the right figure is 0
Ω, the relay is failed.
2 • Wiring between flasher relay When R134 is left displayed with the relay removed, check that 24V is produced on
and controller relay (-) line (C, shown in the upper figure) according to the wiring checking
CN-104F procedure and repair it.
CN-74F
16
16-79
Error Code R144

Trouble Failure of swing flasher left relay
Judging The mechatro controller output line to the swing flasher relay is short-circuited with the power source.
condition
Symptom Swing flasher right relay does not work.

event of failure
condition
Screen 17 D014
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Swing flasher relay When the error is cancelled after removing the swing flasher relay, check the relay
R-19 unit for failure, replace it with a new one if failed.
When the resistance between relay terminals H and D shown in the right figure is 0
Ω, the relay is failed.
2 • Wiring between flasher relay When R144 is left displayed with the relay removed, check that 24V is produced on
and controller relay (-) line according to the wiring checking procedure and repair it.
CN-104F
CN-74F
16-80
Error Code R154

Trouble Failure of travel alarm relay
Judging The mechatro controller output line to travel alarm relay is short-circuited with the power source.
condition
Symptom Travel alarm does not actuate.

event of failure
condition
Screen 17 D015
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Travel alarm relay When error is cancelled after removing travel alarm relay, check relay unit for
R8 failure, replace it with new one if failed.
2 • Travel alarm switch Remove connector (CN-521F) and check that if conduction/non-conduction is
SW-13 switched by switch ON/OFF or not. If failure is found, replace it.
3 • Wiring between travel alarm When R154 is left displayed with the relay removed, check that 24V is produced on
relay, travel alarm switch, and relay (-) line according to the wiring checking procedure and repair it.
controller
CN-105F, CN2–1 When no failure is found after checking on wiring and R154 is left displayed, replace
CN-521F fuse/relay box.
E-1
16
16-81
Error Code R164

Trouble Failure of auto idle stop relay 2
Judging The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power source.
condition
Power source for mechatro controller often turns off.
Symptom
Auto idle stop function does not actuate.

event of failure
condition
Screen 4 K-1 AIS RELAY 2
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Auto idle stop relay 2 When error is cancelled after removing of auto idle stop relay 2, check relay unit for
2 • Wiring between auto idle stop When R164 is left displayed with the relay removed, check that 24V is produced on
relay 2 and controller relay (-) line according to the wiring checking procedure and repair it.
CN-102F, CN2-1
When no failure is found after checking on wiring and R164 is left displayed, replace
fuse/relay box.
E-1
16-82
Error Code R174

Trouble Failure of engine emergency stop relay
Judging The mechatro controller output line to engine emergency stop is short-circuited with the power source.
condition
When key switch is turned off, engine does not stop.
Symptom
Auto idle stop function does not actuate.

event of failure
condition
Screen 4 K-3 ENG STOP
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Engine emergency stop relay When error is cancelled after removing of engine emergency stop relay, check relay
R-25 unit for failure, replace it with new one if failed
2 • Wiring between engine When R174 is left displayed with the relay removed, check that 24V is produced on
emergency stop relay and relay (-) line according to the wiring checking procedure and repair it.
controller When no failure is found after checking on wiring and R174 is left displayed, replace
CN-102F, CN2-1 fuse/relay box.
E-1
16
16-83
Error Code R184

Trouble Failure of lever lock relay
Judging The mechatro controller output line to lever lock relay is short-cricuited with the power source.
condition
Symptom Lever lock timer does not actuate.

event of failure
condition
Screen 4 K-4 LOCK LEVER
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Lever lock relay When error R184 is cancelled after removing of lever lock relay, check relay unit for
2 • Wiring between lever lock When R184 is left displayed with the relay removed, check that 24V is produced on
relay and controller relay (-) line according to the wiring checking procedure and repair it.
fuse/relay box.
E-1
16-84
Error Code R214

Trouble Failure of safety relay
Judging The mechatro controller output line to safty relay is short-cricuited with the power source.
condition
Symptom Safty relay does not actuate.

event of failure
condition
Screen 4 K-2 SAFETY RLY
No.
Service
Screen
diagnosis
No.
checking screen
Screen
No.
1 • Safety relay When error R214 is cancelled after removing of safty relay, check relay unit for
2 • Wiring between safty relay When R214 is left displayed with the relay removed, check that 24V is produced on
and controller relay (-) line according to the wiring checking procedure and repair it.
fuse/relay box.
E-1
16
16-85
16-86
［17. TROUBLESHOOTING(BY TROUBLE)］
17
17. TROUBLESHOOTING(BY
TROUBLE)
17.2 HYDRAULIC SYSTEM ..........................................................................................................17-4
17.3 ELECTRIC SYSTEMS......................................................................................................... 17-31
17.3.1 WIRING CHECKING PROCEDURE .................................................................................. 17-31
17.3.2 TROUBLE ....................................................................................................................... 17-33
17.4 FAILURE DIAGNOSIS TABLE FOR ENGINE RELATED PARTS ........................................... 17-36
17-1
17-2

17
17-3
17.2 HYDRAULIC SYSTEM

Preface:
The troubleshooting for the failures shown below is explained here.
Identify the failure and trouble and carry forward the troubleshooting in order of the failure item number.
• All controls do not function/slow
• Engine down/stalled
• Move at lever neutral position
• Poor fine operability
• Slow boom up, insufficient power
• Slow boom down, insufficient power for lifting up body
• Slow arm in, insufficient power
• Slow independent arm out (in the air)
• Slow bucket digging
• Slow bucket dumping
• Swing operation not functioned/slow
• Noise during swing operation
• Swing on a slope drifts when control lever is in neutral position
• Swing drifts when swing operation is stopped
• Slow travel speed/weak
• Travel deviation
• Travel 1st/2nd speed not changed
• Travel parking on a slope is not held
• Travel does not run straightly when both crawlers and attachment operated simultaneously.
17-4
All controls do not function/slow

No. Sections Contents/normal value Corrective action, others
1 Fuse Check fuse No.4 If the fuse is blown out, check
(10A) on the short-circuited section. 17
2 Lever lock switch Carry out service No.4 K-4 SWITCH: Check action of switch by
diagnosis Push down lever and switch turns on, tester, or check that the power
push up and it turns off. voltage is lowered by pushing
the lever down.
3 Lever lock Check that Measure both terminals of solenoid Check solenoid unit for
switching solenoid is connector. 24V by pushing lock lever possible failure.
switched correctly down, 0V by pushing it up. Check harness for possible
failure.
4 Lever lock relay Carry out service No.4 K-4 LOCK LEVER: Check action of relay by tester.
diagnosis Push down the lock lever and it turns off,
push up lock lever and it turns on.
5 Pilot pressure • Stop engine and turn on key. Check 5V power of controller
sensor All pilot low pressure sensors are for possible failure.
0MPa to 0.1MPa (0 to 15psi).
6 Solenoid valve for Measure pressure About 0MPa (0psi) by pushing lock lever Replace solenoid valve.
lever lock of A1 port of 8 up, and 4MPa (580psi) or more by
section solenoid pushing it down.
block
7 Pilot line filter Disassemble and Check filter for clogging. Clean filter.
check it visually
8 Pilot gear pump Measure pilot Check that it is 4MPa (580psi) or more at Check gear pump and its relief
primary pressure high idle. valve for possible failure.
at gear pump
9 Multi control valve Switched position Since all are blocked if switching is failed,
(in case that travel check that lever is set to proper select
is operable) pattern position.
10 Actually measured Carry out service • No.7 In case where command value
current values of diagnosis D-1 P1 UN-LOAD(BP-CUT) is largely differed from actually
P1/P2 unload D-2 P2 UN-LOAD (BP-CUT) measured value, check
proportional valves proportional valve and
• See Service Diagnosis Data List for
controller for possible failure.
Operation No.3: Boom up in full lever
operation & relief.
11 Secondary Measure Check that both P1/P2 unload valve Replace proportional valve.
pressures of P1/P2 proportional valve secondary pressures are from 0.5 to
unload proportional secondary 1.2MPa (73 to 174psi) in boom up full
valves pressures directly lever operation at high idle.
at A2 and A5 ports
of 8 section
solenoid block
12 Actually measured Carry out service • No.6 E-1 P1 PUMP In case where command value
current values of diagnosis. E-2 P2 PUMP is largely differed from the
P1/P2 pump actually measured value,
proportional valves check proportional valve and
Operation No.18: Travel right in full
lever operation and travel idling, and
Operation No.19: Travel left in full
lever operation and travel idling.
17-5

13 Secondary Measure the pump Check that pump proportional valve Replace proportional valve.
pressures of P1/P2 proportional valve secondary pressure is 2.7MPa (392psi)
pump proportional secondary or more in right (left) travel full lever
valves pressures directly operation at high idle.
in travel idling Right travel: P1 pump proportional valve
operation. Left travel: P2 pump proportional valve
(a4 and a5 ports)
14 Main relief Carry out service • See Service Diagnosis Data List for Measure actual relief pressure
pressure diagnosis Operation No.3: Boom up in full lever
operation & relief.
15 Main relief Check set Check that P1/P2 pump pressures are Reset or replace
pressure pressure 32MPa (4640psi) in boom up full lever
operation at high idle and H mode.
16 Pump regulator Visual check When removing pump regulator, it is free Replace
from abnormal resistance against sliding.
External appearance is free from
abnormal damage.
Spring is free from breakage.
17 Pump body Visual check When removing pump body, inside parts Replace
(cylinder block, piston, valve plate, and
shaft, etc.) are free from abnormal
resistance against sliding, and abnormal
damage, etc.
Engine down/stalle
current values of diagnosis E-1 P1 PUMP is largely differed from actually
P1/P2 pump E-2 P2 PUMP measured value, check
Operation No.1: No.operation.
2 Secondary Measure the pump Check that both P1/P2 pump Replace proportional valve.
pressures of P1/P2 proportional valve proportional valve secondary pressures
pump proportional secondary are from 0.5 to 1.0MPa (73 to 145psi) in
valves pressures directly control lever neutral position at high idle.
(a4 and a5 ports)
3 Pressure sensors Check pressure • See Service Diagnosis Data List for Check pressure sensor and
of P1/P2 pumps values Operation No.1: No operation, and replace it if necessary.
No.3: Boom up in full lever operation
& relief.
abnormal damage.
damage.
17-6
Move at lever neutral position

1 Pilot pressure
sensor
Carry out service
diagnosis
Check that pilot pressure of target sensor
is 0MPa (0psi).
Check remote control valve for
possible failure.
17
2 Remote control Check target Check that spool is free from abnormal Replace
valve remote control damage and spring is free from
valve breakage.
3 Main spool Check target spool Check that spool is free from abnormal Replace
visually damage and spring is free from
breakage.
4 Port relief valve Check target port Check that port relief valve is free from Replace
relief valve visually foreign materials caught in valve.
Seat is free from abnormal damage.
5 Lock valve poppet Check target Seat is it is free from abnormal damage. Replace
(for boom, boom 2 poppet visually
and arm)
6 Lock valve selector Exchange lock Check that the phenomenon is reversed. Replace
(for boom, boom 2 valve selector of
and arm) boom with that of
arm, and vice
versa.
7 Holding valve spool Check smooth Check that holding valve spool for boom Replace
for boom sliding of spool in is free from abnormal resistance against Do not pull spool out of sleeve
sleeve sliding. forcibly.
8 Relief valve in Check target relief Check that filter part is free from Replace
holding valve for valve visually abnormal contamination.
boom
9 Cylinder Check target Check that seals, etc. are normal at Replace cylinders or seals.
cylinder visually inspection after disassembly.
17-7
Poor fine operability

1 Pressure sensor Carry out service • See Service Diagnosis Data List for Replace pressure sensor.
diagnosis Operation No.1: No operation.
• All low pressure sensors are 0MPa to
0.1MPa (0 to 15psi).
current values of diagnosis D-1 P1 UN-LOAD (BP-CUT) is largely differed from actually
Operation No.1: No operation.
3 Secondary Measure Check that both P1/P2 unload Replace proportional valve.
unload proportional secondary are from 2.7MPa (392psi) or more in
valves pressures directly control lever neutral position at high idle.
at A2 and A5 ports
of 8 section
solenoid block
Operation No.1: No operation.
5 Secondary Measure pump Check that both P1/P2 pump Replace proportional valve.
pressures of P1/P2 proportional valve proportional valve secondary pressures Check regulator.
valves pressures directly. control lever neutral position at high idle.
(a4 and a5 ports)
6 Slow return check Visual check Check that the slow return check valve Clean and replace
valve of pilot line installed on the pilot line is free from
(for boom up, or foreign materials caught in valve.
arm in or out)
17-8
Slow boom up, insufficient power

1 Boom up pressure
sensor
Carry out service
diagnosis
Check and replace pressure
sensor.
17
operation & relief. Check remote control valve.
2 Remote control Measure directly Check that pressure is 3.0MPa (435psi) Check remote control valve.
pressure remote control or more in boom up full lever operation at When equipped with multi
pressure of boom high idle. control valve, check it while
up changing lever pattern.
3 Pump pressure Carry out service • See Service Diagnosis Data List for When there is difference
sensor diagnosis for P1/ Operation No.4: Boom up in full lever between P1/P2 pump
P2 pump operation & in operation. pressures, check high
pressures in pressure sensor.
operation.
current value of P1/ diagnosis D-1 P1 UN-LOAD (BP-CUT) is largely differed from actually
P2 unload D-2 P2 UN-LOAD (BP-CUT) measured value, check
proportional valve proportional valve and
operaion & relief.
5 Secondary Measure Check that both P1/P2 unload valve Replace proportional valve.
unload proportional secondary 1.2MPa (73 to 174psi) in boom up full
valves pressures directly lever operation at high idle.
at A2 and A5 ports
of 8 section
solenoid block
P1/P2 pump measured value, check
operation & in operation.
7 Secondary Measure the pump Check that both P1/P2 pump Replace proportional valve.
pressures of P1/P2 proportional valve proportional valves pressures are from
pump proportional secondary 2.1 to 3.0MPa (305 to 435psi) in boom
valves pressures directly up full lever operation at high idle.
(a4 and a5 ports)
8 P2 by-pass cut Visual check Check main poppet for sliding ability and Clean and replace
valve orifice for contamination.
<Trouble> Check internal piston for sliding ability.
Only P2 pressure is
low.
valve breakage.
10 Lock valve poppet Visual check When removing lock valve, it is free from Replace
<Trouble> abnormal resistance against sliding. (Check casing for damage.)
Both P1/P2 External appearance is free from
pressures are high. abnormal damage.
11 Conflux check Visual check When removing conflux check valve, it is Replace
valve free from abnormal resistance against (Check casing for damage.)
<Trouble> sliding.
Only P2 pressure is External appearance is free from
high. abnormal damage.
17-9

12 Holding valve for Visual check When removing holding valve, it is free Replace
boom from abnormal resistance against sliding. (Check casing for damage.)
(poppet) External appearance is free from
<Trouble> abnormal damage.
Both P1/P2
pressures are high.
13 Boom spool Visual check When removing boom spool, it is free Replace
<Trouble> from abnormal resistance against sliding. (Check casing for damage.)
14 Boom spool Inspection after Boom spool is free from abnormal Replace spool assembly.
<Trouble> disassembly resistance against sliding.
Only P1 pressure is Spring is free from breakage.
low.
15 Conflux spool Visual check When removing conflux spool, it is free Replace
16 Main relief valve Check set • See Service Diagnosis Data List for Reset or replace
<Trouble> pressure Operation No.3: Boom up in full lever
Relief pressure is operation & relief.
low.
17 Port relief valve Visual check Pressure is 32MPa (4640psi) or more in When only relief pressure of
<Trouble> (Head side) boom up full lever operation at high idle. boom up is low, replace port
Relief pressure is Free from foreign material caught in port relief valve.
low. relief valve.
17-10
Slow boom down/insufficient power for lifting up body

1 Boom down
pressure sensor
Carry out service
diagnosis
Operation No.5: Boom down in full
sensor.
17
lever & in operation. Check remote control valve.
2 Remote control Measure remote Check that pressure is 3.0MPa (435psi) Check remote control valve.
pressure control pressure of or more in boom down full lever When equipped with multi
boom down operation at high idle. control valve, check it while
directly changing lever pattern.
3 Actually measured Carry out service P1 unload valve In case where command value
current values of diagnosis • See Service Diagnosis Data List for is largely differed from actually
P1 unload Operation No.5: Boom down in full measured value, check
proportional valve lever operation & in operation. proportional valve and
4 Secondary Measure Check that P1 unload valve secondary Replace proportional valve.
pressure of P1 proportional valve pressure is from 0.5 to 1.2MPa (73 to
unload proportional secondary 174psi) in boom down full lever operation
valve pressures directly at high idle.
at the A2 port of 8
section solenoid
block.
current values of diagnosis is largely differed from actually
P1 pump measured value, check
Operation No.5: Boom down in full
lever operation & in operation.
6 Secondary Measure pump Check that P1 pump proportional valve Replace proportional valve.
pressure of P1 proportional valve secondary pressure is from 2.0 to
pump proportional secondary 2.6MPa (290 to 377psi) in boom down
valve pressures directly full lever operation at high idle.
(a4 port)
7 Actually measured Carry out service Check that value is not changed • Check pressure sensor of
current values of diagnosis regardless of operation. travel
travel straight • See Service Diagnosis Data List for • In case where command
proportional valve Operation No.1: No operation, value is largely differed from
Operation No.18: Travel right in full actually measured value,
lever operation & travel idle, and check proportional valve
Operation No.19: Travel left in full and controller for possible
lever operation & travel idle. failure.
8 Travel straight Measure directly Secondary pressure is 0.8MPa (116psi) Replace proportional valve.
proportional valve travel straight or less at high idle regardless of in
secondary proportional valve neutral position / operation.
pressure secondary
pressure.
valve breakage.
10 Lock valve Visual check When removing lock valve poppet, it is Replace
poppet boom 1 free from abnormal resistance against (Check casing for damage.)
and boom 2 sliding.
<Trouble> External appearance is free from
Boom down is abnormal damage.
slow.
17-11

11 Holding valve Visual check When removing holding valve, it is free Replace
(poppet) from abnormal resistance against sliding. (Check casing for damage.)
<Trouble> External appearance is free from
Boom down is abnormal damage.
slow.
12 Boom spool Visual check When removing boom spool, it is free Replace
Boom down is External appearance is free from
slow. abnormal damage.
13 Boom spool Inspection after Check that boom spool is free from Replace spool assembly
<Trouble> disassembly abnormal resistance against sliding.
Machine can not be Spring is free from breakage.
lifted by supporting
with boom.
low.
15 Port relief valve Visual check Check that port relief valve is free from Replace
<Trouble> foreign materials caught in valve.
Machine can not be Seat is free from failure.
lifted by supporting
with boom.
16 Boom 3 Visual check Outside surface is free from abnormal Replace proportional valve.
proportional valve damage.
17 Boom 3 spool Visual check When removing boom 3 spool, it is free Replace
from abnormal resistance against sliding. (Check casing for damage)
Outside surface is free from abnormal
damage.
18 Boom meter in cut Visual check Outside surface is free from abnormal Replace solenoid
solenoid damage.
19 Boom meter in cut Visual check Outside surface is free from abnormal Replace boom meter in cut
valve damage. valve
17-12
Slow independent arm in, insufficient power

1 Arm in pressure
sensor
Carry out service
diagnosis
Operation No.6: Arm-in in full lever
sensor.
17
operation & relief. Check remote control valve.
pressure remote control or more in arm-in full lever operation at When equipped with multi
pressure of arm in high idle. control valve, check it while
changing lever pattern.
sensor diagnosis for P1/ Operation No.7: Arm-in in full lever between P1/P2 pump
operation.
operation & relief.
5 Secondary Measure the Check that both P1/P2 unload valve Replace proportional valve.
unload proportional secondary 1.2MPa (73 to 174psi) in arm-in full lever
at A2 and A5 ports
of 8 section
solenoid block.
7 Secondary Measure the pump Check that both P1/P2 pump proportional Replace proportional valve.
pressures of P1/P2 proportional valve valve secondary pressures are 2.0MPa
pump proportional secondary (290psi) or more in arm-in full lever
valves pressures directly. operation at high idle. (Secondary
(a4 and a5 ports) pressure is affected by oil temperature
and attachment weight)
8 Actually measured Carry out service • See Service Diagnosis Data List for In case where command value
current value of diagnosis Operation No.1: No operation, is largely differed from actually
arm in 2-speed Operation No.6: Arm-in in full lever measured value, check
proportional valve operation & relief, and proportional valve and
Operation No.7: Arm-in in full lever controller for possible failure.
9 Secondary Measure directly Check that proportional valve secondary Replace proportional valve.
pressure of arm in proportional valve pressure at high idle is within the range of
2-speed secondary following.
proportional valve pressure at A8 Lever neutral: 0MPa (0psi)
port (arm 2-speed) Operation in the air: 1.7 to 2.2MPa (247
of 8 section to 319psi)
solenoid block. Arm in relief: 2.5MPa (363psi) or more
17-13

current value of diagnosis regardless of operation. travel.
lever operation & travel idling, and check proportional valve
lever operation & travel idling. failure.
11 Secondary Measure directly Check that secondary pressure is Replace proportional valve.
pressure of travel proportional valve 0.8MPa (116psi) or less at high idle
straight secondary regardless of in neutral position/
proportional valve pressure at A4 operation.
port (travel
straight) of 8
section solenoid
block
valve breakage.
low.
14 Port relief valve Visual check Pressure is 32MPa (4640psi) or more in When only relief pressure of
<Trouble> (Head side) arm-in relief operation. arm in is low, replace valve.
P1/P2 pressures Check that port relief valve is free from
are low. foreign materials caught in valve.
15 Port relief valve Visual check (Rod Pressure is 32MPa (4640psi) or more in When only relief pressure of
<Trouble> side) arm-out relief operation. arm out is low, replace valve.
P1/P2pressures Check that port relief valve is free from
are low. foreign materials caught in valve.
16 Arm 1 spool Visual check When removing arm 1 spool, it is free Replace
P1/P2 pressures External appearance is free from
are high. abnormal damage.
P1/P2 pressures External appearance is free from
are high or low. abnormal damage.
18 Recirculation check Inspection after Check that check valve is free from Replace spool assembly
valve of arm 2 disassembly. abnormal resistance against sliding.
spool Spring is free from breakage.
<Trouble>
Arm in speed is
slow.
19 Lock valve poppet Visual check When removing lock valve poppet, it is Replace
<Trouble> free from abnormal resistance against (Check casing for damage.)
Both P1/P2 sliding.
pressures are high. External appearance is free from
abnormal damage.
17-14
Slow independent arm out (in the air)

1 Arm out pressure
sensor
Carry out service
diagnosis
Operation No.8: Arm-out in full lever
sensor.
17
operation & relief Check remote control valve.
pressure remote control or more in arm out full lever operation at When equipped with multi
pressure of arm high idle. control valve, check it while
out changing lever pattern.
sensor diagnosis for P1/ Operation No.9: Arm-out in full lever between P1/P2 pump
operation.
operation & relief.
5 Secondary Measure Check that P1/P2 unload secondary Replace proportional valve.
pressures of P1/P2 proportional valve pressures are from 0.5 to 1.2MPa (73 to
unload proportional secondary 174psi) in arm out full lever operation
valves pressures directly and high idle.
at A2 and A5 ports
of 8 section
solenoid block
7 Secondary Measure pump Check that both P1/P2 pump Replace proportional valve.
valves pressures directly arm out full lever operation at high idle.
(a4 and a5 ports) (Secondary pressure is affected by oil
temperature and attachment weight.)
lever operation & travel idling, and check proportional valve
lever operation & travel idling failure.
9 Secondary Measure directly 0.8MPa (116psi) or less at high idle Replace proportional valve.
pressure of travel proportional valve regardless of in neutral lever position/
straight secondary operation.
proportional valve pressure at A4
port (travel
straight) of 8
section solenoid
block
17-15

valve breakage.
low.
12 Port relief valve Visual check (Rod Pressure is 32MPa (4640psi) or more in When only relief pressure of
<Trouble> side) arm out relief operation. arm out is low, replace valve.
P1/P2 pressures Free from dust entered in port relief
are low. valve.
P2 pressure is External appearance is free from
15 Recirculation check Inspection after Check that check valve is free from Replace spool assembly.
valve of arm 2 disassembly. abnormal resistance against sliding.
spool (spring side) Spring is free from breakage.
<Trouble>
Both P1/P2
pressures are low.
16 Lock valve poppet Visual check When removing lock valve poppet, it is Replace
<Trouble> free from abnormal resistance against (Check casing for damage.)
Both P1/P2 sliding.
pressures are high. External appearance is free from
abnormal damage.
17-16
Bucket digging is slow

1 Bucket digging
pressure sensor
Carry out service
diagnosis
Operation No.12: Bucket digging in
sensor.
17
full lever operation & relief. Check remote control valve.
pressure remote control or more in bucket digging full lever When equipped with multi
pressure of bucket operation at high idle. control valve, check it while
digging changing lever pattern.
sensor diagnosis for P1/ Operation No.13: Bucket digging in between P1/P2 pump
P2 pump full lever operation & in operation. pressures, check high
operation.
full lever operation & relief.
5 Secondary Measure Check that both P1/P2 unload secondary Replace proportional valve.
unload proportional secondary 174psi) in bucket digging full lever
at A2 and A5 ports
of 8 section
solenoid block
full lever operation & in operation.
7 Secondary Measure pump Check that secondary pressure of P1/P2 Replace proportional valve.
pressures of P1/P2 proportional valve pump proportional valve in bucket
pump proportional secondary digging full lever operation at high idle is
valves pressures directly as follows.
(a4 and a5 ports) P1 pump proportional valve: 2.5MPa
(363psi) or more
P2 pump proportional valve: 1.5 to 2.1
Mpa (218 to 305psi)
8 Power boost Carry out service No.3 F-1 POWER BOOST Check harness.
solenoid command diagnosis In bucket digging operation, COMP. Replace solenoid valve.
OFF, and MEAS. OFF.
9 Power boost Measure switching Check that pressure is 0MPa (0psi) in Replace solenoid valve.
solenoid secondary valve secondary bucket digging full lever operation at high
pressure pressure at A3 idle.
port of 3 section
solenoid block
current values of diagnosis Operation No.12: Bucket digging in is largely differed from actually
travel straight full lever operation & relief. measured value, check
17-17

11 Check stroke Visual check When removing piston from cover, it is Replace
limiter free from abnormal resistance against (Check casing for damage.)
<Trouble> sliding. External appearance is free from
Both P1/P2 abnormal damage.
pressures are high.
valve breakage.
pressure Operation No.3: Boom up in full lever
operation & relief.
14 Bucket spool Visual check When removing bucket spool, it is free Replace
17-18
Bucket dump is slow

1 Bucket dump
pressure sensor
Carry out service
diagnosis
Operation No.14: Bucket dump in full
sensor.
17
lever operation & relief. Check remote control valve.
2 Remote control Measure directly Check that pressure is 3.0MPa Check remote control valve.
pressure remote control (435psi) or more in bucket dump full When equipped with multi
pressure of bucket lever operation at high idle. control valve, check it while
dump changing lever pattern.
sensor diagnosis for P1/ Operation No.15: Bucket dump in full between P1/P2 pump
P2 pump lever operation & in operation. pressures, check high
operation.
lever operation & relief.
5 Secondary Measure Check that both P1/P2 unload secondary Replace proportional valve.
unload proportional secondary 174psi) in bucket dump full lever
at A2 and A5 ports
of 8 section
solenoid block
proportional valves. proportional valve and
lever operation & in operation.
7 Secondary Measure pump Check that the secondary pressures of Replace proportional valve.
pressures of P1/P2 proportional valve P1/P2 pump proportional valves in
pump proportional secondary bucket dump full lever operation and high
valves pressures directly idle is as follows.
(a3 port) P1 pump proportional valve: 2.7MPa
(392psi) or more
P2 pump proportional valve: 1.0MPa
(145psi) or more
current value of diagnosis Operation No.14: Bucket dump in full is largely differed from actually
travel straight lever operation & relief. measured value, check
9 Secondary Measure directly Check that travel straight proportional Replace proportional valve.
pressure of travel proportional valve valve secondary pressure is 2.7MPa
straight secondary (392psi) or more in bucket dump full
proportional valve pressure at A4 lever operation at high idle.
port (travel
straight) of 8
section solenoid
block
17-19

10 Check stroke Visual check Check that external appearance of piston Replace
limiter inside cover is free from abnormal (Check casing for damage.)
<Trouble> damage or wear.
Pilot pressure is
low.
valve breakage.
low.
13 Bucket spool Visual check When removing bucket spool, it is free Replace
17-20
Swing does not move/slow

1 Swing pressure
sensor
Carry out service
diagnosis
Operation No.11: Swing in full lever
sensor.
17
operation & in operation. Check remote control valve.
2 Remote control Measure directly Check that pressures are 3.0MPa Check remote control valve.
pressures remote control (435psi) or more in boom up full lever When equipped with multi
pressures of left operation at high idle. control valve, check it while
and right swing changing lever pattern.
3 Swing parking Carry out service No.3 F-2 SWING-BRAKE Check swing pressure sensor.
brake solenoid diagnosis Swing parking lever neutral: COMP. ON, Check harness.
and MEAS. ON
Swing: COMP. OFF, and MEAS. OFF
4 Swing parking Measure pressure Lever neutral: 0MPa (0psi) Replace solenoid valve.
brake solenoid at A3 port of 8 In operation: 4MPa (580psi) or more
section solenoid
block
5 Pump pressure Carry out service • See Service Diagnosis Data List for Check high pressure sensor.
sensor diagnosis for P2 Operation No.11: Swing in full lever
pump pressures in operation & in operation.
operation
6 Actually measured Carry out service • No.7 D-2 P2 UN-LOAD (BP-CUT) In case where command value
current value of P2 diagnosis is largely differed from actually
unload proportional measured value, check
valve proportional valve and
7 Secondary Measure Check that P2 unload secondary Replace proportional valve.

pressure of P2 proportional valve pressure is from 0.5 to 1.2MPa (73 to
unload proportional secondary 174psi) in swing full lever operation at
valve pressure directly high idle.
at A5 port of 8
section solenoid
block
current value of P2 diagnosis is largely differed from actually
pump proportional measured value, check
valve proportional valve and
9 Secondary Measure pump Check that P2 pump proportional valve Replace proportional valve.
pressure of P2 proportional valve secondary pressure is 2.7MPa (392psi)
pump proportional secondary or more in swing full lever operation at
valve pressure directly high idle.
(a5 port)
(Check this by only Operation No.18: Travel right in full actually measured value,
swing operation) lever operation & travel idling, and check proportional valve
lever operation & travel idling. failure.
17-21

pressure of travel proportional valve regardless of in neutral position/
straight secondary operation.
proportional valve pressure at A4
(Check this by only port (travel
swing operation) straight) of 8
section solenoid
block
valve breakage.
13 Travel straight Visual check When removing travel straight spool, it is Replace
spool free from abnormal resistance against (Check casing for damage.)
<Trouble> sliding.
P2 pressure is low. External appearance is free from
abnormal damage.
14 Swing spool Visual check When removing swing spool, it is free Replace
15 Swing relief valve Check set • See Service Diagnosis Data List for Reset or replace
<Trouble> pressure Operation No.10: Swing in full lever
low.
16 Swing motor Visual check When removing swing motor, inner parts Replace
(cylinder block, piston, and valve plate,
etc.) are free from abnormal resistance
against sliding.
External appearance (brake disk, etc.) is
free from abnormal damage.
17 Swing reduction Take sample oil Sample oil does not include a lot of metal Disassemble and inspect
unit oil from swing powder. reduction unit.
reduction unit
drain
18 Swing reduction Visual check Tooth surfaces are not worn abnormally Replace
unit and not chipped.
17-22
Noise occurred at swing operation

1 Swing parking
brake solenoid
Carry out service
diagnosis
No.3 F-2 SWING-BRAKE
Lever neutral: COMP. ON, and MEAS.
Check swing pressure sensor.
Check harness.
17
ON
Swing: COMP. OFF, and MEAS. OFF
2 Measure pressure Lever neutral: 0MPa (0psi) Replace solenoid valve

at A3 port of 8 In operation: 4MPa (580psi) or more
section solenoid
block
3 Boost check valve Visual check When removing boost check valve, it is Replace
(Sound of free from abnormal resistance against
cavitation at sliding.
stopping) Spring is free from breakage.
4 By-pass check Visual check When removing by-pass check valve, it is Replace
valve free from abnormal resistance against
(Sound of sliding.
cavitation at Spring is free from breakage.
stopping)
5 Swing motor Visual check Disassemble and inspect swing motor for Replace
(Brake disk/friction abnormal wear and scuffing.
plate)
6 Swing motor piston Visual check When removing swing motor piston, it is Replace
free from abnormal resistance against
sliding.
7 Swing reduction Take sample oil Sample oil does not include a lot of metal Disassemble and inspect
unit oil from swing powder. reduction unit.
reduction unit
drain.
8 Swing reduction Visual check Tooth surfaces are not worn abnormally Replace
17-23
Upper structure on slope drifts with lever in neutral position

1 Pressure sensor Carry out service • Engine stop & starter key ON Check and replace pressure
diagnosis All pilot low pressure sensors are from sensor.
0 to 0.1MPa (0 to 15psi).
valve breakage.
3 Swing parking Carry out service No.3 F-2 SWING-BRAKE Check and replace pressure
brake solenoid diagnosis Lever neutral: COMP. ON, and MEAS. sensor.
ON Check harness.
Swing: COMP. OFF, and MEAS. OFF Check parking brake release
switch.
4 Measure pressure Lever neutral: 0MPa (0psi) Replace solenoid valve.
section solenoid
block
5 Swing motor Visual check Disassemble and inspect swing motor for Replace
(Brake disk/friction abnormal wear and scuffing
plate)
6 Parking brake Visual check When removing parking brake, piston Replace
and friction plate are free from abnormal
resistance against sliding. Spring is free
from breakage.
When swing operation is stopped, upper structure drifts.

1 Pressure sensor Carry out service • Engine stop & starter key ON Replace pressure sensor
diagnosis All pilot low pressure sensors are from
0 to 0.1MPa (0 to 15psi).
2 Swing relief valve Check set • See Service Diagnosis Data List for Reset or replace
<Trouble> pressure Operation No.10: Swing in full lever
low.
3 Anti-reaction valve Visual check Check that anti-reaction valve is free Clean or replace
from foreign materials caught in valve.
Sliding part should be free from foreign
materials caught in there, abnormal
damage, and wear.
valve breakage.
5 Swing motor Visual check When removing swing motor, inner parts Replace
(cylinder block, piston, and valve plate,
etc.) are free from abnormal resistance
against sliding.
External appearance (brake disk, etc.) is
free from abnormal damage.
17-24
Travel speed is slow/poor

1 Travel right and left
pressure sensor
Carry out service
diagnosis
sensor.
17
lever operation and travel idling, and Check remote control valve.
valve remote control or more in travel right (left), forward
pressures of travel (reverse) full lever operation at high idle.
right and left
lever operation & travel idling, and
lever operation & travel idling.
4 Secondary Measure Check that P1/P2 unload proportional Replace proportional valve.
pressures of P1/P2 proportional valve valve secondary pressures in travel
unload proportional secondary idling, travel right (left), and forward
valves pressures directly (reverse) full lever operation at high idle
at A2 and A5 ports are as follows.
of 8 section Travel right (P1 unload): 0.5 to 1.2MPa
solenoid block (73 to 174psi)
Travel left (P2 unload): 0.5 to 1.2MPa
(73 to 174psi)
6 Secondary Measure pump Check that P1/P2 pump proportional Replace proportional valve.
pump proportional secondary idling, travel right (left), and forward
(a4 and a5 ports) are as follows.
Travel right (P1 pump): 2.7MPa (392psi)
or more
Travel left (P2 pump): 2.7MPa (392psi)
or more
7 Actually measured Carry out service Check that value is not changed • Check voltage of low
current value of diagnosis regardless of operation. pressure sensor other than
travel straight • See Service Diagnosis Data List for sensor for travel.
proportional valve Operation No.1: No operation, • In case where command
Operation No.18: Travel right in full value is largely differed from
lever operation & travel idling, and actually measured value,
Operation No.19: Travel left in full check proportional valve
lever operation & travel idling. and controller for possible
failure.
17-25

pressure of travel travel straight regardless of in neutral position/
straight proportional valve operation.
proportional valve secondary
pressure
valve breakage.
Check shuttle valve for sealing ability
and orifice for foreign materials caught in
it.
<Trouble> sliding.
11 Travel spool Visual check of When removing travel spool, it is free Replace
<Trouble> target spool from abnormal resistance against sliding. (Check casing for damage.)
Pump pressure is External appearance is free from
12 Travel motor relief Check set Check P1/P2 pump pressures are When P1 pressure or P2 relief
valve pressure 32MPa (4640psi) or more in right and left valve pressure of right travel
travel levers full lever operation (relief motor is low, check and
operation at locked crawler belt) at high replace relief valve of left travel
idle. motor.
13 Travel motor Visual check When removing travel motor, inner parts Replace
(piston, cylinder block, valve plate, and
brake valve spool, etc.) are free from
abnormal resistance against sliding.
abnormal damage.
14 Parking brake in Visual check When removing parking brake, it is free Replace
travel motor from abnormal resistance against sliding.
No sticking on friction plate and
separator.
15 Travel reduction Take sample oil Sampling oil does not include a lot of Disassemble and inspect
unit oil from travel metal powder. reduction unit.
reduction unit
drain
16 Travel reduction Visual check Tooth surfaces are not worn abnormally Replace
17-26
Travel deviation
1 Travel right and left Carry out service Check and replace pressure
pressure sensor diagnosis
Operation No.18: Travel right in full sensor. 17
lever operation and travel idling, and Check remote control valve.
2 Remote control Measure directly Check that pressure in travel idling, Check remote control valve.
valve remote control travel right (left), and forward (reverse)
pressure of travel full lever operation at high idle is 2.1 MPa
right and left (305psi) or more.
3 Actually measured Carry out service Check that value is not changed • Check voltage of low
current value of diagnosis regardless of operation. pressure sensor other than
travel straight • See Service Diagnosis Data List for sensor for travel
proportional valve Operation No.1: No operation, • In case where command
Operation No.18: Travel right in full value is largely differed from
lever operation & travel idling, and actually measured value,
Operation No.19: Travel left in full check proportional valve
lever operation & travel idling. and controller for possible
failure.
pressure of travel travel straight regardless of in neutral lever position/
straight proportional valve operation.
proportional valve secondary
pressure
6 Secondary Measure Check that P1/P2 unload proportional Replace proportional valve.
unload proportional secondary idling, travel right (left), and forward
at A2 and A5 ports are as follows.
of 8 section Travel right (P1 unload): 0.5 to 1.2MPa
solenoid block (73 to 174psi)
Travel left (P2 unload): 0.5 to 1.2MPa
(73 to 174psi)
17-27

8 Secondary Measure pump Check that P1/P2 pump proportional Replace proportional valve.
pump proportional secondary idling, travel right (left), and forward
(a4 and a5 ports) are as follows.
Travel right (P1 pump): 2.7MPa (392psi)
or more
Travel left (P2 pump): 2.7MPa (392psi)
or more
9 Exchange P1 for Exchange delivery Check whether direction of deviation If direction is changed, inspect
P2 pipe of P1 for P2 changes or not. pump. If direction is not
changed, inspect valve and
travel unit.
valve breakage. Check shuttle valve for sealing
ability and orifice for foreign materials
caught in it.
<Trouble> sliding.
12 Travel spool Visual check of When removing travel spool, it is free Replace
<Trouble> targeted spool from abnormal resistance against sliding. (Check casing for damage.)
Pump pressure is External appearance is free from
13 Travel motor relief Check set Check P1/P2 pump pressures are When P1 pressure or P2 relief
valve pressure 32MPa (4640psi) or more in right and left valve pressure of right travel
travel levers full lever operation (relief motor is low, check and
operation at locked crawler belt) at high replace relief valve of left travel
idle. motor.
14 Travel motor Visual check When removing travel motor, inner parts Replace
(piston, cylinder block, valve plate, and
brake valve spool, etc.) are free from
abnormal resistance against sliding.
abnormal damage.
15 Travel reduction Take sample oil Sample oil does not include a lot of metal Disassemble and inspect
unit oil from travel powder. reduction unit.
reduction unit
drain
16 Travel reduction Visual check Tooth surfaces are not worn abnormally Replace
abnormal damage.
damage.
17-28
Travel 1/2 speed cannot be switched

{In case of the traveling under heavy load (traveling on a slope or a soft ground), the operating pressure rises and
the speed may not change from 1st to 2nd due to automatic speed change to 1st speed.}
17
1 Travel 1/2 speed Carry out service Switch travel 1/2 speed to 2nd speed. Check pressure sensor.
switching solenoid diagnosis No.3 F-3 1/2-TRAVEL Check harness.
Lever neutral: COMP. OFF, and MEAS. Check travel 1/2 speed switch
OFF on gauge cluster.
Travel operation: COMP. ON, and MEAS.
ON
2 Measure pressure Lever neutral: 0MPa (0psi) Replace solenoid valve.
section solenoid
block
3 1/2 speed Visual check Check that spool is free from abnormal Replace
switching spool in damage and spring is free from (Check casing for damage.)
travel motor breakage.
4 1/2 speed Visual check Check that orifice is free from foreign Remove dust or replace
switching orifice in materials caught in it.
travel motor
5 Tilting piston in Visual check Check that tilting piston and seal are free Replace
travel motor from abnormal wear. (Check casing for damage.)
Machine cannot keep on traveling on a slope

1 Pilot pressure Carry out service • Engine stop & starter key switch ON Check pressure sensor and
sensor diagnosis Target pilot low pressure sensor: replace as necessary.
0 to 0.1MPa (0 to 15psi) Check remote control valve.
valve breakage.
3 Parking brake in Visual check When removing parking brake, it is free Replace
travel motor from abnormal resistance against sliding.
4 Orifice of passage Visual check Check that orifice is free from foreign Remove dust or replace
for parking brake in materials caught in it.
travel motor
17-29
Machine does not travel straight in simultaneous operation of traveling left and right and attachment
1 Actually measured Carry out service Check that current value in travelling left • Check voltage of low
current values of diagnosis and right and boom up full lever pressure sensor other than
travel straight operation at high idle is as follows. travel sensor.
proportional valve No.7 D-3 S-TRAVEL
• In case where command
COMP. 590 mA and MEAS. 560 to 620
value is largely differed
mA
from actually measured
value, check proportional
valve and controller for
possible failure.
2 Secondary Measure travel Check secondary pressure is from 2.0 to Replace proportional valve.
pressure of travel straight 2.4 MPa (290 to 348psi) in travelling left
straight proportional valve and right and boom up full lever
proportional valve secondary operation at high idle.
pressure directly
at A4 port of 8
section solenoid
block
sliding.
abnormal damage.
17-30
17.3 ELECTRIC SYSTEMS

17.3.1 WIRING CHECKING PROCEDURE
17
Check for continuity between connector terminals, presence or absences of short-circuit with other wires, and
presence or absences of short-circuit with machine body grounding.
Checking for disconnection between connectors CONNECTOR
• When both ends measurement is easy because of
short distance between connectors, measure the
resistance using tester.
WIRE
Pull out opposite connector first.
When the resistance is zero (0), it is in normal
condition. TESTER
• When both ends measurement is difficult because of

long distance between connectors, measure the
resistance using tester. JUMPER
Pull out opposite connector first. WIRE
Where the resistance is zero (0), if the terminal on one
side is connected to frame body grounding with
TESTER
jumper wire, it is in normal condition.
FRAME BODY GROUNDING
The resistance is 1M-ohm or more when the terminal
on one side is not connected to frame body grounding with jumper wire, it is in normal condition.
Checking for presence or absence of short-circuit
with machine body
Measure the resistance using tester.
When the resistance is 1M-ohm or more, it is in normal
condition.
TESTER
FRAME BODY GROUNDING
Checking for presence or absence of short-circuit

between wirings
Measure the resistance using tester.
When the resistance is 1M-ohm or more, it is in normal
condition. TESTER
Checking connector terminal for contact

INSERT
Insert male terminal into female terminal unit, and then
check that the inserting force is equivalent to other
female terminals. MALE TERMINAL FEMALE TERMINAL
If looseness is there, replace the female terminal with
new one.
Clean the dirt terminal.
Do not insert the male terminal the thickness differs. It may cause loose connection.
Caution which should be paid in measuring voltage

When measuring the power supply to electric equipment at connector position with the grounding terminal
contained inside of connector, measure the voltage between grounding inside of connector and power terminal.
When measuring the voltage between frame body grounding and power source, the disconnection of wiring to
grounding inside of connector cannot be identified.
17-31
Since the voltage may vary between with connector connected and with connector not connected. Measure the
voltage with each connector connected whenever possible.
Checking the general view of connector CRIMPED
PART
• Check the terminal crimped condition
Pull one electric cable with the about 3 kg (7 lbs)
RUBBER
force, and make sure that the cable does not come PLUG
RECEPTACLE.
out of the terminal. CONTACT
When came out, replace the terminal and crimp it PLUG
again. SEALING
(is housed in plug)
• Check connector for imperfect insertion DOUBLE LOCK
Check that all top ends form a line on the same PLATE FOR PLUG
position as seen from the connector engaged side. DOUBLE LOCK

PLATE FOR CAP
If any of them are not in line, push them from the wire
CAP
insertion opening.
TAB CONTACT .
• Check connector for water intrusion
RUBBER PLUG
Pull out the connector and check the inner part of it for
water intrusion.
If water intrusion is found, check the rubber plug for damage and the sealing for proper installation.
When abnormality occurs at intervals

When the abnormality situation can not be reoccurred during checking operation, try the following operations.
• Check that variable of display exists or not on the service diagnosis screen while shaking the harness or giving
shock by operating the machine.
• Check that variables of resistance and voltage exist or not using tester while shaking the harness.
• Turn starter switch on and apply electricity continuously, and check it again after the temperature of wiring and
equipment was raised.
Checking on body grounding
Check attaching bolts of grounding terminal for
loosening.
And also check that there is no loose connection due to
corrosion.
There are multiple groundings like centralized grounding
box shown in the figure and battery grounding, engine
grounding, horn grounding fixed together with horn, body
grounding placed on attaching section of boom working
light.
DETAIL aa
Block of grounding is located under cab
17-32
17.3.2 TROUBLE
• Engine does not stop.
• "CPU DATA COMMUNICATION ERROR" is displayed on multi display.
17
• Auto accel does not actuate. (The engine speed does not automatically slow down.)
• Auto accel does not actuate. (The engine speed does not automatically speed up.)
• Wiper does not function.
Engine does not stop.

1 Starter key switch Check signal of No.4 K-3 Key switch • Check continuity between
starter key switch ON Starter switch OFF: KEY SWITCH terminals of starter switch
by carrying out OFF using tester.
service diagnosis. Starter switch ON: KEY SWITCH ON
• Suppose that diode D-9
between starter switch and
auto idle stop relay 1 is
broken and check relay box
assembly.
2 Key ON holding Measure voltage of When starter switch is OFF, voltage is Check key ON holding relay for
relay wire between 62E OFF. possible failure.
wire, which is
between key ON
holding relay and
engine controller, and
machine ground
"CPU DATA COMMUNICATION ERROR" is displayed on multi display.

1 Fuse No.1 fuse (5A) Check fuse for blown fuse. Check harness.
Replace fuse.
2 Wiring 770A and 582A wires See "WIRING CHECKING Repair wiring
in transceiver circuit PROCEDURE".
of mechatro controller
and gauge cluster
3 Mechatro controller Check control of Engine speed varies according to Check mechatro controller and
mechatro controller accel potentiometer operation. replace as necessary.
such as acceleration (Perform remote control lever
control operation because auto accel function
can be working.)
4 Cluster gauge Cluster gauge Replace gauge cluster
17-33
Auto acceleration does not actuate (engine speed does not automatically slow down).
1 Cluster gauge Indication of auto Auto acceleration mark appears/ Replace gauge cluster
acceleration disappears according to operation of
auto acceleration switch on gauge
cluster.
2 Engine coolant Check engine coolant When “No.2 G-5 WATER TEMP” Replace engine coolant
temperature temperature by shows temperature of less than -15 temperature sensor.
carrying out service degrees C (5 degrees F), auto
diagnosis. acceleration does not work. Perform
warming-up operation to raise water
temperature to -15 degrees C (5
degrees F) or more.
3 Low pressure Carry out service When remote control lever operation Check low pressure sensor.
sensor diagnosis is performed, each control pressure of
No.5 and 6 rises and does not fall.
Auto acceleration does not actuate (engine speed does not automatically rise).
1 Low pressure Carry out service When control lever is in neutral Check low pressure sensor.
sensor diagnosis position, each control pressure of No.
5 and 6 is from 0 to 0.1 MPa (0 to 15
psi).
Wiper does not function.
Wiping range of
forward and
reverse movements
Wiper motor
Rise up (storing) position Rise up limit switch's ON range
Upper reversing position Reverse limit switch's ON range
Lower reversing position
17-34
No. S e ctions Conte nts /norma l va lue Corre ctive a ction, othe rs
1 Fus e Che ck fus e No.20 Re pla ce fus e .
2 S W-19: S e rvice dia gnos is No.14 DI4 Che ck wipe r inte rlock s witch
Wiper interlock switch Wipe r s witch dis pla y (DI4) is OFF with front window clos e d. a nd re pa ir it if ne ce s s a ry. 17
Che ck it a ccording to "WIRING
CHECKING P ROCEDURE" a nd
re pa ir it if ne ce ssa ry.
3 Ris e up limit s witch built- Service diagnosis No.19 Wiper sys te m Che ck a nd re pa ir s witch
in wipe r motor a ccording to "WIRING
Re ve rs e limit s witch CHECKING P ROCEDURE" .
S witch a ction in ope ra tion
Norma l condition
Rise up limit switch
Wiper motor (RIS EUP S W) ON OFF OFF
Re ve rs e limit s witch
Wiper motor (REVERSE SW ) ON ON OFF
4 R-31: Service diagnosis No.19 Wiper sys te m

Arc pre ve ntion re la y When started by forward rotation: STO P START (STOP) (REVERSE) (STOP) (NORMAL)
R-29: Wiper motor Arc pre ve ntion re la y
OFF ON ON ON ON OFF ON ON ON OFF ON
norma l rota tion re la y (PR EVENT ARC)
R-30: Wiper motor Norma l rota tion re la y

OFF ON ON ON ON OFF OFF OFF OFF OFF ON
(CW MOTOR RLY)
reverse rota tion relay
Re ve rs e rota tion re la y
OFF OFF OFF OFF OFF OFF ON ON ON OFF OFF
(CCW MOTOR RLY)
Che ck tha t the re la y is worke d a s s hown in the ta ble . Che ck tha t the re la y is e xcite d.
* Whe n the limit s witch doe s not cha nge in OFF a fte r 4 s e conds Che ck re la y & fus e box a nd re pla ce it
from the wipe r s ta rtup, turn OFF a ll re la y's outputs . if ne ce s s a ry.
17-35
17.4 FAILURE DIAGNOSIS TABLE FOR ENGINE RELATED

PARTS
Checking
Filters Liquid Leak, clogging
Air leak between turbocharger and intake manifold

Factors
Leak, clogging of fuel system and intruding of air

Contamination of water and fuel with oil
Breather hose crushed or clogged
Fan belt slipped, fan pulley worn
Poor or deteriorated battery

Shortage of fuel level
Improper fuel in use

Air cleaner clogged
Fuel filter clogged
Oil level of oil pan

Oil filter clogged
Muffler clogged
Engine oil leak
Coolant level
Trouble
Poor start ability (Take a long time)

Faulty starting
Faulty engine starting/engine does not rotate.

Faulty engine starting/engine rotates but no
exhaust gas (No fuel injection)
Faulty engine starting/exhaust gas is emitted

but engine does not start (With fuel injection)
Poor output Insufficient
Engine poor run-up (Low follow-up ability)

rotation
Rotation in bad condition (hunting)

Engine stalled during operation.
Output is lowered.
Overheating
Exhaust smoke is black
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Other failures
Early contamination of oil

Larger fuel consumption
Intruding of oil in coolant, back flow, reduction
of coolant quantity
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Vibration
17-36
Checking Electric equipment

Shovel side Shovel side Engine side
17
Loose mounting bolts, damage of mounting rubber

Factors
Radiator core clogged/fin clogged and crushed

Peeling of space insulation around radiator
Loose connection of battery cable terminal

Failure of radiator pressure cap
Failure of hydraulic system

Startup circuit wiring
Starter switch key
Hydraulic switch
Starter motor
Battery relay
Safety relay
Glow relay
Glow plug
Alternator
Trouble

Faulty starting



rotation

Output is lowered.
Overheating
Other failures

of coolant quantity
Vibration
17-37
Intake and
Fuel system exhaust Lubrication Cooling
system system system
Factors
S e izing a nd inte rfe re nce of turbocha rge r

S e a l of turbocha rge r worn, da ma ge d
Turbocha rge r oil dra in tube clogge d
Le a k a nd crus h of hydra ulic piping
Fa ilure of the rmos ta t (Not ope n)

Fue l le a k into the he a d cove r
Imprope r fue l inje ction time
Fa ilure of re gula tor va lve
Da ma ge of wa te r pump
Fa ilure of s upply pump
Fa ilure of re lie f va lve

Fa ilure of oil pump
Fa ilure of inje ctor
Trouble
Poor start ability (T ake a long time)

Fa ulty s ta rting


P oor output Insufficient

rotation

Output is lowered.
Overheating
Othe r fa ilure s

Intruding of oil in coolant, back flow , reduction
of coolant quantity
Vibra tion
17-38
Engine body
Factors
Wear and damage of rear oil seal and seal surface

17
Damage and seizing of piston and connecting rod

Damage of engine oil cooler core and O-ring
Damage of cylinder head and head gasket
Wear and failure of valve and valve guide
Wear of piston ring and liner, ring stick

Strainer clogged, damage of oil pipe
Failure of injection holder sleeve
Damage of flywheel gear

Hole due to cavitation
Damage of dumper
Trouble

Faulty starting



rotation

Output is lowered.
Overheating
Other failures

of coolant quantity
Vibration
17-39
17-40
［18. ENGINE］
18. ENGINE
18.2 GENERAL ............................................................................................................................18-6
18
18.2.1 Warning ............................................................................................................................18-6
18.2.2 How to read this manual ...................................................................................................18-7
18.2.3 Precautions for work ...................................................................................................... 18-11
18.2.4 Tightening of engine bolts and nuts ............................................................................... 18-14
18.2.5 Tightening of chassis bolts and nuts .............................................................................. 18-17
18.2.6 Tightening of flare nuts and hoses ................................................................................. 18-19
18.2.7 Taper thread sealant for piping ....................................................................................... 18-20
18.2.8 Assembly of joints and gaskets for piping ...................................................................... 18-21
18.2.9 Handling of liquid gasket ................................................................................................ 18-23
18.2.10 Failure diagnosis table for each problem ...................................................................... 18-24
18.2.11 Failure diagnosis using HinoDX.................................................................................... 18-25
18.2.12 Connection method of HinoDX...................................................................................... 18-30
18.2.13 Chassis number and engine number ............................................................................ 18-30
18.3 STANDARD VALUE ............................................................................................................ 18-31
18.3.1 Engine Body ................................................................................................................... 18-31
18.3.2 Fuel System .................................................................................................................... 18-31
18.3.3 Electrical......................................................................................................................... 18-32
18.3.4 Intake.............................................................................................................................. 18-32
18.3.5 Engine Mechanical ......................................................................................................... 18-33
18.3.6 Exhaust .......................................................................................................................... 18-40
18.3.7 Cooling ........................................................................................................................... 18-40
18.3.8 Lubrication ..................................................................................................................... 18-41
18.3.9 Starting and Charging..................................................................................................... 18-43
18.3.10 Turbocharger ................................................................................................................ 18-45
18.4 PARTS TO BE PREPARED ................................................................................................. 18-46
18.4.1 Engine Body ................................................................................................................... 18-46
18.4.2 Fuel System .................................................................................................................... 18-46
18.4.3 Electrical......................................................................................................................... 18-46
18.4.4 Engine Mechanical ......................................................................................................... 18-47
18.4.5 Lubrication ..................................................................................................................... 18-50
18.4.6 Starting and Charging..................................................................................................... 18-51
18.4.7 Turbocharger .................................................................................................................. 18-52
18.4.8 Engine Failure Diagnosis................................................................................................ 18-53
18.5 ENGINE MOUNTING/DISMOUNTING.................................................................................. 18-55
18.5.1 Inspection Before Service............................................................................................... 18-55
18.5.2 Engine Body ................................................................................................................... 18-57
18-1
［18. ENGINE］
18.6 FUEL SYSTEM........................................................................................................................ 18-61

18.6.1 Fuel System......................................................................................................................... 18-61
18.6.2 Air bleeding ......................................................................................................................... 18-66
18.6.3 Fuel filter water drain........................................................................................................... 18-67
18.6.4 Pre-fuel filter replacement ................................................................................................... 18-71
18.6.5 Replacement of the main fuel filter ...................................................................................... 18-73
18.6.6 Replacement of the final fuel filter ....................................................................................... 18-75
18.6.7 Replacement of the supply pump ........................................................................................ 18-78
18.6.8 Inspection of the supply pump ............................................................................................ 18-83
18.6.9 Replacement of the injector................................................................................................. 18-84
18.6.10 Inspection of the injector ................................................................................................... 18-89
18.6.11 Replacement of the common rail ....................................................................................... 18-90
18.6.12 Inspection of the common rail ........................................................................................... 18-95
18.7 ELECTRICAL.......................................................................................................................... 18-96
18.7.1 Electrical System................................................................................................................. 18-96
18.8 INTAKE................................................................................................................................. 18-106
18.8.1 Intake Manifold .................................................................................................................. 18-106
18.9 ENGINE MECHANICAL ......................................................................................................... 18-109
18.9.1 Cylinder Head.................................................................................................................... 18-109
18.9.2 Cylinder Block ................................................................................................................... 18-120
18.9.3 Timing Gear Cover and Flywheel Housing......................................................................... 18-125
18.9.4 Main Moving Parts ............................................................................................................. 18-133
18.9.5 Camshaft and Idle Gear ..................................................................................................... 18-155
18.9.6 Valve System ..................................................................................................................... 18-171
18.10 EXHAUST ........................................................................................................................... 18-178
18.10.1 Exhaust Manifold............................................................................................................. 18-178
18.11 COOLING............................................................................................................................ 18-182
18.11.1 Cooling System ............................................................................................................... 18-182
18.12 LUBRICATION .................................................................................................................... 18-188
18.12.1 Oil Cooler, Oil Filter and Oil Pump ................................................................................... 18-188
18.12.2 Oil Pan ............................................................................................................................. 18-202
18.13 STARTING AND CHARGING ............................................................................................... 18-205
18.13.1 Starter.............................................................................................................................. 18-205
18.13.2 Alternator (50A) ............................................................................................................... 18-225
18.14 TURBOCHARGER .............................................................................................................. 18-240
18.14.1 Turbocharger Assembly .................................................................................................. 18-240
18.15 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS ............................................................ 18-243
18.15.1 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS ......................................................... 18-243
18.16 ENGINE DIAGNOSIS CODE ................................................................................................ 18-250
18.16.1 Engine ECU ..................................................................................................................... 18-250
18-2
［18. ENGINE］
PREFACE
This manual describes the engine unit. Please note that this shop manual uses the service manual of Hino Motors,
Ltd.
18
18-3
［18. ENGINE］
18-4
［18. ENGINE］

18
18-5
［18. ENGINE］
18.2 GENERAL
18.2.1 Warning
Observe the following precautions to work safely and to prevent damage to customers' vehicles.
This manual is prepared for qualified service engineers who are recognized as technical expert. Those who are not
qualified, who are not appropriately trained, who performs service without appropriate tool or equipment, or who
perform service with the way not specified in this manual may not only damage the vehicle, but also put service
engineers and surrounding people in danger.
• Appropriate service and repair are essential to ensure safety of service engineers and safety and reliability of
vehicles. Be sure to use Hino genuine parts for replacement of parts. Do not use deteriorated parts in quality.
• Items described in this manual are the procedures to be observed in service and repair. For service and repair
according to this procedure, be sure to use the special tools designed for each purpose.
• If a method or a tool not recommended is used, safety of service engineers, and safety and reliability of vehicles
may be impaired. Never use a method or tool not recommended.
• This manual shows “Warning” and “Caution” for items that need to be observed so that accidents may not occur
during service or repair, or that damage to vehicle due to improper method may not impair safety and reliability of
vehicles. These instructions cannot give warning for all possible hazards. Note that items with “Warning” or
“Caution” are not absolute for safety.
18-6
［18. ENGINE］
18.2.2 How to read this manual

Scope of repair work
1. Repair work is classified into three large categories of "Diagnosis", "Mounting/removal, replacement,
assembly·disassembly and inspection·adjustment" and "Final inspection".
2. This manual describes "Diagnosis" in the first process and "Mounting/removal, replacement,
assembly·disassembly and inspection·adjustment" in the second process. Explanation of "Final inspection" in
the third process is omitted here.
3. Although the following work is not described in this manual, it should be performed in actual work.
1) Jacking and lifting
18
2) Cleaning and washing of removed parts as required
3) Visual inspection
Standard value
1. Standard value, limit, action and tightening torque described in the text are summarized in tables.
Items to be prepared
1. Items to be prepared before work are SST, tools, gauges and lubricant, etc. These are listed in the list section
of items to be prepared. Items such as general tools, jack, rigid rack, etc. that are usually equipped in general
service shop are omitted.
How to read sections and titles

1. Sections are classified according to J2008, SAE standard.
2. For areas that show system names like "Engine control system", "Inspection", "Adjustment", "Replacement",
"Overhaul", etc. of components are described.
3. For areas that show part names like "Injection pump", "Mounting/removal and disassembly" is described.
4. Illustrations of the parts catalog are shown for part layout. (Part codes in the parts catalog are described in the
illustration. Major names and tightening torque are listed in the table.)
The part layouts in this manual are inserted based on illustrations and part numbers of the parts catalog CD-ROM
issued in April, 2007. (Some areas do not show exploded view. They will be additionally issued when the parts
catalog CD is revised.) Be sure to use the parts catalog for confirmation of illustrations and part numbers and for
ordering parts.
How to read troubleshooting

1. Failure diagnosis in this manual describes Step 2 and Step 3 below :
Hear from customers for conditions and environments of failures and

(1) Question "Step 1"
check the fact.
Perform diagnosis inspection, status inspection, function inspection
(2) Pre-inspection and basic inspection.
"Step 2"
(3) Reproduction method Check the failure status. If it is difficult to reproduce the problem with
status inspection, use the reproduction method.
(4) Troubleshooting for each

Summarize inspection results obtained from Step 2. Perform
diagnosis code
"Step 3" inspection systematically according to troubleshooting procedures for
(5) Troubleshooting for each failure
each diagnosis code or failure status.
status
Check if failure occurs again after repair. If it is difficult to reproduce a
(6) Confirmation test "Step 4" failure, perform the confirmation test under the conditions and
environment of the failure.
18-7
［18. ENGINE］
2. Pre-inspection
• Pre-inspection is performed in the following steps :

Diagnosis inspection→Diagnosis deletion→Failure status check (Use the reproduction method if not
reproduced.)→Diagnosis reconfirmation
• Estimate the failure system before the reproduction test. Attach a tester and evaluate estimated failure
together with failure status. Refer to the troubleshooting chart for estimated cause of a failure.
Pre-
inspection • An error code is displayed if a failure occurs instantaneously. If any specific failure is not found, perform
troubleshooting using the reproduction method.
• Failure status check
If failure is reproduced, perform Step 2 → Step 3 → Step 4.
If failure is not reproduced, use the reproduction method (simulation of external conditions or check of
each wire harness and connector, etc.)
18-8
［18. ENGINE］
How to read explanation details

1. Part layout
Example
ENGINE MECHANICAL [J08E] 9–17
Timing Gear Co ver and Fl ywheel Housing

18
Part layout
JP04117090402003
Part name code
Part catalog Fig. No.
S AP H041170900182
11308 Flywheel housing 11390 End plate

Description of
11309 Oil seal retainer 9828A Front oil seal* part name code
11357 Gasket* 9828B Rear oil seal*
11357A Gasket*
*Parts not to be reused.

Left: Part name code (nut)
Tight ening torque
9069H M14 : 171.5N m{1, 750kgf cm} 9419A M16 : 196N m{2, 000kgf cm}
9069J M12 : 97N m{990kgf cm} 9419B M16 : 196N m{2, 000kgf cm}
Overhaul
Service procedur
item e
I:It is the ID number for parts to prepare electronic data. It is not required for repair work.
18-9
［18. ENGINE］
Definition of terms
Terms in this manual are defined as follows :
1. Direction
1) Individual unit
Front/back direction
The power input side is front and the output side is back.
Rotating direction
When viewed from the rear, the clockwise direction is right rotation and the counterclockwise direction is left
rotation.
Vertical direction
With a unit mounted on the vehicle (chassis), the upward direction is upper and the downward direction is
lower.
Left/right direction
When viewed from the rear, the left direction is left and the right direction is right.
2) Standard value....Basic dimension excluding tolerance and clearance generated by tolerances when two
parts are joined.
3) Repair limit..........It is the value requiring repair. Symbol of + or - with the value means increase or decrease
to the standard value.
4) Service limit........It is the value requiring replacement. Symbol of + or - with the value means increase or
decrease to the standard value.
5) Warning..............It is an item that may result in risk of human life or serious injury by incorrect handling.
6) Caution...............It is an item that should not be performed including inhibited work or an item that require
attention in working procedures.
7) Reference...........It is supplementary explanation in work.
Unit
1. SI unit is used in this manual. SI unit is the international unit to unify the conventional different international
units into one unit per quantity and to promote smooth technical communications.
2. This manual shows both the SI unit and conventional units. The conventional units are shown in { }.
Conversion value*1 Conversion value*1
Conven- Conven-
SI unit (1[Conventional unit] = SI unit (1[Conventional unit] =
tional unit tional unit
X [SI unit]) X [SI unit])
Spring 1kgf/mm=9.80665N/
Force N kgf 1kgf=9.80665N N/mm kgf/mm
constant mm
1kgf·cm=
Torque*2 N·m kgf·cm Volume L cc 1cc=1mL
0.0980665N·m
1kgf/cm2=98.0665kPa
kgf/cm2 Efficiency W PS 1PS=0.735499kW
=0.0980665MPa
Pressure Pa
Calorific
mmHg 1mmHg=0.133322kPa W·h cal 1kcal=1.163W·h
value
r/min 1rpm=1r/min Fuel
Rotational
rpm consump- g/W·h g/PS·h 1g/PS·h=1.3596g/kW·h
speed min-1 1rpm=1min-1 tion rate
*1 : X means the value when 1 [Conventional unit] is converted to the SI unit.
It is used as the conversion factor from the conventional unit to the SI unit.
*2 : The conversion value of the torque may vary depending on the unit.
Observe the standard values described for each unit.
18-10
［18. ENGINE］
18.2.3 Precautions for work

General precautions
To ensure safety in work and to prevent accidents, observe the following items :
1. Appearance
1) Wear safety goggles.
2) Do not wear watch, necktie, ring, bracelet, necklace, etc. to prevent accident before work.
3) Bind long hair at the back.
4) Be sure to wear a cap and safety shoes.
2. Safety work
18
1) Do not touch radiator, muffler, exhaust pipe, tail pipe, etc. after stop of the engine to prevent burn.
2) Do not put your clothes or tools near the rotating part (in particular, cooling fan or V-belt) during operation of
the engine.
3) Remove the starter key when the engine is not started.
4) Start the engine at a well ventilated place so that carbon monoxide may not be filled.
5) Since gas from the fuel or the battery is flammable, do not spark a fire or smoke a cigarette near the area.
6) Since the battery fluid is poisonous and corrosive, be careful for handling.
7) Do not short-circuit the cable of the battery or starter. Otherwise, the cable may be burned or burn may
occur.
8) If a tool or rag is left in the engine compartment, it may be bounced with a rotating part of the engine,
resulting in injury.
9) To tow a failure machine, refer to "Towing" in the "Operation manual" of the machine.
Precautions for service work

Pay attention to the following points before service work
1. Preparation before disassembly
1) Prepare general tools, special tools and gauges before work.
2) To disassemble a complicated area, put a stamp or match mark on the location not functionally affected to
ease assembly. To repair the electric system, disconnect the cable from the minus terminal of the battery
before work.
3) Perform inspection according to the procedure in the text before disassembly.
2. Inspection during disassembly
Every time parts are removed, check the area where the parts are assembled and check for deformation,
damage, wear or scratch.
3. Arrangement of disassembled parts
Place removed parts neatly in order. Separate parts to be replaced from parts to be reused.
4. Washing of disassembled parts
Clean and wash parts to be reused well.
5. Inspection and measurement
Inspect and measure parts to be reused as required.
6. Assembly
1) Keep the specified standard values (tightening torque, adjusting values, etc.) and assemble correct parts in
the correct order.
2) Be sure to use genuine parts for parts to be replaced.
3) Use new packing, gasket, O-ring and cotter pin.
4) Use seal gaskets for some areas where gaskets are used. Apply specified oil or grease to sliding areas
where application of oil is required, and apply specified grease to the oil seal lip before assembly.
7. Check of adjustment
Make adjustments to the service standard values using a gauge or tester.
18-11
［18. ENGINE］
Precautions for electric system

1. Removal of battery cable
1) In an electric system, remove the cable from the
battery minus (-) terminal to prevent burnout due
to short-circuit.
2) When the battery cable is removed, the battery
Loosen
terminal may be damaged. Loosen the nut
completely and never pry it for removal.
2. Handling of electronic parts

1) Do not give impact on electronic parts such as
computer and relay.
2) Do not place electronic parts at a high
temperature and humidity area.
3) Do not expose electronic parts to water in
washing of a vehicle.
3. Handling of wire harness

1) Mark clamps and clips to prevent interference of
a wire harness with body edge, sharp edge and
bolts. Be sure to reassemble it to the original
position.
2) When parts are assembled, be careful not to
pinch a wire harness.
4. Handling of connector
1) When a connector is removed, hold the
connector (as shown by the arrow in the left) and
pull it out. Do not pull the wire harness.
2) Unlock the locking connector before pulling.
3) Insert the locking connector completely until it
clicks.
4) To insert a test lead into the connector, insert it
from the back of the connector.
5) If it is difficult to insert a test lead from the back of
the connector, prepare a harness for inspection.
18-12
［18. ENGINE］
Precautions for electric welding

Inadvertent electric welding on a cab or chassis may cause reverse welding current from the grounding circuit,
resulting in damage to electric and electronic parts. Observe the following items for electric welding.
1. Turn "OFF" the starter switch.
2. Make sure that switches are "OFF".
3. Disconnect the minus (-) terminal of the battery according to the removal procedure of the battery cable.
4. Disconnect connectors of each computer.
5. Remove all fuses. (For locations of fuses, refer to "Electrical System Chapter".)
6. Be sure to connect grounding of the electric welding machine near the welding area.
Connect grounding from a bolt (plated bolt) or a frame near the welding area.
18
Remove paint of the frame for connection of grounding from the frame.
7. Other precautions
1) Put a cover on rubber hoses, wire harnesses, pipes, tires, etc. around the welding area so that they may not
be exposed to spatter.
2) Perform welding under appropriate conditions and minimize heat effect in the peripheral area. Also maintain
welding quality.
8. After welding, connect and assemble in the order of the fuse and the minus terminal of the battery
disassembled. When paint is removed from a frame or cab, apply rust preventive coating with the same color.
9. After reassembly, check the function if it operates correctly.
18-13
［18. ENGINE］
18.2.4 Tightening of engine bolts and nuts

Tightening torque of general standard bolts
1. For bolts with seatings
Unit : N·m{kgf·cm}
Screw diameter x Pitch 7T 9T

M8 x 1.25 (Coarse thread) 28.5{290} 36{370}
M10 x 1.25 (Fine thread) 60{610} 74.5{760}
M10 x 1.5 (Coarse thread) 55{560} 68.5{700}
M12 x 1.25 (Fine thread) 108{1, 100} 136{1, 390}
M12 x 1.75 (Coarse thread) 97{990} 125{1, 280}
M14 x 1.5 (Fine thread) 171.5{1, 750} 216{2, 200}
M14 x 2 (Coarse thread) 154{1, 570} 199{2, 030}
Remark Bolt with number “7” on the head Bolt with number “9” on the head
• 8T bolt is in accordance with 7T bolt.
2. For bolts with washers
Screw diameter x Pitch 4T 7T 9T

M6 x 1 (Coarse thread) 6{60} 10{100} 13{130}
M8 x 1.25 (Coarse thread) 14{140} 25{250} 31{320}
M10 x 1.25 (Fine thread) 29{300} 51{520} 64{650}
M10 x 1.5 (Coarse thread) 26{270} 47{480} 59{600}
M12 x 1.25 (Fine thread) 54{550} 93{950} 118{1, 200}
M12 x 1.75 (Coarse thread) 49{500} 83{850} 108{1, 100}
M14 x 1.5 (Fine thread) 83{850} 147{1, 500} 186{1, 900}
M14 x 2 (Coarse thread) 74{750} 132{1, 350} 172{1, 750}
Bolt with number “4”on the Bolt with number“7”on the

head head Bolt with number “9”on the
Remark
Projection bolt Stud with R Stud with C surface at free head
surface at free end end
• 8T bolt is in accordance with 7T bolt.
R surface (4T) C surface (7T)
18-14
［18. ENGINE］
Precoated bolt
Precoated bolt is the bolt with an application of a seal
lock agent at the thread.
1. When re-application of lock agent is required
1) When precoated bolts are removed
2) When precoated bolts are moved due to
tightening check (for loosening or tightening) Seal Lock Agent
18
• Check torque with the lower limit of the tightening torque allowable value. If movement is found, tighten the bolt
according to the procedure below.
2. Re-use method of precoated bolt lock

1) Clean bolt and screw holes. (Clean screw holes for replacement.)
2) Dry completely by blowing air.
3) Apply the specified seal lock agent to the thread of the bolt.
Plastic region tightening method (angle method)

1. Precautions
One turn by 90°
Some engines are tightened with the plastic region
tightening method.
Since it is different from the conventional method, Tighten it 90°
tighten it according to the instruction in the text.
2. Parts tightened
One turn by 90° Tighten it 45°
Cylinder head bolt, crankshaft main bearing cap One turn by 45° (Second time)
bolt, connecting rod bearing cap bolt, etc.
Tighten it 90°
(First time)
• Measure the overall length of the bolt before assembly and replace the bolt if the length exceeds the service
limit.
Apply engine oil to bolt seating and bolt thread in assembly.
18-15
［18. ENGINE］
3. Tightening method after tightening to seating torque Two turns by 90° Tighten it 90°
Tightening of 90°, 135°(90°once and 45°once) and (Second time)
180°(90°twice) is available. Tighten it 90°

(First time)
18-16
［18. ENGINE］
18.2.5 Tightening of chassis bolts and nuts

Tightening torque of general standard bolts and nuts
1. Selection method of tightening torque
1) Find the applicable strength zone from the table below and select the bolt tightening torque from the table
described later.
2) Select the nut tightening torque from the mating bolt as described above.
2. Identification method of bolt strength zone
1) Identification method with product
Hexagonal bolt 18
Strength zone of hexagonal bolts is, in principle, indicated with recession, relief, surface depression and upset
on the head with the symbol in the table.
Strength zone 6T 7T 8T 9T 10T 11T 12T

Identification symbol for part 6 7 8 q*1 10 11 12
(*1): 9 may be misread with 6. It is expressed in q.
Depression Relief Base depression Upset
Hexagonal nut
Symbol example for identification of the strength zone of the hexagonal nut is shown in the table below :
Formula
3. Types of general standard bolts and nuts
Standard seating Seating A with flange Seating B with flange
18-17
［18. ENGINE］
4. Standard tightening torque table of general standard bolts and nuts

(Representative standard seating is described)
Strength
zone
Bolt 4T 7T 9T
diameter
(mm)
4.5±1.8{50±20}
(Cab)
M6 9.0±1.8{90±20} 11.5±2.0{117±23}
5.5±1.1{60±10}
(Chassis)
14.0±3.5{140±40}
(Cab)
M8 22.0±4.0{220±40} *2 29.0±5.5{300±60} *2
17.0±3.0{170±30}
(Chassis)
43.0±8.5{440±90} *2 57.0±11.0{580±110} *2
(Cab) (Cab)
M10 27.0±5.0{276±55}
51.5±10.0{530±100} 68.5±13.5{700±140}
(Chassis) (Chassis)
76.0±15.0{776±150} *2 100.0±20.0{1, 020±200} *2

(Cab) (Cab)
M12 48.0±9.5{490±98}
91.0±18.0{930±180} 120.0±24.0{1, 220±240}
(Chassis) (Chassis)
M14 77.0±15.0{786±157} 120.0±24.0{1, 220±240} 160.0±32.0{1, 630±326}
M16 120.0±24.0{1, 220±244} 190.0±38.0{1, 940±390} 250.0±50.0{2, 550±510}
M18 165.0±33.0{1, 680±336} 260.0±52.0{2, 650±530} 345.0±69.0{3, 520±704}
M20 235.0±47.0{2, 400±480} 370.0±74.0{3, 770±750} 490.0±98.0{5, 000±1, 000}
M22 320.0±64.0{3, 270±654} 505.0±100.0{5, 150±1, 030} 670.0±130.0{6, 840±1, 370}
M24 405.0±81.0{4, 130±826} 640.0±125.0{6, 530±1, 310} 845.0±165.0{8, 620±1, 720}
• Use the tightening torque value for seating A with flange except for *2 in the table larger by 10% than the
tightening torque value in the table.
• Use the tightening torque value for seating B with flange of *2 in the table larger by 20% than the tightening
torque value in the table.
The tightening torque value of M8 for seating B with flange remaines unchanged.
• Seating B with flange of *2 in the table is interchangeable with the standard seating in pairs. Use the standard
seating for the tightening torque value.
18-18
［18. ENGINE］
18.2.6 Tightening of flare nuts and hoses

1. Tightening torque of pipe flare nut
Pipe outer
diameter ø4.76 ø6.35 ø8 ø10 ø12 ø15
Material
Steel pipe 15±5{150±50} 25±5{250±50} 36±5{370±50} 52±7{530±70} 67±7{680±70} 88±8{900±80}
2. Tightening torque of hoses 18

Hose outer diameter Hose outer diameter Hose outer diameter

ø10.5 fitting ø13, ø20, ø22, fitting at packing PF3/8 fitting
21.5±1.5{215±15}
Air hose Only meter gauge 41.5±2.5{425±25} —
10{100}
Packing
Brake hose — —
51.5±7.5{525±75}
3. Lock nut tightening torque of brass joint
Screw nominal
M12 M16 M20 M27
size
Tightening
15±2{150±20} 66±6{670±60} 97±9{990±90} 209±19{2130±190}
torque
18-19
［18. ENGINE］
18.2.7 Taper thread sealant for piping

The taper thread of the air pipe joint has application of sealant [Loctite # 575 (by Japan Loctite)]. Follow the
procedures below for connection or disconnection of pipes.
1. For disconnection Removal of joint (Example: Use of magnetic valve)
1) The sealant ( # Loctite 575) has strong sealing Magnetic valve
feature. The return torque of the taper joint is Frame Air pipe (Flare joint)
increased about 1.5 times the initial tightening (No application of sealant)
torque. When the joint is disconnected, use a
long wrench for disconnection. Since sealant is
applied to this area,
2) When a joint at a poorly accessible area is remove accessories
replaced, remove accessories first and with the joint
attached and
disconnect the joint. Air hose
remove the joint.
2. For connection 1/4 turn Amount of application: 0.1 g/piece

1) For application of sealant ( # Loctite 575), wipe
the sealing area completely with a rag or thinner.
Apply sealant directly to about three ridges for 3 threads
1 thread
quarter round with offset of one ridge from the
end. Tighten it according to the tightening torque
in the table below.
Remove dirt completely from the mating part
(female) before tightening.
• If your eye or skin comes in contact with sealant, wash it off immediately with water.
Tightening torque of taper joint
Screw diameter
1/4 3/8 1/2
Material
Steel 49±10{500±100} 64±15{650±150}
Aluminum,
25±5{250±50} 34±5{350±50} 44±5{450±50}
brass
2) When a sealing tape is replaced with sealant, remove the tape completely first as in (1).
• Be careful to prevent entry of dirt or foreign matter in the pipe.
3) If air leak is found after assembly with application of sealant, air leak cannot be stopped with additional
tightening. Assemble the part again according to (1) and (2).
18-20
［18. ENGINE］
18.2.8 Assembly of joints and gaskets for piping

1. Tightening torque of joints
Sealing method Metal sealing method

Gasket sealing method (Flare pipe type, nipple connector type)
Tightening screw size (Aluminum + Rubber or Copper)
Type A Type B
M8 13{130}
M10 20{200} 11{110} 18

M12 25{250} 20{200}
M14 25{250} 31{320}
M16 29{300} 39{400}
M18 39{400} 59{600}
M20 *39{400} 64{650} 20{200}
M24 69{700}
M28 *127{1300}
2. Joint assembly procedure and subsequent inspection

1) Before assembly, make sure that there is no dirt or burr on the seating surface (mating part, pipe joint,
gasket, etc.).
2) Since pipes have some degrees of freedom for assembly, the seating surface tends to incline. Tighten pipes
finally after temporary tightening to prevent leak.
3) After tightening, apply the specified pressure to each pipe joint to ensure that there is no leak.
4) Observe the values above for each tightening torque.
*When assembled soft washer # 4840FR-N (aluminum and rubber carbon pressure bonding) is loosened or
removed, be sure to replace it with a new part. This is not necessary for normal retightening.
18-21
［18. ENGINE］
3. Examples of joint methods in various pipes
Metal sealing method

Gasket sealing method Type A Type B
(Flare pipe type) (Nipple connector type)
Joint bolt Sealing surface: 3 places

Flare pipe
Gasket Connector
Flare nut Nut
Joint bolt Connector nipple
Sealing surface
: 4 places
Flare connector
Gasket
One piece eye joint
Gasket
with sleeve Gasket Sealing surface
Gasket : 5 places Sealing surface: 5 places
Joint bolt Nut

Lock washer Bracket
Nut
Sealing surface
: 8 places Connector nipple
Sealing surface: 1 place Sealing surface: 1 place

Flare connector
Nut Lock washer

Box nut
3-way joint
Sealing surface
: 8 places
Joint pipe
Bracket
Sealing surface
: 3 places
One piece eye joint without sleeve
Joint bolt
Sealing surface: 4 places
Joint bolt
Joint pipe
Sealing surface: 6 places
18-22
［18. ENGINE］
18.2.9 Handling of liquid gasket

1. Application of liquid gasket and part assembly procedure
1) Remove old liquid gasket on each part and mating part completely. Clean the parts with a rag to prevent
deposit of oil, moisture, dirt, etc.
Be sure to overap parts at the beginning and at the end of application.
2) Be careful for offset with the mating part when a part applied with liquid gasket is assembled. Apply the
liquid gasket again if offset occurs.
3) Assemble parts within 20 minutes after application of the liquid gasket.
If 20 minutes has passed, remove the liquid gasket and apply it again.
4) Start the engine at least 15 minutes or more after assembly of parts. 18
2. Removal of parts
1) When parts are removed, do not pry one place only. Remove parts by prying each other using collar or
clearance on the flange. When gasket is removed, be careful to prevent entry of gasket offal into the engine.
3. Others
1) When the liquid gasket is contained in a tube, use the accompanying winding tool. When it is contained in a
cartridge, use the application gun.
Winding tool
Application gun
Tube: 150 g Cartridge type: 300 g
For a tube, desired application width may be obtained from the cut position at the nozzle end.
1 : Approx. 2 mm at the 1st section cut

2 : Approx. 5 mm at the 2nd section cut
Nozzle of tube
18-23
［18. ENGINE］
18.2.10 Failure diagnosis table for each problem
Engine m echanical Causes and actions are described for each item.
JP03Z01020601001
Sta tus Ca use Act ion

Engine o ver hea t (c oolant ) Insufficient coolant Replenish coolant
Faulty thermostat Replace thermostat
Water leak from cooling system Correction
Faulty coolant pump Repair or replace
Faulty head gasket Replace head gasket
Engine o ver hea t Clogging of radiator Cleaning of radiator
(ra diator) Corrosion of cooling system Clean and repair cooling system
Clogging of radiator core front part Clean radiator
Faulty radiator cap Replace radiator cap
Engine o ver hea t (c ompre ssion Non-synchronous injection timing Adjust injection timing.
pre ssur e) Faulty fuel injection pressure Adjust injection pressure
Faulty fuel Replace with correct fuel
Faulty injector Replace injector
Engine o ver hea t (lubr ication Deterioration of engine oil Replace engine oil
unit) Faulty oil pump Replace oil pump
Insufficient engine oil Replenish engine oil
Lar ge engine oil con sumpt ion Wear of piston ring and cylinder Replace piston ring and cylinder
(pis ton, cylind er line r and pist on liner liner
ring) Damage to piston ring Replace piston ring and cylinder
liner
Faulty fixing of piston ring Replace piston ring and cylinder
liner
Faulty assembly of piston ring Replace piston ring and cylinder
liner
Faulty engine oil Replace engine oil
Faulty piston ring joint Reassemble piston ring
Lar ge engine oil con sumpt ion Wear of valve stem Replace valve and valve guide
(valve and valve gu ide) Wear of valve guide Replace valve guide
Faulty assembly of valve stem seal Replace stem seal
Excessive oil lubrication to rocker Inspection of clearance between
arm rocker arm and rocker arm shaft
Lar ge engine oil con sumpt ion Faulty oil level gauge Replace with correct level gauge
(others) Excessive filling of engine oil Fill with appropriate amount of oil.
Leak of engine oil Repair or replace the part of oil
leak.
Pis ton seizu re ( in op era tion) Sudden stop of engine Perform warm-up before stop of
engine
Pis ton seizu re ( lubricat ion unit) Insufficient engine oil Replenish engine oil
Deterioration of engine oil Replace engine oil
Incorrect engine oil Replace with correct engine oil.
Low oil pressure Inspection of lubrication unit
Faulty oil pump Replace oil pump
Pi st on se izure Abnormal combustion Refer to overheat section.
Pi st on se izure Cooling unit Refer to overheat section.
18-24
［18. ENGINE］
18.2.11 Failure diagnosis using HinoDX
• HinoDX is used for inspection and adjustment of the system in addition to failure diagnosis.
HinoDX
1. With HinoDX, failure of the common rail fuel
injection system can be diagnosed. The interface 18
box (Hino-Bowie) and the special cable are required
for connection to the vehicle.
List of failure diagnosis tools

Part name Part No. External shape General description and function
• Operating system (OS) :

Windows98 (IE5.0 or later),
Windows2000 (SP3, IE5.0 or later),
WindowsXP (SP1a, IE6.0 or later),
Computer WindowsVista*2, Windows7*2
—
(DOS/V standard) • CPU and memory :
Conditions that assure operation of
the above operating system
• Display : 800 x 600, 256 colors or
more
• Software and CD-ROM
Hino Diagnostic
• Install the software included in the
eXplorer —
Hino Diagnostic eXplorer (Hino-DX)
(Hino-DX)
into the computer. For the
installation method, refer to the
instruction manual included with the
CD.
18-25
［18. ENGINE］
• Computer interface
• It is necessary to update the

hardware.
09993 - E9070
Hino-Bowie
*1
• The cable between the personal
computer and the Hino-Bowie is
bundled with the Hino-Bowie.
• Please use either RS-232C or USB.
Cable bundled
to the Hino-Bowie
• The cable used for connect

between Hino-Bowie and the
adapter cable.
S0904-21220
Connection cable
(09042-1220)
Cable between
unit and Hino-Bowie
DENSO DST-i set • Computer interface

without LCD
95171-01020
without Bluetooth®
without LCD
95171-01040
with Bluetooth®
with LCD
95171-01030
without Bluetooth®
with LCD
95171-01050
with Bluetooth®
Interrupting installation between unit
side harness and ECU allows
Signal check harness inspection with a tester rod while the
09843-E9020
power is supplied.
*1: To use Hino-Bowie (interface box) 09993-E9070, update the hardware. For details, refer to the user’s manual in the
HinoDX CD-ROM.
Keep updating the firmware (software built in the Hino-Bowie) using the software in the HinoDX CD-ROM. For details, refer to
the user’s manual in the HinoDX CD-ROM.
*2: HinoDX (Ver. 3.0.5 or later), only when use DST-i.
18-26
［18. ENGINE］
Conformity table for OS and interface

OK: Available
—: Disabled
Tier3 Tier4 Interim Tier4 Final
OS Software ver. Interface Reprog Reprog Reprog
Hino-DX Hino-DX Hino-DX
manager manager manager
DST-i OK OK OK OK OK OK
3.1.5 Bowie w/ CAN — — — — — —
Bowie w/o CAN — — — — — —
18
DST-i OK OK OK OK — —
3.1.0 Bowie w/ CAN — — — — — —
7
3.04/3.05 Bowie w/ CAN — — — — — —
DST-i — — — — — —
1.0.9 Bowie w/ CAN — — — — — —
DST-i OK OK OK OK OK OK
3.1.5 Bowie w/ CAN OK OK OK OK OK OK
Bowie w/o CAN OK OK — — — —
3.1.0 Bowie w/ CAN OK OK OK OK — —
XP
3.04/3.05 Bowie w/ CAN OK OK OK OK — —
DST-i OK OK — — — —
1.0.9 Bowie w/ CAN OK OK — — — —
18-27
［18. ENGINE］
Deletion of past failures

1. To delete past failures of the engine ECU, use
HinoDX on the PC. (Refer to "HinoDX operation
manual".)
Connection of signal check harness

1. To prevent damage to the ECU connector and to
improve accessibility, connect the signal check
harness and put a testing rod on the signal check
connector of the signal check harness for
meaurement.
1) Disconnect the connector from the ECU.
Unit harness
Signal check harness
Test lead
Signal check connector
• Do not break the locking tab of the connector.
2) Connect the signal check harness to the machine harness and the ECU.
(for common rail fuel injection system)
Part No.
09843-E9020
18-28
［18. ENGINE］
3) Terminal No.
For the signal check harness connector, the ECU terminal number in the text is treated as follows :
ECU unit
18
Signal check
harness
ECU side Unit side
18-29
［18. ENGINE］
18.2.12 Connection method of HinoDX

1. Connection of HinoDX
1) Remove the left side cover at the rear of the
driver's seat and connect the failure diagnosis
connector with a PC which installed HinoDX
through the interface box. Engine ECU
Special tool : 09993-E9070 Hino-Bowie
(Interface box)
09042-1220 Connecting cable
CD-ROM HinoDX
Failure diagnosis
connector
2) Set the starter key to "ON" and start HinoDX. Failure diagnosis connector
Hino-Bowie
Connect to the failure diagnosis Connecting cable

connector at the unit side.
18.2.13 Chassis number and engine number

1. Engine type and engine number
1) Engine type and engine number are stamped at
the left cylinder block when viewed from the
cooling fan. For order of parts, information of this
number will facilitate procedures smoothly.
Ex. J05E TA10101
Stamp position
18-30
［18. ENGINE］
18.3 STANDARD VALUE

18.3.1 Engine Body
Standard value
MPa {kgf/cm2, lbf/in.2}
Inspection item Standard value Repair limit Service limit Action

Compression pressure 3.4 - 3.7 2.7
—
(Engine revolution per cylinder: 150 r/min) {35- 38, 493-237} {28,392}
18
Tightening torque
Unit : N·m{kgf·cm, lbf·ft}
Tightening area Tightening torque Remark
Starter B terminal 7.8 - 8.8 {80 - 110, 5.8 - 6.5}
Alternator B terminal 3.2 - 4.4 {33 - 44, 2.4 - 3.2}
Oil pan drain cock 41 {420, 30}
Radiator hose band 4.5 - 5.0 {45 - 50, 3.3 - 3.7}
18.3.2 Fuel System

Tightening torque

Injector clamp 25 {250, 18}
Supply pump - Bearing holder case 28.5 {290, 21}
Bearing holder case - Pump drive 28.5 {290, 21}
Supply pump coupling flange mounting nut 63.7 {650, 47}
Injector harness 2.2 {22, 1.6}
Fuel filter air bleeding bolt 9 - 11 {91.8 - 112, 6.7 - 8.1}
44 {450, 33} M14

Fuel feed pipe
54 {550, 40} M16
Injection pipe 44 {450, 33}
18-31
［18. ENGINE］
18.3.3 Electrical
Standard value
Inspection item Item Item Standard value Remark

8 - 10mm {0.3152 - 0.394in.}
Compression gauge
Deflection (Reference push force 98 N {10 kgf,
(09444-1210) is used.
When installing 22 lbf})
a new belt Belt tension gauge
490 - 570 N
Tension (95506-00090 Denso part
{50 - 58 kgf, 110 - 128 lbf}
V-belt tension No.) is used.
adjustment 10 - 12mm
Compression gauge
Deflection (Reference push force 98 N {10 kgf,
(09444-1210) is used.
At the time of 22 lbf})
inspection Belt tension gauge
320 - 400 N
Tension (95506-00090 Denso part
{33 - 41 kgf, 72 - 90 lbf}
No.) is used.
Tightening torque

Starter mounting nut 154 {1,570, 114}
Battery cable mounting nut 12 - 15 {125 - 155, 9 - 11}
Alternator through bolt 83 {850, 61}
E terminal bolt 3.2 - 4.4 {33 - 45, 2 - 3}
Fixing bolt at brace 51 {520, 38}
Outside B terminal mounting nut 3.2 - 4.4 {33 - 45, 2 - 3}
Through bolt 7.8 - 9.8 {80 - 99, 6 - 7}
18.3.4 Intake
Tightening torque

Intake manifold mounting bolt 28.5 {290, 21}
18-32
［18. ENGINE］
18.3.5 Engine Mechanical

Standard value
Unit : mm {in.}
IN 0.30 {0.0118} — —
Valve clearance (cold)
EX 0.45 {0.0177} — —
0.01 - 0.08
Cylinder liner protrusion — —
{0.003 - 0.003}
18
Cylinder liner flange width 8 {0.314} — —
Cylinder block flange width 8 {0.314} — —
117 - 117.008
A — —
{4.6063 - 4.6066}
Cylinder block inner 117.008 - 117.014

B — —
diameter {4.6066 - 4.6068}
117.014 - 117.022
C — —
{4.6068 - 4.6072}
116.982 - 116.99
A — —
{4.6056 - 4.6059}
Cylinder liner outer 116.99 - 116.996

B — —
diameter {4.6059 - 4.6061}
116.996 - 117.004
C — —
{4.6061 - 4.6064}
Clearance between cylinder 0.01 - 0.026

— —
liner and cylinder block {0.0003 - 0.0010}
112.15 Cylinder
Cylinder liner inner diameter 112 {4.4094} —
{4.4154} Replace liner
Piston outer diameter

(Pin hole 23mm{0.9 in.} above 111.9±0.008
— —
the lower end of the skirt {4.4089±0.0003}
Square direction)
Cylinder
0.088 - 0.112
Piston clearance — — Liner
{0.0035 - 0.0044}
Replace piston
18-33
［18. ENGINE］

Approx. 11.5
Top — —
Free joint {0.4528}
clearance Approx. 14
Second — —
{0.4921}
0.3 - 0.40 1.5

Top —
{0.0118 - 0.0157} {0.0591}
Gap between
0.75 - 0.90 1.5
ends of piston Second — Replace piston ring
Piston {0.0295 - 0.0354} {0.0591}
ring
ring 0.15 - 0.3 1.2
Oil —
{0.0059 - 0.0118} {0.0472}
2.5 –0.1
Top —
{0.0984} {–0.0039}
Ring width B 2 –0.1

Second — Replace piston ring
dimension {0.0787} {–0.0039}
4 –0.1
Oil —
{0.1574} {–0.0039}
2.5 +0.2
Top —
{0.0984} {+0.0079}
Piston ring 2 +0.2

Second — Replace piston
groove {0.0787} {+0.0079}
4 +0.1
Oil —
{0.1574} {+0.0039}
0.09 - 0.13
Top — —
Clearance {0.0035 - 0.0051}
between
0.04 - 0.08 Replace piston ring or
piston ring Second — —
{0.00016 - 0.0031} piston.
and piston
Piston
ring groove 0.02 - 0.06
Oil — —
{0.0008 - 0.0024}
37 –0.04
Piston pin outer diameter — Replace piston pin
{1.4567} {–0.0015}
37 +0.05
Piston boss inner diameter — Replace piston
{1.4567} {+0.0020}
–0.002T - 0.025
{0.0000 - 0.0010}L
Clearance between piston 0.05 Replace piston pin or
(T : Tightening —
pin and piston boss {0.0020} piston
allowance,
L : Clearance)
37 +0.1 Replace connecting

Connecting rod bushing inner diameter —
{1.4567} {0.0039} rod bushing
Replace piston pin or

0.015 - 0.036 0.08
Connecting rod bushing oil clearance — connecting rod
{0.0006 - 0.0014} {0.0031}
bushing
18-34
［18. ENGINE］

Replace the
64.3
Crank pin outer diameter 65 {2.5590} — crankshaft.
{2.5315}
(Note 1)
Thickness of connecting rod

2.0 {0.0787} — —
bearing
Replace bearing for

0.031 - 0.082 0.2
Connecting rod oil clearance — clearance of 0.3 or
{0.0012 - 0.0032} {0.0079}
more (Note 2)
79.3
Crank 18
Crank journal outer diameter 80 {3.1496} — Replace shaft
{3.1221}
(Note 1)
Thickness of main bearing 2.5 {0.2342} — —

Crank
shaft Replace bearing for
0.051 - 0.102 0.2
Crankshaft oil clearance — clearance of 0.3 or
{0.0020 - 0.0040} {0.0079}
more (Note 2)
+1.00
Center journal width 36 {1.4173} — Replace crankshaft.
{+0.039}
Thickness of thrust bearing 2.5 {0.2342} — —
0.050 - 0.219 0.50 1.219 Replace thrust bearing

Crankshaft end play
{0.0020 - 0.0086} {0.0020} {0.0086} or crankshaft
0.15
Crankshaft runout — — Ground to under-size
{0.0059}
+0.8
Crank pin width 34 {13.386} — Replace crankshaft
{+0.0315}
Note 1 : Correction with re-grinding for eccentric wear of 0.10 or more. Re-grinding for wear of 0.20 or more.
Replace crankshaft for wear of 0.7 or more.
Note 2 : Under-size bearing values are 0.25 and 0.50.
–0.8 Replace connecting

Connecting rod large end width 34 {1.3386} —
{–0.0315} rod
0.20 - 0.5 1.0 Replace connecting
Connecting rod end play —
{0.0079 - 0.0205} {0.0394} rod or crankshaft
Camshaft journal outer –0.15

40 {1.5748} — Replace camshaft
diameter {–0.0059}
Camshaft bearing inner +0.15 Bearing

40 {1.5748} —
diameter {+0.059} Replacement
Camshaft bearing oil 0.020 - 0.063 Replace camshaft or

Cam — —
Clearance {0.0008 - 0.0025} bearing
shaft
IN 50.067 {1.9711} — –0.08
Cam height Replace camshaft
EX 52.104 {2.0513} — {–0.0031}
IN 8.067 {0.3176} — –0.08

Cam lift Replace camshaft
EX 10.104 {0.3978} — {–0.0031}
18-35
［18. ENGINE］

Camshaft journal width
33 {1.2992} — —
(Rear journal)
Cam 0.100 - 0.178

Camshaft end play — — Replace camshaft
shaft {0.0039 - 0.0070}
0.04 0.1
Camshaft runout — Replace camshaft
{0.0016} {0.039}
–0.08
Rocker shaft outer diameter 22 {0.8661} — Replace rocker shaft
{–0.0031}
+0.08 Replace rocker arm

Rocker arm bushing inner diameter 22 {0.8661} —
{+0.0031} bushing
0.030 - 0.101 0.15

Rocker arm oil clearance —
{0.00012 - 0.0040} {0.0059}
IN 7 {0.2756} — —
Valve stem outer diameter Replace valve
EX 7 {0.2756} — —
IN 7 {0.2756} — —
Valve guide inner diameter Replace valve guide
EX 7 {0.2756} — —
0.023 - 0.058
IN — —
Oil clearance between valve {0.0009 - 0.0020} Replace valve or valve
guide and valve stem 0.050 - 0.083 guide
EX — —
{0.0020 - 0.0033}
0.55 - 0.85 1.1

IN —
{0.0217 - 0.0335} {0.0433} Replace valve and
Valve sink
1.15 - 1.45 1.7 valve seat
EX —
{0.0453 - 0.0571} {0.0669}
IN 30° Allowable angle 30°- 30°35'

Valve seat angle
EX 45° Allowable angle 45° - 30°30'
Correction
IN 30° Allowable angle 29°30 - 45°
Valve face angle
EX 45° Allowable angle 44°30 - 45°
18-36
［18. ENGINE］

Set length 44.8 {1.764} — —
Set load 129N {13.1kgf} — —
Inner –3.0
Free length 64.6 {2.5433} — Replace spring
{–0.3543}
2.0
Squareness — — Replace spring
Valve {0.0787}
spring Set length 46.8 {1.8252} — —
Set load 314N {32.0kgf} — — 18

Outer –3.0
Free length 75.7 {2.9803} — Replace spring
{–0.3543}
2.0
Squareness — — Replace spring
{0.0787}
0.030 - 0.167 0.30

Crank - Main idle —
{0.0012 - 0.0066} {0.0012}
Main idle - Pump 0.032 - 0.096 0.10

—
drive idle {0.0013-0.0038} {0.00393}
Pump drive idle - 0.020 - 0.083 0.10

—
Pump drive {0.0008-0.0033} {0.00393}
Back- 0.030 - 0.113 0.30

Main idle - Sub-idle — Gear replacement
lash {0.0012 - 0.0044} {0.0012}
0.030 - 0.131 0.30

Sub-idle - Oil pump —
{0.0012 - 0.0051} {0.0012}
0.050 - 0.218 0.30

Sub-idle - Cam idle —
{0.0020 - 0.0086} {0.0012}
0.030 - 0.253 0.30

Cam idle - Cam —
{0.0012 - 0.0100} {0.0012}
Shaft outer diameter 57 {2.2441} — —
Bushing inner
Timing 57 {2.2441} — —
diameter
gear
Clearance between 0.030 - 0.090 0.20 Replace shaft or
—
Main shaft and bushing {0.0012 - 0.0084} {0.0079} bushing
idle
Gear width 44 {1.7322} — —
Shaft length 44 {1.7322} — —
0.114 - 0.160 0.30

End play — Replace shaft or gear
{0.0045 - 0.0063} {0.0012}
Shaft outer diameter 50 {1.9685} — —
Bushing inner
50 {1.9685} — —
diameter
Clearance between 0.025 - 0.075 0.20 Replace shaft or
—
Sub- shaft and bushing {0.0010 - 0.0030} {0.0079} bushing
idle
Gear width 22 {0.8661} — —
Shaft length 22 {0.8661} — —
0.040 - 0.120 0.30

End play — Replace shaft or gear
{0.0016 - 0.0047} {0.0012}
18-37
［18. ENGINE］

Shaft outer
34 {1.3386} — —
diameter
Bushing inner
34 {1.3386} — —
diameter
Clearance
0.025 - 0.075 0.20 Replace shaft or
between shaft —
Cam idle {0.0002 - 0.0030} {0.0079} bushing
and bushing
Gear width 22 {8.6614} — —
Shaft length 22 {8.6614} — —
0.040 - 0.120 0.30 Replace thrust plate or

End play —
Timing {0.0016 - 0.0047} {0.0012} gear
gear Shaft outer
34 {1.3386} — —
diameter
Bushing inner
34 {1.3386} — —
diameter
Clearance
0.025 - 0.075 0.10 Replace shaft or
Pump between shaft —
{0.0002 - 0.0030} {0.0039} bushing
drive idle and bushing
Gear width 28.5 {0.9605} — —
Shaft length 28.5 {0.9605} — —
0.016 - 0.22
End play — —
{0.0006 - 0.0087}
Longitudinal
direction 0.06 Grinding is inhibited
Flatness under cylinder head {0.0024} 0.2 because backlash
—
Flatness above cylinder block Square direction {0.0079} between cam idle- sub-
0.03 idle gears is changed.
{0.0012}
0.15
Surface runout of flywheel — —
{0.0060}
Camshaft gear mounting bolt — — 31 {1.2205} Replacement
Bearing cap bolt 108

— — Replacement
(Crankshaft mounting) {4.2520}
68.0
Connecting rod bolt — — Replacement
{2.6772}
187.5
long — — Replacement
{7.3819}
156.5
Head bolt middle — — Replacement
{6.1614}
126.5
short — — Replacement
{49.8031}
18-38
［18. ENGINE］
Valve timing
Exhaust valve open (before BDC) 54°

Exhaust valve close (after TDC) 13°
Intake valve open (before TDC) 14°
Intake valve close (after BDC) 30°
Tightening torque
Unit : N·m{kgf·cm, lbf·ft} 18

Crankshaft pulley mounting bolt 118 {1,203, 87}
Head cover mounting bolt 28.5 {290, 21}
Camshaft bearing cap mounting bolt 28.5 {290, 21}
Union bolt of leakage pipe 13.5 {135, 10}
Injector harness mounting nut 28 {290, 21}
Camshaft gear mounting bolt 59 {600, 44}+90°
Rocker arm and crosshead adjusting screw lock nut 25 {250, 18}
Rocker arm support bolt 59 {600, 44}
Head bolt 59 {600, 44}+90°+90°
Cam idle gear shaft mounting bolt 108 {1,100, 80}
Main bearing cap mounting bolt 69 {700, 51}+90°+45° Refer to the main text.
Connecting rod cap mounting bolt 69 {700, 51}+90°+45°
Oil check valve 22 {220, 16}
Sub-idle gear shaft mounting bolt 108 {1,100, 80}
Main idle gear shaft mounting bolt 172 {1,750, 127}
Flywheel mounting bolt 186 {1,900, 137}
196 {2,000, 145} M16

Flywheel housing mounting bolt 55 {560, 41} M10
36 {370, 27} M8
Flywheel housing stay - Flywheel housing 171.5 {1, 750, 126} M14
Rear end plate torx bolt 55 {560, 41}
Supply pump bearing case mounting bolt 28.5 {290, 21}
Air compressor idle gear shaft mounting bolt 108 {1,100, 80}
18-39
［18. ENGINE］
18.3.6 Exhaust
Tightening torque

Exhaust manifold mounting stud bolt 30 {300, 22}
Exhaust manifold mounting nut 53 {540, 40}
18.3.7 Cooling
Standard value

69 - 73℃
Thermostat valve open temperature — — Replacement
{156.2 - 163.4℉}
Thermostat valve lift 10mm

— — Replacement
(Set temperature 85 ℃{185 ℉}) {0.3937 in.} or more
18-40
［18. ENGINE］
18.3.8 Lubrication
Standard value
Unit : mm {in.}
Repair Service
Inspection item Standard value Action
limit limit
39kPa
Hydraulic alarm switch operation pressure — —
{0.4kgf/cm2, 5.66lbf/in.2}
Outer diameter of drive gear 54 {2.1260} — —
Cylinder block side

54 {2.1260} — —
18
Oil pump chamber inner diameter
Clearance between drive gear and 0.100 - 0.202 0.30 Replace drive gear
—
cylinder block {0.0039 - 0.0080} {0.0118} or oil pump
Drive gear width 28.5 {1.1220} — —
Cylinder block side

28.5 {1.1220} — —
Depth of oil pump chamber
0.047 - 0.137 0.15 Replace drive gear

Drive gear end play —
{0.00186 - 0.00539} {0.0059} or oil pump
Outer diameter of driven gear shaft 18 {0.7087} — —
Cylinder block hole diameter 18 {0.7087} — —
Oil Clearance between drive gear shaft

0.040 - 0.099 Replace drive gear
pump outer diameter and bushing inner — —
{0.0016 - 0.0039} or bushing
diameter at cylinder block side
Cylinder block hole diameter 18 {0.7087} — —
Clearance between driven gear shaft

0.030 - 0.075
outer diameter and cylinder block — — Replace oil pump
{0.0012 - 0.0030}
hole diameter
Inner diameter of driven gear bushing 18 {0.7087} — —
Clearance between driven gear shaft

0.040 - 0.083 0.15 Replace oil pump
outer diameter and gear bushing —
0.0016 - 0.0033} {0.0059} or bushing
inner diameter
Backlash between drive gear and 0.073 - 0.207 0.30
— Replace oil pump
driven gear {0.0029 - 0.0081} {0.0118}
18-41
［18. ENGINE］
Tightening torque

Oil pan mounting bolt 30 {300, 22}
Oil strainer 31 {320, 23}
Oil pan drain cock 41 {420, 30}
Oil pump mounting bolt 28.5 {290, 21}
M14 24.5±4.9 {250±50, 18±4}
M20 24.5±4.9 {250±50, 18±4}

Oil circuit spring plug
Oil cooler M22 29.4±4.9 {300±50, 22±4}
M24 34.3±4.9 {350±50, 25±4}
Coolant drain plug 44.1±4.9 {450±50, 33±4}
Oil cooler case assembly mounting bolt 24.5±4.9 {250±50, 18±4}
18-42
［18. ENGINE］
18.3.9 Starting and Charging

Standard value (Alternator 50A)
Standard Repair
Inspection item Service limit Action
value limit
Resistance between stator coil terminals
0.247 - 0.273Ω — — Replacement
(for 2 phases)
Resistance between stator coil core and coil 1MΩ or more — — Replacement
Resistance of feed coil 6.75 - 7.45Ω — — Replacement
Resistance between feed coil core and coil 1MΩ or more — — Replacement 18
25mm 24.98mm
Front —
Shaft outer diameter of rotor {0.9843 in.} {0.9835 in.}
Replacement
assembly 17mm 16.98mm
Rear —
{0.6693 in.} {0.6685 in.}
Forward
Approx. 10Ω — —
Resistance between diode and resistance value
Replacement
rectifier holder Reverse
Infinite — —
resistance value
Forward
Approx. 10Ω — —
Resistance between regulator resistance value
Replacement
terminals F - E Reverse
Infinite — —
resistance value
Tightening torque (Alternator 50A)

Retainer plate mounting bolt 1.9 - 2.5 {20 - 25, 1 - 2}
Pully mounting nut 127 - 157 {1, 300 - 1, 600, 94 - 116}
Feed coil mounting bolt 3.9 - 4.9 {40 - 49, 2.9 - 3.6}
Regulator mounting bolt 1.9 - 2.5 {20 - 25, 1 - 2}
Inside B terminal mounting nut 3.9 - 4.9 {40 - 49, 2.9 - 3.6}
Coupler holder mounting bolt 1.9 - 2.5 {20 - 25, 1 - 2}
Cover mounting bolt 3.3 - 4.4 {34 - 44, 2 - 3}
18-43
［18. ENGINE］
Standard value (starter)
Unit : mm {in.}
Inspection item Standard value Service limit Action

Resistance between coil lead
— 1kΩ or less Replace yoke assembly
Yoke assembly wire and yoke
Brush length 18 {0.7087} 13 {0.5118} or less Replace brush
Resistance between
1MΩ or more 1kΩ or less
commutator and core
Commutator outer diameter 36 {1.4173} 34 {1.1458} or less Replace armature
Armature assembly
assembly Shaft outer diameter A 12 {0.4724} 11.98 {0.4717} or less
Shaft outer diameter B 9 {0.3643} 8.98 {0.3535} or less
Undercut depth 0.5 - 0.8 {0.0197} 0.2{0.0079} or less Correction

Resistance between holder
Holder — 1kΩ or less Replace holder assembly
and plate
assembly
Brush length 18 {0.7087} 13 {0.5118} or less Replace brush
Shaft assembly A 26 {1.0236} 25.90 {1.0197} or less

Replace shaft assembly
outer diameter B 12.1 {0.4764} 12.04 {4.7401} or less
Clutch assembly inner sleeve outer diameter 25 {0.9843} 24.90 {0.9803} or more Replacement
Metal bushing inner diameter of pinion case 25 {0.9843} 25.2 {0.9921} or more Replace brush
Metal bushing inner diameter of center bracket 26 {1.02362} 26.2 {1.0315} Replace center bracket
Metal bushing inner diameter of shaft assembly 9 {0.3543} 9.2 {0.3622} Replace shaft assembly
Replace commutator end

Bearing housing inner diameter of rear bracket 28 {1.1024} 28.1 {1.1063} or more
frame
Between C terminal and M
Start magnet 0.12 - 0.14Ω —
terminal (P coil) Replace start magnet
switch
Between C terminal and body switch assembly
assembly 1.13 - 1.25Ω —
(H coil)
Tightening torque (starter)

C lead wire mounting bolt 3.5 - 5.5 {35 - 55, 3 - 4}
M lead wire mounting nut 12 - 15 {125 - 155, 9 - 11}
Commutator end frame mounting through bolt 15.7 - 17.6 {160 - 179, 12 - 13}
Brush holder set bolts of commutator end frame 3.6 - 4.9 {37 - 49, 3 - 4}
Pinion case switch set bolts 14 - 16 {140 - 160, 10 - 12}
18-44
［18. ENGINE］
18.3.10 Turbocharger
Standard value
Unit : mm {in.}
Axial direction 0.1 {0.0039} — —

Turbine shaft play
Diameter direction 1.0 {0.0393} — —
Tightening torque
18

Turbocharger mounting nut 56 {570, 41}
18-45
［18. ENGINE］
18.4 PARTS TO BE PREPARED

18.4.1 Engine Body
Special tool
Shape Part No. Description Remark
S0949–11010
Wire rope For engine lifting
(09491–1010)
S0955–21030
Compression gauge adapter
(09552–1030)
S0955–21060
(09552–1060)
S0955–21110
(09552–1110)
18.4.2 Fuel System

Lubricant, etc.
Name Remark
Guide pin S0904-81040 (09048-1040) For supply pump positioning
18.4.3 Electrical
Special tool
Shape Part No. Name Remark
S0944–41210
Compression gauge For V-belt tension adjustment
(09444–1210)
95506–00090
Belt tension gauge For V-belt tension adjustment
(Denso part No.)
18-46
［18. ENGINE］
18.4.4 Engine Mechanical

Special tool
S0942–01731 For crankshaft front oil seal

Oil seal puller
(09420–1731) removal
18
S0940–71030 For crankshaft front oil seal
Oil seal press
(09407–1030) press-fit
S0943–31070 For assembly/disassembly of

Eye bolt
(09433–1070) cylinder head

Valve spring press
(09470–1170) valve spring retainer
S0947–11520
Guide For valve guide press-fit
(09471–1520)
S0947–21210
Bar For nozzle seat clamping
(09472–1210)
For nozzle seat clamping

SN441–00610
Steel ball (together with S0947-21210
(9800–06100)
(09472–1210))
S0943–11020
Valve lapping tool For valve adjustment
(09431–1020)
S0947–22100
Bar For valve stem seal mounting
(09472–2100)
18-47
［18. ENGINE］
S0942–02100 For removal and inspection of

Cylinder liner puller
(09420–2100) cylinder liner

Piston ring expander
(09442–1011) piston ring
For mounting of connecting rod

small end bushing
SH691–20825
Bolt (together with S0940-21480
(9191–08252)
(09402-1480) or S0940-21540
(09402-1540))
For assembly/disassembly of
S0940–21530
Press sub-assembly connecting rod small end
(09402–1530)
bushing
connecting rod small end
SL271–01036
Wing nut bushing
(9233–10360)
(together with S0940-21530
(09402-1530))
connecting rod small end
S0948–11130
Guide bushing
(09481–1130)
(together with (S0940-21530
(09402-1530))
S0940–21540
Spindle connecting rod small end
(09402–1540)
bushing
For mounting of connecting rod

S0948–11540 small end bushing
Guide
(09481–1540) (together with S0940-21540
(09402-1540))
S0944–11370
Piston ring holder For piston mounting
(09441–1370)
18-48
［18. ENGINE］

Guide
(09481–1340) flywheel
S0942–01742 For crankshaft rear oil seal

Oil seal puller
(09420–1742) removal
18
S0942–0110
(09420–1100) For main/sub idle gear
Sliding hammer assembly and cam idle gear
S0942–01442 shaft removal
(09420–1442)

Socket wrench
(09411–1300) Torx bolt
S0940–71040 For crankshaft rear oil seal

Oil seal press
(09407–1040) press-fit
S0947–11490
Guide For insertion of cylinder liner
(09471–1490)
S0947–21620
Tool For cooling jet repair
(09472–1620)
SZ910–24098 For cooling jet inspection and

Check bolt
(9001–24262) adjustment
S0947–01280 For cooling jet inspection and

Tool assembly
(09470–1280) adjustment
18-49
［18. ENGINE］
Instruments
Name Remark
Micrometer For measurement of part outer diameter
Cylinder gauge For measurement of part inner diameter
Thickness gauge For measurement of each clearance

Dial gauge For measurement of parts
Lubricant, etc.
Name Remark
Liquid gasket (Threebond TB1207B or equivalent : Black) For sealing of parts
Liquid gasket (Threebond TB1207D or equivalent : Silver) For sealing of parts
Liquid gasket (Threebond TB1211 or equivalent : White) For sealing of parts
Red lead Valve adjustment
Dye penetrant For inspection of crack
18.4.5 Lubrication
Special tool
S0950–31110
Oil filter wrench
(09503–1110)
Lubricant, etc.
Name Remark
Liquid gasket
(Threebond
TB1211 (white) or equivalent
For sealing of parts
TB1207B (black) or equivalent
TB1207D (silver) or equivalent
TB1207G (gray) or equivalent)
18-50
［18. ENGINE］
18.4.6 Starting and Charging

Jig (reference dimensional drawing for manufacture)
This is used for assembly of bearing. Reference dimensions are shown in the figures below:
Jig A (Roller bearing insertion jig) Jig B (Support jig) Unit : mm{in.}
f 23{20.827} f 25{0.984}
1C{0.039}
35{1.378} 18
50{1.964}
70{2.756}
50{1.964}
1C{0.039}
10 - 20 f 50{1.969}
+0.5{0.0196} {0.394 - 0.787}
f 19{0.748}
0
f 30{1.181}
Jig C Jig D
f 34{1.339} f 41{1.614}
20{0.787} 20{0.787}
40{1.575} 40{1.575}
10{0.394} 10{0.394}
f 54{2.126} f 64{2.520}
f 60{2.362} f 70{2.756}
18-51
［18. ENGINE］
Instruments
Alternator
Name Remark
Circuit tester For measurement of parts
Micrometer For measurement of parts
Regulator checker (G&M Machinery ICD–101D or equivalent) For inspection of regulator
Starter
Name Remark
Circuit tester For measurement of parts
Micrometer For measurement of part outer diameter
Growler tester For inspection of armature
Cylinder gauge For measurement of part inner diameter
Lubricant, etc.
Name Remark
Kyodo Yushi Multemp AC-N For lubrication of parts
Nisseki Mitsubishi Pyroknock #2 For lubrication of parts
18.4.7 Turbocharger
Special tool
S0944-41800
End play gauge
(09444-1800)
18-52
［18. ENGINE］
18.4.8 Engine Failure Diagnosis

Special tool
• Operating system (OS) :

Windows98 (IE5.0 or later),
Windows2000 (SP3, IE5.0 or later),
WindowsXP (SP1a, IE6.0 or later),
Computer WindowsVista*2, Windows7*2
—
(DOS/V standard) • CPU and memory :
Conditions that assure operation of 18
the above operating system
• Display : 800 x 600, 256 colors or
more
• Software and CD-ROM
Hino Diagnostic
• Install the software included in the
eXplorer —
Hino Diagnostic eXplorer (Hino-DX)
(Hino-DX)
into the computer. For the
installation method, refer to the
instruction manual included with the
CD.
• Computer interface
• It is necessary to update the

hardware.
09993 - E9070
Hino-Bowie
*1
• The cable between the personal
computer and the Hino-Bowie is
bundled with the Hino-Bowie.
• Please use either RS-232C or USB.
Cable bundled
to the Hino-Bowie
• The cable used for connect

between Hino-Bowie and the
adapter cable.
S0904-21220
Connection cable
(09042-1220)
Cable between
unit and Hino-Bowie
18-53
［18. ENGINE］
DENSO DST-i set • Computer interface

without LCD
95171-01020
without Bluetooth®
without LCD
95171-01040
with Bluetooth®
with LCD
95171-01030
without Bluetooth®
with LCD
95171-01050
with Bluetooth®
Interrupting installation between unit
side harness and ECU allows
inspection with a tester rod while the
Signal check harness 09843-E9020 power is supplied.
*1: To use Hino-Bowie (interface box) 09993-E9070, update the hardware. For details, refer to the user’s manual in the
HinoDX CD-ROM.
Keep updating the firmware (software built in the Hino-Bowie) using the software in the HinoDX CD-ROM. For details, refer to
the user’s manual in the HinoDX CD-ROM.
*2: HinoDX (Ver. 3.0.5 or later), only when use DST-i.
18-54
［18. ENGINE］
18.5 ENGINE MOUNTING/DISMOUNTING

18.5.1 Inspection Before Service
18.5.1.1 Measurement of compression pressure
• Measure the compression pressure before disassembly of the engine and record the result. Regular
measurement of the compression pressure can tell the engine status. 18
1. Preparation before measurement
1) Charge the battery completely.
2) Check the valve clearance and adjust it when exceeding the standard value.
3) Warm the engine and set the water temperature to 80℃{176℉}.
4) Remove the air cleaner.
5) Remove the head cover.
6) Remove all injectors.
7) To prevent spread of engine oil, attach a jig which cuts a head cover in half. (Cut it so that the camshaft may
be covered.
2. Measurement
1) Attach a special tool to the nozzle sheet of the
cylinder where the compression pressure is
measured with nozzle clamp and clamp fixing
bolts.
Special
tool
Engine
Special tool : Compression gauge adapter
Part No. Parts tightened
S0955-21110 Insert in the injector mounting

(09552-1110) area
S0955-21030
(09552-1030)
(3/4-16 UNF) Adjusting to screw size of air
gauge, the adapter which it
S0955-21060 selects
(09552-1060)
(W16 ridges 18)
2) Turn the starter and measure the compression pressure.
• Do not operate the starter for 15 seconds or more.

• Since the air cleaner is removed, prevent entry of dirt.
18-55
［18. ENGINE］
3) Measure the compression pressure of each cylinder continuously.
Engine revolution 150r/min {rpm}
Compression pressure:
Unit MPa {kgf/cm2,lbf/in.2}
Standard value 3.4 - 3.7 {35 - 38 ,493 - 537}
Service limit 2.7 {28, 392}
Difference between
0.3{3, 44} or less
cylinders
4) If the compression pressure is the service limit or less or if the difference between cylinders is over the
standard value, overhaul the engine.
5) After measurement, reassemble the removed parts.
18-56
［18. ENGINE］
18.5.2 Engine Body

18.5.2.1 Removal
1. Preliminary work before removal of engine
1) Place the vehicle on a level ground.
2) Block tires with scotch.
3) Remove the battery cable from the battery minus terminal.
2. Drain of coolant and engine oil Right side of engine
1) Drain coolant from the radiator drain cock and the
oil cooler drain plug. 18
Oil cooler drain plug
• Removal of the filler cap facilitates quick drain.

• Connection of an appropriate hose to the oil cooler drain pipe facilitates drain of coolant without spread.
• To prevent burn, drain coolant after the temperature is sufficiently low.

• To dispose coolant, observe the specified method (waste disposal) or the method with attention to environment.
2) Drain engine oil from the oil pan drain plug as required.
• To prevent burn, drain coolant after the temperature is sufficiently low.

• Dispose coolant according to the specified method (waste treatment) or with a method considering the
environment.
3. Removal of intake hose, intercooler hose and

exhaust pipe
1) Loosen the clamp and remove the intake hose.
Intake manifold
2) Remove nuts and remove the exhaust pipe.
Cylinder head
Cover
• Close the opening of the intake manifold with a packing tape to prevent entry of dirt inside the engine.
18-57
［18. ENGINE］
4. Disconnection of fuel hose

1) Remove the fuel hoses (feed side and return
side). Wrap the removed hose with a plastic
sheet with its end facing upward to prevent spill
of fuel.
• Wipe spilled fuel with a rag.
5. Disconnection of water, engine oil pipes, etc. Fan shroud Cooling

Fan
1) Disconnect the hose between the radiator and
the engine.
2) Disconnect the oil filter hose.
Connector
3) Disconnect the fuel filter hose.
Clip
• Wipe off spilled water and engine oil with waste.
6. Engine lifting (Lifting the engine single unit) Within 30

Shackle
1) Place a commercially available shackle and a
Shackle
special tool wire rope with the engine hanger.
Special tool : S0949–11010 (09491-1010) Wire
rope
2) Keep a little slack of the wire rope.
• Keep the wire inclination 30° from the vertical line.
3) When the wire is completely tense, make sure Image drawing

that the wire is firmly engaged with the engine
hanger. Then, lift the engine slowly.
18-58
［18. ENGINE］
• Work carefully so that the engine may not come in contact with the frame and others.
18
18-59
［18. ENGINE］
18.5.2.2 Installation
1. Connection of fuel hose
1) Insert a fuel hose and fix it with a hose band.
18.5.2.3 Work after installation

1. Inspection of engine oil
1) Make sure that the drain cock is closed.
2) Pour engine oil.
3) Check the amount of oil with an oil level gauge.
Filler cap
Engine oil amount (L{us gal})
Oil pan Oil filter and etc

Approx. 18{4.76} Approx. 2.5{0.66}
• Please use Hino genuine engine oil
Multi grade SAE #10W–30

Single grade SAE #30
2. Air bleeding of fuel system

• In case of a fuel filter with water cup
"Reference : Fuel System, Fuel filter drain (With water cup)"
• In case of a fuel filter without water cup
"Reference : Fuel System ,Replacement of fuel filter element (Without water cup)"
3. Air bleeding of fuel system Priming pump Main fuel filter
1) Prepare a rag under the main fuel filter air air bleeding bolt
bleeding bolt.
2) Loosen the main fuel filter air bleeding bolt.
3) Operate the priming pump.
4) Operate the priming pump until fuel without
bubble comes out.
5) Tighten the main fuel filter air bleeding bolt.
Tightening torque:
9 - 11 N·m {91.8 - 112 kgf·cm, 6.7 - 8.1 lbf·ft}
6) Operate the main fuel filter priming pump again until it becomes hard.
• After work, wipe off spilled fuel. After start of the engine, make sure that there is no fuel leak.
18-60
［18. ENGINE］
18.6 FUEL SYSTEM

18.6.1 Fuel System
18.6.1.1 Fuel system diagram
Feed pipe Injection pipe

Flow damper*
Injector
Common rail
18
Leakage pipe
Pressure limiter
Overflow pipe Through feed pipe
Supply pump
Fuel tank
*There are models which
are not equipped with it.
Final fuel filter Main fuel filter Pre fuel filter
18-61
［18. ENGINE］
18.6.1.2 Part layout
11195 Nozzle clamp holder 23670 Injector
11491A Common rail bracket 23810 Common rail assembly
13691 Bearing holder case 9645A O-ring*
22100 Supply pump 9851A O-ring*
Tightening torque
22825 63.7N·m {650 kgf·cm, 47 lbf·ft} 9068-08320 28.5N·m { 290kgf·cm, 21 lbf·ft}
900124 108N·m {1,100 kgf·cm, 80 lbf·ft} 9068-08400 28.5N·m { 290kgf·cm, 21 lbf·ft}
900124A 25N·m {250 kgf·cm, 18 lbf·ft} 9068-08850 28.5N·m { 290kgf·cm, 21 lbf·ft}
9068-08250 28.5N·m { 290kgf·cm, 21 lbf·ft}
18-62
［18. ENGINE］
18
23081 Leakage pipe 23816A Through feed pipe
23711 Injection pipe* 23816B Through feed pipe
23712 Injection pipe* 9659B Gasket*
23713 Injection pipe* 9659C Gasket*
23714 Injection pipe* 9659D Gasket*
23783A Fuel pipe* 9659E Gasket*
23816 Through feed pipe
Tightening torque
23711 M14 : 44N·m {450 kgf·cm, 33 lbf·ft} 23713 M14 : 44N·m {450 kgf·cm, 33 lbf·ft}
M16 : 54N·m {550 kgf·cm, 40 lbf·ft} M16 : 54N·m {550 kgf·cm, 40 lbf·ft}
23712 M14 : 44N·m {450 kgf·cm, 33 lbf·ft} 23714 M14 : 44N·m {450 kgf·cm, 33 lbf·ft}
M16 : 54N·m {550 kgf·cm, 40 lbf·ft} M16 : 54N·m {550 kgf·cm, 40 lbf·ft}
18-63
［18. ENGINE］
Pre filter
1 Fuel filter head 2 Fuel filter element

3 Water cup
Tightening torque
2 Refer to the main text.
Main fuel filter
Tightening torque
18-64
［18. ENGINE］
Final fuel filter
18
Tightening torque
18-65
［18. ENGINE］
18.6.2 Air bleeding

1. Air bleeding of fuel system Priming pump Main fuel filter
1) Prepare a rag under the main fuel filter air air bleeding bolt
bleeding bolt.
2) Loosen the main fuel filter air bleeding bolt.
3) Operate the priming pump.
4) Operate the priming pump until fuel without
bubble comes out.
5) Tighten the main fuel filter air bleeding bolt.
Tightening torque:
9 - 11 N·m {91.8 - 112 kgf·cm, 6.7 - 8.1 lbf·ft}
6) Operate the main fuel filter priming pump again until it becomes hard.
• After work, wipe off spilled fuel. After start of the engine, make sure that there is no fuel leak.
18-66
［18. ENGINE］
18.6.3 Fuel filter water drain

18.6.3.1 Water drain from pre fuel filter drain valve
1. Precautions
• As air enters into the fuel piping during the work, air bleeding must be performed after completion of the work.
• Take care that no dirt or water gets into the system during the work.
18
2. Prepare a container under the pre fuel filter drain Main fuel filter
valve. air bleeding bolt
Pre fuel filter

drain valve
3. Loosen the main fuel filter air bleeding bolt and the pre fuel filter drain valve. Discharge water at the bottom of
the pre fuel filter case.
• Since discharged water contains fuel, observe the local disposal procedure for disposal.
4. Close the pre fuel filter drain valve.
18-67
［18. ENGINE］
5. Operate the main fuel filter priming pump and bleed

the air from the system.
• Make sure that the main fuel filter air bleeding bolt has been loosened.
• The main fuel filter air bleeding bolt has a slit (groove) as shown in the figure. As air will bleed out even when the
bolt is not removed completely, perform priming work with the bolt loosened to an intermediate position in order
to prevent the entry of foreign matter to the fuel system.
6. Tighten the main fuel filter air bleeding bolt.

Tightening torque:
9 - 11 N·m {91.8 - 112 kgf·cm, 6.7 - 8.1 lbf·ft}
• After work, wipe off spilled water or fuel. After start of the engine, make sure that there is no fuel leak.
18-68
［18. ENGINE］
18.6.3.2 Water drain from final fuel filter drain valve

1. Precautions
2. Prepare a container under the final fuel filter drain Main fuel filter
valve. air bleeding bolt 18
Final fuel filter

drain valve
3. Loosen the main fuel filter air bleeding bolt and the final fuel filter drain valve. Discharge water at the bottom of
the final fuel filter case.
• Since discharged water contains fuel, observe the local disposal procedure for disposal.
4. Close the final fuel filter drain valve.
18-69
［18. ENGINE］
5. Operate the main fuel filter priming pump and bleed

the air from the system.
• Make sure that the main fuel filter air bleeding bolt has been loosened.
• The main fuel filter air bleeding bolt has a slit (groove) as shown in the figure. As air will bleed out even when the
bolt is not removed completely, perform priming work with the bolt loosened to an intermediate position in order
to prevent the entry of foreign matter to the fuel system.
6. Tighten the main fuel filter air bleeding bolt.

Tightening torque:
9 - 11 N·m {91.8 - 112 kgf·cm, 6.7 - 8.1 lbf·ft}
• After work, wipe off spilled water or fuel. After start of the engine, make sure that there is no fuel leak.
18-70
［18. ENGINE］
18.6.4 Pre-fuel filter replacement

1. Pre-fuel filter replacement
1) Place a waste oil container under the pre-fuel
2
filter.
A
18
B
2) Set the cock (1) to the position "Closed + (A)".

3) Clean the area around the air venting plug (2).
4) Loosen the air venting plug and the drain plug
(3), and then drain the fuel from the pre-fuel filter.
5) Set a socket with a width across flats of 27 mm to the hexagonal part (C) at the bottom of the case (4), and
then turn it with a ratchet wrench to remove the case.
Tightening torque:
30±2 N·m {306±20 kgf·cm, 23±1.4 lbf·ft}
6) Prepare a new filter element (5) and a gasket (6).
Install the gasket in the case after applying a thin
layer of oil.
7
18-71
［18. ENGINE］
• Do not reuse filter elements, O-rings, gaskets, etc.

• When replacing O-rings and gaskets, make sure that they match the installation location to avoid damage by
twisting.
7) Remove dirt and foreign matter from the inside of the cover (7).
8) Set a socket with a width across flats of 27 mm to the hexagonal part (C) at the bottom of the case, and then
turn it with a ratchet wrench to securely install it to the case.
9) Tighten the air venting plug (2) and the drain plug (3).
10) Set the cock (1) to the position "Open".
11) Refer to "Air venting" for venting air.
12) Start the engine, let it idle for several minutes, and then confirm that no fuel is leaking from the filter
mounting parts.
18-72
［18. ENGINE］
18.6.5 Replacement of the main fuel filter

1. Precautions
• The frequency for water draining and replacement of the main fuel filter cartridge differs according to the fuel
situation in the use region.
Replace the main fuel filter cartridge every 500 hours or when the engine output decreases, whichever occurs
first.
• Inspection of the main fuel filter cartridge should be performed before each start of operation. 18
• Always use HINO genuine parts fuel filter cartridge.
• Complete the work for removal and installation quickly to prevent entry of foreign matter to the fuel system.
• Before assembly, make sure that there is no dirt on the seating surface of the parts.
• Always do air bleeding after replacing an element.
2. Draining diesel oil

1) Drain the water and diesel fuel from the main fuel filter for “Pre and final fuel filter water drain” to reference.
• Completely remove any dust around the main fuel filter cartridge and case.
3. Removal of the main fuel filter cartridge

1) Remove the main fuel filter cartridge.
Main fuel filter

cartridge
• Completely remove any dust around the main fuel filter head and especially around the air bleeding bolt.
• Since the filter contains diesel oil, prepare a tray.
4. Installation of the main fuel filter cartridge
Main fuel filter

cartridge
• Fuel filter cartridge is not reused.
18-73
［18. ENGINE］
1) The soiling and the foreign material of the clamp face are removed.
2) Install the main fuel filter cartridge with tightening angle 3/4 turn after the O-ring of the main fuel filter
cartridge comes into contact with the main fuel filter head.
• As the O-ring is included in the cartridge kit, do not use an O-ring again after it has been removed once.
• Install the O-ring after applying fuel to the surface of the O-ring.
• Do not use a tool, but tighten by hand.
5. Bleeding air from the fuel system

“Reference: Fuel System, Pre and final fuel filter water drain”.
18-74
［18. ENGINE］
18.6.6 Replacement of the final fuel filter

1. Draining diesel oil
1) Drain the water and diesel fuel from the final fuel filter for "Pre and final fuel filter water drain" to reference.
• Completely remove any dust around the main fuel filter cartridge and case.
2. Removing the final fuel filter element 18

1) Fully loosen the fastener nut by hand.
2) To remove the cap, pull up one side of the cap

and then lift it off.
3) Remove the fuel filter element from the case.

4) Remove the case side O-ring.
3. Install the final fuel filter element
1) Attach 2 new O-rings to a new fuel filter element
and a new O-ring to the case.
2) Install the final fuel filter element to the case.
• Install the O-ring after applying fuel to the surface of the O-ring.
• Do not reuse the fuel filter element.
3) Align the cap's mark and case's mark.
18-75
［18. ENGINE］
4) Push the cap into the case by hand.

Standard clearance (A): 1.5 mm {0.059 in.} or
less
• The clearance between the cap and case should be even around the entire circumference to the cap and case.
5) Turn the fastener nut until a "click" sound is

heard.
• Just before the marks of the case and nut align, the turning difficulty of the fastener nut will increase.
Use a screwdriver and a lever to turn the fastener nut.
6) Measure the distance between the marks on the cap and case, and the clearance between the cap and
case.
Standard clearance (A):
1.0 mm {0.039 in.} or more
Standard clearance (B):
1.0 mm {0.039 in.} or less
18-76
［18. ENGINE］
• Do not use a tool, but tighten by hand.
4. Bleeding air from the fuel system

"Reference : Fuel System, Pre and final fuel filter water drain"
18
18-77
［18. ENGINE］
18.6.7 Replacement of the supply pump

1. Precautions
2. Fuel discharging Priming pump

1) Discharge the fuel from the fuel system using the
priming pump.
3. Disconnecting the connectors Fuel temperature sensor

1) Disconnect the suction control valve connector
and fuel temperature sensor connector from the
supply pump.
Suction control valve
4. Setting the compression stroke top dead center of

No.1 cylinder
1) Unfasten the bolts securing the flywheel housing
cover, and remove the flywheel housing cover
from the flywheel housing.
Flywheel housing
cover
2) Turn the crankshaft counterclockwise when
viewed from the flywheel. Set the timing mark in
the flywheel housing inspection window to "1".
Flywheel
1
Flywheel housing
18-78
［18. ENGINE］
3) Remove the plug in the inspection window

located in the bearing holder case of the supply
pump. Gently insert the guide pin (S0904-81040)
and make sure the base of the pin closely
contacts the bearing holder. Close
contact
With
gap
18
Contact surface
• If the special tool is not seated, it will contact parts other than the coupling flange stopper key; therefore, do not
push too hard.
• If the special tool is not touch the flange, No.1 cylinder is not setting to the Compression Top Dead Center.
Remove the special tool, and rotate the engine and then check again.
• When you rotate the crankshaft, always remove the special tool.
• Do not rotate the crankshaft with the special tool inserted.
5. Removal of the pressure feed pipes

1) Remove the pressure feed pipes from the
common rail and supply pump.
• Do not reuse the pressure feed pipes.
• Prepare a container and a waste cloth because fuel spills when removing the pressure feed pipes.
18-79
［18. ENGINE］
6. Removal of supply pump Supply pump
Pipe A
1) Remove the fuel pipe connected to the supply pump.
• Do not remove pipes A.

• Do not apply any force to pipes of the supply pump.
• Do not carry the supply pump by holding the pipe.
(Twist of the pipe may cause fuel leakage.)
2) Remove the supply pump at the bearing holder case.

3) Remove the drive gear using the special tool designed for that purpose.
Special tool : S0965-01101 (09650-1101) Bearing puller
7. Assembly of supply pump and bearing holder case O-ring
1) Fit a new O-ring to the supply pump and install
the bearing holder case. Supply pump
Tightening torque: 28.5 N·m {290 kgf·cm, 21
lbf·ft}
Bearing holder case
Bolt
2) Secure the supply pump, install the injection
pump drive gear on the shaft, and use a vice or
similar to prevent turning while tightening the nut.
lbf·ft}
• Do not use the guide pin for stopper key of the shaft.
18-80
［18. ENGINE］
8. Installation of supply pump Match
Injection pump drive gear

Bearing holder case
18
Match mark Cut-out
• Take care that no dirt or water get into the system during the work.
• Before assembly, make sure that there is no dirt on the seating surface of the parts.
• Always do air bleeding after replacing an element.
1) Match the match mark of the bearing holder case with the missing tooth of the injection pump drive gear.
2) Install a new O-ring and mount the air
Supply pump O-ring
compressor and supply pump assembly on the
flywheel housing.
lbf·ft}
• Adjust the gear so that the compression top dead center alignment of the No.1 cylinder may not be changed.
• Be sure to remove the guide pin in cranking the engine.
• After assembly, be sure to remove the guide pin and install the inspection window plug.
9. Update of supply pump learning value

1) When the supply pump is replaced, update the learning value memorized in the engine ECU with the failure
diagnosis tool (HinoDX) using PC. (Refer to "HinoDX operation manual".)
18-81
［18. ENGINE］
• If learning value is not updated, correct common rail pressure is not controlled, resulting in engine stall or high
common rail pressure. Therefore, when the supply pump is replaced, be sure to update the learning value.
18-82
［18. ENGINE］
18.6.8 Inspection of the supply pump

1. Inspection of suction control valve and fuel
temperature sensor
1) Measure the resistance of the suction control
valve terminals and the fuel temperature sensor
terminals using a circuit tester. If it is beyond the Fuel temperature
sensor
standard, remove the supply pump assembly and
request for replacement at the Denso service
shop. Suction control
valve(SCV)
18
Between suction control valve terminals
Standard
7.7 - 8.1Ω (20°C {68℉})
value
Terminals between fuel temperature

sensors
Standard
2.32 - 2.59kΩ (20°C {68℉})
value
18-83
［18. ENGINE］
18.6.9 Replacement of the injector

1. Precautions
2. Remove the head cover

3. Removal of the leakage pipe Union bolt Union bolt
1) Remove the union bolts, and remove the leakage
pipe and the gaskets.
Leakage
pipe
• The leakage pipe is twisted easily, be careful for handling.
4. Removal of the injector harness

1) Disconnect the connectors from the each Injector Connector
harness
injectors.
bracket
2) Remove the nuts and remove the injector
Nut
harness together with the injector harness
Injector
bracket. harness
Part of connector
Injector Cylinder
harness head
• Removal becomes easier when the connector part of the camshaft housing is disconnected last.
18-84
［18. ENGINE］
5. Removal of the injection pipes

1) Remove the nuts and remove the clips.
2) Loosen the nuts of the injection pipes, and
remove the injection pipes from the injector and
common rail.
18
View A
• Do not reuse the injection pipe.
• Prepare a container and waste cloth under the fuel pipe.
6. Removal of the injector

1) Remove the injection pipe oil seals from the
cylinder head.
Injection pipe
oil seal
2) Remove the mounting bolts of the injectors

Bolt Injector
clamps, and remove the injectors and injector
clamps.
Injector clamp
18-85
［18. ENGINE］
7. Entry of injector correction value to the engine ECU

(entry using HinoDX and QR code reader) QR code
Injector
• When the injector is replaced, it is necessary to enter the injector correction value (QR code) described on the
new injector to the engine ECU. Incorrect entry of the correction value may result in faulty engine.
• Available entry methods of the injector correction value are the PC tool and the QR code reader.
• The flow of work is described in the following.
If you want details regarding any procedure, however, refer to the PC Tools instruction manual.
1) Read the injector QR code with the scanner of the QR code reader and prepare the correction data file.
2) Enter the injector correction value directly from the PC tools to the engine ECU.
PC
QR Code reader
Hino-Bowie
Engine-use code
QR code
Connector
New injector ECU
8. Installation of the injector harness

1) Install the injector harness together with the Injector Connector
harness
injector bracket by bolts.
bracket
2) Connect the connectors of the injector harness.
Nut
Injector
harness
18-86
［18. ENGINE］
• Before connecting the connector, confirm that the terminal shows no signs of sparking.
Part of connector
18
Injector Cylinder
harness head
• Installation becomes easier when the connector part of the camshaft housing is connected first.
9. Installation of the leakage pipe Union bolt Union bolt

1) Remove dirt and foreign matter around the
mounting surface.
2) Use the union bolts with new gaskets to install
the leakage pipes to the injector and the cylinder
head.
Leakage
pipe
• Do not reuse the gasket.

A:Injector side (M8 x 1.0)

B:Camshaft housing side (M8 x 1.25)
B
A A
Leakage
pipe
• It is noted that the union bolt of the injector and the union bolt of the camshaft housing are different bolt pitch.
18-87
［18. ENGINE］
Camshaft housing side

union bolt
• There is the "X" mark at the union bolt of the camshaft housing.
10. Installation of the head cover

11. Air bleeding of the fuel system
12. Installation of injector Fixing bolt
Injector
Injection pipe
Nozzle clamp
holder
Injection pipe
oil seal
O-ring
• Before assembly, make sure that there is no dirt the seating surface of the parts.
1) Attach a new O-ring to the groove of the cylinder head and insert the injector.
• Apply engine oil to the O-ring and be careful to prevent pinching of the O-ring.
2) Install the nozzle clamp holder and tighten the injector temporarily.
• Do not fix the nozzle holder until the injection pipe is tightened.
18-88
［18. ENGINE］
3) Put a new injection pipe oil seal on the injector.
• Install the injection pipe oil seal to prevent undue force to the injection nozzle. (Offset position between the
injection pipe oil seal and the injection nozzle may cause oil leak or poor assembly of the injection pipe.)
4) Assemble the injection pipe temporarily and tighten the fixing bolt of the nozzle clamp holder.
Tightening torque: 25 N·m {250 kgf·cm, 1.8 lbf·ft}
5) Tighten the injection pipe. 18
Tightening torque: 44 N·m {450 kgf·cm, 33 lbf·ft}
18.6.10 Inspection of the injector

1. Inspection of injector insulation <Cross-section view of injector head>
1) Remove the injector plastic terminal cap (upper).
2) Measure the insulation resistance between the
injector upper body and one terminal (no polarity) Terminal
(harness tightening area) Terminal cap (upper)
of two terminals for the injector harness.
Terminal cap
(lower)
Injector harness
and rubber seal
Upper body
Standard value
1000MΩ or more
(normal temperature)
3) Measure the resistance value between two terminals above.
Standard value (at 20℃) 0.45Ω±0.1
4) If the resistance value in (2) and (3) exceeds the standard value, replace the injector assembly.
2. Cleaning of injector
1) Remove sludge at or around the terminal, if any.
• In removing sludge, do not use a cleaning agent. Wipe it off with a rag. Use of a cleaning agent may result in
electric failure due to penetration of the agent.
18-89
［18. ENGINE］
18.6.11 Replacement of the common rail

18.6.11.1 With flow damper
High pressure pipe inlet

Flow damper
Y X
High pressure pipe
X
Coolant pipe bracket Z
Injection pipe
18-90
［18. ENGINE］
18.6.11.2 Without flow damper
Male screw (High pressure pipe inlet)
Y X 18
High pressure pipe
X
Z
Coolant pipe bracket
Injection pipe
18-91
［18. ENGINE］
18.6.11.3 Removal of common rail

1. Precautions
• Take care that no dirt or water get into the system during the work.
2. Disconnection of the harness

1) Disconnect the connector at common rail
pressure sensor.
• Pull out the female connector from the male connector during pushing the spring lock at the female connector.
• This figure is the common rail with flow damper.

The work method is same the common rail without flow damper and the common rail with flow damper.
3. Disconnection of the fuel pipe

1) Remove the union bolts and gaskets and remove
the return pipe No.1 from the pressure limiter and
cylinder head.
• Prepare a container and waste cloth under the fuel pipe.

4. Removal of the injection pipe

5. Removal of the pressure feed pipe
18-92
［18. ENGINE］
18.6.11.4 Installation of the common rail

1. Installing the pressure feed pipe
Tightening torque: 44 N·m {450 kgf·cm, 33 lbf·ft}(M14)
Tightening torque: 54 N·m {550 kgf·cm, 40 lbf·ft}(M16)
2. Installing the injection pipes
1) Install new injection pipes to the injector and the
common rail.
Tightening torque: 44 N·m {450 kgf·cm, 33 lbf·ft}
18
View A
• Always follow the procedure exactly, because a fuel leakage can be the result when the injection pipe is not
installed correctly.
• Fuel leakage causes engine damage.
• Pressure feed pipe and injection pipes are not reusable.
• Install so that the markings of the tightening nuts for the flared parts of the injection pipes are arranged in the
indicated order.
• The work method is same the common rail without flow damper and the common rail with flow damper.
Mark:2 Mark:4
Mark:1 Mark:3
2) Fix the injection pipes with the clips by nuts.
18-93
［18. ENGINE］
3. Installing the fuel pipe

1) Install the return pipe No.1 to the pressure limiter
and cylinder head with new gaskets and union
bolts.
Tightening torque:
20 N·m {205 kgf·cm, 15 lbf·ft}
(Pressure limiter side)
(Cluster connector side)
(Supply pump side)

• The work method is same the common rail without flow damper and the common rail with the flow damper.
4. Connecting the harness

1) Connect the connector to the common rail
pressure sensor.

• The work method is same the common rail without flow damper and the common rail with the flow damper.
18-94
［18. ENGINE］
18.6.12 Inspection of the common rail

1. Inspection of common rail pressure sensor *There are models
Flow damper* which are not
1) Measure the resistance value between terminals ç equipped with it.
using a circuit tester. If it exceeds the standard
value, replace the common rail assembly.

18
Between 1 and 2 Between 2 and 3

Standard value
(kΩ) 0.5 - 3.0 6.5 - 18.5
At stop of engine

18-95
［18. ENGINE］
18.7 ELECTRICAL
18.7.1 Electrical System
82051 Injector harness 89390 Boost pressure sensor
83420 Water temperature sender gauge 89410 Engine sub revolution sensor
83530 Oil pressure warning switch 89411 Engine main revolution sensor
Tightening torque
9190–06121 4 N·m{40 kgf·cm, 3 lbf·ft}
18-96
［18. ENGINE］
18
12509 Alternator brace 9011-64410 Through bolt
12511 Alternator bracket 9241-10107 Fixing bolt at brace
27040 Alternator assembly 9189A Adjusting bolt
28100 Starter assembly
Tightening torque
9069A 154N·m{1,570kgf·cm, 114 lbf·ft} 9241-10107 51N·m{520kgf·cm, 38 lbf·ft}
9011-64401 83N·m{850kgf·cm, 61 lbf·ft} 9241-14147 154N·m{1,570kgf·cm, 114 lbf·ft}
9189A 5.9N·m{60kgf·cm, 4 lbf·ft}
18-97
［18. ENGINE］
19110 Glow plug
18-98
［18. ENGINE］
18.7.1.2 Layout of components
Boost pressure sensor
Engine sub revolution sensor
Engine main revolution sensor
18
Engine revolution sensor
Common rail pressure sensor Fuel temperature sensor

Suction control valve (SCV)
Left side view
18-99
［18. ENGINE］
Oil pressure warning switch

Coolamt temperature sender gauge
Engine sub revolution sensor
Engine main
revolution sensor
Boost pressure sensor Suction control valve (SCV) Fuel temperature sensor
Upper view
18-100
［18. ENGINE］
Coolamt temperature sender gauge
18
Front view
18-101
［18. ENGINE］
18.7.1.3 Inspection of components

1. Inspection of oil pressure warning switch
(Laid out on the oil filter)
1) Apply pressure with air or oil and check continuity
between terminals using a circuit tester. If it is
faulty, replace it.
Operation Conditions
• When the engine starts, the oil pressure rises, and
after the operating pressure is reached, the
conductivity of the oil pressure gauge is
interrupted, which causes the warning lamp to go out. When the oil pressure is lower than the specified
pressure, conductivity is established, which causes the warning lamp to light up.
Characteristics
• The operating pressure of the oil pressure gauge is Oil pressure warning switch
between 39.2 kPa and 58.8 kPa.
• Replace the oil pressure gauge when there is no 39.2 - 58.8kPa
2 2
conductivity below 39.2 kPa or when there is {0.4 - 0.6kgf/cm ,5.7 - 8.5 lbf/in } ON
2
conductivity above 58.8 kPa. 2.9kPa{0.3kgf/cm ,
2
4.7lbf/in }
Within
OFF Toward pressure increase
2. Inspection of coolant temperature sender gauge Coolant temperature sender gauge

(Installation on thermostat case)
1) Heat the coolant temperature sender gauge Connector color: Dark
using hot water.
2) Measure the resistance between terminals using A
a circuit tester. If it is faulty, replace the gauge.
C
B
Between A and C
Temperature -20 20 80 110

(℃{℉}) {-68} {68} {176} {230}
Resistance 13.84 - 2.32 - 0.31 - 0.1399 -

value (Ω) 16.33 2.59 0.326 0.1435
Between B and body
Temperature 75 100
(℃{℉}) {167} {212}
Resistance 35.5 -
79 - 92
value (Ω) 42.5
3. Inspection of glow plug

1) Measure continuity between the body and the
terminal using a circuit tester. If it is faulty, replace
the glow plug.
18-102
［18. ENGINE］
Standard value
Resistance value :
Ω(Normal temperature 20℃ 2.59-3.29
{68℉})
4. Inspection of suction control valve SCV and fuel

temperature sensor
1) For inspection and replacement of the suction
control valve (SCV) and the fuel temperature Fuel temperature
sensor, refer to the chapter of "J05E FUEL sensor
SYSTEM ". 18
Suction control valve
(SCV)
5. Inspection of common rail pressure sensor

1) For inspection and replacement of the common Flow damper*
rail pressure sensor, refer to the chapter of "J05E

FUEL SYSTEM".
*There are models which
are not equipped with it.
Common rail pressure sensor
6. Inspection of injector
1) For inspection and replacement of the injector, refer to the chapter of "J05E FUEL SYSTEM".
18-103
［18. ENGINE］
18.7.1.4 Installation of component

1. Installation of engine revolution sensor
1) Confirm that there are O-rings on the sensors
and then mount one sensor on top of the flywheel
housing and one on the cam housing.
O-ring
Engine sub-revolution sensor
O-ring
Engine main revolution sensor
• Since this sensor is a flange type, gap does not have to be adjusted.
18.7.1.5 Installation of starter

1. Install the starter with bolts and nuts.
Tightening torque : 154 N·m {1,570 kgf·cm, 114
lbf·ft}
18-104
［18. ENGINE］
18.7.1.6 Installation of alternator

1. Installation of alternator
1) Tighten the alternator temporarily using through bolts and nuts.
2) Tighten the adjusting bolts and fixing bolts temporarily.
2. V-belt tension adjustment Coolant Pump Pulley
?
Alternator 18
Pulley
Crankshaft
Pulley
When installing a At the time of

Item
new belt inspection
8 - 10mm 10 - 12mm
Deflection {0.3152 - {0.394 -
0.394in.} 0.472in.}
490 - 570 N 320 - 400 N

Tension {50 - 58 kgf, {33 - 41 kgf,
110 - 128 lbf} 72 - 90 lbf}
Special tool : S0944-41210 (09444-1210)

Compression gauge (used at the time of measuring the deflection amount)
[Reference push force 98N {10kgf, 22lbf}]
• If the V-belt is replaced with a new one, it becomes loose due to initial fitting. Run the engine for three to five
minutes and adjust the tension of the belt again.
• At the time of inspection, the new V-belt has reached the value after complete initial stretching. A new V-belt
completes initial stretching after running the engine for approximately two hours.
1) Tighten the through bolt of the commutator end frame.

Tightening torque : Through bolt
2) Tighten the lock nut on the brace side.
Tightening torque : Adjusting bolt
3) Tighten the adjusting bolt and make sure the bolt is locked.
5.9 N·m {60 kgf·cm, 4 lbf·ft}
4) Securely connect the ground wire terminal for the alternator.
18-105
［18. ENGINE］
18.8 INTAKE
18.8.1 Intake Manifold
17103 Intake pipe 17113 Intake pipe
17111 Intake manifold 17171 Gasket*
Tightening torque
9068-08320 28.5N·m {290kgf·cm, 21 lbf·ft} 9240-08087 28.5N·m {290kgf·cm, 21 lbf·ft}
9068-08550 28.5N·m {290kgf·cm, 21 lbf·ft}
18-106
［18. ENGINE］
18
17104A Gasket* 17148 Plate
18-107
［18. ENGINE］
18.8.1.2 Replacement
1. Removal of intake manifold
1) Remove bolts and nuts and remove the intake manifold.
2. Installation of intake manifold
1) Clean inside of the intake manifold and the
cylinder head.
2) Assemble a new gasket.
Protrusion
• Install the gasket so that the protrusion may come at the rear end stud bolt of the cylinder head.
3) Install the intake manifold and tighten it with bolts

and nuts.
Tightening torque : 28.5 N·m {290 kgf·cm, 21
lbf·ft}
3. Installation of intake pipe

1) After removing contamination on the contact surface, apply liquid gasket [Threebond TB1207B(black) or
equivalent] to the circumference of the contact surface.
• Apply it continuously.
• Apply the liquid gasket at the width of 1.5 to 2.5 mm {0.0591 to 0.09843 in.}
• Install the oil cooler within 20 minutes after application of the liquid gasket.
2) Install the intake pipe with bolts and nuts.
18-108
［18. ENGINE］
18.9 ENGINE MECHANICAL

18.9.1 Cylinder Head
18
11101 Cylinder head assembly 11135 Exhaust valve seat
11122 Valve guide 11176 Nozzle seat
11131 Intake valve seat 900115 O-ring*
18-109
［18. ENGINE］
11115 Cylinder head gasket 12108 Oil filler cap
11188 Semicircular plug 12505 Silent block
11201 Cylinder head cover 23074 Injection pipe oil seal*
11213 Head cover gasket
Tightening torque
11185 59N·m {600kgf·cm, 44 lbf·ft}+90°+90° 9069B 59N·m {600kgf·cm, 44 lbf·ft}
11185A 59N·m {600kgf·cm, 44 lbf·ft}+90°+135° 9349A 30N·m {300kgf·cm, 22 lbf·ft}
11185B 59N·m {600kgf·cm, 44 lbf·ft}+90°+180° SZ105 59N·m {600kgf·cm, 44 lbf·ft}
9068-08400 28.5N·m {290kgf·cm, 21 lbf·ft}
18-110
［18. ENGINE］
18.9.1.2 Replacement of cylinder head

1. Removal of cylinder head and head gasket
1) First remove the head bolts 1 to 3.

2) Then gradually loosen the head bolts 4 to 21 from
the outside to the inside (approx. 1/4 turn each
time) and remove them.

3) Remove the cylinder head using a special tool

and hoist. Figure is an
18
example of work.
Special tool : S0943–31070 (09433–1070) Eye
bolt
• If it is difficult to remove the cylinder head, insert a chisel between the cylinder head and the cylinder block, and
move the chisel vertically so that the contact surface may not be damaged. Then, separate the cylinder head.
2. Inspection of head bolt length

1) Measure the underhead length of the head bolt
(M12 only) using vernier calipers. If it is beyond
the service limit, replace it with a new one.
Underhead length
short 126.5{4.9803}
Service limit (mm{in.}) middle 156.5{6.1614}
long 187.5{7.3819}
3. Installation of cylinder head gasket and liquid gasket

application procedure
Water hole seal ring
1) Cut the rear end plate gasket to be flush with the
surface of the cylinder block upper surface using
a scraper.
2) Install the cylinder head gasket on the cylinder
block and the flywheel housing.
18-111
［18. ENGINE］
• Remove dirt, water or oil from the mounting surfaces of the cylinder head and the cylinder block before work.
• Never reuse the gasket. Otherwise, it may damage the engine.
• The water hole seal ring of the cylinder head gasket is susceptible to damage. Avoid contact with hand or object.
• Before installation of the cylinder head gasket, make sure that there is no fall of or damage to the seal ring.
3) Apply appropriate amount of liquid gasket

Application area of liquid gasket
[Threebond TB1211 (white) or equivalent] to the
cylinder head gasket hole at the joint surface
The arrow
between the cylinder block and the flywheel shape
area is
housing. different
from the
actual
shape.
Application area of
liquid gasket
Liquid gasket
Cylinder head
Cylinder Flywheel Small

block housing
Rear end plate

Clearance
Too small
Clearance Clearance
Raised from upper

Section A - A surface
• Apply the liquid gasket so that the surface of the liquid gasket may be raised on the cylinder head gasket.
4. Installation of cylinder head

Figure is an
1) Clean the head bolt seat at the cylinder head example of work.
upper surface and the cylinder head lower
surface.
2) Apply engine oil to the head bolt seat and the bolt
thread.
3) Align the dowel pins of the cylinder block using a
special tool and hoist and mount the cylinder
head.
Special tool : S0943–31070 (09433-1070) Eye
bolt
18-112
［18. ENGINE］
• Before mounting the cylinder head, make sure that there is no foreign matter in the cylinder.
• When the cylinder head is mounted, be careful for engagement between the cam idle gear and the sub-idle gear.
(Contact of gear teeth with undue force may cause impact mark or chipping, resulting in abnormal noise or
missing tooth.)
18
• Mounting of the cylinder head with guide bolt can prevent displacement of the liquid gasket.
4) Sequentially tighten head bolts (M12) 1 to 18

from the center to the outside in the order shown
in the figure.
Tightening torque : 59 N·m {600 kgf·cm, 44 lbf·ft}

5) After tightening, tighten head bolts 1 to 18 again from the center to the outside.
6) Mark the head parts of head bolts (M12) 1 to 18 with paint in the same direction.
7) Tighten head bolts (M12) 1 to 18 in tightening order for another 90°. (First time)
8) Tighten head bolts (M12) 1 to 18 according to the
same procedure by the angles shown in the
table. (Second time)
Tightening angle Head bolts No.
90° 1, 2, 7, 8, 9, 10, 15, 16, 17
135° 4, 5, 12, 13
180° 3, 6, 11, 14, 18
9) Make sure the head bolts that have the same Paint mark
tightening angle markings have the same
orientation.
18-113
［18. ENGINE］
• If a bolt is turned excessively in retightening, do not loosen it.
10) Tighten the remaining bolts (M10) 1 to 3 in the This just 3 tighten
order shown in the figure.


18.9.1.3 Liquid gasket application procedure for semicircular plug (only when semicircular plug is
removed)
1. Remove liquid gasket from the cylinder plug and the
Semicircular plug
camshaft housing.
Liquid gasket
application region
2. Coat the semicircular plugs at the front and rear of the cylinder head with liquid gasket (Three Bond TB 1207B-
Black or equivalent), and install the semicircular plugs.
3. Temporarily install the cylinder head cover with the gasket attached, and execute a parallel adjustment of the
semicircular plugs.
• Be sure to wipe protruding liquid gasket.
18-114
［18. ENGINE］
18.9.1.4 Replacement of head cover

1. Installation of head cover
1) Wipe off the liquid gasket stuck to the sides of the semicircular plugs on the front and rear ends of the
cylinder head.
2) Wipe dirt (including liquid gasket) and oil on the Cylinder
joint surfaces of the cylinder head cover and the Head Cover
camshaft housing. Install a new head cover
gasket on the cylinder head cover. bolt
18
Silent Cylinder Head
Block Cover Gasket
3) Coat the semicircular plugs with liquid gasket

(Three Bond TB 1207B-Black or equivalent) just
before you install the cylinder head cover.
4) Put the cylinder head cover on the cylinder head Cylinder

Bolt
Head cover
and tighten bolts.
Silent block
lbf·ft}
Cylinder
Head cover
gasket Cylinder Head
cover lower
surface
Cylinder head
• Silent block the rubber is attached to the spacer
18-115
［18. ENGINE］
18.9.1.5 Overhaul of cylinder head

1. Removing the injector harness connector.
1) Unfasten the 2 bolts to remove the injector
harness connector from the cylinder head.
Injector harness
connector
2) Remove the O-ring from the injector harness
O-ring
connector.
3) Replace the O-ring with new one and fit it to the injector harness connector.
4) Mount the injector harness connector to the
cylinder head with 2 bolts.
Injector harness
connector
2. Cleaning of cylinder head

1) Remove carbon or other deposit using a scraper.
2) Clean the cylinder head.
• To remove carbon or other deposit, do not damage the lower surface of the cylinder head.
18-116
［18. ENGINE］
3. Replacement of valve guide Intake Exhaust
1) Remove the valve stem seal.

2) Remove the valve guide using a brass bar or
press.
3) When a new valve guide is assembled, do not pry
the end in assembly and press fit using a special
tool.
Special tool : S0947–11520 (09471–1520) Guide
Lower surface of cylinder head
18
• In press fit, be careful not to damage the valve stem at the upper/lower ends of the guide.
• In press fit, be sure to apply engine oil to the circumference of the valve guide.
4. Replacement of valve seat

Backing Valve seat
metal
Electric welding
Valve
Cut three areas
from here.
• The valve seat replacement procedure below may damage the cylinder head depending on the case. It is
recommended that a request for replacement be made to a machining vendor.
1) If the valve seat is replaced, use an out-of-use valve. After cutting three pieces from the valve
circumference, weld them to the valve seat.
• Apply grease to protect the cylinder head lower surface from welding spatter before work.
2) Put a backup metal (e.g. brass bar) at the valve stem head and pull out the valve seat using a press.
3) Remove welding spatter or dirt on the valve seat surface.
4) Heat the cylinder head to approx. 80 to 100 ℃
and strike the cooled valve seat into the mounting
area of the cylinder head.
18-117
［18. ENGINE］
5) Apply small amount of lapping compound to the

contact surface between the valve and the valve
seat.
6) Strike gently while turning the valve using a special tool for adjustment.
Special tool : S0943–11020 (09431–1020) Valve lapping tool
5. Replacement of nozzle seat
1) Tap the nozzle seat from the cylinder head lower
part. Then, put an appropriate bolt inside.
2) Hit the bolt head using a hammer and pull out the
nozzle seat toward the the cylinder head upper
part.
3) Remove the O-ring from the cylinder head.
• After pulling out the nozzle seat, be sure to remove deposit such as remaining liquid gasket or dirt.
4) After attaching a new O-ring into the nozzle seat Cylinder head
hole of the cylinder head, apply the liquid gasket
[Threebond TB1211 (white) or equivalent] at the O-ring
lower part of a new nozzle seat and assemble it
on the cylinder head.
Nozzle sheet
• Be sure to replace the O-ring with a new part. Reuse may cause water leak or gas leak, resulting in overheat or
crack of the cylinder head.
5) Clamp the nozzle seat using a special tool. Bar Nozzle seat
Special tool : S0947–21210 (09472–1210) Bar
SN441–00610 (9800–06100) Steel ball
Cylinder
Head
Steel ball
Stamp out and clamp
18-118
［18. ENGINE］
6. Inspection of cylinder head

• Inspection of cylinder head distortion
1) Measure distortion of the cylinder head lower
surface and the manifold mounting surface using
a ruler.
18
Standard value (mm{in.}) Service limit (mm{in.})
Longitudinal direction
0.06{0.0024}
0.2{0.0079}
Square direction
0.03{0.0012}
2) If the measurement value is beyond the service limit, replace it.
• Repair of the lower surface by grinding can change backlash of the timing gear. Do not grind it.
• Inspection of cylinder head crack

1) With dye penetrant test method (red check), make sure that there is no crack or damage in the cylinder
head.
18-119
［18. ENGINE］
18.9.2 Cylinder Block

1 Cylinder block assembly 3 Cylinder liner
2 Cooling jet
Tightening torque
A 69N·m {700kgf·cm, 51 lbf·ft}+90°+45° B 22N·m {220kgf·cm, 16 lbf·ft}
18-120
［18. ENGINE］
18.9.2.2 Overhaul
1. Replacement of cylinder liner
1) Put match marks on the flange surfaces of the
cylinder block and the cylinder liner using a oil
based marker.
Match mark
18
• Store removed cylinder liners for each cylinder number.

• Never provide match marks with a punch.
2) Pull out the cylinder liner toward the cylinder

block upper part using a special tool.
Special tool : S0942–02100 (09420–2100)
• Be careful for handling of the cylinder liner. Do not reuse the cylinder liner which has been dropped.
• Do not touch the cooling jet during work.
3) Apply engine oil to the inner bore of the cylinder

block.
4) Align the match mark of the cylinder liner with that of the cylinder block. Install the cylinder liner using a
special tool.
Liner identification mark Engine type
Block front
Front of engine
18-121
［18. ENGINE］
Cylinder liner
A, B and C marking
position
• When a new cylinder liner is installed, install the cylinder liner with the same identification mark (A, B, C)
stamped on the cylinder block.
2. Inspection of protrusion at cylinder liner flange

1) Fix the cylinder liner using a special tool.
Tightening torque : 9.8 N·m {100 kgf·cm, 7 lbf·ft}
Special tool : S0942–02100 (09420–2100)
2) Measure protrusion of the flange using a dial
gauge.
0.01 - 0.08
Standard value (mm{in.})
{0.0004 - 0.0031}
3. Inspection and adjustment of cooling jet

1) Remove the standard oil check valve and install
the cooling jet on the cylinder block using a
special tool.
Special tool : SZ910–24098 (9001–24262) Check
bolt
Check bolt
2) Connect the injection test oil hose from the lower
part of the cylinder block to the special tool check
bolt.
Check bolt
Oil hose
• Use new engine oil for injection of oil.
18-122
［18. ENGINE］
3) Set a special tool on the cylinder block.

Special tool : S0947–01280 (09470–1280) Tool Special tool
Tool assembly
assembly
Cylinder liner
Cooling jet
4) Inject oil from the nozzle of the cooling jet at the

hydraulic pressure of 196kPa{2kgf/cm2, 28lbf/
Oil injection unit (example)
Pressure 18
Regulator
in.2}. Oil
Hose
Air tank
(Oil tank) Compressed
Air gauge air
Air hose
To cooling jet Valve
• Refer to the drawing for the oil injection unit.
5) When the injection center hits within the specified Injection Gauge target circle
line of the gauge, it is considered normal.
Faulty Faulty Normal Normal
• Oil is susceptible to combustion due to spread. Do not use fire near around.
• Work at well ventilated place.
6) Make sure that the jet position check gauge hole at the tool assembly end may not interfere with the cooling
jet pipe.
7) If injection does not hit the target circle, correct it
with a special tool.
Special tool : S0947–21620 (09472–1620) Tool
8) If it cannot be corrected, install a new cooling jet for reinspection.

9) Remove the check bolt and install the cooling jet on the cylinder block using the genuine oil check valve.
10) After assembly of the piston, make sure that the cooling jet does not interfere with the piston at the piston
bottom dead center.
18-123
［18. ENGINE］
4. Inspection of cylinder block

• Inspection of cylinder block distortion
1) Measure distortion on the cylinder block using a
ruler.
Longitudinal direction
0.06{0.0024}
0.2{0.0079}
Square direction
0.03{0.0012}
2) If the measurement value is beyond the service limit, replace it.
• Repair of the upper surface by grinding can change backlash of the timing gear. Do not grind it.
• Inspection of cylinder block crack

1) With dye penetrant test method (red check), make sure that there is no crack or damage in the cylinder
block.
18-124
［18. ENGINE］
18.9.3 Timing Gear Cover and Flywheel Housing

18
11309 Front oil seal retainer 11390 End plate
11351 Flywheel housing 9828A Front oil seal*

11357 Gasket* 9828B Rear oil seal*
11357A Gasket*
Tightening torque
9068-08000 36N·m {370kgf·cm, 27lbf·ft} 9241-10107 55N·m {560kgf·cm, 41lbf·ft}
9068-10750 55N·m {560kgf·cm, 41lbf·ft} 9339A 55N·m {560kgf·cm, 41lbf·ft}
9068-60850 55N·m {560kgf·cm, 41lbf·ft} 9419A 196N·m {2,000kgf·cm, 145lbf·ft}
90124 196N·m {2,000kgf·cm, 145lbf·ft} Z9102 36N·m {370kgf·cm, 27lbf·ft}
90124A 196N·m {2,000kgf·cm, 145lbf·ft}
18-125
［18. ENGINE］
18.9.3.2 Replacement of flywheel housing

1. Removal of flywheel housing
1) Remove bolts and remove the flywheel housing.
• Remove bolts fixing the flywheel housing from the cylinder block.
2. Installation of flywheel housing Liquid gasket

1) Remove contamination from the joint surfaces of
the flywheel housing and the end plate using a
scraper.
2) Apply the liquid gasket [Threebond TB1207D
(silver) or equivalent] to the flywheel housing as
• Apply the liquid gasket at the width of 1.5 to 2.5 mm{0.0591 to 0.0984 in.}.
3) Install the flywheel housing on the cylinder block B

A A
with bolts.
Tightening torque : B C
196 N·m {2,000 kgf·cm, 145 lbf·ft}(Area A)
36 N·m {370 kgf·cm, 27 lbf·ft}(Area B) C
C
55 N·m {560 kgf·cm, 41 lbf·ft}(Area C) C
A A
A
A
• Tighten bolts fixing the flywheel housing from the cylinder block.
18-126
［18. ENGINE］
18.9.3.3 Replacement of end plate

1. Removal of end plate
1) Remove bolts.
2) Remove the Torx bolt and remove the end plate
using a special tool.
Special tool : S0941–11300 (09411–1300) Socket
wrench
18
2. Installation of end plate
1) Install the end plate and a new gasket with bolts.
• Make sure that there is no dirt or foreign matter on the installation surface of the cylinder block and the screw
holes.
2) Apply sealant (Super 5M or equivalent) to the thread of the Torx bolt.

3) Install the Torx bolt using a special tool.
Special tool : S0941–11300 (09411–1300) Socket wrench
4) Cut the gasket with a scraper to be flush to the Gasket
Cylinder block End plate
upper/lower surfaces of the cylinder block.
Flywheel housing
18-127
［18. ENGINE］
18.9.3.4 Replacement of crankshaft front oil seal

1. Removal of front oil seal
1) Install the plate of the special tool oil seal puller
on the crankshaft using two crankshaft damper
mounting bolts.
Special tool : S0942–01731 (09420–1731) Oil
seal puller
Boplt x 4
Plate
Center bolt Hook x 2
• Special tool kit
2) Hook the special tool oil seal puller with the tab of
the front oil seal and install the hook on the plate
of the special tool oil seal puller with
accompanying bolts.
3) Remove two bolts which installed the plate of the

special tool oil seal puller on the crankshaft.
4) Attach the accompanying center bolt to the special tool oil seal puller and tighten it. Pull out the front oil seal.
18-128
［18. ENGINE］
2. Installation of front oil seal Guide
1) Insert a new oil seal into the guide of the oil seal
press.
seal press
Oil seal
18
• Be careful for front/rear directions of the front oil seal. (The felt surface is at the crankshaft damper side.)
2) Checking that there is no dent or dirt in the oil Check that there are
seal insertion part of the front oil seal retainer and no hit marks or
crankshaft. scratchings.
3) Removeing dirt from the special tool. Oil seal press

seal press Guide bolt
Oil seal guide
Bolt
• Special tool kit
4) Appying the small amount of engine oil to the fitting area (crankshaft and oil seal retainer side) of a new
crankshaft front oil seal.
5) Remove contamination from the joint surface of
the front oil seal and the cylinder block.
6) Apply small amount of engine oil to the fitting area (crankshaft and oil seal retainer side) of the front oil seal.
7) Install the oil seal press guide inserting a new front oil seal with accompanying guide bolts on the
crankshaft.
18-129
［18. ENGINE］
8) Align the oil seal press hole to the guide bolt and
insert the oil seal press.
9) Attach the accompanying center bolt to the oil seal press and tighten it until stop. Press fit the front oil seal.
18-130
［18. ENGINE］
18.9.3.5 Replacement of crankshaft rear oil seal

1. Removal of rear oil seal
1) Install the plate of the special tool oil seal puller
on the crankshaft using two flywheel assembly
mounting bolts.
seal puller
18
• Align the large hole of the plate with the collar dowel of the crankshaft.
2) Hook the oil seal puller with the tab of the rear oil
seal and install the hook on the plate of the oil
seal puller with accompanying bolts.
3) Remove two bolts which installed the plate of the oil seal puller on the crankshaft.
4) Attach the accompanying center bolt to the oil
seal puller and tighten it. Pull out the rear oil seal.
2. Installation of rear oil seal

1) Insert a new rear oil seal into the guide of the oil Guide of oil seal press
seal press.
seal press
Rear oil seal
• Be careful for front/rear directions of the rear oil seal. (The felt surface is at the flywheel side.)
18-131
［18. ENGINE］
2) Remove contamination from the joint surface of

the rear oil seal and the flywheel housing
3) Apply small amount of engine oil to the fitting area (crankshaft and flywheel housing side) of the rear oil seal.
4) Install the oil seal press guide inserting a new rear oil seal with accompanying guide bolts on the crankshaft.
• Align the large hole of the guide with the collar dowel of the crankshaft.
5) Align the oil seal press hole to the guide bolt and
insert the oil seal press.
6) Attach the accompanying center bolt to the oil

seal press and tighten it until stop. Press fit the
rear oil seal.
18-132
［18. ENGINE］
18.9.4 Main Moving Parts

18
11011 Thrust bearing 13260 Connecting rod assembly
11701 Main bearing 13271 Connecting rod bush
11703 Main bearing US 0.25 13411 Crankshaft
11704 Main bearing US 0.50 13450 Flywheel assembly
13005 Piston, Piston ring set 13453 Ring gear
13041 Connecting rod bearing 13470 Crankshaft pulley
13041A Connecting rod bearing US 0.25 13521 Crankshaft gear
13041B Connecting rod bearing US 0.50 9819A Retainer ring*
Tightening torque
13265 69N·m {700kgf·cm, 51lbf·ft}+90°+45° 900125 118N·m {1,200kgf·cm, 87lbf·ft}
13455 186N·m {1,900kgf·cm, 137lbf·ft}
18-133
［18. ENGINE］
18.9.4.2 Replacement of piston and connecting rod

1. Removal of piston Figure is an
1) Remove bolts and remove the connecting rod example of work.
cap.
• Insert a large flat tip screwdriver into the flywheel gear from the flywheel housing inspection hole to prevent
turning of the crankshaft.
• Store removed connecting rod cap for each cylinder number so that combinations of the connecting rod and the
connecting rod cap may not be changed.
2) Remove carbon on the cylinder liner inner

surface with a scraper or a sand paper (No. 150
or so) in the circumferential direction.
• Do not damage parts lower than the carbon deposit area.
3) Fix the cylinder liner with bolts and a plate.

4) Hit the connecting rod from underneath the
engine using a handle of a hammer. Remove the
piston together with the connecting rod.
Cooling jet
18-134
［18. ENGINE］
• In removing the piston, rotate the connecting rod as shown in the figure. Do not bend the cooling jet.
• Store removed pistons and connecting rods for each cylinder number.
• Be careful not to touch the cooling jet. 18
2. Disassembly of piston and connecting rod

1) Remove the retainer ring using snap ring pliers.
2) Remove the piston pin using the brass bar and
disconnect the piston from the connecting rod.
3) Remove the piston ring using a special tool.

Special tool : S0944–21011 (09442–1011) Piston
ring expander
• Since the piston ring is susceptible to damage, be careful for handling.

• Store piston rings for each cylinder number.
• Store the piston rings so that the upper and lower surfaces may be identified.
3. Assembly of piston and connecting rod "0" mark position Piston

1) Install the piston on the connecting rod so that
the "0" mark on the piston may be opposite to the Exhaust side Intake side
match mark stamp on the connecting rod
2) Install a new retainer ring using a snap ring pliers.
Oil hole
Match mark
stamp
• Make sure that there is no backlash in the retainer ring.
18-135
［18. ENGINE］
3) Face the side with the piston ring identification

print upward and install in the order of the oil ring,
second ring and top ring using a special tool.
Top ring Second ring Oil ring

Upper surface
Lower surface
Oil ring joint Clearance
Coil expander Ring

Second ring
Oil ring Top ring
• The identification print is present only on the secondary ring and the top and bottom of the top ring and the oil
ring are not identified.
Special tool : S0944–21011 (09442–1011) Piston ring expander

4) Connect the joint of the coil expander and fit the oil ring inside the ring. Offset the coil expander joint with the
ring joint by 180 deg for installation.
5) Allocate the joints of the piston ring with uniform intervals as shown in the figure.
4. Installation of piston and connecting rod Oil hole
Concave shape
1) Allocate the joints of the piston ring with uniform
intervals as shown in the figure.
2) Install the connecting rod bearing to suit concave Oil hole Bearing
shape of the connecting rod.
Connecting rod
• Make sure that the oil hole of the connecting rod bearing is aligned with the oil hole of the connecting rod.
18-136
［18. ENGINE］
3) Apply engine oil to the piston, cylinder liner and

connecting rod bearing and compress the piston
ring using a special tool.
Special tool : S0944-11370 (09441–1370) Piston
ring holder
18
• Make sure that there is no deformation or damage to the special tool piston ring holder.
4) Insert the piston carefully so that the connecting

rod may not come in contact with the cooling jet.
• Face the "0" mark on the piston toward the exhaust side for insertion.
• Set the crankshaft of the cylinder as the top dead center for assembly.
• Do not damage the cylinder liner, crankshaft and cooling jet during work.
5) Install the connecting rod bearing to suit concave

Cap
shape of the connecting rod cap.
Bearing
6) Align the match mark of the connecting rod cap

with that of the connecting rod and fix it with a Match mark
Stamp
dowel pin.
1234 1234
• Do not change the combination between the connecting rod and the connecting rod cap.
18-137
［18. ENGINE］
7) Measure the underhead length of the connecting

rod bolt using a vernier calipers. If it is out of the
service limit, replace it with a new one.
Underhead length
Service limit (mm{in.}) 68.0{2.6772} or less
8) Apply engine oil to the connecting rod bolt thread and the seat and install it on the connecting rod.
9) Tighten the connecting rod bolt and mark the bolt Paint mark
head in the same direction with paint.
Tightening torque : 69 N·m {700 kgf·cm, 51 lbf·ft} Connecting rod cap
45°
90°
10) Retighten the connecting rod bolt 90°.

11) Retighten the connecting rod bolt further 45°.
12) Make sure that all marks are in the same direction.
• If a bolt is turned excessively in retightening, do not loosen it.
18-138
［18. ENGINE］
18.9.4.3 Inspection of piston and connecting rod

1. Inspection of piston clearance
1) Measure the inner diameter of the cylinder liner
sliding surface using a cylinder gauge.
18
112{4.4095} 112.15{4.4153}
2) Measure the piston outer diameter using a

micrometer.
Standard value
111.9±0.008{4.4055±0.0003}
(mm{in.})
• The measuring position is 23 mm{0.9055 in.} above the piston lower end and square to the pin hole.
3) Calculate the difference between the inner diameter of the cylinder liner and the outer diameter of the
piston. If it is beyond the standard value, replace the cylinder liner and the piston.
Standard value
0.088 - 0.112{0.0035 - 0.0044}}
(mm{in.})
2. Inspection of clearance between piston ring and ring groove

1) Measure the piston ring width using a
micrometer. If it is beyond the service limit,
replace the piston ring.
Standard value Service limit

(mm{in.}) (mm{in.})
Top ring 2.5{0.0984} 2.40{0.0945}
Second ring 2{0.0787} 1.90{0.0748}
Oil ring 4{0.1575} 3.90{0.1535}
18-139
［18. ENGINE］
2) Measure the piston ring groove using a thickness

gauge. If it is out of the service limit, replace the
piston.

(mm{in.}) (mm{in.})
Top ring
2.5{0.0984} 2.70{0.1063}
groove
Second ring
2{0.0787} 2.20{0.0866}
groove
Oil ring groove 4{0.1575} 4.10{0.1614}
3. Inspection of piston ring joint clearance

1) Using the piston to insert the piston ring horizontally to the cylinder liner until it passes through the sliding
surface.
2) Measure the piston ring joint clearance using a Cylinder liner
thickness gauge. If it is out of the service limit,
replace the piston ring.
Piston Ring

(mm{in.}) (mm{in.})
0.3 - 0.40
Top ring 1.5{0.0591}
{0.0118 - 0.0157}
0.75 - 0.90
Second ring 1.5{0.0591}
{0.0295 - 0.0354}
0.15 - 0.30
Oil ring 1.2{0.0472}
{0.0059 - 0.0118}
4. Inspection of piston pin

1) Measure the outer diameter of the contact area of
the piston pin with the piston boss using a
micrometer.
Standard value
Service limit (mm{in.}
(mm{in.})
37 {1.4567} 36.96{1.4551}
18-140
［18. ENGINE］
2) Measure the piston boss inner diameter using a

cylinder gauge.
Standard value
(mm{in.})
37 {1.4567} 37.05{1.4587}
3) Calculate the difference between the outer diameter of the piston pin contact area with the piston boss and
the inner diameter of the piston boss. If it is out of the service limit, replace the piston pin or piston. 18
Standard value
(mm{in.})
–0.002T-0.025L 0.05{0.0020}
T : Tightening allowance
L : Clearance
4) Using the cylinder gauge to measure the inner

diameter of the connecting rod bush
Standard value Operation limit

(mm{in.}) (mm {in.})
37 {1.4567} 37.1{1.4606}
5) Calculate the difference between the inner diameter of the connecting rod small end and the outer diameter
of the piston pin, and if it is beyond the service limit, replace the connecting rod or the bush.
Standard value Operation limit

(mm{in.}) (mm {in.})
0.015L-0.036L
0.08{0.0031}
{0.0005L-0.0014L}
L: clearance
18-141
［18. ENGINE］
18.9.4.4 Replacement of connecting rod bushing

1. Removal of connecting rod bushing
1) Put the special tool press sub-assembly together
Press
with the special tool guide nut and fix them using Sub-assembly
Wing nut
the special tool wing nut.
Special tool :
Guide
S0948–11130 (09481–1130) Guide
S0940–21530 (09402–1530) Press sub-
assembly
SL271–01036 (9233–10360) Wing nut
• Face "H" mark of the guide upward for assembly.

• Assemble it on a level table and make sure that the lower end of the guide and the press sub-assembly is flat.
2) With the large end bearing removed, assemble

the connecting rod and put it on the assembled
special tool.
3) Install the special tool spindle on the bushing of

the connecting rod. Groove
Spindle
Special tool : S0940–21540 (09402–1540)
Spindle
Connecting rod
Press
Sub-assembly
• Align the press sub-assembly groove with the special tool spindle groove for installation.
4) Remove the bushing of the connecting rod using

a press.
• Move the press slowly.
5) Check the small end of the connecting rod with the bush removed, and see if there is deformation to the
inner diameter or scratches or dents on the inner surface.
18-142
［18. ENGINE］
• The presence of deformation, scratches or dents indicates that the bush was not properly installed.
6) Chamfer one side of the connecting rod small Chamfer

end uniformly according to the figure.
18
• Remove burr completely.

• After chamfering, remove dirt from the inner surface at the small end and from the oil hole.
2. Installation of connecting rod bushing

1) Install a new bushing on the special tool spindle
and install the special tool guide and the special Groove
tool bolt. Spindle
Special tool :
S0940–21540 (09402–1540) Spindle
S0948–11540 (09481–1540) Guide Bushing
SH691–20825 (9191–08252) Bolt

Guide
Tightening torque :
5 - 6 N·m {50 - 70 kgf·cm, 3.5 - 4 lbf·ft} Bolt
• Align grooves of the special tool guide and the special tool spindle for installation.
• Make sure that the edge of the special tool spindle and the special tool guide is in close contact.
• Using dry ice to cool the bush to -10℃ (14℉) before assembling it will improve the quality of the assembled bush.
Also, work quickly so that the bush does not warm up during assembling work.
2) Align the connecting rod oil hole with the bushing

oil hole assembled on the special tool. Make sure
that the groove of the special tool spindle is in
alignment with the groove of the special tool Groove
press sub-assembly. Oil hole
18-143
［18. ENGINE］
• Place the connecting rod so that the chamfer side of the connecting rod small end inner diameter may be the
bushing side
• Apply engine oil to the inner diameter surface of the connecting rod.
3) Install the bushing on the connecting rod using a press.
• After press-fitting the bush, make sure there are no machine burrs on the bush.
4) Insert a rod with the diameter of 4 mm {0.1575

in.} from the oil hole at the connecting rod large
end and make sure that it goes through the oil
hole at the small end.
• Displacement of oil holes may cause insufficient lubrication, resulting in seizure.
5) Insert a new piston pin and check if there is no drag or backlash.
18-144
［18. ENGINE］
18.9.4.5 Replacement of crankshaft

1. Removal of crankshaft
1) Remove the main bearing cap and the main shaft
bearing. Remove the crankshaft using a hoist.
18
• Since the part is heavy, be careful for handling.

• Store removed main bearing caps and main bearings for each cylinder number.
2. Installation of crankshaft
1) Face the groove side (front) of the thrust bearing
toward the crankarm and the part number side
(back) toward the main bearing cap or the
cylinder block. Install it on the cylinder block and
the main bearing cap.
• To prevent falling in assembly, apply engine oil or grease to the back of the thrust bearing.
2) Install the main bearing on the cylinder block and each bearing cap.
• Assemble the bearing with oil hole on the cylinder block and assemble the bearing without oil hole on the cap.
• Apply new engine oil to the sliding surfaces of each bearing.
3) Align the crankshaft with the cylinder block.
18-145
［18. ENGINE］
4) Align the main bearing cap which has the thrust

bearing and the main bearing with the cylinder
block.
1 2 3 4 5
• The pentagon mark on the main bearing cap should face the front of the vehicle. Align in the order of 1, 2, 3, 4, 5,
6 and 7 from the front.
• Check the stamp number of each main bearing cap with the stamp number of the cylinder block.
5) Measure the underhead length of the bearing cap

bolt using a vernier calipers. If it is out of the
service limit, replace it with a new one.
Underhead length
Service limit (mm{in.}) 108{4.252}
6) Apply engine oil to the bolt seat and the bolt 2 4 6 8 10

thread of the bearing cap bolt.
1 3 5
7 9
7) Tighten the bearing cap bolt according to the sequence in the figure.
8) Loosen the bearing cap fixing the thrust bearing and hit the crankshaft gently at the front/rear end using a
plastic hammer.
9) Loosen all bearing cap bolts.
10) Tighten the bearing cap bolt as in (7).
11) Mark bearing cap bolt heads in the same direction with paint.
12) Tighten 90 deg (1/4 turn) with the same order as in (7).
13) Retighten 45 deg (1/8 turn) as in (7). Paint mark
45
90
18-146
［18. ENGINE］
14) Make sure that all paint marks are in the same direction.
• If it is excessively retightened, do not loosen it.
15) After tightening, hit the front/rear ends of the crankshaft gently with a plastic hammer for initial fit.
18
• Make sure that the crankshaft turns smoothly.
• Measure the end play of the crankshaft and make sure that it is within the standard value.
Standard value Repair limit Service limit

(mm{in.}) (mm{in.}) (mm{in.})
0.050 - 0.219
0.50{0.0197} 1.219{0.0480}
{0.0020 - 0.0086}}
18-147
［18. ENGINE］
18.9.4.6 Inspection of crankshaft

1. Inspection of end play
1) Measure the end play of the crankshaft using a
dial gauge. If it is beyond the repair limit, replace
the thrust bearing. If it is beyond the service limit,
replace the crankshaft.
Standard value Repair limit Service limit

(mm{in.}) (mm{in.}) (mm{in.})
0.050 - 0.219
{0.0020 - 0.50{0.0197} 1.219{0.0480}
0.0086}}
• Standard width of thrust bearing2.5mm{0.0984in.}
2. Inspection of rotation runout Figure is an

example of work.
1) Measure the crankshaft rotation runout using a
dial gauge. If it is beyond the repair limit, grind
the crankshaft and use the undersize bearing.
Repair limit (mm{in.}) 0.15{0.0060}
3. Inspection of journal wear

1) Measure the outer diameter of the crankshaft
Measure two
journal using a micrometer. If it is faulty, grind or places.
replace the crankshaft. When the crankshaft is 90
ground, use the undersize bearing.
Journal standard value

80{3.1496}
(mm{in.})
Wear value (mm{in.}) Action

Eccentric wear
Regrind for correction.
0.10{0.0039}
Wear of 0.20{0.0079}
Regrind
or more
Wear of 0.7{0.0276} Replace the crankshaft.
18-148
［18. ENGINE］
2) Measure the crankshaft center journal width Figure is an

using a vernier calipers. If it is out of the service example of work.
limit, replace the crankshaft.
36{1.4173} 37.0{1.4567} 18
4. Inspection of crankshaft oil clearance
1) Measure the outer diameter of the crankshaft
journal using a micrometer. 90
Journal standard value

80{3.1496}
(mm{in.})
2) Do not install the crankshaft. Install the

crankshaft bearing and the main bearing cap on
the cylinder block.
3) Measure the crankshaft bearing inner diameter using a cylinder gauge.

4) Calculate the difference between the outer diameter of the crankshaft journal and the inner diameter of the
crankshaft bearing. If it is beyond the repair limit, grind the crankshaft and use the undersize bearing.
Standard value (mm{in.}) Repair limit (mm{in.})
0.051 - 0.102
0.2{0.0079}
{0.0020 - 0.0040}
• Standard bearing thickness : 2.5mm

• Undersize bearing value : 0.25, 0.50
Bearing size Journal outer diameter (mm{in.})
Standard 79.940 - 79.960 {3.1472 - 3.1480}
0.25US 79.690 - 79.710 {3.1374 - 3.1382}
0.50US 79.440 - 79.460 {3.1276 - 3.1283}
18-149
［18. ENGINE］
5) Dimension of fillet "R" Radius is

incomplete. Radius is
Crank pin small. Step Step
2.5 to 3.0mm {0.0984 to 0.1181 in.} R
Journal
2.5 to 3.0mm {0.0984 to 0.1181 in.}
Good Poor
5. Inspection of crack and damage on crankshaft and Figure is an

of oil hole example of work.
1) Check for crack or damage using dye penetrant.

If a faulty condition is found, replace the
crankshaft.
2) Check for clogging of the crankshaft oil hole. If Figure is an

faulty condition is found, replace the crankshaft. example of work.
6. Inspection of pin wear

1) Measure the outer diameter of the crankshaft 90°Measurement
crank pin using a micrometer. If it is faulty, grind at 2 places
or replace the crankshaft.
When the crankshaft is ground, use the
undersize bearing.
Crank pin standard valu 65
Wear value (mm{in.}) Action

Eccentric wear
Regrind for correction.
0.10{0.0039}
Wear of 0.20{0.0079}
Regrind
or more
Wear of 0.7{0.0276} Replace the crankshaft.
18-150
［18. ENGINE］
18.9.4.7 Replacement of crankshaft pulley

1. Removal of crankshaft pulley
1) Remove bolts and remove the crankshaft pulley.
18
2. Installation of crankshaft pulley

1) Apply engine oil to the bolt seat and the bolt 1
thread of the crankshaft pulley mounting bolt. 6 3
2) Install the crankshaft pulley on the crankshaft and

tighten it according to the figure. 4 5
Tightening torque : 118 N·m {1,200 kgf·cm, 87 2
lbf·ft}
18-151
［18. ENGINE］
18.9.4.8 Replacement of flywheel

1. Removal of flywheel
1) Remove the engine revolution sensor.
Flywheel
2) Remove bolts fixing the flywheel. Mounting bolt
3) Install a special tool into the bolt hole of the

crankshaft to remove the flywheel.
• Since the flywheel is heavy, be careful for handling.

• Do not give impact to the special tool during work.
2. Removal of ring gear

1) Heat the entire ring gear circumference with a
burner until it is about 200℃(392℉).
• Do not touch the ring gear and the flywheel with bare hand while they are hot.
18-152
［18. ENGINE］
2) Hit the circumference of the ring gear gently

using a backing rod to remove the ring gear from
the flywheel.
18
3. Installation of ring gear

1) Heat the entire ring gear circumference with a
burner until it is about 200℃(392℉).
2) Face the chamfered side toward the flywheel and

install it on the flywheel quickly.
4. Installation of flywheel
1) Make sure that there is no burr or dirt on the joint
surface of the crankshaft and the flywheel and
the screw hole.
2) Install the special tool into the bolt hole of the
crankshaft.
18-153
［18. ENGINE］
• Install one special tool on the collar dowel and the other at the opposite side of the collar dowel.
3) Insert the flywheel until it comes in contact with the collar dowel of the crankshaft and adjust the position.
• Since the flywheel is heavy, be careful for handling.

• Do not give impact to the special tool during work.
4) Insert the flywheel until it comes in contact with

the crankshaft.
5) Apply engine oil to the bolt seat and the bolt thread of the flywheel mounting bolt.
6) Tighten 6 bolts by 2 to 3 threads temporarily with
hand in the bolt holes without installation of the
special tool.
7) Tighten 6 bolts gradually and tighten temporarily.

8) Remove the special tool and tighten remaining two bolts temporarily as in (6) and (7).
9) Tighten the flywheel according to the order in the
figure. 1
Tightening torque : 186 N·m {1,900 kgf·cm, 137 5 8
lbf·ft} 3 4
7 6
2
10) Loosen all bolts.

11) Tighten the bolts again.
Tightening torque : 186 N·m {1,900 kgf·cm, 137 lbf·ft}
12) Install the engine revolution sensor.
18-154
［18. ENGINE］
18.9.5 Camshaft and Idle Gear

18
13501 Camshaft assembly 13572B Idle gear thrust plate
13505 Cam idle gear 13581 Idle gear shaft
13505A Sub-idle gear 13581A Idle gear shaft
13505B Main idle gear 13581B Idle gear shaft
13520 Camshaft gear 9867A Idle gear bush
13572 Idle gear thrust plate 9867B Idle gear bush
13572A Idle gear thrust plate
Tightening torque
900124 59N·m {600kgf·cm, 44lbf·ft}+90° 900125 172N·m {1,750kgf·cm, 127lbf·ft}
900124A 108N·m {1,100kgf·cm, 80lbf·ft}
18-155
［18. ENGINE］
18.9.5.2 Removal of camshaft

1. Removal of rocker arm and camshaft assembly
1) Loosen the lock nut and turn the adjusting screw
completely. Rock nut
• Removal without turning the adjusting screw may bend the rocker shaft.
2) Loosen the rocker arm support bolts gradually

from the center and remove the rocker arm and
the rocker arm shaft.
18.9.5.3 Disassembly of camshaft

1. Disassembly of camshaft
1) Fix the camshaft gear using a vice to
disassemble the camshaft.
• Prevent faulty conditions on the gear such as deformation, impact, scratch, etc.
18-156
［18. ENGINE］
18.9.5.4 Inspection of camshaft and camshaft bearing

1. Inspection of cam height on camshaft
1) Measure the cam height using a micrometer. If it
is beyond the service limit, replace the camshaft.
18
(mm{in.}) (mm{in.})
Cam IN 50.067{1.9711} 49.987{1.9680}

height EX 52.104{2.0513} 52.024{2.0482}
IN 8.067{0.3176} (7.987{0.3144})
Cam lift
EX 10.104{0.3978} (10.024{0.3946})
2. Inspection of camshaft runout Camshaft runout measuring area

1) Put the journal at both ends of the camshaft on
the V block.
2) Put a dial gauge to each journal of the camshaft
and measure runout of the camshaft. If it is
beyond the service limit, replace the camshaft.
0.04{0.0016} 0.1{0.0039}
3. Inspection of camshaft bearing oil clearance

1) Measure the outer diameter of the camshaft
journal using a micrometer.
40{1.5748} 39.85{1.5689}
2) Measure the camshaft bearing inner diameter using a cylinder gauge.
40{1.5748} 40.15{1.5807}
3) Calculate the difference of the camshaft journal bearing inner diameter. If it is beyond the standard value,
replace the camshaft or the camshaft bearing.
0.020 - 0.063
{0.0008 - 0.0025}
18-157
［18. ENGINE］
18.9.5.5 Assembly of camshaft

1. Measure the camshaft mounting bolt using a vernier
calipers. If it is out of the service limit, replace it with
a new one.
Underhead length
Service limit (mm{in.}) 31{1.2204}
2. Fix the camshaft gear using a vice. Apply engine oil

to the seat and the bolt thread of the camshaft gear
mounting bolt.
3. Set the dowel pin to the camshaft and the camshaft gear and tighten the camshaft gear mounting bolt.
4. Retighten 90 deg (1/4 turn).
• If it is excessively retightened, do not loosen it.

• Prevent faulty conditions on the gear such as deformation, impact, scratch, etc.
18-158
［18. ENGINE］
18.9.5.6 Installation of camshaft

1. Align the No. 1 cylinder to the compression top dead center.
2. Installation of camshaft and rocker arm.
Timing decision
1) Place the camshaft so that two holes at 180
drill hole
degrees from the three drilled holes of the
camshaft gear may be horizontal to the upper
surface of the camshaft housing.
18
Ruler or etc
Misconnection prevention drill hole
• Place a transparent plastic ruler or an edged ruler on the upper surface of the camshaft housing and the side of
the camshaft gear. Make sure that the position of the foolproof drilled hole is above the ruler.
2) Coat the bearing parts with engine oil and then

install the camshaft bearing caps in numerical
order 1-2-3-4-5 from the front of the engine,

making sure the five-sided mark on the cap
points forward.
Engine Foreword
3) Make sure the crosshead is correctly laid across

each valve. Crosshead
• To make sure the crosshead is correctly in place, move it to the left and right by hand and make sure it clicks
against the valves.
• If the crosshead is not sitting properly on the valves, it will push the upper seat and cause the valve to drop out.
4) Make sure the rocker arm is correctly assembled on the rocker arm shaft.
5) Fully unscrew the adjust screw on the end of the rocker arm.
• Securing the rocker arm and nozzle clamp together with a string will facilitate installation work.
18-159
［18. ENGINE］
6) Apply engine oil to the cam threads and set the

rocker arm in position, making sure it is correctly
laid on the crosshead. Then, tighten the bolts in
the sequence shown in the figure, making several
passes and gradually tightening them each time.
lbf·ft}
• After the bolts are tightened, make sure the rocker arm moves smoothly.
18.9.5.7 Gear train layout
18-160
［18. ENGINE］
18.9.5.8 Removal of timing gear

1. Removing the cam idle gear
Cam idle gear
1) Unbolot the idle gear shaft to remove the cam Thrust plate
idle gear, the idle gear shaft and the thrust plare Bush
from the cylinder head.
Cylinder
head
Idle gear shaft
18
• Be careful not to drop the thrust plare in the flywheel housing.
• Turning over the engine vertically or turn it onto the side during work. This prevents workers from dropping parts
in the flywheel housing.
2. Removal of main idle gear

1) Remove the idle gear shaft mounting bolt and
pull out the main idle gear assembly using a
special tool.
Special tool : S0942–01100 (09420–1100)
Sliding hammer
S0942–01442 (09420–1442)
Sliding hammer
2) Remove the idle gear thrust plate.
3) Remove the idle gear shaft from the main idle gear.
3. Removal of sub-idle gear
1) Remove the idle gear shaft mounting bolt and the
idle gear thrust plate and pull out the sub-idle
gear assembly using a special tool.
Special tool : S0942–01100 (09420–1100)
Sliding hammer
S0942–01442 (09420–1422)
Sliding hammer
3) Remove the idle gear shaft from the sub-idle
gear.
18-161
［18. ENGINE］
18.9.5.9 Inspection of timing gear components

1. Inspection of clearance between idle gear shaft and
idle gear bushing
1) Measure the idle gear shaft outer diameter using
a micrometer and the idle gear bushing inner
diameter using a cylinder gauge.
Standard value
(mm{in.})
Main idle Shaft outer diameter 57{2.2441}

gear shaft Bushing inner diameter 57{2.2441}
Sub-idle Shaft outer diameter 50{1.9685}

gear shaft Bushing inner diameter 50{1.9685}
2) Calculate the difference between the idle gear bushing inner diameter and the idle gear shaft outer
diameter. If it is beyond the service limit, replace the idle gear shaft and the idle gear bushing.

(mm{in.}) (mm{in.})
Main idle 0.030 - 0.090

0.20{0.0079}
gear shaft {0.0012 - 0.0035}
Sub-idle 0.025 - 0.075

0.20{0.0079}
gear shaft {0.0010 - 0.030}
18-162
［18. ENGINE］
18.9.5.10 Installation of timing gear

1. Installation of sub-idle gear
1) Install the idle gear shaft on the sub-idle gear. Thrust plate
2) Install the idle gear thrust plate.

3) Provide the lubricating hole of the idle gear shaft
in the vertical direction. Idle gear thrust
plate
4) Install the idle gear thrust plate on the idle gear
shaft. Lubricating
hole
5) Apply engine oil to the bolt seat and the bolt
thread of the idle gear shaft mounting bolt.
Cylinder block
18
6) Install the idle gear shaft mounting bolt.
lbf·ft}
2. Installation of main idle gear

Idle gear thrust plate
1) Install the idle gear shaft on the main idle gear.
Lubricating
hole
Cylinder
Block
3) Face the lubricating hole of the idle gear shaft Sub-idle gear
toward the oil pan (downward). Install A in the
figure by adjusting the timing of the crankshaft
gear and the main idle gear as in the detailed
drawing.
Oil pump
gear
A
Main idle gear
Crankshaft gear
Arrange drilled holes in line.

Detail
18-163
［18. ENGINE］
4) Apply engine oil to the bolt seat and the bolt

thread of the idle gear shaft mounting bolt.
5) Install the idle gear shaft mounting bolt.

Tightening torque : 172 N·m {1,750 kgf·cm, 127 lbf·ft}
6) Measure backlash and end play of each idle gear. Make sure that it is within the standard value.
7) After applying engine oil to the seating surface
and threads of the sub idle gear ahaft mounting
bolt, vertically orient oil holes in the sub idle gear
shaft before installation to the cylinder block. Thfust plate
Sub idle gear

shaft Oil holes
Cylinder block Sub idle gear
18-164
［18. ENGINE］
18.9.5.11 Overhaul of sub-idle gear (bearing case side)

1. Removal of bearing case assembly
1) Remove the supply pump.
"Reference : Replacement, Supply pump".
2) Disconnect the bearing case assembly.
• One bolt is tightened from the timing gear case.

18
3) Fix the bearing case with a vice.
4) Remove the sub-idle gear shaft mounting bolt

and pull out the idle gear shaft using a sliding
hammer.
5) Remove the sub-idle gear.

2. Inspection of clearance between sub-idle gear shaft
and sub-idle gear bushing
1) Measure the outer diameter of the idle gear shaft.
2) Measure the inner diameter of the sub-idle gear.
18-165
［18. ENGINE］
3) Calculate the clearance. If it is beyond the standard value, replace the shaft and the bushing.
0.025 - 0.075
{0.0010 - 0.030}
3. Installation of bearing case assembly

2) Install the gear shaft on the sub-idle gear.
3) Face the lubricating hole of the gear shaft
downward and install it on the bearing case.
4) Install the sub-idle gear shaft mounting bolt.
lbf·ft}
5) Assemble the supply pump and bearing case.
lbf·ft}
• Be careful for fall of the O-ring
18-166
［18. ENGINE］
18.9.5.12 Inspection of installation status for each gear

1. Inspection of backlash between camshaft gear and
cam idle gear
1) Insert a large flat tip screwdriver into the cam idle
gear from the side of the camshaft gear of the
camshaft housing to prevent turning of the cam
idle gear.
18
2) Measure backlash between the camshaft gear
and the cam idle gear using a dial gauge. If it is
beyond the service limit, replace each gear.
0.030 - 0.253
0.30{0.0118}
{0.0012 - 0.011}
2. Inspection of camshaft end play

1) Measure the end play of the camshaft using a
thickness gauge. If it is beyond the standard
value, replace the camshaft.
0.100 - 0.178
Standard value (mm)
{0.0039 - 0.0070}
3. Inspection of backlash between main idle gear and

air compressor idle gear
1) Remove the supply pump drive at the bearing
case.
"Reference : Replacement, Supply pump".
2) Insert a large flat tip screwdriver into the main idle
gear from the timing gear dust cover of the
flywheel housing to prevent turning of the main
idle gear.
18-167
［18. ENGINE］
3) Measure backlash between the main idle gear

and the air compressor idle gear using a dial
gauge and a magnet stand. If it is beyond the
service limit, replace each gear.
• If the magnet stand is not stable, provide a steel plate for measurement using bolt holes of the cylinder block.
0.032 - 0.096
0.10{0.0039}
{0.0013 - 0.0038}
4. Inspection of backlash between idle gear at bearing case and supply pump drive gear
1) Remove the supply pump drive.
"Reference : Replacement, Supply pump"
2) Remove the bearing case assembly.
3) Fix the supply pump drive with a vice and install
Work example
the bearing case assembly.
4) Measure backlash between the idle gear and the supply pump drive gear using a dial gauge and a magnet
stand. If it is beyond the service limit, replace each gear.
0.020 - 0.083
0.10{0.0039}
{0.0008 - 0.0033}
5. Inspection of backlash between main idle gear and

sub-idle gear
1) Insert a large flat tip screwdriver into the main idle
gear from the timing gear dust cover of the
flywheel housing to prevent turning of the main
idle gear.
18-168
［18. ENGINE］
2) Measure backlash between the main idle gear

and the sub-idle gear using a dial gauge and a
magnet stand. If it is beyond the service limit,
replace each gear.
Standard value (mm{in.}) Service limit (mm{in.}) 18

0.030 - 0.113
0.30{0.0118}
{0.0012 - 0.0044}
6. Inspection of backlash between sub-idle gear at

cam idle gear and oil pump gear
1) Insert a large flat tip screwdriver into the sub-idle
gear to prevent turning of the sub-idle gear.
2) Measure backlash between the sub-idle gear and

the oil pump gear using a dial gauge and a
magnet stand. If it is beyond the service limit,
replace each gear.
0.030 - 0.131
0.30{0.0118}
{0.0012 - 0.0005}
7. Inspection of idle gear end play

1) Measure the end play of each gear using a
thickness gauge. If it is beyond the service limit,
replace each gear or shaft.

(mm{in.}) (mm{in.})
0.114 - 0.160
Main idle gear 0.30{0.0118}
{0.0045 - 0.0063}
0.040 - 0.095
Sub-idle gear 0.30{0.0118}
{0.0016 - 0.0037}
18-169
［18. ENGINE］
8. Inspection of backlash between cam idle gear and

sub-idle gear
1) Insert a large flat tip screwdriver into the sub-idle
gear from the side of the cam idle gear of the
cylinder head to prevent turning of the sub-idle
gear.
2) Measure backlash between the cam idle gear

and the sub-idle gear using a dial gauge. If it is
beyond the service limit, replace each gear.
0.050 - 0.218
0.30{0.0118}
{0.0020 - 0.0086}
18-170
［18. ENGINE］
18.9.6 Valve System

18
13706 Crosshead assembly 13735 Valve spring upper seat
13709 Adjusting screw (rocker arm) 13787 Adjusting screw (cross head)
13711 Intake valve 13830 Rocker arm intake

13715 Exhaust valve 13840 Rocker arm (exhaust)
13719 Valve stem seal* 13901 Rocker shaft

13731 Outer valve spring 13951 Rocker arm support
13732 Inner valve spring 900126 Valve spring retainer
13734 Valve spring lower seat
Tightening torque
13788 25N·m {250kgf·cm, 18lbf·ft} 9069B 28.5N·m {290kgf·cm, 21 lbf·ft}
9069A 28.5N·m {290kgf·cm, 21 lbf·ft} 9069C 28.5N·m {290kgf·cm, 21 lbf·ft}
18-171
［18. ENGINE］
18.9.6.2 Overhaul of valve system

1. Inspection of rocker arm oil clearance
1) Measure the outer diameter of the rocker shaft
using a micrometer.
22{0.8661} 21.92{0.8630}
2) Measure the rocker arm bushing inner diameter using a cylinder gauge.
22{0.8661} 20.08{0.7905}
3) Calculate the difference between the outer diameter of the rocker shaft and the inner diameter of the rocker
arm bushing. If it is beyond the standard value, replace the rocker shaft or the rocker arm bushing.
0.03 - 0.101
0.15{0.0059}
{0.0012 - 0.0039}
2. Removal of valve spring Example

1) Compress the valve spring using a special tool
and remove the valve spring retainer.
Special tool : S0947-01170 (09470–1170) Valve
spring press
2) Remove the intake and exhaust valves.
• Attach a tag with the applicable cylinder number to the valve so that combinations of the valve and the cylinder
head may not be mixed.
18-172
［18. ENGINE］
3. Replacement of valve stem seal Valve stem seal

Special tool
1) After removing the valve stem seal, assemble the Valve spring
valve spring lower seat. Apply engine oil to the lip lower seat
and the inner surface of the valve stem seal.
Strike the valve guide using a special tool until
the special tool comes in contact with the valve
spring lower sea
Special tool : S0947-22100 (09472–2100) Bar
18
Oil application
Rubber
• After assembly of the valve stem seal, make sure that there is no deformation, crack or inclination of the rubber.
2) After striking, check the height.
+0.1{0.0039in.}
22.9mm{0.9022in.}
-0.4{0.0157in.}
22.5 - 23.0
{0.8858 - 0.9055}
4. Installation of valve spring

1) Install the valve spring upper seat on the valve
spring.
2) Compress the valve spring using a special tool
and install the valve spring retainer.
Special tool : S0947-01170 (09470–1170) Valve
spring press
18-173
［18. ENGINE］
• Apply engine oil to the contact surface of each part before assembly.
• Be sure to assemble each valve at the original cylinder position.
• When the valve spring is compressed, avoid contact of the valve spring upper seat with the valve stem seal.
• Since the valve spring has equal spacing, vertical direction is not specified for assembly.
• Check for scratch on the valve stem seal when the valve is reused.
5. Inspection of valve spring Clearance A

1) Measure squareness of the valve spring using a
square or a thickness gauge. If it is beyond the
service limit (clearance A), replace the valve
spring.
Clearance A (mm{in.}) 2.0{0.0787}
2) Measure the free length of the valve spring using

a vernier calipers. If it is out of the service limit,
replace the valve spring.

Measuring item
(mm{in.}) (mm{in.})
Inner valve spring (64.6{2.5433}) 61.6{2.4252}
Outer valve
(75.7{2.9803}) 72.7{2.8622}
spring
The value in [ ] is the reference value.
6. Inspection of oil clearance between valve guide and

valve stem
1) Measure the outer diameter of the valve stem
using a micrometer.
Measuring item Standard value (mm{in.})
Intake valve stem 7{0.2756}
Exhaust valve stem 7{0.2756}
18-174
［18. ENGINE］
2) Measure the valve guide inner diameter using a

cylinder gauge.

18
Intake valve guide 7{0.2756}
Exhaust valve guide 7{0.2756}
3) Calculate the difference between the valve stem outer diameter and the valve guide inner diameter. If it is
beyond the standard value, replace the valve or the valve guide.
0.023 - 0.058
Intake valve oil clearance
{0.0009 - 0.0023}
Exhaust valve oil 0.050 - 0.083

clearance {0.0020 - 0.0033}
18-175
［18. ENGINE］
18.9.6.3 Adjustment of valve clearance

1. Precautions before adjustment
• Before adjustment, make sure that bolts of the cylinder head, rocker arm support, nozzle clamp, camshaft
housing and camshaft bearing cap are tightened to the specified torque.
2. Adjustment of valve clearance

1) Make sure that there is no dirt between the crosshead and the valve stem
2) Turn the crankshaft in the forward direction and adjust the cylinder to the compression top dead center.
• Make sure that there is a roller on the cam base circle.
3) Loosen the adjusting screw and the lock nut of Roller

Adjusting screw of rocker arm
the crosshead completely. Cam base
circle Lock nut
Adjusting screw of
crosshead
10 mm or more
Clearance
Close contact
Lock Nut
• Provide the adjusting screw protrusion of 10 mm or more from the top surface of the crosshead. If the adjusting
screw is not completely separated from the valve stem, correct adjustment is not allowed.
4) Insert a thickness gauge between the rocker arm Thickness gauge

Rocker arm
and the crosshead and adjust the clearance with
the adjusting screw of the rocker arm. Tighten the
lock nut.
Close contact
Crosshead
Standard value IN 0.30mm{0.0118 in.}

(cold engine) EX 0.45mm{0.0177 in.}
18-176
［18. ENGINE］
5) Loosen the adjusting screw of the crosshead with Start
Feel of thickness gauge

the thickness gauge inserted. Make sure that feel
on the thickness gauge is not lighter. (No move) Nut fixing position
(Appropriate
contact)
Feel remains the same.

Loosening of adjusting screw Large
18
• If it becomes lighter, make adjustments again from the beginning.
6) Tighten the adjusting screw of the crosshead until

the thickness gauge does not move.
Close contact
Close contact
7) While loosening the adjusting screw of the Start

Feel of thickness gauge
crosshead gradually, tighten the lock nut of the

crosshead at the position where feel on the
(No move) Nut fixing position
thickness gauge is appropriate.
(Appropriate
contact)
Feel remains the same.

Loosening of adjusting screw Large
• Do not over-loosen the adjusting screw. Over-loosening of the adjusting screw reproduces the original status.
Although feel on the thickness gauge is appropriate, there is clearance between the adjusting screw and the
valve of the crosshead. Correct adjustment is not allowed.
18-177
［18. ENGINE］
18.10 EXHAUST
18.10.1 Exhaust Manifold
17104 Gasket* 17141 Exhaust manifold
Tightening torque
9209A 53N·m {540kgf·cm, 401 lbf·ft}
18-178
［18. ENGINE］
18
17104A Gasket* 17148 Plate
18-179
［18. ENGINE］
1. Removal of exhaust manifold
1) Remove nuts and remove the exhaust manifold.
2. Replacement of stud bolt
1) Remove dirt (e.g. sealant) at the female thread of the cylinder head and clean the thread again with tap
(M10 x 1.5).
2) Use the Torx wrench to tighten a new stud bolt.
• Excessive tightening with over torque may cause crack in the cylinder head.
3. Installation of exhaust manifold

1) Assemble a new gasket.
Black side
• Since a gasket has front and back, install the black side on the exhaust manifold.
2) Tighten the mounting nut of the exhaust manifold When a new exhaust manifold is used
according to the order in the figure. 12 11 10 9 8 7 6 5
1 2 3 4
When exhaust manifold is reused
8 9 2 3 5 6 11 12
7 1 4 10
Spacer
• When nuts are tightened, prevent each spacer from riding on the counterbore area of the manifold flange.
• The tightening sequence of the exhaust manifold varies between use of a new part and reuse.
18-180
［18. ENGINE］
3) Tighten the same nuts again according to the order in the figure.
• Be sure to retighten it.
18
18-181
［18. ENGINE］
18.11 COOLING
18.11.1 Cooling System
18.11.1.1 Cooling system drawing
Reservoir
Water temperature
Thermostatcase Cylinder head
Air compressor
Radiator
Thermostat
Cylinder block
Turbo charger
Car
heater
Coolant pump Oil cooler
Drain cock
Drain cock
18-182
［18. ENGINE］
18
16100 Coolant pump assembly 16325 Gasket*
16173 Coolant pump pulley 16331 Thermostat case cover
16303 Thermostat case 16377 Fan spacer
16306 Cooling fan 9851A O-ring*
16323 Thermostat case cover
18-183
［18. ENGINE］
18.11.1.3 Replacement of thermostat case

1. Removal of thermostat case
1) Remove bolts and remove the thermostat case.
bolt2
2) Remove the O-ring from the groove on the
coolant pump.
bolt1
2. Installation of thermostat case Liquid gasket

1) Remove contamination on the joint between the Cylinder head
thermostat case and the cylinder head using a Opening
scraper.
2) Apply liquid gasket [Threebond TB1207B(black)
or equivalent] to the thermostat case as shown in
the figure.
3) Install the new O-ring on the groove of the

coolant pump.
bolt2
bolt1
4) Put the thermostat case mounting bolt through the thermostat case in advance.
5) Align the thermostat case at the mounting position and tighten mounting bolt 1 temporarily to the cylinder
head.
6) Tighten mounting bolt 2 temporarily to the coolant pump.
7) Tighten bolts in the order mounting bolt 1 to the cylinder head and mounting bolt 2 to the coolant pump.
18-184
［18. ENGINE］
18.11.1.4 Replacement of thermostat

1. Removal of the thermostat
Thermostat
1) Remove the bolts and remove the thermostat.
Gasket
Coolant pipe A
Thermostat case
18
2. Installing of the thermostat Thermostat
1) Replace the gasket with new ones, and install the
thermostat and the coolant pipe to the thermostat Gasket
case.
Coolant pipe A
Thermostat case
Flange
Thermostat
Gasket
• As a wrong gasket installation can cause water leakage, make sure during assembly that it is clamped to the
flange part of the thermostat.
TOP
Jiggle valve
• Install the thermostat with the jiggle valve at the top.
18-185
［18. ENGINE］
18.11.1.5 Inspection of thermostat

1. Individual inspection of thermostat Thermometer
1) Put the thermostat in water as shown in the figure Wire
and heat it.
Thermostat Valve lift

Heat source
• Support the thermostat in the center to prevent approach to the heat source.
• Stir the water well so that water temperature in the container may be uniform.
2) Measure the temperature (valve opening T1 : Valve opening temperature

(start of valve opening)
temperature) that opens the thermostat valve.
T2: Full open lift inspection temperature
10mm
{0.3937in.}
Valve lift
0°C{32°F} 10°C Temperature

T1°C{°F} T2°C{°F}
{50°F}
Thermostat valve opening

69 - 73
temperature standard value :
{156.2 - 163.4}
T1(℃{℉})
• The thermostat valve opening temperature (T1) is stamped on the thermostat seat.
3) Increase the water temperature to 85℃{185℉}

and measure the lift of the thermostat valve.
L1 At cold open
L2 :Temperature at (T2)°C{°F}
L : Valve lift
L
L 1
L 2
Thermostat valve full open lift

inspection temperature : Valve lift : L (mm{in.})
T2 (℃{℉})
85 {185} 10{0.3937} or more
4) Put the full open thermostat valve in water at normal temperature. Make sure that the thermostat valve
closes completely within 5 minutes.
5) If faulty item is found with the inspection above, replace the thermostat.
18-186
［18. ENGINE］
18.11.1.6 Replacement of coolant pump

1. Removal of coolant pump
1) Remove bolts and remove the coolant pump.
18
2. Installation of coolant pump
1) Remove contamination on the joint surface between the coolant pump and the cylinder block using a
scraper and degrease the surface.
2) Apply the liquid gasket [Threebond TB1207B Liquid gasket
(black) or equivalent] to the coolant pump as
• Apply the liquid gasket at the width of 2 to 3mm{0.0787 to 0.1181in.}.
• Fill the groove on the water pump flange with the liquid gasket.
3) Install the coolant pump to the dowel pin of the

cylinder block.
• When the coolant pump is installed using a guide bolt, displacement of the liquid gasket does not occur.
18-187
［18. ENGINE］
18.12 LUBRICATION
18.12.1 Oil Cooler, Oil Filter and Oil Pump
18.12.1.1 System drawing
Roller pin
Cam Roller
Adjusting Rocker
Valve Crosshead Rocker arm arm
screw shaft
Camshaft
Oil pan
Cam idle
gear shaft
Sub-idle
gear shaft
Turbocharger
Strainer
Oil pump Main

Oil cooler Oil filter oil hole
Piston pin Connecting Crankshaft

rod
Supply
pump
drive
Sub-idle gear shaft

(supply pump drive)
Piston cooling jet Sub-oil

(check valve) hole
Main idle
gear shaft
: Lubrication
: Return
18-188
［18. ENGINE］
18
15012 Oil pump cover assembly 15710 Oil cooler
15104 Oil strainer 9500-40400 Cotter pin*
15107 Driven gear 9851A O-ring*
15110 Oil pump assembly 9851B D-ring*
15119 Gasket* 15139 Seat2

15132 Relief valve spring 15139A Seat1
15135 Safety valve
Tightening torque
9068-08160 28.5 N·m {290 kgf·cm, 21lbf·ft} 9068-08750 24.5±4.9 N·m {250±50 kgf·cm, 18±41 lbf·ft}
9068-08250 31 N·m {320 kgf·cm, 23lbf·ft} 9068-08900 24.5±4.9 N·m {250±50 kgf·cm, 18±41 lbf·ft}
9068-08320 24.5±4.9 N·m {250±50 kgf·cm, 18±41 lbf·ft} 9068-58100 24.5±4.9 N·m {250±50 kgf·cm, 18±41 lbf·ft}
9068-08550 28.5 N·m {290 kgf·cm, 21 lbf·ft}
18-189
［18. ENGINE］
15662 Drain plug 9644A O-ring*
15675 Safety valve 9739A Elbow
15701 Oil cooler case 9851A O-ring*
15710 Oil cooler assembly 9851B O-ring*
15712 Oil cooler element 9851C O-ring*
15717 Gasket* 9851D O-ring*
15720 Oil cooler case assembly 9851E O-ring*
Tightening torque
15662 44.5±4.9 N·m {450±50 kgf·cm, 33±41 lbf·ft} 9201-10080 24.5±4.9 N·m {250±50 kgf·cm, 18±41 lbf·ft}
18-190
［18. ENGINE］
18.12.1.3 Replacement of oil cooler

1. Removal of oil cooler
1) Remove bolts and hose joint, and remove the oil
cooler.
18
2) If it is difficult to remove the oil cooler due to liquid
Figure is an
gasket sticking to the cylinder block, put a flat tip example of work.
screwdriver at the protrusion in the figure for
removal.
2. Installation of oil cooler D-Ring

Block
1) Assemble the new D-ring into the D-ring groove Oil cooler
of the oil cooler.
Flat area
• Face the D-ring flat area toward the oil cooler.
2) Remove contamination on the joint surface Liquid gasket

between the oil cooler and the cylinder block
using a scraper. Apply the liquid gasket
[Threebond TB1207B (black) or equivalent] to the
oil cooler as shown in the figure.
18-191
［18. ENGINE］
3) Unfasten the 2-4 bolts and mount guide bolts to

the oil cooler assembly to prevent dropping.
Guide bolts
Bolt Oil cooler
4) Insert the positioning stud into the screw hole of

the cylinder block and install the oil cooler.
5) After temporary tightening with bolts, remove the positioning stud and tighten bolts.
Tightening torque :
24.5±4.9 N·m {250±50 kgf·cm, 18±4 lbf·ft}
• Tighten together with the alternator ground.

• Be sure to connect the turbocharger lubricating oil hose.
6) Install the drain plug.

Tightening torque :
44.1±4.9 N·m {450±50 kgf·cm, 33±4 lbf·ft}
• If a new part is used, tighten it to 58.8±4.9N·m {600±50kgf·cm, 43±4lbf·ft} and loosen it.
• Then, tighten it again to the torque above.
18-192
［18. ENGINE］
18.12.1.4 Overhaul of oil cooler

1. Removal of oil cooler element
1) Remove nuts and remove the oil cooler element.
18
2. Inspection of oil cooler element
1) Wash water and oil channels with kerosene oil or washing fluid.
2) Check for crack or deformation on the stud bolt mounting area and element visually.
3) Blow air of approx. 0.5kgf/cm2 into the oil channel to check for leak from parts. If crack, leak or deformation
is found, replace it with a new part.
3. Disassembly of oil cooler case
• Disassembly immediately after stop of the engine may cause blowout of engine oil.
1) Remove valve spring plugs and safety valves using a hexagonal wrench.
2) Remove the oil pressure warning switch.
4. Inspection of safety valve wear and damage

1) If wear or damage is found, replace it.
5. Inspection of oil pressure warning switch

1) For inspection of oil pressure warning switch, refer to "Inspection of components"- "Electrical".
18-193
［18. ENGINE］
6. Assembly of oil cooler case

1) Install a new O-ring and install valve spring plugs
and safety valves using a hexagonal wrench.
Tightening torque :
24.5±4.9 N·m {250±50 kgf·cm, 18±4 lbf·ft} (M14,
M20)
29.4±4.9 N·m {300±50 kgf·cm, 22±4 lbf·ft} (M22)
34.3±4.9 N·m {350±50 kgf·cm, 25±4 lbf·ft} (M24)
2) Apply the liquid gasket [Threebond TB1211

(white) or equivalent] to the sealing surface of a
new soft washer.
3) Install the soft washer in (2) and the oil pressure warning switch.
7. Installation of oil cooler element
1) Assemble new gasket and new O-ring and
assemble the oil cooler element with nuts.
Tightening torque :
24.5±4.9 N·m {250±50 kgf·cm, 18±4 lbf·ft}
• In handling the oil cooler element, be careful not to give damage to it.
18-194
［18. ENGINE］
18.12.1.5 Replacement of oil pump

1. Removal of oil pump
1) Dismount the engine from the machine.
2) Remove the flywheel.
3) Remove the flywheel housing.
4) Remove the timing gear.
5) Remove the oil pump.
2. Installation of oil pump
1) Apply engine oil to the pump case and the 18
bearing (shaded area) of the cylinder block.
Application of engine oil

(Shaded area)
• Without application of engine oil, poor oil suction may occur at the initial start, resulting in seizure or abnormal
wear.
2) To prevent bolt hole offset of the new gasket,

apply engine oil to the cylinder block in advance
and place and fix the gasket.
Gasket
Oil pump
• Assembly with offset gasket may cause faulty sealing. Oil in the oil pump may be completely discharged when
the engine stops. Faulty sealing may cause insufficient suction of oil at initial revolution of engine restart,
resulting in seizure or abnormal wear.
3) Tighten the oil pump according to the order in the figure.

Tightening torque : 28.5 N·m {290 kgf·cm, 21 lbf·ft}
18-195
［18. ENGINE］
• If the tightening order is not observed, the oil pump may be damaged.
• After tightening, make sure that the gear can be turned with hand.
18-196
［18. ENGINE］
18.12.1.6 Overhaul of oil pump

1. Remove the driven gear.
2. Remove the cotter pin and remove seat 2, seat 1,

18
relief valve spring and safety valve.
• When the cotter pin is removed, seat 2 and the relief valve spring may eject out.
3. Inspection of clearance between drive gear and

cylinder block
1) Measure the outer diameter of the drive gear and
the inner diameter of the pump chamber at
cylinder block.
Standard value
Measuring area
(mm{in.})
Outer diameter of drive gear 54 {2.1260}
Inner diameter of pump chamber

54 {2.1260}
at cylinder block
2) Calculate the difference between the outer

diameter of the drive gear and the inner diameter
of the pump chamber at the cylinder block. If it is
beyond the service limit, replace the oil pump
assembly.

(mm{in.}) (mm{in.})
0.100 - 0.202
0.30 {0.0118}
{0.0039 -0.0080} (reference)
18-197
［18. ENGINE］
4. End play inspection between drive gear and cylinder

block
1) Measure the drive gear width and the pump
chamber depth at the cylinder block using a
depth gauge.
Standard value
Measuring area
(mm{in.})
Width of drive gear 28.5 {1.1220}
Depth of pump chamber at

28.5 {1.1220}
cylinder block
2) Calculate the difference between the depth of the

drive gear and the pump chamber depth at the
cylinder block. If it is beyond the service limit,
replace the oil pump assembly.

(mm{in.}) (mm{in.})
0.047 - 0.137
0.15 {0.0059}
{0.00186 - 0.00539} (reference)
5. Inspection of clearance between outer diameter of

driven gear shaft and cylinder block hole diameter
1) Measure the outer diameter of the driven gear
shaft using a micrometer and measure the
cylinder block hole diameter using a cylinder
gauge.
Standard value
Measuring area
(mm{in.})
Outer diameter of driven gear

18 {0.7087}
shaft
Cylinder block hole diameter 18 {0.7087}
18-198
［18. ENGINE］

diameter of the driven gear and the cylinder block
hole diameter. If it is beyond the service limit,
Standard value
(mm{in.})
0.040 - 0.099
{0.0016 - 0.0039}
18
6. Inspection of clearance betweeen outer diameter of
driven gear shaft and inner diameter of driven gear
bushing
shaft using a micrometer and measure the inner
diameter of the driven gear bushing using a
cylinder gauge.
Standard value
Measuring area
(mm{in.})

18 {0.7087}
shaft
Cylinder block hole diameter 18 {0.7087}

diameter of the driven gear and the cylinder block
hole diameter. If it is beyond the service limit,
Standard value 0.030 - 0.075

(mm{in.}) {0.0012 - 0.0030}
7. Inspection of clearance betweeen outer diameter of

driven gear shaft and inner diameter of driven gear
bushing
shaft using a micrometer and measure the inner
diameter of the driven gear bushing using a
cylinder gauge.
18-199
［18. ENGINE］
Standard value
Measuring area
(mm{in.})

18 {0.7087}
shaft
Inner diameter of driven gear
18 {0.7087}
bushing

diameter of the driven gear shaft and the inner
diameter of the driven gear bushing. If it is
beyond the service limit, replace the oil pump
assembly or the driven gear bushing.

(mm{in.}) (mm{in.})
0.040 - 0.083
0.15 {0.0059}
{0.0016 - 0.0033}
8. Inspection of drive gear backlash

1) Fix the oil pump assembly with a vice.
2) Measure backlash between the drive gear and
the driven gear using a dial gauge. If it is beyond
the service limit, replace the oil pump assembly.

(mm{in.}) (mm{in.})
0.073 - 0.207
0.30 {0.0118}
{0.0029 - 0.0081}
9. Assembly of oil pump

1) Install the safety valve, relief valve, seat 1 and
seat 2 on the oil pump cover assembly with new
cotter pins.
2) Install the driven gear.
18-200
［18. ENGINE］
18.12.1.7 Replacement of oil strainer

1. Removal of oil strainer
1) Remove bolts and remove the oil strainer.
18
2. Installation of oil strainer
1) Replace the O-ring with new ones and install the oil strainer.
18-201
［18. ENGINE］
18.12.2 Oil Pan

12111 Oil pan assembly 12149 Drain plug
12151 Oil pan gasket* 9659A Gasket*
Tightening torque
12149 30 N·m {300 kgf·cm, 22 lbf·ft} 9068-08800 30N·m {300 kgf·cm, 22 lbf·ft}
18-202
［18. ENGINE］
1. Installation of oil pan Gasket
Cylinder block Reae end plate
1) Cut the gasket of the rear end plate to be flush to
the cylinder block lower surface using a scraper.
Flywheel housing
Scraper cutting
2) Make sure that there is no deformation,dirt or oil

Oil pan
18
on the joint surface between the cylinder block Liquid gasket apply position
and the oil pan. Apply liquid gasket [Threebond
TB1207D (silver), TB1217G (gray) or equivalent]
to the front rear end of the cylinder block lower
surface.
Cylinder block
Applying all around
the bolt mounting hole
3) Insert several stud bolts (70 mm{2.7559 in.} or

larger) for positioning into the cylinder block
screw hole.
Protrusion
Bolt tightening
attaching direction
Liquied gasket application position
Engine front side
4) Position the oil pan gasket protrusion at the intake side and the flywheel housing (printed seal surface at
cylinder block). Align the new oil pan gasket and oil pan to the cylinder block lower surface and tighten bolts
in the arrow order of the figure.
Tightening torque :
19.6 - 24.5 N·m {200 - 250 kgf·cm, 14 - 18 lbf·ft}
5) Remove positioning stud bolts and install the correct bolts.
6) Tighten bolts in the arrow order of the figure.
18-203
［18. ENGINE］
• Check if the washer is not riding on the flange.

• Make sure that the printed seal is not peeled or damaged before installation of the oil pan gasket.
18.12.2.3 Inspection of lubrication status

1. Inspection of valve system
• Perform inspection with the water temperature at 60℃{140℉}.
1) Remove the head cover.
• To prevent spread of engine oil, attach a jig which cuts a head cover in half. Cut it to the degree that the
camshaft is covered.
2) Adjust the engine revolution to the standard idling revolution [1,000/min{rpm}].

3) After start of the engine, make sure that oil is supplied to the areas below of all rocker arms within about 10
seconds.
• Roller and cam surface
• Cross head and spring upper seat surface through adjusting screw
• If time until lubrication is long or if lubrication is not performed,the oil pressure may be low or the oil channel may
be clogged. Seizure,abnormal wear or abnormal noise may occur due to insufficient lubrication.
18-204
［18. ENGINE］
18.13 STARTING AND CHARGING

18.13.1 Starter
18.13.1.1 Part layout (typical example)
18
28011 Clutch assembly 28138 Packing*
28100 Starter 28140 Brush holder assembly
28111 Bushing 28142 Brush
28111A Bushing 28142A Brush
28113 Lever assembly 28143 Spring
28115 Start drive housing 28150 Center bracket
28117 Packing* 28160 Armature assembly
28117A Packing* 28168 Retainer clip*
28118 Plate 28199 Dust protector
28118A Brake plate 28240 Start magnet switch
28118B Plate 28251 Pinion

28118C Sim 28252 Rear side bearing*
28118D Cover 28255 Shaft assembly
28120 Yoke assembly 28253 Planetary gear
28133 Commutator end frame 28253A Internal gear
18-205
［18. ENGINE］
Tightening torque
28112 3.6-4.9N·m {37-49kgf·cm, 3-4lbf·ft} 28112E 13.7-15.7N·m

{140-160kgf·cm, 10.2-11.5lbf·ft}
28112A 3.6-4.9N·m {37-49kgf·cm, 3-4lbf·ft}
18-206
［18. ENGINE］
18.13.1.2 Disassembly
• Fix the starter on the working table to ease accessibility.
1. Removal of lead wire M lead wire

1) Remove the cap of the M terminal. M terminal
2) Remove nuts and remove the M lead wire. 18
2. Removal of commutator end frame Through bolt

1) Loosen and remove two through bolts.
Commutator end
frame
2) Remove two set bolts and remove the

Set bolt
commutator end frame.
• Hold the M lead wire and remove the commutator end frame by lifting.
18-207
［18. ENGINE］
3. Removal of brush holder assembly

Brush holder
1) Lift the spring using a flat tip screwdriver or pliers. Assembly
Remove four brushes from the brush holder
assembly.
Spring
Brush
Brush lead
Clamp
• Do not cut the brush lead fixing clamp.
2) Remove the brush holder assembly from the armature assembly.

4. Removal of yoke assembly M lead wire
1) Remove the yoke assembly from the center Yoke assembly
bracket assembly.
Center bracket
assembly
• Do not hold the M lead wire and hold the yoke assembly outer diameter for removal.
5. Removal of packing Yoke assembly

1) Remove the packing from the centering parts at
both ends of the yoke assembly.
Packing Packing
18-208
［18. ENGINE］
• Damaged packing must not be resued. Replace it with a new part.
6. Removal of armature assembly

1) Remove the armature assembly by lifting. Armature
assembly
18
Center bracket
assembly
• When the armature assembly is removed, the washer at the end of the gear may be dropped and lost. Be careful
for handling.
7. Removal of rear bearing Rear bearing

1) Pull out the bearing of the armature assembly
using a puller or press.
Puller
• Removed bearing must not be reused. Replace it with a new one.
8. Removal of cover Packing Cover

1) Remove the cover from the center bracket
assembly.
2) Remove the packing.
18-209
［18. ENGINE］
9. Removal of planetary gear

1) Remove the planetary gear from the carrier pin.
Planetary gear
Carrier pin
• Make sure that the gear is not damaged or chipped.
10. Removal of internal gear

1) Remove the internal gear from the center
bracket.
Internal gear
Center bracket
11. Removal of shim washer

1) Remove the shim washer from the center
bracket.
Shim
12. Removal of pinion

1) Remove the retainer clip using a tool such as
snap ring pliers.
Retainer clip
Pinion stopper
Pinion
• Retainer clip must not be reused. Replace it with a new one.
18-210
［18. ENGINE］
• Push upward or pull out the chipped part of the clip mouth.
2) Remove the pinion stopper.

Pinion stopper
Pinion
18
3) Remove the pinion.
13. Removal of center bracket Center bracket

1) Remove two set bolts at the switch using a box
screwdriver or offset wrench.
2) Lift and remove the center bracket.
Clutch
assembly
14. Removal of lever

1) Hold the lever holder and press the entire lever to Plunger
the clutch. Remove the link with the plunger.
Holder
Lever assembly
2) Turn and pull out the lever assembly using the

clutch as the axis.
Lever assembly
18-211
［18. ENGINE］
15. Removal of brake plate

1) Hold the clutch case outer diameter and slide the
clutch assembly upward. Pinch the clip end fixing
the brake plate and remove it by bending.
2) Remove the brake plate.
Brake plate
16. Removal of clutch assembly

1) While pressing the clutch assembly to the center Clutch assembly
bracket assembly, offset the helical spline by one
tooth.
Pull out the clutch assembly upward from the Center bracket
assembly
offset position and remove it.
17. Removal of shaft assembly

Washer
1) Turn the center bracket assembly upside down.
Hold the carrier plate and pull out the shaft
assembly.
Shaft assembly
• Washers are available at the upper and lower parts of the carrier plate. Be careful for loss of the washers.
18. Removal of packing

1) Turn the center bracket upside down again and
remove the packing.
Packing
• Packing must not be reused.
18-212
［18. ENGINE］

1. Inspection of yoke assembly
1) Make sure that the coil lead wire has electric
continuity using a circuit tester.
2) Make sure that there is no discoloration at the
coil.
3) Measure the resistance between the coil lead

18
Tester rod
wire and the yoke with a circuit tester and check
insulation.
When the value is below the service limit, replace Feed coil
it.
Yoke assembly
Service limit 1kΩor less
• After cleaning and drying, take measurements.
4) Measure the brush length using vernier calipers.

When the value is below the service limit, replace
it.
18{0.7087} 13{0.5118} or less
2. Inspection of armature assembly

Piece of steel
1) Turn the armature assembly using a
commercially available growler tester and put a
piece of steel on the armature assembly. Make
sure that the steel piece is not vibrating on the
core circumference. Growler tester
18-213
［18. ENGINE］
2) Make sure that adjacent segments of the

commutator have electric continuity using a
circuit tester.
3) Make sure that there is no discoloration at the coil.

4) Measure the resistance between the commutator
and the core using a circuit tester and check
insulation.
When the value is below the service limit, replace Core
it. Commutator

1MΩ or more 1kΩ or less
5) Measure the commutator outer diameter using

vernier calipers.
it.
Commutator
Commutator outer diameter
36{1.4173} 34{1.3386} or less
• After removing roughness on the surface (after polishing), take measurements.
18-214
［18. ENGINE］
6) Measure the undercut depth between segments.

If the undercut depth is beyond the service limit,
repair it.
Undercut length:
0.5 to 0.8 mm
Segment {0.0197 - 0.0315}
Insulating material
Standard value (mm{in.}) Service limit (mm{in.}) 18

0.5 - 0.8
0.2{0.0079} or less
{0.0197 - 0.0315}
• In repair, do not leave insulation material at the end of the segment.
7) Measure the shaft outer diameter using a

micrometer. If it is beyond the service limit, A
replace the shaft.

B
Measuring Standard value Service limit

area (mm{in.}) (mm{in.})
11.98{0.4717}
Area A 12{0.4724}
or less
Area B 9{0.3543} 8.98{0.3535} or less
3. Inspection of brush holder assembly

1) Measure the resistance between the holder
(plus) and the plate using a circuit tester and
check insulation.
it.
Service limit 1kΩ or less
18-215
［18. ENGINE］
2) Measure the brush length using vernier calipers. Brush Spring

it.
Brush
18{0.7087} 13{0.5118} or less
3) Make sure that the spring has pressure.

4. Inspection of shaft assembly
1) Measure the outer diameter of the shaft using a
micrometer B A
If it is beyond the service limit, replace the shaft.
Measuring Standard value Service limit

area (mm{in.}) (mm{in.})
25.90{1.0197}
Area A 26{1.0236}
or less
12.04{0.4740} or
Area B 12.1{0.4764}
less
5. Inspection of clutch assembly

1) Measure the outer diameter of the inner sleeve
using a micrometer.
If it is beyond the service limit, replace the clutch
assembly.
25{0.9843} 24.90{0.9803} or less
6. Inspection of bearing
1) Measure the bearing metal inner diameter (1 in
the figure) of the pinion case using a cylinder
gauge. If it is beyond the service limit, replace the 1
bushing.
25{0.9843} 25.2{0.9921} or more
2) Measure the bearing metal inner diameter (2 in

the figure) of the center bracket using a cylinder
gauge. If it is beyond the service limit, replace the
center bracket.
18-216
［18. ENGINE］
26{1.0236} 26.2{1.0315}
3) Measure the bearing metal inner diameter (3 in 3 4

the figure) of the shaft assembly using a cylinder
gauge. If it is beyond the service limit, replace the
shaft assembly.
18
9{0.3543} 9.2{3.6220}
4) Measure the bearing housing inner diameter (4 in the figure) of the commutator end frame using a cylinder
gauge. If it is beyond the service limit, replace the commutator end frame.
28{1.1024} 28.1{1.1063} or more
7. Inspection of start magnet switch assembly C terminal

(resistance of P coil)
1) Measure the P coil resistance between the C M terminal
terminal and the M terminal using a circuit tester.

If it is beyond the service limit, replace the start
magnet switch.
Standard value (Ω) 0.12 - 0.14
8. Inspection of start magnet switch assembly

(resistance of H coil)
1) Measure the H coil resistance between the C C terminal
terminal and the body using a circuit tester.
If
it is beyond the service limit, replace the start
magnet switch.
Body
9. Inspection of start magnet switch assembly (electric

continuity inspection) M terminal
1) Check electric continuity between the B terminal
and the M terminal using a circuit tester, and
make sure that there is no electric continuity.
B terminal
18-217
［18. ENGINE］
2) Push the end of the start magnet switch

assembly (close the internal contact) and make
sure that there is electric continuity between the
B terminal and the M terminal using a circuit
tester.
18-218
［18. ENGINE］
18.13.1.4 Assembly
1. Installation of packing
1) Install a new packing on the center bracket
assembly.
Packing
18
2. Installation of shaft assembly
Washer
1) Turn the center bracket assembly upside down
and hold the carrier plate. Lubricate parts (refer
to the lubrication point drawing and the
lubrication list) and install the shaft assembly.
Shaft assembly
• Washers are available at the upper and lower parts of the carrier plate. Be careful for loss of the washers.
3. Installation of clutch assembly

1) Lubricate parts (refer to the lubrication point Clutch assembly
drawing and the lubrication list) and insert the
clutch assembly into the center bracket
assembly. Center bracket
assembly
4. Installation of brake plate

1) Lubricate parts (refer to the lubrication point
drawing and the lubrication list) and install the
brake plate.
Brake plate
5. Installation of lever
drawing and the lubrication list). Turn and install
the lever assembly using the clutch as the axis.
Lever assembly
18-219
［18. ENGINE］
6. Installation of pinion case Center bracket
1) Install two set bolts at the switch using a box

screwdriver or offset wrench.
Tightening torque :
3.6 - 4.9 N·m {37 - 49 kgf·cm, 3 - 4 lbf·ft} Clutch
assembly
7. Installation of pinion
Pinion stopper
Pinion
pinion and the pinion stopper.
2) Install the retainer clip using a tool such as snap

ring pliers.
Retainer clip
Pinion stopper
Pinion
8. Installation of shim washer

Shim
shim washer on the center bracket.
9. Removal of internal gear

internal gear on the center bracket.
Internal gear
Center bracket
10. Installation of planetary gear

Planetary gear
planetary gear on the carrier pin.
Carrier pin
18-220
［18. ENGINE］
11. Installation of cover Packing Cover
1) Install a new packing.

2) Install the cover on the center bracket assembly.
12. Installation of rear bearing

1) Install the bearing on the armature assembly using a press.
18
• When the bearing is removed, replace it with a new one.
13. Installation of armature assembly

1) Install the armature assembly. Armature
assembly
Center bracket
assembly
• When the armature assembly is installed, the washer at the end of the gear may be dropped and lost. Be careful
for handling.
14. Installation of packing Yoke assembly

1) Install a new packing on the centering location at
both ends of the yoke assembly.
Packing Packing
18-221
［18. ENGINE］
15. Installation of yoke assembly M lead wire

Yoke assembly
1) Install the yoke assembly on the center bracket
assembly.
Center bracket
assembly
16. Installation of brush holder assembly

Brush holder
1) Lift the spring using a flat tip screwdriver, long- Assembly
nose pliers or pliers. Install four brushes on the
brush holder assembly.
Spring
Brush
Brush lead
Clamp
17. Installation of commutator end frame Through bolt

1) Tighten the through bolt of the commutator end
frame.
Tightening torque :
13.7 - 15.7 N·m {140 - 160 kgf·cm, 10.2 - 11.5
lbf·ft}
Commutator end
frame
2) Tighten two set bolts.

Set bolt
Tightening torque :
3.6 - 4.9 N·m {37 - 49 kgf·cm, 3 - 4 lbf·ft}
• Hold the M lead wire and remove the commutator end frame by lifting.
18-222
［18. ENGINE］
18. Installation of lead wire M lead wire
1) Install the M lead wire. M terminal
19. Lubrication
Refer to the following figure and table for lubricant to be applied. 18
• There shall be no lubricant on the commutator surface, brush and contact.
18-223
［18. ENGINE］
Table of lubricant
Lubricant
Code Lubricating point Lubricant used Amount (g{oz}) Remark
manufacturer
Pinion case metal and 0.8 - 1.5
1 Multemp AC-N Kyodo Yushi
grease reservoir {0.03 - 0.05}
Bracket center metal and 0.5 - 1.5

grease reservoir {0.03 - 0.05}
0.2 - 0.5 Applied to both sides

3 Shim washer Multemp AC-N Kyodo Yushi
{0.01 - 0.02} of washer.
0.5 - 1
4 Armature front metal Multemp AC-N Kyodo Yushi
{0.02 - 0.04}
0.2 - 0.5 Applied to both sides

5 Shim washer Multemp AC-N Kyodo Yushi
{0.01 - 0.02} of washer.
Internal gear
7 -11
6 Armature gear Multemp AC-N Kyodo Yushi
{0.25 - 0.39}
Planetary gear
Pinion straight 0.5 - 1

Spline {0.02 - 0.04}
0.3 - 0.6
8 Inner sleeve metal Multemp AC-N Kyodo Yushi
{0.01 - 0.02}
0.5 - 1
9 Helical spline Multemp AC-N Kyodo Yushi
{0.02 - 0.04}
1-2 Nippon Oil

10 Clutch case lever shifter Pyroknock No.2
{0.04 - 0.07} Corporation
Bracket rear bearing 0.2 - 0.5 Nippon Oil

11 Pyroknock No.2
housing {0.01 - 0.02} Corporation
1-2
12 Planetary gear metal Multemp AC-N Kyodo Yushi
{0.04 - 0.07}
0.4 - 0.8
13 Lever holder Multemp AC-N Kyodo Yushi
{0.01 - 0.03}
Assemble the roller

after application of
0.2 - 0.5 Nippon Oil
14 Lever roller rod Pyroknock No.2 grease to prevent fall
{0.01 - 0.02} Corporation
of the roller in
assembly.
18-224
［18. ENGINE］
18.13.2 Alternator (50A)

18.13.2.1 Part layout (typical example of 50A)
A
B
D 18
F
E
G
27017 Feed coil 27383A Insulator

27040 Alternator 27389 Insulator
27310 Drive end frame assembly 27392 Cover
27311 Drive end frame 27410 Stator coil
27312 Bearing cover 27412 Collar
27330 Rotor assembly 27431 Pulley
27350 End frame assembly 27441 Fan
27353 Rectifier minus 27445A Coupler holder
27356 Rectifier plus 27700 Regulator
27359 End frame 28252 Front bearing
27383 Insulator 28252A Rear bearing
18-225
［18. ENGINE］
Tightening torque
A 3.2-4.4N·m E 3.9-4.9N·m
{33-44kgf·cm, 2.4-3.2lbf·ft} {40-49kgf·cm, 2.9-3.6lbf·ft}
B 4.9-5.9N·m F 7.8-9.8N·m {80-99kgf·cm, 6-7lbf·ft}

{50-60kgf·cm, 3.7-4.3lbf·ft}
C 127-157N·m G 3.3-4.4N·m {34-44kgf·cm, 2-3lbf·ft}

{1,300-1,600kgf·cm, 94-116lbf·ft}
D 1.9-2.5N·m {20-25kgf·cm, 1-2lbf·ft}
18.13.2.2 Circuit drawing (50A)
Capacitor
Diode
Fuse Load
L Lamp 1.4 to 3W
R
Starter switch
P
Feed coil
N
Regulator
Battery 24V
Stator coil
Alternator
18-226
［18. ENGINE］
18.13.2.3 Disassembly
• Place a rubber mat and perform work on the mat.
1. Disconnection of front from rear

1) Remove fixing bolts and remove the cover.
18
• Press the tabs of the cover for removal. Be careful not to break the tab with excessive force.
2) Remove bolts with a screwdriver and remove the

coupler holder.
3) Remove three through bolts and disconnect the

front from the rear.
2. Disassembly of front
1) Remove nuts and remove the pulley, fan and
collar.
18-227
［18. ENGINE］
• Tie around a general V -belt in the pulley groove and fix the pulley with a vice.
2) Remove the rotor assembly using a press.
• Do not damage the end of the thread.

• Support the rotor assembly to prevent fall of the rotor assembly.
3) Remove three bolts with a screwdriver and

remove the bearing cover.
4) Remove the ball bearing from the front bracket

using a press or jig C. Jig C
• Place jig C at the inner race of the front bearing.

• Removed bearing must not be reused.
18-228
［18. ENGINE］
3. Disassembly of rear
1) Remove solder of the lead wire connecting the
stator coil and the diode using a soldering bit and
suction line or a solder suction device
18
• At solder of the stator coil and the diode, the end of the diode is clamped. Do not damage the diode by prying.
Deformed diode must not be reused.
• Perform soldering in a short time (within 5 seconds).
2) Remove the stator coil from the rear bracket.
• Do not damage the stator coil.
3) Remove solder of the lead wire connecting the

regulator and the field coil using a soldering bit.
Terminal
Lead wire
Regulator assembly
18-229
［18. ENGINE］
• Remove the lead wire of the field coil by raising the terminal of the regulator.
4) Loosen the nut at the B terminal.
• Loosen the nut to some extent and do not remove it from the B terminal.
5) Remove five bolts using a screwdriver and

remove the heat sink assembly (plus), heat sink
assembly (minus) and regulator all together.
• Screw lock is used. Since torque is high until bolt is removed, be careful not to damage the groove of the bolt
head.
• When the rear bracket is reused, clean the screw hole.
6) Remove the capacitor

7) Remove three bolts with a screwdriver and
remove the field coil from the rear bracket.
18-230
［18. ENGINE］
8) Remove the roller bearing from the rear bracket

using a press, jig A and jig B.
18
18-231
［18. ENGINE］
1. Inspection of stator coil and field coil

1) Measure the resistance between U-V, V-W and
W-U terminals of the stator coil using a circuit
tester.
2) Measure the resistance between the stator coil

core and each terminal using a megger tester.
Standard value (MΩ) 1 or more
3) Measure the resistance of the field coil using a

circuit tester.
• Do not damage the circumferential surface of the coil.

• Damaged coil circumference must not be reused.
18-232
［18. ENGINE］
4) Measure the resistance between the core and the

coil using a megger tester.
Standard value (MΩ) 1 or more 18

2. Inspection of rotor assembly
1) Measure the outer diameter of the shaft at the
ball bearing insertion area of the rotor assembly
using a micrometer.
Standard value (mm{in.}) 25{0.9843}
Service limit (mm{in.}) 24.98{0.9835}
2) Measure the outer diameter of the shaft at the

roller bearing insertion area of the rotor assembly
using a micrometer.
Standard value (mm{in.}) 17{0.6693}
Service limit (mm{in.}) 16.98{0.6685}
3. Inspection of diode, capacitor and regulator

1) Measure the resistance of the holder between the
minus diode and the heat sink holder using a
circuit tester.
Standard value
Forward resistance value Approx. 10 Ω
Reverse resistance value Infinite
18-233
［18. ENGINE］
2) Measure the resistance between the capacitor

terminal and the body using a circuit tester. Make
sure that it indicates 800 kΩ and then
immediately indicates infinite value.
3) Inspection of regulator
Measure the resistance between regulator
terminals F and E using a circuit tester.
Standard value
Forward resistance value Approx. 10 Ω
Reverse resistance value Infinite
18-234
［18. ENGINE］
18.13.2.5 Assembly
1. Assembly of front
1) Press fit a new ball bearing into the front bracket Jig C
using a press and jig C.
18
• Place jig C at the outer race of the ball bearing.

2) Install the bearing cover with bolts.

Tightening torque :
1.9 - 2.5 N·m {20 - 25 kgf·cm, 1 - 2 lbf·ft}
3) Install the rotor assembly using a press.

0
0 0
0 0
• Be sure to support the inner race of the bearing for press fit of the rotor.
• Do not damage the shaft.
18-235
［18. ENGINE］
4) Install the space collar, fan and pulley on the

shaft of the rotor assembly.
Tightening torque :
127 - 157 N·m {1,300 - 1,600 kgf·cm, 94 - 116
lbf·ft}
• Tie around a general V -belt in the pulley groove and fix the pulley with a vice.
2. Assembly of rear
1) Press fit a new roller bearing into the rear bracket Jig A
using a press, jig A and jig B.
Roller bearing
Jig B
• Press fit until jig A comes in contact with the rear bracket.
2) Install the field coil on the rear bracket.

Tightening torque :
3.9 - 4.9 N·m {40 - 49 kgf·cm, 2.9 - 3.6 lbf·ft}
• Tighten bolts finally after temporary tightening. Tighten them evenly.
3) Assemble the stator coil on the rear bracket

temporarily.
18-236
［18. ENGINE］
• Do not damage the stator coil.
4) Install parts referring to the part layout.

Tightening torque :
1.9 - 2.5 N·m {20 - 25 kgf·cm, 1 - 2 lbf·ft}
18
• Apply screw lock to the ends of the heat sink mounting bolt and the regulator mounting bolt.
5) Solder the lead wire connecting the regulator and

the field coil, and connecting the stator coil and
the diode using a soldering bit.
Terminal
Lead wire
Regulator assembly
• Perform soldering after tightening of bolts.

• Bend and fix the regulator terminal before soldering the lead wire of the field coil.
• Clamp the end of the diode of the stator coil before soldering.
6) Tighten the nut inside the B terminal.

Tightening torque :
4.9 - 5.9 N·m {50 - 60 kgf·cm, 3.6 - 4.3 lbf·ft}
18-237
［18. ENGINE］
• After installation of the alternator, connect the wire and tighten the outside nut
3. Joint of front and rear

1) Joint the front with the rear with bolts.
Tightening torque :
7.8 - 9.8 N·m {80 - 99 kgf·cm, 6 - 7 lbf·ft}
• Tighten bolts evenly.
2) Install the coupler holder and tighten bolts.

Tightening torque :
1.9 - 2.5 N·m {20 - 25 kgf·cm, 1 - 2 lbf·ft}
3) Align the tab and install the cover. Fix it with

bolts.
Tightening torque :
3.3 - 4.4 N·m {34 - 44 kgf·cm, 2 - 3 lbf·ft}
• Do not hit the cover because the tab may be broken.
18-238
［18. ENGINE］
18.13.2.6 Inspection after assembly
1. Inspection of rotation
1) Turn the pulley with hand to check if there is no
interference with internal parts and if rotation is
smooth.
18
2) Measure the resistance between B and E

terminals and between P and E terminals using a
circuit tester. If it is beyond the standard value (e.
g. 0 Ω), disassemble it again and reassemble the
unit correctly.
Circuit tester lead

Standard value
(+) (–)
B E Approx. 20Ω
E B Infinite
P E Approx. 7Ω
E P Infinite
R L
N P
E
Connector details
18-239
［18. ENGINE］
18.14 TURBOCHARGER
18.14.1 Turbocharger Assembly
15407 Oil inlet pipe 24109 Gasket*
16691 Coolant pipe 24109A Gasket*
16691A Coolant pipe 24135 Gasket*

17291 Exhaust manifold connector 24135A Gasket*
24100 Turbocharger assembly 9654-12100 Gasket*
24107 Oil outlet pipe 9659A Gasket*
Tightening torque
9209A 56N·m {570kgf·cm, 41lbf·ft}
18-240
［18. ENGINE］
18.14.1.2 Inspection
1. Inspection of turbine shaft axial play
1) Inspect play of the turbine shaft at the exhaust
side using a special tool.
Special tool : S0944-41800 (09444-1800) End
play gauge
2) If the measurement value is beyond the standard
value, ask the manufacturer to overhaul the unit.
Standard value Axial direction 0.1 {0.0039}

18
(mm{in.}) Radial direction 1.0 {0.0393}
• Since the assembly is replaced, disassembly and inspection are not allowed.
18-241
［18. ENGINE］
Removal
1. Remove the boost pipe and U-turn pipe.
2. Disconnect all pipes connected to the turbocharger.
• Loosen union bolt of the coolant pipe, drain coolant and remove the pipe. Disconnect the lower pipe similarly and
remove the oil pipe.
• After removing pipes, be sure to seal oil holes, water holes and cylinder block holes to prevent entry of dirt.
3. Remove the bolts fixing the exhaust pipe and the turbocharger and remove the turbocharger.
• After removal, seal holes both at the exhaust manifold and the exhaust pipe to prevent entry of foreign matter.
• If a stud bolt is sticking, remove and replace the stud bolt using a commercially available stud remover.
Installation
1. Install the turbocharger in the reverse order of disassembly. When the turbocharger is installed on the engine
or after installation, observe the following precautions for work. Pay special attention to entry of foreign matter
inside the turbocharger.
Tightening torque :
(Turbocharger to exhaust manifold)
2. Lubrication and cooling system
1) Before installation on the engine, pour new engine oil from the oil inlet and turn the turbocharger with hand
to lubricate the journal bearing and the thrust bearing.
2) Clean the oil pipe, oil hose, coolant pipe and hose. Check for pipe deformation, hose crack or dirt or foreign
matter in the pipe or hose.
3) Do not use sealant at the installation surface of the oil pipe and the coolant pipe or joint between the coolant
hose and the coolant pipe to prevent failures such as damage due to clogging or loosening of tightened
areas.
4) Be sure to use new soft washers, O-rings and gaskets.
5) Be sure to install the oil pipe, oil hose, coolant pipe and coolant hose correctly to prevent leak of oil or water
from connections.
3. Air intake system
1) Make sure that there is no dirt or foreign matter in the air intake system.
2) Do not use sealant at the inlet/outlet of air to prevent failures such as damage due to clogging or loosening
of tightened areas.
3) Be sure to install the air feed pipe and the air hose correctly to prevent air leak from connections.
4. Exhaust system
1) Make sure that there is no dirt or foreign matter in the exhaust piping system.
2) Since heat resistant steel is used for bolts and nuts, do not mix them with normal bolts for installation.
18-242
［18. ENGINE］
18.15 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS

18.15.1 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
18.15.1.1 Engine mechanical
Status Cause Action
Engine overheat (coolant) Insufficient coolant Replenish coolant
Faulty thermostat Replace thermostat
Water leak from cooling system Correction

18
Faulty coolant pump Repair or replace
Faulty head gasket Replace head gasket
Engine overheat Clogging of radiator Cleaning of radiator

(radiator)
Corrosion of cooling system Clean and repair cooling system
Clogging of radiator core front part Clean radiator
Faulty radiator cap Replace radiator cap
Engine overheat Non-synchronous injection timing Injection timing inspection

(compression pressure)
Faulty fuel injection pressure Injection timing inspection
Faulty injector Replace injector
Engine overheat Deterioration of engine oil Replace engine oil

(lubrication unit)
Insufficient engine oil Replenish engine oil
Large engine oil consumption Wear of piston ring and cylinder liner Replace piston ring and cylinder liner
(piston, cylinder liner and piston ring)
Damage to piston ring Replace piston ring and cylinder liner
Faulty fixing of piston ring Replace piston ring and cylinder liner
Faulty assembly of piston ring Replace piston ring and cylinder liner
Faulty engine oil Replace engine oil
Faulty piston ring joint Reassemble piston ring
Large engine oil consumption Wear of valve stem Replace valve and valve guide
(valve and valve guide)
Wear of valve guide Replace valve guide
Faulty assembly of valve stem seal Replace stem seal
Excessive oil lubrication to rocker arm Inspection of clearance between rocker

arm and rocker arm shaft
Large engine oil consumption (others) Faulty oil level gauge Replace with correct level gauge
Excessive filling of engine oil Fill with appropriate amount of oil.
Leak of engine oil Repair or replace the part of oil leak.
Piston seizure Sudden stop of engine Perform warm-up before stop of engine
(in operation)
Piston seizure Insufficient engine oil Replenish engine oil

(lubrication unit
Deterioration of engine oil Replace engine oil
Incorrect engine oil Replace with correct engine oil.
Low oil pressure Inspection of lubrication unit
18-243
［18. ENGINE］
Status Cause Action

Piston seizure Abnormal combustion Refer to overheat section.
Piston seizure Cooling unit Refer to overheat section.
Insufficient engine power Clogging of air cleaner element Clean or replace air cleaner element
(air cleaner)
Insufficient engine power Overheat Refer to overheat section.
Insufficient engine power Faulty injection of injector Replace injector

(fuel unit)
Faulty injector due to deposit of carbon Replace injector
Entry of air into fuel system Air bleeding of fuel system
Faulty fuel filter Replace element
Insufficient engine power Abnormal compression pressure Refer to overheat section.
Insufficient engine power Piston, cylinder liner and piston ring Refer to Large engine oil consumption.
Faulty engine start Faulty battery Check battery

(electric unit)
Faulty wiring of starter Replace starter wiring
Loose battery cable Tighten battery terminal connection or

replace cable
Faulty operation of starter Replace starter assembly
Faulty start assist unit Replace start assist unit
Faulty engine start Clogging of air cleaner element Clean or replace air cleaner element
(air cleaner)
Faulty engine start Insufficient fuel Replenish fuel and bleed air from fuel
(fuel unit) system
Clogging of fuel system Clean fuel system.
Air intake from connection of fuel system Tighten connections
Clogging of fuel filter Replace fuel filter
Loose connection of injection pipe Tighten connecting nut of injection pump
Faulty engine start Injector seizure Replace injector

(injector)
Faulty engine start Excessive viscosity of engine oil Replace with engine oil with correct
(lubrication unit) viscosity
Faulty engine start (others) Piston seizure Replace piston, piston ring and cylinder
liner
Bearing seizure Replace bearing and crankshaft
Low compression pressure Overhaul engine
Damage to ring gear Replace ring gear and replace starter

pinion gear.
Faulty idling (injector) Faulty injection pressure Injection pressure inspection
Faulty injection status Adjust or replace injector.
Faulty idling (nozzle) Faulty injection pressure Injection pressure inspection
Faulty spray status Adjust or replace nozzle
Carbon deposit at nozzle end Remove carbon
Seizure of needle valve Replace nozzle
18-244
［18. ENGINE］
Status Cause Action

Faulty idling (engine) Faulty valve clearance Adjustment of valve clearance
Faulty contact of valve seat Adjust or replace valve and valve seat.
Low coolant temperature Perform warm-up.
Large variation of compression pressure Overhaul engine

between cylinders Training of engine difference not
performed after exchange of the engine
ECU
Training of engine difference not Perform training of engine difference
performed after exchange of the engine after exchange of the engine ECU 18
ECU
Gas leak (head gasket) Reuse Replace gasket.
Damage Replace gasket.
Replace gasket. Replace gasket.
Gas leak (head bolt) Loose head bolt Tighten bolt.
Incorrect tightening sequence or Tighten bolt to correct torque according

incorrect tightening torque to the correct tightening sequence.
Extension of head bolt Replace bolt.
Gas leak (cylinder block) Crack Replace cylinder block.
Distortion of cylinder block upper Repair or replace cylinder block.

surface
Depression of cylinder liner insertion Replace cylinder liner or block.
(insufficient protrusion of cylinder liner)
Gas leak (cylinder head) Crack of cylinder head Replace cylinder head.
Distortion of cylinder head lower surface Repair or replace cylinder head.
Gas leak (cylinder liner Crack of cylinder liner Replace cylinder liner.
Corrosion of cylinder liner Replace cylinder liner.
Insufficient protrusion of cylinder liner Replace cylinder liner or block.
Gas leak (others Incorrect injection timing Injection timing inspection
18-245
［18. ENGINE］
18.15.1.2 Alternator
Status Cause Action
Lamp is ON.→Charge current does not Faulty regulator (open PTr) Replace regulator.
run (alternator).
Faulty stator coil (disconnection, rare Replace stator coil.
shorting)
Fault feed coil (disconnection, rare Replace feed coil.

shorting)
Faulty diode (open, shorting) Replace rectifier.
Disconnection or poor contact of lead Repair or replace lead wire.

wire (plate, support, etc.)
Lamp is ON.→Charge current does not Disconnection of wire (fuse) Replace wire (fuse).
run (wiring).
Lamp is ON.→Voltmeter indicates 29V Faulty regulator (shorting of PTr) Replace regulator.
or more (alternator).
Faulty tightening of voltage detection Repair, replace voltage detection circuit
circuit (e.g. support) or replace regulator.
Lamp is ON.→Charge current is Faulty regulator (open Tr) Replace regulator.

correctly running (alternator).
Lamp is OFF.→Charge current is Faulty stator coil (disconnection of 1 Replace stator coil.
always limited.→Battery goes flat phase, rare shorting)
(alternator).
Faulty diode (open, shorting) Replace rectifier.
Disconnection or poor contact of lead Repair or replace lead wire.

wire (plate, support, etc.)
Lamp is OFF.→Charge current is Operation load is large (Load balance is Reduce load
always limited.→Battery goes flat poor).
(operation load).
Lamp is OFF.→Charge current is Faulty regulator (shorting of PTr) Replace regulator.

always large.→Battery fluid runs short
Faulty tightening of voltage detection Repair or replace voltage detection
in a short period of time (alternator).
circuit (e.g. support) circuit.
Lamp is OFF.→Charge current is Battery is close to the service life. Replace battery.
always large.→Battery fluid runs short
in a short period of time (battery).
Others→Abnormal noise Faulty stator coil (rare shorting, Replace stator coil.
(alternator) grounding)
Contact of inner surface (faulty bearing, Repair or replace bearing.

wear of bracket)
Others→Abnormal noise (V belt) Faulty tension of V belt (belt slip) Correction
18-246
［18. ENGINE］
18.15.1.3 Starter
Status Cause Action
Starter does not turn. Turning is low. Faulty connection of starter key Repair connecting area.
Flat battery Charge or replace.
Disconnection, loosening or corrosion of After cleaning, tighten.

battery terminal
Grounding wire is disconnected. Be sure to connect it.
Use of incorrect engine oil Replace with correct oil.
Faulty contact of start magnet switch Replace start magnet switch assembly 18
assembly.
Faulty contact or failure of starter relay Replace starter relay.
Wear of starter brush Replace brush
Seizure of commutator Repair commutator.
Wear of commutator Undercut

Shorting of armature Replace armature assembly
Insufficient tension of brush spring Replace brush spring.
Faulty operation of clutch Clean or replace.
18-247
［18. ENGINE］
18.15.1.4 Turbocharger
Status Cause Action
Exhaust smoke is black (insufficient Clogging of air cleaner element Clean or replace air cleaner element.
intake air).
Air intake inlet is closed. Recover normal status.
Leak from connection of air intake Check and repair.
system
Revolution of blower impeller and Disassembly and repair.

turbine shaft is heavy
Exhaust smoke is black Oil impurities are deposited at the Replace engine oil and disassemble the
(Turbocharger is not operating). sealing part of the turbine and revolution turbocharger for cleaning.
of the turbine shaft is heavy.
Seizure of bearing Replace turbocharger.
Seizure of bearing (insufficient Check the oil system of the engine and
lubrication or clogging of oil pipe) repair faulty areas. Also, replace engine
oil.
Seizure of bearing (Oil temperature is Check the oil system of the engine and
too high.) repair faulty areas. Also, replace engine
oil.
Seizure of bearing (Balance of revolving Replace or clean revolving part.
body is poor.)
Seizure of bearing (insufficient warm-up Observe the precautions strictly in the

or sudden stop from loaded operation: operation manual.
Unloaded operation)
Contact of or damage to turbine shaft Check and repair engine parts.

and blower impeller (excessive
operation)
Contact of or damage to turbine shaft Check and repair engine parts.

and blower impeller (excessive increase
of exhaust gas temperature)
Contact of or damage to turbine shaft Disassemble the engine to remove

and blower impeller (entry of foreign foreign matter completely. Check and
matter) repair the air cleaner and engine parts.
Contact of or damage to turbine shaft Replace turbocharger.

and blower impeller (wear of bearing)
Contact of or damage to turbine shaft Reassemble or replace.

and blower impeller (faulty assembly)
Exhaust smoke is black Exhaust gas is leaking before the Check and repair mounting area.
(due to exhaust gas resistance). turbocharger. Revolution is not
increased.
Since pipe of the exhaust system is Recover normal status.
deformed or clogged, revolution of the
turbocharger is not increased.
18-248
［18. ENGINE］
Status Cause Action

Exhaust smoke is white. Engine oil runs out to the blower or the Repair or replace pipe.
turbine due to clogging or deformation of
the oil return pipe.
Negative pressure at the back of the Check and replace the pipe. Replace or
blower impeller is increased and engine clean the air cleaner element.
oil runs out to the blower.
Seal ring is excessively worn or Disassemble and repair turbocharger.
damaged due to excessive wear of the
bearing.
Entry of water into the cylinder Exchange or repair of the parts where
18
water has entered
Oil is quickly reduced. Seal ring is excessively worn or Disassemble and repair turbocharger.
damaged due to excessive wear of the
bearing.
Engine oil enters into exhaust gas Check and service engine parts.
before the turbocharger.
Low engine output Gas leak from exhaust system parts Check and repair faulty areas.
Air leak from blower outlet Check and repair faulty areas.
Clogging of air cleaner element Clean or replace air cleaner element
Contamination of or damage to Replace turbocharger.

turbocharger
Acceleration (follow-up of Carbon deposit at the turbine (disc Replace engine oil and clean
turbocharger) is poor (slow). sealing area) makes revolution of the turbocharger.
turbine heavy.
Air and gas leak from intake/exhaust Check and repair faulty areas.
system parts
Combustion is faulty. Check the engine fuel system and

recover correct combustion status.
Abnormal noise If the gas passage is extremely Replace turbocharger.
narrowed due to clogging at the turbine
case nozzle or if acceleration is
performed, reverse flow (usually called
surging) occurs due to clogging of
blower discharge air.
Revolving part is in contact. Replace turbocharger.
Air and gas leak from intake/exhaust Check and repair faulty areas.
system parts
Vibration Loosening between turbocharger and Check the turbocharger mounting status
intake/exhaust pipe and between oil and repair faulty areas.
pipe and mounting area.
Failure of metal, contact between Replace turbocharger. Remove foreign

revolving part and peripheral parts, or matter completely, if any.
damage to the blower impeller of the
turbine rotor due to entry of foreign
matter is found.
Balance of revolving body is poor. Replace revolving body.
18-249
［18. ENGINE］
18.16 ENGINE DIAGNOSIS CODE

18.16.1 Engine ECU
18.16.1.1 Precautions
• Make sure that each connector is connected before inspection.

• Do not place a tester rod on the connecting surface of the connector. Otherwise, terminals are damaged or
short-circuited.
• Delete the past failure memory after recording. Perform failure diagnosis again to check current failure.
• After failure analysis, delete the past failure memory. If the past failure memory is not deleted, the failure
indicator lamp remains ON.
• All connector drawings are viewed from the connecting surface. Place the tester rod from the back.
18-250
［18. ENGINE］
18.16.1.2 System block diagram
ACT Relay
Fuse
Each Sensor Power
Main relay
Key switch signal Fuse
Starter signal
- + Battery
Accelerator signal 1,2
Diagnosis switch
Diagnosis tool 18
Accelerator sensor for operation
I/F
PC Diagnosis tool
OUTP UT
CAN 250K
Mechatro controller
Glow relay
INP UT
Injector drive signal

Supply pump
Supply pump control valve drive signal

Supply pump drive signal S/P
T
Othe rs
CAN communication 250K Outside send and

receive
communication
Engine speed main sensor

Fuel temperature sensor (Supply pump)
Engine speed sub sensor

Common rail pressure sensor1
Water temperature sensor
Engine ECU
Common rail T
G
N Engine
P
18-251
［18. ENGINE］
18.16.1.3 Inspection
Pre-inspection
1. If an error occurs on the system, The DTC code is indicated in the console panel.
2. Reading of failure code
1) Connection of Hino-DX
Remove the left side cover at the rear of the
driver's seat and connect the failure diagnosis Engine ECU
connector with a PC which installed Hino-DX
through the interface box.
Failure diagnosis
connector
Special tool : 09993-E9070 Hino-Bowie (Interface Failure diagnosis connector

box)
09042-1220 Connecting cable CD-ROM Hino-DX
Hino-Bowie
Connecting cable
Connect to the failure diagnosis
connector at the vehicle side.
Deletion method of past failure

1. To delete past failures of the engine ECU, use Hino-
DX on the PC. (Refer to "HinoDX operation
manual".)
18-252
［18. ENGINE］
18.16.1.4 Table of failure code
• For the system status by indication of DTC code in the table, refer to "1. Pre-inspection, Inspection, Engine
ECU".
"Reference : Inspection, Engine ECU, Engine diagnosis code"
[a] Failure diagnosis and

[b] Alarm display (alarm status)
DTC code Estimated failure cause 18
a. Engine does not start P0335 Engine speed main and sub sensor circuit malfunction
Engine stopped.
P0606 CPU malfunction (Hard detection)
b. DTC code indication.
P0629 Supply pump SCV malfunction
(Power source line short)
a. Low output P0200 ECU charge circuit high input

P0611 ECU charge circuit low input
a. Low output (LOW idle 800rpm fixing) P2120 Accelerator sensor 1 and 2 malfunction
a. Low output P0217 Engine overheat
P0335 Engine speed main and sub sensor circuit malfunction
a. Difficult to start engine. P0540 Preheat circuit malfunction

a. Low output P0234 Turbocharger over boost
P0088 Excessive common rail pressure
P0088 Excessive common rail pressure, supply pump excess

forced feed
P0108 Boost pressure sensor circuit high input
P0117 Coolant temperature sensor circuit low input
P0118 Coolant temperature sensor circuit high input
P0191 Common rail pressure sensor malfunction
P0192 Common rail pressure sensor circuit low input
P0193 Common rail pressure sensor circuit high input
P0201 Injector circuit malfunction -cylinder 1
a. Low output P0203 Injector circuit malfunction -cylinder 3

P0237 Boost pressure sensor circuit low input
P0605 Flash ROM error

P0607 Monitoring IC malfunction in CPU
P0628 Supply pump SCV malfunction

(Full discharge mode)
P1211 Injector common 1 ground short
P1212 Injector common 1 power source line short
P1212 Injector common 1 open circuit
18-253
［18. ENGINE］
[a] Failure diagnosis and

DTC code Estimated failure cause
[b] Alarm display (alarm status)
P1214 Injector common 2 ground short
P1215 Injector common 2 power source line short
P1215 Injector common 2 open circuit
P1601 Injector correction data conformity error
P2228 Atmospheric pressure sensor circuit low input
P2229 Atmospheric pressure sensor circuit high input
P2635 Supply pump SCV sticking
P2635 Supply pump malfunction
a. Other problems P0182 Fuel temperature sensor circuit low input

P0183 Fuel temperature sensor circuit high input
P0340 Engine speed sub sensor circuit malfunction
P0336 Abnormal engine main rotation sensor pulse count
P0341 Abnormal engine auxiliary rotation sensor pulse count
P0686 Main relay malfunction
P2122 Accelerator sensor circuit 1 low voltage
P2123 Accelerator sensor circuit 1 high voltage
P2127 Accelerator sensor circuit 2 low voltage
P2128 Accelerator sensor circuit 2 high voltage
P1133 Emergency accelerator sensor malfunction high input
a. Other problems P0219 Engine overrun

b. No indication
P0263 Cylinder 1 contribution/balance fault
P0617 Starter signal malfunction
P2635 Supply pump abnormal pressure record
U1001 Interruption of CAN communication (machine)
U110A Engine ECU CAN communication
18-254
［18. ENGINE］
18.16.1.5 Signal check harness

1. Signal check harness
• When measuring terminal of the engine ECU, connect the signal check harness to prevent damage to the
connector. Place the tester rod on the contact box of the signal check harness for measurement.
18
• Terminal numbers in the text and the illustrations correspond as shown below in the "Computer pin
arrangement".
ECU terminal name
[Example] For A8 terminal ECU terminal number

(contact box)
18-255
［18. ENGINE］
2. Connection of signal check harness

1) Set the starter key to "OFF" and disconnect the
connector from the engine ECU.
2) Connect the signal check harness to the the
engine ECU and the machine harness.
Special tool : Signal check harness (09049-1080)
Vehicle harness
Test lead
Signal check connector
18-256
［18. ENGINE］
18.16.1.6 Computer pin arrangement
18
18-257
［18. ENGINE］
18.16.1.7 Check the ECU power supply voltage
1 Measurement of voltage between terminals
1. Set the starter key to "OFF" and connect the signal check
harness.
2. Turn the starter key "ON" and measure voltage between

terminals A5, A6, A7 and terminals D1, E4, E5.
S ta n d a rd va lu e : 20 V o r m o re
NG • 0 V : Blown fuse, harness failure, ground failure,

etc.
• 20 V or less : Battery deterioration, ground
failure, etc.
OK
Normal
18-258
［18. ENGINE］
18.16.1.8 Check the ground
1 Measurement of resistance between terminals
D1 D E4 E E5 harness.
2. Disconnect the ECU side connector of the signal check

Frame harness and measure the resistance between terminals D1,
E4, E5 and the terminal (-) of the battery.
S ta n d a rd va lu e : 1 Ω o r le s s 18
NG Disconnection of ground harness, contact failure,
etc.
OK
Normal
18-259
［18. ENGINE］
18.16.1.9 Engine speed main sensor circuit malfunction (DTC code P0335)
B6 B B7 harness.

harness and measure the resistance between terminal B6 and
terminal B7.
S ta n d a rd va lu e : Ap p rox. 125.5 ± 17 Ω (20 °C{68 °F})
NG [3] Go to measurement of resistance between sensor

terminals.
OK
2 Check of diagnosis code
1. Connect the ECU side connector of the signal check harness.

After deleting the past failure, Start the engine and confirm that
no diagnostic code is put out.
S ta n d a rd : No d ia g n o s tic c o d e
NG Contact failure of ECU connector, ECU failure,

short-circuit of harness
OK
Normal
1. Disconnect the connector of the engine speed main sensor and

measure the resistance between No. 1 and No. 2 terminals at
the sensor.
S ta n d a rd va lu e : Ap p rox. 125.5 ± 17 Ω (20 °C{68 °F})
NG Failure of engine speed main sensor
OK
Harness disconnection or connector failure
18-260
［18. ENGINE］
18.16.1.10 Abnormal engine speed main sensor pulse count (DTC code P0336)
1 Measuring the input waveform on the engine ECU side
B6 B7
harness.
3. Measure the waveform between terminals B6 and B7 of the

signal check harness. 18
S ta n d a rd : 56 p u ls e s fro m m is s in g to o th to m is s in g
to o th
4. Stop the engine after measuring.
1 rotation
56 peaks (pulse)
0V
no pulse (No gear tooth)
NG Go to [2] Measuring the resistance between

terminals.
OK
Defective ECU, defective ECU connector
2 Measuring the resistance between terminals
1. Leave the connector of the engine speed main sensor

connected.
B7
2. Measure the resistance between terminal No. 1 of the engine

speed main sensor connector (unit harness side) and terminal
B7 of the signal check harness.
• Th e c o n n e c to r o f th e e n g in e s p e e d m a in
s e n s o r is s h o wn fro m th e e n g a g e m e n t s id e .
18-261
［18. ENGINE］
3. Measure the resistance between terminal No. 2 of the engine

B6
B6 of the signal check harness.
s e n s o r is s h own fro m th e e n g ag e m e n t s id e .
S ta n d a rd va lu e : 2Ω o r le s s
NG Defective harness
OK
Go to [3] Measuring the output waveform on the sensor side
3 Measuring the output waveform on the sensor side
1. Leave the connector of the engine speed main sensor

connected.
3. Measure the waveform between terminal No. 1 of the engine

No. 2.
s e n s o r is s h own fro m th e e n g ag e m e n t s id e .
S ta n d a rd : 56 p u ls e s fro m m is s in g to o th to m is s in g
to o th
1 rotation
56 peaks (pulse)
0V
no pulse (No gear tooth)
NG Defective engine speed main sensor or defective

flywheel pulser
OK
Defective connector contact
18-262
［18. ENGINE］
18.16.1.11 Engine speed sub sensor circuit malfunction (DTC code P0340)
1 Measurement of voltage between sensor terminals
harness.
GND +5V
2. Disconnect the connector of the engine speed sub sensor.
3. Set the starter key to "ON" and measure voltage between the
+5V terminal and the GND terminal of the engine speed sub 18
sensor connector (at machine harness side).
S ta n d a rd va lu e : 5.0 ± 0.5 V
NG [2] Go to measurement of voltage between terminals.
OK
[3] Go to measurement of voltage between terminals.
1. Measure voltage between terminal D32 and terminal D30 of

D the signal check harness.
D32 D30
S ta n d a rd va lu e : 5.0 ± 0.5V
NG Engine ECU failure, connector failure
OK
Harness failure
18-263
［18. ENGINE］
1. Set the starter key to "OFF" and connect the connector of the
D engine speed sub sensor.
D19
D30
2. Start the engine and keep idling status.
3. Measure voltage between terminal D19 and terminal D30 of

the signal check harness.
4. After measurement, stop the engine.
S ta n d a rd : P u ls e wave fo rm o f 0 ↔ 5V
NG [4] Go to measurement of resistance between

terminals.
OK
Engine ECU failure, ECU connector failure
1. Leave the connector of the engine speed sub sensor

SIG connected.
D19
2. Measure resistance between the No. 1 terminal at the machine
harness of the engine speed sub sensor connector and
terminal D19 of the signal check harness.
! CAUTION • Th e c o n n e c to r o f th e e n g in e s p e e d s u b
s e n s o r in th e fig u re is viewe d fro m th e fittin g
s u rfa c e .
S ta n d a rd va lu e : 2 Ω o r le s s
NG Harness failure
OK
Failure of sub-speed sensor
18-264
［18. ENGINE］
18.16.1.12 Abnormal engine speed sub sensor pulse count (DTC code P0341)
1 Measuring the voltage between the sensor terminals
harness.
GND +5V
2. Disconnect the connector of the engine speed sub sensor.
3. Set the starter key to "ON" and measure the voltage between
the +5 V terminal of the engine speed sub sensor connector 18
(unit harness side) and the GND terminal.
NG Go to [2] Resistance between terminals.
OK
Go to [3] Measuring the input waveform on the engine ECU side.
2 Measuring the resistance between terminals
SIG engine speed sub sensor.
D19
2. Measure the resistance between terminal SIG of the engine
speed sub sensor connector (unit harness side) and terminal
D19 of the signal check harness.
OK
Go to [3] Measuring the input waveform on the engine ECU side.
18-265
［18. ENGINE］
3 Measuring the input waveform on the engine ECU side
1. Set the starter key to "OFF" and connect the conector of the
engine speed sub sensor.
D19
D30
3. Measure the waveform between terminals D19 and D30 of the

signal check harness.
S ta n d a rd : Five p u ls e s fro m exc e s s to o th to exc e s s

to o th
5V
0V
NG Go to [4] Measuring the output waveform on the

sensor side.
OK
Defective engine ECU, defective ECU connector
18-266
［18. ENGINE］
4 Measuring the output waveform on the sensor side.
1. Leave the connector of the engine speed sub sensor

SIG GND
connected.
3. Measure the waveform between terminal SIG of the engine

speed sub sensor connector (unit harness side) and terminal
GND.
18
S ta n d a rd : Five p u ls e s fro m exc e s s to o th to exc e s s

to o th
5V
0V
NG Defective engine speed sub sensor or defective

pulser
OK
Defective connector contact
18-267
［18. ENGINE］
18.16.1.13 Engine speed main and sub sensor circuit malfunction (DTC code P0335)
1. Inspection item
1) Take actions of (DTC code P0335) and (DTC code P0340).
"Reference : Engine speed main sensor circuit malfunction (DTC code P0335), Engine ECU, Engine
diagnosis code"
"Reference : Engine speed sub sensor circuit malfunction (DTC code P0340), Engine ECU, Engine
diagnosis code"
18-268
［18. ENGINE］
18.16.1.14 Coolant temperature sensor malfunction (DTC code P0117, P0118)
DTC P0117 Coolant temperature sensor circuit low input
DTC P0118 Coolant temperature sensor circuit high input
D E harness.
E19 18
D34 2. Disconnect the ECU side connector of the signal check
harness and measure the resistance between terminal E19
and terminal D34.
S ta n d a rd va lu e (Me a s u re e ith e r o n e p o in t o f th e
fo llowin g .)
: 2.45 kΩ (Co o la n t te m p e ra tu re a t 20 °C{68 °F})
: 584 Ω (Co o la n t te m p e ra tu re a t 60 °C{140 °F})
NG [2] Go to measurement of resistance between sensor

terminals.
OK
Engine ECU failure, ECU connector failure, harness short-circuit
1. Disconnect the connector of the coolant temperature sensor

and measure the resistance between No. 1 and No. 2 terminals
at the sensor.
fo llowin g .)
NG Failure of coolant temperature sensor
OK
Harness disconnection, connector failure
18-269
［18. ENGINE］
18.16.1.15 Engine overheat (DTC code P0217)
1. Set the starter key to "OFF", disconnect the connector of the

coolant temperature sensor and measure the resistance
between No. 1 and No. 2 terminals at the sensor.
fo llo win g .)
: 2.45kΩ (Co o la n t te m p e ra tu re a t 20 °C{68 °F})
: 1.15kΩ (Co o la n t te m p e ra tu re a t 40 °C{104 °F})
: 584Ω (Co o la n t te m p e ra tu re a t 60 °C{140 °F})
: 318Ω (Co o la n t te m p e ra tu re a t 80 °C{176 °F})
NOTICE • Th is c o d e is d is p laye d wh e n th e c o o la n t
te m p e ra tu re s e n s o r is n o rm a l a n d th e c o o la n t
te m p e ra tu re is 108 °C{226 °F} o r m o re .
• Wh ile th is fa ilu re c o d e is d e te c te d , th e
m a xim u m in je c tio n vo lu m e is re s tric te d .
Wh e n th e c o o la n t te m p e ra tu re is 80 °C{176°F}
o r le s s , n o rm a l c o n tro l is re s u m e d .
NG Failure of coolant temperature sensor

Take actions of (DTC code P0117,P0118)
OK
Failure of engine cooling system
18-270
［18. ENGINE］
18.16.1.16 Engine overrun (DTC code P0219)

1. This failure code is displayed when the engine speed of 2,600 r/min or more is detected. While this failure code
is detected, fuel injection is stopped. When the engine speed is lower than 2,500 r/min., fuel injection is
resumed.
• The objective of this failure code is not to detect overrun due to failure of this system, but to memorize high
revolution of the engine.
• Engine speed may be incorrectly recognized with noise on the speed sensor signal due to harness failure or 18
modification, resulting in detection of overrun.
18-271
［18. ENGINE］
18.16.1.17 Fuel temperature sensor malfunction (DTC code P0182, P0183)
DTC P0182 Fuel temperature sensor circuit low input
DTC P0183 Fuel temperature sensor circuit high input
D34 E27 harness.

harness and measure the resistance between terminal E27
and terminal D34.
fo llowin g .)
Te m p e ra tu re in
Re s is ta n c e (kΩ )
m e a s u re m e n t (°C{°F})
-20 {-4} 15.04 (+01.29, -1.20)
20 {68} 2.45 (+0.14, -0.13)
80 {140} 0.318 (+0.008, -0.008)
110 {230} 0.1417 (+0.0018, -0.0018)

terminals.
OK
Engine ECU failure, ECU connector failure, harness short-circuit
18-272
［18. ENGINE］
2 Measurement of sensor resistance
1. Disconnect the connector of the fuel temperature sensor and

measure the resistance between No. 1 and No. 2 terminals at
the sensor.
fo llo win g .)
Te m p e ra tu re in
Re s is ta n c e (kΩ )
m e a s u re m e n t (°C{°F}) 18
-20 {-4} 15.04 (+01.29, -1.20)
20 {68} 2.45 (+0.14, -0.13)
80 {140} 0.318 (+0.008, -0.008)
110 {230} 0.1417 (+0.0018, -0.0018)
NG Failure of fuel temperature sensor
OK
Harness disconnection, connector failure
18-273
［18. ENGINE］
18.16.1.18 Boost pressure sensor malfunction (DTC code P0108, P0237)
DTC P0108 Boost pressure sensor circuit high input
DTC P0237 Boost pressure sensor circuit low input
harness.
GND +5V
2. Disconnect the connector of the boost pressure sensor.
+5V terminal and the GND terminal of the boost pressure
sensor connector (at machine harness side).
S ta n d a rd va lu e : 5 ± 0.5 V
OK
1. Measure the voltage between terminal D25 and terminal D33

D of the signal check harness.
D25
D33 NG Engine ECU failure, ECU connector failure
OK
Harness failure
18-274
［18. ENGINE］
D boost pressure sensor.
D27
terminal D27 and terminal D33 of the signal check harness.
D33
S ta n d a rd va lu e : 0.2 to 4.8 V
NG [4] Go to measurement of voltage between terminals. 18
OK
1. Leave the connector of the boost pressure sensor connected.

GND SIG
2. Measure the voltage between the SIG terminal and the GND
terminal of the boost pressure sensor connector (at machine
harness side).
NG Boost pressure sensor failure
OK
Harness failure
18-275
［18. ENGINE］
18.16.1.19 Turbocharger over boost (DTC code P0234)
1 Inspection with failure diagnosis tool
1. After failure, perform failure diagnosis with a failure diagnosis

tool (HinoDX) using PC.
2. Connect the failure diagnosis tool (HinoDX) using PC and set

the starter key to "ON".
OK
Perform diagnosis of the boost pressure sensor (DTC code P0108, P0237).
18-276
［18. ENGINE］
18.16.1.20 Excessive common rail pressure (DTC code P0088)
D D20 harness.
D31 2. Set the starter key to "ON" and measure the voltage between
D33 terminals D20/D31 and terminal D33 of the signal check
harness.
18
NG Engine ECU failure or harness/connector contact
failure
OK
Failure of common rail pressure sensor
18-277
［18. ENGINE］
18.16.1.21 Excessive common rail pressure, supply pump excess forced feed (DTC code P0088)
D20 harness.
D31 2. Start and warm-up the engine until the coolant temperature
D33 gauge moves.
3. Set the engine speed to idling. PFIN = Approx. 30 MPa

(approx. 1.5V)
4. Measure the voltage between terminal D20/D31 and terminal

D33 of the signal check harness.
S ta n d a rd va lu e : 1.56 V o r le s s
NG Failure of common rail pressure sensor
OK
2 Check of failure code
1. Make sure that other failure code is not output.

If other failure code is output, repair the failure code and make
sure again that DTC code P0088 is output. In particular, if a
failure code of the main and sub-engine speed sensor systems
is output, make necessary repairs to prevent output of the
code.
2. Check the fuel injection timing of the supply pump. If the timing
is not set 0° for the top dead center, set it correctly.
3. When there is no error after the check above, delete the past
failure using the PC diagnosis tool and start the engine.
If the same code is output again, possible failures are the
supply pump, common rail pressure sensor system and engine
ECU. Perform more detailed diagnosis with failure diagnosis
18-278
［18. ENGINE］
18.16.1.22 Common rail pressure sensor malfunction (DTC code P0191)
D D20 harness.
D33 terminals D20/D31 and terminal D33.
18
NG Engine ECU failure or harness/connector contact
failure
OK

D20
2. While measuring the voltage between terminals D20/D31 and
D31 terminal D33 of the signal check harness, repeat full opening/
D33 closing of the accelerator.
S ta n d a rd : Vo lta g e mu s t c h a n g e . (1.0 to 3.2 V)
NG Common rail pressure sensor failure or harness/

connector contact failure
OK
Engine ECU failure, connector contact failure
18-279
［18. ENGINE］
18.16.1.23 Common rail pressure sensor malfunction (DTC code P0192, P0193)
DTC P0192 Common rail pressure sensor circuit low input
DTC P0193 Common rail pressure sensor circuit high input
D33 D harness.
D20
terminals D20/D31 and terminal D33 of the signal check
harness.
OK
1. Set the starter key to "OFF" and disconnect the connector of

the common rail pressure sensor.
GND +5V
+5V terminal and the GND terminal of the common rail
pressure sensor connector (at machine harness side).

terminals.
OK
18-280
［18. ENGINE］
1. Set the starter key to "OFF" and disconnect the ECU side
connector of the signal check harness.
D
D20
D31 2. Measure the resistance between terminals D20/D31 of the
signal check harness and the SIG terminal of the common rail
SIG
18
NG Harness failure
OK
Connector contact failure
1. Set the starter key to "OFF" and disconnect the ECU side
2. Measure the resistance between terminals D24 of the signal

D +5V
D24 check harness and the +5 V terminal of the common rail
3. Measure the resistance between terminal D33 of the signal

check harness and the GND terminal of the common rail
GND pressure sensor connector (at machine harness side).
D
NG Harness failure
D33
OK
18-281
［18. ENGINE］
18.16.1.24 Accelerator sensor 1 malfunction (DTC code P2122, P2123)
DTC P2122 Accelerator sensor circuit 1 low voltage
DTC P2123 Accelerator sensor circuit 1 high voltage
harness.
terminal A21 and terminal B20 of the signal check harness.
B20
A21 S ta n d a rd va lu e : 0.7 - 1.5V (id le s ta tu s )
NG [3] Voltage measuring at the output port of the

mechatronic controller
OK
1. While increasing the throttle, measure the voltage between

S ta n d a rd va lu e
B20 En g in e revo lu tio n

A21 Me as u ring ite m Vo lta g e (V)
(r/m in )
Low id le 1,000 Ap p rox.1.4
Hig h id le 2,000 Ap p rox.3.3
NG Defective mechatronic controller
OK
Harness failure
18-282
［18. ENGINE］
3 Voltage measuring at the output port of the mechatronic controller
1. With the starter key set to "ON", do not open the slot and
measure the voltage between pin 25 of the pin connector 28 of
the mechatronics controller and B21 of the signal check
harness.
When an abnormal value is detected, the mechatronics
controller becomes defective.
Ab n o rm a l va lu e
: 0.3 V o r le s s
18
: 4.85 V o r m o re
NG Engine ECU failure, ECU connector failure or

disconnection of harness, short-circuit of harness
OK
Defective mechatronic controller
18-283
［18. ENGINE］
18.16.1.25 Accelerator sensor 1 malfunction (DTC code P2127, P2128)
DTC P2127 Accelerator sensor circuit 2 low voltage
DTC P2128 Accelerator sensor circuit 2 high voltage
harness.
A22
B21
S ta n d a rd va lu e : 0.7 - 1.5V (id le s ta tu s )
NG [3] Voltage measuring at the output port of the

mechatronic controller
OK
1. While increasing the throttle, measure the voltage between

A22
B21
En g in e revo lu tio n
Me as u ring ite m Vo lta g e (V)
(r/m in )
Low id le 1,000 Ap p rox.1.4
Hig h id le 2,000 Ap p rox.3.3
NG Defective mechatronic controller
OK
Harness failure
18-284
［18. ENGINE］
3 Voltage measuring at the output port of the mechatronic controller
1. With the starter key set to "ON", do not open the slot and
measure the voltage between pin 25 of the pin connector 28 of
the mechatronics controller and B21 of the signal check
harness.
When an abnormal value is detected, the mechatronics
controller becomes defective.
Ab n o rm a l va lu e
: 0.3 V o r le s s
18
: 4.85 V o r m o re
NG Engine ECU failure, ECU connector failure or

disconnection of harness, short-circuit of harness
OK
Defective mechatronic controller
18-285
［18. ENGINE］
18.16.1.26 Accelerator sensor 1 and 2 malfunction (DTC code P2120)
1 Inspection item
1. Take action of DTC code P2120.

"Reference : Accelerator sensor 1 malfunction (DTC code P2122,
P2123), Engine ECU, Engine diagnosis code"
"Reference : Accelerator sensor 2 malfunction (DTC code P2126),
Engine ECU, Engine diagnosis code"
18-286
［18. ENGINE］
18.16.1.27 Emergency accelerator sensor malfunction (DTC code P1133)
1 Power supply voltage measuring
1. With the ECU connector connected, disconnect the sensor

connector and measure the voltage between the power
+5V terminal (+5 V) and the GND terminal.
! CAUTION • Th e c o n n e c to r in th e fig u re is s e e n fro m th e

fittin g s u rfa c e .
GND S ta n d a rd va lu e : 5.0 ± 0.5 V
18
OK
1. Measure the voltage between terminals B20 and B23 of the

signal check harness.
NG Engine ECU, engine ECU connector failure
OK
Harness failure
18-287
［18. ENGINE］
1. Connect the sensor connector and measure the voltage

between terminals A23 and B20 of the signal check harness.
S ta n d a rd va lu e : Ap p rox. 0.0 to 3.2 V (id le to fu ll

th ro ttle )
OK
Engine ECU failure, engine ECU connector failure
1. Leave the emergency accelerator sensor connected.
2. Connect the sensor connector and measure the voltage

GND between the terminals SIG and GND of the sensor.
! CAUTION • Th e c o n n e c to r in th e fig u re is s e e n fro m th e

SIG
fittin g s u rfa c e .
S ta n d a rd va lu e : Ap p rox. 0.0 to 3.2 V (id le to fu ll

th ro ttle )
NG Emergency accelerator sensor failure
OK
Harness failure
18-288
［18. ENGINE］
18.16.1.28 Atmospheric pressure sensor malfunction (DTC code P2228, P2229)
DTC P2228 Atmospheric pressure sensor circuit low input
DTC P2229 Atmospheric pressure sensor circuit high input
1. After deleting the past failures with the failure diagnosis tool
(HinoDX) using PC, check again if the same code (DTC code
P2228, P2229) is output. 18
S ta n d a rd : No rm a l
NG Engine ECU failure
OK
Since it may be a temporary malfunction due to radio interference, it is acceptable when the system recovers
normal operation.
18-289
［18. ENGINE］
18.16.1.29 Injector common 1 ground short (DTC code P1211), Injector common 2 ground short (DTC
code P1214)
harness.

harness.
3. Measure the resistance between each terminal of the signal
D5 D D6 check harness and the ECU case ground.
ECU case ground
(ECU mounting bolt)
DTC c o d e Te rm in a l to m e a s u re re s is ta n c e
ECU c a s e
E6 E E7 P 1211 D5, D6
g ro u n d
ECU c a s e
P 1214 E6, E7
g ro u n d
S ta n d a rd va lu e : ∞ Ω

injector terminals.
OK
1. Set the starter key to "OFF" and connect the ECU side
2. Start the engine and delete the past failures with the failure
diagnosis tool (HinoDX) using PC.
3. If the same failure code is output again, replace the engine

ECU. If the normal code is output, it is considered that a
temporary error has occurred.
18-290
［18. ENGINE］
3 Measurement of resistance between injector terminals
1. Set the starter key to "OFF".
2. The injector clustered connector at the front side of the engine

shall be disconnected.
1 2 3 4
5 6 7 8 3. Measure the resistance between terminals of the injector
9 10 11 12 clustered connector (at machine harness side).
Te rm in a l to m e a s u re re s is ta n c e
18
DTC c o d e
+ s id e – s id e
ECU c a s e
P 1211 3, 7, 8, 11
g ro u n d
ECU c a s e
P 1214 2, 5, 6, 10
g ro u n d
S ta n d a rd va lu e : ∞ Ω
NG Harness failure (failure including pinching of harness

which has not satisfied the standard value)
OK
Inspection of harness inside head cover (Short-circuit of the harness inside the head cover to the ground line may
have occurred.)
18-291
［18. ENGINE］
18.16.1.30 Injector common 1 power source line short (DTC code P1212), Injector common 2 power
source line short (DTC code P1215)
D5 D D6 harness.
ECU case ground
(ECU mounting bolt)
harness and set the starter key to "ON".
E6 E E7
3. Measure the voltage between each terminal of the signal check
harness and the ECU case ground.
! CAUTION • Neve r s ta rt th e e n g in e b e c a u s e it m ay c a u s e
fa ilu re o f th e u n it o r e le c tric s h o ck.
Te rm in a l to m e a s u re vo lta g e
DTC c o d e
+ s id e – s id e
ECU c a s e
P 1212 D5, D6
g ro u n d
ECU c a s e
P 1215 E6, E7
g ro u n d
S ta n d a rd va lu e : 14 V o r le s s
NG [3] Go to measurement of voltage between injector

terminals.
OK
3. If the same failure code is output again, replace the common

rail ECU. If the normal code is output, it is considered that a
18-292
［18. ENGINE］
3 Measurement of voltage between injector terminals
1. Set the starter key to "OFF".

shall be disconnected and set the starter key to "ON".
1 2 3 4
5 6 7 8 3. Measure the voltage between terminals of the injector
9 10 11 12 clustered connector (at machine harness side).
! CAUTION • Neve r s ta rt th e e n g in e b e c a u s e it m ay c a u s e 18
fa ilu re o f th e u n it o r e le c tric s h o ck.
Te rm in a l to m e a s u re vo ltag e
DTC c o d e
+ s id e – s id e
ECU c a s e
1212 7, 8
g ro u n d
ECU c a s e
1215 5, 6
g ro u n d
S ta n d a rd va lu e : 14 V o r le s s
NG Harness failure (harness failure of terminal that has

not satisfied the standard value)
OK
Inspection of harness inside head cover (Short-circuit of the harness inside the head cover to the power line may
have occurred.)
18-293
［18. ENGINE］
18.16.1.31 Injector circuit malfunction (DTC code P0201 to P0204)
DTC P0201 Injector circuit malfunction -cylinder 1

harness.

D6
D2 D5 harness and measure the resistance between terminals.
D3
Te rm in a l to
Fa ilu re a re a
E1 DTC c o d e m e a s u re
E2 E7
(in je c to r)
E6 re s is ta n c e
P 0201 #1 D2 ↔ D5
P 0202 #2 E2 ↔ E6
P 0203 #3 E1 ↔ E7
P 0204 #4 D3 ↔ D6

injector terminals.
OK
3. If the same failure code is output again, replace the common

rail ECU. If the normal code is output, it is considered that a
18-294
［18. ENGINE］

shall be disconnected.
2. Measure the resistance between terminals of the injector

4 3 2 1
clustered connector (male) at the cam housing.
8 7 6 5
12 11 10 9
Te rm in a l to m e a s u re
DTC c o d e
re s is ta n c e 18
P 0201 8↔ 11
P 0202 6↔ 10
P 0203 2↔ 5
P 0204 3↔ 7

injector terminals.
OK
Machine harness disconnection (Check the harness between the ECU and the injector clustered connector.)
1. Remove the head cover and disconnect the injector connector

(injector side) of the cylinder indicated by the failure code.
Measure the resistance between the No. 1 terminal and the No.
2 terminal.
S ta n d a rd va lu e : 0.45 ± 0.1 Ω

injector terminals.
OK
Contact failure of harness or connector inside the head cover
18-295
［18. ENGINE］
1. Remove the terminal cap of the injector of the cylinder

indicated by the failure code and measure the insulation
resistance between the terminal and the upper body.
S ta n d a rd va lu e : 10 MΩ o r m o re
NG Injector TWV coil disconnection (Replace the injector

assembly.)
OK
Injector harness disconnection (Replace the injector harness.)
18-296
［18. ENGINE］
18.16.1.32 Cylinder contribution/balance fault (DTC codes P0263, P0266, P0269, P0272)
DTC P0263 Cylinder 1 contribution/balance fault

NOTICE • Th is d iag n o s is is th e c a s e with flow d a m p e r.

18
1 Check the flow damper
1. Turn the starter switch to "OFF" position. Stop the engine.
2. Wait for about 30 seconds and then start the engine.
3. Perform warm-up until the coolant temperature becomes 60°C

{140°F} or higher. And erase the DTC.
4. If the same DTC is displayed again after erasing it, replace the
common rail.
18-297
［18. ENGINE］
2 Recheck the DTC
1. Check that the other DTC is not displayed.

• If the other DTC is displayed, repair the trouble.
• If the same DTC is displayed again, it is possibly from the
following problems.
a
b a. Excessive fuel flow will cause fuel leakage from injection
pipe (between common rail and injector) by bending,
cracking and pipe connection looseness.
→ Check leakage.
b. Excessive or shortage fuel flow will cause injector
operation malfunction.
→ Check by replacing the injector.
c. Shortage fuel flow will cause clogging of the fuel supply
system.
→ Check fuel filter.
2. The above problems can be diagnosed using the "Data

Monitor" menu to determine the cylinder contribution quantity
and "Activation Test" menu to stop the injector.
(1) When there is a cylinder whose cylinder contribution is

larger than other cylinders (the engine behavior will not
change even if fuel injection is stopped by active test for
the cylinder), the cylinder will not contribute to the engine
rotation.
→ Inspecting the injector harness (disconnection)
→ Checking the piston for compression leakage
(2) When there is a cylinder whose cylinder contribution is
smaller than other cylinders, the contribution of the
cylinder to the engine rotation is excessive.
→ Inspecting the injector harness (+B short circuit)
18-298
［18. ENGINE］
18.16.1.33 Supply pump SCV malfunction (DTC code P0628, P0629)
DTC P0628 Supply pump SCV malfunction (Full discharge mode)
DTC P0629 Supply pump SCV malfunction (Power source line short)
1 Measurement of resistance between solenoid terminals
1. Set the starter key to "OFF", disconnect the connector of the

supply pump solenoid valve and measure the resistance
between No. 1 and No. 2 terminals at the supply pump solenoid 18
valve.
S ta n d a rd va lu e : 7.9 ± 0.2 Ω (20 °C{68 °F})
NG Failure of supply pump solenoid valve
OK
1. Set the starter key to "OFF", connect the signal check harness
and disconnect the ECU side connector.
2. Measure the resistance between terminals E10/E11 of the

E E8 signal check harness and the No. 1 terminal of the supply
E9 E10
E11 pump solenoid valve (at machine harness side).
In a similar manner, measure the resistance of terminals E8/
E9 of the signal check harness and the No. 2 terminal of the
supply pump solenoid valve connector (at machine harness
side).
NG Harness disconnection, connector failure
OK
18-299
［18. ENGINE］
1. Turn "ON" the starter key.
E E8 2. Measure voltage between terminal E4 and terminals E8/E9 of

E4 E9
the signal check harness.
S ta n d a rd va lu e : P u ls e wave fo rm a t 24V ↔ 0V
NG Failure of ECU connector
OK
Engine ECU failure
! CAUTION • Afte r tu rn in g "ON" th e s ta rte r key, ta ke m e a s u re m e n ts with in 40 s e c o n d s .
18-300
［18. ENGINE］
18.16.1.34 Supply pump SCV sticking (DTC code P2635), Supply pump abnormal pressure record (DTC
code P2635)
1 Inspection of supply pump
1. Set the starter key to "OFF" and stop the engine.
2. Wait for approx. 30 seconds and start the engine.
3. Warm-up the engine until coolant temperature is 60 °C{140 °F}

or more, and delete the past failure with the failure diagnosis 18
4. Run the engine at no load up to HI idle. Or repeat no-load

operation from LOW idle to HI idle two or three times and
confirm that the same fault code is displayed again.
NG Replace supply pump.
OK
2 Check of failure code
1. Make sure that other failure code is not output.

If other failure code is output, repair the failure code and make
sure again that DTC code P2635 is output.
2. When there is no error after the check above, delete the past
failure and operate the engine.
If the same code is output again, possible failures are the
supply pump and engine ECU. Perform more detailed
diagnosis with failure diagnosis tool (HinoDX) - Hino–DX
[Inspection Menu], using PC.
18-301
［18. ENGINE］
18.16.1.35 Preheat circuit malfunction (DTC code P0540)
C2 harness.
C1 C D1 D E4 E E5

harness and measure the resistance between terminals C1, C2
and terminals D1, E4, E5.
S ta n d a rd va lu e : 25 ± 2.5 Ω

terminals.
OK
2 Measurement of relay resistance
1. Remove the heater relay and measure the resistance between

terminals.
S ta n d a rd va lu e : 24.8 ± 0.5 Ω
NG Heater relay failure
OK
Harness failure, connector failure
18-302
［18. ENGINE］
18.16.1.36 Injector correction data conformity error (DTC code P1601)
1 Inspection of QR code
1. Read the QR code data with the failure diagnosis tool (HinoDX)
using PC.
Re fe re n c e va lu e : Th is s h a ll c o in c id e with th e QR c o d e
m a n ag e d b y th e m a c h in e m a n u fa c tu re r.
NG Write the QR code again.

18
OK
Replace engine ECU.
18-303
［18. ENGINE］
18.16.1.37 ECU internal error (DTC code P0605, P0606, P0607)
DTC P0605 Flash ROM error

DTC P0606 CPU malfunction (Hard detection)
DTC P0607 Monitoring IC malfunction in CPU
1. Set the starter key to "OFF" and set it to "ON" again.
2. After deleting the past failure, check if the same code (DTC
code P0605, P0606, P0607) is output again.
OK
normal operation.
18-304
［18. ENGINE］
18.16.1.38 ECU charge circuit malfunction (DTC code P0200, P0611)
DTC P0200 ECU charge circuit high input
DTC P0611 ECU charge circuit malfunction
1 Check of ECU
1. Set the starter key to "OFF" and set it to "ON" again.
2. After deleting the past failure, check if the same code (DTC
18
code P0611, P0200) is output again.
OK
normal operation.
18-305
［18. ENGINE］
18.16.1.39 Main relay malfunction (DTC code P0686)
A6
A5 A A7 harness.

harness and set the starter key to "ON". Measure the voltage
Frame
between terminals A5, A6, A7 and the chassis GND.
S ta n d a rd va lu e : 0 V
OK
Engine ECU failure, engine ECU connector failure
18-306
［18. ENGINE］
18.16.1.40 Starter signal malfunction (DTC code P0617)
B B14 C C4
harness.
C3 2. Disconnect the ECU side connector of the signal check

harness and set the starter key to "ON".
3. Measure voltage between terminal B14 and terminals C3/C4. 18

! CAUTION • Me a s u rin g s h a ll b e d o n e in a n e nviro n m e n t
wh e re th e e n g in e m ay b e s ta rte d .
: 0 V (wh e n s ta rte r key is a t "OFF")
: 24 V (wh e n s ta rte r key is a t "S TART")
NG Harness failure
OK
18-307

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HYDRAULIC EXCAVATOR

Book Code No.S5YN0051E01

2) WARNING- Indicates a potentially hazardous

The proper and safe lubrication and maintenance

2015-11 ATTACHMENT DIMENSIONS 3 2

2015-11 HYDRAULIC SYSTEM 8

2015-11 AIR-CONDITIONER SYSTEM 11

2015-11 UPPER STRUCTURE 14

2015-11 TRAVEL SYSTEM 15 14 6

2015-11 BY ERROR CODES 16

YN15T17101∼/ APPLICABLE MACHINES

1.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL

1.2 GENERAL PRECAUTIONS FOR MAKING REPAIRS

Read Operator's Manual

Knowledge of operating procedure

Arrangement and cleaning in service shop

1.2.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING

1.2.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT

Disassembling hydraulic equipment

Reassembling hydraulic equipment

Installing hydraulic equipment

– Removing and attaching swing motor

Checking method for oil level of hydraulic oil tank

WHEN AIR BLEEDING IS REQUIRED

WHEN AIR IS BLED FROM HYDRUALIC CYLIDNER

1.2.4 ELECTRICAL EQUIPMENT

BATTERY FLUID IS DANGEROUS. 1

• The disassembly of electrical equipment is not allowed.

1.2.5 HYDRAULIC PARTS

Flexible hose (F hose)

1.2.6 WELD REPAIR

1.2.7 ENVIRONMENTAL ISSUES

1.3 INTERNATIONAL UNIT SYSTEM

Although this manual uses the SI units system. Outline

2.1 ABOUT THE COPYRIGHT OF THIS SHOP MANUAL

2.2 BASIC COMPONENTS OF THE MACHINE

31 Indicate the right side

No. Name No. Name No. Name

2 Hydraulic pump 14 Left side door 26 Boom cylinder

3 Control valve 15 Right side door 27 Boom

4 Hydraulic oil tank 16 Engine hood 28 Arm cylinder

5 Fuel tank 17 Counterweight 29 Arm

6 Swing motor 18 Swing bearing 30 Bucket cylinder

7 Swivel joint 19 Crawler 31 Idler link

10 Oil cooler 22 Lower roller 34 Swing flusher

11 Radiator 23 Track guide 35 Battery power-off switch

12 Intercooler 24 Upper roller

2.3 GENERAL DIMENSIONS

Dimensions marked * do not include the height of the shoe lug.

2.3.2 SK210LC-10[5.65m(18ft-6in) Boom + 2.94m(9ft-8in) Standard Arm +

Dimensions marked * do not include the height of the shoe lug.

2.4 WEIGHT OF COMPONENTS

1. Upper structure (including following items) 9,470 (20,880) ←

2. Undercarriage (including following items) 6,900 (15,210) 7,270 (16,030)

3. Attachment (including following items) 4,120 (9,080) ←

4. Lubricant and water (including following items) 650 (1,430) ←

Marks * show dry weight.

2.5 SPECIFICATIONS FOR TRANSPORTATION

Length X Height X Width 5.86 x 1.61 x 0.67

Weight: kg (lbs) 1,760 (3,880)

2.5.1.2 ARM AND BUCKET

Length X Height X Width 5.29 x 0.9 x 1.16

Weight: kg (lbs) 1,860 (4,100)